Ef El WSM

INDEX
EP.F5 - FALCON I FAIRLANE - 1994 to 1998 - EF EL - Automotive Repair Manual

INDEX
CONTENTS
GENERAL INFORMATION 5
ENGINE TUNE-UP and MAINTENANCE 7
Service Operations ................................................ -.................................................................................................... 8
Battery Inspection II
EMISSION CONTROL .......................................................................................................................................... . 15
General Precautions ................................................................................................................................................... 15
Emission Control Systems .......................................................................................................................................... 17
6 CYLINDER ENGINE MAINTENANCE AND REBUILD ..................................................................................... 20
Engine Maintenance .. ................................................................................................................................................ . 22
Major Repairs & Rebuild ... .. ..................................................................................................................................... . 34
V8 ENGINE MAINTENANCE AND REBUILD .... ......... .... ... .............. .............. ......... .... ......... ....... .. ....... .. ....... ....... 52
Engine Maintenance ......... ........... ...................... ...... ............... ................ .............. ....... ........ .............. ... ..... ....... .......... 54
Major Repairs & Rebuild ............................................................................................................................. .............. 72
STARTER SYSTEM ................................................................................................................................................ 91
Removal and Installation ........ ......... ... .... .... .. .... ................ .... ............... ........... ............ ....... ....... ......... ............. .......... . 92
Repairs ..................................................................................................................................................................... . 92
Specifications .......................................................................................................................................................... . 98
ALTERNATOR SYSTEM ................................................... .................................................................................. 99
Removal and Installation ......................................................................................................................................... 100
COlnponetChecking ............................................................................................................................................. ... . 102
Specifications ...................................................................................................................................... ................. .. 104
COOLING SYSTEM .............................................................................................................................................. 105
Maintenance .......................................................................................................................................................... . 106
Problem Solving and Diagnosis ................................................................................................................................ 11 2
IGNITlON SYSTEM .............................................................................................................................................. 113
Distributor Removal 6 Cylinder and V8 .................................................................................................................... 115
Dismantle and Inspection ......................................................................................................................................... 116
Distributor Installation 6 Cylinder and V8 ................................................................................................................. 11 7
FUEL SYSTEMS .................................................................................................................................................. 121
Adjustments .......................................................................................................................................................... . 123
6 Cylinder MPEFI ................................................................................................................................................ 123
8 Cylinder SEFI ...................................................................................................................................................... . 123
Specifications ........................................................................................................................................................ . 129
CLUTCH ........... ............. ........................................................................................................................................ 130
Maintenance .......................................................................................................................................................... . 131
Major Repairs ......................................................................................................................................................... 132
Problem Solving and Diagnosis .......................................... ................... ................................................................... 133
AUTOMATIC TRANSMlSSION BTR 93/97LE .. ...................................................................................... .......... 135
Maintenance .......................................................................................................................................................... . 136
Major Repairs and Rebuild ...................................................................................................................................... 141
Problem Solving & Diagnosis .................................................................................................................................. 155
5 SPEED MANUAL TRANSMISSION ................................................................................................................. 160
Maintenance .................... ........................ ................ .... ........... ... ............ .... .... ... ........ ... ....... ......... ....... .... ....... ........ . 161
Major Repairs and Rebuild ..... ................. ....... .. .... .... .......... ................. ........... ........... ....... ..... ....... ............. .............. 162
Problem Solving and Diagnosis ................................................................................................................................ 174
DRIVEffAll . SHAfT AND UNIVERSAL JOINTS ............................................................................................... 176
Removal and Installation ......................................................................................................................................... 176
INDEX
ProblemSolving 179
REAR AXLE .......... . 180
General Maintenance 181
Major Rebuild 187
Problem Solving .................................................................................................................................................... . 198
STEERING .......... ...................................................................................................................................................201
Minor Maintenance ..................................................................................................................................................202
Major Repair and Rebuild ....................................................................................................................................... . 204
Power Steering Auid Testing ................................................................................................................................... . 212
Problem Solving ..................... ................................................................................................................................. 212
FRONT SUSPENSION & AXLE ........................................................................................................................... 215
Wheel Alignment ..................................................................................................................................................... 216
Minor Maintenance .................................................................................................................................................. 218
Major Repairs ........................................................................................................................................................220
ProblemSolving .................................................................................................................................................... .226
REAR SUSPENSION .............................................................................................................................................229
Maintenance ............................................................................................................................................................230
Automatic Self Levelling .......................................................................................................................................... 236
Problem Diagnosis ................................................................................................................................................... 238
BRAKE SYSTEMS .. .................. ............. ............................ ......... ......... ... ............ ....... ...... ............ .. ....... ...... ... ... ... . 239
RoutineMaintenance ........................................ ............. ......................................................................................... 240
Major Repairs ........................................................................................................................................................243
ABS System Repairs and Diagnosis ......................................................................................................................... 250
Problem Diagnosis and Testing ................................................................................................................................ 252
EXHAUST SYSTEM .............................................................................................................................................253
General Maintenance .......................................................... ................................................................................... .253
V8Diagrams ........................................................................................................................................................... 255
6 Cylinder Diagrams ................................................................................................................................................ 257
FUEL TANK and EFI FUEL PUMP ....... .................................................................. .............................................. 258
General Information ............................................................................................................................................... . 258
WHEELS and TYRES ............................................................................................................................................ 263
Tyre Pressure and Wear Patterns ............................................................................................................................. . 264
WiNDSCREEN WIPERS A.N D WASHERS .................................................... ...................................................... . 265
Component Replacement ... ....... .. ............ ... .... ...... .. ..... ......... .... ........................................... ..... ........... ............. ....... .. 265
Wiper Alignment ..................................................................................................................................................... 266
BODY ................................................................................ ................................................................... ................. 268
Generallnformation ................................................................................................................................................ 268
Floor Pan/Chassis ........ ..... ...... ........ ......... ..... ........ ...... ..... ............. ...... .. ............ ....... ..... ......... ........ ... .......... ..... ...... . 269
DashllnstrumentPanel ..................... ......................................... .......... ............................................ ............... .......... 271
Rear Compartment (Boot) Lid & Tail Gate .. ............................................................................................................. 273
Front and Rear Door Assemblies ..............................................................................................................................778
Stationary Glass ...................................................................................................................................................... 285
Seats and Seat Belt Assemblies ........... ............... ............. ..... ...... ........ ... .. .. ....... .......... ......... ....... ......... ............. ... ..... 288
Headlining and Trim ................................................................................................................................................ 294
Paint and Exterior Ornamentation ............................................... .. ..................... .... ......................... ....... ................... 295
Front Sheet Metal .................................................................................................................................................... 297
RadiatorGrille ....................................................................................................................................................... .299
Bumper Bars ........................................................................................................................................................... 300
HEATING. AIR CONDmONlNG and AUTOMATIC CLIMATE CONTROL ...................................................... 302
HeatingOperation ................................................................................................................................................... . 303
Heating Component Replacement ........ ............. ..... ........ ........ ........ ...... ...... ........ ..... ....... ......... .. ............ ... ... ..... ......... 303
Problem Diagnosis ................................................................................................................... ................................ 307
AirConditioningMainlenance ..................................................................................................................................309
Problem Diagnosis ....... .......... ............... ...... ............................................................................................................. 313
INDEX
Automatic Climate Control ............................... .. .. ............ _........................................................................ .............. 314

INSTRUMENTS, RADIO - TAPE PLAYER & HORN .......................................................................................... 3 17
InSlrument Cluster Removal and Dismantle ...... .. .......... ................................. ...... .. ........ .. ........ .. ............ .. ............ .. .... 31 8
Instrument Cluster Assembly and Installation ......_..................................................................................................... 31 9
Radio - Stereo Systems _,..... _,............................................................................................... ............. ................... .... 321
Sender Unil~ Removal and Installation .......................... ............................................................................................ 324
BODY ELECfRONI S MODULE & SMARTLOCK ............................................................................................ 327
LIGHTS, SWITCHES and BATTERY SYSTEMS ...... .. ......................................................................................... 330
Generdl Maintenance ....................................................................................... ........ ................................................ 33 1
Component Removal and Installation ........................................................................................................................ 332
BulbSpccitications ..... .................................................................................. ................ ....... ................ .. .. .............. .. 339
ELECI 'RlCAL .... ........... .. ........ ............ ............ .................................................................... ....... ............. ...... ....... .. 340
Fuses. Relays, Circuit Breaker, Fusible Links .................................................... ....................................................... 340
Wiring Harnesses ....................................................... .......... .............. ......... ................................ ......... .. ................. 341
WiringDiagraIlls ................................................................................................................................. ................. ... 342
DIAGNOSTIC CHARTS ............................................................................................... ..................... .................... 39 1
ABS Brakes ............................................................................................................................................................ 392
Selfl..evellingSuspension ..................................................................................................... ................................... . 395
Transm.ission ..... ............................................. ......................................................................................................... 397
Ignition .............................................................. ...................................................................................................... 400
Engine ..................................................................................................................................................................... 403
Automatic Climate Control ...................................................................................................................................... 415
Air Bag Diagnostics .............. ............... .................................................................................................................... 41 8
MEMO ........ ... ... ......... .......... .. .................. ....... ........ .... ........ ............... .. ............ ...... ........ ... ... ... ............ ....... ......... ... 420
GENERAL INFORMATION -- MODEL IDENTIFICATION

BODY STYLE
GLi
FUlUra
Sedan
Sedan
Sedan
Wagon
Wagon
Wagon
XR
GLi
Fulura
XR
SW
SW
SW
WA
WA
WA
Fainnont
Fainnont
Fairmont Ghia
Fairmont Ghia
Fairlane Ghia
LTD
Sedan
Wagon
Sedan
Wagon
SW
WA
SW
N/A
LW
LW
BUILD DATE:
The last two letters of the Prefix Body identifies the year and month of vehicle production.
Year
Code
1994 - R
1995 - S
1996 - T
1997 - V
1998 - W
1999 - X
2000- Y
Jan.
L
C
B
J
L
C
B
Feb.
Y
K
R
U
Y
K
March
S
D
A
M
S
D
A
April
May
June
July
J
L
C
B
J
L
C
U
Y
K
M
S
D
A
M
S
D
E
G
P
T
E
G
U
Y
K
Aug.
P
T
E
G
P
T
E
Sept.
B
J
L
C
B
J
L
Oct.
R
U
Y
K
R
U
Y
Nov. Dec.
A
G
M
P
T
S
D
E
A
G
M
P
S
T
GENERAL INFORMA TION
GENERAL INFORMATION -- Model Identifiacation (C'td)
MODEL CODE
Body Type Sedan Wagon
Body Style GLi
GLi
EFI
18433 18463
EFIT
18633 18663
EL
18733 18763
Sedan
Futura
18434
19634
18734
Body Type Sedan

BodyStyle Fairlane Ghia
EFI
18449
EF II
18649
EL
18749
Sedan
LTD
18446
18646
18746
Wagon Sedan
Futura XR
18464 18435
18664 18635
18764 18735
Wagon
XR
18465
Wagon
F' mont Pmont
18432 18462
18632 18662
18732 18762
Sedan
Sedan
PmontGhia
18438
18638
18738
PAINT COLOUR AND CODE

Colour
Dynamic White
Hot Chilli Red
Victorian Taxi Yellow
GunmctaJ
Herit.1ge
Bermuda Green
ArcticBlue
Mercury
Navy Blue
Regancy
MochaFoarn
Argon Silver
Code
H
P4
Colour
Sparkling Burgundy
RecfGreen Q3
Biscayne Blue
Mauritius Blue
Cardinal Red
LeMans Red
Polynesian Green
Cobalt Blue
Bordeaux
Black Pearl
Classic Cream
T7
KI
E3
F5
Q9
X5
N9
C2
A6
07
TRIM TYPE, COLOUR AND CODE

Trim Colour
Luna Mist (EF only)
Mako Grey (EL only)
Capuccino
Code
G
G
T
Code
B5
W4
QI
X4
G5
R
F3
C9
B8
14
C8
ENGINE TUNE-UP & MAINTENANCE
SUBJECT
Page
Page
Check Oil Level

8
Lubrication ................................................................. 8
Oil Filter ..................................................................... 8
Replacement 8
Air Filter (6 Cyl, MPEFI) ........................................ 8
RelTlOval ...................................................................... . 8
Installation ................................................. .. ................. 8
Air Filter (8 Cyl, SEFI) ............................................ 8
BeltAdjustment (idlerpulley) ...................................... 10

Cooling System ..................................................... .. 10
~~t ~lll"e CI~~l1ce ....................................... . 10
BA'I"I'ERY INSPECI'ION .................................... . 11
Testing Battery Electrolyte (Acid) ........................ 11
Using The Hydrometer .......................................... . I I
Battery Charging .................................................. .. 11
Inspection Of Spark Plugs 6cyl. & V8 .............. 11
FIRING OR.DER .................................................. .. 11
Fuel System Depressuriz,ation .............................. . 11
Fuel Filter ............................................................... 12
0 0 0 0
ReITlOval ....................................................................... 8
Installation .................................................................... 8
Inspect Air Filter .................................................. 8
Inspection of High Tension Lead ......... 9
Compression Check ................................................ 9
Compression Test Results ....................................... ...... 9
Replace Drive Belt & Adjust Bell....................... 9
Inspection ..................................................................... 9
VisuaJ Inspection .......................................................... 9
~ta!ies ()f E1"lt ~"'" ..................................................... SI
Drive Belts ............................................................... 9
Belt Adjustnlent .................. .......... ................................ 9
Removal .. ........ ............ .................... .......................... . 12
Installation .................................................................. 12
Checking Base Idle .... .................................. .............. . 12
' T mlng
i'
I gn)' t
Ion
..................................................... .. 12
Ignition Coil lns.,ection ........................................ . 13
C()iJ Pac:lt ~~ti()11 13
Ignition Coil ............................................................ 13
Removal .. ... ................................... ............................. 13
Installation .................................................................. 13
Coil Pack Replacement ......................................... 13
Checking Fuel Mixture 13
Belt Tension ............................................................... 10
PROBLEM DIAGNOSIS ...................................... 14
ENGINE TUNE UP & MAINTENANCE
ENGINE TUNE-UP &

MAINTENANCE
OILLEVEL
Oil Filter
Metal casting
Screw on
Oil Filter
, ,
The oil level should be between the L & H marks on the level
gauge. Inspect for leakage, and fill oil up to the "H" mark if
level is low.
-.
>
~. '
4. Screw tilter onto oil filter moulding. Once the filter starts
to feel firm tighten another 3/4 of a turn.
5. Add 1.0 litre of specified oil.
Specified Oil ................. SG/CE or SG/CD Engine Oil
6. Check oil level, then start engine, check for oil leaks
around the oil fi Iter.
7. If a minor leak tighten the oil filter another 1/3 of a tum.
If a major leak check the seal is correctly located into seal
groove, or check the filter has been installed correctly.
Engine Oil Dip Stick
Tu020
Oil Capacity:
6 Cylinder (including filter): ......................... 5.5 litres
8 Cylinder (including filter): ......................... 5.0 Iitres
AIR FILTER
6 Cylinder MPEFI Engine

Remove
1. Disconnect air filter lower housing upper housing snap
clips.
2. Remove air filter element.
LUBRICATION
The recommended oil quality should be used, as vehicles

under go extreme conditions, therefore the engine must be
correctly lubricated at all times.
Oil Quality .................... SG/CE or SG/CD Engine Oil
",I"'I-
o
SAE
viscosin
Install
1. Fit the new or cleaned air filter element into air filter
housing.
2. Replace the clips on the air filter housing.
8 Cylinder SEFI Engine
Remove
clips.
2. Remove air filter element.
Install
I. Fit the new or cleaned air filter element into air filter
-20
Tu019
OIL FILTER
* The oil filter should be changed every 10,000 Kilometres

or6 months whieheveroccurs first, the filteris a replacement
type and can not be serviced.
Replacement
I. Unscrew oil filter with a suitable oil filter wrench, then
remove taking care not to spill oil.
2. Before fitting new oil filter smear the sealing ring with oil
to help prevent oil leaks.
3. Fit a new seal to oil filter, it should be located in the groove
on the top of the filter.
hou~ing.
2. Replace the clips on the air filter housing.

INSPECT AIR FILTER
(a) Inspect the air cleaner element to ensure it is not
excessively damaged, dirty oroily.

(b) Clean the filter element with compressed air. First clean
the inside thoroughly, then clean the outside of the clement.
to cross thread the compression tester into the head.

4. Remove the and fuel injection relay found in the fuse box
behind the front suspension strut tower left side.
5_ Have an assistant hold the accelerator down to the floor.
HIGHTENSION LEADS
6. Crank the engine over several times on the starter motor
Inspection of High Tension Lead.

1. Carefully remove high tension Lead and robber boot from
Spark Plugs.
Pulling on or bending the cords may damage the conductor
im;ide.
2. Examine resistance of high tension lead with distributor
cap.
Check that the resistance does not exceed the maximum
using an ohmmeter.
Maximum resistance ....................... 25 k ohms I lead
and record the highest test.

7. Repeat this test on all cylinders.
The readings should be similar and be between 100 to 650
kPa.
Compression Test Results
EVEN PRESSURE ON ALL CYUNDERS Even pressure
on all cylinders after several cranks of the engine on the
starter motor. This would be expected from an engine in good

state of repair.
LOW BUTIMPROVES WITH OIL Low compression with
the first compression test, however after adding a table spoon
of oil through the spark plug hole the test reading is vastly
improved. This would indicate womrings.
WW DOES NOT IMPROVE WITH OIL This would
indicate either broken rings on faulty valves.
TWO CYUNDERS GWE WW READING EVEN WITH
OIL OTHERS OK. This would indicate a faulty head gasket
or warped head.
Resistance: 25k ohms f lead
Ohm meter
Spark plug lead
REPLACE DRIVE BELTandADJUSTBELT

TENSION
High Tension Leads
Inspection
Some belt squeal when the engine is started or stopped is
normal and has no effect on durability of drive belt.
Visual Inspection
Condition of the belt is bestjudged byviewing the bellS ribed
surface.
Inspect the terminals, and replace the high tension lead and!
or distributor cap if more than maximum specified.
COMPRESSION CHECK
Use a screw in type of compression tester gauge, as these

are much more accurate than the testers which are held
against the spark plug hole.
1. Engine must be at normal operating temperature.
2. Remove all of the spark plugs.
3. Install the compression tester into No I spark plug hole.
the tester unit must be screwed in fll1l1ly.
Stages of Belt Wear:
1. NEW BELT: Cracks or chunks.

2. MODERATELY USED BELT: Few cracks; some
wear on surfaces. Replacement not required.
3. SEVERELY USED BELT: Several cracks per inch.
Should be replaced before chunking occurs.
4. FAn .ED BELT: Separationofbeltmaterial from backing
(chunking). Replace belt immediately.
---'----the spark plugs and

Install a compression gouge
In the spark plug hole. Screw
DRIVE BELT
Drive belt must be checked often to ensure that it is still in

good operating condition, also pulley misalignment should be
checked to reduce belt wear. Damaged belts should be
replaced.
compression testers
give the most accurate
BELT ADJUSTMENT
Incorrectly adjusted drive belts will cause belt squeal and

components will not be driven. Belts that areovertensioned
can damage component bearings. Belts that are tensioned
correctly reduce noise and extend the life of the drive belt.
Aluminium heads are quite soft, so care must be taken not
Coolant Specification: e.g_

6 Cylinder Engines ______________________ Motorcraft RI-3B
V8 Engines _______________________ Motorcraft Rl-32, Rl-33
Do not combine different types of antifreeze or
corrosion inhibitors as they may be incompatible_ If a
different type has been used in the cooling system
rinse the system with clean water_
2_ Tum the heater control to maximum heat, this will help
disperse any air trapped in the heater.
3_ The engine coolant will need the coolant bleed plug
removed to allow the air trapped to be released trom the
engine. 6-Cylinder engines have two air bleeder plugs,
situated on the intake manifold.
After the air has been dispersed from the system refit the
bleed plugs, and continue to fill the cooling system.
4_ Fill the radiator, replace the radiator cap.
Replace
Belt Mar1<ing
Belt Tensioner
Assembly
Wear
Idler
Marking
Pully
New Belt
Mar1<ing
Co016
Belt's that have operated for 10-15 minutes are treated as a

used belt, and adjusted to used belt specification.
BELTTENSION_
The vehicles havea self adjusting idJerpulley setup on them,

which means they will neverneedadjustingforthe lifeofthe
belt. They have a wear mark indicator on the idler pulley
mounting swivel bracket that indicates when the belt will
need replacing.
BELTREPLACEMENTwlth Idler Pulley
1_ Fit3/S" dri ve socket bar to idler pulley mount bracket, and

remove tension from belt by moving clockwise.
Tensioner
Assembly
Slot For Socket

Bar To Release
Tensioner
S_ Run the
until it reaches
temperature,
allow the engine to cool, relea<;e the radiator cap this will also
help remove any air locks in the system.
'Loosen the air bleed plug, if air is present allow airloescape
from the system, after the air has been di spersed retighten the
bleed plug.
6_ Top-up system with specified coolant if required.
Tensioner
Mounting Point
Tensioner
Idler PUlly
Co021
2. Remove the belt from all pulleys, then remove belt from
vehicle.
3_ Fit new belt over pulleys and apply tension by releasing
idlertensionerpulley.
4_ Check that tensioner markings are incorrect position if out
of tension markings replace tensioner.
COOLING SYSTEM
INSPECTVALVECI EA.R ANCE
Top-up or refill of Coolant

1. Removecoolant cap and fill cooling system with specified
coolant mixture.
Six cylinder and VS's have non adjustable rocker arm

assemblies.
10

BATTERY INSPECTION
BATTERY CHARGING
TESTING BATTERY ELECTROLYTE (ACID)
WARNING: When batteries are being charged explosive

gas mixture Jorms beneath the cover oj each cell.
Do not smoke near batteries on charge or which have
A hydrometer should be used to detennine the specific

gravity ofbattery electrolyte. The reading obtained indicates
amount ofunused sulphuric acid remaining in electrolyte and
state of charge of battery.
The reading obtained will vary in relation to the temperature
of the electrolyte. As the temperature rises the density of the
electrolyte decreases and the specific gravity falls. As the
temperature falls the density increases and the specific
gravity rises.
recently been charged.

Do not break live circuit at tenminalsofbatteries on charge.
A spark will occur where the live circuity is broken. Keep
all open flames away from battery.
NB: Fast charging will provide sufficient charge after one
hour to enable the battery and alternator to carry electrical
load however, whenever possible, slow charging is preferable.
Specific gravity of 1.26 indicates

a fully charged battery.
SPARK PLUG INSPECTION-6 cylinder & V8
1. Clean and Inspect Spark Plugs.

(a) Clean the spark plugs using a spark plug cleaner or wire
brush.
(b) Examine the spark plugs for electrode wear, thread
damage and insulator damage. Replace the plugs ifa problem
is found.
2. Adjust Electrode Gap.
Bend the outer electrode carefully to obtain the correct
electrode gap.
_Hydrometer
Feeler Gauge
Battery
USING THE HYDROMETER

1. Liquid level ofbattery cell should be at nonnal height and
electrolyte should be thoroughly mixed with any battery
water which may have just been added by charging battery
before taking hydrometer readings.
2. Draw electrolyte in and out of hydrometer barrel several
times to bring temperature of hydrometer float to that of the
acid in the cell.
3. Draw sufficient electrolyte into hydrometer barrel with
the pressure bulb fully expanded to lift float so that itdoes not
touch the sides, bottom or top of barrel.
4. Read the hydrometer with the hydrometer in a vertical
position.
TEST RESULT INDICATIONS
Electrolyte specific gravity ... Battery Charge Level.
1.240 to 1.260 .................................................... 100 %
Bend the outer electrode carefully

to obtain the correct electrode gap.
--
~----~-
gap:
V8 Correct electrode gap:
mm
1.3 - 1.4 mm
3. Spark plug type.

6 Cylinder:
4.0L
Motorcraft- AGS33CC
4.0L (XR6) Motorcraft- AGS23CC
3.2/3.9L
Motorcraft- AGR47Cull
V8: 5.0L
Motorcraft- ASF42C
5.0L Sprint Motorcraft- A WSF-32C
4. Torque plug to correct specification.
Spark Plug Torque specification:
20 Nm
1.210 to 1.24() ...................................................... 75%

1.180 to 1.210 ...................................................... 500/0
Below 1.130 .............. _....... _.. Completely discharged.

Abattery should be charged if the specific gravity is less than
1.210.
!fthereis more than 0.25 specific gravity variation between
cells then a fault is most likely with the battery itself.
!f battery charge is low and battery is serviceable, check
alternator operation and all electrical connections.
FIRING ORDER
The fitingorderforlhe6cylinderengines is 1-5-3-6-2-4 and

the fIring order for V8 engines is 1-3-7-2-6-5-4-8.
DEPRESSURISE FUEL SYSTEM
1. Tum engine off.

2. Remove the Fuel Pump fuse, situated near the battery.
11
ENGINE TUNEUP & MAINTENANCE
3. Turn ignition on and start engine. allow engine to idle until

it stops. Turn key off and try to start engine again. 1bis will
depressurise the fuel system.
FUEL FILTER
Remove
1. Relieve fuel pressure as described earlier.
2. Place a container under the fuel line at the rear of the
vehicle near the fuel tank. release the fuel pipe fittings
attached to the fuel ftlter.
3. Allow the excess fuel to drain into the container.
4. Remove ftlter retaining bolt and remove the filter.
Install
1. Check for the direction flow arrow on the side of the fuel
ftlter, the arrow must point towards the front of the vehicle.
2. Slide the fuel ftlteronto position and install retainer bolt.
3. Connect pipe fittings to filter and tighten.
4. Start engine, with pressure in fuel line. check for leaks at
pipe fittings. ensure that there are no leaks before moving
vehicle.
\\
Plug Lead
5. Starr engine, the engine idle speed will increase to about

1500 RPM, this indicates the self test mode is in operation and
the base timing can now be checked using timing light.
6.Ifbase timing is not correct loosen thedistributorretaining
boltand movedistributoruntil thedesiredreading is achieved,
lock up the retainer bolt and check timing again.
Base Timing:
6 Cylinder ................................................... 10" BTDC
V8 ....................................................... 3()'1 BTDC +/- 2
Checking Base Timing

1. Connect Tachometer and Timing Light to engine.
7. Ignition Timing will move away from the base timing

marks when the self test is disconnected.
A tachometer connection is found in the loom near the brake

booster, along with the sel ftest unit connections, the connec
tor is located within the fuse panel.
* As some tachometers and timing lights are not compatible
with this ignition system, we suggest that you check the
compatibility of your unit before using.
Ignitiontiming:
The ignition timing is not able to be changed, once the base

timing has been set in the correct position and the selftest has
been disconnected the computer will take control of the
timing and return to normal operation.
Inspection of Ignition Coil.
1. Disconnect High Tension Lead
Inlake Manifold
temperature
must at
the base timing should bechecked or altered, also ensure that
the timing marks are clean and easy to distinguish. Engine
must be switched off before continuing.
3. Using the diagnostic unit connect into the self test
connector and follow instruction manual until base tinting
check can be done.
4. (a) If diagnostic unit is notavalible a piece of wire with an
al ligatorcJip one end and spade terminal theothercan also be
used.
(b) The spade terminal is to be connected into the self test
inputterminal and the alligatorclip is to be connected toearth.
2. Check Primary Coil Resistance. Measure the resistance

between the positive (+) and negative (.) terminals using an
ohrnnleter.
Primary coil resistance (ohms):
25C +1- SoC ................................................. 0.41-0.45
12
5. Fit the high tension leads tothetopofthecoil pack,ensuring

that they are on there correct posts, then clip the wiring loom
IOtO Its connector.
6. Lower the vehicle from its stands and fit the battery
terminal, then start the vehicle and check its operation.
CHECK FUEL MIXTURE
Ohmmeter
Method with CO Meter

1. Visually Inspect E.F.1. system
(a) Check for loose screws or a loose mounting to the
manifold.
(b) Check for wear in the linkage, missing snap rings or
excessive looseness in the throttle shaft. Correct any
problems found.
2.lnitial Conditions:
(a) Air cleaner installed.
(b) Normal operating coolant temperature.
(c) All accessories switched off.
(d) All vacuum lines connected.
Cables
Ignition
Coli
Primary
Tennlnals
Tu112
3_ Check Secondary Coil Resistance. Measure the resistance between the positive (+) and high-tension tenuinal,
using an ohmmeter at idling.
Secondary coil resistance (ohms):
25C +/a SoC ................................................. 7.12-7.87
4. Examine Power Source Line.
With the ignition at ON and using a voltmeter, connect the
positive (+) probe to the (+) tenninal of the coil and the
negative (-) probe to the body ground.
Voltage ................................................... Approx. 12V
Examine the ignition switch and wire harness if a problem is

found.
INSPECTION OF COIL PACK
Check electrical connections and tenninals, condition of

component.
IGNITION COIL
(e) Ignition timing set correctly.

(I) Transmission in the .oN" range.
(g) CO meter operating normally.
3.Check Idle Speed.
(a) Start the engine.
(b) Using a CO meter to measure the CO concentration in
the exhaust before the catalytic converter.
Idle speed:
Remove
1. Remove the wiring connector to the coil.
2. Remove coil block by removing the 2 attaching bolts.
Install
1. Install coil and tighten attaching bolts to specified torque.
Coil Attaching Bolts
6 Cylinder .................................................... 7 - 8 Nm.
vs ............................................................. 17-23Nm.
2. Connect wiring looms.
16 .................................................................... 700-800
V8 ................................................................... 700-800
3. Start engine and ensure engine operates corrcctly.
4.Jnspect CO Concentration.
(a) Check that the CO meter is properly calibrated.
(b) Race theengine30-60secondsatabout2,OOOrpm before
measuring concentration.
(c) Wait 1-3 minutes after racing the engine to allow the
concentration to stabilize.
Idle CO concentration:
COILPACK
Replacement
1. Reomve negative battery terminal, then raise the vehicle
and support on stands.
2. Detach the wiring loom from the botom of the coil pack,
then the high tension leads from the top.
3. Release the retaining screws, then lift the coil pack and
suppressor from the vehicle.
4. Fit the new coil pack and suppressor to its mounting point,
then secure using the retaining screws.
6 Cylinder ................................................ 0.50/0-1.00/0

V8 ............................................................. 0.5%-1.00/0
13
Problem Diagnosis:
a sensitive volt meterthatcan be adjusted to read milli amps

is required. If using a test light make sure the light is a low
powered unit to obtain an accurate result.
The ECCS has the ability to diagnosis information from the
The battery earth cable must be disconnected from the

battery before any sensors or the Electronic Control Combustion System is removed or disconnected. If a vehicle has
been painted and the paint is to be cured in a paint oven the
ECCS must be removed. The ECCS is a small complicated
computer located behind the kick panel in the front passenger
side.
Electrical connections arc developing into a major problem
with vehicle break downs. Therefore check that all connections including battery connections are clean and making
good electrical contact.
As the ECCS is very sensitive to electrical fluctuations,
therefore always have the ignition system tumedoffbefore
disconnecting any wiring looms at the ECCS. For the reason
just described electrical welding should neverbecarried out
to the vehicle or any trailer etc. attached to the vehicle while
the battery earth cable is still connected to the battery.
Most voltmeters arc now digital type, whilecarryingoutany
tesl'or problem solving itnecessary to use adigital voltmeter,
various sensors on the engine.
lfthe ECCS diagnosis a fault, the fault is stored in the ECCS.

However the ECCS will loose codes stored, if the power
supply is removed from the ECCS. This can be done by
disconnecting the battery for 10 seconds or more, or removing the "fuse number 10" for I0 seconds or more.
Faultcodes stored by the ECCS can be interpreted by checks
the flashing of LED lights.
The ECCS will flash the code via the two LED lights on the
side of the ECCS unit. Provided that:
Diagnostic mode selector has been turned fully anti
clockwise, if not already in this position.
'Throttle valveswitch must be connected with wiring looms.
* Engine at operating temperature and operating between
l800-2200rpm.
NOTE: For futher information see trouble shouting and
disgnosis chart chapter of this manual.
Memo
14
EMISSION CONTROL
Page
GENERAL PRECAUTIONS.
General Precautions ................................ 15
1. Know the importance of periodical maintenance.

a) Every service item in the periodic maintenance list must be
performed.
b) Failing to do even one item can cause the engine to run
poorly and increaseexhaustemission.
2. Determine if its an engine or emission system problem.
a) Engine problems are usually not caused by the emission
control systems.
b) When troubleshooting, always check the engine and the
ignition system first.
3, Check hose and wiring connections first.
The most frequent cause of problems is simply a bad wiring
or vacuum hose connection. Always make sure that all
Description
Vehicles Precautions with Catalytic Converter ............. 16
Emission Control SysteDlS ......................................... 17

PositiveCrankcaS<!VentiiationSystem(pCV) .......... 17
Evaporative Emission Control System (EVAP) ........ 18
Fuel Vapour Lines, Tank & Cap Inspection ................. 18
Carbon Canister Inspection ........... ,' ............................ 18
Heated Exhaust Gas Oxygen Sensor ......................... 18
Exhaust Gas Recirculation System (EGR) ................ 19
connections are secure and correct.
4. Observe the following precautions to avoid damaging

parts:
a) To disconnect vacuum hoses, pull on the end, not the
middJe of the hose.
b) To pull apart electrical connectors, pull on the end, not the
middle of the wire(s).
c) Be careful not to drop electrical components, such as
sensors or relays. If they are dropped on a hard surface, they
should be replaced and not reused.
d) When steam cleaning engine, protect the distributor, coil,
air filter, manifold intake and EGR vacuum unit from water.
e) Never use an impact wrench to remove or install thermo
switches or thermo sensors.
f) When checking continuity at a wire connector, insert the
tester probe carefully to prevent terminals from bending.
g) When using a vacuum gauge, never force the hose onto a
connector that is too large. Use a step-down adapter instead.
Once the hose has been stretched, it may leak
5. Tag hoses before disconnecting them:
a) When disconnecting vacuum hoses, use tags to identify
Exhaust & Catalytic Converter ................................. 19
Exhaust Pipe Inspection ..............................................

Catalytic Converter Inspection .....................................
Heat Insulator Inspection .............................................
Catalytic Converter Replacement .................................
19
19
19
19
15
EMISSIONS
hoses and mark how they should be reconnected.

b) After completing a job, double check that the vacuum
hoses are properly connected.
6. When replacing components use a new component if a
second hand component can not be tested.
7. Perfonn work safely.
a) Uthe vehicle is to be jacked up only at the frontorrearend,
be sure to block the wheels.
b) After vehicle isjacked up always support it on stands. It
is extremely dangerous to do work on the vehicle raised on a
jack alone, even for a small job that can be finished quickly.
c) Disconnect the battery cable from the negative tenninal of
the battery to make work safer when replacing electrical parts
'F
'00
..
201-
60
'01'0
20
o
-20
SAE VtSCOSIH
or working on parts near an electrical source.
(7) Allow enough time for the piston rings to seat. Replace
worn or broken rings as needed, ifrings have been incorrectly

installed, worn or broken, or not seated.
(8) Piston incorrectly installed or misfitted.
Gaskets.
(I) Incorrectly tightened fastenersordamagcdldirty threads.
(2) Worn or damaged gasket (cracking or porosity).
(3) Ruid pressure/level too high.
(4) Incorrect sealant used (when required)
Inspection of Seals.
(I) Damaged seal bore (burred, nicked, scratched)
(2) Worn or loose bearing which causes excessive seal wear.
(3) Worn or damaged seal or incorrect installation.
(4) Fluid pressurellevel too high.
Oil Leak Investigation
Oil leaks are easily located and repaired by visually finding
the leak and replacing or repairing the required parts.
(I) Determine whether the fluid is transmission lubricant,
PRECAUTIONS FOR VEHICLES EQUIPPED

WITH A CATALYTIC CONVERTER
WARNING: lfIarge amounts of un-burnt gasoline flow into

the catalytic converter, it may overheat and create a fire
hazard.
To prevent this, observe the following precautions:

I, Use only unleaded gasoline.
2. Avoid prolonged idling.
Avoid running the engine at fast idle speed for more than 10
minutes and at idle speed for more than 20 minutes.
3. Avoid sparkjump test.
a) Pcrfonn spark jump test only when absolutely necessary
and as quickly as possible.
b) Never race the engine while testing.
4.A void prolonged enginecompressionmeasurement.Enb~ne
compression tests must be made as quickly as possible.
S. Do not run engine when fuel tank is nearly empty.
This may cause the engine to misfIre and create an extra load
on the catalytic converter.
6. Avoid coasting with ignition turned off and prolonged
engine braking.
7. Do not dispose of used catalytic converter along with parts
engine oil, powcrsleering OuidclC.
(2) Run the carat normal operating temperature and park the
car over a large sheet of paper. After a few minutes, you
should be able to find the approximate location of the leak by
drippings on the paper.
(3) Using a degreaser or steam to clean the area of the leak,
drive the car for a few kilometres. The visually inspect the
suspected part.
Black Light and Dye Method.
There are many dye and light kits available for finding leaks.
(a) Pour required amount of dye into leaking part.
(b) Operate the car under nonnal operating conditions as
instructed in the kit.
(c) Shine the light in the suspected area. The dyed fluid will
appear as a yellow path leading to the problem.
Low Oil Pressure
(I) Blocked oil filter.
(2) Incorrect oil viscosity for expected temperature, or oil
diluted with moisture or un-burnt fuel mixtures.
(3) Excessive bearing clearance.
(4) If the oil level is low, fill to mark on dipstick.
(5) Oil pump dirty/worn, or oil pump suction pipe screen
contaminated with gasolineoroil.

EXCESSIVE OIL CONSUMPTION.
High Oil Loss
(I ) Tighten bolts and/or replace gaskets and seals as required

for external leaks.
(2) Check oil with car on a level surface and allow adequate
drain down time to ensure a correct reading of dipstick.
(3) Severe usage such as towing or continuous high specd
driving will normally cause oil consumption to increase.
(4) PCV system failure.
(5) Use recommended S.A.E viscosity for current temperatures. Refer to LUBRICATION Section for details on
incorrect oil viscosity.
(6) Valve guides and/or valve stem seals worn, or seals
omitted. Ream guides and install oversize service valves and/
or new valve stem seals.
16
EMISSIONS
blocked, or hole in oil pump suction pipe.

(6) Incorrect or failing oil pressure sender.
Check that air passes through easily.

WARNING: Do not suck air through the valve.
Petroleum substances inside the valve are harmful.
ENGINE KNOCKS
WHEN ENGINE COLD AND CONTINUES KNOCKING FOR TWO OR THREE MINUTES
Increa<es with torque
(I) Tighten or replace as required ifdri ve pulleys or balancer
are loose or broken.
(2) Replace piston if clearance from piston to bore is excessive. (Cold engine piston knock usually disappears when the
cylinder is grounded out. Cold engine piston knock which
disappears in 1.5 min. can be considered acceptable.
(3) Connecting rod bent.
HEAVY KNOCK WITH TORQUE APPLIED
(I) Replace as required, pulley hub or balancer broken.
(2) Loose torque converter to tlexplate bolts.
(3) Check if exhaust system contacting underbody.
(4) Check for cracked tlexplate/tlywheel.
(5) Main bearing clearance or connecting rod bearing c1ear.
anceexcesslve.
PCV VALVE 8 Cylinder
LIGHT KNOCK HOT

(I) Inspect fuel quality if pre-ignition or spark knock.
(2) Check for loose toque converter to tlexplate bolts.
(3) Check connecting rod bearing clearance is notexcessi ve.
KNOCKS ON FIRST START-UP ONLY LASTING A

FEW SECONDS
(I) Incorrect oiviscosity. Install correct oil viscosity for
expected temperatures.
(2) Hydraulic lifter bleed down.
Some valves will be open when the engine is stopped. Spring
force against lifters will tend to bleed lifter down. Only if the
problem is consistent should repairs be anempted.
(3) Replace crankshaft thrust bearing shells if excessive
crankshaft end tloat.
(4) Replace worn parts if front main bearing clearance is
VALVE 6Cylinder
4. Blow from intake manifold side.

Check that air passes through with difficulty.
If the PCV valve fails either of these checks, replace it.
5. Reinstall PCV valve into rocker cover.
INSPECfION OF PCV HOSES AND
CONNECTIONS.
Visually inspect hoses, connections and gaskets.
Check for cracks, leaks or damage.
excessIVe.
EM MISSION CONTROL
SYSTEMS
Postive Crankcase Ventilation (PCV) valve operation

Engine not operating or backfire
while engine operating
Engine operating under

normal conditions
POSITIVE CRANKCASE
VENTILATION (PCV)
SYSTEM.
INSPECTION OF PCV VALVE
1, Remove PCV valve from rocker cover.

2, Attach clean hose to PCV valve.
3. Blow from cylinder head side.
Em004
17
EMISSIONS
Check operation of PCV valve by
gently blowing through a PCv valve
Air should blow through one way only
Clean hose
Em005
HEATED EXHAUST GAS

OXYGEN SENSOR
(HEGO)
EVAPORATIVE EMISSION
CONTROL (EVAP)
SYSTEM.
The exhaust gas oxygen sensor uses a signal to provides the

ECU with information determining iftheengine is running to
rich or lean, so fuel mixturecan beadjusted to accommodate.
Remove MPEFJ
Disconnect the electrical connection and unscrew the sensor
from the exhaust manifold .
Install
INSPECTION OF FUEL VAPOUR LINES,

FUEL TANK AND TANK CAP.
..... Sender Unit
and Pump
Assembty
Location
Sedan Fuel Tank
Apply antiseize compound to the thread of the sensor the

screw into mani fold and reconnect electrical connections.
HEGO Sensor torque specification .................... 40 Nm
Remove - SEFI
Disconnect the electrical connections from the sensors, then
unscrew sensors from the catalytic converter inlet pipes.
Install
Apply antiseize compound to the thread of the sensors then
screw the sensors into the catalytic converter inlet pipes and
reconnect electrical connections.
HEGOSensortorquespecification .................... 40 Nm
1. Visually Inspect Lines And Connections.

Look for loose connection, kinks or damage.
2. Visually Inspect Fuel Tank.
Look for deformation, cmcks or fuel leakage.
3. Visually Inspect Fuel Filler Cap.
Look for a damaged or deformed gasket and cap.
Tf necessary, repair or replace the cap.
INSPECTION OF CARBON CANISTER.
1. Visually Inspect Carbon Canister.
Look for cmcks or damage.

2. Check for fuel leakage around bottom of canister.
NOTE: Do not attempt to wash the canister. No activated
carbon should come out.
18
EMISSIONS
EGR VALVE
INSPECTION OF CATALVTIC
CONVERTER.
TheEGR valvecontrolstheamountofexhaustgasrecirculated
back into the inlet manifold which helps keep reduce the
combustion temperatures of the fuel air mixture.
Remove
1. Disconnect the electrical connections for the EVP sensor
and the vacuum hose for EGR, then remove the nuts securing
the EGR valve.
Check For Dents or Damage.

lf any part of protector is damaged ordented to the extent that
it contacts the catalyst, repair it or replace it.
INSPECTION OF HEAT INSULATOR.
I. Check heat insulator for damage.

2. Checkforadequatecleamncebetweencatalyticconverter
and heat insulator.
REPLACEMENT OF CATALVTIC
CONVERTER.
I. Remove Catalytic Converter.

(a) Jack up the vehicle.
(b) Check that the converter is cool.
(c) Remove the bolts at the front and rear of the converter.
(d) Remove the converter and gaskets.
2. Install Catalytic Converter.
(a) Place new gaskets on the converter front and rear pipes,
and connect the converter to the exhaust pipes.
(b) Tighten the bolts.
2. Remove EGR valve assembly and disregard gasket.
ImtaII
1. Install the EGR valve using a new gasket, then install and
tighten the retaining nuts.
EGR valve retaining nut specification ....... 15-17Nm
2. Reconnect electrical connection to EVP sensor and EGR
Catalytic Converter
Exhaust
Pipe ___
I
.'
.-"
vacuum line.
EXHAUST & CATALYTIC

CONVERTER
--/
Exhaust
Pipe
Catalytic Converter
Stainless Steel Outer Shell
,/
Ceramic monlith
with platinum rhodium

palladium
EX0021
ExOO71
Catalytic Converter- ExhaustPipe ............... 31-42Nm

(c) Reinstall bracket bolts and tighten them.
INSPECTION OF EXHAUST PIPE

ASSEMBLY.
Exhaust Gas
In
Catatytic Converter
Exhaust
Pipe
Exhaust Gas
Nitrogen & Water Vapour
1. Check Connection For Looseness or Damage.

2. Check Clamps For Weakness, Cracks, or Damage.
19
6 CYL ENGINE MAINTENANCE &

REBUILD
Subject
Page
Subject
GENERAL DESCRIYfION .................................... 22

Engine Serial Number .................... ....................... .. .... 22
MaintenanceHints ................................... _.................. 22
Page
Cylinder Head ........................................................... 26

Removal .... ....... _'.' .'.. '.' .'.'.. '.................. _, _, .................. 26
Inspection ... ..... .... ..... ....... ...... ... ..... .. ........... ..... _.......... 27
Installation ................................................................. 27
Cylinder Head Recondition.ing .................................. 28
Dismantle ..... ....... .... ..... ... ..... ...... ... ........... .................. 28
Clean ......................................................................... 28
Cylinder Head Inspection ............................................ 28
Valve Guides .............................................................. 28
Clearance Checking ............................ ........................ 28
Val ve ScalS ................................................................ 29
Replacing Valve Seat .................................................. 29
Valve Springs ............................................. ............. .. . 29
GENERAL MAINTENANCE ................................. 22

Oil Filter .................................................................... 22
Replacement ............................................................... 22
Compression Check .................................................... 23
Compression Test Results ........................................... 23
Drive Belts ................................................................ 23

Inspection .... .... ... ......................... ............................... 23
Stages of Belt Wear .................................................... 23
ReplaceIt1enl ............................................................... 23
Intake Manifold Assembly ................................. 23
ReIllOve ...................................................................... 23
Jnstall ......................................................................... 23
ExhaustManifold ...................................................... 24
ReI110val ..................................................................... 24
Installation ... .............................................................. 24
Rocker Cover &lor SeaJ ........................................... 24
Removal ..................................................................... 24
Installation ........ ........... .............................................. 24
w_ ........................................................................ ~
Valve Spring Install Height ......................................... 30

Assemble ..................................................... ....... ..... ... 30
Cran.k.shaftBalancer ................................................. 30
ReTTlOvai ..................................................................... 30
Installation ................................................................. 30
Timing Chain Tensioner ........................................... 31
Removal ......................... .............................. ...... .. ..... . 31
Clean & Inspect ....................................................... ... 31
Installation ....................... ................................. ....... .. 31
Timing Chain Cover and Chain ................................ 31
Removal ..................................................................... 3 1
Installation ... .............................................................. 3 1
Timing Cover Chain Oil Seal .................................... 32
Replace ...................................................................... 32
Camshaft ................................................................... 32
CheckVa]veTiming ................................................... 32
Measure Camshaft Lobe Lift ....................................... 32
ReI110vai ..................................................................... 32
Inspection ................................................................... 32
Camshaft Bearing Service .......... ................................. 32
Rocker Arms & Shaft Assembly ............................... 24

Removal .. ... ......... .... ....... ........................................ .... 24
Clean & Inspect ..................... ..................................... 25
Installation ...... ........................................................... 25
Valve Stem Oil Seals ................................................. 2S

Replacement ............................................................... 25
HydraulicLashAdjusters ......................................... 25
Removal ............................. ........................................ 25
Dismantle ....... ........... ........... ... ..... ................. ............ . 26
Clean & Inspect .... ... .. ......... ......... ......... .. ..... .... ....... .... 26
Assembly ......... ...... .................................................... 26
Testing Lifter .............................................................. 26
Installation ................................................................. 26
20
6 CYLINDER ENGINE Maintenance & Rebuild
Subject
Subject
Page
Engine Mounts ......................................................... . 32

Front Mounts ............. ................................................ 32
Page
Assembly ...... .. ............. .. ........................ .................... 37

Main Bearings ........................................................... 37
Inspeclion .................................................................. . 37
Replacement With Crankshaft Installed ....................... 38
Replacement With Crankshaft Removed ...................... 39
Connecting Roo Bearings ......................................... 39
Inspection & Replacement ........................................... 39
CamshaftJournais .................................................... 42
Piston & Connecting Rod Assem bly ........................ 42
Removal .................................. .............................. ..... 42
Dismantle .................................................................. . 43
Inspection ................................................................... 43
Assembly & Installation .............................................. 43
Piston Rings .............................................................. 44
Installation ................................................................ . 44
Crankshaft .. ............................................................. . 45
Removal .... ....... ........ ....... ...... ... .... ........... ..... ....... ..... .. 45
Inspection ...................................... ................ ............ . 46
Installation ........ ........................................................ . 46
Rear Main Oil Seal ................................................... 47
Replace ..................................................................... . 47
Cylinder Block .......................................................... 47
tnspection ........................................................... ........ 47
Cylinder Reconditioning & Piston Fitting ..................... 48
Rel1lOval ,_ .................................................................. . 32
installation ................................................................. 33
Rear Mount 33
Removal ... ................................................................. . 33
Installation ....................................... _... _.... _._............. . 33
FlywheeVDriveplate ................................................. . 33
Removal .......................................................... ...... ..... 33
fnspection .. .. .............................................................. . 33
Installation .. ... ... ............ ... ....... .... ................ ..... .......... 33
Ring Gear 33
Replacement ......................... ......... ............ ........ ......... 33
Spigot Bearing ......................................................... . 34
Replacement ........................................ ....... .... ......... ... 34
ENGINE REBUILD 34
Engine Assembly ...................................................... . 34
Rernova1 .. ..................................... ............................. . 34
Dismantle ................................................................... 35
Assembly .. .. .. .......... ..... ... .......... ... ...... .. .. ..... .. ............. 36
Insta1lation .. .. .................... ...................... .................. . 36
Oil Pan (Sump) & Gasket ....................................... 36
Remova1 ..................................................................... 36
tnstallation .......................................................... ....... 36
Oil Pump Suction Pipe & Screen .............................. 36
Remova1 ........ ...... ....................................................... 36
PROBLEM DIAGNOSIS ........................................ 49
Installation .............................................. ................... 37

Dismantle ................. .................................................. 37
Inspection ................................................................... 37
SPECIFICATIONS .................................................. 50
TORQUE WRENCH SPEClFICATlONS .... 51
21
6 CYL ENGINE
MAINTENANCE &
REBUILD
4. (a) When raising or supporting the engine for any reason,

do not use a jack under the oil pan. There aresmall clearances
between the oil pan and the suction pipe screen, so jacking
may cause the oil pan to be bent against the screen, with
damage being done to the oil suction pipe assembly.
(b) If the air flow ducLing is removed or disconnected, the
intake opening should be covered to avoid accidental entrance
offoreign material (which could follow the intake passage
into a cy linder and cause extensi ve damage when the engine
is started).
GENERAL DESCRIPTION
GENERAL MAINTENANCE
The engine is an in line 6 cylinder with overhead camshaft.

They were produced ina4.0litre with aboreof92.25 mmand
astrokeof99.31 mm .
The 4.0 litre engine is a multi point injected engine only.
CHECKING ENGINE OIL PRESSURE
1. Ensure that engine is at operating temperature and disconnect wiring harness connector from oil pressure sender unit.
2. Loosen and remove oi Ipressure sender unit from cyl inder
block.
3. Install a suitableoil pressure gauge assembly intocylinder
block oil pressure sender unit hole.
4. Start engine and check oil pressure reading with engine
running under no load.
Oil pressure: ...................... 2000 rpm - 280 kPa (min)
5.(a) Aftercompleting test, apply LOCfITE 243 sealant or
equivalent to sender unit threads.
(b) Install and torque sender unit.
Torque .................................................. 12.0 - 14.0 Nm.
(c) Install wiring harness connector, start engine and check
for oil leaks.
ENGINE SERIAL NUMBER
Engine No. Location for 6 cylinder engines.

*6cylinderenginenumberissituatedon thefrontupperright
hand sideofthecylinderblock directly below the numberone
spark plug.
OIL FILTER
II Filter
Metal casting
Screw on type Oil Fitter
MAINTENANCE HINTS
I. (a) When any internal engine parts are serviced, care and
cleanliness are imponant.
(b) An engine is a combination of many machined, honed,
polished and lapped surfaces with tolerances that are measured in thousandths of a millimetre.
(c) Friction areas should be coated liberally with engine oil
during assembly to protect and lubricate the surfaces on
initial operation.
(d) Propercleaning and protection of machined surfaces and
friction areas is part of the repair procedure and is considered
standard workshop practice.
2. When valvetraincomponentsareremoved for service, they
should be kept in order and should be installed in the same
locations (with the same mati ng surfaces) as when removed.
3. Battery terminals should bedisconnecred before any major
work is begun. If not, damage to wiring harnesses or other
electrical componentseould result.
;-=:-._-:. 7'-
r .
..--' -
>
* The oil tilter should be replaced every 10,000 Kilometres

or6 months which ever occurs tirst, or when the engine oil is
contaminutcd in any way.
Replacement
1. Unscrew oil filter with a suitable oil filter wrench, then
remove and discard.
2.(a) Make sure seal is plaeedcorrectly in recess in new tilter.
(b) Pour some clean engine oil into tilter until level is
approximately 2 ems below top of tilter.
3. (a) Smear some engine oil over tilter seal.
(b) Screw filter into place until seal contacts mating surface
of adaptor, then tighten through a funher 213 of a tum.
22
4. (a) Clean any excess oil from filter and adaptor.

(b) Check oil level, then start engine and check for oi I leaks.
(c) Repair as necessary.
o Afterrunning the engine, theoillevel must be rechecked and
oil added as necessary, to compensate for oil used to refill the
oil filter.
Condition of the belt is best judged by twisting the belt so

as to see the "Ribbed" surfaces.
I. NEW BELT: Cracks or chunks.
2. MODERATELY USED BELT: Few cracks; some wear
on surfaces. Replacement not required.
4. FAn .ED BELT: Separation of belt material from backing
(chunking). Replacebeltimmediately.
Replacement
Release belt tensioner using a 3/8" square drive socket bar
turning it clockwise. Remove drive belt from drive pulleys.
Replace belt, taking care the belt is fitted correctly. Tension
belt by releasing tensioner.
COMPRESSION CHECK
1. Make sure of the following:

(a) Engine is at operating temperature;
(b) Battery is at (or near) full charge;
(c) Spark plugs are removed;
(d) Remove the start relay and fuel injection relay from near
the battery housing (this stops both fuel injection and ignition
duringenginecranking).
2.(a) install suitable compression tester, then depress accelerator pedal to fully open position and crank engine.
(b) Read compression gauge indication.
3. Check remaining cylinders.
INTAKE MANIFOLD ASSEMBLY
Removal
1. Withdraw theair intakeducting, then disconnect the wiring
loom, vacuum hoses, accelerator and cruise control cables
and any other connections from the upper intake manifold
a<sembly.
2. Release the upper inlet manifold retaining bolts, then lift the
upper inlet manifold from the loower inlct manifold.
3. Detach fuel lines, vacuum hoses from the lower intake
manifold, then disconnect lower intake manifold loom at fire
wall and any components not attached to the manifold.
,ove the spark plugs and

InstaU a compression gauge
In the spark plug hole. Screw
compression testers
give the most accurate
Fuel Rail __
Assembly
oThe lowest reading of any cylinder should not be less than

IOOkPa of the highest and should not be less than 650 kPa.
01 fcylinder compression in I or more cylinders is low, pour
a small amount of engine oil into the cylinders through the
spark plug holes and test compression.
NORMAL Compression builds up quickly and evenJy on
each cylinder.
PISTON RINGS Compression low on I st stroke, tending to
build up on following strokes, but does not reach normal.
Improves considerably with addition of oil.
VALVES Low on I st stroke and does not tend to build up on
following strokes. Do not improve much with addition ofoil.
HEAD GASKET If cylinder compression in any 2 adjacent
cylinders is low (if adding oil does not help compression),
cylinder head gasket has blown out.
4. Release the lower intake manifold retaining bolts, then

withdraw the lowermanifold from the engine assembly.
Installation
1. Clean lower manifold to cylinder head gasket surfaces,
then with new gasket filled install the manifold assembly.
securing it in position with retaining bolts. Tension retaining
bolts to specifications.
2. Connect the wiring loom, fuel hoses and vacuum hoses,
then clean lower and upper manifold gasket surfaces.
3. Fit the upper manifold to the lower manifold with a new
gasket between, then insert and tension retaining bolts.
4. Connect vacuum hoses, loom connectors and accelerator
DRIVE BELT
Inspection
o Some belt squeal when the engine is started or stopped is
VNIallnspection
23
and cruise control cables.

5. Fit the air intake ducting, then start the vehide and test run
to ensure everything is in order.
2. Remove spark plug leads and breather hose.

3. Remove accelerator cable from mounting bracket.
4. Remove airdeaner and hot air inlet tube, on centre point
injection models only.
5. (a) Unscrew rocker cover to cylinder head fastenen; and
remove rocker cover from cylinder head.
Exhaust Manifold
Removal
t. Take the heat shield and the airdeaner intake shroud out.
2. Remove the HEGO (Oxygen)sensor using a 22 mm ring
spanner.
(b) If replacing rocker cover seal, remove seal from rocker
cover to head flange of cylinder and carn shaft bore plugs.

Installation
I.lf necessary, replacecarnshaft bore plugs and place seal on
rocker cover for rubber seal or cylinder head forcorkgasket.
* Make sure seal is correctly installed in rocker cover.
2. Install rocker cover to cylinder head and torque nuts.
Torque: Retaining nuts ................................. 7-12 Nm.
3. Install leads to spark plugs.
4. Install air deaner, hot air inlet tube, breather hose and
acceleratorcable.
5. (a) Connect battery earth lead.
(b) Start engine and check for oil leaks.
3. Detach the converter inlet pipe at the manifold flange and

remove the retaining bolts and the manifold, spark plug heat
shield and gaskets.
4. Detach the two sections of manifold.
Installation
t. Clean mating surfaces of the cylinder head and the
manifold.
2. Using anti-seize coat the threads of all nuts and bolts.
3. Place a new sealing ring on theconverterinlet pipe and new
sealing ring between the two sections of manifold and
construct leaving the nuts finger tight.
4. To align the gasket, install four guide studs in the cylinder
head. Place the gaskets and spark plug heat shield on the
studs. Placethemanifoldonthestuds. Install the bolts on the
lower holes, remove the guide studs. install the upper bolts
except for the two securing heat shield. Gradually tighten the
bolts to specification.
Exhaust Manifold Bolts specification ............ 37-45 Nm
5. Tighten the manirold flange nuts to specification.
Front Exhaust Pipe to Manifold Flange nuts .. 4O-55Nm
6. Install the air cleaner intake shroud and duct and the heat
shield.
7. Install and connect the HEGO (Oxygen)sensor after
coating the threads with anti-seize.
MEGO (Oxygen) Sensor tension ................... 37-45 Nm
ROCKER ARM AND SHAFT ASSEMBLY

It;s imp0l1ant that the original/oealian of aLI pivots and
arms is retained during assembly. so place components on
a suitable rack.
Removal
l.(a) Disconnect battery earth lead.
(b) Remove rocker covers as described above.
(c) Undo rocker arm shaft support bolts little at a time to
prevent distortion of the cam shaft working from the out side
to the middle, and remove bolts.
Gear
ROCKER COVER ANDIOR SEAL
-'.
Removal
1. Disconnect battery earth lead.
24
2. Lift rocker assembly and remove taking care not to drop

the lash adjusters out of the rocker arms.
3. Place assembly on clean bench, remove shaft suppons,
rocker arms and wave washers keeping them in order.
Clean & Inspect
1. Clean all components in a suitable cleaning solvent, then
dry with clean dry compressed air.
2. Clean rocker shaft support bolt threads.
3.lnspectall components for wear and replace as necessary.
4. If there is excessive wear of support shaft surfaces, refer
to PROBLEM DIAGNOSIS Section in this Chapler.
Installation
1. Before assembly, coat rocker arm pivots and contact
surfaces with engine oil.
2. Replace all rocker assembly components onto assembly
VALVE STEM OIL SEALS
Rep1acement
2. Remove the following:
(a) Rocker cover as previously described in this Chapter.
(b) Rocker arms as previously described in this Chapter.
(c) Spark plug leads from spark plugs.
(d) Spark plug from relevant cylinder and screw air adaptor
into spark plug hole.
3. Apply air pressure to hold valves in closcd position.
4.(a) Compress valve spring with valve spring compressor.
(b) Remove valve collets.
Before installing valve spring compressor. it may be
necessary to tap top of valve eap with a soft-faced hammer
to overcome the binding ofthe valve collets in the valve spring
cap.
5. (a) Remove spring, cap and compressor as an assembly.
(b) Remove and discard valve stem oil seal.
6. Install new valvestemoil seal using special tool No. E9339
and make sure the seal fully seats on top of the valve guide.
(a) There are specific valve stem seals for intake and exhaust
valves.
(b) The colour of the replacement seal may not be the same
colour as the original seal.
(c) Make sure the correct type of seal is fitted to the
appropriate valve, based on part no. and package description.
7. (a) Install spring, cap and compressor as an assembly on
the valve stem.
(b) Install valvccolletsand slowly release spring compressor,
then remove spring compressor.
(c) Disconnect air line to special tool.
8. Install the following:
(a) Rocker arms as previously described in this Chapter.
(b) Rocker coverts as previously described in this Chapter.
9. Remove special tool and install and torque spark plug.
Rocker Assembly
Retaining
Rocker
shafts making shore to keep in correct order. Replace end

shaft support bolts to hold assembly together.
3. Fit assembl y to cyl inder head coating with engine oil, also
coat carn shaft .
4. Coat shaft support bolt threads with LOCfITE 243
sealant or equivalent. Replace bolts and tighten slowly until
shaft supports meet the cylinder head, making sure the lash
adjusters remain in contact with the valve heads.
5. Torqueshaft support bolts and at the same time make sure
'rorque ....................................................... 20 - 3() Nm.

10. Install spark plug leads and battery earth lead.
11. (a) Start engine and check for oil leaks and valve train
nOI~.
(b) Repair as necessary.

HYDRAULIC LASH ADJUSTERS
Removal
Make sure that all valve train components are kepI in order
so they can be installed in their original locations.

(a) Rocker covers as previously described in this Chapter.
(b) Rocker assembly as previously described in this Chapter.
3. Lash adjusters are removed from the rocker arm by
pushing them ou~ if tight they can be pressed out using tool
No. E9335. Adjusters and shims must stay in order when
the lash adjusters remains in contact with the

Torque ......................................................... 20-25 Nm.
6. Install rocker covers as previously described in this
Chapter.
(b) Start engine and check for oil leaks or valve train noise.
25
removed.
DmlantJe
Hydraulic lash adjuster may not be dismantled for cleaning
as they are designed as a throwaway unit.
Clean & Inspect
1. (a) Clean all parts in a suitable cleaning fluid .
(b) Ball valve must be held of its seat and compressed when
cleaning to expel all engine oi I
2. (a) Inspect adjuster body for wear and scuffing.
(b) Also inspect adjuster bore in rocker arm.
(c) Dry with compressed air.
3. Theadjusterassembly unit must be replaced if there is any
damage or excessi vely worn.
Assembly
Lash adjuster should not have been disassembled and there
for will not need assembly. Once washed and cleaned
hydraulic lash adjuster is now ready for checking as outlined
in the next operation.
Testing Lifter
After it is has been cleaned and inspected, it will need to be
tested before it is installed in the engine.
1. (a) Adjuster must be filled with test fluid, holding the ball
valve of it< seat submerge adjuster in test fluid.
(b) Compress and release, repeating until all air is bleed out.
2. (a) Place asscmbly in test rig with plunger up.
(b) Lower test fixture ram to rest on la<h adjuster.
(c) Ensure that lash adjuster is submerged in test fluid .
3. (a) Ram will need adjusting so pointer is set at start point
when resting on lash adjuster.
(b) Scale on test rig must range from start point to at least
2.4mm of travel.
(c) Release ram and allow lash adjuster to be compressed.
4. Use a stop watch to check the time required for the indicator
to move from the 'START' to 2.4mm position on the scale.
5. The leak down rate (time between start and 2.4mm
position) must be between 5 to 30 seconds to ensure satisfactory lifter operation.
A doubtful lash adjuster should be tested 3 or 4 times.
Any lash adjuster which does not test within the specified
limit< should be replaced.
In<tallation
1. Make sure lash adjuster bodies and rocker arm bores are
clean.
2. (a)Install lash adjuster into rocker arm.
(b) Install rocker shaft assembly as previously described in
this Chapter.
(c) Install rocker covers as previously described in this
Chapter.
(b) Start engine and check for oi I leaks and valve trai n noise.
CYLINDER HEAD
Removal
(a) Powersteering pump drive belt as previously described in
this Chapter.
(b) Throttle body and fuel lines described previously in this
chapter.
(c) Draincooling system by removing bottom radiator hose.
(d) Intake manifold as previously described in this Chapter.
(e) Exhaust manifold as previously described in this Chapter.
(f) Rocker covers as previously described in this Chapter.
3. Remove power steering pump

(a) Remove nut off pump to rear mounting bracket.
(b) Remove front mounting bracket bolts.
(d) Move power steering pump assembly to one side.
(a) Remove rear mounting bracket.
4. Set timing marks on camshaft and crankshaft in position.
(a) Tie camshaft gear and chain together.
(b) Remove gear retaining bolt.
5. Removing chain tensioner.
(a) Remove timing chain tensioner as described in this
chapter.
(b) Remove damper pin and slide camshaft gear of the
camshaft.
6. Remove rocker assembly as previously decrepid, and
remove camshaft.
7. Gradually slacken cylinder head bolts in the sequence
shown.
26

13
* Clean out bolt holes with an air hose.
InstaJJation
1. Place head gasket in position overdowel pins on cylinder
block.
Cylinder Head sequence
8. Remove cylinder head bolts, cylinder head and gaskets.
2.(a) Carefully guide cylinder head into place overdowel pins

and gasket.
(b) Coat threads of cylinder head bolts with LOCfITE 243
sealant or equivalent and tighten with fmger.
.. . .
'\1"
571:
...
Inspedion
I. Taking care not to scMch machined surfaces, clean mating
surfaces of cylinder head and cylinder block.
Do not use a motoriscd wire brush on any gasket sealing
surface.
2. Check cylinder head deck, intake and exhaust manifold
mating surfaces for distortion. These surfaces may be
refaced by parallel grinding.
If more than .30 mm must be removed from any surface,
replace cylinder head.
To detenmille if cylinder head deck surface has sufficient
deck surface thickness for resurfacing, measure head height
from deck surface.
Newcylinderheads measure from 1.372mmto 1.676mm.
If cylinder head does not meet the minimum thickness after
machining, the cylinder head must be replaced.
3. Inspect the following:
(a) Cy Ii nder head for cracks, especially between val ve seats
or exhaust ports.
(b) Cylinder head deck surface for corrosion, casting sand
inclusions or blow holes.
(c) Cylinder block deck surface with a suitable straightedge.
4. Clean cylinder head bolts and replace any bolt that has
suspect threads, or stretched or damaged heads caused by
improper use of tools.
5.(a) Clean cylinder head bolt hole threads in cylinderblock
using an appropriate size thread tap.
(b) If necessary, threads may be reconditioned with suitable
thread inserts.
3.(a)Tighten head bolts to the following sequence and in the

ordershown.
13
Cylinder Head Sequence
* It is important to follow the given procedure to avoid head

gasket failure and possible engine damage.
(b) Tension bolts to specified torque.
* Ifa torqueof40Nmat anytimeinfollowing step is reached,
STOP tightening that particular head boll.
(c) Further tighten all bolts 9a' in sequence
4. Install camshaft and valve a~sembly after covering the
components with a light coat of oil.
27
i
(a) Placecamshali in position, aligning with gear,and placing

gear on camshaft,tightening bolt fingertight.
(b) Replace rocker assembly as previously described.
tensioning bolts to correct specifications.
Rocker Shaft Support Bolt tension ........... 2O-25Nm
(c) Tension camshaft sprocket to specified torque.
CamshaftSprocket tension .................................. SONm
S.(a) Install intake manifold as previously described. tighten
Intake manifold tension ....................................... 2SNm
(b) Install exhaust manifold as previously described tightening bolL~ in correct sequence and to correct torque.
cylinder head
bench , use a
c ompressor to
remove valve
Valve
Spong
Cap
'.-=--,
Valve
Valve $eal
Collets
lJIJl\
~
Exhaustmanifoldtension .................................... 3()Nm
6. (a) Replace damper pin and timing chain tensioner. release

tensioner, remove timing chain sprocket tie.
Check timi ng mark position is still correc~ if wrong remove
tensioner and cam sprocket and check position again.
(b) Install rocker cover with new gasket and tighten nuts to
specification.
Rocker Cover Nut tension ................................ 7-12Nm
7. Install power steering unit.
(a) Install power steering rear mounting bracket.
(b) Move powersteeringpump into position and secure front
mounting bracket.
(c) Replace nut on rear pump to mounting bracket.
(d) Replace power steering pump belt and tension.
S. (a) Install fuel lines.
(b) Install kick down cable for automatic trans.nissions and
accelerator cable.
(c) Install air cleaner and air duct hose.
9. (a) Fit radiator hose.
(b) Fill radiator with appropriate coolant.
10. Install the earth cable to the battery.
11. (a) Start engine and check for oil, coolant, fuel and
exhaust leaks.
(b) Repair a~ necessary.
Clean
I. (al Clean all carbon from combustion chambers, valve
ports. etc., with a rotary-type carbon removing wire brush.
Do not wire brush on any gasket sealing surface.

(b) Clean cylinder head gasket surface of cylinder head.
2. Thorough clean valve guides with a suitable cleaning
solvent or a wire brush.
3. Clean valve heads with a drill and wire brush.
Do not scratch the valve stem.
4. Wash all componcnL' in a suitable cleaning solvent and air
dry with dry compressed air.
Cylinder Head Inspt.'Ction
I. Cylinder heads should beinspected forcracks in valve seats
and combustion chambers, and for external cracks to water
jackets.
2. Check cylinder head deck surface for corrosion.
3. (a) Using a straight edge and feeler gauge, check cylinder
head deck, intake and exhaust manifold surfaces for distor
tion.
(b) Check cyJinder head deck surface diagonally, longitudi

nally and transversely.
(c) These surfaces may be refaced by par.illel grinding. If
more than .30 mm must be removed from any surface, replace
cylinderhead.
To determine if cylinder head has sufficient deck surface
thickness for resurfacing, measure head height from deck
surface to cast pads.
* ThecyJinder head must be replaced ifthecyJinder head does
not meet the minimum thickness aftermachining.
CYLINDER HEAD RECONDITIONING
Make sure that all valve train components are kept together
and identified so that they can be installed in their original
locations.
Dismantle
1. Compress valve springs in turn with a conventional spring
compressor and remove valve collets.
(a) Valve spring caps, springs and valve stem oil seals.
(b) Valves from cylinder head.
Caution: Do notforce valves out ofguides, as mushroomed
valve ends, due to rocker arm wear or dirt in the guide, will
damage guide. Remove burrs bychamfering valve stem with
an oil stone or file.
VALVE GUIDES
Clearance Checking
1. Excessive valve stem to guide bore clearance will cause
lack of power, rough idling and noisy valve operation.
2. Insufficient clearance will result in noisy and sticking of the
valve and will interfere with smoothness of operation of
engllle.
3. Measure clearance as outlined in following steps:
(al Insert valve into its guide.
(b) Clamp a dial indicator on I side of cylinder head rocker
28
cover seating rail, locating the indicator so that movement of

the valve stem from side to side (crosswise to the head) will
cause adirect movement to the indicatorstem. (The indicator
stem must contact the side of the valve stem, just above the
valve guide.)
of valve stem to measure the
of valve guide wear

dial gauge
_f--I-_volveStem
* Valve seat angles ....................................... 4SO
* Valve seat width:
Exhaust ........................................................ l.8-2.3mm

Intake ................................................. 1.5-2.()rnm
S.lftheseatis too wide after grinding, it may be narrowed by

using a 20" or 70" grinding stone. The 20" stone will lower
the seat and the 70" stone will raise the seat.
6. If the val ves seats are reconditioned. the valves must also
be reconditioned (refer VALYES) or replace valves as
necessary.
REPLACING VALVE SEAT
seat,move
the stem of the valve side to side using a little force to obtain
a clearance reading. (If clearance exceeds specification, it
will be necessary to ream valve guides for oversize valves.)
It is important to check the clearance with a new standard
valve before attempting to ream the valve guide.
Valve stem to Guide Clearance 0.025 0.070 mm

4. When using a new valve. jf valve stem to valve guide
clearance is within specification, check original valve stem
diameter (refer VALYES) and replace any worn valves as

necessary.
S. Valve guides may be reamed to accept an oversize valve.
*A void breaking reamer flutes or jamming the reamer into
the valve guide due to packing of chips or carbon.

Clean the valve guides before reaming. Do not push down
l. Using a lathe. tum down the out side diameter of a valve

head so it will fit neatly into inside of the valve seat.
2. Cover the head that surrounds the valve seat with an
inflammable paste. such as soap paste. TIris win stop damage
from weld spatter.
3. Weld acontinuous run of weld around the edge ofthe valve.
so it is welded to the inside of the valve seat.
4. Lift the head so the top of the valve can be tapped to free
the valve seat.
S. Slide the machined valve and valve seat out of the head.
6. Machine the head as the new valve seat is over size by
0.38mm diarneterand depth.
7. The new valve seat should not to be hit or forced into the
head as this will cause damage to the seat and head.
S.Place the new valve seat in liquid nitrogen ordry ice so the
seat will shrink in size.
9. Carefully place the valve seat into position with an old
valve (converted into a special tool a< shown in diagram)
positioned through the seatinto the valve guide. Gently tap the
special tool to position and centre the valve seat
on the reamer.
VALVE SPRINGS
Instaned Height Valve Spring .. 46.0-46.Smm
I. Inspect valve spring surfaces on cylinder head and valve

cap for wear or gougi ng. Replace components as necessary.
2. (a) Check spring ends. If they are not par.illel, the spring
is bent.
(b) Replace valve springs that do not meet specification.
Max allowable variance in spring end length 2.0 mm,
while rotating spring on level desk.
VALVESEATS
I. Reconditioning the valve seats is very important because
the seating of the valves must be perfect for the engine to
deliver the power and performance its develops.

2. Another important factor is the cooling of the valve head.
Good contact between each valve and its seat in the head is
impemtive to ensure thaI the heat in the valve head will be
properly carried away.
3. Several different types of equipment are available for
reconditioning valve seats. The recommendations of the
manufacturer ofthe equipment being used should becarefulJy
followed to attain proper results.
4. Check val ve seats for any evidence of pitting or damage at
valve contact surface. Ifpitting is evident. the valve seats will
needtobereconditioned.
Because the valve guide serves to support and centre the
valve seat grinder. it is essential that the valve guide is
serviced before reconditioning the valve seats.
Valve Spring Free length .................................. 55.1mm
3. (a) Check valve spring load with a spring tester.

(b) Springs should becompressed to the specified height and
checked against specifications.
Valve spring compressed heightJIoad:
Valve height:
!ipril1g ....... 3:1l1 31'4 rom (<IIi.23 mm).
Assembled height:
Spring .................................................... 46.0-46.8 mm.
(c) Replace any valve spring ifnot to specification.
29

(b) Insert valve and rotate about 1/6 of a revolution.
VALVES
(c) Remove valve and check for full contact with seat.
i) If partial contact is indicated, insert valve again and tum
through a full revolution.
ii) If blue on seat indicates full contact, reface valve.
iii) If partial contact is still indicated, regrind cylinder head
valve seat.
(dJ Clean all traces of bearing blue from valves and seats.
Valve Spring Install Height
Excessive valve spring installed height, caused by valve seat
wear or valve and seat reconditioning, has to be compensated
for, by adding shims under the valve springs.
1. Place valve in its guide, then install valve spring cap and
collets.
2. Pull up on valve spring cap to seat collet and valve.
3. Measure from machined spring seat to spring side of cap,
using a verniercaJliper. Valve spring installed height should
be as follows:
ValveSpring .................................................... SS.lmrn
Installed Height .....
46.0 46.8mm
Shim valve spring seat as needed if any measurement is not
as indicated.
Straightness
of
valve stem
Diameter
Valve Length
valve Head
Thickness
................................
Eng039
ASSEMBLE
t. Dry and clean all components thoroughly.
2. Using clean engine oil, lubricate valve stems and valve
guides thoroughly. Install valves in corresponding guides.
3. Making sure that seals fully seat on top of guide, install
valve stem oil seals.
The original seals may not be the same colour as the
replacement seals.
There are particular valve stem seals forintake and exhaust
valves. Make sure the exact type is fined to therelevant valve,
based on package description and part number.
4. Place valve springs and cap over valve stem.
5. Using a suitable spring compressor, compress valve
spnngs.
Excess compression could cause spring cap to damage
valve stem oil seal, ensure to compress valve springs only
enough to install valve collets.
6. Install valve collets, making sure that they locate accurately in groove in top end of valve stem. Release the valve
spring compressor slowly ensuring that the collets sit properly. Grease may be used to hold colleL. in place.
1. (aJ Inspect valve stem for burrs and scratches. (Burrs and
minor scratching may be removed with an oil stone.)
(b) Valves with excessive stem wear or that are warped
should be replaced.
(c) Inspect valve stem tip for wear. The valve tip may be
reconditioned by grinding.
(d) Follow the grinder manufacturers instructions. Make
sure the new tip surface is at right-angles to the valve stem.
2. Inspect valve stem collet groove for damage.
3. (a) Check valve face for burning or cracking.
(b) If pieces have broken off, inspect corresponding piston
and cylinder head area for damage.
4. (a) Inspect valve stem for straightness and valve head for
bending or distortion using 'V' blocks.
(b) Bent or distorted valves must be replaced.
5. Valves with pitted or grooves faces can be reconditioned
with a valve refacing machine, ensuring correct relationship
between head and stem.
Valve face angle ....................................................... 44.
* Ifpitting or grooving is so deep that refacing would result
in a 'knife' edgeatthe valve head, the valve must bereplaced.
Measure valve margin after refacing valves. If margin is
less than minimum specified, the valve must be replaced.
Minimum valve head margin thickness .......... O.63mm.
6. Lightly lap reconditioned valves into valve seat.
New valves must not be lapped. Lapping destroys the
protective coating on the valve face.
7. After refacing or installing a new valve, check for correct
seating as follows :
(a) Lightly coat valve face with bearing blue.
CRANKSHAFT BALANCER
Removal.
1. Disconnect battery earth lead and remove drive belts as
shown in the BELT DRIVE section.
2. Pull park brake fully on, chockrearwheel and transmission
In gear.
3. Loosen and remove balancer retaining bolt.
4. Remove balancer from crankshaft with pulley puller.
IrtstaIlation.
30
3. Remove rocker cover as described previously in this
Installation is the opposite of removal techniques, ensuring to

take note of the following points:
Using engine oil, lubricate front seal surface of balancer.
Install balancer, engaging key on crankshaft with slot in
balancer.
Tighten balancer retaining bolt to the propertorque specification.
chapter.
Crankshaft Balancer Bolt Tension 125Nm
Inspect drive belt operation and starter motor.

TIMING CHAIN TENSIONER
Removal
1. Detach power steering belt and remove.
2. (a)Remove power steering housing to rear mounting
bracket nut.
(b) Remove power steering front mount retaining bolts.
(c) Move pump to one side, place out of the way.
(d) Remove rear pump mounting bracket.
3. Remove centre retaining plug and filter, making sure that
the outer retainer does not undo at the same time.
4. (a) Lock tensioner in the compressed position by inserting
tool No. E9338 through outer retainer.
(b) Pushing tool inward and turning clockwise to lock it in
position.
5. Using tool No. E9338-A remove outer retainer and with
draw the compressed tensioner.
Clean and inspection
1. Clean all parts with ~uitable cleaning fluid.
2. Inspect all threads and piston for wear or damage.
Installation
1. (a) Replace tensioner and outer retainer using tool No.
E9338-A.
(b) Then release tensioner using tool No. E9338.
2. Insert filter and centre retaining plug.
3. (a) Replace rear pump bracket.
(b) Insert pump into po~ition and replace front mount bolt'.
(c) Replace pump housing to rear mount nut.
(d) Fit power steering belt and retension.
4. (a) Remove the crankshaft damper bolt and washer, using

a pulley remover.
(b) Remove air conditioner and power steering tensioner
plates.
(c) Remove the timing chain cover, gasket, exposed section
of sump gasket and the oil slinger.
5. Tum the engine to align the timing mark~ on No.1 TDC
on all three gears.

6. Remove tinting belt tensioner as described previously in
this chapter.
7. (a) Remove damper pin, camshaft sprocket bolt and slide
sprocket of cam~haft.
(b) Remove idler sprocket bolt, slide sprocket of idler shaft
and remove from timing chain, marking sprocket first.
(c) Lowertimingchain off crank sprocket and remove chain
from engine.
Installation
I .(a) Slide chain through frontofheadand replace carns haft
gear into chain.
(b) Align the tinting marks of the gears, with the chain fitted
slid the unit back into position onto the shafts.
(c) Lubricate all components with clean engine oil.
2. Fit the camshaft gear bolt and washer.
Camshaft Gear bolt tension ................................. SONm
Auxilary Gear bolt tenion ................................... SONm
TIMING CHAIN COVER and CHAIN
Removal
1. (a) Detach the battery cables and remove the battery
shroud.
(b)Empty the cooling system by disconnecting the lower
radiator hose.
(c) Detach the transmi~~ion oil cooler pipes from the radiator
(auto).
(d) Detach the upper radiator hose from the thermostat
housing. Remove the fan shield and radiator
2. Detach belts from the fan, power steering, air conditioner
etc. Remove the fan/clutch from the water pump.
31
3 .(a) Replacedamperpin ,timing chain tensionerthen release

lensioncr.
4.1fcamshaft lobe liftis satisfactory, install the rocker cover.

Removal.
I. Disconnect battery earth lead.
2, Remove rocker cover rerer to Rocker Cover removal.
3. Remove timing chain tensioner, refer to Timing Chain
Tensionerremoval,
(b) Proceed to cheek all timing markes arc conect.

4, Replace the timing chain cover with new gaskets, apply oil
resistant sealer to the gaskets before assembly.

S. Tighten the bolts for the cover, then the bolts on the sump.
Front Cover attaching bolts ................................ 20Nm
Oil pan/sump attaching Bolts ................................ 8Nm
6. (a) Reinstall power steering belt and air conditioning belt
adjuster plates.
(b) Refit crankshaft balancer as described previously is this
chapter.
(c) Replace the fan/clutch. all belts to their corrccltension.
7. Refit rockercoveras previously described in this chapter.
8. Reinstall the upper radiator hose from the thermostat
housing. Reinstall the fan shield and radiator
9. Fit the transmission oil cooler pipes from the radiator
(auto).
10. Refill the cooling system after connecting the lower
radiator hose.
11. Connect the battery cables and the battery shroud.
4, Tie camshaft sprocket before removing gear from camshaft.

6. To remove rocker shaft assembly refer to Rocker AIIU
and Shaft assembly,
7, Li ft camshaft out of cylinder head and place on clean work
area.
Avoid damaging camshaft surfaces when removing.
Inspection,
1. Check camshaft journals and lobes for overheati ng, dam
age or wear (discolouration).
2. Inspect camshaft journal diameter and runout with suitable
measuring equipment.
Replacecamshaft ifjournals are within specifications.
CamshaftJournalDiameter ................. 37.94-37.96mm
Camshaft Journal Max. Out of Round ........... O.013mm
3. Position camshaft on 'V' blocks and check each camshaft
lobe lift.
Refer to camshaft lobe lift in specifications.
TIMING COVER CHAIN OIL SEAL
Replace
1. Remove crankshaft balancer as described previously in
this chapter..
2. Remove the old seal with a screw driver or seal remover.
3.lnstaIl the new seal withasealinstaller(taking note that the
seal is fining as itshould), lubricate the seal with grease before
fining.
4. Reinstall the cmnkshaft balancer as described in this
chapter.
CAMSHAFT.
Check Valve Timing.

It will be necessary to remove the rocker coverto check the
engine valve timing, and also thetiming chain cover to do this
refer to Timing Chain Cover and Chain section in this
manual.
Tum crankshaft until timing marks on crankshaft and camshaft sprockets are adjacent to each other. The location of the
timing marks when the valve timing is correct is shown in the
diagram above.
Measuring Camshaft Lobe Lift
1. Remove the rocker cover.
2. Mount a dial indicatorso that its stylus is resting on top end
of a rocker arm roller, tum the crankshaft and measure
camshaft lobe lift.
Camshaft lobe lift Intake and exhaust:
Intake ..................................................................... 6.00
ExhallSt .................................................................. 5.76
3. Repeat step2, above, on the remaining rocker arms. If any
lobe lift is not as specified remove and replace camshaft to do
this refer toRemoval and Installation in this section.
Camshaft Bearing Service.
The camshaft has no bearings to run on as such and is set

directly on to the housing, ifhousings are badly damaged the
cylinder head will need to be replaced. Minimal damage the
housing will be alright as long as it is cleaned properly.
Should the journals be badly damaged orworn the camshaft
wi II need to be replace.
ENGINE MOUNTS.
Front Mounts.
Removal.
1. Release the right hand engine mount to bmcket retaining
nut and withdraw the heat sheild.
2. Use a engine bay support bar to hold the engine in place,
then relea~ the 'K' frame 'U' bolt retaining nuts.
32
3. With vehicle raised and supported, release the steering

shaft to rack.
4. Release the 'K' frame mount nuts, then allow the 'K' frame
to lower and gain access to the engine mounts.
5. Withdraw the engine mount to 'K' frame retaining bolts
and withdraw the mounts.
Installation.
1. Fit the engine mount to ' K' frame, then the retaining bolts
are able to be fitted and tensioned.
2.Liftthe 'K' frame into place, then fitthemountingnuts, and
tighten to specitications
3. Fit the steering shaft to rack, then lower the vehicle.
4. Fit the 'K' frame 'u' bolt retaining nut then withdraw the
engine bay support bar.
5. Fit the right hand engine mount to heat shei Id and retai ni ng
nut.
6. Tension all retaining nut and bolts to specifications.
manual.
2. Vehicles with manual transmission:
Remove the clutch pressure plate and driven plate as per
CLUTCH section in this manual.
3. Block flywheel driveplate from turning, using a screwdriver or suitable locking tool. Remove flywheeVdriveplate
crankshaft bolts and flywheeVdriveplate.
Flywheel
Torque Wrench
REAR MOUNT
Removal.
1. Raise vehicle front and rear and place on safety stands.
2. Using a garage jack, support rear of transmission.
Use a block of wood between transmission and jack.
3. Remove nut.s, washers and bolts attaching support to
crossmember.
4, Remove rear mount from support nuts and remove support.
5. Remove rear mount from transmission rear extension boll'i
Inspection.
The flywheel and flex plate are purposely out of balance and
no attempt should be made to rebalance theseas an indi vidual
unit.
t. Check flywheeVdriveplate ring gear for badly worn,
damaged or cracked teeth.
If needed, replace flywheel ringgearordriveplate, fordetails
refer to "ring gear" section in this chapter.
Check starter motor pi nion gear fordarnage, if ring gear teeth
are damaged replace pinion gear, fordetails refer to "Starting System chapter".
2. Inspeetcrankshaftand flywheeVdriveplate matching surfaces for burrs. Using a fine mill file remove burrs if present.
InstaIIation.
Installation is the reverse of removal techniques, please note
the fOllowingpoints:
(a)Install flywheeVdriveplate tocrankshaft, and lighten bolts
to the correct specification.
FlywheeVDrivepiatebolttension ............... l00-115Nm
(h) Mount a dial indicator on the rear of cylinder block for
vehicles with automatic transmission. Inspect tlexplate mnout
at the three torque converter mounting bolt holes. Runout
should not exceed the following specifications.
Flexplate Runout ....................................... 20 mm max.
Try to correct by tapping high side with a mallet if mnout
exceeds specification. Replacedriveplateifthisconditioncan
not be corrected.
(c) Inspect starter motor operation.
and remove rear mount.
Installation.
1. Install rear mount and bolts to transmission rear extension.
Tighten bolts as specilied.
Rear Mount to Extension Bolt ...................... 40-55 Nm
2. Install support to rear mount and attach nuts. Lower rear
of transmission slightly to allow nuts to be tightened as
specified.
Support to Rear Mount Nut ........................... 4O-55Nm
3. Install crossmember to support, making sure that bolts are
fitted correctly and threads are not damaged.
4. Install crossmemberto support bolts, washers and nuts and
tighten nuts finger tight.
6. Lowerjack and tighten crossmemberto support nutslbolts.
CrossmembertoSupportNut ....................... 40-55 Nm
7. Remove safety stands and lower vehicle to ground.
FLYWHEEUDRIVEPLATE
Removal.
Before removal of flywheel/driveplate take note of the location of paint aligning marks on flywheel and pressure plate,
before removing clutch pressure plate, the driveplate and
torque converter also have paint aligning marks.
If not visible, scribe aligning marks on all part.,.
1. To remove transmission refer to MANUAL TRANSMISSION or AUTOMATIC TRANSMISSION in this
RING GEAR
Replacement.
The ring gear is welded to the driveplate and is serviced only
as an assembly for vehicles with automatic transmission.
Therefore must be replaced as a complete unit.
33
For vehicles with manual transmission, the ring gear is a

shrink fit on the flywheel flange, and if damaged, can be
removed and replaced.
Replacement techniques are as follows:
1. To remove flywheel refer to FL YWHEELI
DRIVEPLA TE section in this manual for details.
2. To remove ringgeardrill ahole between two ring gearteeth
and split gear at this point using a chisel.
3. Make sure that there are no foreign maller or burrs on new
ringgearand flywheel matching surface. Removeburrsusing
a fine mill file (ifpresent).
4. Heat and shrink a new gear in place as follows:
(a) Using an emery cloth, polish several spots on ring gear.
(b) Using a hot plate or a slow moving torch, heat ring gear
until the polished spots turn blue (approximately 320degrees
Celsius).
Heating the ring gear in excess of427 degrees Cekius will
destroy ring gear heat treatment.
(c) Quickly place ring gear in position against shoulder of
flywheel using 2 pairs of pliers. A1I0w ring gear to cool slowly
until it contracts and is lirmly held in place.
5. To install flywheel refertoFL YWHEELIDRIVEPLATE
bolts and hood.

5. To remove cooling fan and radiator assembly refer to
"Cooling systems" chapter section fordetails.
6. Disconnect heater supply and return hoses from engine
heater pipe connections.
7. Disconnect hose from oil filler on rocker cover.
8. Disconnect main wiring harness from engine and battery
harness.
9. Unclip wiring harness from engine to fire wall.
10. To remove power steering pump (if applicable) refeno
Power Steering section for details.
11. Disconnect air cleaner.
12. Disconnect thronlecable from thronle linkage and mount
ing bracket.
13. Disconnect cruise control cable (if applicable) from
throttle linkage and remove mounting bracket boll.
If vehicle is littcd with automatic transmission, disconnect
kick down cable from throttle linkage and mounting bracket.
18. Remove fuel feed and return lines from fuel rail..
19. Disconnect emission control canister hoses from throWc
body connections, and separate canister lines from fuel tail
clips.
20. Disconnect brake booster and heater control hoses from
engine vacuum connections.
21. Fully raise vehicle and place on safety stands.
22. To remove tail shaft refer to "Propeller shafts and
universal joints"chapter fordetails . Place a suitable plug in
end of transmission.
23. Disconnect engine exhaust pipes from manifold assem
blies.
24. To disconnect gear shift control from transmission refer
IJ MANUAL TRANSMISSION cr AUTOMATIC
TRANSMISSION sections for details.
25. Disconnect clutch slave cylinder (for vehicles with
manual transmission only) for details refer to CLUTCH
section.
26. Disconnect speedo cable or wiring harness connector
from speedometer speed sender at transmission rear exten-
seclion in this manual.
SPIGOT BEARING
Before removing plate, take note of the position of the paint
aligning marks on flywheel and pressure plate. If marks are
not visible, scribe aligning marks on both parts.
Replacement.
1. To remove transmission refer to MANUAL TRANSMISSION section in this manual for details.
2. To remove clutch pressure plate and driven plate refer to
CLUTCH section in this manual.
3. To remove spigot bearing use a Slide hammer.
4. Use a piloted screwdriverto replace spigot bearing. Place
new bearing on pi lot oftool with radius in boreofbearing next
to shoulder on tool. Drive bearing into crankshaft to the
dimension as shown in the diagram. Use thin filmof SAE90
Gear Oil to lubricate the bearing.
6. To install clutch assembly and tnlllsmission refer to
CLUTCH and MANUAL TRANSMISSION sections in
this manual.
510n.
Manual Tnmsmission: Disconnect transmission harness from

back-up lamp switch.
Automatic Transmission: Disconnect transmission harness
from solenoid.
27. Raise engine slightly to take weight off mounts by
attaChing an appropriate lifting hook and chain to engine
lifting brackets iflitted. Otherwise care must be taken not to
damage engine components with rope orchain while lifting
engme.
28. Removeengine front mounting from mounting brackets.
29. Remove engine rearcrossmember from frame bolts and
washers. Remove crossmember to rear mounting support
bolts and remove crossmember.
30. Disconnect wiring harness connector from compressor
clutch for vehicles with airconditioning.
ENGINE REBUILD.
ENGINE ASSEMBLY.
Removal.
1. Disconnect battery leads
2. Remove bottom radiator hose from radiator to allow
coolant to drain, and disconnect radiator hoses from engine.
3. Drain engine oil sump.
4. Using a felt tipped pen mark engine hood to hinge positions.
Disconnect windshield washer hose. Remove hood hinge
34
Raiseengine slightly and removeaircompressorfrom engine

mount bracket mounting bolts. Tie compressor back way
from the engine.
31. Raise engine with front tilted upwards and a floor jack
supporting rear of transmission a<sembly, make sure that
engine exhaust manifolds, starter motor or transmission do
not rest on steering gear.
Do not allow engine to swing forward and damage air
conditioning condenser (on vehicles with air conditioning
condenser fitted at front) or optional transmission cooler.
32. Separate engine and transmission assemblies if necessary. Refer to MANUAL TRANSMISSION or AUTOMATIC TRANSMISSION for details.
Dismantle.
l. Mount engine assembly in an appropriate engine stand.
2. Remove the following parts:
(a) Starter motor, refer STARTING SYSTEM chapter.
(b )Ignition coi Iand mounting bracket, high tension leads and
spark plugs.
(e) Alternator and brackets, refer to alternator chapter.
3. Remove the following parts as previously described or
about to be described, in this chapter.
(a) Rocker cover, rocker a<sembly andcarnshaft,
(j)Intake manifold,
(k)Cylinderhead,
(I) Oil pump, suction pipe and screen,
(b) Exhaust manifold,

(e)Oiltilter,
(d) Drive belts,
(e) Crankshaft balancer,
(I) Front cover,
(g) Engine sump,
(m)AywheeUflexplate
(n)Crankshaft,
(b)Timing chain tensioner,

(i) Timing chain, sprockets and shaft gears,
(0) Piston and connecting rod assemblies.
35
2. Apply a strip of sealant (RTV 732) on the cylinder block

at the joints of rear main bearing cap and front cover, and on
the oil pan as shown above. Install new seal onto oil pan,
aligning recesses on seal with matching dimples in oil pan rail.
Assembly.
Assembly is the reverse of dismantle techniques for each part
as outlined in this section. The relevant assembly instructions
for each part is listed under Dismantietechniques.
Installation.
Installation is the reverse of removal techniques, taking note
of the following point<;
1. Make sure that all fasteners are tightened as speci tied at the
end of this section.
2. Use specified engine lubricamand coolant when retilling.
3. Inspecttransmission fluid level, add lubricant as required.
4. Inspect for fuel , coolant, oil and exhaust leaks. Repair as
required.
5. Check engine hood alignment.
3. Install oil pan and seal to crankcase, and tighten as

specified.
Oil Pan (Sump) Bolt Tension ............................... 8 Nm
OIL PAN (SUMP) & GASKET.
Removal.
2. Removeengine mount tochassis bolt, lift engine and chock
engine in raised position.
3. To steady engine assembly use chocks under front engine
mounts.
4. Make sure oil pan drain plug is tightened as specified.

Oil Pan (Sump) Drain Plug tension .................... 25Nm
5. Lower engine into position and replace chassis to engine
mount bolts.
6. Replace dip stick.
7. Refill oil pan with the correct amount of engine oil as
described in theLUBRICA TION section.
8. Start engine and inspect for oil leaks. Repair as required.
4. Drain oil from oil pan.

5. Remove the dip stick.
6. Remove the flywheel cover plate.
7. Remove oil pan bolts, oil pan and seal, dispose of oil seal.
Do not reuse the formed rubber oil pan seal.
.....-~
OIL PUMP, SUCTION PIPE AND SCREEN.
Removal.
l. Disconnect battery earth lead.
2. Drain oil from oil pan (Sump).
3. To remove oil pan (Sump) refer to "Oil pan (Sump)&
Gasket" in this section.
4. Remove the 2 bolts securing suction pipe flange to oil pump
and remove pipe and screen assembly.
S. Removesuction pipe from crankcase gasket and disposeof
gasket.
6. Remove 2 bolts securing oil pump to cylinder block.
Installation.
1. Clean all matching surfaces of oil pan and cylinder block
thoroughly.
36
3. Check the cover surface for damage by rotor and rotor

clearance (use a straight edge).
Rotor assembly clearance ........................... 0.03-0.1 nun
Ifcomponents are to be replaced. replace as a complete unit.
Assembly
1. Cover all parts with oil.
2.Install oil pressure relief valve plunger. spring, and a new
cap, cap is to be 0.2mm below pump body surface.
3. Install outer race, shaft and rotor assembly. The idenrification mark on rotor and outer race both face to the bottom
of the pump.
4. Install pump cover and tighten screws to specification.
Pump cover to pump screw specification: 20 Nm
ImtaIIation.
l. Make sure that the screen is cleaned of any foreign matter.
2. Clean suction pipe flange and crankcase matching surfaces.
3. Usea new gasket between suction pipe flange and oil pump.
Install and tighten bolts as specified.
Suction Pipe Flange to Oil Pump ........................ 20 Nm
4. Install pump to cylinder block en.uring pump drive shaft
is still in place and tighten bolts to specification.
Oil Pump to Block Bolt Tension .................... 20 Nm
spa:ified.
Oil Pan (Sump) Bolt Specification ........................ 8 Nm
Oil Pan Drain Plug Specification ........................ 25Nm
7. Refill oil pan with the conect amount of engine oil as
described in theLUBRICA TION section.
S. Start engine and inspect for oil leaks. Repair as required.
Dismantle
l. Remove cover to pump screws and cover.
2. Remove the inner rotor, shaft assembly and outer race.
3. Use a selftapper screw to remove oil pressure relief valve
chamber cap. Remove spring and plunger.
Inspection
PUiliP Suction
Pipe Assembly
Suction Pipe
To Housing Gasket
MAIN BEARINGS.
Each crankshaft main bearingjournal has 2 bearing halves or

shells which are not the same and not interchangeable in the
bearing cap or crankcase. The upper (crankcase) shell is
grooved to supply oil to the connecting rod bearing, while the
lower (bearing cap) shell is not grooved. The 2 bearing shells
must not be interchanged. TheNo.5. bearing is flanged to take
end thrust.
The main bearings are of the precision insert type and do not
require reaming to size or utilise shims for adjustment.
Standard size upper shells are used in the crankcase with
.0254mm undersized or standard size shells in the bearing
caps, depending on bearing clearance.
When shells are placed in crankcase and bearing cap, the end
extends slightly beyond the parting surfaces so that when cap
bolts are tightened, the shells clamp tightly in place toensure
positive seating and to prevent turning.
The ends of the bearing shells must never be filed nush with
parting surface. of crankcase or bearing cap.
Inspection.
2. Remove oil sump as described in OIL PAN (SUMP)
AND SEAL section.
3. To remove oil pump, suction pipe and .creen refer toOlL
PUMP, SUCTION PlPE AND SCREEN section for
details.
4. Remove main bearing cap bolts from bearing to be
inspected, and remove cap and lower bearing .hell.
Tap rear main bearing cap to break cap to crankcase seal
to remove. Install slide hammers into cap oil pan bolt holes
and remove cap.
S. Check lower bearing shells and crankshaft journals. If the
journal surface is ridged or heavily scored, replace crankshaft, refer to CRANKSHAFf section for details.
To ensure satisfactory engine operation, new bearing shells
must be installed as described inMAlN BEARlNGsection
and if necessary CONNECTING ROD BEARlNGSsection.
Inspect inner surface of bearing shells for gouges, wear or
embedded foreign material . If foreign material is found,
Relief
Valve
Gears
l. Wash all parts and dry. layout parts on a clean bench.
2. Check for damage and wear to the outer race to pump

housing.
Outer Race to housing radial clearance .... 0.lS-O.33mm
37
detennine its nature and source. Inspect outer surface of

bearing shells for surface wear (indicates movement of shell
or high spot in surrounding material), looseness, rotation
(flattened tangs and wear grooves), and overheating
(discolouration).
Inspect thrust surfaces of thrust bearing shell for grooving or
wear. Grooves are caused by irregularities in the crankshaft
thrust surfaces or dirt as described-in CRANKSHAFT
section.
Ifcondition oflower bearing shells and crankshaft journals is
satisfactory, inspect bearing clearance as follows :
6. In orderto accurately inspect main bearing clearance, it is
necessary to have the crankshaft pushed toward the upper
main bearing shells.
To achieve this, locate a small screw jack beneath crankshaft
web, next to bearing to be inspected. Raise jack so that it just
takes the weight of the engine.
7. Wipe oil from crankshaft journal and inner and outer
surfaces oflower bearing shell.
Install bearing shell in original position in bearing cap.
8. Place a piece of plastigage across full width of crankshaft
journal, parallel to crankshaft centreline.
Make sure plastigage will not seat across oil hole in journal.
I
exceed specification.
Main Bearing Clearance ......................... 0.02-0.04mrn
This method of checking main bearing clearance does not
give any indication of crankshaft journal taper or out of
round.
To measure taper, out of round orundersized, the crankshaft
must be removed from the cylinder block as described in
CRANKSHAFTsection.
13. Remove screw jack.
14. It is advisable to install new bearing shells if bearing
clearance exceeds specification and recheck clearance as
previously described.
If lower bearing is standard size. install a .0254 mm
undersized shell and check clearance again.
Replace crankshaft as described in :Crankshaft" section if
clearance is still not as specified.
Main Bearing Clearance
PrefeI I 00 .................................................. O.02..o.04mm
Allowable ................................................. O.02-O.06mm
15. Make sure that main bearing cap bolt threads and
crankcase threads are clean and dry. Apply some engine oil
to the cap bolt threads.
Before fmal installation ofcap bolts, determine ifbolts have
stretched by comparing with new one. Replace boills as
required.
16. With main bearing caps installed (refer to earlier step)
install and tighten cap bolts as specified.
platigauge on the journal
Plastigauge
Tighten bearing cap to sp",ea:i!i
'fi,cation,
check plastigauge wide with
card for clearance of bearing .
9. Install bearing cap and bolts into cylinder block.

Install bearing caps by loosely installing cap bolts and then
lightly tap bearing cap into position, in order to prevent the
possibility ofcylinder block and or main bearing cap damage.
Do not pull the bearing cap into place with the bearing cap
bolts.
10. Tighten bearing cap bolts as specified.
Ensure that crankshaft does not rotate with plastigage
installed.
Main Bearing Cap BoltSpecilication ................. 85 Nm
11. Remove bearing cap bolts and cap. Look for flattened
plastigage stiCking to either crankshaft or bearing shell in
bearing cap.
12. Check bearing clearance by comparing width of flattened
plastigage at widest point with graduation on plastigage
envelope. The nurnber within the graduation on the envelope
indicates theclearance.
Main bearing and crankshaft journal clearance should not
If the thrust bearing shell is distUl bed or replaced, coat the

surface using Molybdenum Disulphide Grease. It is also
necessary to line up the thrust surfaces of the bearing shells
before the cap bolts and tightened. To do this, move the
crankshaft fore and aft the length of its travel several times
(last movement forward) with the thrust bearing cap bolts
fingertight.
*If rearmain bearing cap was removed. clean all sealant from
cap and cylinder block matching surfaces. To reseal cylinder
block and cap refer to CRANKSHAFT REAR MAIN
BEARING OIL SEAL section this is important to stop
possible future oil leaks.
Main Bearing Cap BoItSpecilication ................. 8S Nm
38
17. Push crankshaft forward and measure crankshaft end

float between front of No.5 main bearing and crankshaft
thrust faces using a feeler gauge.
Crankshaft End Float .............................. O.OI-O.25mm
Feeler
Gouge
6. Clean crankshaft journal, crankcase bearing seat and

bearing cap thoroughly.
7. Lubricate new selected upper bearing.
8. Inset unnotched end of shell between crankshaft journal
and notched side of crankcase.
Makesurethatthecolleetbearingshell is filled between the
crankcase journal and crankcase.
No.5 bearing shells are flanged to take crankshaft end thrust.
Bearing lower shells are not grooved and are either undersized or standard size.
9. Turn bearing shell into place using crankshaft and coller
pin and then remove pin.
10.Inspect bearing to crankshaft clearance using plastigage
as outlined in MAiN BEARING section.
II. Using engine oil lubricate journal and bearing shells.
* If replacing No.5 main bearing shells, coat thrust surfaces
using Molybdenum Disulphide grease orequivalent.
* Before final installation ofcapbolts,determine ifbolts have
stretched by comparing with a new bolt. Replace bolts as
nceded.
13. Install bearing cap and tighten all bearing cap bolts to the
cOllectspecification.
* Make sure that the bearing cap is installed into the
/'
o
drtver
to move crankshaft
and forwards to measure endtloot wtth a feeler
To replace No.5 main bearing shells refer to replacement

procedures if clearance is excessi ve.
Replacement.
The main bearing shells can be replaced with or without the
crankshaft installed.
With Crankshaft installed.
1. Disconnect battery earth lead and remove spark plugs.
2. To remove oil pan refer to Oil pan and gasket" section.
3. Toremoveoil pump, suction pipe and screen referto "Oil
pump, suction pipe and screen" section.
4. Loosen all main bearing cap bolts 112 tum, and remove
bolts and cap of bearing to be replaced.
crankcase in the correct manner.
*Toeliminatethepossibilityofcylinderblockorbearingcap
damage, install bearing cap by installingcapboltslooselyand
then lightly tap the bearing cap into position using a soft faced
hammer. Do not pull the caps into place by using the bearing
cap bolts.
* It is necessary to line up the thrust surfaces of the bearing
shells before the cap bolts are tightened if the thrust bearing
shell has been disturbed or replaced. To do this, move the
(last movement forward) with the thrust bearing cap boll'
fingertight.
* lfithas been necessary to remove the rear main bearing cap,
clean all sealant from bearing cap and crankcase. Install
bearing eap and reseal, refer to CRANKSHAFT REAR
MAIN BEARING OLL SEAL section this is important to
stop possible future oil leaks ..
Main Bearing Cap BoltSpecilication ................. 85 Nm
14. Turn crankshaft and it should turn without binding. If
binding, inspect orientation of bearing cap, COil eet fitting of
bearing shells or bearing clearance.
15. To install oil pump, suction pipe and screen, refertoOLL
PUMP, SUCI'lON PIPE AND SCREEN section.
16. To install oil pan, refer to Oil Pan (Sump) and Seal
section.
Main Bearing Cop
(Thrust)
* To remove the rear main bearing cap, tap cap to break cap
from crankcase seal. Install side hammers into cap oil pan bolt
holes and remove cap.
5. Remove upper bearing shell as follows:
(a) Install in the oil hole of the crankshaft journal.
* Use a COller pin.
(h) Turn crankshaft anticlockwise as viewed from front of
engine. This will roll upper shell out ofcrankcase and remove
coller pin.
39
bearing shells in bearing caps, making sure the notches in the

shells line up with the recesses in the caps and correct bearing
is installed in the appropriate cap.
t 7. Install spark pi ugs and tighten to the correct specification.

Spark Plug Specification ................................. 25 Nm
18. Using the correct amount of engine oil refill the oil pan,
refer to LUBRlCAnON section in this manual for details.
19. Startengineand inspect foroilleaks,repairas needed. To
inspect oil pressure refer CHECKING OIL PRESSURE
section in this manual for details.
8. Measure bearing to crankshaft clearances as described in

MAIN BEARINGS section.
* Make sure that bearing cap is installed into the crankcase
in the appropriate way.
* In orderto prevent the possibility of cylinder block and or
bearing cap damage, install bearing cap by installing cap
bolts loosely, and then tapping into position using a soft faced
hammer.
DO NOT USE THE CAP BOLTS TO PULL THE CAP
lNTOPLACE.
9. Ifclearances are satisfactory, continue assembly of crankshaft, refer to CRANKSHAFf section for installation
details.
With Crankshaft Removed.
1. To remove crankshaft refer to CRANKSHAFT section.

2. Remove bearing shells from crankcase and bearing caps.
3. Remove rear main bearing oil seals, install new seals and
reseal rear main bearing cap, refer to CRANKSHAFT
REAR MAIN BEARING OIL SEAL section fordetails.
4. Clean crankshaft journals, crankcase bearing seals and
bearing caps thoroughly .
S. Tnstall new bearing uppershells in crankcase, making sure
notches in bearings line up with recesses in crankcase.
CONNECTING ROD BEARINGS
Each connecting rod bearing consists of2 bearing halves or

shells which are interchangeable in the rod and cap.
When the shells are in place, the ends extend slightly beyond
the parting surfaces of the rod and cap. Whcn the rod bolts are
tightened, the shells are tightly clamped in place to ensure
positive seating and to prevent rotation.
The connecting rod bearings are of the precision insert type
and do not use shims for adjustment. Theendsofthebearing
shells must never be filed flush with parting surface of rod or
cap.
Inspection and Replacement.
Connecting rod bearings can be replaced without removing
the rod and piston assembly from the engine.
\. Disconnect battery earth lead and remove spark plugs.
2. To remove oil pan (Sump) refer to OIL PAN (SUMP)
AND SEAL section for details.
3. To removeoil pump, suction pipe and screen refertoOIL
PUMP, SUCTION PIPE AND SCREEN section.
4. Using an etChing marker or felt tipped pen, mark connecting rods and caps to indicate cylinder number and orientation
of cap.
* Make sure the bearing shells are fined into the correct
crankcase bearing seat.
All bearing upper shells are grooved.
No.5 bearing shells are flanged to take crankcase end thrust.
Bcari ng lowershells are not grooved and are either .0254mm
undersized or standard size.
6. Using Molybdenum Disulphide grease lubricate No.5
main bearing shell thrust surfaces.
7. Lay cmnkshaft in upper bearing shells, and install lower
40
bearing is seated against crankshaft journal.

12. Place a piece of plastigage across width of bearing
journal, parallel to cr'.mkshaft centreline.
Makesureplastigageisnotplacedacrossoil hole in joumal.
13. Install connecting rodcap in original position asdescribed
in step 4. Tighten bolts as specified.
Hammer
~- -
Main Bearing
Cap --~
I--
'-', Main Beonng

Cap
Torque Wrench
Connecting Rod
& Cap
=----lh:::I-
Connecting
Rod cap
S. Remove connecting rod cap securing bolts and remove cap

and lower bearing shell.
6. Push piston and connecting rod up cylinder bore, so that
connecting rod i. free from crank.haft journal. Remove
bearing shell from connecting rod.
7. Clean crankshaft journal and mea'ure for out of round or
Engine
Stand
connecting rod cop to
torque ,
ta(X!r usmg a mIcrometer.
Replace crankshaft, if not a, 'pecified in CRANKSHAFT

section.
Rod BearingJournalDiamctcr ............ S3.93-S3.9Smm
8. Wipe oil from both inner and outer .urfaces of bearing
shell .
9.ln.pect innersurfaceofbearingshells for gouges, wear or
embedded foreign matter.
If foreign matter is found, determine its nature and source.
Inspect outer surface of bearing shell for surface wear
(indicate. movemcnt of shell or high spot in surrounding
material). looseness or turning (flattened tangs and wear
grooves), oroverheating (discolouration).
Thecrankshaft may be bent or have tapered bearingjournals
if uneven side to side wear is found. If needed, remove
crank.haft, refer to CRANKSHAFT section and inspect
crankshaft for bend or journal taper.
Bearing failure, other than normal wear, mustbeexamined
carefully. With crankshaft removed, check all connecting rod
and cr'dllkshaft bearing bores.
To check bearing bores:
(a) Install bearing caps with bearing shells installed. Tighten
cap bolts as specified.
(b) Measure bearing bores for taper and out of round.
Replace any pan if not as specified, refer to the applicable
pan description in thi. section.
Con Rod Bearing Bore Diameter ...... S6.871-S6.891mm
MaximumOutofRound .................................. O.Olnun
Maximum Ta()Cr .............................................. O.Olmm
Crankshaft Bearing Bore Diameter .... 6O.91-60.93mm
MaximnmOutOfRound ................................. O.Olmm
Maximum Taper .............................................. O.Olmm
10. Install bearing shells in original positions in connecting
rod and cap if inspection reveals that crank.haft is OK.
II. Pull connecting rod down onto crankshaft so that upper
Make sure that crankshaft does not rotate with plastigage

installed.
Connecting Rod Cap Bolt Specification 3S Nm
14. Remove connecting rod cap bolts, and cap. Inspect for
tlattened plastigage sticking to either crankshaft or bearing
shell in cap.
IS. Determine bearing c1eamnce by comparing width of
tlattened plastigage at widest point with graduation on
pla'tigageenvelopc. The number within the gmduation on the
envelope indicates the clearance.
Clearance between connecting rod bearings and crankshaft
should not exceed specitication.
* If a bearing is being fitted to an out of round journal, ensure
to fit plastigage to the maximum diameterof the journal.lfthe
bearing is fitted to the minimum diameter, and the journal is
out of round O.OOSmm, interference between the bearing
journal and journal will result in rapid bearing failure.
Connecting Rod Bearing Clearance ......... O.02-O.06mm
16. Make sure that connecting rod cap bolt threads and
connecting rod threads areclean and dry. Apply some engine
oil to the cap bolt threads.
Before final installation ofcap bolts, determine ifboltshave
stretched by comparing with a new bolt. Replace bolt!s as
needed.
17. Install bearing shells in connecting rod and cap making

sure notches in shells match up with recesses in connecting
rod and cap.
In.pect clearance of new bearing with plastigage as previouslydescribed.
18. Remove all remains of plastigageaftermeasuring. Using
clean engine oil lubricate bearing shells and journal. Install
connecting rod cap in original position as described in step4.
Tighten bolts and then loosen one full tum. Finally tighten cap
bolts as specified.
41
PISTON AND CONNECTING ROD

ASSEMBLY.
Connecting Rod Cap Bolt Specification ............ 35Nm
Piston and connecting rod assemblies can be removed while

the engine remains in the vehicle.
If the cylinder bore requires machining, remove the engine
assembly as described in ENGINE ASSEMBLY section.
remove piston and connecting rod, replace pistons and rings
in oversize seL'i.
Both piston and cylinder bore condition must be considered
together when fitting new pistons. Production and service
pistons have the same nominal weight and can be intermixed
without affectingenginebalance.lf needed, used pistons may
be fitted selectively to any cylinder ofthe engine. providing
they are in good condition.
Piston pin assembl ies and ring sets are available in oversizes.
Removal.
1. Disconnect battery earth lead and remove cylinder head as
described inCYLTNDER HEAD section.
2. To remove oil pan (sump) refer to OIL PAN (SUMP)
section and toremoveoil pump, suction pipe and screen refer
toOIL PUMP, SUCTION PIPE AND SCREEN section.
3.1nspectcylinderboresabove piston ring travel. Ifbores are
worn so that a ridge or similar exists. with a ridge remover,
remove.
Tum crankshaft so that piston is at bottom of stroke and cover
piston with a cloth to collect cuttings. this is to be done for
each cylinder.
4. Using an etching marker or felt tipped pen. mark all
connecting rods, caps and pistons to indicate cy Iinder identi-
19. With bearing shells installed and cap bolts tightened, it

should be possible to move connecting rod backwards and
forwards on crankshaft journal 3' allowed by end clearance.
Also, the crankshaft should tum without binding.
Connect Rod tocrankshaft end clearance 0.09-0.27mm
allowable .................................................. O.36mm
If connecting rod binds on crankshaft journal, loosen and
retighten bearing cap bolts.
If rod still cannot be moved or crankshaft binds, inspect
bearing cap to rod orientation, bearing clearance orconnecting rod alignment.
20. Install oil pump, suction pipe and screen as described in
OIL PUMP, SUCfION PIPE AND SCREEN section.
21. To install oil pan refertoOlL PAN (Sump)section in this
manual for details.
22. Install spark plugs and tighten as specified.
Spark Plug Specification .................................... 2S Nm
23. Using the correct amount of engine oil, refill the oil pan.
refer to LUBRJCAnON section for details.
24. Start engine and inspect for oil leaks, repair as needed.
also inspect engineoi Ipressure as described in CHECKING
OlL PRESSURE section.
fication.
S. As follows, remove rod assemblies and piston:

(a) With connecting rod crankshaft journal straight down
(Bottom Dead Centre), remove connecting rod cap bolts and
remove cap with bearing shell.
(b) Push piston and connecting rod from cylinder using a long
guide. Remove guides and install cap and bolts toconnecting
rod.
"
CAMSHAFT JOURNAL
Care must be taken during bearing removal and installation.

not to damage bearings that are not being replaced.
Camshaft does not run on bearings, it is installed directly
into cylinder head.
Using clean engine oil, lubricate the camshaft journals. Make
sure camshaft rotates without binding.
Ifcamshaft binds, remove camshaft, check journals for high
spots. heat discolouration or damage. Remove any burrs if
present. Inspect camshaft journal clearances.
Journal Diameter ................................ 37.94-37.96 mm
Joomalout-or.. round ..................................... O.013mm
Replace the camshaft, if camshaft journals are not as specified.
(i!J ,
-\,
" -l
.;~{
\,
~)
-:D\..
"
~\'
,' J
I
Use a hammer handle to push
assembty
6. Remove all other piston and connecting rod assemblies

usi ng the same procedure.
42
or have excessive clearance in ring grooves. Pistons should be

replaced if faulty or darnaged.
Pistons are cam ground, which means that the diameter at
right angles to the piston pin is greater than the diameter
parallel to the piston pin. When a piston is checked for size,
it must be done at points 90" to the piston bore.
Dismantle.
Rod Assembly
Compression Rings -
__
Oil Ring Spacer _ _

Oil Ring - - --
~ ;:::-
the piston pin hole axis

Piston
Oil Ring Spacer _ _
........
Piston _ _ _ _ __
Connecting
Micrometer
Connecting Rod
Cap BoH
- -- i
Upper Connecting
Rod Bearing ----''--c=
Lower Connecting
Rod Bearing
Available in Oversizes
4. Check piston pin bores and piston pins for wear. Piston pins
and piston pin bores must be free of scuffing or varnish when
beingmeasurcd. Use a micrometertomeasurc the piston pin,
and a dial bore gauge or an inside micrometer to measure
piston pin bore.
Piston and pin should be replaced if not as specified.
PistonPin Diameter .......................... 23.172-23. J85mm
/J
"\\..
Connecting Rod
Cap
_ _ conned___
in:g..:R:::od==~.::~~~
Piston Pin Clearance ............................ 0.008-0.013mm
1. Expand and slide piston rings off to remove and dispose of

!hem.
Worn rings may have sharp edges ensure to take care when
removing piston rings.
2. Piston pin can now be removed as follows:
(a) Install remover guide into base, and put assembly in a
press.
(b) Install mandrel, into piston pin.
(c) Using care to locate piston on support and base and press
piston pin out of connecting rod.
(d) Remove assembly from press. Remove pin from support
and remove mandrel from piston and connecting rod.
Inspection.
l. ThoroughJyclean carbon from piston heads and from ring
grooves using a suitable tool and remove any gum or varnish
from piston skirts using a suitable cleaning solvent.
2. Check cylinder walls for ridges, roughness or scoring
which indicates excessive wear. Inspect cylinder bores for
taper and out-of-round using an accumte cylinder gauge at
top, middle and bottom of bore, both parallel and at right
anglestocentrelineofengine.RefertoCYLINDERBLOCK
section fordetails.
3. Examine piston skirt thoroughly for scored or rough
surfaces, cracks in skirt orcrown, chipping, broken ring lands
or uneven wear which would cause rings to seat improperly
S. Remove bearing shells from connecting rod, install cap and

boll. Tighten bolts as specified.
Connecting Rod Cap BoltSpecification .............. 3SNm
6. Place connecting rod assembly on a checking flxtureand
inspect rod for twist or bend.
Replace if twisted or bent, do not attempt to straighten rod.
Inspect new connecting rods using the sarne procedure before
usinglhem.
Connecting Rod Alignment Max. Specification

Bend ................................... 0.020mmper25.4mm
Twist ................................... 0.038mm per 25.4mm
7. Check outside ofconnecting rod bearing shells and internal
diameter of connecting rod big end for wear indicating high
spots in the rod big end.
8. Remove cap bolts and inspect boll' for stretching by
comparing them with a new bolt, if stretched, replace.
Assembly and Installation.
J. Using engine oil, lubricate piston pin and piston pin bore.
Z.lnstall piston pin on mandrel.
3. Assemble installer guide and piston support to base.
4. Using temperature indicating crayon, heat connecting rod
to 28O"C.
Support rod as illustrated. The flre brick prevents excessive
heat loss. [f the small end is laid flat on the hotplate, heat flow
is more even and rapid.
43
S. The green colour of the crayon will tum black when the
temperature is reached (28O'C).
6. Using a heat proof glove, pick up connecting rod.
7. Quickly install piston and connecting rod over guide.
8. Quickly push piston pin into place with a mandrel. until
piston pin bottoms spring inside base.
* You may need an assistant to help, by holding the parts as
the piston pin should be installed within 3-4 seconds once
connecting rod has been removed. After 4 seconds, the pin
willjam in the connecting rod. requiringtheuseofahydraulic
press.
9. To install piston rings refer to PISTON RINGS section.
10. Make sure connecting rod bearing shells, pistons, cylinder bores and crankshaft journals are totally clean, then,
using clean engine oil, coat cylinder bores and all bearing
19. Measure side clearance between crankshaft journal and

connecting rod.
Connecting Rod Side Clearance ............. 0.09-O.036mm
Irsidecleamnce is not as specified, to check bearing clearance
refer to CONNECTING ROD BEARING section, or
connectingrodalignment.
20. Install remaining piston and connecting rod assemblies
using the same procedure.
21. To install cylinder head refer to CYLINDER HEAD
section, and to install oil pump, suction pipe and screen refer
to OIL PUMP, SUCTION PIPE section.
22. To install oil p,mrefertoOlL PANsection in this manual.
23. Start engine and inspect for oil leaks, Repair as needed.
PISTON RINGS.
surfaces.
11. Position thecrankpin straight down before installation of

a piston and rod assembly in its bore.
12. Remove cap, and with bearing upper shell seated in
connecting rod, install the 'short' guide tool into inner bolt
hole. Install 'long' guide tool into the other bolt hole.
Guides hold upper bearing shell in place and protects crankshaftjournal from damage during installation of connecting
rod and piston assembly.
13. Make sure piston ring gaps are separated as described in
PISTON RINGS section.
14. Using clean engine oil, lubricate piston and rings. With a
suitable ring compressor, compress rings. Instal Ieach piston
and connecting rod assembly into its cylinder bore.
15. Lightly tap piston into its bore, using a hammer handle,
whi Ie holding ring compressor firmly against cylinder block
until all piston rings have entered bore.
Front of Engine
into
Oil Ring Rail Gap
'-......
'nd compres
gap
Oil ring
~pacergap
TOp
compression
nng gap
Eng067
Installation.
*Thepistonshavethreerings(twocompressionringsandone
oil ring). The top ring is a molybdenum filled, balanced
section, barrel lapped type. The second ring is an inverted
torsional taper faced type.Theoil ring is of three piecedesign,
comprising two segments and a spacer.
16. Push piston down bore until connecting rod scats against
crankshaft journal.
17. Remove connecting rod guides. Install bearing cap and
lower bearing shel Iassembly. Install cap bolts and tighten and
then loosen one full turn. Then tighten again as specified.
1. Using a set of rings comparable in size to the piston being

used install compression ring in relevant cylinder bore, then
using the head of a piston, press ring down into the bore.
Using a piston in this manner will place ring square with
cylinder wall.
* Ensure not to diston the ring during this operation, orit may
bind in the piston ring groove. Fit each ring separately to the
cylinder in which it is going to be installed.
2. Using a feeler gauge, measure gap between ends of ring.
Compression Ring End Gap Specification:
Both Rings ............................................... O.25"().5Ontm
Remove ring and try another, if the gap between the ends of
a compression ring is below specification. The ring gap may
be enlarged by filing.
Connecting Rod Cap BoltSpecilication .............. 3SNm
18. Turn crankshaft to make sure crankshaft and connecting

rod can move freely. if crankshaft binds, check bearing cap
to rod orientation again and bearing clearance orconnecting
rod alignment.
44
Cylinder Bore
Ring

2. To remove oil pump, suction pipe and screen refertoOIL
PUMP, SUCTION AND PIPE section and to remove
crankshaft balancer refer to CRANKSHAFf section.
3. To remove timing chain and crankshaft sprocket refer to
TIMING CHAIN COVER AND CHAIN section.
4. Remove spark plugs, and using an etching marker or felt
tipped pen to mark connecting rod caps to indicate cylinder
number and orientation of cap.
s. Removeconnecting rod caps and bolts and push connecting rods away from crankshaft.
6. Remove main bearing cap bolts and caps.
Feeler
Eng066
3.lnspeet gap between ends ofeach oil control ring segment.

Oil Ring Steel Rail Gap Specification:
Oil Ring Steel Rail Gap .......................... 0.38 - l.40mm
4. Carefully remove all traces ofcarbon from ring grooves in
piston and check grooves for any chips or burrs that might
cause ring to bind when fitting.
S. Slip outer surface of each compression ring in respective
piston ring groove and roll ring entirely around groove to
ensure that ring is free. Also measure ring to piston groove
sideclearance.
Piston Ring Side Clearance:
BothCompression Rings .......................... O.OS-O.lOmm
Wear Limit ...................................................... O.lSmm
on Control Ring .................................. O.028-O.2()6mm
Try another ring ifit is too tight. Tfno ring can be found that
fits the specification, the ring may be ground to size using
emery paper placed on a piece of glass.
*High spots in the ring groove may becleaned up with careful
use of a fine tile, do not try to cut the piston ring groove.
6. Install oil ring spacer in bottom piston ring groove.
* The ends of the spacer butt against each other.
7. Install one steel segment from top of piston downward into
oil ling groove and install remaining steel segment from
bottom of piston skirt upwards into the oil ring groove.
8. Install compression rings in first and second grooves of
each piston.
* Make sure theconectcompression ring are installed in the
first and second grooves, and the correct way up.
9. Do a final test of ring fit in piston grooves. Separate ends
as illustrated.
*Donotinstall piston with ring gaps in line, as this will allow
compression leakage at this point.
* Remove the rear main bearing cap by removing cap bolts,

and using a soft faced hammer tap the cap to break cap to
crankcase seal. Install side hammers into cap oil pan bolt
7. Lift crankshaft fTOm crankcase and remove flywheel!
driveplate from crankshaft bolts and remove flywheel!
driveplate.
8. Remove key from front end ofclIDlkshaft, if needed, using

and hammer.
CRANKSHAFT.
RemoVal.
* To check bearing clearance before removing crankshaft
from crankcase refer to CONNECTING ROD BEARINGS and MAIN BEARING section for details.
1. When engine is removed from vehicle and mounted in a
suitable stand, remove oil pan, refer toOIL PAN (SUMP)
45
1. To replace rear main bearing oil seal refer to CRANK

SHAFf REAR MAIN BEARING OIL SEAL section.
2. Install key to front end of crankshaft if required.
3.lnstall flywheelldriveplate to crankshaft and tighten bolts
a.specified.
* The bolt holes are unevenly spaced so they can only be
installed with the flywheelldriveplate in the Cullect position.
FlywheeVDriveplate Bolt Specification .............. 1l0Nm
4.lnspect main bearing clearance, if needed, refer toMAIN
BEARINGS section for details.
5. Using a clean engine oil lubricate all crankshaft journals
and main bearing upper shells in crankcase.
6. Sit crankshaft in place in main bearing upper shells in
crankcase. Ensure not to damage crankshaft thrust flange and
No.5 main bearing thrust faces. Also ensure not to contact
connecting rod journals with connecting rod and install main
bearing caps.
Using a thin film of Loctite 515 Gasket Eliminator or
equivalent apply to rear main bearing cap to crankcase
mating surface. Keep sealant out of bolt holes and use
sparingly.
Make sure that the bearing cap~ are installed onto the
Inspection.
1. Using a suitable cleaning solvent, wash crankshaft and dry
with compressed air.
2. Check crankshaft oil passages for obstructions.
3. Check all bearing journals and thrust surfaces for:
(a) Gouges
(b) Overheating (Discoloumtion)
(c) Cracks
(d) Grooving
(e) Chips
(I) Roughness
The crankshaft must be machined or replaced if it has any
burned spots, cracks or sever gouging. Slight roughness may
beremoved using afine polishing cloth soaked inclean engine
oil. Burrs may also be removed using a fme oil stone.
4. Check connecting rod and main bearing shells forembed
ded foreign material and determine its source.
5. Using a micrometer measure bearing journals for taper,
times in different positions
crankcase in the correct manner.
Tighten the bolts finger tight.

7. It will be necessary to line up thrust surfaces of No.5
bearing shells, before tightening main bearing cap bolts.
Move crankshaft fore and aft the length of its travel several
times (last movement forward) to do this.
8. Ensure all main bearing cap bolts are tightened as speci
fied.
Main Bearing Cap Bolt Specification ................. 85 Nm
9. Use a feeler gauge to measure crankshaft end float between
front of No.5 main bearing shell and crankshaft thrust faces,
you will need to force crankshaft forward to do this.
Crankshaft End Float Specification ........ O.IOO.20mm
Wear Limit ...................................................... O.3()rrun
Replace No.5 main bearing shells if clearance is excessive.
10. Using RTV 1080 sealant or equivalent, inject into rear
main bearing cap side grooves. Continue to inject sealant until
you can see sealant at joint gaps.
11. Pull connecting rods up to crankshaft journals, using
Main Journal
excessive wearorout-of-round.
Main BearingJournal Diameter

Sta.rldard .............................................. 6().91-60.93mm
Ovality .................................................. O.OIOrrtm max.
Out-Of-ROlI.J1d. ....................................... O.OlOmm max.
Connecting Rod Journal Diameter
~lIlIIIJJJrlI
~:J.!J~~:J.!J~11lUrIl
Ovality .................................................. O.OlOmmmax.

OUtOfRoond ....................................... O.Ollhnmmax.
6. Inspectcrankshaft forrun-outby supporting front and rear
main bearing journals in 'Y' blocks and checking journals
with a dial gauge.
Crankshaft RunoutSpecification .............063mm max.
7. Place a dial gauge indicator at crankshaft rear flange and
inspectreartlangerunout. During this inspection, make sure
that crankshaft is thrust forward on 'Y' blocks so that there
is no possibility of crankshaft end float affecting dial gauge
reading.
Cr.mkshaftRearFlangeRunout ..................... O.OSmm.
8. If not as specified, replace crankshaft.
9. Ensure all traces of sealant are cleaned from rear main
bearing cap and cmnkcase.
lnstaUation.
46
guide pin tools.

12. inspect connecting rod bearing clearances. if needed.
refer to "Connecting rod bearing" section for details.
13. Lubricate crankshaft connecting rod journals and bearings, install connecting rod caps and bolts.
14. Tighten connecting rod cap bolts and then loosen onefull
turn. Tighten bolts as specified.
Connecting Rod Cap Boit Specitication .............. 35Nm
nicks or burrs and correct as required.

Inspect crankshaft seal surface for nicks, burrs or damage.
Repair or replace crankshaft as required.
7. Apply engine oil to new seal inner and outer surfaces.
Ensure thatT-handle of tool is loosened right off. Slide seal
over mandrel until itbottoms squarely against outer collar of
tool.
S. Attach tool to rear of crankshaft by tightening two knurled
attaching screws until tight.
** :Before continuing with step 9, the crankshaft must be in
the fully rearward position before installing the new seal. To
achieve this, either pull on special tool or push on crankshaft
balancer. Ensure that crankshaft is held in this position while
installingseal.
9. Turn T-handle of tool so that outer collar pushes seal into
its bore and continue to turn handle until additional resistance
is felt. Do not over tighten T -handle otherwise damage to the
tool may result. This will ensure the seal is installed to the
correct dimension inside thecylinder block.
Should the seal be installed further than required, the oil
return slot in the rear main bearing cap would be cut offand
this would result in an overloading of the seals lipcapability
and cause oil leakage.
10. Remove seal installing tool from crankshaft.
11. If necessary, reinstall spigot bearing, as previously
described in "SPIGOT BEARING - INSTALL" in this
chapter.
12. Clean flywheeVflexplateattaching bolt threads in rearof
crankshaft using a thread tap.
Install new flywheeVflexplatc and attaching bolts, tighten
bolts to the correct torque specification.
FlywheeVflexplate bolt tightening order:
initially .................................. torque bolts at IS-22Nm
finally .......................... tighten the bolts to lOO-IISNm.
* The retainer plate is installed with the dimple on the plate
facing away from the flex plate.
13. Reinstall transmission, check engine and transmission
lubricantlevels.
14. Road-test vehicle and check for lubrication leaks.
Engine
Stand
Torque Wrench
Connecting
Rod cap
connecting rod cap to

torque .
15. Using a feeler gauge, mea~ure clearance between connecting rod caps and crankshaft journal flanges.
Connecting Rod Side Clearance .............. 0.10-0.20 mm
16. Tumcnmkshaft to make sure crankshaft andconnecting
rods have free movement. Inspect orientation ofbearing caps,
correct fitting of bearing caps (mains and connecting rods) or
fitting of bearing shells or bearing clearance, if crankshaft
binds.
17. Toinstall flywheeVdriveplaterefer"FlywheeVdriveplate"
section.
18. To install crankshaft sprocket, timing chain, and fronl
cover refer to 'Timing chain, SprockeL~ & shaft gears"section
for details and to install crankshaft balancer referto Crankshaft balancer section.
19. [nstall spark plugs and tighten as specified.
Spark Plug Torque Specification ................ _...... 20 Nm
20. To install oil pump suction pipe and screen refer to "Oil
pump suction pipe and screen" seclion and to install oil pan
refer to "Oil pan (Sump) and gasket" section.
REAR MAIN OIL SEAL
Replace
l. Disconnect battery earth lead.
CYLINDER BLOCK.
Inspection.
l. When engine is removed from vehicle and mounted in a
suitable engine stand, remove all parts as outlined under the
particular part heading in this section.
2. Clean all cylinder block gasket surfaces.
3. Remove all coolant jacket welsh plugs, oil gallery screw
plugs.
4. Clean cylinder block thoroughly using a suitable cleaning
solution. Rush with clean water or steam. Spray or wipe
cylinder bores and machined surfaces using engine oil.
* Caustic cleaning solutions destroy all bearing and alloy
materials. All bearing and alloy parts if not removed before
cleaning must be replaced.
2.Remove transmission, as described under"Manuai transmission" and "Automatic Transmission" in this manual.
3. Remove flywheeVdriveplate, as described in "Flywheel/
driveplate" in this manual.
4. Vehicles with manual transmission, remove spigot bearing, as previously described in "Spigot bearing" section.
5. Locate a piece of shim brass between seal lips and
crankshaft. This is necessary so as to protect crankshaft seal
surface. Using a suitable lever, pry out seal, levering against
shim brass strip and remove seal.
6. Check seal bore in cylinder block and rear bearing cap for
47
Do not use caustic solutions toclean bearing material or alloy

pans.
S. Check all oil passages for obSb"Uctions.
6. Using a straight edge and feeler gauge, inspect cylinder
block deck surface for natness.
If any distortion or irregularil y is less than speci lied, cyl inder
block surface may be machined.
Cylinder Block Deck Surfaces Flatness Specification ....
................................. 0.18 max or .076mm per 152mm
Replace cylinder block if irregularity or distortion is more
than specified.
7. Check oil pan and front cover area for burrs or damage.
Minor changes may be cleaned up with a line mililile.
8. Tf needed, clean all threaded holes using a suitable threaded
tap or drill out and install thread insen.
The following cylinder block checks require the main bearing
caps to be installed and bolts tightened as specified.
Main Bearing Cap BoltSpecification ................. 8S Nm
Make sure that the main bearing caps are installed into the
crankcase using the correct procedure.
By lightly tapping into place, install bearing caps to cylinder
block.
DO NOT PULL THE CAP INTO PLACE USTNG THE
CAP BOLTS.
9.lnspecl crankshaft and camshaft bearing bore for concentrically and alignment. Measure crankshaft and camshaft
bearing bore.
Crankshaft Bearing Bore
Do not try to machine oversize pistons to fit cylinder bores,

this will desrroy the surface rrearrnentand affect the weight.
The smallest possible oversize service pistons should be used
and the cylinder bores should be honed to size for proper
clearances.
Mea.ureall new pistons at right angles to the piston pin bore,
as per diagram, before the honing or reboring operation is
started.
Honing is recommended forb"Uing bore ifcylinder bore wear
does not exceed specification. The bore should be trued up
by boring and then hone finished, if wear or out-of-round
exceeds specification.
All crankshaft bearing caps must be in place and tightenedas
speci lied when reboring cylinder bores, to prevent distonion
of bores in linal assembly.
Leave 0.025 mmon the diameter for final honing togive the
specified clearance when taking the final cut.
Follow the Hone Manufacturers recommendations for the
use of the hone and cleaning and lubrication during honing.
Noting the following points.
Pa,s the hone through the entire length ofthe cylinder bore at
therate ofapproximately 60cycles per minute when fi nished
honing. This should produce the desired 45 cross hatch
pattern on cylinder walls which will ensure minimum oil
consumption and maximum ring life.
Each piston must be fitted individually to the bore in which
it will be installed and marked to ensure correct assembly
during the final honing. Afterthe final honing and before the
piston is inspected for tit, each cylinder bore must be washed
and dried thoroughly to remove all b"aces of abra.ive and then
allowed to cool. Applycleanengineoil to cylinder bores. The
pistons andcylinder block must be at a common temperature
before inspecting.
The glazed cylinder walls should be slightly dulled when new
piston rings are installed without reboring cylinders, but
without increasing the bore diameter, by means of the linest
grade of stone in a cylinder hone.
Proceed as follows to inspect piston to cylinder bore.
1. Using a clean cloth wipe cylinder walls and pistons and
apply clean engine oil to cylinder bores.
2. Measure the bore accurately using an inside micrometer.
3. Measure piston diameter and subrract piston diameter
from cylinder bore diameter to detennine piston-to-bore
clearance.
Piston to Bore Clearance ......................... 0.01-0.03 mm
4. Mark each piston with cylindernumberto which it will be
fitted and proceed to hone cylinders and fit pistons.
Handle the pistons with care and do not attempt to force
them through thecylinderuntil cylinder has been honed to the
COllect size, as pistons can be damaged through careless
handling.
Assemble parts as described under the COllect heading in this
section. Ifcoolant and oil gallery plugs were removed when
dismantling, install using specified sealant.
MaxinlumOut-Of-Round ............................ 0.010 mm
Replacecylinder block if not as specified. If examination of

the outside of the bearing shells shows rrtinor high spots,
remove high spol. from seats using a fine rrtill file.
10. Measure cylinder bore walls for taper, excessive ridging,
oversizeandout-of-round.
Standard Bore Diameter
4.0L ..................................................... 92.2592..31 mm
TaJ)er ............................................................ 0.025 mm

Wear Limit .................................................. 0.245 max
4:),jt~c:J1f-IRt()llI1ct ........... 0.025 I11Ill
Wear Limit .................................................. 0.127 max
Ifbore is worn beyond limits, it may be rebored, honed and
lilled with oversize pistons. The smallest available oversize
piston should beselected, refertoCYLlNDER RECONDITIONlNG AND PISTON FITTlNG section for details.
Cylinder Reconditioning and Piston
Fitting.
It will be necessary to smooth bores to fit new pistons, if one

or more cylinder bores are scored, rough or worn beyond
lirrtits.
It will not be necessary to rebore all cylinders to the same
oversi7..e order to maintain engine balanceif few bores require
correction, since all oversize service pistons are held to the
same weight a. standard size pistons.
48
Problem Diagnosis.
Low Oil Pressure
I) Blocked oil filter.

2) Incorrect oil viscosity for expected temperature, or oil
diluted with moisture or unburned fuel mixtures.
3) Excessive bearing clearance.
4) If the oil level is low, fill to mark on dipstick .
S) Oil pump dirty/worn, or oil pump suction pipe screen
6) Incorrect or failing oil pressure sender.
Problems and Possible Causes.
Problems should be corrected, whcn proper diagnosis is

made, by repair, adjustment or part replacement as needed.
Refer to the correct section in this manual.
High Oil Loss
I)Tighten bolt' andlor replace gaskets and seals as required
for external leaks.
2) Check oil with caron a level surface and allow adequate
drain down time to ensure a correct reading of dipstick.
3) Severe usage such as towing or continuous high speed
driving will nonnally cause oil consumption to increase.
4) PCV system failure.
S) Use recommended S.A.E viscosity for current temperatures. Refer to LUBRICATION Section for details on
incorrect oil viscosity.
6) Valve guides andlor valve stem seals worn, or seals
omitted. Ream guides and install oversize service val ves andl
Engine Knocks
WHEN ENGINE COLD AND CONTINUES KNOCKlNG FOR TWO OR THREE MTNUTES
Increases with torque
\) Tighten or replace as required if drive pulleys or balancer
2) Replace piston if clearance from piston to bore is
excessive.(Coldengine piston knock usually disappears when
the cylinder is grounded out. Cold engine piston knock which
disappears in 1.5 min. can be considered acceptable.)
3) Connecting rod bent.
HEAVY KNOCK WITH TORQUE APPLIED
1) Replace parts as required of pulley hub or balancer broken.
2) Loose torque converter to flexplate bolts.
3) Check if exhaust system contacting underbody.
4) Cracked flywheellflexplate.
S) Main bearing cleamnce or connecting rod bearing clear-

7) Allow enough time for the piston rings to seat. Replace
worn or broken rings as needed, if rings have been incorrectly
installed, worn or broken, or not seated.

8) Piston incorrectly installed or misfitted.
G~kets.
I) Incorrectly tightened fasteners ordamagedldirty threads.

2) Worn or damaged gasket (cracking or porosity).
3) Fluid pressure/level too high.
4) Incorrect sealant used (when requircd)
Inspection ofSeals.
I) Damaged seal bore (burred, nicked, scratched)
2) Wornorioose bearing which causes excessive seal wear.
3) Worn or damaged seal or incorrect installation.
4) Fluid pressure/level too high.
Dilleaks are easily located and repaired by visually finding
the leak and replacing or repairing the required parts.
I) Detennine whether the fluid is transmission lubricant,
engine oil, power steering fluid etc.
1) Run the Car at normal operating temperature and park the
sboold beable to find the approximate location of the leak by
3)Useadegreaserorsteam to clean the area of the leak,drive
the car for a few kilometres. Then visually inspect the
suspected part for signs of an oil leak.
Therearernany dye and light kits available for finding leaks.
a) Pour required amount of dye into leaking part.
b) Operate the Car under normal opemting conditions as
c) Shine the light in the suspected area. The dyed fluid will
anccexceSSJVc.
Light Knock while Hot
I) Inspect fuel quality if preignition or spark knock.

2) Loose torque converter to flexplate bolts.
3) Connecting rod clearing clearance excessive.
KNOCKS ON FIRST START -UP ONLY LASTING A
FEW SECONDS
1) Incorrect oil viscosity. Install correct oil viscosity for
2) Hydraulic lifter bleed down.
Some valves will bcopen when the engine is stopped. Spring
problem is consistent should repairs be attempted.
3) Replace crankshaft thrust bearing shells if excessive
crankshaft end float.
4) Replace worn parts if front main bearing clearance is
excessive.
Hydraulic Lash Adjusters
The lifters are extremely simple in design and mrely need

attention, readjustments are not required and servicing requires only that care and cleanliness be exercised whilst
handling the parts. Using a piece of garden hose nearthe end
ofeach intakeand exhaust valve with the other end of the hose
to the ear, is the easiest method for locating a noisy lash
adjusters. Using this method, the sound is localised, which
makes it easier to find out which lifter is faulty . Or place a
49
finger on the face of the valve spring relainer. If the lifter is

not functioning collcclly. adefinite shock will be fclt when the
Clearance in guide mm
All .............................................................. 0.015-0.060
Valve spring installed height ................... 46.0-46.8mm
Valve head margin thickness ................... O.794mm min.
Valve oversize available ................................. 0.254mm
valve returns to its seat.
Specifications
VALVE - EXHAUST
Material ........................ High Alloy Exhaust ValveSteel

Diameter head
GENERAL
Type .................................................. ... In line 6 cyJinder
4.0 L ............ .............. ....... ......... ....... ....... ...... 39.00 mm
Displacement
16HO ............................................................. 41 .00mm
Multi Point Injection M.P.E.F.1. .......................... 4.0 litre

Compression ratio:
All (except T6HO) ................................................... 9.3: 1
161-10 ................. .. ......... ............ ...... ........ ............. 9.35: 1
BoreandStroke(nominal):
4.0 ......................... ....... .............................. 92.26x99.31
FiringOrder ............................................... 1-5-3-6-2-4
Cylinder numbering ....... ............................. front to rear
Fuelrequirements ........ ................................... Unleaded
.'owerkW ................................................ kW @R.P.M.
4.0 M.P.E.F.l. .............................. ............... 157 @ 4900
4.0 16HO ................ .. ................................... 160 @ 5000
Fairmont Ghia (EFII & EL) ......................... 162 @ 5000
TorqueNewtonmetre ............................... kW @R.P.M.
4.0 M.P.E.F.I .............................................. 355 @ 3000
4.0 16HO .................................. ................... 366 @ 3150
Fairmont Ghia (EFLI & EL) ......................... 36 1 @ 3150
Taxable Horsepower- (RAC):
4.0L ........... ........... ......... ............. ......... ... .............. .. 31.7
Diameterstem .......................................... 8.67-8.69mm
Angle face valve ................. ,' .................................... 44

Angle valve seat .......... ..... .... ........... ... ...... ..... ... .... ..... 45
Width valve seat .......... ....... ......... ....... ...... 1.78-2.29mm

ClearanceinbFUide ............... ....... .............. O.04-O.08mm
ValvespringinstaJJedheight ....................... 4646.8mm
Valve head margin thickness .. ................. 0.794mmmin.
Valve oversize avail ........................................ O.254mm
VALVE SPRINGS
Spring length
4.0 L ................................................................ 55.1 mm
16HO ............................................................... 55.5 rnm
Allowable variance in spring end length ........... 1.6Omm
Valvespringcompressed ........................ Ioad @ height
4.0 L .............................................. 39.43 kg @ 34.0 mm
16HO ............................................ .41 .43 kg @ 34.0 mm
Val ve spnng
. .IDstalIedh eIght
' ....................... 46.0-46.8mm
VALVE TIMING
CYLINDER BLOCK
4.0 litre
Inlet
Borcdiameter .............................................. 92.25-92.3 1

Boreout-of-round ................................... 0.127 mm max .
Bore taper .............................................. 0.254 mm max.
Cylinder block to cylinder head surface flatness ............... .
................. 0.18mm max ,overall orO.076mm per 152mm
Opens - BTC ................................ ..... .. .. 16'

Closes - ABC ........... ............................. 68"
Opens - BBC ......................................... 6~
Exhaust
Closes - ATC ............... ....................... .. 18"
4.0 litre 16HO
Inlet
Opens - BTC ......................................... 14"
Closes - ABC .. ... ............. ..... .... ...... ..... .. 7C!
Exhaust
Opens - BSe ......................................... 58"
Closes - ATC ........................................ 22'
CYLINDER HEAD
Deck Hight ................................................... 0.0-0.3 mm

Combustion chamber volume "cc"
(with valves and spark plugs inslalled)

4.0 ................................................... ...... ..... 62.25-64.75
4.0 16HO ........................ ........................... 58-60 approx
CAMSHAFT
BearingJournaIDiameter(mm)
All .............................................................. 37.94-37.96
XR6 run unique camshaft
CamshaftJollmal Out-of-round .............................. 0.013
Camshaft Free Play ................ ......... .............. .... 0.05-0.6
VALVE -INTAKE
Material ................. High Manganese Med . Carbon Stccl

Diameter head (mm)
4.0 ................................................................. 47.00lnm
Diameterstem (mm)
All .................................................................. 8.67-8.69
Angle valve face ........................................................ 44
Angle valve seat ......................................................... 45
Width valve seat ............................................ 1.5-2.Omm
PISTONS
Material .............................................. Cast Alum Alloy

Piston d'lameter .................................... 92.23-92.29 mm
Piston Pin Bore Dia. (AII engines) ..... 23. 172-23. 185 nun
50

Piston to bore clearance ............... ... ........... 0.010-0.030
COOLANT
Ring Groove widths:

Compression ring upper ............................. 1.52-1 .54 mrn
Compression ring lower ........... .................. 1.52- I .54 mOl
Oil control ring ...................... .................... 3.03-3.06 mm
Aluminium Head ............. ................... MotorcraftRI -3 B
Torque Wrench Spec
Nm
AutomaticTransmission ............................... ......... 44-56

Camshaft sprocket bolt .......................................... 50-60
Clutch pressure plate to flywheel bolt... ................... 20-25
Connecting rod cap nuts .............................................. 35
Coolant temperature sensor ...................................... 8- I2
Cylinder block coolant drain plug ........................... 34-54
Cylinder head bolts:
Step 1 ................................................................. ........ 40
Step 2 ............... ......................................................... 90'
Exhaust manifold to cylinder head ............................... 27
Manifold slip joint ............................................ Studs 30
.... ................................................................... Nuts 25
Crankshaft balancer bolt .................................... I 15-I 35
Engine mount to bracket and front crossmember nut 35-65
Engine mount bracket to cylinder block bolt ............ 35-65
E.F.1. Fuel rail to manifold .. .. ......... ..... ................... 18-24
FI ywheellDriveplate bolt .................................... 100-1 15
Front cover bolt ...................................................... . 9-12
Generator support bolt/stud .................................... 40-50
Intake manifold Lower .............. .................................. 20
Intake manifold Upper ................................................ 16
Main bearing cap bolts ......... .. ................................ 81-95
Manual Transmission ............................................ 36-50
Oil filter insert ....................................................... 14-20
Oil filter ..................................... Hand tight then 3/4 tum
Oil Pump to Cy linder Block ................................... 16-20
Oil Pump Cover Plate ................................... ......... 12- I 6
Oil Pan (Sump) ...................................................... 10-12
Oil Pan (Sump) Drain Plug .................................... 20-25
Oil Suction Tube to Oil Pump ................................ 16-20
Rockercover .................. ......................... .................. 4-7
Rocker assembly bolt ................................... .......... 24-34
Rear mount to extension bolt .................................. 40-50
Rear crossmcmber to side frame bolt ...................... 40-50
Spark plug .......................... _............. ......... ... .. ..... .. 20-30
Support to rear mounting nut .................................. 20-25
Starter motor to engine mount bracket bolt ............. . 15-35
Water pump to cylinder block bolt ............................... 20
Water pump pulley to hub bolt ............................... 12-20
PISTON RINGS
AU Engines:
Compression ring upper

Ring width ... ............................. .............. 1.465- I .490mm
Side clearance ............................................ O,05-0.10mm
Gap " ................._.......................... ,............ O.25-0.50Inm
Compression ring lower
Ring width ............................ .................. 1.465- I .490mm
SidecJeamnce ............................ .. .............. 0.05-0. 10mm
Gap ........................................................... O.25-0.5Omm
O~ Control
Ring.
Type .............................. Segmented with Circumferential
Rail gap(Steel Rail) ................................. .. 0.38-1 .40mm
CONNECTING ROD
Type ... ............................. Malleable Ca.t Iron 'I' Section

Length (centre to centre) +/- 0.025 ... .......................... nm
3.2 ........................................................... 159.36-159.28
3.9,4.0 ..................................................... 149.38- 149.33
Alignment
Bend .......................................... O. I 0 mm
Twist ............... ,_ ......................... 0.02 mm
PISTON PINS
Material ................... Steel-Case Hardenedand Tempered

Length - All (except 4.0L) ...................... 76.45-77 .22 mOl
4.0 L .................................................... _64.50-65.00rnm
Diameter All engines .......................... 23.162-23. 175 mm
Piston to pin clearance All engines ............. 0.008.013 mrn
CRANKSHAFT
Material ............................................. Nodular Cast Iron

Main Bearing Journal
Diameter All engines .............................. 60.91-60.93 nun
Out-of-round .................................................. 0.0 I0 mm
Taper .......................................... ................... 0.008 nlln
Crankshaft end float .................................... 0.10-0.2 mm
Wear Limit ................................ 0.30 mm
Bearing Clearance ............... O.02-0.04mrn (max 0.6 mm)
End Thrust .. ......... .. ....... ....... Against Main Bearing No.5
Connecting Rod Journal Dia: +/- 0.025 ...................... mm
All .. .................................................. ......... . 53.93-53.95
Out-of-round .................................................. 0.0 I0 mm
Taper .................. _.... _..................................... O.OJOrrun
Bearingclearance .............. 0.02-0.04mrn (max 0.06 mm)
51
va ENGINE MAINTENANCE &

REBUILD
Subject
Page
Subject
Page
GENERAL DESCRIPTION ........................ 54
Valve Lifters ................................................................ 60
Engine Serial Number .. .... ........................................ .... . 54

Engine Construction .. .... .. ...... ....................... .. ... ... .. ...... 54
RemovaJ ... .................................................................... 60

Dismantle ... ................. .. ... ....
61
Clean & ]nspecl .............................. ...... .. ...................... 61
Assembly ... ..... ....... ... ............................ .... ... ... .. , ........... 61
Testing Lifter ................. .. ......................................... .... 61
Installation .. .. ................................................................ 62
Cylinder Heads ........................................................... 62
Removal ........................... .. .................................. .. ...... 62
Lnsrxx:tion ..................................................................... 62
lnstallation .................................................................... 63
Cylinder Head Re<Xlditioning ................................... 64
Disnlalltle .. ............................... .. .................................. 64
Clean ............................................................................ 64
Cylinder Head Inspection .............................. .. .............. 65
Valve Guide.Iii ..... .. ......................................................... 65
Cleanmce Checking ..................... ................................. 65
Valve Seats ,....... ............ " .................... .. ................. ".".65
Valve Springs ............. .. ........................................ .. ...... 66
Valves .......................................................................... 66
Valve Spring Install Height ........... ... .... .. ....................... 61
Assemble ...................................................................... 67
BalarK:er ................................................... 67
Removal ....................................................................... 67
Installation ......... ............. ,................... .. .................. " .... 67
Timing Chain Cover, Chain and Gears ..................... 68
Remova1 .................................. ..................................... 68
Installation .. ...................... ,............................... ," ........ , 6S
TIming Olain Cover Oil Seal ..................................... 69
Replace ......................................................................... 69
Replace TIming Chain Cover Oil Seal With Cover IittOO
to Erlgirle ..................................................................... 69
Replace ............................................... ,................ .. ..... .. 69
CarnsI1aft: ..................................................................... 69
0
Cylinder Block .............................................................. 54
Maintenance llints ........................................................ 54

GENERAL MAINTENANCE ........................ 54
01ecking EngiIJe Oil J>ressu.re .................................... 54

Oil }llter ...................................................................... 55
Replacement ................................................................. 55
Compnssion Check .................................................... 55
Compression Test Result, ............................................. 55
Drive Belts ................................................................... 55
Inspection ..................................................................... 55
Visual Lnspection ..... .. ........................................... .. ...... 55
Stages of Belt Wear ......................................... .. ........... 55
Replacement ................................ ................................. 56
Intake Manifold Carbureltor Engine ......................... 56
RelTIOva1 ....... ,..... ,..... ,.. .... .. .......... .. ................... ,......... ,.56
Installation ......................................... .. ......................... 57
Exh.aust Manifolds ...................................................... 57
Removal Left Side ......................... .... .. ......... ................ 57
Installation Left Side ........ ,................. .. .... ..................... 58
Removal Right Side ............................ ... ... .. .... .. .... ........ 58
Lnstallation Right Side ................................. ..... ..... ........ 58
Rock.cr Covers ml<IIor Caskets .................................. 58
Removal ....................................................................... 58
Installation ......................................... .. ......................... 59
RocI<.er An'ns & Jlusilrods .......................................... 59
Removal ....................................................................... 59
Clean & Inspect ............................................................ 59
Installation ... .. ............................................................. .. 59
Valve Stem Oil Seals ................................................... 6()
Replacement ... ................................ ,.... ,........... .. ........... 60
52
VB ENGINE Maintenance & Rebuild
Subject
Page
Subject
Page
Assen1bly .............................. ............ ............................ 75

Installation ............................................................ ...... .. 75
Main ~ ............................................................. 75
fnspection ............................... .. .................................... 75
Replacement ........................................................... " .... 77
Main Bearings with Crankshafllnstalled in Engine ..... .. 77
Rod. ~ ........................................... 78
Inspection & Replacement ............................................ 78
CarnsI1aft ~ ...................................................... 79
Replacement ........................................ .. .... .. ................. 79
J>istor1 &
Rod Assernl>ly .......................... 80
Removal .................................................. ,.................... 80
Dismantle ..................................................................... 80
Inspection ............................................................ ,........ 81
Assembly & Installation ............................................... 81
Jliston ~ ................................................................. 82
Installation .................................................................... 82
Check Valve Timing ... .. ................................................ 69

Measuring Camshaft Lobe Lift ..................... _._ ............. 69
Removal ................... ... ... ... ............................... ... ... .. .... 69
Inspection ........................................ ............................. 70

EngirIe Moonts ............................................................ 70
Front Mounts ....................................... _................ __ ...... 70
Inspection ..................................................................... 70
RemovaJ ...... ................... _........ ..................................... 70
lnstallation .................................................................... 70
Rear Mount ................ .. .... .. .......................................... 70
Removal .. ....... .......... ...................................... .............. 70
Installation .................................................................... 70
li1ywheeVJ>riveplate .................................................... 7 1
Removal ....................................................................... 71
Inspection ..................................................................... 71
Installation .............................................. .. ................. ... 7 1
Ring Gmt- .................................................................... 71
Replacement ............ .................. .. .. ............................... 71
Cranksltaft ................................................................... 83
RenlOval ....................................................................... 83
Inspection .. .. ....................... ,...... ......... ... ,............. ,........ 84
Installation .................. .. ................................................ 84
Rear Main ()il Seal ..................................................... 85
Replace ......................................................................... 85
Cylil1der Block ............................................................ 86
Inspection ............................................... " ............ ,....... 86
ENGINE REBUILD ..................................... 72

Engirle Asoe.nbly ......................................................... 72
Removal ...... .. .,... .............. .. ............. .. ................... ,....... 72
Dislnantle ." .... " ...............................,.... ,..............." ...... 72
Assclnbly ..,......... ,....." .... ,............................................. 73

Installation ...........,.. .. .... .. .............. .. .,........ ,... .. .,.........,.. 73
Cylinder Reconditioning & Piston Filting ..................... 86
Oil Pan (Swnp) & GMkct ................................. .......... 74

Removal ....................................................................... 74
Installation .................................................................... 74
00 Punlp Suction. l'iJM! & Screen ............................... 74
Removal ...................................................................... . 74
Dismande ..................................................................... 75
Inspection ., ....., ..., ......, .......... , .... , ........." ...., ... .., ..." .. .. , .. 75
PROBLEM DIAGNOSIS ............................. 87

SPECIFICATIONS ...................................... 88
TORQUE WRENCH SPECIFICATIONS ..... 90
53
va ENGINE
(b) An engine is a combination of many machined. honed,
polished and lapped surfaces with toleHUlces that are measured in thousandths of a millimetre.
(c) Friction areas should be coated liberally with engine oil
during assembly to protect and lubricate the surfaces on
initial operation.
(d) Proper cleaning and protection of machined surfaces and
friction areas is part of the repair procedure and is considered
standard workshop practice.
2. When valve train component' areremoved for service. they
should be kept in order and should be installed in the same
locations (with the sarne mating surfaces) as when removed.
3. Battery terminals should be disconnected before any major
work is begun. If not, damage to wiring harnesses or other
electrical components could result.
4. (a) When raising or supporting the engine for any reason,
do not use a jack under the oil pan. There are small clearances
between the oil pan and the suction pipe screen, so jacking
may cause the oil pan to be bent against the screen, with
damage being done to the oil suction pipe assembly.
(b) If the air flow ducting is removed or disconnected, the
intake opening should becovered to avoid accidental entrance
of foreign material (which could follow the intake passage
into a cylinder and cause extensive damage when the engine
is started).
MAINTENANCE &
REBUILD
GENERAL DESCRIPTION
The engine isa V80verhead valve unit with a 101.6mm bore
and a stroke length of, 76.2 which results in the capacity of
the engine being available in a 5.0 (4942cc) and produces
185KW at 4500rpm. Compression ratio is 9.0:1.
ENGINE SERIAL NUMBER
Engine No. Location

The engine number location is on a machined surface at the
left side rear of the block.
ENGINE CONSTRUCTION
Cylinder Block
I. The cylinder block is made of cast iron and has 8 cylinders

arranged in 9(j' V.
2. The cylinder numbering is as illustrated.
1
GENERAL MAINTENANCE
CHECKING ENGINE OIL PRESSURE

--
--
1. Ensure that engine is at operating temperature and disconnect wiring harness connector fTOm oil pressure sender unit.
2. Loosen and remove oil pressure sender unit from oil filter
adaptor.
/
5
Firing Order: 1 3 7 2 6 5 4 8
EAV8001
3. Firing order is I 3 7 2 6 5 4 8.
4. (a) 5 main bearings support the crankshaft (this is retained
by bearing caps that are machined with the block for proper
alignment and clearances).
(b) Cylinders are completely surrounded by coolant jackets.
EAV8003
3.lnst.aJl a suitable oil pressure gauge assembly into oil filter

adaptor oil pressure sender unit hole.
4. Start engine and check oil pressure reading with engine
running under no load.
MAINTENANCE HINTS
1. (a) When any internal engine parts are serviced, care and
cleanliness are important.
54
Oil pressure:
2000 rpm and above - 280420 kPa (minimum).
a small amount of engine oil into the cylinders through the

hoes and test compression.
S. (a) After completing test, apply LOCfITE 243 sealant or

equivalent to sender unit threads.
(b) Install and torque sender unit.
Torque:
12.0 - 14.0 Nm.
(c) Install wiring hamess connector, start engine and check
for oil leaks.
Install on air line with an adopter

In the sparl< plug hole,
Air Hose
OIL FILTER
The oil filter should be replaced every 5,000 Kilometres or
3 months which ever occurs fIrst, or when the engine oil is
contaminated in any way.

V8032
Replacement
1. Unscrew oil filter with a suitable oil filter wrench, then
remove and discard.

2. (a) Make sure seal is placed correctly in recess in new filter.
(b) Pour some clean engine oil into fUter until level is
approximately 2 cms below top of fUter.
3. (a) Smear some engine oil over fUter seal.
(b) Screw fUter into place until seal contacts mating surface
of adaptor, then tighten through a further 'lJ3 of a turn.
Oil Filter
NORMAL Compression builds up quickly and evenly on

each cylinder.
PISTON RINGS Compression low on 1st stroke, tending to
build up on following strokes, but does not reach normal.
Improves considerably with addition of oil.
VAL VES Lowon 1st stroke and does not tend to build up on
following strokes. Do not improve much with addition of oil.
HEAD GASKET If cyJindercompression in any 2 adjacent
cylinders is low <and ifadding oil does nothelpcompression),
cylinder head gasket has blown out.
Metal casting
Screw on
,.,
,
Oil Filter
, ,
r.
-' ---
DRIVE BELTS
>
Inspection
Some belt squeal when the engine is started or stopped is

Visual Inspection
Condition of the belt is best judged by twisting the belt so
as to see the "Ribbed" surfaces.
EogOO4
4. (a) Clean any excess oil from fUter and adaptor.

(b) Check oil level, then start engine and check for oil leaks.
Afterrunningtheengine, theoil level must berecheckedand
oil added as necessary, to compensate for oil used to refill the
oil filter.
va Ribbed Fan Bett

Rib $eclion
Broken Away
COMPRESSION CHECK
1, Make sure of the following:

(a) Engine is at operating temperature;
(b) Battery is at (or near) full charge;
(c) Spark plugs are removed.
2. <a) Install suitable compression tester, then depress
arrelerator pedal to fully open position and cmIlk engine.
(b) Read compression gauge indication.
10leck remaining cylinders.
The lowest reading of any cylinder should not be less than
llXlPa of the highest and should not be less than 650 kPa.
Hcylindercompression in I or more cylinders is low, pour

2. MODERA! iii ,Y USED BELT: Few cracks; some wear
on surfaces. Replacement not required.
55
3. SEVERELY USED BELT: Severill cracks per inch.

4. FAlI.EDBELT: Sepamtion of belt material from backing
(chunking). Replace belt immediately.
Replacement
Release belt tensioner using a 3/8" square drive socket bar

turning it clockwise. Remove drive belt from drive pulleys.
Replace belt, taking care the belt is fitted cOllectly. Tension
belt by releasing tensioner.
Upper Intake Manifold

and Throttle Body
INTAKE MANIFOLD
Removal
1. Remove the aircleanertubeand empty the cooling system.
2. Disconnect the vacuum hoses from the manifold and
detach the PCV if fitted.
7. Disconnect the fuel inlet and outlet pipes from the fuel rail.
8. Disconnect engine wiring harness and remove from engine.

9. Detach heater hoses and byps hose from heater pipes
assembly.
lO. Set timing on No. I TOC, mark distributor and remove.
3. Disconnect the spark plug lead. and remove distributor

cap.
DIstributor
4. Detach the cruise control and accelerator cables from

throttle body.
S. Detach electrical connections and vacuum hoses from
upper intake manifold and throttle body.
6. Remove upper intake manifold and throttle body.
11. Remove the bolts attaching the manifold to the

heads and remove. As required remove the fittings from
manifold.
56
Inlet manifold attaching bolt torque:

Step 1:
25Nm
Step 2:
34Nm
5. Install disnibutor timing it correctly.
6. Attach heater hoses to heater tube assembly and fuel lines.
7. Rcplace engine wiring harness and connect.
8. Replace upper intake manifold and torque boll< to specifications.
Upper intake manifold bolt torque: 20Nm
Installation
I. Ensure that the surfaces of manifold and cylinder heads are
clean and nee from of any burrs.
2. Using Permabond A 168 or equivalent install fittings on the
manifold
threads.
3. Install the gaskets and two rubber seals at the front and
back of the manifold. Fit the manifold to the cylinder heads.

and Throttle Body
9. Replace vacuum hoses and elecnical connections to upper

intake manifold and throttle body.
10. Connect accelerator and cruise control cables to throttle
body.
11. Replace disnibutor cap and spark plug leads.
12. Install intake tube and refill cooling system using COllect
coolant.
13. Stan engine and check for oil, water, fuel and vacuum
leaks.
Exhaust Manifolds
4. Apply Permabond A 115 or equivalentto the bolt threads.

Place the bolts and tighten in sequence to the specified torque.
: 1256783
: 8734215
Removal left hand side
1. Take the air cleaner intake ducting off .

2. Remove the attaching nul, from the engine pipe.
57
3. Disconnect engine pipe from exhallst manifold.

4. Disconnect spark plug leads and place to one side.
S. Remove the attaching bolts from the exhaust manifold and
remove the manifolds and gaskets.
Indallation left hand side
1. Clean mating surfaces of the cylinder heads and the
manifolds.
2. Using anti-seize coat the threads of all nuts and boilS.
3. Place new sealing rings on the exhaust pipes and new
gaskets between the heads and manifolds.
4. (a) To align the gasket, install guide studs in the cylinder
ncaa.
(b) Place the gaskets on the studs.
(c) Place the manifold on the studs.
(d) Install the bolts on the lower holes, remove the guide studs.
install the upper bolts.
(e) Gmdually tighten the bolts to specification.
Exhaust Manifold Bolts specification:
18-2SNm
S.lnstall the exhaust pipes and tighten to specification.
Exhaust Pipe to manifold specification:
18-2SNm
6. Refit spark plug leads.
7. install the air cleaner intake ducling.
8. Start engine and check for exhaust leaks.
(d) Install the bolts on the lower holes, remove the guidestuds,
install the upper bolts.
(e) Gmdually tighten the bolts to specification.
Exhaust Manifold Bolts specification:
18-2SNm
S. Install the exhaust pipes and tighten to specification.
Exhaust Pipe to manifold specification:
18-2SNm
6. Refit spark plug leads.
7. Install rear alternator bmcket, EGR solenoid etc.
8. Start engine and check for exhaust leaks.
ROCKER COVERS ANDIOR GASKETS
Rocker Cover
,
6 Attaching screws
~ EavSOOS
n erside of Rocker Cover
Eav8006
Removal
2. Rcmove spark plug I""ds.
3. Remove the air cleaner intake ducting tube.
4. Remove upper intake manifold as described in Intake
Manifold Removal in this chapter.
S. Remove the PVC closure tube from the right hand side
RCIl1Ov.d right hand side

I. Remove the attaching nuts from the enb~ne pipe.
2. Disconnect engine pipe from exhaust manifold.
3. Disconnect alternator rear support bmcket and remove.
4. Rcmove spark plug leads. EGR solenoid etc and place to
one side.
S. Remove the attaching boilS from the exhaust manifold and
remove the manifolds and gaskets.
In<tallation right hand side
1. Clean mating surfaces of thc cylinder heads and the
manifolds.
2. Using anti-seize coat the threads of all nuts and bolts.
3. Place new sealing rings on the exhaust pipes and new
gaskets betwcen the heads and manifolds.
4. (a) To align the gasket, install guide studs in the cylinder
head.
(b) Place the gaskets on the studs.
(c) Place the manifold on the studs.
rocker cover.
6. (a) Unscrew rocker cover to cylinder head fasteners and

remove rocker cover from cylinder h""d.
(b) If replacing rocker cover seal, remove gasket from reccss
in rocker cover to head flange of cylinder.
58
Installation
I. (a) If necessary. install new seal in rocker cover. it is
advisable to install new gaskcts. to stop possible oil leaks.
(b) Install rocker cover bolts.
Make sure the gasket is conectly installed in rocker cover.
2. Install rocker cover to cylinder head and torque bolts to
specification.
15Nm
Rocker Cover Torque specification:
3. Install leads to spark plugs.
4. Replace upper intake manifold as described in Intake
Manifold Replacement in this chapter.
S. Install air cleaner intake duct.
6. Install PVC closure tube to the right side rocker cover.
(b) Start engine and check for oil leaks.
ROCKER ARMS AND PUSHRODS
Clean & Inspect

I. Clean all components in a suitable cleaning solvent. then
dry witl] clean dry compressed air.
Sercuring
BoR
It is important that the original location of all pivots and

arms is retained during assembly. so place componeflfs on
a suitable rack.
Removal
l,(a) Disconnect battery earth lead.
(b) Remove rocker covers as described above.
2. (a) Remove rocker arm pivot bolts. pivots and rocker anns.
(b) Remove pushrods.
Fulcrum
Gultll
2. Clean rocker arm pivot bolts threads.

3. Inspeel all components for wear and replace as necessary.
Installation
1. Before assembly. coat rocker arm pivots and contact
surfaces with engine oil.
2. Coat pushrod contact surfaces with engine oil and lhen
install pushrods.
3. Coat pivot bolt threads with LOCI11'E 243.
4. Assembly pivot bolts. pivOlS and rocker anns in thcir
original positions on cylinder head.
S. Torque pivot bolts and at the same lime make sure the
pushrod remains in contact with tifler and rocker arm.
2S - 35Nm.
Torque:
6. Install rocker covers as previously described in this
59
(b) The colour of the replacement seal may not be the same
colour as the original seal.
(c) Make sure the COllect type of seal is fined to the
Chapter.
7. (a) Conoect banery earth lead.
(b) Start engine and check for oil leaks or valve train noise.
appropriate valve, based on part no. and package description.

7. (a) Install spring, cap and compressor as an assembly on
the valve stem.
(b) Install valve collets and slowly release spring compressor,
then remove spring compressor.
(c) Disconnect air line to special tool.
8. Install the foUowing:
(a) Rocker arms as previously described in this Chapter.
(b) Rocker coverls as previously described in this Chapter.
9. Remove special tool and install and torque spark plug.
Torque:
20 - 30 Nm.
10. Install spark plug leads and battery earth lead.
It. (a) Start engine and check for oil leaks and valve train
VALVE STEM OIL SEALS

Replacement
1. Disconnect banery earth lead.

(a) Rocker coverls as previously described in this Chapter.
(b) Rocker arms as previously described in this Chapter.
(c) Spark plug leads from spark plugs.
(d) Spark plug from relevant cylinder and screw air adaptor
into spark plug hole.
3.
to hold valves in closed
nOH;e,

Install an air Une with on
In the spark plug hole,
VALVE LIFTERS
Air Hose
V8032
4. (a) Compress valve spring with valve spring compressor.
(b) Remove val ve coUel,.

Before installing valve spring compressor, it may be
necessary to tap top of valve cap with a soft-faced hammer
to overcome the binding ofthe valve collets in the valve spring
cap.
5. (a) Remove spring, cap and compressor.
(b) Remove and discard valve stem oil seal.
Removal
Make sure that all valve train componelllJ are kepi ill order
so they can be installed in their orixinallocatiolls.

(a) Rocker cove" as previously described in this Chapter.
(b) Rocker arms and pushrods as previously described in this
Chapter.
3. Remove intake manifold as described in this chapter.
Place cytlnder head

bench, use a vo
compressor to
one remove valve
Valve
Spring
Cop
Ieo.., .....
Valve
Valve
I
Collets
'=--IJJG
~
6. Install new valve stem oil seal and make sure the seal fully
seats on top of the valve guide.
(a) There are specific valve stem seals for intake and exhaust
valves.
60
4. Remove the guide retainer plate bolts and guide retainer

plate.
plunger assembly with small fine-bladed screwdriver.

Clean & Impect
1. (a) Clean all parts in a suitable cleaning fluid.

(b) Dry with compressed air.
2. (a) Inspect lifter body for wear and scuffmg.
(b) Also inspect lifter bore in cylinder block.
3. Inspect roller for:
- Freedom of movement - replace lifter if roUer binds or
roughness can be felt.
- Excessive looseness in the roUer bearing.
- Aat spots - replace lifter if roller is worn.
- Pitting - replace lifter if roller is pitted.
4. If, when inspected, the pushrod seat is worn, replace it.
S. The lifter assembly unit must be replaced if there is any
damage or excessively worn.
S. Remove the hydraulic guide plates.
Assembly
1. With the check ball on small hole in plunger.

2. Carefully place check ball spring and retainer over ball and
press retainer into position in plunger with a small fine-bladed
screwdriver.
3. (a) Half fill valve lifter body with test fluid .
(b) Reinstall plunger spring into lifter body.
(c) Install plunger a.sembly in body, taking care to align oil
feed holes.
(d) Fill lifter assembly with test fluid.
4. (a) Insert a I mOl diameter pin into plungerto unseat check
ball and push plunger down to full extent of its tmvel.
(b) Insert special tool through oil feed holes in body and
plunger and remove pin from plunger.
5. Fill lifter assembly with test fluid.
6. Install oil mctcring valve. push rod seat (cup side up) and
retaining clip.
* The hydraulic lifter is now ready for checking as ouLiined
6. Remove lifters from cylinder block bores and place in order

on rack.
in the next opemtion.
Testing Lifter
Afteritisha.beencleaned, inspected and assembled, it will

need to be tested before it is installed in the engine.
1. Place lifter into lifter tester and fit ball bearing supplied
with test fixture in push rod seat of lifter.
2. Lower test fixture ram to rest on ball bearing.
3. (a) Push lifter plunger through its maximum !rdvelto foree
all air out of lifter by using a vigorous pumping action on test
figure weight arm.
(b) Continue pumping action until considerable resistance is
built up in lifter and it becomes solid.
4. Raise weight arm to allow lifter plunger to come up to its
retainer, then lower arm to rest of ram.
5. Use a stop watch to check the time required for the indicator
to move from the 'START' to .125 in. position on the scale.
6. The leak down rate (time between start and .125 in.
position) must be between 12 to 90 seconds to ensure
Dismantle
I. Remove push rod seat retaining clip, using a small fmebladed screwdriver.
1 Remove push rod seat, oil metering valve, plungerassembly and plunger spring from lifter body.
If the plunger is stuck in the lifter body, turn lifter body
upside-down and tap on a block of wood.
If the plunger cannot be moved, soak lifter assembly in a
suitable cleaning fluid.
3. Remove and inspect valve retainer, spring and ball from
61
satisfactory lifter operation.

A doubtful lifter should be tested 3 or 4 times.
Any lifter which does not test within the specified limits
should be replaced.
Stand tested lifters upright so that fluid does not drain from
oil holes.
(b) Intake manifold as previously described in this Chapter.

(c)Exhaust manifolds as previously described in this Chap-
ter.
(d) Rocker covers as previously described in this Chapter.
(e) Rocker arms and pushrods as previously described in this
Chapter.
Installation
3. Remove alternator if required to remove the right side head.

(a) Remove nuts from alternator adjuster bracket studs and
remove engine harness earth wire connection and wiring
harness retainer bracket.
(b) Remove alternator, remove alternator support bolts, then
remove support assembly.
4. Remove airconditioning compressor and place toone side.
S. Power steering if required to remove left side head.
(a) Remove nut from belt tensioner bmcket lower mounting
stud.
(b) Remove drive belt tensioner bracket and power steering
assembly anaching bolts.
(c) Move power steering pump assembly to one side.
6. Gradually slacken the ten cylinder head bolts in the
sequence shown.
I. Instal] make sure lifter bodies, rollers and lifter bores are
clean.
Note: 77", oil hole in the silk of the hydraulic lifter must
face the cylinder bore.
2. (a) Install rocker arms and pushrods as previously described in this Chapter.
(b) Install rocker covers as previously described in this
Chapter.
(e) Install intake manifold as previously described in this
Chapter.
S. (a) Connect battery earth lead.
(b) Start engine and check for oil or fuel leaks and valve train
4
1 5 9 7 3
nOise.
(c) Repair as nccessary.

CYLINDER HEADS
Tighten Sequence: 9 5 1 3 7
7. Remove cylinder head bolt', cylinder head and gaskets.

InspectIon
1. Taking care not to scratch machined surfaces, clean mating
EAVBOO9
surfaces of cylinder head and cylinder block.

Do not use a motorised wire brush on any gasket sealing
surface.
2. Check cylinder head deck, intake and exhaust manifold
mating surfaces for distortion. These surfaces may be
Removal

(a) Drive belt as previously described in Uris Chapter.
62
refaced by parallel grinding.

3. Inspect the following:
(a) Cylinder head foremcks. especially between valve seats
or exhaust pons.
(b) Cylinder head deck surface for corrosion, casting sand
inclusions or blow holes.
(c) Cylindcr block deek surface with a suitable straight edge.
Head tightening steps & torque:

Step 1:
upto 65Nm
Step 2:
upto 85Nm
Step 3:
upto lOONm
Step J: Tighten all cylinder head bolts to 65 Nm.
Ifa torqueof88 Nmatany time in following step isreachcd.
SlOP tightening that panicular head boll.

Step 2: Funher tighten all bolts in the specified order to
SSNm.
Step 3: Funher tighten all bolts in the specified order to
lOONm.
4. Install all of the valve assembly after covering the components with a light coat of oil
(a) Push rods must be refilted in their COllect order.
(b) Rocker arms, and bolts making sure that the push rods are
aligned cOlleetly. Torque boll~ to cOlieet torque .
a straight edge to check machined surfaces of the head,

each surface on aUeast 3
4. Clean cylinder head bolts and replace any bolt that has
suspect threads. or stretchcd or damaged heads caused by
improper u", of tools.
5. (a) Clean cylinder head bolt hole threads in cylinder block
using an appropriate size thread tap.
(b) If necessary. threads may be reconditioned with suitable
thread insens.
Clean out bolt holes with an air hole.
Rocker Arm Bolt specifICation torque:
30Nm
(c) Install rocker cover with new gasket and tighten boll~ to
specification.
InstallatIon
1. (a) Place head gaskets in position over dowel pins on
cylinder block.
2. (a) Carefully guide cylinder head into place over dowel
pins and ga~ket.
(b) Coat threads of cylinder head bolts with LOCfITE 243
sealant or equivalent and tighten with fmger.
3. (a) Tighten head bolts to the following "'quence and in the
order shown.
It is imponant to follow the given procedure to avoid head
gasket failure and possible engine damage.
Rocker Cover Torque speciJkation:
ISNm
(b) Install inlet manifold as previously described tighten

manifold bolts to specification.
Inlet manifold bolt torque speciJkation:
Step 1:
2SNm
Step 2:
34Nm
S.lnstall e"haust manifolds tighten bolts in correct sequence
and to COllect torque, install exhaust pipe manifolds.
Loosen Sequence: 2 6 10 8 4
1 5 9 7 3
Tighten Sequence: 9 5 1 3 7
10 6 2 4 8
Exhaust manifold to cylinder head :

6. Install power steering unit if removed.
EAVB0091
63
30Nm
Use a straight edge to check machined surfaces of the head,

check each surface on atleast 3 angles.
EAV8028
(b) Valves from cylinder head.
(a)lnslal l power steenng mounting bracket and adjuster arm.

(b) Install power steenng pump
7. Install air conditioner compressor.
8. Install alternator if removed
(a) Install mounting bmcket boll~
(b) Install adjusting bmcket bolt
(c) Install alternator and wiring loom.
9. (a) InstaU kick down cable for automatic !TImsmissions.
(b) Insl<~1 air cleaner ,md air duct hose.
10. (a) Fit mdiator hose.
(b) Fill mdiator with appropriate coolant.
Coolant
Coolant CoITOSion Inhibitor:
RI32JR133
11. Install dIe earth cable to the battery.
12. (a) Start engine and check for oil, coolant, fuel and
exhaust leaks.
cylinder head
bench. lise a
compressor to
remove valve
Valve
Valve
Spring
Cop
Valve
Valve
Collets
\...-,
IJJI\
~
Caution: Do notforce valves out ofguides, as mushroomed

valve ends, due to rocker ann wear or d;n in the guide. will
damage guide. Remove burrs by chamfering valve stem with
an oil stOlle or file.
CYLINDER HEAD RECONDITIONING
Make sure that all valve Intin components are kept together
and identified so that they can be instaUed in their onginal
locations.
Clean
1. (a) Clean all carbon from combustion chambers, valve

ports, etc., with a rotary-type carbon removing wire brush.
Do not wire brush on any gasket sealing surface.
(b) Clean cylinder head ga~ket surface of cylinder head.
2. Thoroughly clean valve guides with a suitable cleaning
solvent or a wire brush.
Dismantle
1. Compress valve springs in tum with a conventional spring

compressor and remove valve collets.
(a) Valve spring eaps, springs and valve stem oil seals.
64
VB ENGINE Maintenance & Rebuifd
3. Clean valve heads with a bufting wheel.

Do not scratch the valve stem with the bumng wheel.
4. Thoroughly wash all components in a suitable cleaning
solvent and blow dry with dry compressed air.
3. Measure clearance as outlined in following steps:

(a) Insert valve into its guide.
(b) Clamp a dial indieatoron I side of cylinder head rocker
cover seating rail, locating the indicator so that movement of
the valve stem from side to side (crosswise to the head) will
cause a direct movement to the indicator stem. (1bc indicator
stem must contact the side of the valve stem, just above the
valve guide.)
(c) With the valve head dropped about3mmoffitsseat, move
the stem of the valve side to side using a little force to obtain
a cleanmce reading. (If clearance exceeds specification, it
will be necessary to rerun valve guides for oversize valves.)
* It is important to check the clearance with a new standard
valve before anempting to ream the valve guide.
Maximum Clearance Valve stern to Valve Guide:
Intake
0.0250.068 mm
Exhaust
0.038-0.081 mm
Service Clearance
O.I40mm
4. When using a new valve, if valve stem to valve guide
clearance is within specification, check original valve stem
diameter (refer VALVES) and replace any worn valves as
necessary.
5. Valve guides may be reamed to accept an oversize valve.
* Avoid breaking reamer flutes or jamming the neanler into
the valve guide due to packing of chips or carbon.
Clean the valve guides before reaming. Do not push down
Cylinder Head Inspection

1. Inspect cylinder heads for cracks in valve seats and
combustion chambers, and for external cracks to water
jackets.
2. Check cylinder head deck surface for corrosion.
3. (a) Using a straight edge and feeler gauge, check cylinder
head deck, intake and exhaust manifold surfaces for distortion. Maximum distortionallowed O. 76mm in any 150mm or
O.152mm overall..
(b) Check cylinder head deck surface diagonally, longitudinally and transversely.
4. Check deck height for specification height .36-.97mm.
on the reamer.
Installed Height. Valve Spring: (nl")

Intake
44.545.7
Exhaust
40.141.6
VALVE SEATS
1. Reconditioning the valve seats is very important bocause
the seating of the valves must be perfect for the engine to
deliver the power and performance which it develops.
2. Another important factor is the cooling of the valve head.
Good conlact berween each valve and its seat in the head is
imperative to ensure that the heat in the valve head will be
properly carried away.
3. Several different types of equipment are available for
reconditioning valve seats. The recommendations of the
manufacturerofthe equipment being used should be carefully
foUowed to anain proper results .
4. Check valve seats for any evidcnce of pitting or damage at
valveconlact surface. Jfpining iseviden~ the valve seats will
need to be reconditioned.
* Because the valve guide serves to support and centre the
valve seat grinder, it is essential that the valve guide is
servieed before reconditioning the valve seats.
* Valve seat angles are 45'.
* Valve seat width:
VALVE GUIDES
Clearance Checking
I. Excessive valve stem to guide bore clearance will cause
lack of power, rough idling and noisy valve operation.
2. Insufficient clearance will result in noisy and sticking of the
valve and will interfere with smoothness of operation of
engme.
Mtrometer dial gauge on stand
of valve stem to measure the
side movemen'
of valve guide wear
dial gauge
I-H- Valve Stem
Exhaust
Intake
V8037
65
1.522.03mm
1.52-2.03mm
(e) Replace valve springs that do not meet specification.

Maximlun allowable variance in spring end length: 1~
rum, while rotating spring on level desk.
Valve Spring Flee length: (mm)
Inlet 51.3
Exhaust 45.5
3. (a) Check valve spring load with a spring tester.
(b) Springs should be compressed to the specified heigbt and
checked against specifications.
Valve spring oompn,..;ed heightJ1ood: (kg@mm)
Intake 33.5-37.2 @ 45.2 - 95.5-104.5 @ 33.8
Exhaust - 35.0-38.0 @ 40.6 - 90.5-102.5 @ 29.2
Assembkd heiglU: (mm)
Inlet 44.5-45.7
40.1-41.6
Exhaust (c) Replace any valve spring if not to specification.
Verner to measure
width of valve seat
,-
,, , -
Valve Seat
width
Varve seat must be
5. If the seat is too wide after grinding, it may be narrowed by

using a 20" or 70" grinding stone. The 20" stone will lower
the seat and the 70" stone will raise the seat.
6.lf the valves seal' are reconditioned, the valves must also
be reconditioned (refer VALVES) or replace valves a,
necessary.
VALVES
1. (a) Inspect valve stem for bum; and scratches. (Burrs and
minor scratching may be removed with an oil stone.)
(b) Valves with excessive stem wear or that are warped
should be replaced.
(c) Inspect valve stem tip for wear. The valve tip may be
reconditioned by !,'linding.
(d) Follow the grinder manufacturers instructions. Make
sure the new tip surface is at rightangles to the valve stem.
2. Inspect valve stem collet groove for damage.
3. (a) Check valve face for burning or craCking.
(b) If pieces have broken off, inspect corresponding piston
and cylinder head area for damage.
4. (a) Inspect valve stem for stmigbtness and valve head for
Valve seat
cutting tool
If valve seats need to be
use a cutting
then a grinding tool
with the correct angle.
Valve Seat
VALVE SPRINGS
1. Inspect valve spring surfaces on cylinder head and valve

cap for wear or gouging. Replace components as necessary.
2. (a) Check spring ends. lfthey are not parallel, the spring
is bent.
(b) Usea square on a bench with a level surface to check thai
sprmg are square.
Straightness
of
valve stem
Diameter
valve Length
Use a square on a flat bench

to check that vavle springs
are straight.
Valve
Spring
Square
valve Face
Angle
valve Head
Thickness
Eng039
V8041
66
VB ENGINE Maintenance & Rebuifd
bending or distortion using 'V' blocks.

(b) Bent or distorted. valves must be replaced..
5. Valves with pined. or grooved. faces can be reconditioned
with a valve refacing machine, ensuring conect relationship
between bead and stem.
Valve race angle:
44'.
If pitting or grooving is so deep that refacing would result
in a 'knife' ed.ge at the val ve head, the valve must be replaced..
Measure valve margin after refacing valves. If margin is
less than minimum specified., the valve must be replaced..
Minimum valve head margin thickness: .63 mm.
6. Lightly lap reconditioned. valves into valve seal.
New valves must not be lapped.. Lapping destroys the
protective coating on the valve face.
7. After refacing or installing a new valve, check for conect
seating as follows:
(a) Lightly coat valve face with bearing blue.
(b) insert valve and rotatc about 1/6 of a revolution.
(c) Remove valve and check for full contact with scat.
40,1-41.6
ExhaustShim valve spring seat a~ needed. if any measurement is not
as indicated..
ASSEMBLE
1. Dry and clean all components thoroughly.
2, Using clean engine oil, lubricate valve stems and valve

guides thoroughly. Install valves in corresponding guides.
3, Making sure that seals fully seat on top of guide, install
valve stem oil seals.
The original seals may not be the same colour as the
replacement seals.
There are particular valve stem seals for intake and exhaust
valves. Make sure the exact type is fitted to the relevant valve,
bao;ed on package description and pall number.
4. Place valve springs and cap over valve stem.
5, Using a suitable spring compressor, compress valve
spnngs.
Excess compression could cause spring cap to damage
valve stem oil seal, ensure to compress valve springs only
enough to install valve collel~.
6. Install valve collets, making sure that they locate accurately in groove in top end of valve stem. Release the valve
spring compressor slowly ensuring that the collets sit properly. Grea~ may be used to hold collets in place.
CRANKSHAFT BALANCER
i) If partial contact is indicated, inscrt valve again and turn

through a full revolution.
ii) If blue on seat indicates full contact, reface valve.
iii) [fpartial contact is still indicated., regrind cylinder head
valve seat.
(d) Clean all traces of bearing blue from valves and seats.
......... Socket Handle
Valve SprIng Install HeIght
EAV80SO
Excessive valve spring installed. height. caused. by valve seat

by wear or valve and seat reconditioning, has to be compensated for, by adding shims under the valve springs.
\. Place valve in its guide, then install valve spring cap and
collets.
2. Pull up on valve spring cap to seat collet and valve.
3. Measure from machined spring seat to spring side of cap,
using a vemier calliper. Valve spring installed. height should
be as follows:
Valve Spring (nun)
51.3
Intake Exhaust 45.5
insIalled Height (nun)
44.5-45,7
Intake -
Removal.
I. Disconnect banery earth 1e.1d and remove drive belts as

shown in the BELT DRIVE section.
2. Pull park brake fully on, chock rear wheel and transmission
in gear or ir necessary remove starter motor and chock the
flexiplate with a screw driver or bar.

3. Loosen and remove balancer retaining bolt.
4. Remove balancer from crankshaft with pulley puller.
Installation.
Installation is the opposite of removal techniques, ensuring to

take note of the following points:
67
Using engine oil, lubricate front seal surface of balancer.

Install balancer, engaging key on crankshaft with slot in
balancer.
Tighten balancer retaining bolt to the proper torque specification .
Cmnkshaft BaJancer Nut Torque Specification:
95-122Nm
* Inspect drive belt operation and starter motor.
Timing Chain
Cam Shaft Gear
TIMING CHAIN COVER, CHAIN and GEARS
Removal
I. Detach the battery cables and remove the battery shroud.
Remove Oil Slinger

to reveal lower sprocket.
2. Empty the cooling system by disconnecting the lower

radiator hose.
3. Detach the transmission oil cooler pipes from the radiator
(auto).
4. Detach the upper radiator hose from the thermostat
housing. Remove the fan shield and radiator.
5. Remove the fan/clutch from the water pump.
6. Detach belt from the fan, power steering, air conditioner
etc.
10. Turn the engine to align the timing marks, remove the
camshaft gear bolt and washer. Carefully remove the gears
and timing chain as one unit by sliding forward.
In!.tallation
I. Align the timing marks of the gears, with the chain fitted
slid the unit back into position. Lubricateall components with
clean engine oil.
2. Fit the camshaft gear bolt and washer and oil slinger.
Cmmhaft Galr bolt tightening specification: SO-6ONm
Align Timing Marks
Camshaft Gea~_-;
Timing chain
Timi
Crankshaft _ _ _ _~
7. Remove the crankshaft damper bolt and washer and using

a pulley remover remove the crankshaft damper.
8. Remove water pump from timing cover.
EAV8054
3. Replace the timing chain cover with new gaskets. apply oil
resistant scaler to the gaskets before asscmbly.
4. Tighten the bolts for the cover.
Front Cover attaching bolts:
20Nm
5. Replace crankshaft damper to front of crankshaft.
Tighten balancer retaining bolt to the proper torque specification.
Crankshaft BaJancer Nut Torque Specification:
95-1 22Nm
6. Reinstall the fan/clutch and belt to their correct tension.

7. Reinstall the upper radiator hose from the thennostat
housi ng. Reinstall the fan shield and radiator
8. Fit the transmission oil cooler pipes hom the rddiator
(auto).
radiator hose.
9. Remove the timing chain cover, gaske~ and the oil slinger.
68
CAMSHAFT.
10. Connect the battery cables.

II. Start engine and check for oil, fuel or water leaks.
Check Valve Timing.

It will be necessary to remove the engine front covertocheck
TIMING CHAIN COVER OIL SEAL
the engine valve timing to do this refer to Timing Chain

Cover and Chain section in this manual.
Tum crankshaft until timing marks on crankshaft and camshaft sprockets arc aligned. The location of the timing marks
when the valve timing is correct is shown in the diagram
above.
Replace
I. Remove the liming chain cover as described above.
2. Remove the old seal with a screw driver or punch.
3. Install the new seal with a seal installer(takingnotethat the
seal is fitting as it should), lubricate the seal with grease before
fitting.
4. Reinstall the timing chain cover as described above.
Align Timing Marks

Camshaft
Seal insertion tool
Timing ehai
Front
seal
I{
Crankshaft
Front seal is installed with a seal insertion tool
REPLACE TIMING CHAIN COVER OIL

SEAL WITH COVER FII I ED TO ENGINE.
1. Empty the cooling system by disconnecting the lower
----..J
EAV8054
Measuring Camshaft Lobe Lift

1. Remove the rocker cover and remove rocker arm assemblies.
radiator hose.
2. Detach the transmission oil cooler pipes from the radiator
(auto).
3. Detach Ihe upper radiator hose from the thermostat
housing. Remove the fan shield and radiator.
4. Detach belts from the fan, power steering, air conditioner
etc. Remove the fan/clutch from the water pump.
5. Remove lhecrankshaftdampcrbolt and washer and using
a pulley remover remove the crankshaft damper.
6. Remove the front seal with a seal remover or use screw
driverto lever out or a slide hammer and sclftapper.
7. Lightly lubricate a new seal with grease.
S.Install new seal with a seal replacement tool.
9. Reinstall the crankshaft balancer.
Tighten balancer retaining bolt to the proper torque specifi-
2.Mountadial indicator so that its stylus is resting on top end

of a pushrod, tum thecrankshaft and measure camshaft lobe
li ft.
Camshaft lobe lift Intake and exhaust: 7.061mm with
allowable lift loss of O. 127
3. Repeat step 2, above, on the remaining pushrods. If any
lobe lift is not as specified remove and replace camshaft to do
this refer to Camshaft Removal and Installation in this
section.
4.lf camshaft lobe lift is satisfactory, assemble rocker arm
assemblies and install the rocker cover.
cation.
CrankshaftBaJancerNutTorqueSpecification:
95-122Nm
10. Reinstall the fan/clutch, all belts to their correct tension.
11. Reinstall the upper radiator hose from the thermostat
housing. Reinstall the fan shield and radiator
12. Fit the tnmsmission oil cooler pipes from the radiator
(auto).
radiator hose.
14. Start engine and check for oil or water leaks.
69
Removal.
ENGINE MOUNTS.
Camshaft can beremoved with engine in vehicleifbumper,

condenser, radiator, receiver drier and support bracket are
removed.
2. To remove cooling fan shroud, radiator and cooling fan.
3. To remove crankshaft balancer refer to Crankshaft Balancer section in this manual.
4. To remove front cover and timing chain/gear and sprocket
refer to Timing Chain Timing Chain section.
6. Remove rocker covers refecto Valve Rocker Cover and
Valve Rocker Arms section.
7. To remove rocker arms and pushrods referto Rocker Arms
and Pushrods section.
8. To remove hydraulic valve lifters refer to Valve Rocker
Cover and Valve Rocker Arms section.
9. Ensure to carefully withdraw camshaft from front of
engme.
Avoid damaging bearing surfaces when removing camshaft.
Front Mounts.
Inspection.
Raise the engine with either a block & taclde or place ajack
under the sump (place a piece of wood between the jack and
sump to protect the sump) to remove weight from mounts.
Ensure that mounting rubber has not split, separated or
deteriorated from metal plates. Replace mount if this is the
case.
Removal.
1. Remove engine front mounts to side rail nuts.

2. Remove mounts as follows:
(a) Remove mount to mounting bracket nuts.
(b) Raise engi ne slightly to remove weight from the mounts.
(e) Remove mount bracket tocylinderblock bolts, remove
bracket and mount.
Installation.
Inspection.
1. Check camshaft bearing journals and lobes for overheat-
Install mounts as follows:

1. Fit mount bracket to cylinder block bolts.
ing, damage or wear (discolouration).

2.lnspect camshaft journal diameter and runout with suitable
measuring equipment.
Replace camshaft if journals are not as specified.
Tighten nuts as specified.

Engine to Engine mount bmeket:
68-81Nm
2. Fit mount to mounting bracket nuts.
Tighten nuts as specified.
Engine Mount bmeket to rubber insulator Nuts:
20-JONm
3. Lowerenginc to enable engine mount to be bolted to side
rai I bracket.
Tighten nuts as specificd.
Rubber insulator to Side rail bracket:
45-70 Nm
Measure camshaft Journals

wtth a micrometer
Camshaft
REAR MOUNT
Micrometer
Removal.
1. Raise vehicle front and rear and placc on safety stands.
Camshaft Journal Diameter maximum out of round:

0.013mm
Camshaft Journal Diameter: +/- 0.012mm
1
2
3
4
5
52.84-.87 52.46-.48 52.08-.10 51.70-.10 51.32-.34
Camshaft Journal Max. Out of Round: O.013mm
3.Position camshaft on 'V' blocks and check each camshaft
lobe lift.
Camshaft Lobe Lift
7.061 mm
2. Using a garage jack, support rear of transmission.

Usc a block of wood between transmission and jack.
3. Remove nuts, washers and boll' attaching support to
erossmember.
4. Remove cross member from frame bolts and washers and
removecrussmembcr.
S. Remove rear mount from support nuts and remove suppon.
6. Remove rear mount from transmission rearcxtension bolts
and remove rear mount.
Installation.
l.lnstall rear mount and bolts to transmission rcarextension.
70
Tighten bolts as specified.

Rear Mount to Extension Bolt
4OS0Nm
2. Install support to rear mount and attach nuLS. Lower rear
of transmission slightly to allow nuts to be tightened as
specified, tit split pins.
Support to Rear Mount Nut
2025 Nm
3. Install crossmembertosupport, making sure that bolts are
fiued correctly and threads arc not damaged.
4.Install cross member to support bolts, washers and nuts and
tighten nuts fingertighl.
S. Install cross member to side frame bolts and washers.
Tighten bolts as specified.
Crossmember to Side Frame Bolt
4OS0Nm
6. Lower jack and tighten crossmember to support nuts.
Crossmember to Support Nut
2025 Nm
7. Remove safety stands and lower vehicle to ground.
Tighten Flywheel Bolts to specified torque
Flywheel
Torque Wrench
V8028
Inspection.
The flywheel and flexplate are purposely out of balance and

no attempt should be made to rebalance these as an individual
unil.
1. Check flywhecl/driveplate ring gear for badly worn.
damaged or cracked teeth.
If needed, replace flywheel ring gearordri veplate, fordetails
refer to "ring gear" section in this chapter.
Check starter motor pi nion gcar for damage, if ringgear teeth
are damaged replace pinion gear, fordetai Is refer to "Stating
System chapter".
2. Inspect crankshaft and flywheel/driveplate matching sur
faces for burrs. Using a fine mill file remove burrs ifpresent.
FL YWHEELJDRIVEPLATE
Removal.
Before removal of flywheel/driveplate take note of the loca

tion of paint aligning marks on flywheel and pressure plate,
before removing clutch pressure plate, the driveplate and
torque converter also have paint aligning marks.
If not visible, scribe aligning marks on all parts.
Clutch and pressure
plate assembly
Clutch plate
centering tool
marks
I
plate and fly wheel
Installation.
Installation is thercverseof removal techniques, please note

the following poinLs:
(a) Install fl ywhcel/dri veplate to crankshaft, and tighten bolts
to the correct specification.
FlywbeeVDriveplate bolt specification 100115 Nm
(b) Mount a dial indicator on the rear of cylinder block for
vehicles with automatic transmission. Inspect flexplaterunout
at the three torque converter mounting bolt holes. Runout
should not exceed the following specifications.
Flexplate RUDOU!:
20 mm max
Try to correct by tapping high side with a mallet if runout
exceeds specification. Replacedriveplate ifthis condition can
not be corrected.
(c) Inspect starter motor operation.
CIOOS
I. To remove transmission referlo Manual Transmission or
Automatic Transmission in this manual.

2. Vehicles with manual transmission:
Remove the clutch pressure plate and driveplate as per Clutch
section in this manual.
3. Block flywheel/driveplate from turning, using a screw
driver or suitable locking tool. Remove flywheel/driveplate
crankshaft bolts and flywheel/driveplate.
RING GEAR
Replacement.
The ring gear is welded to thedriveplate and is serviced only

as an assembly for vehicles with automatic transmission.
Therefore the driveplate/ring gear must be replaced as a
complete unil.
For vehicles with manual transmission. the ring gear is a
shrink fit on the flywheel flange, and if damaged, can be
71
removed and replaced.
13. Remove fuel feed and return lines from fuel rail..
14. Disconnectemission control canister hoses from throttle
body connections, and separate canister lines from fuel rail
clips.
IS. Disconnect brake booster and heater control hoses from
Replacement technIques are as follows:
1. To remove nywheel refer to FL YWHEELI

DRIVEPLATEsection in this manual fordetails.
2. To remove ri ng geardrill a hole between two ring gear teeth
and split gear at this point using a chisel.
3. Make sure that there are no foreign maneror burrs on new
ring gear and flywheel matchi ng surface. Remove burrs using
a tine mill tile (if present).
4. Heat and shrink a new gear in place as follows:
(a) Using an emery cloth. polish several spots on ring gear.
(b) Using a hot plate or a slow moving torch. heat ring gear
until the polished spots tum blue (approximately 320 degrees
Celcius).
* Heating the ring gear in excess 01'427 degrees Celcius wi II
destroy ring gear heat treatment.
(c) Quickly place ring gear in position against shoulder of
flywheel using 2 pairsof pliers. Allow ring geartocool slowly
until it contracts and is fmnly held in place.
S. To install flywheel refer to Flywheel I Driveplate section
in this manual.
engtne vacuumconnectJons.
16. Raise vehicle with ajack and place on safety stands.

17. Disconnect engine exhaust pipes from manifold assem
blies.
18. Remove the anaching bolts from:
Manual transmissions, the clutch bell housing.
Automatic transrnissions. the torque converter housing.
19. Disconnect clutch slave cylinder (for vehicles with
manual transmission only) fordetails refertoClutchsection.
20. Raise engine slightly to take weight off mounts by
attaching an appropriate lifting hook and chain to engine, care
must be used not damage engine components with chain or
rope while liftingengine.
21. Removeengi ne front mountings from mounting brackets.
22. Disconnect wiring harness connector from compressor
clutch for vehicles with airconditiOlling.
Raiseengine slightly and removeaircompressor from engine
mount bracket mounting bolts. Tie compressor back away
from the engine.
23. (a) Raise engine with front tilted slightly upwards and a
floor jack supporting transmission assembly, make sure that
engine exhaust manifolds, starter motor or transmission do
not rest on steering gear.
(b )Separate the engine from the bell housing taking care not
to damage the clutch or torque converter.
If necessary refer to Manual transmission or Automatic
transmission.
* Do not allow engine to swing forward and damage air
conditioning condenser(on vehicles with airconditioning)
ENGINE REBUILD.
ENGINE ASSEMBLY.
Removal.
1. Disconnect battery leads

2. Remove bottom radiator hose from radiator to allow
coolant to drain, disconnect radiator hoses from engine.
3. Drain engine oil sump.
4. Using a felt tipped pen mark engine hood to hinge positions.
Disconnect windshield washer hose. Remove hood hinge
bolts and hood.
S. To remove cooling fan and radiator assembly refer to
"Cooling systems" chapter section for details.
6. Disconnect heater supply and return hoses from engine
heaterpipeconnections.
7. Disconnect main wiring harness from engine and battery
harness.
8. Unclip harness from ignition coil, idle fuel shut off
solenoid, oil sender unit and temperature sender unit.
9. To remove power steering pump (if applicable) refer to
Power Steering section fordetails.
10. Disconnect air cleaner
11. Disconnect throttle cable from throttle Jinkageand mounting bracket.
12. If vehicle is titted with automatic transmission, discon
nect kick down cable from throttle linkage and mounting
bracket. Disconnectcruiseeontrol cable (if applicable) from
throttle linkage and remove mounting bracket bolts.
Dismantle.
I. Mount engine assembly in an appropriate engine stand.

2. Remove the following parts:
(a) Ignition coil and mounting bmcket, high tension leads and
spark plugs.
(b) Alternator and brackets, refer Alternator System.
3. Remove the following parts as described in this chapter.
...,
.....

and Throttle Body
72
(a) Rocker covers, rocker arms and pushrods

(b) Exhaust manifolds,
(e) Intake manifold,
(h) Timing chain, sprockets and shaft gears

(i) Hydralic lifters,
(j) Front cover,
(k) Crankshaft balancer,
(l) Drive belts,
(m)Oil filter,
(n) Valve liftcrs,
(0) Exhaust manifolds,
(p) Rocker covers, rocker anns and pushrads
(q) Intake manifold,
3. Replace the following parts:
(a)lgnitioncoil and mounting bracket, high tension lcadsand
spark plugs.
(b) Alternator and bracket', refer Alternator System.
Installation.
(d) Valve lifters,
Do not allow engine to swing forward and damage air

conditioningcondenser(on vehicles with aireonditioning)
1. (a) Raise engine with front tilted slightly upwards, move
vehicle engine bay under engine, have a floor jack supporti ng
transmission assembly, make sure that engine exhaust mani
folds, starter motor or transmission do not rest on steering
gear or other components in engine bay.
(b )Join the engine assembly and the transmission assembly
at the bell housing taking care not to damage the clutch or
(e) Oil tiltcr,

(0 Drive belts.
(g) Crankshaft balancer,
(h) Front cover.
Timing
Cam Shaft Gear
torqueconverter.
Remove on Slinger
10 reveal lower sprocket.
Tighten bell housing bolts to the engine block to specification:

Bell housing attaching bolts:
54-68Nm
If necessary refer to Manual transmission or Automatic
transmission.
2. Fit engine front mountings to mounting brackets.
Tighten nuts a, specified.
Engine Mount bracket to rubber insulator Nuts:
2030Nm
3. Connect clutch slave cylinder (for vehicles with manual
transmission only) for details refer to Clutch section.
3. Reconnect wiring harness connector to the compressor
clutch for vehicles with air conditioning.
4. Connect engine exhaust pipes to manifold assemblies.
5. Lower vehicle from safety stands.
6. Reconnect brake booster and heater control hoses to engine
EAVB053
(i) Timing chain. sprockets and shaft gears

(j) Camshaft,
(k) Cylinder heads,
(I)Enginesump,
(m) Oil pump, suction pipe and screen,
(n )F1ywheelldriveplate
(0) Crankshaft,
(P) Piston and connecting rod a.semblies.
vacuum connections.
7. Connect emission control canister hoses to connections,

and fit canister lines from fuel rail clips.
8. Replace fuel feed and return lines to carburettor.
9. If vehicle is litted with automatic transmission, connect
kick down cable to throttle linkage and mounting bracket.
Connectcruisc control cable (i rapplicable) to throttle linkage
and mounting bracket bolts.
10. Connect throttJe cable to throttJe linkage and mounting
bracket.
11. Connect air cleaner.
12. Replace power steering pump (if applicable) refer to
Power Steering section for details.
Assembly.
I. Mount cngine block on an appropriate engine stand.
2. Replace the following parts as in this chaptcr.
(a) Piston and connecting rod assemblies.
(b) Crankshaft,
(c)F1ywheelldriveplate
(d) Oil pump, suction pipe and screen,
(e) Engine sump.
(I) Cylinder heads,
(g) Camshaft,
73
13. Connect electrical harness to ignition coil, idle fuel shut

off solenoid, oil sender unittempemture sender urut.
14. Connect main wiring harness to engine and battery
harnesses.
15. Connect vacuum hose to oil filler on rocker cover.
16. Connect heater supply and return hoses from engine
heater pipe connections.
17. To remove cooling fan and radiator assembly refer to
"Cooling systems" chapter section for details.
IS. Replace hood ,md hinge bolts, align hood to pen mark on
hood to hinge positions. Connect windshield washer hose.
19. Refill engine oil sump, with specified engine oil.
20. Replace radiator hoses and till with coolant.
21. Connect battery leads
Use specilied engine lubricant and coolant when refilling.
Inspect transmission fluid level, add lubricant as required.
Inspect for fuel , coolant, oil and exhaust leaks. Repair as
required.
Check engine hood al ignment.
1. Clean all matching surfaces of oil pan and cylinder block

thoroughly.
2. Apply a strip of sealant (RTV 732) on the cylinder block
at the joints of rear main bearing cap and front cover, and on
the oil pan. Install new seal onto oil pan, aligning recesses on
seal with matching dimples in oil pan rail.
specified.
Oil Pan (Sump) Bolt Specification
1012 Nm
Oil Pan (Sump) Drain Plug Specification 2025 Nm
5. (a) Replace front suspension stabilizer bar mounting
bracket bolts which are bolted to chassis.
(b) Tighten to specification.
Stabilizer Bar Mounting bracket bolts: 6O-75Nm
6. Replace starter motor. Tighten bolts to specification
Starter Motor bolts:
15-35Nm
7. (3) Lower engine from safety stands.
(b) Fit attaching nuts to front engine mounts and tighten to
specification.
Engine Mount bracket to rubber insulator Nuts:
20-30Nm
S. Replace dip stick and tube retainer bolt.
described in theLUBRICATIONsection.
10. SUm engine, inspect for oil leaks. Repair as required.
OIL PAN (SUMP) & GASKET.

Engine Sump
Drain Plug
OIL PUMP, SUCTION PIPE AND SCREEN.
Pump Assembly
Cover & Botts .........
Oil Pump
Housing
Removal.
I. Disconnect battery earth lead.
2. Raise vehide with jack and place on safety stands.

3. (a) Remove front suspension stabilirer bar mounting
bracket boiLS which are bolted to chassis.
(b) Allow front suspension stabilirer bar to hang down,
allowing clearance for sump removal.
4. Remove starter motor.
5. (a) Remove front engine mount attaching bolts.
(b) Raise the engine with either a block & tackle or place a
jack underthe sump (place a pieceofwood between the jack
and sump to protect the sump).
6. To steady engine assembly use safety stands under front
engine mounts.
4. Drain oil from oil pan.
5. Remove the dip stick and tube retaining bolt.
6. Remove the flywheel cover plate.
7. Remove oil pan bolts, oil pan and seal, dispose of oil seal.
Do not reuse the formed rubber oil pan seal.
lmtaIIation.
EAV8002
Removal.

2. Drain oil from oil pan (Sump).
3. To remove oil pan (Sump) refer to "Oil pan (Sump)&
Gasket" in this section.
4. Remove the 2 bolts securing suction pipe flange tooil pump
and remove pipe and screen assembly.
5. Remove suction pipe from crankcase gasket and disposeof
gasket.
6. Remove bolts securing oil pump to cylinder block.
7. Remove pump.
74
Dismantle
I. Remove cover to pump screws and cover.

Oil Pan Drain Plug Specification
20-25Nm
described in theLUBRlCA T10Nsection.
8. Start engine and inspect for oil leaks. Repair as required.
Relief
Pump Suction
Pipe Assembly
Valve
MAIN BEARINGS.
Each crankshaft main bearingjournal has 2 bearing halves or

shells which are not the same and not interehangeable in the
bearing cap or crankcase. The upper (crankcase) shell is
grooved tosupplyoil to the connecting rod bearing. while the
lower (bearing cap) shell is not grooved. The 2 bearing shells
must not be interehanged. TheNo.3. bearing is Oangedtotake
end thrust.
The main bearings are of the precision insert type and do not
require reaming to size or utilise shims for adjustment.
Standard size upper shells arc used in the crankcase with
.0254mm undersized or standard size shells in the bearing
caps, depending on bearing clearance.
When shells are placed in crankcase and bearing cap, the end
extends slight! y beyond the parting surfaces so that when cap
bolts are tightened,theshellsciamp tightly in place toensure
positive seating and to prevent turning.
The ends of the bearing shells must never be filed !lush with
parting surfaces of crankcase or bearing cap.
Pump
Suction Pipe
To Housing Gasket
Gears
2. Remove the inner rotor, shaft assembly and outer race.

3.Use a self tapper screw to remove oil pressure relief valve
chamber cap. Remove spring and plunger.
Inspection
1. Wash all parts thoroughly and dry.

2. Check for damage and wear the outer race to pump
housing.
Outer Race 10 housing radial clearance: 0.IS0.33nun
1 Check the cover surface for damage by rotor and rotor
clearance (use a straight edge).
Rolor assembly clearance to cover assembled:
0.03-0.lmm
If components are to be replaced. replace as a complete unit
Assembly
I. Cover all parts with oil.
2. Install oil pressure relief valve plunger, spring. and a new
cap, cap is to be 0.2mm below pump body surface.
llnstall outer race, shaft and rotor assembly. The identifi
cation mark on rotor and outer race both face to the bottom
of the pump.
4.lnstalJ pump cover and tighten screws to specification.
Pump cover to pump screw specification: 12-16Nm
Inspection
I. Remove main bearing cap bolts, remove bearing cap and

lower beari ng shell.
Tap rear main bearing cap to break cap to crankcase seal
to remove. Instal l slide hammers into cap oil pan bolt holes
and remove cap.
Socket and Handle
Installation.
I. Make sure that the screen is cleaned of any foreign matter.
2. Clean suction pipe !lange and crankcase matching sur

faces.
3. Use a new gasket between suction pipe !lange and oil pump.
Install and tighten boll' as specified.
Oil Pump Suction Pipe Flange 10 on Pump:
16-20Nm
4. Install pump to cylinder block and tighten bolts to
specification.
Oil Pump to Cylinder Block Boll Specification:
1620Nm
specified.
Oil Pan (Sump) Bolt Specification
1012 Nm
2.lnspect inner surface of bearing shells for gouges, wear or

embedded foreign material. If foreign material is found,
determine it" nature and source. Inspect outer surface of
bearing shells for surface wear (indicates movement of shell

or high spot in surrounding material), looseness, roultion
(flattened tangs and wear grooves). and overheating
(discolouration).
3. Inspect thrust surfaces of thrust bearing shell forgnooving
75
or wear. Grooves are caused by irregularities in the crankshaft thrust surfaces or dirt.
Ifcondition oflower bearing shells and crankshaft journals is
satisfactory, inspect bearing clearance as follows:
wear
Effects of tappered journal
This bearing has
suffered from lack of oil
Plastigauge
Tighten bearing cap to specification,
check plastigauge wide with plsstgauge
card for dearance of bearing .
11. Removejack if ajack was used because the engine is in
the vehicle.
12. It is advisable to install new bearing shells if bearing
clearance exceeds specification and recheck clearance as
If lower bearing is standard size, install a .0254 mm
undersized shell and check clearance again.
Replace crankshaft as described in :Crankshaft" section if
clearance is still not as specified.
Main Bearing Clearance: Preferred 0.01-0.031mm
Allowable O.Ol-O.OSmm
13. Install new bearing upper shells in crankcase. making
~ng062
4. If the engine is in the vehicle it is importantto accurately

inspect main bearing clearance, it is necessary to have the
crankshaft pushed toward the upper main bearing shells.
To achieve this, locate a small screw jack beneath crankshaft
web, nextto bearing to be inspected. Raisejack so that it just
takcs the weight of the engine.
S. Wipe oil from crankshaft journal and inner and outer
surfaces oflower bearing shell.
Install bearing shell in original position in bearing cap.
6. Place a piece of plastigage across full width of crankshaft
journal, parallel to crankshaft centreline.
* Make sure plastigage will not seat across oil hole in journal.
7. Install bearing cap and bolts into cylinder block.
* Install bearing caps by loosely installing cap bolts and dlen
lightly tap bearing cap into position, in order to prcvcnlthe
possibility ofcyLinder block and or main bearing capdamage.
S. Tighten bearing cap bolts as specified.
Ensure that crankshaft docs nol rotale with plastigage
installed.
Main Bearing Cap Bolt Specification
90Nm
9. Remove bearing cap boilS and cap. Look for flattened
plastigage sticking to either crankshaft or bearing shell in
bearing cap.
1O.Check beari ng clearance by comparing width offlattened
plastigage at widest point with graduation on plastigage
envelope. The number within the graduation on the envelope
indicates the clearance.
Main bearing and crankshaft journal clearance should not
exceed speciRcation.
Main Bearing Clearance
0.01-0.031 mm
This method of checking main bearing clearance does not
give any indication of crankshaft journal taper or out of
round.
To mea<ure taper, out of round or undersized, the crankshaft
must be removed from the cylinder block as described in
CRANKSHAFfsection.
sure notches in bcaring~ line up with recesses in crankcase.
Make sure the bearing shells are fitted into the COllect
crankcase bearing seat.
All bearing upper shells are grooved.
No.3 bearing shells are flanged to take crankcase end thrust.
Bearing lower shells are not grooved.
14. Using Molybdenum Disulphide grea<e lubricate No.3

main bearing shell thrust surfaces.
I S.Lay crankshaft in upper bearing shells, and install lower
bearing shells in bearing caps, making sure the notches in the
shells line up with the recesses in the caps and conu;t bearing
is installed in the appropriale cap.
Before final installation ofcap bollS,determineifboltshave
76
stretched by comparing with new one. Replace boltls as

required.
17. With main bearing caps installed (refer to earlier step)
install and tighten cap bolts as specified.
If the thrust bearing shell is disturbed or replaced, coat the
surface using Molybdenum Disulphide Grease. It is also
necessary to line up the thrust surfaces of the bearing shells
before the cap bolts and tightened. To do this, move the
(last movement forward) with the thrust bearing cap bolts
fmgertight.
If rear main bearing cap was removed, clean all sealant
from cap and cylinder block matching surfaces. To reseal
cylinder block and cap, this is important to stop possible
future oil leaks.
Main Bearing Cap Bolt Specification 90 Nm
18. Push crankshaft forward and measure crankshaft end
float between front of No.3 main bearing and crankshaft
thrust faces using a feeler gauge.
(a) Install in the oil hole of the crankshaft journal.

Use a cotter pin.
(b) Turn crankshaft antic10ckwise as viewed from front of
engine. This will roll uppershell outofcrankcase and remove
cotter pin,
Crankshaft 011 hole
.-I
@
lcm
Crankshaft
Eng060
6. Clean crankshaft journal, crankcase bearing seat and

bearing cap thoroughly.
7. Lubricate new selected upper bearing.
8. Inset unnotched end of shell between crankshaft journal
and notched side of crankcase.
Make sure that the correct bearing shell is fitted belween
the crankcase journal and crankea,e.
No.3 bearing shells are flanged to take crankshaft end
thnlSt.
Beari ng lower shells are not grooved and are either undersized or standard size.
9. Tum bearing shell into place using crankshaft and cotter
pin and then remove pin.
10. Inspect bearing to crankshaft clearance using plastigage
50 - 65 Degrees
./
as outlined in previous section.
Crankshaft End Float

0.102-0.203 mm
To replace No.3 main bearing shells refer to replacement
procedures i rclearance is excessive.
11. Using engine oil lubricate journal and bearing shells.

* I f replacing No.3 main bearing shells, coat thrust surfaces
using Molybdenum Disulphide grease or eq ui valent.
12 Make sure that main bearing cap bolt threads and
* Before final installationofcap bolts, determine ifboltshave
stretched by comparing with a new bolt. Replace bolts as
needed.
13.lnstall bearing cap and tighten all bearing cap bolts to the
REPLACEMENT
The main bearing shells can be replaced with or without the

crankshaft installed.
Main Bearings with Engine in Vehicle
I. Disconnect battery earth lead and remove spark plugs.
2. To remove oi I pan refer to Oil p,m and gasket" section.

3. To remove oil pump. suction pipe and screen refer to "Oi l
pump, suction pipe and screen" section.
4. Loosen all main bearing cap bolts 112 tum, and remove
bolts and caps.
To remove the rear main bearing cap, tap cap to break cap
fromerankcascseal.Install sideharnmers inlocapoil pan bolt
S.Remove upper bearing shell as follows:
correct specification.
Main Bearing Cap Bolt Specification. 90 Nm

* Make sure that the bearing cap is installed inlo the
crankcase in the correct manner, refer to diagram.
* Toel iminate the possibility ofcy linder block or bearing cap

damage, install bearing cap by lightly taping the bearing cap
into position using a soft hammer then install cap bolts.
* It is necessary to line up the thrust surfaces ofthe bearing
shells before the cap bolts arc tightened if the thrust bearing
77
shell has been disturbed or replaced. To do this, move the

cr.mkshaft forward and backwards several times (last movement forward) with the thrust bearing cap bolts linger tight.
Ifithas been necessary to remove the rear main bearing cap,
clean all sealant from bearing cap and crankcase. lnstall
bearing cap and reseal, refer to Rear main bearing oil seal.
14, Tum crankshaft and it should tum without binding. If
binding, inspect orientation of bearing cap, correct fining of
bearing shells or bearing clearance.
IS. To install oil pump, suction pipe and screen, refer to Oil
pump, suction pipe and screen section.
16. To install sump (oil pan), refertoOil pan (sump) and seal
section.
17 .Install spark plugs and tighten tothecorrectspeci lication.
Spark Plug Specification
20-30 Nm
18. Using the correct amount of engine oil relill the oil pan,
referto Lubrication section in this manual for details.
19.5tart engine and inspect for oil leaks, repair as needed. To
inspectoil pressurereferCheckingOil Pressuresection in this
manual for details.
Replace crankshaft, if not as specified in CRANKSHAFT

section.
Crankshaft Connecting Rod BearingJournal Diameter
S3.919-S3.939mm
8. Wipe oil from both inner and outer surfaces of bearing

shells.
9. Inspect inner surface of bearing shells for gouges, wearor
embedded foreign matler, i f any is found, delennine its nature
and source.
Check outer surface of bearing shell for surface wear (indicates movement of shell or high spot in surrounding material),
looseness or turning (flattened tangs and wear grooves), or
overheating (discolouration).
The crankshaft may be bent or have tapered bearingjournals
if uneven side to side wear is found.
Bearing failure,otherthan normal wear, must be examined
carefully. With crankshaft removed, check aJ Iconnecting rod
and crankshaft bearing bores.
To check bearing bores:
(a) Instal l bearing caps with bearingshells installed. Tighten
cap bolts as specified.
(b) Measure bearing bores for taper and out of round.
Replace any part if not as specilied, refer to the applicable
part description in this section.
Connecting Rod Bearing Bore Diameter
CONNECTING ROD BEARINGS

Inspection and Replacement.
I. Disconnect battery earth lead and remove spark plugs.
S6.870-S6.891mm
2. To remove oil pan (Sump) refer to OIL PAN (SUMP)

3. To remove oil pump, suction pipe and screen refcrtoOIL
PUMP, SUCTION PIPE AND SCREEN section.
4. Usingan etching marker or felt tipped pen, mark connecting rods and caps to indicate cylinder number and orientation
of cap.
Maximum Out of Round

O.Olmm
Maximum Taper
O.Olmm
10.lnstall bearing shells in original positions in connecting
rod and cap if inspection reveals that crankshaft is OK.
11. Carefully, so as not to damage the crankshaft, pull the
connecting rod down onto crankshaft so that upper bearingis
seated against crankshaft journal.
12. Using a piece of plastigage on the journal take care the
plastigage is not placed across oil hole in journal.
13. lnstall connecting rod cap on to the connecting rod.
Tighten bolts as specified .
Make sure that crankshaft does not rotate with plastigage
installed.
Connecting Rod Cap Bolt Specification 30 Nm
14. Removeconnecling rod nuts andcap. Inspect for flattened
plastigage sticking to either crankshaft or bearing shell in cap.
IS. Inspect the bearing clearance by comparing width of
flattened plastigage at widest point with graduation 0t1
plastigageenvelope. The nurnberwithin the graduation on the
envelope indicates the clearance.
Clearance between connecting rod bearings and crankshaft
should not exceed speci Iication.
If a bearing is being fitted loan outof round journal,ensure
to fit plastigage to the maximum diameterofthe journal. If the
bearing is Iitted to the minirnumdiameter, and thejoumalis
out of round 0.008mm, interference between the bearing
journal and journal will result in rapid bearing failure.
Connecting Rod Bearing Clearance
O.02-0.06mm
Hammer
Moln Beonng
Cop -~_
Main Bearing
Cap
Connecting Rod
& Cop
Identtfy connecting
S. Remove connecting rod cap nuts, cap and lower bearing

shell.
6. So that the rod is away from the crankshaft and will not
damage the shaft, coverthe connecti ng rod bolts with a small
section of hose. Push the piston and connecting rod up the
cylinder bore. Remove bearing shell from connecting rod.
7. Clean crankshaft journal and measure for out of round or
taper usmg a mlcrometer.
78
ing rod alignment.

ZO.lnstall oil pump, suction pipe and screen as described in
OIL PUMP, SUCfJON PIPE AND SCREEN section.
21. ToinstaU oil pan referlO OIL PAN (Sump) section in this
manual for details.
Spark Plug Specification
20-30 Nm
23. Using the COllect amount of engine oil, refill the oil pan,
refer to LUBRICATION section for details.
24. Start engine and inspect for oil leaks, repair as needed,
also inspect engine oil pressure as described in CHECKING
OIL PRESSURE section.
Plastigauge
Tighten bearing cap to specification,
check plastigauge wide with plastgauge
card for clearance of bearing .
16. Make sure that connecting rod cap bolt threads and
connecting rod threads are clean and dry. Apply some engine
oil to the cap bolt threads. Before final installation of cap
bohs, detennine ifbolts have stretched by comparing with a
new bolt.
17. Install bearing shells in connecting rod and cap making
sure notches in shells match up with recesses in connecting
rod and cap.
Inspect clearance of new bearing with plastigage as prcviouslydescribed.
IS. Remove all remains of plastigageaftermeasuring. Using
clean engine oil lubricate bearing shells and journal. Install
connecting rod cap in original position as described in step4.
Tighten bolt' and then loosen one fuU tum. Finally tighten cap
bohs as specified.
Connecting Rod Cap Bolt Specification 30 Nm
19. With bearing shells installed and cap bolts tightened, it
should be possible to move connecting rod backwards and
forwards on crankshaftjournal a, allowed by end clearance.
Also, the crankshaft should tum without binding.
CAMSHAFT BEARINGS
Camshaft bearings should be inspected visually and with an

inside micrometer before replacing. Check specifications.
Camshaft bearing diameter installed mm +/- 0.012mm
1
section.
3. Remove welsh plug from rear of bearing bore.

4 .lnstaU camshaft bearing and a,semble puller screw .lnstaU
receiving sleeve, washer and puUer screw nut onto pullcr
screw.
5. Tighten nut and pull bearing from bore. With bearing

relea,ed from its bore, dismantle tool and remove bearing.
6. Remove all bearings using the same procedure.
7. Install new bearings into and install into cylinder block,
lining up oil holels in bearing with holes in cylindcr block.
S. InstaU pullcr screw, receiving sleeve, washer and puller
--~
nut.
9. Tighten nut until bearing is installed into the correct

position.
The new bearing is a loose fit on tool. As the bearing is
installed in its bore, the bearing wi II 'collapse' to the correct
installed size.
10.lnstail all bearings using the sanle procedure.
11. Using a piece of2.4mrn diameter bra" rod with a 9(}>
bend at the end, probe thecarnshaft bearing oi Iholes toensure
that thcy are properly lined with oil feed holes in thecylinder
block.
Correct alignment of the oil holes is very important.
Restriction oftheoil flow will cause severe engine damage.
Check clearance between
52.S9-52.92,52.51-52.54, 52.13-52.16,51.45-51.77,51.37
51.39
Slightly scored camshaft bearings will be satisfactory if the
surfaces of the camshaft journals are polished and bearings
are cleaned up to remove burrs, and the fit of the camshaft in
bearings is free and within specifications.
Should the bearings be badly damaged or worn the bearings
will need to be replace.
Replacement
I. Remove camshaft as described in Camshaftsection.
Check camshaft and lifters for contact damage.
2. To remove Aywheelldriveplme, referto nywhccl/drivcplale
Feeler Gouge
Connecting Rods
Eng073
Connect Rod to crankshaft side clearance:

0.254-0.50Smm
aUowable: 0.584mm
If connecting rod binds on crankshaft journal, loosen and
retighten bearing cap bolts.
If rod stiU cannOl be moved or crankshaft binds, inspect
bearing cap to rod orientation, bearing clearance or connect-
79
12. Using Loctitc 620 sealant orequi valcn~ coat the camshaft
bore rear welsh plug and install.
13. Using clean engine oil, lubricate the camshaft bearings
and joumals. Make sure camshaft rotates without binding.
If camshaft binds, remove camshaft, check bearings for high
spols or incorrect installation. Remove any burrs ifpresent.
Inspect camshaft journal to bearing clearance.
Journal Diameter:
1
2
3
4
5
52.8487 52.46-49 52.08-11 51.10-1I 51.32-35
CamshaftBearingtoJoumal Clearance O.025-0.096mm
Worm Limit
0.152mm
piston with a cloth to collect cuttings and remove ridge with

ridge remove. this is to be done for each cylinder.
5. As follows, remove rod assemblies and piston:
(a) With connecting rod crankshaft journal at bottom dcad
centre, remove cOImecting rod cap nuts and remove cap with
bearing shell.
(b) Push piston and connecting rod up cylinder careful not to
drop bearing from rod.
PISTON AND CONNECTING ROD

ASSEMBLY.
Piston and connecting rod assemblies can be removed while

the engine remains in the vehicle.
If the cy lindcr bore requires machining, remove the engine
assembly as described in Engine Assembly section, and
remove piston and connecting rod as described in Piston pin
a.semblies and ring sets are available in oversizes.
Both piston and cylinder bore condition must be considered
together when fitting new pistons. Production and service
pistons have the same nominal weight and can be intermixed
without affecting engine balance.lfneeded, used pistons may
be fitted selectively to any cylinder of the engine. providing
they are in good condition.
Piston pin assemblies and ring sels areavai lable in oversizes.
\,
"'"
".I
handle
Use a hammer handle to push
and out of the
~~bo=re:;._ _ _ _ _ _ _ _.::..:::..:~
(c) Remove piston from cylinder and install cap and nuls to
connecting rod.
6. Remove all other piston and connecting rod assemblies
Dismantle.
Removal.
1. Disconnect battery earth lead and remove cylinder heads
1. Expand and slide piston rings off to remove.

2. Piston pin can now be removed as follows:
(a) Install remover guide into base, and put assembly in a
press.
(b) Install mandrel, into piston pin.
(c) Using care to locate piston on support and base, press
as described in CYLINDER HEAD section.

2. To remove oil pan (sump) refer to OIL PAN (SUMP)
section and to remove oi Ipump, suction pipe and screen refer
toOIL PUMP, SUCTION PIPE AND SCREEN section.
3. Using an etching marker or felt tipped pen, mark all
connecting rods, caps and pistons to indicate cylinder identification. Tum crankshaft so that piston isat bottom of stroke.
PIston and ConnectJflg

Rod
~'SFmbty
011 Ring SpaOllr
0011 Ring
Hammer
Piston
Piston
Pin -
Punch
(0)
Main Bearing
Cap
Moin Bearing
Connectir1g Rod
____
Cap Bolt
Cap
Connecflng Rod
& Cap
U",." "OM",
Rod Beanng
'Lower Conne<:tJng
Rod Sealing _ _
Identity connecting
4. (a) Inspect cylinder bores above piston ring travel.

(b)1f bores are worn so that a ridge or similar exists, cover
Connl!cbng Rod
C.p
CliP Nul
80
piston pin out of connecting rod.

(d) Remove assembly from press. Remove pin from support
and remove mandrel from piston and connecting rod.
4. Check piston pin bores and piston pins for wear. Piston pins
and piston pi n bores must be free of scuffing or varnish when
being measured. Use a micrometer to measure the piston pin,
and a dial bore gauge or an inside micrometer to measure
piston pin bore.
Piston and pin should be replaced if not as specified.
Piston Pin Diameter:
23.16223.175mm
Piston Pin Clearance
: in Piston
0.0050.01 Omm
5. Remove bearing shells from connecting rod. install cap and
bolts. Tighten bolts as specified.
Connecting Rod Cap Bolt Specification
30 Nm
6. Place connecting rod assembly on a checking ftxture and
inspect rod for twist or bend.
Replace if twisted or bent, do not attempt to stnughten rod.
Inspect new connecting rods using the same procedure before
using them.
Connecting Rod AligrumentMax. Specification
Bend
0.305mm
Twist
O.609mm
7 .Check outsideofconnecti ng rod bearing shells and internal
diameter of connecting rod big end for wear indicating high
SpoLS in the rod big end.
8. Remove cap bolts and inspect bolts for stretching by
comparing them with a new bolt, if stretched, replace.
Inspection.
1. Thoroughlycleancarbon from piston heads and from ring
grooves using a suitable tool and remove any gum or varnish

from piston skirts using a suitable cleaning solvent.
2. Check cylinder walls for ridges, roughness or scoring
which indicates excessive wear. Inspect cylinder bores for
taper and outofround using an accurale cylinder gauge at
top, middle and boUom of bore, hoth parallel and aI right
angles tocentrelineofengine. ReferlO Cy linder B lock section
fordetails.
Slot
Ring
.
,,
.......:.+I-'+,
Piston
Pin
Cleaning
Toal
Piston
--
Roc
I
j/
Clean ring grooves

and all slots In piston.
Assembly and Installation.

l. Using engine oil, lubricate piston pin and piston pin bore.
Eng063
2.lnstall piston pin on mandrel.

3. Assemble installer guide and piston support to base.
4. Using temperature indicating crayon, heat connecting rod
to 28O"C. A ftre brick will help prevent excessive heat loss.
5. The green colour of the crayon will tum black when the
temperature is reached (280"C).
6. Using a heat proof glove. pick up connecting rod.
7. Quickly install piston and connecting rod over guide.
8. Quickly push piston pin into place with a mandrel, until
piston pin bonoms. After a few seconds, the pin will jam in
the connecting rod, requiring the use of a hydraulic press.
9. To install piston rings refer to PISTON RINGS section.
10. Make sure connecting rod bearing shells, pistons, cylin
der bores and crankshaft journals are totally clean, then,
using clean engine oil. coat cylinder bores and all bearing
surfaces.
11. Position thecrankpinstraight down before installation of
a piston and rod assembly in its bore.
12. Remove cap, and with bearing upper shell seated in
connecting rod, install protection guides (a section of hose)
onto the connecting rod bolts. The guides will help protect
crankshaft journal from damage during installation of con
necting rod and piston assembly.
13. Make sure piston ring gaps are separated as described in
Piston Rings section.
3. Examinc piston skirt thoroughly for scored or rough

surfaces, cmcks in skirt orcrown, chipping, broken ring lands
or uneven wear which would cause rings to seat improperly
orhaveexcessi veclearance in ring grooves. Pistons should be
replaced if faulty or damaged .
Pistons are cam ground, which means that the diameter at
right angles to the piston pin is greater than the diameter
parallel to the piston pin. When a piston is checked for size.
it must be done at points 90" to the piston pin bore.
Piston Size Standard
101.53101.61 mm
Available in Oversizes
I
the piston pin hole axis

Piston
Micrometer
81

tap
the piston
assembly down
through ring
Gent~
Plastic
Hammer Handle
compressor Into
cylinder bore.
Piston
Assembly
compressor
This mark
front of engine
_ _ _ Connecting
Rod
o
Eng064
17. Remove connecting rod guides. Install bearing cap and

lower bearing shell assembly. Install cap nuts and tighten and
then loosen one full tum. Then tighten again as specified.
Connecting Rod Cap Bolt Specification: 30 Nm
rod can move freely. If crankshaft binds, check bearing cap
to rod orientation agai n and bearing clearance or connecting
rod alignment.
19. Measure side clearance between crankshaft journal and
connectingrod.
Connect Rod to crankshaft side clearance:
0.2S4-0.S08mm
allowable: O.S84mm
Ifside clearance is not as specified, to check bearing clearance
refer to Connecting Rod Bearing section, or connecting rod
alignmenL
20. Install remaining piston and connecting rod assemblies
21. To install cylinder head refer to Cylinder Head section,
and to install oil pump, suction pipe and screen refer to Oil
Pump, Suction Pipe section.
22. To install oil pan refer to Oil Pan section in this manual.
23. Start engine and inspect for oil leaks, Repair as needed.
14. Using clean engine oil, lubricate piston and rings. With a
suitable ring compressor, compress rings. Tnstall each piston
and connccting rod assembly into its cylinder bore.
I
Ring compressor
tightening key
and Connecting
RodAssemb~
Install piston ring compressor onto

piston and rings to enable the
Installation of the piston
15. Lightly tap piston into its bore, using a hammer handle,
while holding ring compressor fmnly against cyl inder block
until all piston rings have entered bore.
Assemb~
PISTON RINGS.
Compressor
Installation.
Pistons have three rings (two compression rings and one oil
ring). The oil ring is of three piece design, comprising two
segments and a spacer.
1. Using a set of rings comparable in size to the piston being
used install compression ring in relevant cylinder bore, then
using the head of a piston, press ring down into bore
approximately.
* Using a piston in this manner will place ring square with
cylinderwalJ.
* Ensure not todistortthe ri ng during this operation, orit may
16. Push piston down bore until connecting rod seats against
crankshaft journal.
82
bind in the piston ring groove. Fit each ring separately to the
cylinder in which it is going to be installed.
2. Using a feeler gauge. measure gap between ends of ring.
Compression Ring End Gap Specification:
Both Rings
O.2S0.S0mm
Remove ring and try another. if the gap between the ends of
compression ring is below specification. The ring gap may
be enlarged by filing.
Try another ring if it is too tight. If no ring can be found that

fits the specificalion. the ring may be ground to size using
emery paper placed on a piece of glass.
High spots in the ring groove may be cleaned up with careful
usc of a finc filc. do not try to cut the piston ring groove.
6. Install oil ring spacer in bollom piston ring groove .
* The ends of the spacer butt against each other.
Front of Engine
Measure gap between ends of ring

Cylinder Bore
Ring
Carefully roll rings

into
'
.....,.
Feeler Gauge
,
Oil Ring Rail Gap
"'...
compres on
gap~ .....
Oil ring
~pacer
gap
Top
Oil Ring Rail Gap
Eng066
Eng067
7. Install one steel segment from topofpiston downward into

oil ring groove and install remaining steel segment from
bottom of piston skirt upwards into the oil ring groove.
8. Install compression rings in first and second grooves of
each piston.
Make sure the correct compression ring are installed in the
first and second grooves, and the correct way up.
9. Do a final test of ring fit in piston grooves. Separate ends
as illustrated.
Do not install piston with ring gaps in line. as this will allow
compression leakage at this point.
J.lnspectgap between ends ofeach oil control ring segment.

Oil Ring Steel Rail Gap Specification:
Oil Ring Steel Rail Gap
0.38 I.40mm
4. Carefully remove all traces ofcarbon from ring grooves in
piston and check grooves for any chips or burrs that might
cause ring to bind when fitting.
5. Slip outer surface of each compression ring in respective
piston ring groove and roll ring entirely around groove to
ensure that ring is free. Also measure ring to piston groove
side clearance.
to measure I
gap of piston
h piston "ng
compression
ring gap
CRANKSHAFT.
____ Piston
Piston
Ring
Feeler Gouge
Removal.
Eng058
Piston Ring Side Clcarance:

Both Compression Rings
Wear Limit
Oil Control Ring
To check bearing clearance before removing crankshaft

from cnmkcasereferto Connecting Rod Bearings and Main
Bearing section for detai Is.
suitable stand, remove oil pan, refer to Oil Pan (Sump) and
Seal section for details.
O.OSO.lOmm
O.lSmm
Snug fit
83
2. To remove oil pump. suction pipe and screen refer to Oil

Pan (Sump) and Seal section and to remove crankshaft
balancer refer to Crankshaft section.
3. To remove timing chain and crankshaft sprocket refer to
Timing Chain. and Sprockets section.
4. Remove spark plugs, and using an etching marker or felt
tipped pen to mark connecting rod caps to indicate cylinder
number and orientation of cap.
5. Removeconnecting rod caps and bolts and push connecting rods away from crankshaft.
6. Remove main bearing cap bolts and caps.
Remove the rear main bearing cap by removing cap nulS.
and using a soft faced hammer tap the cap to break cap to
crankcase seal. Install side hammers into cap oil pan bolt
7. Lift crankshaft from crankcase and remove flywheeU
driveplate from crankshaft boll. and remove flywheeU
drivepl"te.
8. Remove key from front end of crankshaft, if needed, using
a suitable punch and hammer.
Out-Or-Round
.015mm max.
Connecting Rod Journal Diameter
...... .
Connecting Rod Jou

Check each journal
23 times in different positions
S3.919-53.939mm
Standard
.015mm max.
Ovality
.01Smm max.
Out-Of-Round
6. Inspect crankshaft for run-out by supporting front and rear
main bearing journals in 'Y' blocks if not in engine and
checking journals with a dial gauge.
Crankshaft Runout Specification
.O.l27mm max.
7. Place a dial gauge indicator at crankshaft rear flange and
inspect rear nangerunout. During this inspection, make sure
that crankshaft is thrust forward on 'Y' blocks so that there
is no possibility of crankshaft end float affecting dial gauge
reading.
Crankshaft Runout clutch face ofnywheel: O.254mm.
8. If not as specified, replace crankshaft.
9. Ensure all traces of sealant arc cleaned from rear main
bearing cap and crankcase.
Inspection.
1. Usingasuitablecleaningsolvent. wash crankshaft and dry

2. Check crankshaft oil passages for obstructions.
3. Check all bearing journals and thrust surfaces for:
(a) Gouges
(b) Overheating (Discolouration)
(d) Grooving
(I) Roughness
The crankshaft must be machined or replaced if it has any
burned Spol., cracks or sever gouging. Slight roughness may
be removed using a tine polishing cloth soaked in clean enb~ne
oil. Burrs may also be removed using a fine oil stone.
4.Check connecting rod and main bcaringshells forembcdded foreign material and determine its source.
5. Using a micrometer mea.ure bearing journals for taper,
Installation.
1. To replace rear main bearing oil seal refer to Crankshaft

Rear Main Bearing Oil Seal section.
2. Install key to front end of crankshaft if required.
3. Install flywheeUflexplatetocrankshaft and tighten boilS as
specified.
The bolt holes are unevenly spaced so they can only be
installed with the flywheeUflexplate in the correct position.
FlywheeUDriveplate Bolt Specification
100-11 SNm
4. Inspect main bearing clearance, if needed, refer to Main
Bearings section fordetai Is.
5. Using a clean engine oil lubricate all crankshaft journals
excessive wearoroul-of-round.
Main BearingJournal Diameter
,
I
/'
Oil Can Spout
_~
icrome
Standard
Ovality
57.12S-57.104mm
.01Smmmax.
~=;:.a:;.th;;;i":..;fi::;;.m.:.;..:o:..;fcIe=a;;;"= ==='::;",,:..m=ai,,"== shells.
84
11. Inspect connecting rod bearing clcamnces, if needed,

refer to "Connecting rod bearing" section for details.
12. Pull connecting rods up to crankshaft journals, using
guide pin tools.
13. Lubricate crankshaft connecting rod journals and bearings' install connecting rod caps and bolts.
14. Tighten connecting rod cap bolts and then loosen one full
tum. Tighten bolts as specified .
Connecting Rod Cap Bolt Specification
30Nm
15. Using a feeler gauge, measure cleamnce between connecting rod caps and crankshaft journal flanges.
Connecting Rod Side Clearance Spec: 0.10-0.20 mm
16. To install crankshaft sprocket, timing chain, and front
cover refer to ''Timing chain, Sprockets & shaft gears"
section for details and to install crankshaft balancer refer to
Cmnkshaft balancer section.
rods have free movement. Inspect orientation ofbearing caps,
correct fitting of bearing caps (mains and connecting rods) or
fitting of bearing shells or bearing clearance, if crankshaft
binds.
Spark Plug Torque Specification
20-30 Nm
19. To install oil pump suction pipe and sereen refer to "Oil
pump suction pipe and screen" section and to install oil pan
refer to "Oil pan (Sump) and ga.ket" section.
and main bearing upper shells in crankcase.

6. Sit crankshaft in place in main bearing upper shells in
crankcase. Ensurenottodamagecrankshaftthrustflangeand
No.3 main bearing thrust faces. Also ensure not to contact
connectingrodjournals with connecting rod and install main
bearing caps.
Engine
Block
MaIn Bearing Cap
I
(ll'lrust)
Using a thin film of Loctite 515 Gasket Eliminator or

equivalent apply to rear main bearing cap to cmnkcase
mating surface. Keep sealant out of bolt holes and use
sparingly.
Make sure that the bearing caps are installed onto the
crankcase in the COllect manner.
REAR MAIN OIL SEAL

Replace

2. Remove tmnsmission, as deseri bed under "Manual Transmission" and "Automatic Transmission" in this manual.
3. Remove f1ywheel!driveplatc, a. described in "Flywheel!
Driveplate" in this manual.
4. Locate a piece of shim brass between seal lips and
crankshaft. This is necessary so a. to protect crankshaft seal
surface. Using a suitable lever, pry out seal,leveringagainst
shim brass strip and remove seal.
5. Check seal bore in cylinder block and rear bearing cap for
nicks or burrs and correct as required.
Inspect crankshaft seal surface for nicks, burrs or damage.
Repair or replace crankshaft as required.
6. Apply engine oil to new seal inner and outer surfaces.
Ensure that T-handle of tool is loosened right off. Slideseal
over mandrel until it bottoms squarely against outercollarof
tool.
7. Attach tool to rearofcmnkshaftby tightening two knurled
attaching screws until tight.
Before continuing with step 8, the crankshaft must be in
the fully rearward position before installing the new seal. To
acllieve this, either pull on special tool or push on crankshaft
balancer. Ensure that crankshaft is held in this position while
installingseal.
Tighten the bolts finger tight.

7. It will be necessary to line up thrust surfaces of No.5
bearing shells, before tightening main bearing cap bolts.
Move crankshaft fore ,md aft the Icngth of it. tmvel several
times (last movement forward) to do this.
8. Ensure all main beming cap bolts are tightened a. specified.
90Nm
9. Usea feeler gauge to measure crankshaft end float between
front of No.3 main bearing shell and crankshaft thrust faces,
you will need to forcecmnkshaft forward to do this.
Crankshaft End Float Specification 0.102-0.203 mm
Wear Limit
0.3Omm
Replace No.3 main bearing shells if clearance is excessive.
10. Using RTV I080 sealant or equivalent, inject into rear
main bearing cap side grooves. Continue to inject sealant until
you can see sealant at joint gaps.
85
S. Turn T-h'mdle of tool so that outer collar pushes seal into

its bore and continue to turn handle unti Iadditional resistance
is felt. Do not over tighten T-handle otherwise damage to the
tool may result. This will ensure the seal is installed to the
correct dimension inside the cy linder block.
Crankshaft
Rear Seal
Rubber Up
block surface may be machined.

CylinderBlockDeckSurfacesFlatnessSpecification
0.152 max or 0.076mm per 150mm
Replace cylinder block if irregularity or distortion is more
than specified.
7. Check oi I pan and front cover area for burrs or damage.
Minor changes may be cleaned up with a fine mill file.
S. If needed, clean all threaded holes using a suitable threaded
tap or drill out and install thread insert.
The following cylinder block checks require the main bearing
caps to be installed and bolts tightened a~ specified.
90 Nm
* Make sure that the main bearing caps are installed into the
crankcase using the correct procedure.
By lightly tapping into place, install bearing caps to
cylinder block. Do not pull the bearing cap into place using
the bearing cap bolts.
9. Inspect cnillkshaft and camshaft bearing borc for concentrically and alignment.
Crankshaft Bearing Bore
MaximumOut-Of-Round .010 mm
Camshaft Bearing Bore
Maximum Out-Of-Round .015 mm
Replacecylinder block if not as specified. If examination of
the outside of the bearing shells shows minor high spots,
remove high spots Ii-om bearing seats using a fine mill file.
10. Measurecylinder bore walls for taper, excessive ridging,
oversize and out-of-round.
Standard Bore Diameter
101.6-101.72 mm
Taper
.025 mm
Wear Limit
.245 max
Out-Of-Round
.025 mm
Wear Limit
.127 max
Ifbore is worn beyond limits, it may be rebored, honed and
fitted with oversize pistons. The smallest available oversize
piston should be selected.
Dowl Pin
Collar
V6090
Should the seal be installed any further than the dimension

shown in diagram below, the oil return slot in the rear main
bearing cap would be cut off and result in an overloading

of the seals lip capability and oil leakage.
9. Remove seal installing tool from crankshaft.
10. Clean f1ywheeVdri veplate attaching bolt threads in rearof
crankshaft using a thread tap.
Install new f1ywheel/driveplate and attaching bolts, tighten
bolts to the correct torque specification.
FlywheeVdriveplate bolt tightening order:
initially torque bolts at IS22Nm
fmally
tighten Ibe bolts to 100-1 15Nm.
1 I. Reinstall transmission, check engine and transmission
lubricant levels.
12. Road-test vehicle and check for lubrication leaks.
CYLINDER BLOCK.
Cylinder Reconditioning and Piston

Fitting.
Inspection.

suitable engine stand, remove all parts as outlined under the
particular part heading in this section.
2. Clean all cylinder block gasket surfaces.
3. Remove all coolant jacket welsh plugs, oil gallery screw
plugs, and camshaft bearings if needed.
4.Clean cylinder block thoroughly using a suitable cleaning
solution. Flush with clean water or steam. Spray or wipe
cylinder bores and machined surfaces using engine oil.
* Caustic cleaning solutions destroy all bearing and alloy
materials. All bearing and alloy parts if not removed before
cleaning must be replaced.
5. Check all oil passages for obstructions.
6. Using a straight edge and feeler gauge, inspect cylinder
block deck surfaces for flatness.
If any distortion or irregularity is less than specified, cyl inder
It will be necessary to smooth bores to fit new pistons, ifone

or more cylinder bores are scored, rough or worn beyond
linlits.
It will not be necessary to rebore all cylinders to the same
oversize order to maintain engine balance if few bores require
correction, since all oversize service pistons are held to the
same weight as standard size pistons.
Do not try to machine oversize pistons to fit cylinder bores,
this will destroy the surface treatment and affect the weight.
The smallest possible oversize service pistons should be used
and the cylinder bores should be honed to size for proper
clearances.
Measureall new pistons at right angles to the piston pin bore,

as per diagram, before the honing or reboring operation is
started.
86
Honing is recommended for truing bore ifcylinder bore wear

does not exceed specification. The bore should be trued up
by boring and then hone fmished, if wear or out-of-round
exoeeds speci fication.
AU crankshaft bearing caps must be in place and tightened a~
specified when reboring cylinder bores, to prevent distortion
of bores in final assembly.
Leave 0.025 mm on the diameter for fi nal honing to give the
specified clearance when taking the final cut with boring bar.
Follow the Hone Manufacturers recommendations for the
use of the hone and cleaning and lubrication during honing.
Noting the following points.
Pass the hone through theentire length of the cylinder bore at
therate of approximately 60 cycles per minute when finished
honing. This should produce the desired 45 cross hatch
pattern on cylinder walls which will ensure minimum oil
consumption and maximum ring life.
2. Measure the bore using an inside micrometer.

3. Measure piston diameter and subtract piston diameter
from cylinder bore diameter to determine piston-to-bore
clearance.
Piston to Bore Clearance
0.762-0.965 mm
4. Mark each piston with cylinder number to which it will be
fitted and proceed to hone cylinders and tit pistons.
Problem Diagnosis.
Problems and Possible CSllses.
Problems should be corrected, when proper diagnosis is

made, repair, adjustment or part replacement as needed.
High Oil Loss
(I) Tighten bolts andlorrcplace gaskel~ and seals as required
for external leaks.
(2) Check oil with car on a level surface and allow adequate
drain down time. This will give a correct reading.
(3) Severe usage such as towing or continuous high speed
driving will nonnally cause oil consumption to increase.
(4) PCV system failure.
(5) Use recommended S.A.E viscosity forcurrenttempemtures. Refer to LUBRlCA nON Section for details on
incorrectoil viscosity.
(6) Valve guides andlor valve stem seals worn, or seals
omitted. Ream guides and install oversize service val ves andl
(7) Allow enough time for the piston rings to seat. Replace
worn or broken rings as needed, if rings have been incorrectly
installed, worn or broken , or not seated.
(8) Piston incorrectly installed or mistitted.
Gaskets.
( I) Incorrectly tightened fasteners ordamagedldirty threads.
(2) Worn or damaged ga~ket (cracking or porosity).
(3) Fluid pressurcllevel too high.
(4) Incorrect sealant used (when required)
Inspection of Seals.
(I) Damaged seal bore (burred, nicked, scratched)
(2) Worn or loose bearing which causes excessi ve seal wear.
(3) Worn or damaged seal or incorrect installation.
(4) Ruid pressurellevel too high.
Oil leaks areea~ily located & repaired by visually finding the
leak and replacing or repairing the required pans.
(I) Detennine whether the fluid is tmnsmission lubricant,
engine oil, power steering fluid etc.
(2) Run thecarat nonnal operating temperature and park the
should be abletofmd theappro,imate location of the leak by
(3) Using a degreaser or steam to clean the area of the leak,
drive the car for a few kilometres. The visually inspect the
suspected part.
Each piston must be fitted to the bore in which it will be

installed and marked to ensure correct assembly during the
final honing. After the final honing and before the piston is
inspected for fit, each cylinder bore must be washed and dried
thoroughly to remove all tmees of abra~i ve and then allowed
to cool. Applyclean engine oil to cylinder bores. The pistons
and cylinder block must be at a common temperature before
inspecting.
fl
~/r:;
s -
Engine Block . .
(Ij
~-------..
QUean
ON the Pistons and cylinder bores before assembly
The gl.zedcylinderwaUs should be slightly dulled when new

piston rings arc installed without reboring cylinders, but
without increasing the bore diameter, by means ofthe finest
grade of stone in a cylinder hone.
i. Using a clean cloth wipe cylinder walls and pistons and
apply clean engine oil to cylinder bores.
87
Hydraulic Valve Lifters

There are dye and light kits available for finding leaks.
(a) Pour required amount of dye into leaking pan.
(b) Operate the car under normal operating conditions as
(c) Shine the light in the suspected area. The dyed fluid will
Low Oil Pressure
(I) Blocked oil filter.
(2) Incorrect oil viscosity for expected temperature. or oil
diluted with moisture or unburned fuel mixtures.
(3) Excessive bearing clearance.
(4) !fthe oil level is low, fill to mark on dipstick.
(5) Oil pump dirty/worn, or oil pump suction pipe screen
(6) Incorrect or failing oil pressure sender.
The lifters are extremely simple in design and rarely need

attention, readjustments are not required and servicing re-
quires only that care and cleanliness be exercised whilst

handling the parts. Using a piece of garden hose near the end
of each intakeand exhaust val vc with the other end orthe hose
to your ear. is the easiest method for locating a noisy valve
lifter. Using this method, the sound is localised, which makes
it easier to find out which lifter is faulty.
Another method is to place a finger on the face of the valve
spring retainer. If the lifter is not functioning correctly, a
definite shock will be felt when the valve returns to seat.
SpeCifications
GENERAL
EngIne Knocks
Type ......................................................................... V8
Displacement ..................................................... 5.0 litre
Compression ratio ................................................. 9.0: 1
BoreandStroke(nominal) ............................ 101.6-76.2
Firing Order .......................................... 1-3-7-2-6-5-4-8
Fuel requirements ............................................. Unleaded
WHEN ENGINE COLD AND CONTINUES KNOCKING FOR TWO OR THREE

Increases with torque
( I)Tighten orreplaceas required ifdrive pulleys or balancer
(2) Replace piston if clearance from piston to bore is
excessive.(Cold engine piston knock usually disappears when
thecylinderis grounded out. Cold engine piston knock which
disappears in 1.5 min. can be considered acceptable.)
(3) Connecting rod bent.
HEA VY KNOCK WITH TORQUE APPLIED
(I) Replace pans as required of pulley hub or balancer
broken.
(2) Loose torque convener to driveplate bolts.
(3) Check ifexhaust system contacting underbody.
(4) Cracked drivewheellnyplate.
(5) Main bearing clearance or connecting rod bearing clear-
PowerkW ................................................ kW@R.P.M.
5.0 litre ........................................................ 165
4500
Torque Newtonrnetre ............................... kW@R..P.M.
5.0 litre ........................................................ 388
3000
CYLINDER BLOCK
Borediametcr .................................... 101.60-IOl.72mlTI

Boreout-of-round ................................... 0.038 mm max.
Bore taper .............................................. 0.254 mm max.
Cylinder block to cylinder head surface
natness ...... 0.152mm max.overall or .076mm per 15001m
anceexcesslVC.
CYLINDER HEAD
Thickness .................................... 1.372mm to 1.676mm

Combustion chamber volume (cc) 5.0 litre ............... 4942
(with valves and spark plugs installed)
LIGHT KNOCK HOT

(I) Inspect fuel quality if preignition or spark knock.
(2) Loose torque convener to driveplate bolts.

(3) Connecting rod bearing clearance excessive.
KNOCKS ON FIRST START-UP ONLY LASTING A
FEW SECONDS
(I) Incorrect oil viscosity. Install correct oil viscosity for
(2) Hydraulic lifter bleed down.
Some valves will be open when engine is stopped. Spring
problem is consistent should repairs be attempted.
(3) Replace crankshaft thrust bearing shells if excessive
crankshaft end tloat.
(4) Place worn pans if from main bearing clearance is
excessive.
VALVE -INTAKE
Material ................... High Manganese Med.CarbonSteel

Diameter head 5.0 litre ....................... 44.958-45.568 mm
Diameter stem 5.0 litre ........................... 8.677-8.694 mm
Diameterstemoversizes ..................... 0.381 & 0.762 mm
Angle val ve race ........................................................ 440
Angle valve seat ......................................................... 45'-'
Width valve seat ........................................... 1.5-2.0 mm
Valveseatrun-out ........................................... 0.051 nun
Clearance in guide 5.0 litre ..................... 0.025-0.068 mm
WearLimit ....................................................... 0.14mm
Valve installed height (valve tipto spring
seat) ......................................................... 44.5-45.7 mm
88
Valve head margin thickness ................... . 0.794 mm min.

Valveoversi7..cavailable .... ........................ ...... 0.254 mm
Compression ring upper ......................... 1.524-1.549 mm

Compression ring lower ......................... 1.524-1.549 mm
Oil control ri ng ......... ....... ..... ...... ........... 4.0314.056 mm
VALVE - EXHAUST
Material ..................... .... High AlIoy Exhaust Valve Steel

Diameter head 5.0 litre ........................... 36.90-37.28 mm
Diameterstem ....................................... 8.664-8.682 mm
Diameter stem oversizes .... ........... ...... 0.381 & 0.762 mm
PISTON RINGS
Compression ring upper
Ring width ...... ................ ....... ........... .. ... 1.466-1.491 mm

Sidccleamnee ....... ......... .... ....... ............. 0.051-0.102 mm
Gap ............................................. ,........ ,0.254-0.508 mm
Compression ring lower
Ring width ............................................. 1.466- 1.491 mOl
S ide clearance .......... .... ....... ..... .......... .... 0.051-0. 102 mm
Gap ........................................................ O.254-0.635mrn
Oil Control Ring.
Type .............................. Segmented with Circumferential
Rail gap(Steel Rail) .................... ........... 0.381- 1.397 mm
Angle face valve ........................................................ 44u
Angle valve seat ...... .......... ... ......... ... ................... ..... .. 45
Width valve seat ........................................ 1.78-2.29 mm
Valve seat run-out ..................... _..................... 0.051 mm
Clearance in guide .................................. 0.038-0.081 mm
Valve installed height (valve tip to spring
seat) ......... .............. ................................... 40.1-41 .6 nUll
Valveheadmarginthickness .................... 0.794 mm min.
Valveoversizeavail .................................. ...... 0.254 mm
CONNECTING ROD
Type ................................ Malleable Cast Iron'!' Section

Length (centre to centre) ................ . 129.248-129.324mm
Alignment
Bend ....... ........ ..................................... .......... 0.305 min
Twist .............................................................. O.6()9 rnm
VALVE SPRINGS
Spring length
Intake ............................................................... 51.3 mm
Exhaust ..... .. ................................. .. ..... .. ........... 45.5 ITIITl
Allowable variance in spring end length ............. 1.60 mm
Valvespringcompressedheightlload: ............... kg @ mm
Intake .................................................. 33.5-37.2 @ 45.2
................. .................... .................... 95.5-104.5 @ 33.8
Exhaust ............................................... 35.0-38.0 @ 40.6
.................. ....................................... 9().5-102.5 @ 29.2
Valve spring installed height:
Intake ........................................................ 44.5-45.7 mm
Exhaust ..................................................... 40.1-4 J .6 mm
PISTON PINS
Material ................... Steel-Case Hardened and Tempered

Lcn!:,rth ................................................... 76.45-77.22 mm
Diameter ........................................... 23.162-23.175 mm
Piston to pin clearance ........................... 0.005-0.010 mm
CRANKSHAFT
Malerial ............................................. Nodular Cast 1mn
Main Bearing Journal

Diameter .................. ......................... 57.125-57.I04mm
Out-of-round .................................................. 0.015 mm
Wear Lintit ....................................................... O.()9lnm
Taper ............................................................... 0.0 I mm
Crankshaft end float ............................... 0.102-0.203 mm
Wear Limit ..................................................... 0.305 mm
BearingClearance .. ......... 0.01-0.031 mm (max 0.05mm)
End Thrust ........................... Against Main Bearing No.5
Connecting Rod Joumal Diu ............... 53.919-53.939 mm
Out-of-round ................. .. ....... .......... ...... ...... .. 0.015 mm
Taper ...... ........ ......... ..... .... .......... ...... ..... ........ 0.0 I mIn
Bearingcleanmce .............. 0.02-0.03 mm (max O.06mm)
CAMSHAFT
BearingJoumal
Diameter mm :
3
4
1
2
5
52.84-.87 52.46-.48 52.08-. 10 51.70-11 51.32-.34
Clearance in bearings .............................. 0.025-0.076mm
Wear Limit ...................................................... O.127mrn
Camshaft bearing diameter (installed): rom
VS mm (dia below +1-.012)
1
2
3
4
5
52.S9-.92 52.51 -.54 52.13-.15 51.75-.77 51.37-.39
InstailNol Bearing recessed intothe face of block 3.05 mm
PISTONS
Material ............................................... Cast Alum Alloy

Piston diameter
Red Colour Code ............................... 101.53-10 1.55 mm
BlueColourCode .............................. 101.56-101.58 mm
Yellow Colour Code .......................... 101.59-101.61 mm
Piston Pin Bore Dia ........................... 23.175-23.183 mm
Piston to bore clearance .......................... 0.762-0.965 mm
Ring Groove widths
LUBRICATION
Main bearings .................................................... Pressure

Connecting rod bearings ...... ............................... Pressure
Piston pins ..................... .............. ...................... ... Splash
Camshaft bearings ................................. ............ Pressure
Cylinder walls ............. ......................................... Splash
Oil Pump type ............. ... ........... ... ...................... Gemtor
Oil Pump
89
Oil pressure regulator ............................. Approx. 340kPa

Oil pressure hOI ........ 290kPa min @ 2000rpm and above
Oil filter bypass valve .......................................... 69 kPa
Oil Pump Gears
Inner gear lip 10 outer gear clearance ......... 0.15 mm max.
Outer gear to housing clearance .. .... 0.152-0.330 mm max
Inner & outer gear end 10 housing
cleardIlce ............................................... 0.025-0.104 nun
Oil capacity including filter ............................... 5.0 litres
Oil Filter Capacity .......................................... 0.97 1itres
Exhaust manifold to cylinder head:

V 8 .................................................................... ......... 30
Intake manifold
Intake Tubes to Lower Manifold ................................. 20
Lower Manifold to Cylinder Hcad
Stepl ............... ....... ............ ....................... ................ 25
S~p2 ...... ........ ....................................... .................... ~
Crankshaft balancer bolt .. .................................. 115-135
Engine mount to bracket and front crossmember nut 35-65
Engine mount bracket 10 cylinder block bolt ........ ... . 35-65
E.F.1. Fuel rail 10 manifold ..................................... 18-24
AywheellDrivepla~ bo lt .................................... 100-115
Front cover bolt ......... ... ,' ...................................... ...... 20
Generator support bolt/stud ........... ....... .................. 40-50
Main bearing cap bolts ................................................ 90
Manual Transmission .. .......................................... 36-50
Oil tilter insert ....................................................... 14-20
Oil filter ..................................... Hand tight then 3/4 tum
Oil Pump to Cylinder Block ................................... 16-20
Oil Pump Cover Plate ............................................ 12-16
Oil Pan (Sump) .. .................................................... 10-12
Oil Pan (Sump) Drain Plug .................................... 20-25
Oil Suction Tube to Oil Pump ................................ 16-20
Rockercover ............................................................. 4-7
Rocker arm pivot bolt ............................... ............ . 24-34
Rear mounllOextension bolt .................................. 40-50
Rear cross member to side frame bolt .. ................. ... 40-50
Spark plug ............................................................. 20-30
Starter motor support to rear mounling nut ............. 20-25
Starter motor to engine mount bracket bolt ... ........... 15-35
Waler pump to front cover boll ....................... ........ 16-20
Water pump pulley to hub bolt ............................... 12-20
COOLANT
6Cylinder ..... ..... .. ............. .. ................ ...... ... ........ Rl -38
V8 .... ....... .. ............................................... .. . RI 321R133
Torque Wrench Spec
Nm
Air condi tioning compressor boll ............................ 35-65

AutomaticTransmission ..... .. ................................. 44-56
Camshafl sprocket bolt .............. ............................ 50-60
Clutch pressure plate to flywheel boiL ... ................. 20-25
Connecting rod cap nuts ......................................... 30-35
Coolanllemperature sensor ...................................... 8- 12
Cylinder block coolant drain plug ........................... 34-54
Cylinder head holts:
V8Engine:
Step I ...................................................... .................. 65
Step 2 .......... ..................... ....... .... ..... ....... ............. .... . 85
Step 3 ...................................................................... 100
90
STARTING SYSTEM
Subject
Page
Bosch 6 Cylinder Reduction Gear Starter
NO LOAD TEST ..................................................... 91

MA')OR MAINTENANCE ...................................... 92
Removal ... ... ................ ... ............................................ 92
Dismantle Bosch l.4kw Reduction Starter ................... 92

Dismantle Reduction Gear Starter (8 cylinder) ............. 92
Clean and Inspect ....................................................... 93
Component Checking .................................................. 93
Assemble Bosch 1.4kw Reduction Starter .................... 95
Assemble Reduction Gear Starter (8 cylinder) .............. 96
St002
InstaJ larion ................................................................. 96
Should a pinion tooth come up against a ring gear tooth, the

engaging lever compresses the spring on the drive assembly
until the solenoid switch contacts close. The pinion is then
turned and engages with the ring gear under spring force.
Before the pinion is completely in mesh the contacts in the
solenoid switch are closed by the action of the solenoid
plunger, and the starter rotates and cranks the engine. When
the starter rotates, the pull-in winding is de-energised by the
isolation of its ground cranking. As the starting speed of the
engine exceeds that of the starter, the pinion rotates freely and
engine acceleration docs not affect the starter.
NO LOAD TEST
Check the armature is not seized before performing a NO
LOAD TEST. Prise the pinion in a counter clockwise
direction with a screwdriver. [fthe armature will not rotate
freely, Do Not perform the No Load Test.
Clamp starter motor seeurely to test bench and makeconnections. Close the switch and compare the RPM, current,
voltage readings with the following specifications.
Battery Inspection ....................................................... %
PROBLEM SOLVING & DIAGNOSIS . 97
SPEClFlCA nONS .................................................. 98
General Information
There are two different types of starter motors used , the 6
cylinder engines are fitted with a standard Bosch Starting
System. The 8 cylinder engines arc fitted with a Reduction
Gear Starting System only.
When the ignition switch is turned to the START position, the
solenoid pull-in and hold-in windings are energised and the
solenoid plunger is drawn in. The plunger moves the
engaging lever and fork which in tum moves the drive
assembly towards the ring gear. The drive assembly rotates
on the coarse thread of the drive shaft to facilitate engagement.
Battery
Switch
Pile
RPM
STOOl
91
STARTING SYSTEM
Bosch Starter 1.4 Kw (6 Cylinder)

Starter Motor Speed: 5300 RPM
Starter Motor Current: 50 AMPS (max.)
Terminal Voltage:
12 Volts
Gear Assembly
Housing
Drive
Assembly
Stop Ring
Reduction Gear Starter (VS Engine)

Starter Motor Speed:
190-220 RPM
Starter Motor Current:
S5 AMPS (max.)
Terminal Voltage:
12 Volts
Shaft
Assembly
Check Problem Solving & Diagnosis if No Load test

indicates that the starter motor is defective.
Engaging
Folk
MAJOR MAINTENANCE
6. Disassemble the drive shaft assembly by, removing the

stop ri ng, retainer, drive assembly, 'E' ring and then separate
the gears from the shaft.
7. Remove two assembly securing bolts, which secures the
commutator end cover and field coil housing to drive end
Removal
Disconnect battery negative terminal. Raise vehicle (V8),
detach electrical connectors from starter motor solenoid.
Loosen the starter motor mounting bolts, suppon staner
motor, remove mounting boll<. MovestartermotorfolWards,
then withdraw re3lWards from beneath vehicle (V8), or up
through engine bay (6 cyl).
housing, remove commutator end cover and brace.
S. Brush spring retaining lugs will need to be bent back to

allow the brushes and springs to be removed, then the brush
holder is able to be removed from the conullutator.
Brush Earthed
Dismantle Bosch Reduction Gear Starter

1.4 Kw. (6 cylinder)
Front Housing
Assembly
ST015
To Mounting Plate
Commutator
End Cover
Mountmg
Insulated Brush
Mount
Brush Earthed
To Mounting Plate
ount
Field Housing
Assembly
Alignment
Markings
Non - Insulated
Brush Mounts
ST016
ST014
9. Sliding armature through the Field coi Ihousing towards the

dri veend housing, disconnect the drive end housing from the
field coil hou,ing and remove the armature a<sembly.
1. Remove nut and washer from the solenoid field coil

terminal, then separate the lead from the terminal.
2. Release solenoid by undoing the retaining screws. Remove
solenoid by lifting and unhooking solenoid plunger from drive
assembly engaging lever.
3. Mark starter motor assembly down one side to ensure
correct alignment for re assembly.
4. Remove drive end housing with drive and planetary
a<sembly still attached from motor frame.
5. Carefully remove drive assembly, shaft and gear assembly
from the drive end housing.
Dismantle Reduction Gear Starter

(8 cylinder)
1. Remove nut and washer from the solenoid field coil

terminal, then separate the lead from the terminal.
2. Remove the two solenoid retaining screws, and solenoid by
sliding backwards and lifting clear of housing.
3. Remove two assembly securing bolts, which secures the
housing, remove drive end housing.
92
STARTING SYSTEM
Solenoid
I
Screws
2. Make sure brushes are not touching the field coil housing,
then connect a 240 volt powered test lamp bet ween field coil
winding connection and field coil housing. Thelampwill not
illuminate if winding insulation is satisfactory.
Starter Motor
Starter Housing
,
Front Hoosing
Starter Motor
Assembty
Assembly
ST017
4. Carefully remove drive assembly, shaft and gear assembly

from the drive end housing.
Gear Assembly
Housing
Drive
Assembly
3. Visually inspect field coil windings for signs of insulation

breakdown andlor bums.
4. Remove and replace defective field coil withan approved
pole shoe screwdriver such a, Bosch Tool KDA W 9999.
Armature Insulation Test
Connect a 240 volt powered test lamp between the armature
core and a commutator segment. If lamp illuminates,
armature is grounded and should be replaced. Repeat
procedure on the remaining commutator segments.
ArmatureContinuityTest
Using an Ohmmeter (or 12 volt powered D.C. test lamp).
Touch one probeontoacommutatorsegment, then touch the
remainingprobetoan adjacent segment, repeatprocedureon
each adjacent set of segments. Ifany adjacent set of segments
indicates continuity (test lamp illuminants), the armature
windings are shonened, armature to be replaced.
Stop Ring
Shaft
Assembly
Engaging
Folk
ST015
S. Disassemble the drive shaft assembly by, removing the
stopring, retainer, drive assembly, 'E' ring and then separate
the gears from the shaft.
6. Dismantle the remainder of the motor frame by removing
the brush plate screws, end platea,<;embly and brush a,sembly.
7. Slide armature from the motor frame.
Cleaning and Inspection
With the starter motor completely disassembled, all components should be cleaned and inspected. Wash components
except the armature and field coils in a suitable cleaning
agent.
CAUTION: Do not clean armature or field coils with
cleaning solvent as damage to the insulation could occur.
Cleanallltatureandlicldcoilscarefullyusingcompl-essro
arr.
Armature Short Circuit Test

Test armature for short circuits on a growler
Place armature on growler and switch on growler. Hold a

hacksaw blade approx. 6mm above armature core and rotate
annature. If hacksaw blade vibmtes, undercut between the
commutator segments (to a depth of approx. 0.7mm) using a
suitable small file, then re-check armature.
Ifhacksaw bladestill vibrates, the armature isshoncircuited
and must be replaced.
Component Checking
Freid Coils
I. Connect a 12 volt powered D.C. test lamp or ohmmeter
between field coil winding connection and a positive brush.
The lamp will illuminate or the meter will show a reading to
indicate continuity. if the field coil circuit is serviceable.
Repeat on remaining positive brush.
93
STARTING SYSTEM
Cut brush lead at field coil, dispose of brush and spring.

Clean field coil terminal and any remaining section of the
brush lead, 'Tin' the field coil terminal.
* Replacement brushes have ends ofleads 'tinned'.
Hold the new brush lead in place the field coil Lenninal, using
a pair of pliers. Solder brush lead to field coil end.
When soldering the new brush lead into place, don't
allow the solder to run to far up the lead.
Negative Brushes
Cut brush lead at the brush holder terminal. Disposeofbrush
and spring. Clean the brush holderterminal, and any remaining section of the brush lead. Clean remaining brush lead on
brush holder. 'Tin' brush holderternlinal. Hold new brush
lead in place on the brush holder tenninal, using a pair of
pliers. Solder brush lead to brush holder.
When soldering the new brush lead into place, do not
allow the solder to run to rar up the lead.
Test brushes as described in the following infonnation.
Brush Holder Assembly
Using an Ohmmeter, check insulation between the place
brush holders and earth. !fcontinuity exists, replace holder
assembly. Check continuity between negative brushes and
earth. If continuity does not exist, replace holder assembly.
Check the condition of the positi vc brush spring tabs. Where
tabs are weak, broken or if the tabs have been bent open more
than twice before, replace brush holder assembly.
Allnature to Commutator Leads

Examine, re-solderif required.
CommutatorSurface
Checkcommutatorforout-of-round.
Brush Earthed
To Mounting Plate
Micrometers
Insulated Brush
Mount
Commutator Maximum Pel IIIissibleout-of-round:

Bosch Starter 1.1 kw
0.05 mm
Bosch Starter Reduction 8 Cylinder
0.12 mm
Bosch Starter Reduction 6 Cylinder
O.lmm
If the armature is otherwise satisfactory but commutator is
worn, burn~ out-of-round, orhas high insulation between the
segments, the commutator should be machined.
Brush Earthed
To Mounting Plate
aunt
After machining the commutator, undercut the insulation,
betweenthecommutersegmentstoadepthofapprox.O.7mm
using a suitable small file.
After undercutting, clean all dirt and debris from the segment
slots, and lightly polish commutator with fine emery cloth to
remove any burrs left by the undercuning procedure. Clean
commutator and armature thoroughly with compressed air.
Brushes
Brushes must move free Iy in their holders. Brush cotUlections
must beclean with no grime buildup, they must not have small
chips broken from them.
Brush Length:
Bosch Starter 1.1 kw
12.7mm
Bosch Starter Reduction 8 Cylinder 16.8mm
Bosch Starter Reduction 6 Cylinder 4.5 mm
If required replace brushes as follows:
Positive Brushes
Non ~ Insulated
Brush Mounts
ST016
Drive Assembly Check

Examine pinion gear for burrs and worn or chipped teeth.
Check operation of pi nion, the pi nion gear should rotate free
and smooth in relation to the pinion housing when turned in
a clockwise direction, but not rotate when turned inacounter
clockwise direction.
Bushes
Check fit of annature shaft in commutator end cover and
driveendhousing. lfbushesareexcessivelywom, the starter
motor is likely to operate inefficiently andlor the armature
may foul on field coil poles.
To remove bushes, support the commutator end cover or
drive end housing (as appropriate), carefully tap bush out
94
STARTING SYSTEM
tenninal and the solenoid '50' terminal, then adjust the

maximum resistance. Connect a jumper lead from battery
negative terminal to a good ground on the solenoid housing.
Connect ajumper lead from solenoid field coil terminal to a
good ground on solenoid housing. Connect the voltmeter
positi ve lead to solenoid '50' terminal and negative lead to a
good ground on solenoid housing.
Slowly adjust variable resistor until solenoid plunger 'pulls
in' and note voltmeter reading. Quickly adjust variableresistorto minimum resistance. Full voltage is therefore applied
to saturate the magnet core.
Immediately detach jumper lead from solenoid field coil
terminal. Slowly adjust variable resistoruntil solenoid plunger
springs out, and note voltmeter reading.
If solenoid does not operate within voltage limits, replace
solenoid. Measurements at 20 DEG C.
Solenoid 'Pull In' Voltage
7,8 Volts min.
Solenoid Plunger Spring Out Voltage 4.0 Volts max.
using a suitable mandrel.

Ifnew busbes are to be installed, tbey must besoaked in
clean engine oil for one bour prior to instaJJation.
To install new bushes, press ortap into place with a suitable
shouldered mandrel.
Do not ream bushes after they have been installed as self
lubricating qualities of the bush will be diminished.
Solenoid
,....,
Solenoid
Rod
Solenoid
LUBRICATION
(6 CYL.)
Bearing Cups ...................... Included in relpacement parts

Slip Yoke Splines .............................. Transmission Fluid
ST020
a) The following tests require a 20 Ohm, 30 amp variable

resistor, a voltmeter(0-20 voltscale) anda fully charged 12V
battery.
b) The tests arc to be carried out quickJy so that the resul ts are
not affected by increasing temperature.
c) Test cables are required to be at least 10 gauge.
Connect a variable resistor in series with the battery positive
Assemble Bosch Reduction gear Starter

1.4 Kw (6 cylinder)
1. Slide artllature into the field coil housing, then the brush
holder is able to be installed in position onto the commutator.

2. Replace brushes and springs into the holder, then brush
spring retaining lugs will need to be bent overto secure the
Solenoid
Assembly
Field Coil
Assembly
Commutator
End Bearing Cap
Front Housing
Brush Holder
Assmebty
Engaging Assembly
Commutator
End Cover
Armmature
Assembly
Engaging
Fork
St0211
95
STARTING SYSTEM
brushes and springs.

3. Assemble the drive shaft assembly by, slide the gear over
the dri ve shaft, then fit the 'E' ring, drive assembly, retainer,
and the stop ring.
4. Fit drive lever to the drive assembly, then carefully place
drive assembly, shaft and gear assembly into the drive end
housing.
5. Filthedri ve end housing with dri ve and planetary assembly
attached to the field coil housing and armature, ensure the
housings are aligned with the disassembly marks.
6. Install commutator end cover into place and fit securing
clip, fit two assembly securing bolts, which secures the
housing.
Gear Assembly
Housing
Drive
Assembly
Stop Ring
Shaft
Assembly
Engaging
Folk
sr015
Starter Motor
Cover
-Solenoid
Screws
Front Housing
Assembly
Holder
Starter Molor
Assembly
ST017
7. Connect the lead to the solenoid terminal and fit the

securing nut and washer to the solenoid field coil terminal.
For all tensions see specification chart at the end of this
chapter.
Installation
Fit the stal1er motor into position in the vehicle, fTom
undemeath on the V8and in the engine bay on the 6cylinder.
Fit the retaining boilS and tension them to specified torque,
then connect the wiring to the terminals.
Reconnect the negati ve battery terminal to the battery, then
lower the vehicle (V8). Stan the vehicle to ensure the starter
motor wi II operate correctly.
Starter Motor To Block Bolls:
4O-60Nm
Assembly
7. Replace commutator end bush cnd cover.
S. Replace solenoid by placing solenoid plunger over drive
assembly engaging lever. Replace solenoid retaining screws.
9. Fit the field coil lead on the solenoid terminal, then replace
retaining nut and washer.
For all tensions see specification chart aUhe end of this
chapter.
Assemble Reduction Gear Starter (8
cylinder)
1. Slide armature into position in the field coil housing.

2. Assemble the bush assembly, end plate assembly and bush
plate retaining screws to the armature and field coil housing.
3. Assemble the drive shaft .~sembly by, sliding the gear
assembly into place, then fit the 'E' ring, slide the drive
assembly into place, then the retainer and stop ring.
4. Fit the drive assembly lever to the drive assembly, then
carefully fit drive .sembly, shaft and gear .~sembly in
position in thedriveend housing.
5. Fitdri veend housing to the field coil housing and install two
assembly securing bolts, which secures the commutatorend
cover and field coil housing to drive end housing.
6.lnstall solenoid by sliding into thedriveend housing and fit
the solenoid retaining screws.
BATTERY INSPECTION
A hydrometer should be used to determine thespeciftc gravity
ofbattery electrolyte. The reading obtained indicates amount

of unused sulphuric acid remaini ng in electrolyte and state of
charge of battery.
Thereadingobtained will vary in relation to the temperature
gravity rises.
1. Liquid level of battery cell should be at normal height and
96
STARTING SYSTEM
Problem Solving &

Diagnosis
electrolyte should be thoroughly mixed with any battery

times to bring temperattue of hydrometer float to that of the
acid in the cell.
3. Drawsufficientelectrolyte into hydrometer barrel with the
pressure bulb fully expanded to lift float so that it does not
'PROBLEM
Speed low.
*FAULT
Check battery electrolyte specific gravity.
Check battery terminal for corrosion or loose fitting .
'PROBLEM
Speed, torque and current consumption low.
'.FAULT
High resistance in motor. Check lieldtoterminal connection.
condition of bushes and their connections and check brushes
for dirty or burnt commutator.
*PROBLEM
Speed and torque low, current consumption high.
'FAULT
Tight orwom bearings, bent armature shaft, insufficient end
play, armature fouling pole shoe, short-circuited armature,
earthed armature or field coil.
'PROBLEM
Speed and current consumption high, torque low.
'FAULT
Short circuited windings in field coils.
'PROBLEM
Armature does not rotate, no current consumption.
'FAULT
Open circuited armature, field coils or solenoid. If commutator is badly burned, there may be poor contact between
brushes and commutator, owing to excessively worn or
sticking brushes.
'PROBLEM
Armature does not rotate. high current consumption.
'FAULT
Earthed field winding or short-circuited solenoid. Armature
physically prevented from rotating.
'PROBLEM
~~-----------SpeciflC gravity of 1.26 indicates
_------.Hydrometer
Battery

position.
Electrolyte specific gravity
Battery Charge Level.
1.240 to 1.260
100%
1.210 to 1.240
75%
1.180 to 1.210
50%
Below 1.130
Completely discharged.
A battery should be charged if the specific gravity is less than
1.210.
If there is more than 0.25 specilic grdvity variation between
If battery charge is low and battery is serviceable, check
alternator operation and all electrical connections.
BATTERY CHARGING
Excessi ve arcing at commutator.
'FAULT
Defective armature windings, sticking brushes ordirty commutator.
'PROBLEM
Armature rotates but pinion does not mesh with ring gear.
'FAULT
Pinion bearing fouled, burred, damaged ring gear or broken
pinion teeth.

gas mixture forms beneath the cover of each cell.
Do not smoke nearbatteries on charge or which have recently

beencharged.
Do not break live circuit at terminals of batteries on charge.
A spark will occur where the live circuity is broken. Keep all
open flames away form battery.
NB: Fast charging will provide sumcient charge after one
97
STARTING SYSTEM
SPECIFICATIONS
REDUCTION GEAR STARTER

8 Cylinder Engines
Commutator:
Out of Round: ..... ............................................... O.12mm
BOSCH STARTER 1.1KW

6 cylinder Engines
Brush Gear:
Length: .... .. .. ................................ ".

16 Smm
Spring Tension: ................................ ................. .. .. .. ISN
Commutator:
Maximum permissible out of round: ................... O.OSmm
Depth of undercut: ... ................... ......... .............. O.08mm
MinimumDiameter: ........................................... 33.5mm
TORQUE
SPECIFICATIONS
Brushes:
MinimumLength: .............................................. 12.7nun

Spring Tension : ....... ........ .., ............................... 15-17N
AI mature:
End Play: ............................................... O.OSI0.30Smm
BOSCH STARTER 1.lKW (6 Cylinder)

Solenoid Temtinal Nut ........................... ...... ,., ....... 7 Nm
Solenoid Screws .... ...................................... ...... .... 8 Nm
CapScrew ............... ... ........... ............................ ... . 2Nm
BrakingTorquc: .......................................... 250400Nm

Solenoid:
Through Bolt .... ..................................................... 8 Nm

Pole Screw .......................................................... 50 Nm
Pullin Voltage @20degrccs: ........................ 7.SV(min)

Drop-Out Voltage: ........................................ 4.0V (max)
BOSCH REDUCTION GEAR 1.4KW (6 Cylinder)
BOSCH REDUCTION GEAR STARTER 1.4

KW
Ii cylinder Engines
Commutator:
Out of Round: ...................................................... 0.1 mm
Mica Undercut: .................................................... O.Snun
Solenoid Terminal Nut ..... ................................ .. ... . 7 Nm

Solenoid Screws .............................................. ...... 5 Nm
Cap Screw ........................................................... .. 2 Nm
Through Bolt .................... .. ................................. .. 5 Nrn
Pole Screw ........................ .......... ........................ 25 Nm
Minimum Diameter: ..... ......... ............................. 31.2mm

Brush Gear:
REDUCTION GEAR STARTER (8 Cylinder)
SolenoidMTcrminal NUL .................................... 13 Nm

Solenoid B Temlinal Nut ................................. .... 13 Nm
Solenoid Screws ............................ ........................ 6 Nm
TIl rough Bolts ....................................................... 6 Nm
Brush Plate Screw ................................................. 3 Nm
Mounting Bolts .................................................... 40 Nm
Minimum Length: ................................................ 4.5null

Annature:
End Play: ...................................... .............. O.05-0.3mrn
Braking Torque: ................... 3000 rpm to stop in 2.S sec.
Solenoid:
Pull-In Voltage @20degrees: ....................... 7.SV(min).

Drop-Out Voltage: ............................ ........... 4.0V (max).
Memo
98
ALTERNATOR SYSTEM
Subject
Page
spinning of the rotor causes the stator windings to cut the

magnetic Ii nes of force of the rotor, this creates an AC current
ON VEHICLE TESTS ................................. 99
voltage in the stator windings.
Alternator Operating Test .......................................... 100

Charging Circuit Voltage Drop Test .......................... 100
Rectifiersconvert the AC current to DCcurrentattheoutput

terminal, rectifiers also stop thecurrent flowing back through
dIe alternator from the battery.
ALTERNATOR ........................................ 100
ON VEHICLE TESTS
Removal (6Cylinder) ............ .................................... 100

Removal (8 Cylinder) ................................................ 101
DismantleMitsubishi ................................................ 101
Clean and Inspect ..................................................... 101
Component Checking ...... .......................................... 102
AssembleMitsubishi ............... .................................. 103
Instaliation(6Cylinder) ............................................ 103
Installation (8 Cylinder) .......... .................................. 103
Before carrying out on vehicle tests check:
Current Output Test .................................................. tOO

a fully charged baHery.
_ - -- - - - - Hydrometer
PROBLEM SOLVING & DIAGNOSIS ...... 104

SPECIFICATIONS .................................. 104
TORQUE WRENCH SPECIFICATIONS .. 104
_ _ _ _ _ Battery
operating, ifit is not the test

results wiU be inaccumle.
2. The battery must be fully charged.
3. Engine must be at normal operating engine temperature.
4. Engine idle must be within specification:
GENERAL INFORMATION
There one alternator fitted to all EF & EL vehicles. Although
the 8 Cyl. & 6Cyl. are built with different housings. The EFI
ELaltematorproducedifferent outputs, theEFisa I 10 amp
output and the EL is a 100 amp output.
A,theengine is operating with the ignition switch tumedon,
aflow of electrical current pass through the rotor coi I wiring
which energises the rotating electro-magnet (the rotor). The
Check Tuneup chapter, but as a guideAutomatic Transmission:

625-67SRPM
Manual Transmission:
77S-82SRPM
99
AL TERNA TOR SYSTEM
Alternator Operating Test
1. Make sure all electrical equipment is turned off, and the

ignition system is in off position. Disconnect battery earth
cable at battery.
2. Detach generator positive lead from the 'B+' generator
terminal.
3. Connect positive lead of an ammeter (0-100 Amp scale)
to the generator' B+' terminal, and the negative ammeter lead
to the disconnected generator positive lead.
4. Connect positive lead of a voltmeter (0-20 Volt scale
minimum) to the generator 'B+' terminal, and negative
voltmeter lead to a good ground on generator body.
5. Insulate the generator positive lead terminal to prevent
contact with any metal part of the vehicle. If the terminal is
Alternator
Terminal B+
Amp
Earth
Metre
i=-__ Volt Metre
Terminal
Amp
Metre;--- ...{
Metre
,--'=:+t
t-
Carbon Pile
(Load
I
The positive voltmeter lead connected to the battery positive

terminal, not the generator 'B+' terminal.
2. Connect a loading device (lE. an adjustable carbon pile)
across the battery terminals, and regulate to maintain a
current flow of9.5 - 10.5 AMP.
3. Operateengineatapprox. 2000 RPM, maintain this engine
speed for 15 seconds and check theregulated voltage reading.
4. If regulated voltage reading is not 14.25- 14.55 volts,
replace voltage regulator.
5. Detach balteryeableatbattery. Removethevoltmeterand
anuneter, then reconnect the generator JX>sitive lead to the
+
Battery
generator 'B+' terminal. Connect battery earth cable.

Earth
AL01S
grounded, damage to the charging circuit will result when the

battery is reconnected.
6. Connect battery earth cable. Connect an electrical load
instrument 10 the battery, this should have a power consumption of 8 to 10 amps.
If you do not have an instrument for tllis turn on lights and
other known power rated accessories to obtain power COIlsumption of 8-1 0 amps.
7. Start engine and check alternator amperage output against
rated output on the alternator specification plate with approximately 12-14 volts.
If generator doesn't provide rated output, carry out the
"Current Output Test" or disassembled and inspected for
faults.
When the Generator Output Check, is completed, to prevent
excessive battery discharge occurring, the engine should be
returned to idle speed and the loading device detached from
battery terminals.
Detach the battery earth cable at battery, remove bolt and
ammeters, then reconnect the generator positive lead (red
wire) to the generator 'B+' terminal. Connect battery earth
cable to the battery.
Current Output Test
1. Connect ammeter and voltmeter as described in 'OUTPUT CHECK', with the following alteration;
Charging Circuit Voltage Drop Test
With normal connections made at generator, charging circuit

can be checked for voltage drop as follows:
1. Connect positive lead of a low range voltmeter at the
generator 'B+' terminal and the negative voltmeter leadtothe
battery positi ve terminal.
2. Start engine, switch on headlamps, then increase engine
speed to approx. 2500 RPM and note voltmeter reading.
3. Stop engine and transfer voltmeter connections, negative
lead to generator body and the positive lead to battery
negative tenninal. Start and operate the engine at approx.
2500 RPM and again note voltmeter reading.
4. if readings exceedO.5 volts on positive side and 0.25 volts
on negative side, there is a high resistance in charging circuit
which mustbe traced and corrected. Stop engine, detach the
voltmeter.
Alternator
Removal (6 Cylinder)
1. Detach battery earth cable at battery, loosen the generator
top attaching/tensioner bolts. Remove wiring harness connector from generator terminal and belt from the pulley ..
2. Pull back cap from genemtor 'B+' terminal, remove nu~
washer and generator positive lead. Loosen genemtor brace
bolt, and remove the generator retaining bolt.
3. Support generator, withdraw the through bolt then remove
the generator from vehicle.
100
AL TERNA TOR SYSTEM
Removal (8 Cylinder)
I. Detach battery earth cable at battery, remove drive bell as
described in the Cooling System Chapter under bell replace-
Rotor Fan Blade
Rotor
ment. Remove wiring harness connector from generator

teJluinal.
-Assembly
Rotor Assembly
Slip Rings
Rotor Fan Blade

Assembly
Rotor Rear
Bearing Assembly
AlOIO
5. To remove recti fler and brush holder .sembly withdraw

retainer screws, B terminal nut and insulator.
6.Spl it the stator and rear housing carefully, then rectifiercan
be sepamted from stator by unsoldering the terminals.
Regulator ____
Stator
Assembly
2. Pull back cap from generator 'B+' terminnl, remove nut,

washerand generator positive lead. Loosen generator brace
boilS, and remove the generator retaining boll.
3. Suppon generator, withdraw the through bolt then remove
the generator from vehicle.
Rectifier / '
:...._ Connections
Soldered From
Underneath
Dismantle Mitsublshl Alternator

Back View
Front View
ALOII
7. Front housing benring will need 10 be pushed out of the

housing using a socket, a vice can be used as a press. The
bearing is replaced in the same manner.
8. The rear bearing is removed from the rotor with a bearing
puller, then replaced ngain by pressing it onto the rotor.
9. Brushes are replaced by unsoldering the connections
removing the brush. install the new brush 2-3mmout from the
wear line and solder it back into plnce .
.I,"I
Mitsubishi Allertalor
Regulator
Assembly
A1D02
I. Murk relative positions of front cover, stator nnd rear

cover, remove the four housing retaining screws from the
assembly.
2. To separate the front cover from the rear cover and stator
(as un assembly), the rear cover bearing mounting box will
need to be heated to a temperature of 50-We.
3. Using a flat blade screw dri verearefully lever the assembly
apart when at correct temperature, do not mark the stator with
the screw driver. as it will then need to be replaced.
4. With stator in vice undo pulley retainer nut, then remove
puUey, rotor, four front housing to bearing retainer screws
and bearing retainer.
Assembly
- Brushers
Solder Point . /
For The Brushes
AlOO8
Clean and Inspect
With generator completely disassembled. clean and inspect

all components. Wash the components, excluding stator,
rotor. rectifier and regulator in a suitable cleaning agent.
101
AL TERNATOR SYSTEM
Don't clean stator or rotor windings with cleaning sol vent.. a.

damage to the insulation may result.
Rotor _ _ _ __
Component Checking
Recti/ier Assembly
The rectifier can't be overhauled, and is serviced as an
assembly only.
1. Using a powered D.C. test lamp (of less than 24 volts),
touch probes to positive heat sink and connections. Reverse
probe connections and repeat test to check that current has
passed in one direction only.
2. Repeat procedure with probes on negative heat sink and
Battery
COIUlectiOns.
_-Test Light
AI006
All six diodes will show a short circuit if anyone diode is
grounded, when using a test lamp. Replace the rectifier

a"embly if required.
Brush Gear
1. Measure length of brushes installed in the voltage
regulator. Replace brushes if not at required specified length.
Alternatorsspecified brush length is:
16.5 nun - New Brush
3.0 nun - Service Minimum
2. Inspect brushes for damage and replace if required, unsolder brush lead. from regulator connections, carefull y bend
back the retaining lugs just enough to free the brush leads.
Remove and dispose of the brushes and springs.
3. Place silicon tubing over brush leads, install new brush
springs over brush leads, then install bmshes into regulator
and carefully solder leads to connections.
4. Bend the retaining tabs back into the original places and
check that the bmshes are free and move smooully in and out
of holder.
Rotor Insulation Test
Rotor Open Circuit Testing
,
,
'
Slip Rings
Check slip rings for wear or damage and polish with emery
cloth until smooth or replace rotor as necessary, on occasions
slip ring can be machined.
AI"'"
Bearings
Examine the beari ngs forevidence of overheating, cracks or
other damage. Check bearings for operation that is free and
smooth. Check bearing bores in drive end slip ring end plates
for wear. Ifbearingouterraee is allowed to rotate in its bore,
it will causeovalityoftheboreanda lip will form in the bore .
If the bearings arc serviceable, pack bearings with grease.
Replace damaged bearings if required.
Rotor-..,
Stator
Battery
Stator
Connections
Test Ught
\.
Check insulation between stiprings and rotor core and shaft.
using an ohmmeter. If continuity exists, replace rotor.
Rotor Open Circuit Test
Connect ohmmeter probes to slip rings and measure resistance of rotor windings. Replace the rotor if the resistance is
not within the specification given in the following:
Stator Insulation Test

Connect an ohmmeter ora test light to any stator lead and the
stator frame.
102
AL TERNA TOR SYSTEM
If there is current reading or the test light glows, this indicates

earthed wiring, replace stator.
Stator
,, ,
Test
therearcoverbearing mounting box will need to be heated to

a temperature of 50-6Q'C.
7. When rear bearing box is at the correct temperature,
carefully assemble the two sections together.
8. Align the mark on the front cover, stator and rear cover,
then replace the four housing retaining screws into the
assembly.
Alternator
Leads
Alignment
". Mal1tings
Stator
Connections
Stator Open Circuit Test

Connect ohmmeter to any two stator leads and note resistance, repeat the operation on remaining stator leads. Replace
thestatorifthe resistance is not within the specitication gi ven
inthefollowing:
Assemble Mitsubishi Alternator
I. Bearing and brush replacement is described at the end of
thedismantle section.
2. Carefully join the rectifier to the stator by soldering the
tenninals together. Then the stator can be assembled to the
rear cover, aligning the markings.
Regulator _
.....
'.
Stator
Assembly
*For all screw tensions see Torque Specifications at the

end of this chapter.
Installation (6 & 8 Cylinder)
1. Fit alternator to mounting bracket, and install mounting

bolts. Tighten the generator mounting bolts to specification.
2. Fit belt using removal procedure in reverse.
3. Install generator positive lead, washer and nut on 'B+'
temtinal. Tighten nut to specified torque, then refit cap over
Rectifier . /
_
Connections
Soldered From
Underneath
AL011
3.Replace rectifier and brush holder assembly in position and

fit retainer screws, 'B" temtinal nut and insulator.
4. The brushes can be pushed back into the holder and a piece
of wire can be installed in through the back of the housing to
hold them in position for easy assembly.
'Remember to remove the piece of wire when assembly
proeedureiscompleted.
5. With stator in vice replace bearing retainer, four front
housing to bearing retainer screws, tensioning screws, then
replace the rotor, pulley and pulley retainernu~ tensioning the
retainingnu!.
6. To assemble the front cover/rotono the rear cover/stator,
103
'B+' leonina!.
4. Connect wiring harness at the generator terminal block.
Connect battery earth cable at battery.
oSee specifications for tension"
AL TERNA TOR SYSTEM
Problem Solving &

Diagnosis
SPECIFICATIONS
INDICATOR LIGHT DOES NOT GO ON

Globe broken or blown
Defective regulator
* Defective Wiring
Open circuit in rotor winding
INDICATOR LIGHT STAYS ON
Positive diode failure
Defective voltage regulator
Faulty alternator
B + cable off or broken
* S cable off or broken
* Battery Overcharged
NOISY ALTERNATOR
* Worn bearings
* Loose alternator drive pulley
* Open or shorted diodes
* Open or shorted Stator winding
* Generator mounting brackets loose
* Worn or frayed drive belt
BATTERY OVERCHARGES
* Battery acid specific gravity not correct
* Shorted battery cell
Faulty voltage regulator
Short circuit in rotor winding
ALTERNATOR WILL NOT CHARGE
Faulty regulator
* Brushes worn or sticking
Brushes springs broken or lost tension
* Faulty rectifiers
Open circuit in stator wiring. charging circuit or field circuit
Loose drive belt
MITSUBISHI ALTERNATOR
Earth polarity ............... ............. ....................... Negative
Nominal voltage ..................................................... J4 V
Generator DC Output (EF)............................... 110 amps

Generator DC Output (EL) .............................. 100 amps
Stator phases ................................................................ 8
Rotor Windings Resistance (ohms) ....................... 2.1-2.5
Stator Winding Resistance: ............................. continuity
Number of poles ...................................................... "_ 12
Brush Length ........................................... 16.5 mm (new)
............ .... .. .. ..... ................................ 3.0mm(minimum)
TORQUE WRENCH
SPECIFICATIONS
Nm
MITSUBISHI ALTERNATOR
ThroughBolt ................ .................................. ..... 3.5-5.3
Bearing Retainer Plate Screw ............................... 5.9-7.8

Drive Pulley Retaining Nut .................................. 83-140
Regulator and Brush Assembly Screw .................. 5.9-7.8
B+' Terminal Stud Nut ....................................... 13-16.7
Battery Harness Terminal to B+Terminal Stud Nut. II - IS
Recti fier Plate Retaining Screw ............................ 5.9-7.8
Alternator
Upper Mounting Bolt ......................... .............. ...... ... .. 20
Lower Mounting Bolt ................................................. 35
Memo
104
COOLING SYSTEM
Subject
Page
COOLING SYSTEM
Description ............................................. 105
Coolant .. ... .. ....... ........... ......... .. .............. .......... ........

General Maintenance .........................................
Coolant Level Inspection ........................................ ...
Radiator Cap Pressure Test .......................................
Anti Freeze Solution .................................................
Radiator Hose Replacement ......................................
Coolant Replacement ................................................
Drain .......................................................................
The engine cooling system consists of a horizontal flow fin

and tube type radiator with a pressure sealing cap as part of
the coolant recovery bottle, a belt drive waler pump, a
thermostat and a belt driven fan.
I()6
1{)6
106
106
106
107
107
107
Refill ........................................................................ 107

DRIVE BELTS .......................................... 107
Belt Adjustment ........................................................ 107

Belt Tension ..................... ....... ...... ............ .... ....... .... 108
THERMOSTAT ........................................ 108
Thennostat test ..... ..................... .............................. 1 08
Insta11ation ........... ............................. ...... ... .... .......... 108

WATER PUMP ................................... 109
6Cylinder (Remove & Install) ................................... 109

VS Engine (Remove & Install) .................................. 109
RADIATOR .............................................. 110
Removal ..... .............................................. ........... .....

Installation ...... ............ ........... ... ..... ..... ......... ............
Radiator Inspection ...................................................
Cleaning a Radiator ........................................... .......
Pressure Test Radiator & Cooling System .................
110
I 10
III
111
III
FAN DRIVE CLUTCH .............................. 112

ReOlOval ................................................................... 112
Install ..... .... ... ........................................ .. .......... ....... 112
PROBLEM SOLVING & DIAGNOSIS ...... 112
SPECIFICATIONS ................................... 112
TORQUE WRENCH SPECIFICATIONS . 112
Water iscirculated by pump through cylinder block, head and

then through top hose to top tank of radiator.
Water pa.sing down through radiator is cooled by air flow
through radiator fms.
Heated water is drawn from cylinder head to inlet manifold
and heater unit.
An effective concentration of recommend coolantlinhibi tor
must be maintained in the cooling system.
The radiator cap is a pressure sealing type. It incorporates
two valves; a pressure release valve and a vacuum released
valve, and has two functions:
1. To increase pressure in cooling system and thus raise
boiling point of coolant.
2. To allow built up pressure to escape when it reaches a
certain pressure.
As the coolant is heated it expands and pressure in the system
increases. When pressure reaches a predetennined point
pressure release valve in radiator cap opens and air in tap of
the supply tank is forced out of the system.
As the engine cools the coolant contracts thus creating a
vacuum in the radiator. The vacuum release valve in the
radiator cap opens and allows the air to be drawn back into
the supply tank.
Coolant recovery system will not operate if the cooling
105
Cooling System
system has an air leak.

The water pump isacentrifugaltype pump. It is mounted at
the front of the mOlar and is belt driven by a pulley mounted
to cmnkshaft.
Common misconception is that by removing the thermostat

the engine wi II run cooler, this is ineoll eet, as it can quileorten
increase the running temperature and induce overheating.
The thenmostat acts as a restrictor as well as stop coolant flow

in a cold engine, if you remove the restriction of the coolant
flow, fast flowing coolant docs not have time to disperse the
store heal from the engine thereforecausi ng the engine to run
hotter.
COOLANT
The alloy content of components makes it essential that an
effective coolant additive is maintained in thecooling system.
Some of the properties of coolant are:
Coolant comes in two different colours Green and Red.
Most red coolant has a reagent grade indicator dye built into
it and as a result should any corrosive acids build up in the
cooling system from exhaust gas leaking past the head gaskct
the coolant will change from red to brilliant yellow. If the
coolant does change colour it should be replaced.
As a general rule coolant manufactured by different companies should not be mixed even ifthecoohmt is thesamecolour.
Glycol coolant has several propeniesotherthan anti freeze, it
will help lubricate various valves in the cooling system,
thermostat slides and water pump seal surfaces.
Glycol wi II also raise the builing point of coolant.
GENERAL MAINTENANCE
Coolant Level Inspection
Thecoolantlevel is inspected byexamining the height of the
coolant fluidcomparcd to the level marks on the supply tank.
When the coolant is cold the coolant level should be at the

FULL mark. Depending on the engine temperature the level
will vary. Alwaysensurethesupply tank is kept between the
max. and min. lines.
RADIATOR CAP PRESSURE TEST.
1. With cap removed from supply tank.

2. Wash cap with clean water before testing, ensure that
valves are washed as well, then connect cap to test unit.
3. Increase the pressure applied on the cap until the highest
reading of the cap before the pressure valve opens is achieved
on the pressure test unit gauge.
Radiator Pressure
Tester with
Radiator Cap
Testing Accessory
GLYCOL BOlLING POINT CHART

kPa Pressure
0
25
50
75
100
150
200
PSI Pressure
0
3.7
7.4
11.0
14.7
22.1
26.4
33% Glycol 55% Glycol

104.5oC
\OS.5OC
114.00C
1I 0.5oC
116.5oC
119.5oC
121.00C
I 25.00C
I 25.00C
I 29.00C
I 32.5oC
I 36.00C
139.00C
I 42.5oC
....".
Co017
4. Thereadingon the test gauge should beas specified on the

radiator cap, also the pressure relief valve should release at
its spccifiedreading.
5. Re-test a couple of times and if pressure tester reading is
not as cap specification replace cap.
ANTIFREEZE SOLUTION.
Add antifreeze to engine coolant if vehicles are to be driven

in districts where the temperature will be under 4"<:.
106
Cooling System
RADIATOR HOSE
4. Fill system with clean water through the supply tank to just
above the max line.
S.lnstall cap, turning it until fully locked.
Replace
# Radiator hoses should be replaced if they show any signs of
being split, ronen or badly perished.
l. Drain radiator.
2. Loosen hose clamps at either end or the hose.
3. Slide hose orrconnections by twisting the hose back wards
and forwards at same ti me, irhose sti II cannot be disconnected
cut end of the hose longways with a razor blade then remove.
4. Fit clamps onto hoses and then install the hoses so they do
notcontact any surraces that my damage or deteriorate them.
S. Tighten hose clamps.
6. Tum heater control onto maximum "HOT".
Fan Speed
7. Operate engine for Iominutes onake for I Omin . testdrive

to allow themlostat to open and bleed air from the system.
S. Fill supply tank to FULUMAX line.
9. Replace cap.
Note: This bleeding orair from the cooling system must take
place, otherwise problems will occur with the cooling system.
DRIVE BELTS
6. Cooling system can then be filled with coolant and water

until the "FULUMAX" mark is reached.
7. Fill the cooling system with coolant.
Dri ve belts must be checked orten to ensure that they are sti II
in good operating condition, also pulley misal ignment should
be checked to reduce belt wear. Damaged belts should be
replaced.
COOLANT REPLACEMENT.
BELT ADJUSTMENT
DRAIN.
Incorrectly adjusted drive belts will cause belt squeal and

components will not be driven. Belts that are over tensioned
can damage component bearings. Belts that are tensioned
correctly reduce noise and extend the life of the drive belt.
Belt's that have operated for 10- 15 minutes are treated as a
used belt, and adjusted to used belt specification.
1. Remove radiator cap and disconnect the lower radiator

hose and remove.
2. Also drain plug can be removed from the side or the
radiator.
REFILL.
l.lnstaJl radiator drain plug if it has been removed.
2. Install bottom radiator hose and tighten clamps.
3. Add the specified coolant or clean water to the radiator.
107
Cooling System
BELT TENSION.
The belt tension is automatically adjusted by a spring loaded

belt tensioner pulley assembly, there is no need to adjust the
belts tension.
Adjust With Idler Pulley.
thermostat is open, coolant nows through coolant outlet

(thermostat housing) to the radiator.
ThCillostat
Asse.nbly
Control
Replace
Belt Marking
Spring
Belt Tensioner
Assembly
Thennoslat
Retum Spring
Wear
Heater Pipe
Flow Valve
Idler
Marking
Co027
New Belt
Marking
THERMOSTAT TEST.
# Used thermostats should be tested before installing, replace
Co016
The self adjusting idler pulley setup means they will never
need adjusting forthe life of the belt. They have a wear mark
indicator on the idler pulley mounting swivel bracket that
indicates when the belt will need replacing.
BELT REPLACEMENT with Idler Pulley
I .Fit 3/8" drive socket barto idlerpulley mount bracket, and
remove tension from belt by moving clockwise.
if necessary.
1. With thermostat removed from vehicle submerge in hot
water until it is fully opened and remove.
2 .Place a feeler gauge into the opening of the thermostat and
place thermostat in cold water to allow it to close on feeler
gauge.
3. Place a thermometer and have the thennostat hanging from
a feeler gauge in a container of warm water, heat water.
4. When thermostat opens and falls off feeler gauge, reeord
the temperature, this will be the opening temperature of the
thermostat.
Feeler Gauge
Tens;oner
AssembI Y......:-:;:::
Tensioner
Mounting Point
Thermostat
-- -
- -
Slot For Socket

Bar To Release
Tensioner
Tensioner
Idler Pully
-- - -- - - - -
Co021
2. Remove the belt from all pulleys, then remove belt from
vehicle.
3. Fit new belt over pulleys and apply tension by releasing
idler tensioner pulley.
4. Check that tensioner marki ngs are in correct position if out
of tension markings replace tcnsioner.
THERMOSTAT
# The thermostat is situated in the thermostat housing at the
ThemlOstatOpeningTemperature ............. 8993 +/.2"C

ThermostatOpeningTemperature .......... 87 to 91 +/2"C
ThemlOstatOpeningTemperature ............. 8993 +/2"C
Thermostat full travel is 7.1 mm .................. 103 to 106"C
INSTALL (Applies to both 6 & 8 Cylinders)
I. Clean thermostat housing and engine outlet mounting
surface to remove all corrosion.
front of the engine. Coolant flows to the water pump through

the intake manifold, when thermostat is closed. When
108
Cooling System
pump ga.ket from pump mount if applicable.

Install
Thermostat
Water
Pump
Water Pump - .
Retaining Bolts
Ctean
Surface
Scraper
2. Coat new thermostat gasket with water proof sealant and

fit to thermostat housing with thermostat already in place,
ensuring thermostats top mark is facing upwards ..
3. Install themlOstat housing to engine outlet mounting
surface, tightening bolts to specification.
Thermostat Coverto Block Securing Bolt ........... 20 Nm.
Top Radiator
Clutch Fan
Mount - - -
1. Clean cylinder block pump mounting surface, then fit new

ga!)ket using water resistant sealer.
2. Replace water pump on thecylinderblock fitting bolts and

tighten to specification.
Water Pump Securing bolts ................................... 20Nm
3. Install camshaft balancer, ( rerer to appropriate section in
engine chapter).
4. Fit drive belt, check belt tension markings are still within
spec's.
4, Fill and bleed system as previously described.
WATER PUMP
Water Pump
A centrifugal water pump with impeller is situated on the
front orthecylinder block and provides coolant now through
the water pump outlet port and cylinder block.
If a pump is faulty it must be replaced, as it is a disposable
sealed unit.
6 Cylinder:
Remove
1. Disconnect lower radiator hose from water pump and
radiator, emptying coolant from system, then remove hose
from vehicle.
2. Remove ran shroud and fan assembly as described in this
section, then remove all drive belt from pulleys.
3. Remove the cranks hart balancer as described in the
appropriate section in the engine chapter.
4. Remove water pump retaining bolts, then remove water
pump from front or the engine. Remove and discard water
109
S. Install ran and shroud assembly as described in this

chapter.
6. Install the lower radiator hose, fitting it to the pump and
radiator, tightening hose clamps when in position.
7 Refill cooling system and bleed as previously described in
this section.
va Engines:
Remove
1. Remove engine top cover, air intake assembly & battery
cover to enable excess to the front of the engine. See photo
located on the next page.
2. Take out the fan shroud and fan assembly a. a assembly
as described under Fan Clutch section in this chapter.
3. Release idler pulley tensioner and remove drive belt from
the vehicle then remove the accessory pulley attached to the
crankshaft pulley.
Cooling System
3. Replace the accessory pulley attached to the drive belt

cmnkshaft pu Iley then refitdri ve belt toall pulleys and relea<;e
teosloner.
4. Install the lower radiator hose to water pump and radiator.

S. Connect bypass hose and heater hose to water pump,
tightening clamps when positioned conrectly.
6. Replace fan and shroud assembly as described in this
chapter.
7 .Refill cool ing system and bleed as previously described in
this section.
RADIATOR
4. Disconnect the lower radiator hose from the radiator and
pump emptying cooling system, then remove hose from the
vehicle.
S. Disconnect heater and bypass hoses from the water pump
asscmbly.
Removal
1. Detach lowermdiator hose. emptying cooling system, then
detach upper radiator hose and place out of the way.
2. Detaeh transmission oi Icooler pipes from radiator tank, on
vehicles with automatic transmissions.
3. Detach coolant supply hose from side of radiator.
4. Loosen the battery clamp and tenninals, then remove
battery cover, as well as the air cleaner intake.
Air Filter
Intake & _.::.;,:
Heater
6. Remove water pump bolts, then remove water pump from

front of the engine.
Install
1. Clean pump mounting surfaces, then fitnew gasket coated
with water resistant sealer.
2. Place new water pump into position on mounting surface,
then install bolts and tighten to specification.
Water Pump Securing Bolt Torque Specs 20 Nm.
S. Detach the fan shroud top mounting screws from the

radiator, lift shroud and position out way.
6. Undo mounting bolts from the top of the radiator, then
gently liftmdiatoroutofthe vehicle without catching the fan
shroud.
Install
I. Instal radiator in the vehicle, ensuring that the bottom ofthe
mdiator is sitting correctly in the bottom insulators and then
install mounting bolts.
2. Fitoi Icooler line fittings and pipes in tonew mdiator(auto
trans), then fit ran shroud clips if non are fitted. See photo
located On the next page.
3. Fit fan shroud into securing clips at the bottom of the
radiator and install screws at the top of the fan shroud.
4. Install the upper, lower and radiator hoses.
5. Install the air cleaner intake ducting.
6. Fit battery cover and cables to vehicle.
110
Cooling System
cleaning. The acid base flushes are more effective for scale
removal but nowhere near as effective the al kal ine nushes
in the removal of oils and general organic materials.
Acid based nushes usually have reasonably severe attack rate
on the metal components in the cooling system.
The alkaline flushes wi II attack al uminium components ifleft
in contact at elevated temperatures for extended periods of
time. Itis most importanttostrietly follow the manufacture's
instructions regarding the time of flush should be left in the
cooling system.
Radiatorflush should be seen more in the light of preventive
maintenance rather than a problem solver.
a,
On
Fitting
Spanner On
Cooler Line
PRESSURE TEST RADIATOR and

COOLING SYSTEM
7.Fiiland bleed cool ing system a' previously described in this

chapter.
1. Fill radiatorto the full mark or within IOmm of the supply

tank neck.
2, Wipe the filler neck sealing surface clean.
3, Using a suitable adaptor, attach pressure tester to filler
neck and apply a pressure of I IOta 120 kPa to the cooling
system.
4. I f pressure gauge holds steady, the system is satisfactory.
If pressure drops, continue as follows.
RADIATOR INSPECTION
1. Check for damage to fins and core tubes from stones and
other projectiles that can cause damage.

2. Clean radiator of any foreign matter that will obstruct air
flow and possibly cause over heating problems. Radiatorfins
can be cleaned with an air hose, blowing air from the back of
the radiator or a pressure washer will do the same thing.
3. Check inside the radiator for foreign materials that could
block the flow of the coolant through the tubes.
Blocked radiators are the most common cause ofoverheating
vehicles, as the tubes become blocked with corrosion or
fouling caused by incompatible coolants mixed in your
coolingsystem.
Radiator Pressure
Tester with
CLEANING A RADIATOR
There are two methods of cleaning a blocked radiator.

a) Use a radiator nush.
b) Pull the radiator down by removing the end tanks andcle,m
the tubes by rodding each tube.
Radiator Cap .. ,
Testing Accessory
Co017
5. Check aU points f OTCx.tcrna\ \caks. if none are evident after
dial gauge show a drop in pressure, continue test.

6. Remove tester, fit radiator cap and run engine unti Inormal
operating temperdture is reached, reattach tool, apply recommended pressure and increase engine speed to half throttle.
Do not leave tester attached to radiator as this could caused
damage to the COOling system because of the excessive
pressure.
7.lf needle on dial fluctuates, it indicates a combustion leak,
generally the head gasket.
8. If needle on dial did not fluctuate in step (6), sharply
accelerate the engine several time. Ifan abnonnal amount of
water emits from tail pipe it indicates a head gasket leak,
cracked block or head.
There are two basic types of radiator flush in the market
place, one is the strong alkaline type and the other is acid
based. Each of these products are suited to different types of
111
Cooling System
THERMO FANS
Remove
1. Remove the engine top cover from engine (8 cylinder).
2. Detach fan shroud retaining screws from the radiator.
Place bleeder hose clear of shroud and working area (6
cylinder).
Thermostat has been removed - Install thermostat

Temperature sending unit inoperative - Replace Unit.
Temperature gauge inoperative - Check installation or replace.
PROBLEM: Low Coolant Level.
POSSmLE CAUSES & REMEDY'S:
Leaky radiator - Repairdamaged section or replace radiator.

Cylinder head gasket - Replace bead gasket.
Impropertightening ofcylinder head bolts - Re-tighten bolts
evenly to specifications, or replace cylinder head bolts.
Cylinder block or head welsh plugs leaking - Repair.
Cracked or warped cylinder head or block - Replacecylinder
head or machine surface.
Intake manifold - Replace intake manifold.
Heater hose or radiator hose - Replace hose.
Heaterhoseorengine hose notsealedcottectly -Tighten hose
clamps or replace hose clamps.
Airtmpped in cooli ng system - bleed air from cooling system.
3 .Detach aircleanerintake and remove from the vehicle, then

disconnect the thermo ran loom.
4. Remove fan and shroud assembly from vehicle careful not
to damage the radiator core.
Install
1. Fit fan and shroud assembly into place in the vehicle.
2. Dropping it into the bottom retaining clips, then fit top
retaining screws and connect the loom.
3. Put air cleaner intake and bleeder hose into place.
4. Refit the engine top cover from engine (8 cylinder).
SPECIFICATIONS
Thel'mostat:
6Cylinder
Start to Open ..................................................... 89-93"C
Open Fully .. .................................................. I03 106OC
V8: Type ............ .............. ...... ........ .......... ........ .... Choke
Start to Open ................................................... 87 - 91"C
Open Fully .... .............................. ......... ................ 1050C
Radiator Cap Pressure Rating .................. 100- 125 kPa
PROBLEM SOLVING &

DIAGNOSIS
Coolant Capacity:
6 Cyl. ...................................................................... 16 L
V8 ...................................................................... .... 15L

PROBLEM: Engine Coolant Temperature
High
POSSIBLE CAUSES & REMEDY'S:
Coolant Level Low- RefIll System, pressurize and check for

leaks.
Drive Belt Loose - Adjust.
Radiator Fins Blocked - Remove obstruction.
Thermostat Not Operating - Replace Thermostat.
Radiator or Engine Block blocked by rust, scale or other
foreign material - Flush system.
Water pump faulty - Replace water pump.
Fan clutch faulty - Replace Clutch.
Airtrapped in cooling system - bleed air from cooling system.
Fan Speeds (RPM @ 12.0V)

DriversSide .................................................. 1400, 2300
Passangers Side ................................... 1400, 1900. 2300

Fan Motor Rating ................................................ 180 W
Torque Wrench Specs Nm

Radiator support bracket ..... .......... ........ ....... ............... 10
Transmission oil cooler pipes ...................................... 20
Water pump to cylinder block .................................... .. 20
Thennostat Housing ...... ......... ..... ...... ... ...... ......... .... .... 20
HoseCI3J11ps ................................................................ 5
Fan Shroud ............................................................... .. .. 7
PROBLEM: Engine Coolant Temperature

Low.
POSSmLE CAUSES & REMEDY'S:
Thermostat stuck open - Replace Thermostat.
112
IGNITION SYSTEM
Subject
IGNITION
SYSTEM
Page
Precautions ............................................. 113
On Vehicle Inspection " ... " ... " .. " .......... 113
Spark Test ................................................................ 1J3

Inspection of High Tension Lead ............................... 114
Inspection of Spark Plugs .......................................... 114
Inspection & Adjustment oflgrtition Timing ............... liS
Base Timing ............................................................. 115
IgrutJon
.. T Iffilng
. .. .... ................................................... J 15
inspection oflgnition Coil ......................................... lIS
I
EFI - EEC V Distributor """"""""""""" 115
Removal MPEFI ............................................ .......... liS

Removal5 .0L 8 Cylinder .......................................... 116
Dismantle. ... ....... .... ....... ............. ... ....... .... ....... ....... .. 116
Inspection ....... ......... ................................................. 117
Assembly ......... ........................................................ 11 7

Installation MPEFI ................................................... 117
Installation 5.0L 8 Cylinder ....................................... 118
Electronic Distributorless Ignition System
(EDIS) ....................................................... 118
Coil Pack Replacement ............................................. 118

Crankshaft Position Sensor (CKP) Replacement ........ 118
EDlS CPU Replacement ........................................... 119
Knock Sensor Replacement ....................................... 119
Syncbrortizer Assembly Replacement ......................... 119
Precautions.
1. Do not leave the ignition switch on for more than 10
minutes after the engine does not start.
2. When a tachometer is connected to the system, connectthe
tachometer positive (+) terminal to the igrtition coil negative
(.) tenrtinal.
3. When a tachometeris connected to the system, connect the
tachometer test probe to the service connector at the distributor.
4. As some tachometers arenotcompatible with this ignition

system, we suggest that you confmn compatibility of your
unit before using it.
5. NEVER allow the ignition coil tenninals to touch ground
as it could result in damage to the distributor and/or ignition
coil.
6. When the engine is fUnrting do not disconnect the battery.
7. Ensure that the distributor is properly grounded to the
body.
On Vehicle Inspection.
System Testing ....................................... 120

Spark Test.
Problem Diagnosis ................................. 120
Specifications ......................................... 120
Connect thehigh tension lead to a spark gap or spark plug and

earth to the body of the car. Check if sparks occurs while
engine is being cnmked over, DO NOT CRANK ENGINE
OVER FOR MORE mAN A FEW SECONDS, if it does
not, perform the following tests:
113
IGNITION SYSTEM
Check thaI the resistance does not exceed the maximum using
an ohmmeter.
Maximum resistance:
21 k ohms! cord.
SPARK TEST
BAD
CHECK RESIST ANCEOFHIGHTENSIONLEADS AS
DESCRffiED IN Tl-llS SECfION. IF NEEDED REPLACE THE LEADS.
OK
Resistance: 25k ohms J lead
Ohm meter
CHECK POWER SUPPLY TO IGNITION COIL

I. Ignition switch tum to ON
2. Ensure thal there is battery voltage
at ignition coil positive (+) terminal.
BAD
CHECK WIRING BETWEEN IGNITION SWlTCHTO
IGNITION COIL
OK
CHECK RESISTANCE TO IGNITION COIL
Resistance (Cold)
Primary (Sec below)
Secondary (See below)
Spark plug lead
High Tension leads
3. InspectthetenninaIs, andreplace thchigh tension lead and!

or distributor cap ir more than maximum specified.
Inspection of Spark Plugs. 6 Cylinder & VB
I. Clean and Inspect Spark Plugs.
(a) Clean the spark plugs using a spark plug cleaner or wire
brush.
(b) Examine the spark plugs for electrode wear, thread
damage and insulator damage. Replace the plugs ira problem
is found.
2. Adjust Electrode Gap.
BAD
REPLACE THE IGNITION COIL
OK
Feeler Gouge
CHECK AIR GAP OF DISTRmUTOR

Air Gap: 0.2-0.4 mm
OK
TRY ANOTHER TFI UNIT or EST unit if EST model
Inspection of High Tension Leads.

I. Carefully Remove High Tension Lead by Rubber Boot
Bend the outer electrode carefully

to obtain the correct electrode gap.
rrom Spark Plugs.

~''::::::::-__ Rocker Cover
'"
Pulling on or bending the cords may damage the conductor

inside.
2.Examine Resistance of High Tension Lead with Distri bulor Cap.
Bend the outer electrode carefully to obtain the correct

electrode gap.
Spark Plug Gap Correct electrode gap:
4.0L
1.0 - 1.1 rum
5.0L
1.3 - 1.4mm
3. Spark plug type.
Spark Plug Type General use:
MotorcraftAGS33CC
4.0L
MotorcraftAGS23CC
4.0L (16HO)
MotorcraftASF42C
5.0L
MotorcrolftA WSF-32C
5.0L
4. Torque plug 10 correct specification.
Spark Plug Torque specification:
14-20Nm
114
IGNITION SYSTEM
Inspection and Adjustment of Ignition Timing.
Base Timing:
6 Cylinder ...........................................
10 BTDC
V8 ...................................................... 30 BTDC +/- 2
Checking Base Timing

I. Connect Tachometer and Timing Light to engine.
7. Ignition Timing will move away from the base timing

marks when the self test is disconnected.
The tachometerconncction (diagnostics plug) is found under

the dash in the fuse panel.
Ignition timing:
The ignition timing is not able to be changed, once the base

timing has been set in the COl I ectposition and the selftest has
been disconnected the computer will take control of the
timing and return to normal operation.
Inspection of Ignition Coil.
l. Disconnect High Tension Lead
2. Check Primary Coi I Resistance. Measure the resistance

between the positive (+) and negative (-) terminals using an
ohmmeter.
Ignttlon
Coli
* As some tachometers and timing light' are not compatible

with this ignition system, we suggest that you check the
compatibil ity ofyour unit before using.
2. Engine must be at normal operating temperature before
the base timing should be checked or altered, also ensure that
the timing markes are clean and easy to distinguish. Engine
must be switched off before continuing.
3. Using the diagnostic unit connect into the self test
connector and follow instruction manual until base timing
check can be done.
4. (a) If diagnostic unit is not available a piece of wire with
analligatorclip one end and spade terminal the other can also
be used.
(b) The spade terminal is to be connected into the self test
input terminal and the alligator clip is to be connected to earth.
Self TestIng Diagnostic connector front on view.
Base Timing, short ENG-STI and ENGGND with a jumper wire
ENG
ENG
FUEL
CCl
ENG
GNO
GNO
TACHO
B+
12v
Ohmmeter
Ohmmeter
Test Cables
Ignition
Coli
Primary
Terminals
Tu112

25C +/- 5C ........................................ 0.41-0.45
3. Check Secondary Coil Resistance. Measure the resistance between the positive (+) and high-tension terminal,
using an ohmmeter at idling.
Secondary coil resistance (ohms):
25C +/- SOC ...................................... 7.12-7.S7
4. Examine Power Source Line.
With the ignition at ON and using a voltmeter, connect the
positive (+) probe to the (+) terminal of the coil and the
negative (-) probe to the body ground.
Voltage:
Approx. 12V
Examine the ignition switch and wire harness ifa problem is
found.
efelstdl
5. Start engine, the engine idle speed will increase to about

1500 RPM, this indicates the selftest mode is in operation and
the base timing can now be checked using timing light.
6. I[hase timing is not correct loosen the distributorretaining
bolt and move distributor until thedesired reading is achieved,
lock up the retainer bolt and check timing again.
EFI - EEC V Distributor

Distributor Remove MPEFI
I. Set No.1 Cylinder to TOC/Compression.
Set to TDC/Compression in the following way:
(a) Remove the No.1 spark plug.
(b) Place your fingeroverthe hole of the No.1 spark plug and
115
IGNITION SYSTEM
tum the crankshaft clockwise to TDC. If pressure is felt on

your finger, this isTOCIcompression of the No.1 cylinder. If
not, repeat the process.
(c) Install the No.1 spark plug.
2. Remove air cleaner intake and distributor cap. Move
distributor cap to one side out of the way ..
3. Disconnect TFI wiring.
distributor cap out of the way, not necessary to remove from

vehicle.
3. DisconnectTFI wiring.
Distributor
- - Cap
4. Loosen the distributor retaining bolt and remove.

S. Remove distributor.
(a) Make scratch marks or felt pen marks on distributor and
engine block to help when installing distributor.
4. Disconnect and remove idle speed sensor and ga~ket also
crank ventilation hose.
S. Loosen the distributor retaining bolt and remove.
6. Remove distributor.
Distribute< Cap
Addaptor & Rotor
Distributor
Assembly
T.F.I. Module
H .I. Module
Assembty
,,
Loom Connector
o.stnbutor _
Dnve Gear
T.u017
(a) Make scratch marks or felt pen marks on distributor and

engine block to help when installing distributor.
(b) Carefully remove distributor, mark the edge of distributor
to note position of rotor as this will help when installing
distributor.
Distributor RemovaIS.OL:
1. Set No.1 Cylinder to TDClCompression.
(b) Place your finger over the hole of the No. I spark plug and
your fi nger, thisisTOC/compressionoftheNo.1 cylinder. If
not. repeat the process.
2. Remove intake mani fold cover and distributor cap. Move
(b) Carefully remove distributor, mark theedge ofdistributor

to note position of rotor a~ this will help when installing
distributor.
DismantlcofDistributor.
1. Remove Distributor Cap, Rotor.
2. Remove adaptor
3. Remove the Driven Gear.
* Ensure not to damage the distributor shaft and housing.
(a) Drive out the pin using a punch and hammer and remove
the dri yen gear.
4. Remove distri butor and PIP rotor.

S. Remove the PIP rotor.
(a) Remove the top cirC\ip.
(b) Remove lowercirclip.
(c) Remove the PIP rotor, it may be firmly attached to the
shaft, if tap off with the aid of two blocks of wood.
116
IGNITION SYSTEM
Clrcllp _ _..
-e
'e
"Alignment Pin
"'Circtip
- - P.I. P. Rotor
Distributor Cap
Retaining Clips
--~..., iii....... Stator Retaining

Screws
T.F.1. Module
Distributor - - - - - '
Assembly Housing
Oistributor
Main Shaft
Distributor _______..
Drive Gear
Retaining
Pin
,.
"
Assembly of Distributor.
I. Coat the di stributor shaft lightly with hightemperature
grease.
2. Replace the stator and base plate.
(a) Replace stator and base plate.
(b) Replace two allen head screws.
3. Replace electronic 'l'FI unit.
(a) Replace the electronic TFI unit and 2 screws.
(b) Connect the wiring connector.
4. Replace the PLP rotor.
(a) Replace lower circlip.
(b) Replace the PIP rotor. it may be necessary to tap the PIP
rotor on to the shaft, with the aid of two blocks of wood.
(c) Replace the top cirelip.
FuOOO
6. Remove electronic TFI unit.

(a) Disconnect the wiring connector.
(b) Remove the 2 screws and electronic TFI unit. pull down
on the unit to remove.
7. Remove the stator and base plate.

(a) Remove two allen head screws.
(b) Remove stator and base plate.
Inspection and Replacement of Distributor.
1. Examine PIP rotor. Rotate the PIP rotor and examine for
contamination. bums, orcracks replace if defective.
2. Examine distributor shaft bearing. Rotate the distributor
shaft and ensure that the bearing is not rough or worn.
Replace the distributor shaft or bearing if necessary.
5. Replace distributor and PIP rotor.

(d) Line up the pin holes of the driven gear and distributor
shaft.
6. Remove the Driven Gear.
(e) Drive in the pin using a pin punch and hammer.
* Ensure not to damage the driven gear and housing.
7. Remove adaptor
8. Remove Distributor Cap, Rotor.
Distributor Installation MPEFI
I. Set No.1 Cylinder to TDC/Compression.
(b) Place yourfmgerovertheholeoftheNo.1 spark plug and
yourfmger, this is TDC/compression ofthe No. I cylinder. If
2. Install Distributor.
(a) Coat the spiral gear and governorshaft tip with engine oil.
(b) Install distributor so that the rotor is at the mark on the
distributor that was made during removal.(No I cylinder
spark plug lead).
(c) Insert the distributor, lining up the scratch marks or felt
pen marks are aligned on the distributor and engine block
which you made when removing distributor.
(d) Lightly tighten the hold-down bolt.
117
IGNITION SYSTEM
3. Replace distributor cap.

4. Connect 'I'F1 wiring.
. __ Distributor
':""
Cap
4. Connect TFJ wiring and replace intake manifold cover..

S.Adjust ignition timing as previously described.
5. Connect and replace idle speed sensor and gasket also
crank ventilation hose.
6. Replace air cleaner intake.
7 .Adjust ignition timing as previously described.
Distributor Installation S.OL:
1. Set No.1 Cylinder to TDClCompression.
(b) Place yourfingerovertlleholeoftheNo.1 spark plug and
your finger, this is TDC/compression of the No. I cytinder.lf
Plug Lead
TuOO
2. Install Distributor.
(a) Coat the spiral gear ,md governor shaft tip with engine oil.
(b) Install distributor so that the rotor is at the mark on the
distributor that was made during removal.(No 1 cylinder
spark plug lead).
(c) Insert the distributor, lining up the scratch marks or felt
pen marks arc aligned on the distributor and engine block
which you made when removing distributor.
(d) Lightly tighten the hold-down bolt.
3. Replace distributor cap.
Electronic Distributorless
Ignition System (EDIS)
COIL PACK REPLACEMENT
1. Reomve negative battery terminal, then raise the vehicle
and support on stands.
2. Detach the wiring loom from the botom of the coil pack,
then the high tension leads from the top.
3. Release the retaining screws, then lift the coil pack and
suppressor from the vehicle.
4. Fit the new coil pack and suppressor to its mountingpoint,
then secure using the retaining screws.
5. Fitthehigh tension leads tothetopofthecoil pack, ensuring
that they are on there correct posts, then clip the wiring loom
into its connector.
6. Lower the vehicle from its stands and tit the battery
temlinal, then start the vehicle and check its operation.
CRANKSHAFT POSITION SENSOR (CKP)
REPLACEMENT
1. Detach the negative battery terminal, then withdraw the
radiator shroud and fan assembly, air cleaner intake duct and
drive bell.
2. Release the sensor loom clip, then withdraw the sensor
protection cover.
118
IGNITION SYSTEM
3. Release the sensor retaining screws and withdraw the
1. Withdraw the air cleaner intake, then fan and shroud

assembly from the vehicle.
2. Detach the wiring loom from the synchronizer, then release
the retaining bolt and bracket.
sensor from the vehicle.

4. Fit the new sensor to the engine, then protection cover,
retaining in position.
S.Connectthe wiring loom, then fitthe fan belttothe pullies.
6. Fit the fan and shroud assembly, then start the vehicle and
check that system is functioning correctly.
EDIS CPU REPLACEMENT
I. Pull the pasangersidc kick panel out to relea.scthe retaining
lugs then withdraw .
3. Carefully slide the synchronizer from the engine.

Installation
1. Set the engine timing at cylinder one TDC ready to lit the
synchronizerassembly.
2. Fit the locating pin tool no. E9359 toenable thesynchroniwr
to be aligned on installation.
3. Position the synchronizer with the locating pin 200 from the
2. Relea.sc the CPU retaining bracket and lower the CPU to

gain access to the wiring terminal.
3,Releasc the wiring terminal, then withdraw the CPU from
the vehicle.
4, Refit the wiring tenninal to the relpacement CPU, then
position the CPU and lit retaining bracket.
5, Refit the kick panel, then run the vehicle and check the
operation.
KNOCK SENSOR REPLACEMENT
!.Jack vehicle up and place on safety stands, then detach the
loom from the sensor.
2. Release the sensor from the engine block, then fit the new
sensor tensioning to specifications.
3.Clip the wiring loom to the sensor and lower the vehicle to
theground.
SYNCHRONIZER REPLACEMENT
Removal
retainer bolt hole, then lowerthe scmbly into the bore until
it seats on the block.
4. When the assembly is seated correctly the locating pin will
be pointing towards the retai ncr bolt hole, if not withdraw and
reinstall.
5. Fit the retaining bolt, then remove the locating pin and
connect the wiring loom.
6. Run through the correct installation check to ensure the
synchronizer assembl y is positioned correctly.
7. Fit the shroud and fan assembly ,then the air intakeducting.
Con ect Installation Check
J. The breakout box is filled to the CPU and wiring loom, then
usea voltmeterto fit topin 85 and earth of the breakout box.
2. Ensure engine is at TDC on no. I, then detach spark plug
leads and tum ignition to the on position.
3. Tum the crankshaft to40mm before TDC,the reading on
the voltmeter should be <O.2Y.
119
IGNITION SYSTEM
4. Turn thecraank while observing the change in readings on

the voltmeter, at a high point of>6.0V the timing mark need
to be inside 30mm either side ofTDC.
S. The breakout box is able to be withdrawn if the results are
positive, if not withdraw the synchronirer and repeat the
installation procedures.
* Ignition wiring faulty. Remedy-lnspeet wiring.

Incorrect ignition timing. Remedy-Reset timing.
Problem: Engine runs after Ignition switch
is turned offl
Possible Cause & Remedies:
* IncolI ect ignition timing. Remedy-Resettiming.
SYSTEM TESTING
TEST PROCEDURES
Problem: Muffler explosion (after fire) all

the timel
* Incorrect ignition timing. Remedy-Reset timing.
1. The battery must be fully charged before ignition system

testing.
2. Manufacture test leads and only use test equipment as
outlined in "IGNITION SYSTEM TESTING."
3. DO NOT OPEN CIRCUIT any high tension cable with
ignition switched on orwith enginc running as the control unit
can be damaged.
4. When testing leave the ignition switched offuntil voltage
or current check is necessary and switch off immediately
check is complete.
S. AVOID CONTACT WITH PRIMARY AND SECONDARY WIRING WlTH IGNITION SYSTEM ENERG1SED. THE HIGH VOLTAGES PRESENT MAY BE
HAZARDOUS.
*Incol iect ignition timing. Remedy-Resettiming.
Problem Diagnosis.
SPECIFICATIONS
Problem: Engine will not start or hard to

start but cranks OKI
Possible Causes & Remedies:
Incorrect Ignition Timing. Remedy-Reset timing.

* Ignition coil faulty or igniter faulty. Remedy-Examinecoil
* Distributor faulty. Remedy-Inspect distributor.
* High tension lead faulty. Remedy-Inspeet high tension lead.
* Spark plugs faulty. Remedy-Check plugs.
* Ignition wiring disconnected or broken. Remedy-Examine
wmng.
Problem: Rough Idle or Stallsl
* Spark plugs faulty. Remedy-Examine plugs.

* Ignition wiring faulty. Remedy-Examine wiring.
* Incorrect ignition timing. Remedy-Reset timing.
Ignitioncoil faulty. Remedy-lnspeetcoil.
* Distributor faulty. Remedy-Check distributor.
* High lension lead faulty. Remedy-Inspeethigh lension lead.
Problem: Engine backfires!

"Incorrect Ignition timing. Remedy-Reset timing.

Problem: Poor Fuel Economyl
* Spark plugs faulry. Remedy-Examine plugs.

"Incorrect Ignition timing. Remedy-Reset timing.
Problem: Engine overheats!
Firingorder:
6Cylinder ........................................... I - 5 - 3 - 6 - 2 - 4
V8 ........................................... 1-3-7 -2-6-5-4-8

Spark Plug Gap Correct electrode gap:
4.0L ......................................... ........... ........ 1.0 - I.lmm
5.0L .............................. .............................. 1.3 - 1.4mm

Spark Plug Type Generul use:
4.0L ............................................. Motorcraft AGS33CC
4.0L (I6HO) ................................. Motorcraft AGS23CC

~.O~
............................................ .... ~otort:f(lft A~~4:!c:

SparkPlugTorquespecification: ................... 14-20Nm
25"C +/- 5"C .................................................... 0.41-0.45
Secondary coil
25"C +/- 5"C .................................................... 7.12-7.87
Base Timing:
6Cylinder ........ .............................................. 1(jJ BTOC

V8 ........................................................ 3(jJ BTDC +/- :20
Problem: Engine hesitates/poor

acceleration I
* Spark plugs faulty. Remedy-Check plugs.
120
FUEL SYSTEM
Subject
Page
General Description .............................. 122
6CyUnderMPEFI ........................................_..... _..... 122

8Cylinder SEFI ........................................................ 122
Adjusbnents ............................................................ 123
BaseldleSpeed ........................................................ 123
AdjustnlentMPEFI ................................................... 123
Adjustment SEFI ...................................................... 123
Check Fuel Mixture ................................................ 123
Fuel Evaporative Emission Control System 124
Inspection of Fuel Vapour Lines, Fuel Tank and Tank
Cap .......................................................................... 124
Inspection of Carbon Canister ................................... 124
Inspection of Purge Control Valve ............................. 124
IJepressurise Fuel System ........................................ 124
Fuel Mixture .......................................................... . 124
Injector .................................................................. . 124
Remove MPEFI ....................................................... . 125
RemoveSEFI ......... ........... .... ........... ........ ....... ........ . 125
Test Injectors ........................................................... 125
Assemble .... ..... ....... ................................................. . 125
Install MPEFI .......................................................... . 125
Install SEA ... ......... .......... .... ... ........ .......... .. ........... .. 126
121
Subject
Page
Air Filter ..................................................... 126

Remove MPEFI & SEFI .......................................... 126
Install MPEFI & SEFI .......................... ................... 126
Inspect Air Filter ....................................................... 126

Fuel Tank Sedan ..................................................... 126
RefTlOve ..................................... _.............................. 126
Install ....................................................................... 127

Fuel Tank Wagon ................................................... J27
Remove .......................................... _......................... 127
Install ........................................................ ............... 127
Fuel Gauge Tank Unit and Pump Assembly ......... 128

Rernove ................. 0
.................................................. 128
Install ... ........... ......... ......... ....... ................................ 128
Fuel Filter ................................................................ 128
Remove ......... ........... ....... .................... ...... ...... ..... .... 128
Install ....................................................................... 128
Problem Diagnosis ............................... 128
Specifications .....
..................................
129
Torque Wrench Specifications ....... 129
FUEL SYSTEM
ELECTRONIC
FUEL INJECTION.
GENERAL DESCRIPTION
6 Cylinder - MPEFI
There are two fonns of ignition system litted, one system is

anTFI (Thick film ignition module), this system usesa thick
film ignition module on the distributor. The second system is
an EDIS (Electronic distributorless ignition system), this
system incorpomtes a ignition coil pack, synChronizer
assembly and crankshaft position sensor (CKP).
Fuel Injection Systems contain an electronic control unit
(ECU), mani fold absolute pressure (MAP), throttle position
sensor (TPS), fuel injectors, vehicle speed sensor (VSS),
heated oxygen sensor (HEGO), and air & coolant temperature sensors.
Sensors are connected electrically to the ECM which interprets the data it recei ves and computes when and for how long
the electrically operated injectors are held open. The basic
fuel requirement of the engine is detennined from the data
supplied to the ECM by the MAP sensor. The other sensors
increase or decrea.e the quantity of fuel injected.
MPEFl idle RPM iscontrollcd by an air bypass valve control
system, which channels air from the air from the out. ide ofthe
throttle body to the intake manifold via the bypass valve
which alters the amount of air flow, when the valve is open
the rpm is higher and as the valve closes the rpm decreases.
Injectors are used to inject fuel into the intake port zone
(MPEFI), these are operated by an electronic pulse which
comes from thedistributororcrank sensor via the ECM. It is

the ECM which fine tunes the length of time that the injector
stays open. Therefore allowing mO/eor less fuel to enter the
cylinder through the intake. The injectors have an even
amount unit of fuel pressure available to them from the fuel
rail. (Not all fuel injection systems opemte in this manner).
The fuel tank is located at the rear of the vehicle, on sedan
models. the standard fuel tank is68 litre capacity , with an 80litre capacity long range fuel tank as optional equipment.
Utilities have a 68-litre capacity fuel tank.
Station Wagons also have a 72 litre capacity fuel tank.
The fuel tanks have an Evaporative Control System, which
means that they are not vented 10 the atmosphere. Instead they
arc vented to the fuel vapour carbon canisterto be stored and
dispersed through emission control system.
MPEFI engine vehicles are fitted with a two stage turhi ne typc
in-tank pump. The constant fuel pressure in the supply line
is controlled by a fuel pressure regulator mounted on the
outlet of the fuel rail.
8 cylinder SEFI
8 Cylinder SEFI
Sequential Electronic Fuel lnjection(SEFI) is available inthe

5.0L V8 engines, it is considerably different to the EFl and
MPEFI engines, but still uses an injector per cylinder, and
each injector is controlled on its own.
Sequential Fuel Injection Systems main features are electronicenginecontrol computer(EEC-l V), barometricabsolute pressure (BAP), fuel injectors, mass airflow sensor
(MAF), air charge tempemture sensors (ACT), throttle
position sensor (TP), engine coolant temperature (ECT),
heated exhaust oxygen sensor (HEGO L&R), idle speed
control (lSC) and EGR valve position sensor (EVP).
Sensors are connected electrically to the EEC-I V which
interprets the data it receives and computes when and for how
long the electrically operated injectors are held open. The
basic fuel requirement of the engine is detennined from the
data supplied totheECMby the Air Mass Sensor. The other
sensors increa.e or decrease the quantity of fuel injected.
Injectors are used to inject fuel into the intake portzone, these
are operated by an electronic pulse which comes from the
distributor via the ECM. It is the ECM which operates and
fine tunes the length of time that each injector stays open.
122
FUEL SYSTEM
Therefore allowing more or Ie" fuel to enter the cylinder

through the intake. The injectors havean even amount umtof
fuel pressure available to them from the fuel rail. (Not all fuel
injection systems operate in this manner).
The fuel tanks have an Evaporative Control System. which
means that they are not vented to the atmosphere. Instead they
are vented to the fuel vapour carbon canisterto be stored and
dispersed through emission control system.
Vehicles with standard fuel tanks are fitted with a two stage
tU/bine type in-tank. pump. The constant fuel pressure in the
supply line is controlled by a fuel pressure regulator mounted
on the outlet of the fuel rail.
ADJUSTMENTS
6. Stop engine. connect ISC wiring loom and disconnect

Base Idle Speed
tachometer. Start engine.
The Sase Idle Speed is manufacturesetand should never be

adjusted, only adjust if diagnostic codes are being shown
when run in 'self-test' or idle specd is irregular.
AdjustingMPEFI
I. Engine running and at normal running tcmperature.
2. All sensors and vacuum hoses must be fitted properly.
3. Tum off cngincand disconncct the ISC wire when normal
idle speed has returned.
AdjustingSEFI
I. Enginc running and at normal running temperature.
2. All sensors and vacuum hoses must be fitted properly.
3. Tum engine off, disconnect the ISC wire
ISC Moto,_-,-_ _,
Assembty
4. Connect a tachometcr to engine if one is not fitted, use

tachometer wire connector. located in the diagnostic port
undemeath fuse panel .
5. Slartengine and allow to idle. check RPM should be 450600, tum base idle screw to adjust rpm until correct.
Idle RPM (lSe disconnected) .................. 450-600 rpm
4. Connect a tachometer to engine if one is not fitted, use

~tchome[er wire connector, located behind front right strut.
5. Start enginc and allow to idle for at least I min.
6, Check RPM it should be 560-600.
7. COllect rpm by turning base idle screw until a setting of580
+/- 20 idle RPM without ISC connected.
8. Stop engine, connect ISC wiring loom and disconnect
tachometer. S[artengine.
CHECK FUEL MIXTURE
Method with CO Mcter

1, Visually Inspect E.F.I. System
(a) Check for loose screws or a loose mounting [0 [he
manifold.
(b) Chcck for wear in the linkage, missing snap rings or
excessive looseness in the throttle shaft. Correct any problems found .
123
FUEL SYSTEM
INSPECTION OF CARBON CANISTER.
Fuel
/Rall
2. Initial CondiLions:
(a) Aircleaner insLalled.
(b) Nonnal operaLing coolanL Lemperature.
(c) All accessories switched off.
(d) All vacuum lines connected.
(e) IgniLion timing seLcorrectly.
(f) Transmission in the "N" range.
(g) CO meteroperaLing normally.
3. Check Idle Speed.
(a) SLart the engine.
(b) Using a CO meteflo measure the CO concentration in the
exhaust before the catalytic converter.
Idle speed:
V 6 .................................................................... 700-8()()
V8 .................................................................... 7008()()
4. InspecL CO Concentration.
(a) Check thaL the CO meter is properly calibraLed.
(b) Race the engine 30-60 seconds al aboul2,000 rpm before
measuring concentration.
(c) Wait 1-3 minules after racing the engine 10 allow the
concentration Lostabilize.
Idle CO cOllcentration:
6 Cylinder .................................................. 0.50/0-1.0 %
V8 .............................................................. 0.50/0-1.00/0
1. Remove Carbon Canister.

2. Visually Inspecl Carbon Canisler.
Look for cracks or damage.
3. Check for clogged filter and stuck check valve.
(a) Using low-pressure compressed air, blow into the tank
pipe and check that the air nows without resistance fromthe
olherpipes
(b) If a problem is found, replace the charcoal canister.
4. Clean Filter In Canister
Clean the filter by blowing 3 kg/cm sq. (43 psi, 294kPa)of
compressed air into the pipe to the outer venl control valve
whi Ie holding the other upper canisLcr pipes closed.
NOTE:
Do not a\templ La wash the canister.
No activated carbon should come out.
S. InsLall Carbon CanisLer.
INSPECTION OF PURGE CONTROL VALVE
Check Purge Control Valve Operation.

(a) Disconnecl the hoses from the valve.
(b) Check that the valve is open when a vacuum is applied to
lhe vacuum control connection.
(c) Check that the valve is closed when there is no vacuum
present.
(d) Reconnecl the hoses to the proper locations.
If Ihe valve does nOI operate, replace the valve.
DEPRESSURISEFUELSYSTEM
1. Tum engine off.

2. Remove the Fuel Pump fuse, situated near Ihe battery.
FUEL EVAPORATIVE EMISSION CONTROL

SYSTEM.
INSPECTION OF FUEL VAPOR LINES,

FUEL TANK AND TANK CAP.
1. Visually Inspect Lines And ConnecLions.
Look for loose connection, kinks ordamage.
2. Visually Inspect Fuel Tank.
Look for defonnaLion, cracks or fuelleakage.
3. Visually Inspecl Fuel Filler Cap.
Look for a damaged or defonned gasket and cap.
If necessary, repair or replace the cap.
....., =-__ Fuel Pump

Relay
3. Tum ignition on and start engine, allow engine to idle until

iL SLOpS. Tum key off and try Lo start engine again. This will
depressurise the fuel system.
NaM Broken
FUEL MIXTURE
The fuel mixLure is adjusted aL 14.7: I and ideally maintained

at that by the ECM .
INJECTOR
Label all wiring connectors and hoses, so as to help in
124
FUEL SYSTEM
installation and assembly process.
Removal SEFI (V8)

1. Remove intake manifold cover and air cleaner to intake
Electrical
Electrical
Terminal '-
Body -,-,Assembly
'0' Ring &

Spaoer " -
Pintle
Cap
Dismantled
Fuel Injectors
Assembled
Removal MPEFI (6 cylinder)

1. Withdraw the intake pipe and resonator assembly.
2. Relieve fuel pressure from fuel line as described in this

chapter.
3. Disconnect injector wiring loom from injectors and move
loom to one side out of the way.
manifold pipe.
2. Relievecoolingsystem and fuel system pressure.
3. Disconnect vacuum lines, cooler lines, hoses, wiring
connectors, accelerator cable, etc., from upper intake manifold.
4. Remove upper intake manifold, see engines section for
more information if needed.
5. Disconnect remaining wiring loom connectors and place
loom to one sidc.
6. Remove fuel supply and return lines from fuel rail, then
place to one side.
7. Loosen fuel rail retaining bolts and then remove.
8. Ensure that area around injectors is cleaned.
9. Lift fuel rail up and remove fuel rail and injectors as an
assembly.
to. Remove injectors from fuel rail.
Test Injectors
Injectors should be tested on a commercial testing bench.

Each injector should give an even spmy of fuel that is
atomised. There should not beany droplets, ora spray pattern
to one side.
Inspect Injector Spray
4. Remove fuel supply line from fuel rail.

5. Remove fuel return line from pressure regulator, place fuel
hoses to one side so that fuel will not leak from them.
6. Loosen fuel rail retainer bolts and then remove.
7. Ensure that area around injectors is cleaned.
8. Carefully remove fuel rail with injectors attached.
9. Remove injector retaining clips and remove injectors.
OK
FauJity
Faulity
0lu019
Injectors can be cleaned with petrol, if scraping off carbon

build up, ensurc no damage is done to the injector nozzle, a
brass brush can be used with care.
Installation MPEFI
I. Replace injectors and retaining clips.
2. Ensure that area around injectors mountings is c1eaned.
3. Carefully replace fuel rail with injectors attached.

4. Install fuel rail retainer bolts and then tension.
5. Replace fuel return line on pressure regulator.
6. Replace fuel supply line from fuel rail inlet.
7. Connect injector wiring loom to injectors.
125
FUEL SYSTEM
INSPECT AIR FILTER
(a) Inspect the air cleaner element to ensure it is not excessivelydamaged, dirty or oily.
Air Filter
Intake &
Injector Electric-'
Wiring Loom cap
8. Fit the air intake pipe and resonator assembly.

9. Prime fuel system by turning ignition on and otf a few
times. then start the vehicle.
I nslallation SEFI
1. Install injectors into fuel mil.
2. Ensure that area around injectors mountings is cleaned.
3. Install fuel rail and injectors in position as an a"embly.
4. Replace fuel rail retaining bolts and then tension.
S. Replace fuel supply and return lines on fuel rail.
6. Connect remaining wiring loom connectors.
7Install upper intake mani fold, see engines section for more
information if needed.
S.Connect vacuum lines, cooler lines, hoses, wiring con nectors, accelerator cable, etc., to upper intake martifold.
9. Replace intake manifold cover and air cleaner to intake
manifold pipe.
10. Refill cooling system and prime fuel system by turning
igrtition on and off a few times, then start the vehicle.
(b) Clean the filter element with compressed air. First clean
the inside thoroughly ,then clean the outside ofthe element.
FUEL TANK - Sedan
Removal
l. Drain the tank
Beware of distorting the fuel filler pipe deflector, with

syphon hose.
2. Open rear compartment, remove the floor covering then
remove the sender unit cover plate from the floor ofthe rear
compartment.
3. Disconnect the fuel line between the fuel gauge tank urtit
and the fuel feed pipe, then the fuel return tine from the tank
connecoon.
AIR FILTER
Remove MPEFI & SEFI

clips.
2. Remove upper housing and air filter element.
Install MPEFI & SEFI
1. Fit the new or cleaned air filter element into air filter
housing.
2. Replace upper housing and snap clips on the air housing.
. .
4. Disconnect tank vent hoses at filler neck and check for

kinks in hoses and replace if necessary.
S. Disconnectelectrical connectors from fuel gauge tank uni~
then the fuel tank to canister vapour hose from vapour pipe
at front of tank.
6. Remove the rear bumper bar assembly as descri bed in body
chapter.
126
FUEL SYSTEM
the spare wheel cover and wheel.

3. Disconnectlhc fuel line between the fuel gauge lank unit
and the fuel feed pipe, then the fuel return line 1T0m the tank
connection.
7. Support fucltank with suitable jack.

* Locatca blockofwood between the jack and tank to prevent
damage to tank.

kinks in hoses and replace ifnecessary.
S. Disconnect electrical connectors rrom fuel gauge tank unit,
then the fuel trulk to canister vapour hose from vapour pipe
at front of tank.
6. Remove the screws securing the fuel tank to the noorpan.
then carefully lift the fuci tank from the vehicle.
Ins1allation
8. Remove the bolts and nut securing the fuel tank straps to
the body, and lower tank.
Before removing the tank, lower tank slightly so that the
vent hoses that arc routed through the side frame aredisconnected from the tank.
Ins... llation
Installation of the fuel tmll< is the reverse of REMOVAL
procedures, noting the following points:
I. To assist when installing the liller neck through neck seal,
lubricate upper end of filler tube with petroleum jelly.
2. Check vapour and vent hoses for crimping or damage
before installing fuelfi IIcrpipe stoneguard.
3. Install and torque strap attaching boits and nut.
Torque:
Bolts ........................................................... 2632 Nm.
Nuts ............................................................ IS - 2S Nm.
4, Before starti ng vehicie, carry out fuel system leak test refer
to ENGINE TUNEUP & MANAGEMENT Chapter of
this Manual].
FUEL TANK - Station Wagon
Removal
1. Drain the tank
Beware of distorting the fuel filler pipe deflector, with
syphon hose.
2. Open reartailgate, remove the noor covering then remove
Installation of the fuel tank is the reverse of REMOVAL

procedures, noting the followingpoints:
1. Toassist when installing the fillerneck through neck seal,
lubricate upper end offillertube with petroleum jelly.
2. Check vapour and vcnt hoses for crimping or damage
before installing fuel filler pipe stoneguard.
3. Install and torque attaching screws.
Torque:
Screws ........................................................ 26 . 32 Nm.
4. Beforestarting vehicle, carry out fuel system leak test [refer
to ENGINE TUNE-UP & MANAGEMENT Chapter of
this Manual].
127
FUEL SYSTEM
FUEL GAUGE TANK UNIT AND PUMP

ASSEMBLY
PROBLEM DIAGNOSIS
Removal
remove the sender unit cover plate from the floor of the rear
compartment.
2. Disconnect the fuel line between the fuel gauge tank unit
and the fuel feed pipe, then the fuel return line from the tank
coTlJle(,.l1on.
3. Clean around the sender unit assembly, then remove the
band clamp and unscrew the retaining ring.
Fuel
Tank
Problem: Cold engine is hard to start.
Cause: 'Cold start system faulty.

Action: 'Test MAF (manifold air flow) sensor.
Cause: 'Fuel pump not operating
Action: 'Check fuel pump fuse and pump relay.
Cause: 'Engine coolant temperature sensor faulty .
Action: *Test sensor.
Cause: 'Fuel pressure incorrect
Action: 'Test fuel pressure.
Cause: ' MAP (manifold absolute pressure) sensor not correct.
Action: ' Test MAP sensor.
Cause: Fuel injectors faulty or clogged.
Action: ' Test fuel injectors.
Problem: Hot engIne hard to start.
4.Remove the sender unit/pump assembly from the fuel tank,

then replace the lock ring to the tank to prevent distortion.
Installation
Installation is the reverseofREMOV AL procedure, noting
the following:
1. Ensure strainer is firmly attached to the fuel pump inlet
fitting.
2. Check electrical connections and connector retainer and
make sure pulsator seals engage pump outlet fitting firmly.
FUEL FILTER
Remove
1. Relieve fuel pressure as described earlier.
2. Place acontainer under the fuel line at therearofthe vehicle
near the fuel tank, release the fuel pipe fittings attached to the
fuel filter.
3. AUow the excess fuel to drain into the container.
4. Remove filter retaining bolt and remove the filter.
Install
1. Check for the direction flow arrow on the side of the fuel
filter, the arrow must point towards the front of the vehicle.
2. Slide the fuel filter onto position and install retainer bolt.
3. Connect pipe fittings to filter and tighten.
4. Start engine, with pressure in fuel line, check for leaks at
pipe fittings, ensure that there are no leaks before moving
vehicle.
Cause: 'Insufficient fuel pressure .

Action: ' Test fuel pressure.
Cause: ' Fuel pressure incorrect.
Action: ' Test fuel pressure.
Problem: Engine stalls or Idles roughly
(cold or warm).
Cause: 'Vacuum (intake air) leak.

Action: Check for leaks.
Cause: ' ldlesystem faulty.
Action : ' Test lKS (Idle Tracking Switch).
Cause: 'Engine coolant temperature sensor faulty.
Action: Testsensor.
Cause: 'MAP (manifold absolute pressure) sensor faulty.
Action: 'Test MAP sensor.
Cause: ' Fuel injectors faulty or clogged
Action: ' Test fuel injectors.
Cause: ' lnsufficient fuel pressure or fuel delivery
Action: ' Test fuel pressure and delivery.
Problem: Engine idles too fast
Cause: 'Vacuum (intake air) leak

Action: 'Check for leaks.
Cause: ' IKS system faulty
Action: 'Test IKS switch or DiagnosticcodeforTP(Thronle
position) sensor.
Problem: Engine misses, hesitates, or
stalls under load
Cause: 'Fuel injectors faulty or clogged

Action: 'Test fuel injectors.
Cause: 'Vacuum (Intake air) leak
Action: 'Check for leaks
Cause: ' MAP sensor faulty
128
FUEL SYSTEM
Cause: ' Sufficient fuel pressure or fuel delivery

Action: 'Test fuel pressure and delivery.
SPECIFICATIONS
Problem: Low power
Engine Idle RPM (In Neutral):

Automatic Trans ............... ................................. 650-750
Manual TrdIls .................................................... 650-750
Cause: 'Throttle not opening fully

Action: *Checkthrottlecable.
Cause: 'Insufficient fuel delivery
Action: *Testfueldelivery.
Cause: 'TP (throttle position sensor) faulty.
Action: 'Test TP sensor.
Cause: 'MAP (manifold absolute pressure) sensor faulty.
Cause: 'Ignition system faulty.
Action: 'Check ignition timing and knock sensor control.
IdleCOLevel: ............................................... 0.5%-1.0%

Fuel Tank Capacity
Sedan ............................................................... 68 Litres
Station Wagon .................................................. 72 Litres

V8 & optional .................................................. 80 Litre~
Electric Fuel Pump
Problem: Fuel Delivery Pressure Low!
Possible Cause: ' Twisted or leaking fuelline.

Remedy:
Check fuel lines for leaks as described in
installation of fuel tank.
Remedy. Check hose and pipe connections.
Possible Cause: * Fuel pump gauze filter clogged.
Remedy: Remove fuel pump and check condition offuel
pump gauze.
Possible Cause: Fuel pump relief valve faulty.
Remedy: * Replace fuel pump.
Possible Cause: * Fuel pump faulty.
Remedy: ' Replace fuel pump.
Possible Cause: * In line filter blocked.
Remedy: ' Replace in line filter near fuel lank.
Problem: Fuel Delivery Pressure High!
Possible Cause: 'Fuel pump relief valve faulty.

Remedy: * Replace fuel pump.
Problem: No fuel at Fuel Rail
Possible Cause: * Kinked fuel line.

Remedy: *Check fuel hoses and lines replace if necessary.
Possible Cause: * In line fuel filter blocked.
Remedy: * Replace in line filter near fuel tank.
Possible Cause: 'Fuel pump relief valve faulty.
Remedy: Replace fuel pump.
Possible Cause: Fuel pump in operative.
Remedy: See below.
Problem: Fuel Pump Not Operating!
Possible Cause: Fuel pump faulty.

Remedy: Test fuel pump.
Possible Cause: Wiring looms or connections faulty.
Remedy: 'Check wiring with testlightormultimeterreplace
as required.
Possible Cause: * Fuel pump control unit faulty.
Remedy: * Replace control unit.
129
MPEFI / SEFI 6&8 Cylinder

Delivery(min) ......................... 240cc in IOsec @ 275kPa
(XR6) ..................................... 280cc in 1000c @ 300kPa
Pressure at Idle .......................... 225kPa, 250kPa (XR6)
EngineStationary ...................... 275kPa, 300kPa (XR6)
'Maximum pressure drop on engine shutdown is 10% in
I Osee.
TORQUE SPEC
Nm
Fuel Pressure Regulator to Fuel Rail ............................ 25

Fuel Pressure Regulator to Bracket Nut ....................... 20
Fuel Rail to Manifold .................................................. 20
Fuel Tank Screws ......................................................... 8
Fuel Tank Strap Nuts .................................................. II
Fuel Pipe Hose Clamps ................................................. 9
Fuel Gauge & Pump Lockring ..................................... 40
CLUTCH
CLUTCH
Page
Subject
GENERAL DESCRIPTION ...................... 130
MINOR MAINTENANCE .................................... 13 1

Visual Inspection ...................................................... 131
Clutch Cable ........................................................... 13 1
Removal ..... ........ .... ..... ................. ........ ....... ............. 13 1
Installation ............................................................... I 3 1
Adjusbnent ............................................................... 13 1
Clutch Pedal ............................................ 132
RCTnovaJ .... .................................................... ........... 132
lnstallaLion ........ ....................................................... 132
MAJOR REPAIRS .................................... 132
Clutch Assembly ..................................................... 132

Renloval ................................................................... 132
Inspection ............................................. .. .................. 132
lnslaHation Single Plate ..... .. ............................... ....... 133
Spigot Bearing ........................................................ 133
PROBLEM DIAGNOSIS ........................... 133
SPECIFICATIONS ................................... 134
Six cy linder models with manual tr.msmission use a single

platedry disc type elutch. Clutch diameter is 254 mm forthe
4.0L engines and 268 mm for the 5.0L engines, they are all
cable operated. The cable hooks into the upper end of the
elutch pedal and into the clutch fork.
Theelutch used is a cable actuated single dry disc type. The
cable is mounted at one end to the fire wall, then connected to
theelutch pedal and to theelutch bell housing at the other end
which acts on the release beari ng lever. There is no provision
for pedal free play adjustment however it is importaot to
maintain the pedal height adjustment.
The elutch plate and faci ng .sembly has a non-asbestos
conventional clutch facing ri veted tocach sideofcurveddisc
springs which provide axial cushioning during engagement.
The disc springs are ri veted to the circumference of the hu b
assembly, which incorporates coil springs aod ru bber dampers, for torsional cushioning, friction washers for torsional
damping and an internal spline that mounts the assembly on
the external splined transmission main dri ve gear elutch
shaft.
The press ure place is a diaphragm spring type. The dia
TORQUE SPECIFICATIONS ................... 134
Clutch Plate
C lutch Pressure Plate

Clutch Pressure
Attaching Bolts
COOl
130
CLUTCH
4. Check condition of all engine and tnmsmission mountings .

. - Pressure Plate
Diaphragm
Spnng
Housing
CLUTCH CABLE
Pressure
Plate
Removal
1. Disconnect battery earth cable and jack up front of vehicle
and support on safety stands.
2. Wind back adjusting nut on outer cable lower fitting at
clutch housing.
3. Lift the cover on clutch fork shield (for 6 cylinders), or
remove shield (for 8 cy linders) to expose clutch cable clevis.
4. (a) Disconnect cable lower clevis from clutch fork and
withdraw cable from clutch housing lug by pulling toward
front ofthe vehicle, and remove shield, for6cylindervehicles.
(b) Disconnect cable lower clevis from clutch fork, remove
cable retaining clip, and with draw cable from vehicle, for 8
cylindervehicles ..
5. Swing panel away from steering column.
6. Lift clutch pedal upward and at the same time, disconnect
upper clevis from the upper end of clutch pedal, do not loose
the retaining pin or bushes, remove cable from clevis.
7. Remove cable assembly from engine compartment side of
dash panel by pulling through.
8. (a) Unclip clutch cable from steering rack and remove it
from the vehicle, 6 cylinder vehicles.
(b) Undocableassembly from spring tower and remove cable
from vehicle, 8 cylindervehicles.
Installation
1. Ensure washers and gronunets are installed in the correct
position at end of cable.
2. Lubricate the clevises at each end of cable with Molybdenum Disulphide grease.
3. Pass upperendofcable through dash panel and hook upper
clevis to clutch pedal ensuring that bushes and retai ner pi n are
all in place.
4.( a) Feed clutch cable around steering rack and under engine
and down toward clutch housing, securing in placc on the
steering rack, for 6 cylinder vehicles.
(b) Feed clutch cable through to clutch housing, retaining it
to the spring tower, for 8 cylinder vehicles.
5.(a) Asscmbleclutch fork shield to clutch housing, then pass
lower end ofcable through clutch fork shield and attach lower
end clevis to clutch fork, for 6 cylinder vehicles.
(b) Pass cable through mounting bracket, installing retainer
clip, then connect cable through clutch fork and replace
clutch fork shield, for 8 cylinder vehicles ..
Ensure that the cable is routed correctly.
6. Adjust the clutch cable as described below.
Do not operate the clutch until this adjustment has bem
completed.
7. Remove safety stands and lower vehicle.
Adjusbnent
* II is essential to carry out clutch control cable adjuj'tmenl
before the clutch is operated to avoid clutch diaphragm
damage.
CL002a
phragm lever height is not adjustable and the unit is serviced

only as an assembly.
The cover, pressure plate and diaphragm spring assembly is
mounted over the clutch plate assembly and bolted to the
flywheel. The pressure plate is held to the cover by tangential
straps. Thestraps are attached to the pressure plate at one end
and theclutch cover at the other. This holds the pressure plate
concentrically, but allows it to move axially. Retraction of
the pressure plate by means of retracting springs and release
of the driven plate, is achieved when thediaphmgm spring is
operated.
A sintered bronze bush, orncedle roller bearing is located in
the end of the crankshaft, is used as a main drive gear clutch
shaft spigot bearing.
MINOR MAINTENANCE
There are several items which affect good clutch operation,
therefore it is necessary before performing any majorclutch
service, to make preliminary inspections todetennine whether
the trouble is actually in the clutch.
VISUAL INSPECTION
1. Check condition of control cable and ensure correct
component assembly. For clutch control cable installation
details refer to figures.
2. Check condition of clutch pedal bushes and shaft.
3.Checkclutch pedal height and control cable adjustment, as
outlined in following section of this chapter.
Pedal Height:
140+/-3mm
Pedal Height is Measured from top of Pedal to Floor PaR
Pedal
Floor
Pan
Pedal Height
CI006
131
CLUTCH
With the clutch primary adjustment set as described

previously, the cable must be adjusted to obtain the ,\pecijied
distance between the clutch pedal andfloor paT/.
I. Remove clutch pedal trim pad and lightly load clutch pedal
so that throw-out bearing contacts diaphragm fingers ,
2. Measure dislUnce from pedal to floor pan, floor covering
removed,
3. Adjust nuton firewall mount to achieve l40mm dimension
from clutch pedal to noor pan,
4. Check the cable clearance not less than 2.5mm clearance
between the adjuster nut and the fire wall mount.
After the pedal height has been checked and adjusted if
necessary carry out the following adjustment.
5. The clearance between the pedal and pedal stop must be set
at 12.5 mm, then the clutch switch c,m be adjusted,
6.(a) Using an ohmmeter set on Rx I range, placing it across
the tcrminals,
(b) Loosen the clutch switch and slide it until the ohmmeter
reads zero and tighten switch.
(c) Release pedal and connect wiring.
should only require attention when the clutch is removed from

tile vehicle, at which time it should be inspected and lubricated
with a high temperature grease, or if necessary, replaced,
The clutch thmw-out bearing is lubricated during manufacture then sealed. Furtber lubrication is not necessllIY with the
exception of the clutch fork contact surfaces and the inner
recess of the throw-out bearing, which should be lubricated
with grease.
CLUTCH ASSEMBLY
Removal
J. Remove transmission assembly as outlined inMANUAL
TRANSMISSION Chapter of this Manual.
2.(a) Remove clutch throw-out bearing.
(b) Pull clutch fork from it' pivot and remove fork from clutch
housing.
3. MlIIk nywheel and clutch pressure plate cover correctly
making them easy to locate them when reinstalling (balance
can be then maintained),
CLUTCH PEDAL
Removal
t. Remove clutch pedal from pivot bolt and pull clutch pedal
down slightly and disconnect upper clevis of clutch control
cable from clutch pedal,
2. Disconnect upper end of return spring fmm c1utchlbrake
pedal support and remove pedal.
3. Remove return spring from pedal. Remove bushes and
spacer from pedal pivot bore.
Installation
1. Install pedal bushes and spacer into pedal pivot bore,
2. Assemble clutch pedal return spring to clutch pedal.
3. Install pedal to c1utch/brake pedal support with spring
positioned as illustrated,
4.(a) Connect clutch control cable to top of clutch pedal,
(b) Install clutch pedal to pivot.
. Chcckclutch control cableadjusunent as previously described
in this Chapter.
MAJOR REPAIRS
Theclutch pedal should not beopcrated fully after installation
of a new clutch pressure plate, throw-out bearing or clutch
cable without fin;t carrying out the appropriate clutch contTol
adjustments, as danlage may occur to the clutch diapbragm,
After inslUllation of a new driven plate, nywheel or pressure
plate, sudden engagement of the clutch with the engine
running at an abnormal speed, or continual slipping of the
clutch, may permanently injure driven plate facings and
cause scoring of the nywheel and pressure plate. When these
parts are new, they should be gi ven moderate use for several
days until they are burnished.
The transmission main drive gearclutch shaft spigot bearing
* The pressure plate and flywheel have white paint marks

which arc aligned as close as possible on assembly,
4.(a) Loosen and remove attaching bolts of clutch pressure
plate cover (do this evenly to avoid pressure plate distortion),
(b) Remove clutch plate and pressure plate a,semblies,
Inspection
1. With a soft cloth dampened with a cleaning solvent, wipe
pressure plate and flywheel surfaces clean (DO NOT USE
PETROLEUM BASED CLEANERS).
Do not wa,h the pressure plate assembly - blow dust out
with compressed air,
Do not soak the throw-out bearing in cleaning solvent(this
will destroy Lhe bearing lubricant),
2. a) Check spigot bush of main drive gear shaft for wear,
b) If necessary, replace the bush as outlined in ENGINE
MECHANICAL Chapter oftltis Manual.
* Only remove the bush if, when inspected, you feel it must
be replaced.
3. a) Check clutch fork pivot point and housingpi vot forwear
and replace if necessary,
132
CLUTCH
* Driven plates are installed with the long end of the splined
b) Check for retaining spring for damage or distortion.

c) Check clutch fork for cracks or wear on fmgers.
4. a) Check throw-out bearing for roughness of operation of
signs of wear and replace if necessary.
b) Examine bearing hub bore for burrs - any burrs should be
removed. (I fburrs are found, inspect transmission main dri ve
gear bearing retainer for scoring. Ifscoring is sligh~ remove,
using fine emery cloth. Replace retainer if seoring is
excessive. RefertoMANUAL TRANSMISSIONChapter
of this ManuaL)
5,Checkflywhecl and clutch pressure plate friction surfaces
for burn marks,
hub facing forward and the damper springs inside the pressure plate.
3. Line up paint marks made during dismantle procedure on
pressure plate cover and flywheel.
plate assembly
Clutch plate
centering
CtooB
4. Install pressure plate anaching bolts.
* If installing a new pressure plate assembly:
- align the white paint marks on the flywheel and pressure
plate as elose as possible.
- Tighten screws gradually and in rotation to avoid pressure
platedistonion.
- Torque bolts and remove elutch centring tool.
Torque:
20 - 27 Nm
S. Pack recess insidethrow-out bearing and smearelutch fork
groove area with grease. DO NOT OVER-LUBRICATE.
6. a) Lubricate pivot and elutch fork pivot point with
Molybdenum Oisulphidet,'I"CaSC.
b) Assemble throw-out bearing to elutch fork .
c) Install clutch fork (locating iton pivot stud) and throw-out
bearing assembly into clutch housing.
7. Install manual transmission as deseribed in the manual
-Slight roughness may be smoothed with fine emery cloth.

- Deep scoring of flywheel or pressure plate surfaces will
require replacement of damaged component/so
-Slight scoring of the tlywheel surface may be removed by
taking a slight cut across flywheel face in a lathe.
6,a)Checkdriven plateof clutch for lining wear, broken hub
springs or loose rivets.
tmnsmis!)ion chapter.
b) Examine clutch driven plate linings for oil or fluid

contamination.
'!foil or/luid is found on thcclutch linings, locate and correct
thecauseofthe leak before proceeding with theeluteh repairs.
'Check clutch hub for a free sliding fit on main drive gear
clutch shaft splines.
iINallation
I. Lubricate spigot bush with a few drops of high temperature
grease.
2. Assemble driven plate of elutch, together with cover and
pressure plate assembly and insert a suitable clutch centring
tool, through driven plate, into spigot bearing.
S. Adjust clutch control cable as previously outlined in this

Chapter.
9. Stan engine and check exhaust system for leaks and then
check clutch operation.
SJ'IGOT BEARING
* For spigot bearing replacement procedure, refer to ENGINE MECHANICAL Chapter in this Manual.
PROBLEM DIAGNOSIS
Problem: Clutch fails to release (pedal pressured to tloorshift lever does not move freely in and out of reverse gear
without gear clash) !
Possible Causes and Remedies:
133
CLUTCH
Improper pedal travel. Remedy - Adjust cable.

Faulty cable. Remedy - Replace as necessary.
Faulty driven plate. Remedy - Rcplace plate.
Fork and bearing nota,sembled properly. Remedy -Install
properly and (vety lightly) lubricate fingers at relea<;c bear.
mg.
Driven plate hub binding on main drive gear clutch shaft
splines. Remedy - Repair or replace main drive gear and/or
dri ve plate assemblies.
Driven plate wruped or bent. Remedy - Replace dri ven
plate.
Problem: Slipping!
* Improper cable adjustment. Remedy - adjust cable.
Improper dri ver operation. Remedy - Observe correct
operauon.
* Oil soaked driven plate.
Remedy - Install new plate and
correct leak at its source.

Worn facing or facing tom from driven plate. Remedyreplace plate.
Warped pressure plate or flywheel. Remedy - Replace
pressure plate or fl ywhccl.
Weak diaphragm spring. Remedy -Replace pressure plate.
Driven plate not scated in. Remedy - Make 30 -40 normal
starts. (Caution: Do /lot overheat!)
* Driven plate overheated. Remedy - Allow to cool and
recheck.
Problem: Grabbing(chattering)!
Oil on facing; burned or glazed facings. Remedy - Install
new driven plate and correct leak at its source.
* Worn splines on main drive gear clutch shaft splines.
Remcdy - Replace main drive gear assembly.
Loose engine mountings. Remedy - Tighten or replace
mountings.
Warped pressure plate or nywheel. Remedy - Replace
pressure plate or nywheel .
Burned or smeared resin on flywheel or pressure plate.
Remedy - Sand off if superficial. Replace burned or heataffected part,.
Problem: Rattling - transmission click!
Release fork loose. Remedy - Install properly.
Oil in driven plate damper. Remedy - Replacedriven plate
and correct leak.
Driven plate damper spri ng failure. Remedy - Replace
driven plate.
Problem: Noisy!
Worn throw-out bearing. Remedy - Replace bearing.
Fork shaft improperly installed. Remedy - Install properly
and lubricate fork fingers at bearing.
Problem: Pedal stays on floor!
Binding throw-out bearing. Remedy - Lubricate and free

up bearing.
High friction in cable. Remedy - Replace cable.
Spring wear in pressure plate. Remedy - Replace pressure
plate.
Problem: Hard pedal effon!
Bind in pedal. Remedy-Lubricate bushes and free up.
Driven plate worn. Remedy - Replace driven plate.
Cable friction high. Remedy - Rcplace cable.
SPECIFICATIONS
CLUTCH ........................................... (6 CYL.)
Type ........................................ Single Plate - Diaphragm

Actuation ............................................. ................. Cable
Disc Facings: Outer Diameter ............................. 254mm
Free Play at Pedal (Downwards) ................................ Nil
Pedal Stroke .............. ............................... l40+/-3.0 mm
CLUTCH ........................................... (8 CYL.)
Type ........................................ Single Plate - Diaphmgm

Acruation .............................................................. Cable
Disc Facings: Outer Diameter ............................ 268 mm
Free Play at Pedal (Downwards) ............... .. ............... Nil
Pedal Stroke ............................................. 140+/-3.0mm
LU BRICATION .................. _..... __ ..... _.. (6 CYL.)

SUp Yoke Splines .............................. Transmission Fluid
LU BRICATION ... ___ .... ___ ... ___ .... ___ .... __ .. (8 CYL.)

Slip Yoke Splines .............................. Transmission Auid
TORQUE
SPECIFICATIONS
CLUTCH AND DRIVELINE 6 Cycllnder ... Nm
Flywheel housing to cylinder block bolts ...................... 55

Clutch pressure plate retaining bolts ............................ 27
Univcrsal joint to pinion flange bolts .................. .......... 75
Release leverpivot shoulder bolt ................... ....... .. ........ 8
CLUTCH AND DRIVELINE V8 Cycllnder Nm
Fl ywhcel housing to cylinder block bolt' ...................... 65

Clutch pressure plate retaining bolts ................. .... ....... 20
Universal joint to pinion nange bolts ................. ........... 75
Release lever pi vot shoulder bolt ...................... .............. 8
134
BTR 93/97LE AUTOMATIC

TRANSMISSIONS
Subject
Page
Subject
MAINTENANCE AND ADJUSTMENT ..... 136
Lubrication.............................................................. 136
Fluid I...evel ..............................................................
Changing Auid .... ............. .......................................
Lubricant .. .. ...... .................. ................... ................ .
. Str'dlner
. ...... ..... ............... ...........................
MruntaJn
Maintenance Notes ................................................. .
Oil Cooler Pipes ........... .......................................... .
Clean and Inspect ................................................... .
Console Shift Lever Assembly ............................
Removal ..................................................................
136
136
137
137
137
137
138
138
138
138
138
138
138
138
138
139
139
139
140
140
140
140
141
141
J4J
141
141
Installation . ... ........... ............. ................... ...............

BandAdjustJnent ..................................................
Front Band .............. ........... ....................... ..............
Rear Band ........... ........... ............... ..........................
Oil Pan/Sump & Valve Body Assembly ............
ReITlOval ....... .... ........ ...............................................
Valve Body Dismantle .............. ... ..................... .......
Valve Body Assembly.... ............. ........... ........ ..........
Installation ......... ,....... .............. ...............................
SERVO VALVF~ .................................................
Front Servo Remove ............. ,.......... .. .. .... ................
Front Servo Installation ........................... ............... ..
Rear Servo Remove .......... ,......................................
Rear Servo Installation .............................................
COOLER Replacement .........................................
SELECTOR LINKAGE Adjustment ...................
Speed Sender Unit and l'itting Assembly ...............
Remove ............. ... .. .. ... .. .. .. .. .. ... .. .. .. .. .. .. .. ... .. .. .. .. .. .. ..
lnsta11 ...................................................................... 141
Page
Installation ..............................................................
TrnnsmissionAsscmbly ..........................................
Dismantle ............................. .................. ......... ........
Transmission Case ... ....... ... ...... .................. ....... .......
Forward Clutch Cylinder .................... ......... ...... .... ...
C3 Clutch CyJinder .................................... ..... .. ..... ..
Planet Carrier & Centre Support ..... ......... ....... ..... ....
Pump ......................................................................
Assemble .................................................................
Rear Band Assembl y.... ......... ........... ....... ....... .........
Output Shaft and Ring Gear Assembl y .....................
Rear Servo Assembly ...............................................
Planet Gear Carrier & Centre Support ...... ....... .........
Extension Housing ................................ ....... ............
Front Servo Assembly..... ....... ........... ......... .. ....... .... .
Front Band Assembly................... ........... .......... ......
C2/C4Clutch Assembl y ....................... ......... ....... ...
C3 Clutch. Reverse & Forward Sun Gear .................
Forward Sun Gear & C3 Clutch Pack ........... ...........
C J Cl utch Ovendri ve & Input Shaft ..........................
Pump Cover & Converter Support ...... .....................
Valve Body. Oil Filter & Pan .. .................................
142
142
142
143
144
144
146
146
146
J47
147
J48
148
J49
149
149
150
15 J
152
152
J53
155
PROBLEM SOT"VlNG AND DIAGNOSIS .......

Oil Pressure Check ............... . ........... ......... ..... .........
Hydraulic Diagnosis ..................... ........ .......... .........
Road Test ............................................... .................
Torque Convertor Clutch Diagnosis ............ ....... .......
TorqueConverter Evaluation .......... .........................
155
155
156
156
J57
157
SPEClFlCATIONS ............................................... 157

MAJOR REPAIR .................................................. 141
TORQUE WRENCH SPEClFICA TIONS .......... 159
Removeand Install Transmission .......................... 141

Remove .. ... .................. .. ... .. .. .. .. ... . ... .. .. .. .. ... .. .. .. .. .. .. . J4 J
135
BTR 93/97LE AUTOMA TIC TRANSMISSIONS
AUTOMATIC
TRANSMISSIONS
dipstiCk is properly seated. Maintaining transmission to

correct level with recommended fluid is essential for correct
operation of unit.
Transmission Fluid Level Dip Stick
The illustration on this page shows the Falcon 93197LE

automatic transmissions.
A metal identification plate is anached to the transmission.

The model code for vehicles equipped with differenttnms
rruSSlOns are:
Type
Code
Ford
BTR
The transmission should not be overfilled, otherwise the

transmission fluid will cause undue transmission-fluid high
pressure, this could result in fluid leakages, foaming and
difficulty in gear changes.
I. Raise vehicle and place a large drain tray under transmission oil pan.
2. Remove transmissions drain plug and allow fluid to drain,
refer below.
3. Remove oil pan retaining bolts and tap pan at one comer
to break it loose, allow fluid to drain and then remove pan.
Oil Pan Retaining Botts
Oil
6 Cylinder
8Cylinder
93LE
97LE
MAINTENANCE AND
ADJUSTMENT
LUBRICATION
Ifadding or changing the transmission fluid, use only speci-
fied Automatic Transmission fluid TQ95 (Castrol).

FLUID LEVEL
Thedipstick is located in the right section of enginecompanment. To check level, follow this procedure:
Apply parking bmkeand with engine idling and transmission
at normal operating temperature, engage each gear briefly,
ending with selector in "N" neutral.
*The transmission must be at normal operating temperature
to obtai n an accurate dipstick reading.
The transmission should not be overfilled, otherwise the
transmission fluid will cause undue transmission-fluid high
pressure, this could result in fluid leakages, foaming and
difficulty in gear changes.
Withdraw dipstick and wipe clean with a lint free cloth.
Install dipstick into transmission, withdraw and check level.
The level must be within "hot" range on dipstick, refer below.
NOTE: Avoid entry ofdirt into transmission by ensuring that
4. Clean transmission ca.e gasket surface and oil pan.

S.lnstall oil pan with a new gasket, tighten bolts to specified
torque.
Oil pan bolt torque specification:
4.5 Nm
6. Firstly pour sufficient automatic transmission fluidTQ95
to bring fluid level to lower mark on dipstick. Add automatic
transmission fluid into transmission through dipstick hole.
7. Start engine and allow to idle for at least two minutes. With
park brake on, move selector lever momentarily to each
position ending in "N" neutral position.
S. Add sufficient automatic transmission fluid to bring fluid
level to lower mark on dipstick. Re-check fluid level after
transmission has reached operating tempemture. The fluid
level should be between upper and lower marks of "HOT"
range on dipstick. Insert the dipstick fully to prevent dirt entry
IntotransmlSSlon.
136
BTR 93197LE AUTOMA TIC TRANSMISSIONS
LUBRICANT
10.0 titres including converter
MAINTENANCE NOTES
TQ95 (castrol).
While maintaining the transmission, all parts should be

cleaned and inspected. Individual units should be reassembled before disassembly of other units to avoid confusion and
interchanging of parts.
I. Thoroughly clean the exterior before disassembly of the
unit.
2. Disassembly and assembly must be made on a clean work
bench. Cleanliness is of the utmost importance. The bench,
tools, and parts must be kept clean at all times.
MAINTAIN STRAINER
Take care when removing sump from transmission as hot

oil can cause serious bums. Avoid this by allowing transmission to cool down.
I. Raise vehicle and support on safety stands.
2. Clean all dirt from around oil pan and transmission case,
place drain tray under transmission.
3.Holdoil pan in place, leaving one bolt loose at the front of
the oil pan, remove therernaining bolts. Allowtherearofthc
oil pan to drop, emptying oil into drain tray.
4. Remove remaining bolt and oil pan and empty fluid from
Clean Transmission
pan.
/
3. Before installing screws into aluminium parts, dip screws
into transmission fluid prevent galling aluminium threadsand
to prevent screws from seizing.
4. To prevent thread stripping, always use a torque wrench
when installingscrews.
S.lf threads in aluminium parts are strippedordanJaged the
part can be made serviceable by the use of suitable thread
S.lf necessary, remove strainer, by relea.ing retaining clip,

also remove '0' -ring and discard.
inserts.
6. Protective tools must be used when assembling seals to

prevent damage. The stightest flaw in the sealing surface of
the seal can cause an oil leak.
7. Aluminium ca'tings and valve are very susceptible to
nicks, burns, burrs, etc., and should be handled with care.
S.lnternal snap rings should be expanded and external snap
rings compressed if they are to be re-used. This will ensure
proper seating when reinstalled.
9. "0" rings, gaskets and oi Iseals that areremoved should not
bere-used.
10. During assembly of each unit, all internal moving parts
must be lubricated with transmission fluid.
Filter Retainer
6. If necessary install new strainer and '0' ring.

7. Clean oil pan and case mating surfaces. Check that
magnets arefunctional and located in the designated position
in the oil pan.
8. Install new seal and reinstall oil pan. Tighten bolts to
specified torque.
Oil pan bolt torque specification:
1.5 Nm
9. Lower vehicle and add automatic transmission fluid.
Check transmission nuid level.
OIL COOLER PIPES
If replacement of transmission steel tubing cooler pipes is

required, only use double wrapped and brazed steel tubing
meeting transmission manufactures specifications orequivalent. Underno condition usecopperor aluminium tubing to
replace steel tubing. These materials do not have satisfactory
fatigue durability to withstand normal car vibrations.
Steel tubing should be flared using the double flare method.
137

rran$u .... kwt Cooler
Line Fittings
BAND ADJUSTMENT
Front Band
1. Loosen the lock nut on the band adjusting bolt.
2. Tighten band adjusting bolt to initial specification.
Front Band AdjustingScrew:
10 Nm
3. Unscrew the band adjusting bolt exactly three (3) turns.
4. Usc a spanner to grip adjusting bolt in place and tighten
lock nut to specification.
Front Band Adjusting Screw Lock Nut:
40 Nm
Rear Band
I. Loosen the lock nut on the band adjusting bolt.
2. Tighten band adjusting bolt to initial specitication.
Rear Band Adjusting Screw:
15 Nm
After complete disassembly of a unit, wash all metal parts in

a clean solvent and dry with compressed air. Blow oil
passages out and check to make sure they are not obstructed.
Small passages should be checked with tag wire. All parts
should be inspected to determine which parts are to be
replaced.
Pay particular attention to the following:
1. Inspect linkage and pivot points for excessive wear.
2. Bearing and thrust surfaces of all parts should be checked
for excessive wear and scoring.
3. Check for broken score seal rings, damaged ring lands and
damaged threads.
4. Inspect seal and '0' rings.
5. Mating surfaces of castings should be checked for burrs.
Irregularities may be removed by lapping the surface with
emery paper. The emery paper is laid on a flat surface, such
as a piece of plate glass.
6. Castings should be checked for cracks and sand holes.
* Do not usc solvents on neoprene seals, composition faced
clutch plates orthrust washers a,damage to parts may occur.
CONSOLE SHIFT LEVER ASSEMBLY
Removal
1. Removecentreconsole from vehicleasdescribed in body
chapter.
2. Raise vehicle. From beneath vehicle, disconnect rod from
shift lever by removing nut securing trunnion to lever.
3. Disconnect park/neutral/reverse switch electrical connec
tor.
4. Lower vehicle, then remove screws securing selectorshi ft
lever assembly to floor pan and remove assembly.
lnstaJJation
I. Clean mating surfaces of floor pan and shift lever assembly.
2. Apply a bead of sealer around opening in floor pan between
serew holes.
3. Install selector lever assembly using retaining screws.
4. The remainder of the installation is the reverse of the
removal procedure.
S. Adjust linkage
Band
Nut
3. Unscrew the band adjusting bolt exactly one (1) tum.

4. Use a spanner to grip adjusting bolt in place and tighten
lock nut to specification.
Front Band Adjusting Screw Lock Nut:
40 Nm
OIL PAN I SUMP & VALVE BODY
ASSEMBLY
Remove
J. Place vehicle on safety stands.
2. Place an oil collection tray underneath the transmission.
3. Remove the oil pan I sump and seal.
4. Remove the filter, then disconnect the solenoid wires from
each solenoid.
Winng Loom
5. The manual valve link lever must be removed from the

manual valve link.
6. Remove the valve body assembly by pullingdownevenJy.
138
Valve Body Dismantle

Valve body problems are usually caused by theelecb'ical
solenoids more than the valves them selves.
I. Remove the retainer plate for the detent spring and also
remove the spring, then pull out the manual valve.
2.Make note ofthe angle the solenoid terminals make with the
valve
forassembly .
3. Remove the S I, S2 and S3 solenoids also remove the No.

3solenoid sleeve.
4. Remove the CAR valve but do not remove the sleeve.
5.Remove theS4solenoid, sleeve and BAR valve, but do not
remove the BAR valve sleeve.
6. Remove the S5 solenoid, S6 solenoid and assembly,
(damper valve. supply valve and the spring).
7. Remove the 25 retaining screws, then lift the uppervalve
body and separator plate froll1 the lower valve body as an
assembly.
8. Lay the upper valve body on the bench then remuve the
separator plate and gaskets.
9.Fivenyloncheck balls will be exposed, remove these from
the upper valve body, then remove the two filters from the
lower valve body. Plus a large nylon check ball.
10.Tum the val ve body overso the keeper plates securing the
1-2,2-3 and 3-4 shift valves fall ou~ then remove shift valves.
11.Remove the4-3 sequence valve keeper by depressing the
4-3 sequence valve, then remove the valve plug, valve and
spnng.
12.Remove the keeper pin forthedamperval ve, then remove
the valve, and spring.
13.Remove the keeper pin forthe line pressure release val ve.
then remove a disc if one is fitted plus, spring and valve.
14. Adjacent to the BAR valve drive out the roll pin, then
remove spring plus ball check valve.
15. Adjacentlo the 3-4 shift valve drive out the roll pin, then
remove the spring and ball check valve.
Valve Body Assembly
I.Clean the upper and lower val ve bodies and all eumponents
then dry with compressed air.
2. Inspect valve body ports, holes and cavities for imperfections and wear.
3.lnstall the locating pin for the detent lever.

4. To the valve body install theS5 damperspring, piston and
the retaining pin, then install the 1-2 shift valve, plug and the
retaining plate.
5. To the valve body install the 3-4 shift valve and secure with
retaining plate, then install the 2-3 shift valve and retaining
plate.
6. To the valve body install the 4-3 sequence valve, spring,
plug and secure with retaining plate.
7. To the valve body install the nylon ball, then install the two
filters for S5 and S6 solenoids.
S. To the lowervalve body install the lower valve body g.~ket,
then install the five nylon check balls in the upper valve body
in same locat.ions as removed.
9. To the upper valve body install the gasket and the separator
plate.
10. Carefully install the upper valve body assembly to the
lower valve body assembly, install retaining screws and
tighten to specification in order shown.
Valve body upper to lower retaining screws: 15 Nm
11. To valve body assembly install the band apply regulator
valve, inner spring, valve, outer spring, plunger and the
solenoid sleeves, then install the S4 solenoid and tighten
retainer screw to specification .
S4solenoid retainer screw:
15 Nm
12.Tu valve body .,scmbly install the cI uteh apply regulator
valve and associated components. (innerspring, valve, outer
spring, plunger and the solenoid sleeve) then install the S3

solenoid and tighten rctainer~crew to specification.
S 3 solenoid retainer screw:

15 Nm
13. To valve body install the solenoid supply valve and
spring, then install the No. 6dampersleeveandeomponents.
(spring, plunger, retaining pin and the locating pin) then
install the S 6 solenoid.
14. To the valve body install the S2solenoid (2-3 shift valve
solenoid), then install the S I solenoid (3-4 shift valve solenoid).
IS. Install the S5 solenoid and earth wire into position and
secure with retaining screw, tighten to specification.
S5 solenoid retainer screw:
IS Nm
16. On the side of the valve body adjacent to the 3-4 shift
valve, install the line 70 ball and spring, plus retaining pin.
17. Next to the BAR valve, install the manual feed ball and
spring assembly plus retaining pin.
18. The line pressure valve, spring. disc and retaining pin is
to be installed nexl.
19. Install the manual shift valve, then install the detent
spring, support plate and screw, tighten to specification.
Detent spring assembly retaining screw: 20 Nm
Install
1. Lift valve body into position, install retaining screws and
tighten in order as shown on previous page to specification.
Valve body retaining screws:
10 Nm
139
2. Connect the manual valve lever link to the manual valve,

then check thedetent roller is aligned.
Manual
_Valve
3 .Reconnect electrical conneclions to solenoids.

4. Tnstall the n Iter into position ensuring to fIrStly lubricate the
'0' ring, then install the retaining clip.
5. Rent oil pan I sump and a new gasket.
6, Tighten the sump boIlS to spccincation.
Torque Transmission Oil Sump
4,5 Nm
7. Fill tmnsmission with fluid.
S. Remove from safety stands and road test vehicle.
SERVO VALVES
Front Servo
Remove
1, Remove the circlip retaining servo cover.
2. Force out the servo piston by screwing in the b,md adjuster.
In,taI1
l.Beforeinstallation inspect piston and '0' rings, ifdamagcd
or warn replace.
2. Install the servo piston ensuring to lubricate the '0' rings
with transmission fluid. Ensure the strut is engages with
piston rod.
3, Apply pressure to piston while loosening band adjuster,
then install cover and retaining circlip.
4. Adjust the bands as previously described.
5. Fill transmission with fluid .
Rear Servo
Remove
1. Place vehicle on safety stands.
2. Place an oil collection tray underneath the transmission.
3, Remove the oil pan I sump, seal and nItcr.
4. Remove the bolts securing the servo cover to the transmis
sion. then remove the servo ac;;scmbly.
Rear Servo
Housing
Servo Retaining Circlip
Servo
. / Front Servo
5. Separate the piston from the housing. Remove the gasket

and '0' rings, replace with new ones on assembly.
3.Rcmove servo piston and do not slacken off band adjuster
until servo piston is back in transmission during installation.
Rear Servo
Asaembty
Compressed Air Blower
Rear
140
Piston
SPEED SENDER UNIT AND FITTING

ASSEMBLY
I.Lubricateall '0' rings, then install assembly intotransmisstoncase.

2. Install and tighten cover retaining bolts to specification.
Servo Cover retaining bolts:
20 Nm.
3. The band struts must be positioned.
4.Jnstall filter, sump gasket and sump, then check the band
adjllStment
5. Refill with transmission fluid and inspect fluid levels.
Transmission
Assembly
COOLER REPLACEMENT
Thecooler is located inside the radiator, if the cooler is to be

replaced the radiator must also be replaced. See cooling
system for radiator replacement.
There is an optional transmission cooler that is mounted in
front of the radiator for models that do not have an airconditioner fitted.
SELECTOR LINKAGE ADJUSTMENT
1. Loosen clamp nut at the sloned rod.

2. Position transmission selector lever in ' D'.
3. Position gear shift lever in 'D' ,then install the6mm serting
in into the boss on the case passing through the hole in the
lever.
4.Holdtheselectoragainst its stop in '0', then tighten clamp
nut.
5. Lower vehicle and test.
6. Ensure that engine can be started only in 'PARK' and
'Neutral'. The Park INeutrallBackup switch is
automatically adjusted when linkage is correctly adjusted. It
can also be tested for correct operation using a ohm meter.
LE85079
Remove
I.Raise rear of vehicle and placeon safety stands. Place drip
tray beneath speed sender.
2. Disconnect sender unit electrical connector.
3. Remove vehicle speed sender unit by unscrewing.
4. Unscrew bolt securing fitting assembly retainer to
extension and remove retainer. Withdraw firting assembly
including driven gear from case extension.
Inslall
1. Inspect tirting assembly '0 ' ring seal and replace it if
unsatisfactory .
2. Installation is the reverse of the removal procedure.
3. Tighten retainer bolt to specified torque.
Relainer bolt torque specification:
8 Nm
* The vehicle speed unit is tightened by hand only.
MAJOR REPAIR
REMOVE & INSTALL TRANSMISSION
Remove
1. Disconnecttheearth cable from the banery, disconnect the
air clcaner on EFI only.
2. Place vehicle on safety stands.
3. Place drip tray beneath rear of transmission.
4. Remove the tail shaft and install a plug or seal into the
extension housing to stop oil from leaking out.
5. At park brake joiner separate the brake.
6. Remove the engine brace bolts from the cylinder block and
converter housing, and remove brace.
7. (95LE only) Remove the con venercover at the lower side

of the converter housing and remove the cover.
8. Disconnect the speedo transducer, inhibitor switch and

solenoid wiring connectors.
9. At the exhaust manifold disconnect the catalytic convener, and disconnect catalytic convener from muffler inlet
pipe and remove.
141
Converter housing to engine bolts:

60 Nm
Converter housing to engine brace bolts:
40 Nm
4. Fit the flywhecltoconverter bolts and torque to specifica
lion .
Flywheel to Converter bolts:

60 Nm
5. Fit the converter housing cover and torque to specification,
ensuring to install the earth cable.
Converter hOIL~ing cover bolts:
15 Nm
6. Install the starter motor and torque bolts to specification.
Stator Motor bolts:
16-20 Nm
7. Fit the fillertubc and tighten the retaining bolt, then loosely
install the cooler lines.
8. Raise rear of transmission, then install the crossmember
and rear mounting, torque mounting bolts to specification.
Crossmember attaching bolts:
45 Nm
45 Nm
Mounting boll~ to crossmember:
Mounting bolts to Transmission:
45 Nm
Mounting bolts to Transmission Late Models Vertical
Plate:
18 Nm
9. Remove the mobile jack.
10. Connect the speedometer transducer, inhibitorswitch and
solenoid wiring.
11. Connect the control lever, then install the catalytic
converter.
10. Remove the extension housing to crossmember boilS.

11. Remove the filler tube and oil cooler tubes.
12. Disconnect the tnmsmission control lever from transmission cross shafl.
13. Remove the starter motor.
14. Remove the bolts attaching the con verter to the flywheel.
15. Place ajack underneath the transmission and secure the
transmission to the jack if possible.
16. Remove the crossmember to body bolts, then lower the
cross member and remove.
17. Remove the bolts attaching the converter housing to the
engme.
18. Lower and move back the transmission and converter
a.sembly ,md remove from the car with care, holding the
12. Install the parking brake cable and adjusl.

13. Install the tail shaft, torque bolts to specification.
Tail shaft bolts (universaljointlpinion flange): 9-14 Nm
14. Adjust gear selector linkages.
15. Remove vehicle from safety stands.
16. Fill transmission with correct amount of specified automatic transmission fluid.
Fordspceificationfluid:
TQ95 (castrol)
Capacity including converter:
10 Iitres
17. Install aircleaneron EFI vehicles and reconnect the earth
cable to the battery.
18. Road test vehicle.
TRANSMISSION ASSEMBLY.
Dismantle
1. Remove the converter housing from transmission then

install transmission in a transmission cradle on a clean work
bench.
Clean Transmission Ready Dismantle
converter.
Install
1. Install the converter to the transmission.
2. Place the transmission on a mobile jack and secure the
transmission.
3. Move the transmission under the car, lift and slide forward
the transmission up to the rear of the engine. Install the bolts
attaching the converter housing to the engine, torque to
specification.
Bench
142
BTR 93/97LE AUTOMATIC TRANSMISSIONS
2. Remove the oil pan I sump and gasket.

3. Remove the filter retainer and filter, then disconnect the
solenoid wires from each solenoid.
4. Remove the manual valve lever to link. then remove the
screws securing the valve body.
5. Remove the val ve body assembly by pulling down evenly.
6. Remove the circlip, retaining servo cover.
7.Remove servo piston by forcing out by screwing in the band
FOfWard Clutch
Assembty
adjuster, then remove servo piston.
S.Remove the boILS securing the rear extension and remove

rearextenslon.
Le85017
case
cylinder, sun gears, front band struts and the front band.
Sun Gear &
C3 Assembly
Extension Housing
9. Remove speedo drive gear by pushing in the retaining clip

and sliding speedo drive gear from shaft.
10.Remove the '0' ring from the input shaft and remove the
oil pump retaining bolts.
II. Using a puller and adaptors remove the pump from the
transmission case.
14.Remove the two boILS securing thecentre support a.sembly then remove Ule circlip for the centre support.
IS. From the transmission case remove a~ an a~sembly the
ccntrcsupport, 1-20newayclutch, planetary gears including
the output shaft.
Transmission Fluid Pump

Tool
'\ lransmlss.," Case
Transmision Fluid Pump Assembly
Output Shaft
12. From the front of the case, as an assembly remove the

input shaft, forward clutch cylinder and overdrive shaft.
Support
16.Remove the boltsecuring the parking rod cam plate, then

remove the cam plate.
17. From the transmission case remove the rear band struts
and rear band.

Transmission Case
1. From the transmission case remove the inhabiter switch,
and using the tool E 1540 remove the cross shaft seals.
143
adjustment shims, then at the front of the clutch cylinder

remove the circlip and remove the input shaft.
Clutch Cylinder
---
Clutch Pack
Inhibator
.. _ _....;
Switch -
Transmission Case
2. From the cross shaft remove thecirclips, release the drive

pin from selector quadrant by pulling the shaft.
3. Press the pin from thecross-shaftusingspecial tool E 1539,
then slide the cross shaft from the transmission case.
4. Remove the park rod and manual valve lever, then
disconnect (press in side lugs) the wiring loom plug from the
case.
S. From the front of the transmission case disconnect the No.
7 solenoid wire, then retainer for the wiring connector.
connector and loom.
Input Shaft
2 Remove the overdrive shaft and the C I clutch hub

assembly, as shown.
Clutch Cylinder
Assem~
Wiring loom Connector

C1
Assembly
& Overdrive Shaft
3.From theclutchcylinderremove theC I clutch plates, then

remove the C3 clutch hub circlip and remove clutch hub.
4. From clutch cylinder remove the C2IC4 clutch hub
components, then from the C4 hub remove the thrust bearing.
S. Remove the clutch plates for the C2 clutch.
6.From theopposileend of the clutch cylinder remove theC4
clutch sleeve, clutch plates and the two wave washers.
6. From the case remove the parking pawl pivot, pawl and
spnng.
7. From the case remove the rear servo lever and shaft, then
remove the rear servo cover and piston assembly.
8. Remove the release exhaust val ve for the front servo, then
remove both band adjusters.
9. It is not necessary to remove the park rod lever from the
transmission case unless it is being replaced.
Removal of park rod lever.
a) Remove the circlip from the inner most end of the shaft
then gently at the outer end of the shaft tap to release from
C4 Sleeve
Clutch Plates
Clutch Cylinder
Assembly
case.
b) Gently punch the pin from the inside of the case, then
remove the lever and spring from transmission case.
IO.Inspect the output shaft bushing in case, the cooler line
fittings and the case for water and damage. Any component
damage replace before assembly.
Forward Clutch Cylinder
l From the input shaft remove the thrust bearing and
144

C2 & C4 Hub
Clutch Cylinder
Assembly
Forward Sun Gear
Clutch Pack - -
7. Separate the C2 & C4 clutch hubs by rotating one hub

clockwise and withdrawing, then remove the 3-4 one way
clutch.
Le85029
2 Hub
Clutch 4 Hub
2. Then remove the thrust bearing assemblies, nylon thrust

bearing and support, needle thrust bearing and block.
3.Installlheclutchcylindertothetool E1543, then compress
the piston return spring and remove the circlip, keeper and
spnng.
4.Remove the '0' ring forthereversesun gear, then remove
thecirlip securi ng the clutch plates and remove clutch plates.
S. Apply compressed air to the apply port on the bearing
journals between the iron sealing rings of the cylinder and
remove the pistons.
One Way Clutch
8. From the C4 clutch hub remove the thrust block, then

installtheclutchcylinderon thcspecial tool E 1543 ensuring
the C2IC4 cnd facing up.
9. Compress the piston return spring, then remove the
retaining circlip and remove thecirclip, keeper and the spri ng.
C3 Clutch
Pack
--
C3
Cylinder '---...,
Compressed Air
Nozzle
10. Tum the cylinder assembly up the opposite way on the

special tool,andremove theC I clutch piston return spring by
compressing the C I piston return spring, then remove the
retaining circlip and remove thecirclip, keeper and the spring.
II. Apply compressed air to the apply ports of the cylinder
and remove the pistons.
C3 Clutch Cylinder
1. Slide the forward sun gear and thrust bearing away from
theassembly.
----
Apply Port
C3 Clutch
145
remove the cover plate.

3. From the pump coverremove the two ball check val ves and
the spring.
4. From the cover remove the retaining pins securing the 4
valves, then remove the 4 sealing plugs and valves.
5.From theouteredgeofthe pump cover remove the '0' ring
seal, then remove the inner and ouler gears from the pump
body.
6. Remove the rear (reverse) sun gear.

Rear Sun
Gear
C3 Clutch
Outer Pump
Gear ........,
Planet Carrier & Centre Support

I. From the output shaft slide the planet carrier and centre
suppon, then from the output shaft and planet carrier remove
the thrust bearings.
2.Rotate the centre suppon anti-clockwise to release it from
the planet carrier, then remove the one way clutch from the
planet carrier.
Planet Carner
Assembly - - -
One Way Clutch - - - - -
Centre . / . /
Support
Le85032
3.From the planet carrier remove the circl ip retai ning the one
way clutch outer race and remove the mce.
4.From the planet carrier remove the one way clutch retainer.
Pump
Transmission Pump
Assembly _ _
Pump
Housing
Inner Pump
Gear
L085034
6. From the pump body remove the '0' ring seal, and the lip
seal from the front of the body.
Assemble
I. To the transmission case install all the plugs, fittings and
breather, then in any sections requiring sealant apply, sealant.
Inspect that any ori fices including breather and lube fining in
rear of case are clean and not blocked.
2.lnstall the BIR valve and spring to the transmission case,
then secure in position with circiip.
3. To the transmission case install the rear servo lever and
pivot pin.
4. Install the park rod lever, spring and pivot pin into the
transmission case, ensuring the lever pivots freely and the
spring fully returns the lever.
5. To the transmission case install the parking pawl, spring
and pivot pin.
6, To the park lever install the park rod and ensure that the
cam collar moves on the rod without catching.
7. From the linkage side of the case stan to install the cross
shaft, installing the inhibitorswitch end first, then install the
anti mttle spring to the shaft.
8.lnstall the manual valvedetentlever,ensuring italigns with
Support
Retaining Bolts
Ball Check
Valve & Spring
....__ Transmission
Case
Ban Check _ - Valve
Support
Front Of
1. Remove the wiring loom, and the No.7 solenoid.

2. From the cover plate remove the 5 bolts and 5 screws and
Case
146
!he cross shaft bore in !he case, then push the shaft through
the detent lever until it starts in the opposite side of the case,
9. Using the special tool E 1539 install the detent lever dri ve
pin in the shaft, until the tool bottoms.
10, Install the spring retaining circlip and the end float circlip
to the shaft, then using tool E 1541 install thecross shaft seals.
Screw Driver
3. To the band install the reaction strut. them install the

adjuster screw engaging the strut and on the end of the
adjuster install the HC" clip.
--
IUnstall the inhibitor switch, then inspcctthc wiring loom

for damage then install into case, the S7 solenoid wire is
installed behind the park rod and cross shaft, then the S7
solenoid terminal is located in the pump mounting t1ange at
!hefront.
4. Slacken off the band adjustrnentthen install the cam plate

and tighten screws to specification.
Cam Plate Retaining Screws:
20 Nm
le85037
12, Install to the case the ten pin connector, then install the
spring retainer, then connect the intemalloom to theconnector.
Rear Band Assembly
1. Inspect the band for any cracks or deterioration and if
damaged replace band, if using a new band insure to soak in
transmission fluid for six minutes before assembly.
2, To the transmission case install the rear band, then install
the apply strut to the rear band and servo lever.
Output Shaft and Ring Gear Assembly

t. Tfthe output shaft bush is damaged replace the bush, also
inspect the ring gear, if damaged replace the ring gear.
2. Inspect the sealing ring grooves for damage, if so, use a
small filetoremoveany burrs. Apply transmission fiuidtothe
sealing ring.
3 .Install sealing ring (have the diagonal cut at the top, this will
help keep the seal in position) to the output shaft, then install
the ring gear to the output shaft and secure with circlip.
Centre
Output Shaft
Assembly
Ring Gear
Assembly
147
4. To the output shaft install the No. 10 thrust bearing

assembly.
5. Carefully install the output shaft assembly into the transmission case, then lubricate the bush and install the speedo
drive gear.
Rear Servo
Assembly
Gear
Rear
Retaining Botts
5. Install the wiring loom upwards and retain with clip.

Output Shaft
Rear Servo Assembly

# Inspect the piston '0' rings and gasket for damage, it is good
policy to use new "0" rings and gasket
1. Fit the three '0' rings and gasket to cover.
2.Apply transmission fluid to lubricate the servo piston '0'
rings, then install the '0' rings to the piston and install the
piston to the cover, ensuring the '0' ring is not damaged
Planet Gear Assembly Carrier and Centre Support

1. Inspect the carrier and planet gear assembly for damage,
replace or repair if necessary, also check pinions turn with
ease and that the free play is to specification 0.1 - 0.5 mm.
Planet Carrier
Assembty
duringcomprcssion.
3. To the piston spigot fit and align the spring, then install the
servo rod in the spigot and install assembly to transmission
case.
Rear Servo
Housing
Feeler Gauges
2. With the inneredge facing down install the one way clutch
retainer to the carrier, the one way clutch race and spmg
assembly must be in excellent condition.
3. Inside the drum install the outer race. then secure with
retainingcirclip.
4. Install and tighten retaining bolts to specification. (use

loctite 567 or equivalent on bolts)
Rear Servo Cover retaining boll"
4. With the lip edge facing upwards install theonc way clutch
into the outer race, apply transmission fluid to lubricate the
sprags.
5. Ensure dIe plugs are properly installed to the centre
support, then install the centre support into the one way
clutch, rotation mustbeantic1ockwiseonly.
20Nm
148
take care not to damage the '0' ring.

S.Compress the servo cover and install the retaining circlip.
Centre
Support
Transmission - - Case
6. Install into the rear of the canier the No.9 needle thrust
bearing, use petroleum jelly to position and lubricate.
7. To the transmission case install the planet carrier and
centre support assembly aligning the bolt holes for the centre
support, then loosely install thecentresupport retaining bolts.
S.lnstall the retaining circlip, then remove retaining bolts,
coat with loctite 222 and reinstall to centre support. Tighten
tospeci lication.
Centre Support Retaining Bolts:
2S Nm
Torque
Front Band Assembly

l.lnspect the band for deterioration or datnage, if installing
a new band it needs to be soaked for 5-6 minutes in
transmission nuid.
2. Install the front band adjuster screw to the transmission
case, then position the strut retainer on the band .
3. To the transmission case install the front band assembly it
must be seated correctly and not caught on the case side.
-----,
Wrench
Transmission
Case
Centre Support
9. Adjust the rear band to specification as described in

appropriate section of chapter.
Extension Housing Assembly
I. Inspect the housing rear bushing and replace if required,
replace the rear oil seal is also a good policy.
2.lnstall a new gasket to the extension housing, then install
the rearextension and tighten retaining bolts to specification.
Rear Extension Retaining Boll.:
60 Nm
Front Servo Assembly
I.Apply transmission nuid to the cover '0' ring and piston
'0' rings, then install the '0' rings.
l (85 LE) Apply transmission fluid to sealing rings and
install to push rod.
1 To the front servo cover install the piston push rod
assembly, do not damage '0' ring.
4. To the tmnsmission case install the front servo assembly,
4. Install the reaction strutto its retaining clip, then install the
it to the band and adjuster serew.
S.lnstall the apply strut in the retaining clip, and fit the clip
with the front band and servo piston rod as shown.
6. Loosen off the band adjustment to enable the clutch

cylinder to be fitted.
149
C2IC4 Clutch Assembly
# All cylinderbore feed ducts and piston bleed ducts must be

clear and clean.
# Apply transmission fluid toall '0' rings and toboth pistons.
then install the '0' rings to the inner grooves and the larger
'0' rings to the outer grooves.
1. To the C2 piston fit the C4 piston. ensuring the bleed

orifices arealignedand that the C4 piston outer '0' ring is not
damaged.
retainingcirclip.
4. Check the C I piston check valves are operating OK.
S. Lubricate all C I '0' rings. then install the '0' rings into
position.
6. With theC I opening of the clutch cylinder facing upward.
install into the cylinder the C I piston assembly.
7. To the piston fit the piston spring and spring retainer. then
compress the spring using tool E I 543 and install the retaining
circlip.
Clutch 4
- - Piston
OrifICeS
Bleed Holes
8. To the cylinder install the C2 wave washer with the top of

the washer covering one of the C2 piston bleed ducts.
9.Measure the thickness of the flangeoftheC2 piston. write
thi s down for later use.
Clutch 2
Piston
2. With the C2IC4 opening of the clutch cylinder facing
10. Into the C2 actuating sleeve install the C4 clutch plates

and wave wa,her starting with a steel plate. ensuring the
rounder edge of the steel plates facing down.
upward. thcn install into the cylinder the C2IC4 piston

assembly until theC2 piston enters the innerdiarneter orthe
cy linder. ensuring thc blecd ducts are aligned with the holes
in the outside ofthe cylinder.
Clutch Cylinder
Assembly
Clutch Padt
C2IC4 Pistons
Front Clutch
Cylinder
11. Position the cylinder horizontally then install the clutch

plate and sleeve a,sembly to the cylinder until the sleeve
contacts theC2 wave washer. Ensure thatthetopofone wave
of the wa,her is aligned with one of the holes in the outer
surface ofthe cylinder.
12. Use special tool No. 1545 and vernier callipers to check
the C4 clutch pack clearance. pressure plate thickness plus a
clearance of IA-I.8mm. if not as specified. correct with
selective plates.
C4 Clutch Pack Clearance:
6.4 - 6.6Smm
3. To the piston fit the piston return spring and spring retainer.
then compress the spring using tool EI543 and install the
150
17. Assemble the C4 hub and the C2 clutch and OWC

assembly, then check that while looking at theC2 section of
theC4/C2 hub assembly theC2 wi II tum anti-clockwiseonly.
Vemier
-~
Calipers
Clutch 4 Hub
Assembly
Piston Spring
Compressor
Clutch 2 Hub
Assembly
Thrust
Clutch Pack
Weight ':.;;...--
Note: /fnew friction plates are required. after clearance

is checked remove friction plates alld soak in transmissioll
flilidfor six minutes. Reassemble.
13.0verthe inner hub install the thrust plate, then install the
C2clutch plates into thecylinderstarting with a friction disc.
14. Using only the weight from special tool No. 1545 check
the C2 clutch pack clearance from the friction plate surface
to the C3 hub locating step.
0.80 1.05 mm
_---Vernier
Calipers
One
Clutch
Le85057
IS.Fit the No.5 thrust bearing to theC4 hub, then remove all
the C2 clutch plates.
19.Assembly and locate theC2IC4 hub assembly in the C4
clutch plates, then reinstall the C2 clutch plates and C3 hub.
Lock these in position with circlip.
C3 Clutch, Reverse Sun Gear & Forward Sun Gear
Assemblies
1. Inspect the cylinder ducts are clean, then measure the C3
cylinder bush 0 .0 . and the J.~ . of centre support, if not
compatible, replace damaged part.
2.Apply transmission fluid to the sealing ring and install into
the sealing ring grooves of the C3 cylinder.
3. Check the all surfaces and thrust face of the reverse sun
gear, lhen using new clean transmission fluid lubricate the
Clutch Pack
Weight
'O'ring and install it the reverse sun gear seal groove.

4. To theC3 cylinder install the reverse sun gear, make sure
that the '0' ring is not damaged.
Clutch Cylinder
Assembly
Reverse Sun Gear

Assembly
Le85054
* Note: ({new friction plate.\' lire required, a/terc/earallce

is checked remove friction plates and soak in transmission
flilidfor six lIIint"es. Reassemble.

IS. Lubricate the 3-4 OWC and ule C2 OWC, install the 340WC then, install theC2 OWC and endcaps to theC2 hub.
16.TotheC4 hub install the nylon thrust washer aligning the
tangs, as shown.
151
Clutch
5. Apply new clean transmission fluid to the '0' ringsforthe

C3 piston, then install the small '0' ring to the inner groove
and larger '0' ring to the outer groove of the C3 piston.
6. Align and install the C3 piston to the cylinder until the
piston fits into the inner diameter of the cylinder.
a) Install the weight to the pressure plate and measure the

distance from lOp of the pressure plate to the end of the
cylinder. Record reading.
b) Lift pressure plate up againstthecirclip, then measure the
distance from the top of the pressure plate to the end of the
cylinder. Record reading.
c) Subtract the second reading from the first reading, this new
reading is the clutch pack clearance.
* Note:JfnewJrictionplatesare used, afterclutchclearallce

is measured removefriction plates and soak in t ransmiss;on
Clutch 3 Cylinder
Piston
fluid Jor six minutes. Reassemble.
Forward Sun Gear & C3 Clutch Pack

1. Install No.7 needle thrust bearing over the forward sun
gcar with the washer face to gear, then install the C3 clutch
assembly over the forward sun gear shaft.
Rear Sun Gear
Assembly
Le85059
7. To the piston install the spring and spring retainer, then

compressthcspring using tool E 1543 and install the retaining
circlip.
8. To the C3 piston face install the C3 wave plate ensuring one
top of the wave plate covcrs one of the piston dUClS, then
install the clutch plates and discs staning with a steel plate.
9. Fit the pressure plate ensuring it is aligned and the
counterbore surfacc is not against the clutch plates, then
install the retaining circlip.
to. Using only the weight from special tool No. 1545 check
the clutch clearance as follows:
Forward Sun Gear

Assembly
2. Over the reverse sun gear finnly install the thrust plate.
3. Install No.6 ncedle thrust bearing over reverse sun geano
the thrust plate, ensuring that the bearing lugs locate in the
thrust plate counterbore.
4. To the thrust plate fit the plastic thrust washer, then install
the assembly against the No.6 thrust beari ng over the forward
_ _ _ _ Vermer
Calipers
sun gear.
ClutchPack
Cl Clutch Overdrive Shaft & TnputShaft

t. Inspect the surfaces of the overdrive shaft, if faulty repair
or replace, also inspect the input shaft, then coat the sealing
rings with petroleumjelly.
2. Fitthe sealing rings to the overdrive shaft, then install the
clutch plates and discs into the cylinder starting with a steel
plate.
Pack
152

Clutch 1 Hub
Friction Clutch
Plate
Steel Clutch
Plate
Over Drive
Clutch Cylinder
Assembly
le85002
3.Using special tool E 1545 check the clutch pack clearance

whilesupporting 2 kg weight, measure the clearance between
the friction disc and input shaft locating step. If nOI correct
clearance is not obtained correct using selective plates.
0.70 - 0.90 mm
6. Install the bronzeC I hub thrust washer into position, then

install the input shaft into the cylinder and retain using the
eirclips.
7. Apply petroleum jelly to both front and rear sealing rings
and then outer '0' ring, then install to input shaft.
8. To the overdrive shaft install the No.8 thrust bearing and
the spigot fits into the forward sun gear.
9. To the C3 clutch and sungear assembly install theClIC2I
C4 clutch assembly, then install this complete unit into
transmission case.
Clutch 1,4 &2 Cylinder
Assembly
Vemier
Sun Gear
Assembly
Shaft
Le85065
Pump Cover & Converter Support

I.Inspeet the pump body for foreign matter or darn age, also
inspect the bush to ensure it is tirmly fixed in the drive gear,
then to the pump body install a new seal so it is flush with the
front face,
2. Using new clean transmission fluid lubricate lhe bush,
dri ve and dri ven gears, then install the dri ven and drive gears,
ensuring the side marked top is facing upward.
Pack
Pump Housing
Cylinder
Inner Pump
Gear
Assembly
Note: Ifnewfriction plates are used, after clutch clearance

is measured removefriction plates and soak in transmission
fluidfor six minutes. Reassemble.
4.lftheC I clutch hub fits loosely on the overdrive shaft, the
shaft and hub are not repairable and must be replaced.
5. To the cylinder hub install the small nylon thrust spacer
coated in petroleum jelly, then carefully without damaging
the sealing rings install the overdrive shaft into the C I
cylinder.
Outer Pump
Gear
Le85067
3. Using a straight edge and feeler gauge check the pump end
clearance, to adjust clearance if not to specification replacement of gears is required.
Pump End Clearance Specification: 0.04 - 0,018 mm
153

Pump Housing &
Streight Edge
Pump Housing
Assembty
Gear Assembly
Solinotd
-.:. No. 7
Le85066
4. Using transmission fluid lubricate the pump body '0' ring,

then install '0' ring to pump body.
S. Inspect the pump cover for damage and that no foreign
matter is in the cover, lubricate all components before
installation.
6. To the pump cover install the primary regulator valve,
ensuring that the '0' ring compression is not excessive then
secure with retaining pin.
7. To the pump cover install the converter clutch regulator
valve and plug, check that the '0' ring is not being damagcd
then secure with retaining pin.
S. To the pump cover install the converter clutch control
valve, spring and plug, check that the '0' ring is not being
damaged, then secure with retaining pin.
9. To the pump cover install the C I bias valve spring, valve
and plate, check that the '0 ' ring is not being damaged, then
secure with retaining pin.
10.Tnstall the two steel balls and spri ng, then install the gasket
to the pump cover, apply petroleum jelly to hold the ga.ket in
position.
Transmission Pump
Assembly _ _
Ball Check
Varve & SprIng
13. Using the alignment tool E 1536 install the pump cover,
then tighten the retaining bolts and crescent screw to initial
specification, make sure the pump cover is aligned. Tighten
retaining bolts and crescent screw to final specifications.
Pump Housing
Assembly
Pump Aligning
Tool
LeS5070
Pump Boll. & Crescent Screw Initial:

14Nm
l>ump to Pump Cover Bolts Final:
27 Nm
Crescent Screw Final:
19 Nm
14. Install pump gasket and pump to the transmission case,
take care not to damage the sealing rings. Tighten the
retaining bolts to specification.
Pump Assembly to Transmission Case Bolts: 30 Nm
Transmission
Case
8all Check - - Valve
I1.Tothe pump cover install thecoverplateand thesolcnoid

wiri ng retainer, then tighten rctaini ng screws to specification.
I>ump Cover Plate Remining Screws: IS Nm
12. Install the No.7 solenoid, wiring must not be able to
contact the input shaft or C I/C2 clutch cylinder.
Torque
Wrench
Pump Body
154
8TR 93/97LE AUTOMA TIC TRANSMISSIONS
15. Cheek the transmission end float by:

a) Install a dial indicator to the transmission case with the
needle resting on the input shaft.
b) Push down with a weight to the input shaft of appmx. 25
kg, then zem the dial indicator.
c) Lever ule forward clutch cylinder forward using a screw
driver, and record reading.
for the filter, then install '0' ring to filter.

5. Install the tilter to the valve body assembly, then secure
filter with retainer.
Screw Driver
Dial Gauge
Mount
Transmission
Case
Assembly
Input Shaft
Transmission End Float 85LE:

0.4 - 0.55 nun
Transmission End Float 95LE: 0.5 0.65 nun
d) If the end float is greater than specification and is
unshimmed, add shims between the No.4 bearing and input
shaft bearing to adjust end float.
e) If there are no shims and the end float is under 0.4 nun
(85LE) 0.5 mm (95LE) or over I .65 mm the transmission
needs attention by pulling down for inspection. Because
components are either installed incorrectly or not within
specification.
16.Adjust the front band as described in appropriate section
of this chapter.
Valve Body Oil Filter & Pan Assembly
1. Lift the valve body into position, install retaining screws
and tighten to specification.
Wrench
Socket
6.lnspect the oil pan and ensure the four magnets are in each
of the comers, then install to oil pan gasket to the pan.
7. Install the oil pan to the transmission case and tighten
retaining bolts to specification in correct order.
Oil Pan
Torque
Wrench
Socket
Pan Retaining Bolts
Oil Pan Retaining bolts:

4.5 Nm
8. Install the torque converter housing to the transmission
case, install and tighten the retaining bolts.
Torque Converter Housing Bolts:
60 Nm
PROBLEM SOLVING &

DIAGNOSIS
Oil Pressure Check
FLUID CHECK
Transmission fluid changes colour and smell very early in

life, these indicators should not necessarily be relied on to
diagnose either transmission internal condition nor fluid
deterioration.
Valve body retaining screws:

10 Nm
2. Install manual valve leverto manual valve link, then check
the alignment of the detent roller.
3.Reconnect electrical connections to solenoids.
4. Using automatic transmission fluid lubricate the '0' ring
The chart on the next page shows that a dark brown tluid
colour, coupled with a delayed shift panern, llIay only
indicate that the fluid requires replacement and a/one, is not
a definite indication of a potential transmission failure.
The fluid level should only be checked when the trans mission
reaches normal operating temperature (82-93 degrees Cel-
155
sius).
Transmission fluid colour when new and unused, is red. A
red dye is added so lhal it can be distinguished from other oils
and lubricants. The red dye is nolan indicatoroffluidquality
and is nol permanent. As the vehicle is driven, the transmission fluid will begin 10 look darker in colour. Thecolourwill
then appear light brown. A DARK brown colour with a
distinctively burnt odour MAY indicate fluid deterioration
and a need for the fluid to be changed.
Details of transmission oil pressure check procedures refer to
'Oil pressure check informalion' chart at the start of this
chapler.
HYDRAULIC DIAGNOSIS
OIL PRESSURE CHECK INFORMATION
Preliminary Check Procedure

Check tmnsmission oil level and condition
Check out~ide manual linkage and correct
Check engine tune
Install oil pressure gauge
Connect tachometertoengine
Check oil pressure as follows :
Minimum Klckdown Line Pressure Check
Setthc Kickdown cable to specification; and with the brakes

applied, take the line prcssurcreadings in the ranges and at the
engine r.p.m.s indicated in the chart below.
Full Kickdown Line Pressure Check
Full Kickdown line pressure rcadings are obtained by tying
orholding the Kickdown cable to the full extent ofi!" travel ;
and with the brakes applied, take lhc line pressure readings in
the ranges and at the engine r.p.m.' s indicated in lhe chart
shown later.
NOTICE - Total running time for this combination nOlto
exceed 2 mins.
CA UTION - Brakes must be applied at all times.
Road Test
Drive and Reverse EngagementShift Check.

1. Start engine.
2. Depress brake pedal.
3. Move gear selector:
a) ' P' (Park) to 'R' (Reverse)
b) 'R' (Reversc) to 'N' (Neutral) to 'D' (Drive).
c) Gear selections should be immediate and not harsh.
Upshifts and Torque Converter Clutch (TCC) Applieation
With gear selector in ' D':J. Accelerate using a steady increasing throttle application.
2. Note the shi ft speed point gear engagements for:
a) 2nd gear
b) 3rd gear
c) Overdrive
3. Note the specd shi ft point for the Torque Converter Clutch
(TCC) application. This should occur while in 3rd gear.
IMPORTANT
The TCC will nOl engage if engine coolant temperature is
below 45 degrees Celsius or road speed is 10 low.
Part Throttle Downshift
At a speed of70-90 kmlh, quickly depress the accelemtorto
half open position and observe:
a) TCC releases.
b) Transmission downshafts to 2nd gear immediately.
Full Throttle (Detent) Downshift
Operatethevehicleat70-90kmlh in 'D', lhenquicklydepress
to wide open throttle position and observe:
a) TCC releases.
b) Transmission downshifts to 2nd gear immediately.
Manual Downshift
J. Operate lhe vehicle at 70-90kmlh in ' D' ,then release the
accelerator pedal (closed throttle posilion) and simultaneously move the gear selector to ' D' (Drive), and observe:
a) TCC release occurs at zero throttle.
c) Engine should slow vehicle.
2. Operate lhe vehicle at 70-80 kmIh in 'D' .
Release the accelemtorpedal and simultaneOUSly move the
gear selector '2' (second) gear position, and observe:
a) TCC release occurs at zero thronle.
c) Engine should slow vehicle.
3. Move gear selector to 'D' and accelerate to 4Okm/h.
Relea~e the accelerator pedal (closed throttle posilion) and
simultaneously move the gear selectorto ' I (tirst) gear and
observe:
a) Transmission downshifts to Ist gear inUllediately.
b) Engine should slow vehicle.
Coasldown Downshift
1. With the gear selector in ' D' ,accelerate to engage 4th gear
with TCC applied (approx. 75km1h).
2. Release the accelcrator pedal (closed thronle posilion) and
lightly apply the bmkes to observe:
a) TCC release occurs at zero throllie.
b) The point at which downshift occurs.
Manual Gear Range Selection.
Ma1lual Third "D".
I. With vehicle stopped, place gear selector in' D' (Drive) and
accelemte to observe:
a) The first to second gear shifl point.
b) The second to third gear shift point.
Manual Second (2).
I. With vehicle stopped, place gear selector in '2' (second)
and accelerate to observe:

a) The first to second gear shift point.
2. Accelerate to 60kmIh and observe:
a) That a second to third gear shift does not occur.
b) That TCC does not engage.
156
SPECIFICATIONS
Manllal First ( I )
1. With vehicle stopped, place gear selector in ' I ' (first) and
accelerate t040km/h and observe:
a) That no upshift occurs.
b) That TCC does not engage.
Reverse.
/. With vchiclestopped. Placegearselectorin 'R' (Reverse)
and slowly accelerate to obscrve reverse gear operation.
This publication does not include all possible throttle
positions and the corresponding shift point information.
Actual shift points will vary in accordance with transmission
build variation.
Application
93LE
97LE
LUBRICANT:
10.0litres including converter
TQ95 (castrol)
GEAR RATIOS:
Reverse
Fourth
Third
Second
First
Torque Converter Clutch Diagnosis
Functional Check Procedure

/. Install a tachometer.
2, Operate the vehicle until operating temperature is reached.
3,Drive vehicle at 80-88 km/h with light throttle (road load)
4, Release the throttle to allow the TCC to disengage, then reapply throttle slowly and notice if engine speed drops.
6Cylinder
8Cylinder
2.09: I
0.68: I
l.OO: I
1.45: I
2.39: I
CONVERTER:
Stall Speed: 93LE

2000 - 2200 rpm.
97LE
2000 - 2400 rpm.
Mean Diameter of Fluid Circuit:
279.4
2.1 (max)
TorqucMultiplication:
Torque Converter Evaluation
Torque Converter Stator

The torque converter stator roller cl utch can have one of two
different type mal functions:
a) Stator assembly freewheels in both directions.
b) Stator assembly remains locked up at all times.
Condition A:- Poor Acceleration, Loll' Speed
The vehicle tends to have poor acceleration from a standsti U.
Theenginetune is correct and the transmission is in first (I st)
gear when starting oul.
Chccking for poor pertonnance in 'D' (Drive) and 'R'
(Reverse) will helpdeterrnine if the stator is free wheeling at
all times.
Condition B:- Poor Acceleration, High Speed
Engine rpm and carspeed limited or restricted at high speeds.
Performance when accelerating from a standstill is normal.
Engine may overheat. Visual examination of the converter
may reveal a blue colour from over heating.
lfconverter has been removed, the stator roller clutch can be
checked by inserting a tingerinto thesplined inner race of the
fOllerei utch and trying to tum tile race in both directions. The
inner race should tum Ii eely clockwise, but not tum or be very
difficult to tum counter-clockwise.
The Converter Should be Replaced if:Leaks externally, such as the hub weld area.
Converter has an imbalance which can not be corrected.
Converter is contaminated with engine coolant containing
anti freeze.
The Converter Should Not be Replaced if:Theoil has an odour, is discoloured, and there is no evidence
of metal or clutch facing particles.
The threads in one or more of the converter bolt holes are
damaged. Concet with thread insert.
GEAR TRAIN ENDFLOAT

91195 LE
0.50 - 0.65 !TIm
GEAR SET PINION END FLOAT
All Transmissions 0.10 - 0.50 nun

CLUTCH PLATES
Cl
C2
C3
C4
Steel
5
4
4
4
"2
"2
*2
*1
Composition
5
5
4
3
157
Number of selective thickness steel plates to achieve

specified clutch pack clearance.
LINE PRESSURE (HOT) 93/97LE
Idle - Drive
Stall Drive
Idle Reverse
Stall Reverse
450 -750
1400 - 1800
700 - l200
1970 - 2220
SHIFT SPEEDS
Economy Mode(km/h)
4.0 Litre MPEFI
(except column shift wagon, Fair/ane and LTD)
Shift
0% throttle 40% throttle 100% throltle
1-2
15
26
73
2-3
22
54
123
3-4
70
101
175
M3L-U
42
64
123
3L-U
42
64
123
BTR 93/97L AUTOMA TIC TRANSMISSIONS
Normal Mode(krnlh)
4.0 Litre MPEFl
(except column shift wagon, Fairlane and LTD)
Shift
0% throllic 40% thronle 100% thronle
1-2
15
71
50
2-3
27
85
129
3-4
117
179
60
129
M3L-U
54
92
120
179
4L-U
88
Economy Mode(krnlh)
4.0 Litre MPEFl
(column shift wagon, Fairlane and LTD)
Shift
0% throille 40% throttle 100% thronle
1-2
15
73
26
2-3
22
54
123
3L-U
90
175
37
M3L-U
42
64
123
4L-U
105
175
85
Normal Mode(krnlh)
4.0 Litre MPEFI
(except column shih wagon, Fairlane and LTD)
Shin
0% throttle 40% throttle 100% throttle
1-2
50
71
15
2-3
27
85
129
3-4
117
179
60
M3L-U
92
129
54
4L-U
88
120
179
Economy Mode(k.rnJh)
16HO
Shift
0% throttle
1-2
15
2-3
23
M3L-U
60
3-4
36
4L-U
77
Normal Mode(kmlh)
16HO
ShifJ
0% throltle
1-2
15
2-3
31
M3L-U
60
3-4
45
4L-U
84
40% throttle
31
58
60
86
96
I 00% throllie
73
123
123
129
175
40% throttle
47
82
82
118
126
100% throttle
67
114
114
163
175
Economy Mode(krnlh)
5.0 Litre SEFl
0% throttle 40% throttle
Shift
1-2
14
29
2-3
24
56
3-4
81
38
4L-U
107
61
100% throttle
65
108
156
163
Normal Mode(kmlh)
5.0 Litre SEFl
0% throttle 40% throttle
Shift
1-2
14
44
2-3
27
76
3-4
39
106
4L-U
72
III
100% throttle
66
114
158
170
KICKDOWN MAXIMUM SPEEDS (kmlh)
93LE
ShifJ
4-3
4-2
4-1
3-2
3-1
2-1
Economy Mode
147
106
55
106
55
55
NonnalMode
154
112
55
115
55
55
97LE
Shift
4-3
4-2
4-1
3-2
3-1
2-1
Economy Mode
149
102
57
102
57
57
NonmalMode
151
108
57
108
57
57
93LE 16HO
Economy Mode
Shift
4-3
149
104
4-2
4-1
58
3-2
104
3-1
58
2-1
58
Normal Mode
159
108
58
108
58
58
MANUAL DOWNSHIFT MAXIMUM SPEEDS

93LE (downshifts are inhibited above these speeds. krnlh)
Manual 2-1
Manual 3-2
Manual 4-3
Manual 4-2
75
I 16
160
87 (direct 4-2)
115 (4-3-2 sequence)
97LE (downshifts are inhibited above these speeds. k.rnJh)

Manual 2-1
75
Manual 3-2
115
Manual 4-3
165
87 (direct 4-2)
Manual 4-2
I 15 (4-3-2 sequence)
158
LINE PRESSURE kPa
93197LE
Gear
Drive
Reverse
Idle
450-750
700- 1200
Stall
1400-1800
1970-2220
TORQUE CONVERTER:
93LE
97LE
R.P.M.
2000-2200
2000-2400
Torque SpeCifications Nm
Converter Housing to Engine ......................................... 60
Transmission Ca<e to Converter Housing ....................... 60
Extension Housing lO Transmission ............................... 60
Converter to FlywheeVDrive plate ................................. 60
Coverter Housing LowerCoverto Housing .................... 15
Converter housing to Engine Brace ........ .. ....................... 40
Engine Brace to Cylinder Block ...................................... 40

Transmission Oil Pan (Sump) ....................................... 4.5
Valve Body to Transmission Case ................................... 15
Upper Valve Body to Lower Valve Body .............. ........... 15
OnlOffSolenoids Valve Body .. ....................................... 15
[)etcnt Spring ....................................... ......................... .. 20
Rear Servo Cover .... .......... ........... .......... ........ .. ...... .. ..... 20
Band Adjusting Screw LocknuttoCase; ..............................40
Fluid Cooler Line to Case ....................... ___ ..................... 16
Fluid Cooler Line to Radiator ......................................... 20
Fluid Cooler Line Tube Nuts ........................................... 20
Front Pump to Case ....................................................... 30
Pump to pump cover ...................................................... 25
Cover Plate to PumpCover .................................................. 18
Cover Plate to Crescent ................................ ,................. 18
Centre Support to Case .................... .. .......................... .. . 25
Parking Pnlwl ................ .. ............................................... 20
Speedo Tmnsducer .. ........................................................ 8
Line Pressure Take Off Plug ............................................. 5
Memo
159
5 SPEED MANUAL TRANSMISSION
Subject
Page
DFSCRlYfJON ......................................................
Mainte.narlce ............................................................
Checking and Replacing Tran ~mission Oil ............ .....
Spccdo Sender ......................................... .................
] 61
161
161
161
Remove ............ ................. ....................................... 161

Install ....................................................................... 161
Reversing LightSwitch ............................................. 161

Rcmove ........................................ ...... .... ................. . 161
Install ......................................................... .............. 161
Extension Housing Rear Seal ...... ......................... ..... 162
Rernovc ,................................................................... 162
Install ,................ ,........ ,............................................ 162
Shift Lever and Boot Assembly ........... ...................... 162
Rcmove .................................................................... 162
lnstall ................................. , ............. ......., ....... ,...., ... 162
Transmission ............................................................ 162
RerTlOve .................................... , ............ , ........ ,., ..... ,. 162
Install .................................................................... ... 162
Major Repairs and Rebuild .................................... 162
Dismantle................................................................. 162
As..'iembly .....................................,..................,........ 165
GearandShaftAssemblics ............ ...... ............... ...... . 168
Output Shaft and Gear Assemblies ....... .............. ....... 168
Subject
Synchronizes .......... .............. ......... ............. .. ............ 170

Dismantle ................ _.................................. _... _......... 171
Asselnbly ................................................................. 172
Shift Cover ............... ................................................ 172
DisnlaJltJc ............. _.... _._ ............................................ 172
Assenlbly ................................................................. 172
Input Shaft Bearing .................. ..... ........... ................. 173
Renlove ... ...... ................................ .. ......................... 173
Install ..... .................................................................. 173
input Shaft to Output Shaft Bearing Cup ....... ....... ... .. 173
Rcrnove ... ...,., ... " ..... ...,., .... ,., ........,., .... ,., .... ,.,., .. ,., .. ,. 173
lnstall .............. ......................................................... 173
Bearing Retainer Seal- Front .................................... 173
RcnlOve .................................................................... 173
Install ,.,., .. ,.. ... ,..,., .............,., .... ,.......... ,., .... ,........... ,. 173
Counter Shaft Bearing - Front ................................... 173
Remove ..,.,.,., .. ,..........,...... ,...... ,........ ,., ......,... .,.,...... 173
Install .......... ............................................................. 173
Bearing lnspection .................................................... 173
8earingRaccways .................................................... 173
Inspect ..,................. ,................................................ 173
Bearing External Surfaces ......................................... 173
Dismantle ............ ......., ......... .................................... 168
Clean .......................................................................
Inspect ..................... , ........... ..., .... ...... ....,., ............ ,.,
Transmis~ion Caseinspcction ....... .............. ..... .........
Asselnbly ......................... ,..............,... ,..........,., ..... ..
169
169
170
170
Page
PROBLEM SOLVING AND DIAGNOSIS. 174

SPECIFICATIONS ................................... 175
160
5 Speed Manual
Transmission
sideofthetransmission, fill the transmission with the co, ,ect

amount of specified oil.
DESCRIPTION
This transmission is fully synchronised with the I st, 2nd, 3rd

and 4th gears located in the transmission case. Fifth gear is
an overdrive gear, and situated in the rear extension
This transmission is used extensively with Ford vehicles.
Gears are shifted viaasingle shifting lever mounted in ashift
box (turret) at the top and rearof the rearextension. There are
two shift forks 1st!2nd and 3rd14th located in the transmission
case topcoverwith 5th and reverse shifting mechanism at the
rear of the case in the rear extension.
Oil Capacity of Transmission:

2.05 litres
See Specifications For Type OfTransmission Oil
Check oil level by inserting your finger intotheoil filler hole
to check on oil level. Theoillevel should beat the same level
as thefillerplug, but so high that oil will run out when the plug
5 Speed Manual Transmission T500
is removed.
Replace oil filler plug and tighten plug to specification.

Filler Plug specified torque:
35 Nm
Speedo Sender
Remove
1. Disconnect the wiring connection.
2. Remove the clamp securing the unit to the tmnsmission.
3. Remove sender unit from transmission.
Imtall
1. Install a new '0' ring to sender unit.
2. Install sender unit into transmission, install clamp and
tighten securing bolt.
3. Reconnect wiring loom connector.
Reversing Light & Neutral Drive Switch
Neutral Drive
Swftch
T5 Transmission Internal Assembly
Maintenance
Checking and Replacing Transmission Oil
T5016
Position an oil catching tmy under the transmission, make

sure it has the capacity to hold the oil from the transmission
(if oil level is at the full level the transmission will hold 2.05
Remove
Detach wiring connectors, then with a22mm socket unscrew
the switch from the left side of the transmission case, neutraV
drive switch is located on the top front of the box. Ensure to
remove neutraVdrive switch pin from casing as well.
Tostall
Check threads of switches, apply Teflon tape to switch,
install switchs and tighten to specification, remember to
replace neutraVdrive switch pin.
20-27Nm
Reverse Light Switch specified torque:
litres).
Remove the drain plug from the lower right side of the
transmission, ifthe vehicle has been recently driven takecare
as the oil could be hot enough to bum skin on contact.
Replace the drain plug and tighten to specification.
Drain Plug torque specification:
35 Nm
Remove the filler plug approximately half way up the right
161
Extension Housing Rear Seal
Remove
1. Jack vehicle up and safely support vehicle to allow access
to the transmission and drivel tail shaft..
2. (a) Place a drain tray beneath transmission extension.
(b) Removedrive/tail shaft as described in TaillDriveShaft
and Universal Joints chapter in this manual.
3. Remove seal using seal remover and discard seal.
4. (a) Inspect seal lip surface on slip yoke of propeller shaft
for damage.
(b) Clean (or replace) as necessary.
Tail Shaft - - - - - - - -
Yoke - - -_ _ _-:
Universal
Joint
Check The
Seating Surface
T5043
Install
1.(a) Apply a little transmission lubricant to seal lip.
(b) Install seal into the extension with a seal inscrtion tool.
2. Replace tail I drive shafta~ described in Taill Drive Shaft
and Universal Joints chapler in this manual.
3. Check Imnsmission lubricanllevel a~ previously described
in this Chapler.
Shift Lever and Boot Assembly
Remove
I. Remove the gearshift knob (unscrew) from Ihe gear shift
lever, take care and case the boot from the console and rai se
tlteboot over and off the gear lever, then repeat procedure for
noorboot.
2. Remove centre console if required or from the lOp of the
console opening remove the two bolts securing the shi ft lever
to the transmission and remove the lever.
Install
I . Install the gearshi ft leverlothe transmission lever, tighten
the bolts. lnstalilhe bool and relainerover the gearshi ftlever
secure it to nom and repeat procedure for console bool
pressing the retainer lugs into the console.
2. Install the knob onto the shift lever lighten, so Ihalthe gear
position markings on the knob are correct.
2. Removedrive/tail shaft asdescribed in Tail/Drive Shaft

and Universal Joints chapter in this manual. Install dummy
yoke into extension housing to prevent lubricant leakage.
3.Disconnect transmission loom from main loom at fire wall.
4. Remove transmission mount to cross member nuts, then
disconnect hand brake cable at equalizer, and mounting

points allowing it to be moved out of the way.
S. Support the transmission assembly with transmission jack
lifting weight of crossmember. Remove nuL~ and washers
securing cross member to body and remove crossmember.
6. Remove transmission mount and exhaust support bracket
from tranSITtission extension housing, then detach bmckel
from exhaust system.
7. Lowertr,msmissionjack slowly until the weight is relea~
from jack and the engine is resting against the fIrewall.
8. Remove the transmission ca<;e to bell (clutch) housing bolts
9. Move transmission rearward until the inputshaftclears the
nywheei, clutch and bell housing then lower the jack and
remove the transmission .
lnstaIl
1. Place transmission on transmission jack. raise transmission into place, sliding it forward until the inputshaftsplines
enter the clutch hub splines and the ca<;e is against the bell
housing.
2. Install the transmission casing to bell housing bolts and
torque all bolts to specification.
Transmission to Clutch Housing boltsspecitied torque:
70-84Nm
3. Reconnect the wiring loom at fire wall then raise transmission into place.
4. Fit transmission mounl and exhaust support bracket into
place and tension all bolts.
S. Replace crossmember to the body, torqueing nuts to
specification. Remove the transmission jack, installlmnsmission mounttocmssmembernut. Torqueto specification .
Rear Crossmember to Side Frame bolt: 40-S0Nm
Rear Crossmember to Transmission bolt: 3O-40Nm
Exhaust Pipe bracket bolt specified torque: 3O-S0Nm
6. Remove dummy yoke from extension housing, lubricanl
will leak so be ready. Replace drive I tail shaft as described
in Tail I Drive Shafl and Universal Joints chapter in this
manual.
7. Fill transmission 10 fuillevel with specified luhricant and
torque filler plug.
Oil Capacity ofTran.~mission:
2.05 litres
Specified Transmission Oil:
Dexron liD
Drain Plug torque specification:
3S Nm
8. Lower vehicle, install the gearshift lever and boot as
described above. Drive vehicle, test tmnsmission function.
Major Repairs and Rebuild
Transmission
Remove
1. Remove the gearshift boot and lever and raise vehicle.
Dismantle
I. Drain transmission fluid before placing transmission on a
clean bench to enable a complete pull down and rehuild.
162
Drain plug on RIH side of casing as shown in previous ill.

2. Remove the backup lamp and neutral/drive switchs, as
well as neutral/drive switch pin.
3. With ~hift lever in neutral, remove shift cover securing
bolts. & pry ~hift cover from shift pot.
7. With ~hi ft cover bolts removed, break ease-to-cover bond.

S. Lift shirt cover, tilting it towards the right side of casing,
fifthlreverseshift lever will need tobedisengaged from ~hift
cover before removal.
Shift
Cover
Extension
Housing
Offset
lever
Shift Pot
u~ing pliers, then loosen pivot pin with Torque bitdriver, and
remove.
10. The fifth gear synchronizer snap ring, retainer, reverse

cone and synchronizer blocking ring can be withdrawn from
the countershaft by releasing snapring with circlip pliers.
Il.(a) Now fifth gear, ~hift fork, shift rail and synchronizer
can be removed as a complete assembly.
(b) When the assembly has passed over the end of the
countershaft it will have to be twi~ted to release the ball stud
from the fifth/reverse shift lever.
4. With pin punch and hammer, move offset lever roll pin
through ~hifter shaft.
5. Loosen and remove extension housing bolts. pry the
extension housing from the case. carefull y breaking the seal.
6. Extension housing and offset lever can then be slid
backwards from the case. Then lift the off~et lever from the
shifter pot and remove the roll pin, detent spring and detent
ball from the detent plate.
Shift Fork &
Shift Rail
Shifter Cover
ExtenSlOn
Housing
Auemb~
Output
Synchronizer --:;
Assembly
Counter
Shaft
Transmission
ea..
12. Remove input shaft bearing retainer plate bolts and

retainer plate, marking top of retainer to help with a<sembly.
Transmission
Offset
/ / Case
Lever -.::
Spanner
Front Bearing
Shift
Retainer
Pot _
T5008
163
13. Input shaft has a cut out section on the 4th gear clutchi ng
teeth which wi II need al igning with countellihaft toenable the
removal of the input shaft from the case
*Takecarenottodroporloosethe 15 bearings ofthe back
of the input shaft when removing it from the case.
* Take note ofsmet lever, shift fork and inhibitor spring

positions prior to removal, and the rotation of the reverse
positioning spring, for assembly purposes.
18. The revellie idler shaft can be removed by punching the
roll pin from the shaft, then slide reverse idlershaftoutofthe
case, withdrawing the reverse idler gear and over-travel
rubber stop from casing at the same time.
Hammer
Input
Shaft
Reverse
Idler
& Gear
T5009
14. Remove speedo drive gear from output shaft.

15. Movc output shaft backwards to release bearing race
from its bond to the case. Remove bearing race rearward off
output shaft.
Beanng
TransmiSSion
Case
Main Shaft
Assembly
Reverse
Idler Gear=-
T5010
16. Tip front of output shaft upward then lift, this will help
you to remove the output shaft assembly from the case.
Reverse
Idler Shaft
Counter Shaft
Transmission
Case
19. Flatten counlershaft retainer tabs and remove retainer

bolts.Then countershaft retainer and shim/s and rear counter
shaft bearing race can be removed from counter shaft.
If race is locked in casing work the shaft back and forth
to released its bond from the case.
Main
Shaft
17. Withdraw from the case the fifth/reverse shift lever,

reverse shift fork and revellie positioning spring. When
replacing the case the reverse positioning spring anchor pin
wi II need to be removed by withdrawing the Tizz bushing
from the anchor bolt and then the anchor bolt itself.
T5014
164
Beanng
Retainer
Counter
Shaft
20. Using tools No. El673 & El673U 15A remove bearing
from counter shaft being careful not to damage shaft or
bearing.
21.Removecountcr shaft in same manner as output shaft was
removed.
ensuring retaining bolts are secured.

Dial Gauge
Dial Gauge
Mount & Magnetic
_~Base
Transmission
Case
Counter
Shaft
Transmission
Case
Main Shaft
Assembly
1. Using tool No. E7518B install frontcountershaft bearing
onto shaft, then install counter shaft into
ca~e
in reverse
procedure as removal.
2. Fit counter shali rcar bearing to shaft using tool No.
E7518B.
CAUTION: Countcr shaft must be supponed correctly to
prevcnt any distonion of the caseduri ng bearing installation.
Suppon counter shaft with steel barthat is 7mm (114 inch)
thick.
3. Fit rear counter shaft bearing race into position and replace
counter shaft bearing retainer and shims, fitting bolts and
tighten to specification
Rear Counter Gear Shaft Bearing Housing: 20Nm.
This should be done initially without any shims installed .
T5014
Bearing
Retainer
Counter
Shaft
4. End play to be mea.ured using dial indicator, if measurements not within specs install orremoveshims as necessary.
from between counter shaft bearing race and retainer.
Counter Shaft End Play:
O.0254-0.127mm
When countcrshaft end play is COIl ect bend retainer tabs ovcr
165
T5018
5. Fit reverse idler gear, reverse idler>haft, rubberover-travel

stop and shaft into case, with shift lever groove towards rear
of casing, .
6. With pin punch, install roll pin into idler shaft.
7. Pipe Sealant with Teflon is to be applied to the reverse
positioning spring anchor pin threads upon installation, then
tighten to specifications.
Reverse Idler anchor Pin specified torque: 815Nm
Install Tizz bushing over anchor pin head by softly tapping
into place with hammer.
8. Fit tifth/reverse shift lever, reverse shift fork and reverse
positioning spring in shift lever.
9. With reverse idler gear in neutral position, align revcrse
shift fork on reverse idler gear and push down until engaged
correctly into reverse idler gear.
* The reverse positioning spring rotation should be
counter clockwise into its correct installed place.
10. Output shaft assembly can now be fined into the casing.
Apply multi-purpose grease to the thrust bearing and
race. Install the 15 roUer bearings into input shaft.
11. The input shaft can be fitted into the casing, with the
synchronizer teeth flat aligned with counter shaft.
*Make sure 3-4 synchronizer blocking ring is correctly
located.
To Align
Th Input Shaft
__
TS020
--Input Shaft
Assembly
Transmission
Assembly
12. Fit bearingcapinto bearing retainer, without shimsat this

point.
Fit with narrow or smaller notch upward, do not apply sealant
until later. Tighten retaining holts to specification.
Input Shaft Bearing retaining holts specified torque:
15-27 Nm
15. The fifth gear synchronizer snap ring, retainer, reverse

cone and synchronizer blocking ring can be replaced onto the
countershaft, and ensure that the snap ring is correctly in
place.
Spacer tabs must be locked into the counter shaft
splines, the reverse cone tab should be vertical forthe rear
extensioninstaUation.
* do not install the pivot pin until the ball stud forthe shift
lever and shift ball is fully engaged.
16. With tenon applied to pivot pin threads, install it into
position and tension.
Pivot Pin specified torque:
34 - 47 Nm
17. Fit C-Clip on shift lever pivot pin, and speedometer gear
to output shaft.
* Install the speedometer drive gear and retainingclipto
theoutputshaft, retaining clip mustlockinto the gear and
the shaft.
Retaining
CirC/ip
_ - - - - Transmission
Case
Shift Lever
Pivot Pin
Front Bearing
Retainer
TS02t
13. Output shaft rear bearing race can be fitted using soft face
hammer if necessary to tap into place.
14. (a) Now fifth gear, shift fork, shift rail and synchronizer
can be fitted into the ca<ing as an assembly.
(b) When the assembly is being fitted it will have to betwisted
to engage the ball stud to the fifth/reverse shift lever.
Shift rail must slide through return spring.
IS. Apply small amountof siliconeSealer RTV Silastic 1080

or equivalent to the shift cover assembly, align shift cover
tilting it slightly to the right side of the transmission and place
down into position.
All synchronizes must be in the neutral position to allow
the shift forks in the cover which must also be in neutral
position to function properly.
19. Fit shift cover securing holts, tightening to specified
torque.
Transmission Cover bolt specified torque: 8-1SNm
20. Place a bead of Silicone Sealer RTV Silastic \080 or
equivalent to the rearextension, before fitting apply silicone
sealer to the lubrication funnel and fit to counter shaft.
166
21. Apply petroleum jelly to the detent spring and ball before
installation, fitspring to offset lever, and detent ball to detent
plateinneutral position, placing offset leverin shi fterpot with
spling over detent baIl.
OI!..t
lever -...;
Shott
Pol -.,.
24. Outputshaflgeartrain end play will need to be mea.ured

as follows:
Tum transntission so it is vertical with output shaft pointing
up with the dial indicator mounted on extension housing.
Tum both input and output shafts to allow them to settle,
then zero the dial indicator.
Using a wood block, lift the input shaft up and record the
dial indicator reading.
* Install a shim that is the same thickness of the dial
indicator recording which will give zero end play.
Note: With zero end play at specification, it is acceptable
to havea plus or minus .050mm (0,(102 inch) tolerance. If
the shim is too thick it will overload the bearing.
The thickest shim is to he installed against the front
bearing cup.
Detent Plate
Dial Gauge
& Mount
Assmebly
22. Fit extension housing into position, with offset lever press
down and aligned on thedetent spring and ball, then slide lever
andhousing into place. Ensuring reverse cone tag engages the
recess in the housing.
23, (a) Fit and tension extension housing retaining boll.
Extension Housing bolts specified torque: 50-60Nm
Transmission
Assembly
Output
Shaft
Socket
Torque
Wrench
Extension
Housing _ _..:
T5025
(b) Align the hole in the shifter shaft and offset lever, then fit
roll pin, use pin punch and hammer.
Input _ _-
Check output shaft end play now.
Shaft
Sit Front Of
Case OnA
Bench
T5027
T r .n .. <n;s .. lo ....
_
rnbty
P,n
Pu. ~ h
__
25. Tum over transntission to excess front bearing retainer

and remove. when the required shims are in placeand bearing
race is installed, applying sealant to the bearing retainer
before installation ..
S h.n POI
167
1. Remove 3rd gear, 3rd14th synchronizeraod blocking ring

as ao assembly by pressing them from the output shaft.
2. (8) Slide needle bearing from output shaft, then spacer.
(b) Fifth gear snap ring can then by removed using circlip
pliers.
(c) Press lifth gear from the output shaft.
Press Ram ______
T5028a
Output
Shaft _ _ _ _ _...,
Remover
Jaws
Movable Centre
Plates
Race
Press Bed
Front Bearing
Retainer
26. Install bearing retainer as described previously, tighten

retaining bolts to specified torque.
Main Drive BearingRetainerspecified torque: IS-2SNm
CAUTION: Take care not to allow sealer to enter the
bearing retainer notch.
27. Fit shifter cover to shifter pot aod tighten the retaining
bolts to specitication.
Extension Cover Top bolts specified torque: IS-20Nm
28. Fit aod tension dmin and liller plugs to specification.
Drain Plug specified torque:
18 -29 Nm.
3. (8) Press output shaft rear bearing, then slide the first gear
from the shaft.
There is a snug fit betwccn the sleeve and output shaft.
(b) Slide ncedle bearing and sleeve as an assembly from the
output shaft, then using a magnet or pointy no><: pliers
withdmw roll pin from the shaft.
Gear and Shaft

Assemblies
Needle Bearing
& Sleeve
Output Shaft and Gear Assemblies
Gear and shaft assemblies may not require to he

dismantled. Inspect all gears, synchronizes, bearings and
shaft surfaces
Shaft
Assembly
Output Shaft
4. From theoutput shafts longer end slide the three-piece first

gear synchronizer blocking ring assembly off.
Input
Shaft
Section A & B for Sprint & GT only:

(8) Press the bearing from the output shaft using bearing
puller aod press.
(b) Remove snap ring from the shaft.
168

Piece BlOCk
I
Output Shaft
Assembly
Output Shaft Assembly

In Dismantled State
Synchronizer
Assembly
T5032
T5035
Oeaning
Using cleaning solvent to clean all the components of the
gearboxexceptforthesealsand '0' rings. Removealldebris
from transmission components using a brush, screw driveror
scraper, do not damage any of the components.
5. Second gear snap ring and thrust washer can be removed

from the shaft, then the second gear and the 2nd gear needle
bearing and spacer.
Output Shaft
Asembly
Scraper - - -
T5034
6. (a) Disconnect spiral snap ring from its retaining groove

and slide from shaf~ then remove thrust washer from shaft as
well.
(b) Press the 2nd gear synchronizer blocking ring a.sembly,
and Istl2nd synchronizer from output shaft.
Press Ram _::::::~~~

Remover
1sU2nd Synchronizer
Assembly
Movable Centre
Plates
Sealing
Surface
*All bearings will need to be thoroughly cleaned of all

lubricants, by rotating the bearings in cleaning fluid and using
a brush on them to dislodge any grime.
*Once all components have been cleaned, dry them offwith
compressed air, do not allow the bearing to spin when doing
this, as damage may occur.
"Bearing will need inspecting and if they are found to be
serviceable they can then be packed with a mUlti-purpose
grease and placed where they will stay clean and free of
foreign matter. RefeHo 'Bearing Inspection' .
"The casing bottom magnet will need to be cleaned with
kerosene or mineral spirits to remove all traces of metal
particles, then dry with compressed air.
Inspect
*The transmission component housings will need to be
7. Detent ball and spring can be removed from the output

shaft synchro hub.
The 1st/2nd speed syncheoni7.er, hub and output shaft
areservic~>dasacompleteassembly. Noattemptshould
be made to separate the hub from the shaft.
S. The sleeve, springs and inscrt., can be removed from hub
after putting alignment marks on hub and sleeve. The springs,
inserts and detent ball and spring are not serviceable. If hub
orsleeve is worn ordarnaged, oUlput shaft and synchronizer
are to be replaced as an assembly.
T5().45
169
inspected vcry carefully for cracks, fractures, broken orwom

component mounts and damaged threads, also any other
damage that could cause transmission misalignment and
failure.
Any damage to nat mounting surfaces that need to mount
nush and seal will need to be cleaned to obtain the sealing
surface that is required. Any that are bent or distorted will
need to be replaced.
'Ensure the transmission vent hole is not blocked. The shift
lever and cover assembly will need to be checked for wear,
damage and distortion on all parts, ifexcessive wear found to
be in the assembly the damaged components will need
replacing.
'Teeth on all gears must be checked for brakes, wear, and
chipping. U any gears are found to be damaged they must be
replaced. If counter shaft gears are damaged the entire shaft
will nee replacing as the gears are part of the shaft.
_ _ Main Shaft
Assembty
- - Fifth Gear
Broken Tooth
and aligned correctly . Thesynchronizerblocking rings must

be checked for widened index slots, rounded clutch teeth, and
smooth internal surfaces (must have machined grooves), and
shou Id have adistance of not be less than 0.5mm (0.020 inch)
fTOm the synchronizerblocking ring face to the clutch teeth on
the gear.
Transmission Case Inspection
"For damaged threads in aluminium transmission case, the

most effective form of repair is using a helicoil kit that may
be purchased from local automotive part suppliers.
'To repair damaged thread, drill it OUl, using the drill size
described in the helicoil kit. Use the t<lp size described to cut
a new thread large enough to lake the helicoil, which after it
is installed, the original thread size is obtained again ..
'With thehelicoil fined to the insert tool, screw into the tapped
hole and until it sit< in one-half tum below the face of the
housing. Bend thehelicoil tang up and down until it breaks off
at the notch.
"Once the helicoil is in place, the thread is fully repaired and
serviceable again. Repeat this procedure to all threads that
nced repairing.
Assembly
J, Istl2nd synchronizer hub detent ball and spring can be
fined.
2. (a) Fil I stl2nd synchronizer a<sembly onto the output
shaft, then the three-piece 1st gearsynchronizerblockingring
to the output shaft, slide on as an assembly.
_ _-Inserts
Any shafts that have been bent or distorted, orhavedamage

to the splines and bearing surfaces will need to be replaced.
Check the speedometerdri ve gear to ensure that the teeth have
not been stripped ordamaged, if it needs replacing the correct
size gear must be fitled .
All bushes and seal in the transmission should be replaced
on arebuild, otherwise they should be thoroughly inspected
for wear or damage and replaced if any is found.
Synchronizer
Hub
Front Bearing
Retainer Seal
.....--...............
TS037
(b) Fillhe three-piece 2nd gear synchronizer blocking ri ng to
the output shaft, fit as an assembly.

Note: The syncbronizer blocking ring slots must be
aligned with Istl2ndsynchronizertabs.
# Synchronizer assemblies are described under 'Synchronizer
Dismantleand Assembly'.
Front
RetaIner
'Thesynchronizersleevcs must be f, ee movi ng on their hubs
170
(b) Press the gear carefully onto the output shaft with a
capped lengthofpipe,31.75mmIDx356mm(I-1/4inch to
output Shaft
T5038
x 14 inch).
# Note: The output shaft and gear splines should be
aligned with care. If the splines arc not aligned in the
correct manner, the gear wil1 damage the splines as it is
pressed onto the output shaft.
8. Fit fifth gear snap ring into its retaining groove on the
output shaft using circlip pliers. then fit the spacer and needle
bearing into place on the output shaft.
Three Piece Synchronizer
~~
3. (a) Fit thrust washer and then spiral snap ring, use Spirul
Snap Ring Replacer.
(b) Replace 2nd gear needle bearing and spacer to output
shaft, then fi t second gear over the output shaft and seat it on
the needle roller.
* The 2nd gear slots must be aligned wilh tabs on
synchronizer blocking ring assembly.
Output Shaft
Assembly
Circlip
Pliers
Asembly
Circlip
T5040
9. Press the3rdl4th synchronizer blocking ring and third gear

onto the output shaft carefully aligning it with the splines ..
*Check that the synchronizer hub faces the shortest end
of outputshaft before pressing the various parts onto the
shaft. The synchronizer and third gear will need to kept
as a unit so the synchronizer hlocking ring is still aligned.
Section A & B for Sprint and GT ollly
(a) Replace snap ring from the shaft.
(b) Press bearing onto output shaft.
T5034
4. Fit 2nd gear thrust washer by sliding it over the shaft and
then using snap ring pliers fit the snap ring into place.
S.Roli pin will need to befitted intotheoutputshaft, then slide
the I st gear sleeve with needle roller bearing fitted over the
outputshaftand into place ensuring to align the notch with the
roll pin.
* Use pencil magnet if required for the rol1 pin.
6. (a) Fit firstgearoverthe needle roller and into place on the
output shaft.
Synchronizes
Dismantle
These operations apply to all synchronizer assemblies,
gear synchroni7-CS which are different in design, procedures are noted.
I. Alignment marks need to be applied to the synchronizer
sleeves and hubs to cnsure that they are rea.sembled correctly.
2. (a) The insert retainer which is fitted to the 5th gear
synchronizer will need to be removed. this is the only
synchronizer with it filted.
(b) Leverthe two synchronizer retaining springs from the hub
using a screw driver. then withdraw the inserts.
1st/2nd gear synchronizer hub is only serviceable as an
assembly incorporating the output shaft, as the
synchronizer hub is pressed with an interference fit onlo
the oUlput shaft and no attempt to separate the hub and
shaft should be made.
Needle Roler
*Thefirstgearslots must be aligned with tabs on first gear

synchronizer blocking ring as'lCmbly.
(b) Fit the rear output shaft beari ng with the taper towards the
rear of the shaft, ensure that it is seated properly.
7. (a) Apply a small amount of petroleum jelly to the fifth gear
splines before instaUatioD, then place gearinto position on the
output shaft.
171

Output Shaft
Assembly
Synchronizer
Hub
Synchronizer
T5041
Sleeve
3. (a) The Istl2nd will needtobeslowlyandcarefullyslidoff

the hub to prevent losing the detent ball and spring.
(b) The other gear synchronirer sleeve can be sUd off with out
worrying about detent balls and springs going missing.
Ensure that the sleeves and hubs are marked
Synchronizer
Assembly
Shift Cover
Dismantle
Forks must be marked for assembly purposes. With selector
ann and plates in the Neutml position and rotate shiftershaft
anti clockwise until selectorarrn disengages theselectorarm
plate, once disengaged pull shaft backwards.
Using pin punch and hammer push selector arm roll pin from
the shifter shaft and slide shaft from thecover using a twisting
motion to withdraw. Remove shift forks. roll pin and shift
interlock from shift cover.
Synchronizer
Assembly Markings
Assembly
Thesynchronizerslccvcllndhubalignmentmark~must
bealigned for assembly. The sleeve and hub must be held

square during assembly to prevent jamming. The sleeve
must not be forced onto the hub.
J. Slide the sleeve onto the hub and then install the insens into
the sleeve and hub, once in position the retaining springs can
be fitted to the inside of the hub to hold the insens in place.
2, The 5th gearsynchronizera~sembly will need the Reverse
Blocking Ring fitted to the synchronizer.
3, The detent ball and spring will need to be fitted into the hub
of the Istl2nd gearsynchronirer before theslceve, insert.' and
retaining springs are fitted.
Assemble retaining springs, insens and sleeve onto hub.
Refer to diagram for placing of the retaining springs and
inserts.
Assembly
New Oring seal must be fitted if the shifter cover was
dismantled.
* The narrow sideof selector interlock plate is positioned
in the shift cover slot. The control selector arm roll pin
hole is toward the rear of the cover.
*With control selector interlock plate fitted as an assembly.
place shift forks in the cover with there corresponding
identification marks. With shi ft shaft lubricated sl ide through
shift cover and components until its hard through the cover.
* J2 shift fork is the larger fork of the two, and the otTset
faces the rear of the cover. The 3-4 gear shift selector arm
plate, the smaller plate is fitted under the 12 gearshift
selector arm plate.
CAUTION: The roll pin is installed just below the selector
arm surface. If the roll pin is not countersunk the result may
be interference between the pin and interlock plate during
shifts.
172

Front
Retainer
Driver
Front Bearing
Retainer Seal
'Ensure nat on shifter shaft is facing upward and install the

control selector arm roll pin using a pin punch.
T5053
Install
Fit new seal using uleappropriate seal installer, then replace
the shims and bearing mce into the bearing retainer.
Ifthe transmission is being overhauled with a new seal,
the end play shim is not installed.
Front Counter Shaft Bearing Race
Input Shaft Bearing
Remove
' lnput shaft bearing will nced to becarefullypressed form the
shaft.
InstaU
*The bearing will need to bepressed backontothcinput shaft.
Input Shaft to Output Shaft Bearing Cup

For the Sprint & GT only.
Remove
Remove bearing cup from the end of the input shaft using a
bearing cup puller and slide hammer.
InrutII
Bearing cup will need to be pressed into the input shaft pockct
with a bearing cone replacement tool.
CAUTION: Ensure bearing cup is fully seated.
Bearing Retainer Seal, Front
Remove
Bearing mceand shim need removing, then pry seal from the
bearing retainer using a screw driver, careful not to damage
the bearing retainer.
Remove the front counter shaft bearing mce ifit is

showing evidence of wear or damage. Loctite and sealcr
will need to be applied if a bearing is to be installcd.
Replace the "0" ring with a new "0" ring if replacing the
Iront bearing.
Remove
I. MounL the case in a press and press the old bearing out,
however support the press properly other wise the transmission case could distort.
InstaU
I. O-ring litted to bearing race.
2. Loctite and sealer will need Lo be applied to thc outcr
surface of the bearing.
3. Position the bearing race at the case. press the bearing
cone into place.
Bearing Inspection
Bearing Raceways
Inspect
Inner Raceway: While holding outer ring stationary, rotate
inner ring at least three revolutions. Inspect the raceway of
the inner ring from both sides for pits orspalling. A bearing
asscmbly should be replaced when damaged. Light particlc
indentation is allowable.
Outer Ring Raceway: While holding inner ring stationary,
rotate outer ring at Ica.t three revolutions. Inspect the
raceway of the outcrring from both as with thc raceway of the
inner ring. If the raceway is spalled or pitted, replace the
bearing assembly. Light particle indentation is allowable.
Bearing External Surfaces
Theberuing must bereplaeed ifdamage is found in any of the
following area.:
Radial cracks on front and rear faces of outer or inner rings.
173
Cracks on outside diameterofouterring (particularly around

snap ring groove). Deformation or cmcks in ball cage
(particularly around rivets).
SpinTesl
Lubricate bearing raceways with a slight amount of clean
automatic transmission fluid turn the bearing back and forth
slowly until the raceways and balls are coated.
With bearing in vertical position. Vertical movement between inner and outer rings is allowable. Spin outer ring
several times by hand. lfthere is roughness orvibmtion. the
bearing should be cleaned again and re-Iubricated. Roughness could beforeign particles in the bearing. Ifbeari ng is stil I
rough after cleaning and relubricating several times, it must
be replaced.
Repeat the above with the bearing in the horizontal position.
PROBLEM SOLVING
PROBLEM
Transntission Noisy in Gear.

CAUSE
, Lubricate level low or wrong type.
ACTION
* Fill to bottom of filler plug hold with proper lubricant.
CAUSE
* Transmission to flywheel housing and flywheel housing to
engine block bolts loose.
ACTION
* Tighten boilS to specification.
CAUSE
* Pilot bushing worn or damaged.
ACTION
Remove transmission. If noise is howling during start-up,
check pilot bushing. Check for loose flywheel and housing
alignment. Service or replace as required.
CAUSE
* Improper transntission pilot engagement into flywheel
housing.
ACTION
* Replace housing or input shaft bearing retainer as required.
Refer to 'Clutch'.
CAUSE
* Worn or damaged internal components.
ACTION
* Disassemble transntission. Inspect input, output and
counter shaft bearings, gear and gear teeth for wear and
damage. Service or replace as required.
PROBLEM
Transmission Shifts Hard.

CAUSE
* lmpropercJuteh release.
ACTION
Refer to 'Clutch'.
CAUSE
' Internal shift mechanism binding.
ACTION
* Remove transmission and free up shift mechanism.
CAUSE
* Synchronizer sleeve to hub tit.
ACTION
Remove and check for burrs or fit.
CAUSE
Bindingcondition between inputshaftandcrank shaft pi lot
bearing.
ACTION
Check alignment and service as required.
CAUSE
* Improper Fluid.
ACTION
* Drain and refi II with specified fluid or equivalent tobonom
of filler plug hole.
PROBLEM
Transmission Will Not Shitt into One Gear- All OtherGears

OK.
CAUSE
* F1oorshift, interference between shifthandleandconsoleor
floor cut out.
ACTION
* Adjust console or cut out floorpan to eliminate interference.
CAUSE
* Restricted travel of internal shifter components.
ACTION
* Remove transmission. Inspect shift rail and fork system,
synchronizer system and gear clutch teeth for restricted
travel. Service and replace as required.
PROBLEM
' Transmission is Locked in One Gear. Jt cannot be shifted

Out of that Gear.
CAUSE
Internal Shifter components worn or damaged.
ACTION
* Remove transntission. Inspect the problem gcaror gearshift
rails and fork and synchronizerforwearordanlage. Service
or replace as required.
CAUSE
* Selector arm finger broken.
ACTION
* Remove transmission. Replace selector ann assembly.
CAUSE
* Bent shifter forks at pads and selector slot.
ACTION
, Service or replace as required.
174
PROBLEM
GEAR END FLOAT & CLEARANCES
Tl1lJ1smission WilJ Not Shift Into Reverse (All Others OK).

CAUSE
'Worn or dam aged internal components.
ACfION
'Remove transmission. Check fordamaged reverse geartrai n,
misaligned reverse relay lever, shift rail and fork system.
Output Shaft
1st Gear .................................................. 0.18 -0.33 mm
2nd Gear ................................................. 0.18 - 0.76 mm
3rd Gear ................................................... 0.18- 0.69 mm
Countershaft
5th Gear .................................................. 0.04 - 0.98 mm
Countershaft End AOa! .. .... . .. ........... ........ 0.08 - 0.10 mm
Output Shaft Bearing Adjustment ... ....... 0.05 mm preload
to 0.05 end float
SPECIFICATIONS
TRANSMISSION
Type ........................................ ............. 5-Speed Manual

Model ..................................... .... .. ................. .... ". T50D
Lubrication ... ............. ESR-M2C-163A (DEXTRON II)
Oil Additive .......... ...... ... ....................... .... Lubrizol7906
Dry Capacity ..................................................... 1.9 litres
TRANSMISSION RATIOS:
5,OL
4.0L
V8
16
1st ... ........................................ 2.95:1 ............... 3.25:1
2nd .......................................... 1.94: 1 .............. . 1.99:1
3rd .......................................... 1.34: 1 ............... 1.29: I
4th .......................................... 1.00: 1 ............... 1.00: 1
5th .............................. ............ 0.73: ] ............... 0.72: 1
Reverse ................................... 2.76: 1 .. .. ...... ..... 3.15: I
Torque Specifications Nm
Drain Plug .................... ................ ...... ..... ................... 35
FillerPlug ...................... .................................... ..... ... 35

5th/Revcrse Shift Lever Pivot Pin ................................ 60
Back Up Lamp Switch ........................... ..................... 25
Cao;e Cover to Transmission Case Anaching Bolt .. ....... 12
Extension to Transmission Case Attaching Bolt ........... 50
Transmission Case to Clutch Housing Bolt ....... ........... 65
PropeIJer Shaft Rear Universal Joint ............................ 12
Memo
175
DRIVE / TAIL SHAFT AND

UNIVERSAL JOINTS
Subject
DRIVE/TAIL
SHAFT
Page
DRIVE I TAIL SHAFT .............................. 176

Removal ................................................................... 176
Installation ............................................................... l77
Universal Joints ...................................... 177
ReTllOval .... .............. .... ....... ............ ............... ........... 177
Installation ............................................................... 178
DRIVE I TAIL SHAFT

SPECIFICATIONS ................................... 179
Removal
1. Raise rear or vehicle and suppon rear axle assembly on

safety stands.
2. Remove boIlS and nuls holding propeller shaft rear uni ver
sal joint flange to pinion flange. Disengage rear universal
joint flange rrom pinion flange.
Rear Axle
I
Tail Shaft
Universal
Spider
Retaining
Bons
Tail Shaft
Flange
Searing
Cap
,
Snap Ring
P012
Universal
Joint
The 2 flanges have paint alignment marks that are assem

bled as close together as possible.
* Ifthese are not visible, scribea mark on both tlanges so that
they may be installed in their original positions.
3. Remove propeller shaft by pulling it toward the rear of
vehicle to disengage front universal joi nt yoke from transmis
S10n.
176
DRIVEirAIL SHAFT AND UNIVERSAL JOINTS
Take care to protect the outer diameter of the front yoke.

Nicks or abra,ions will damage the transmission extension
seal during assembly and result in lubricant leakage past the
seal.
Insen a suitable plug in the end of the transmission rear
extension to preventloss of transmission lubricant.
In<taIIation
# Remove any foreign matter that may have adhered to the
front universal joint yoke and lubricate with transmission
lubricants. Guide propeller shaft over park brake cable and
insert yoke on to transmission mainshaft.
# Before attaching propeller shaft rear uni versal joi nt flange
to pinion flange. align marks on pinion flange and rear
universal jointflange(or marks madeon removal}. as nearas
possible.
I. Check the seal installed in the end of the transmission
extension housing, if it is danlaged in any way install a new
seal.
2. Lubricate the yoke spline with transmission lubricant.
install the yoke on the transmission output shaft.
3. Remove the plug placed in the transmission extension
housing.
4.Slide the shaft assembly in to the transmission extension so
that yoke is located on the transmission output shaft.
5. Install the bolts and four nuts attaching the tail shaft to the
differential flange, suppon the shaft. Tighten to specification .
Care must be taken to use only genuine bolt, and nuts.
rail Shaft to Dill' Flange nut tonlue spec: 9 - 14 Nm.
Measure runout with micrometer gauge
Tall shaft
Micrometer gouge
---
-r
:.~
POO2
UNIVERSAL JOINTS
Removal
Scribe or dab paint a mark on both flanges so that they may
be installed in their original positions
Point Marks ..c.~
alignment marks on pinion flange

and universal joint flange to help with installation
Rear Axle
Tail Shaft
POO41
l. Remove propeller shaft as per prior Section[REM OVAL
- PROPELLER SHAFf).
2. Mount propeller shaft in vice. Remove bearing cap
retaining snap rings from grooves at inner ends of bearing
caps.
3. Remove bearing caps from ends of the propeller shaft
assembly as follows :
(al Suppon front universal joint yoke. or rear universal joint
flange ears on open jaws of a vice.
Retaini~
Botts
...
Tail Shaft
Flange
Joint
Inspection
On Vehicle:
I. Raise rear of vehicle and suppon rear axle assembly on
safety stands.
2 Measure propeller shaft runout at several points by
rotating final drive flange by hand.
Runout maximum:
O.6mm
Off Vehicle:
I. Remove propeller shaft as described above.
2. Place propeller shaft on "V" blocks, mea,ure runout with
micrometer gauge.
Umversal
Jomt ______
_ _ Tali
Shaft
_ _ _ \,jce
Yoke _ __
UJOO4
177
DRIVEITAIL SHAFT AND UNIVERSAL JOINTS
(b) Tap propeller shaft adjacent to bearing cap with a hammer

so that universal joint spider forces bearing cap out.
4. Pull dislodged bearing cap from front universal jointorrear
universal joint.
5. Rotate propeller shaft assembly ISO" so that ears on
opposite side of yoke, or flange, rest on the vice.
6. Remove 2nd bearing cap from propellershaft as per Steps
3 and 4.
7. Separate yoke or tlange from universal joint spider.
Snap Ring
Universal
Spider
Bearing
Cap
Tail
"
Shaft
P012
Snap Ring
1. Remove bearing caps from spider.

2. Position spider in yoke or nange. Hold spider to one side
in yoke or flange and position a bearing cap on the end of
spider.
3. While holding spider in bearing cap, push by hand then use
a "G" clamp to push bearing cap into yoke or n,mge until
bearing cap snap ri ng groove is fully visible. Install snap ring
Universa:,.1_
Joint
IOto groove.
8. Remove bearing caps from yoke or flange by resting

exposed end~ of spideron the vice, and removing bearing caps
". previously described.
9. Remove the spider from the yoke or flange.
10. (a) Thoroughly clean yoke or flange and propeller shaft
universal joint bearing cap bores.
'G' Clamp
Tall _ _ _ _~
Shaft
Tail
Shaft
Yoke
UJ007
Wire
Brush
4. Tum yoke or flange around and install opposite bearing

cap by positioning spider into bearing cap to prevent needle
rollers from being dislodged.
~~~~--~Be:a:n:n:g---------------Cap
Tail
Shaft
(b) Check bearing cap bores and remove any burrs.

Installation
Before installing universal joint, note the following:
* Cleanliness is of prime importance to ensure maximum
universaijoint life.
* Do not allow any needle rollers to become dislodged. Install

bearing caps in the upright position.
* Universal jointassembliesareprepaeked with lubricant and
do not require any further lubrication.
Take care not to damage bearing cap seals during installation. Gently ease bearing caps into their bores during
assembly.
Umversal
Joint
"/"
5. (a) To fully install 2nd bearing cap, position yoke or flange

in vice with 20ftheold universaljoinlbearingcaps. Squeeze
178
DRIVEITAIL SHAFT AND UNIVERSAL JOINTS
new bearing caps into position using the vicejaws orG clamp.
PROBLEM DIAGNOSIS
Onve
Problem: Noise!

* Sleeve yoke spline worn. Remedy - replace sleeve yoke.
* Spider bearing worn or stuck. Remedy - replace spider
bearing.
Problem: Vibration!
Ensure that the 2 old bearing caps are positioned centrally

on the new bearing caps, and not up against the edge of the
flange or yoke.
(b) Install 2nd snap ring.
6. Install spider and yoke or flange assembly to propeller
shaft. Install remaining bearing caps and snap rings a~
7. Tap propeller shatt, yoke and flange ears with a hammer
and ensure that all bearing cap snap rings are seatedcorrectIy
in bearing cap grooves and that universal joints arc free to
move in all directions.

Propeller shaft runout. Remedy - replace propeller shaft.
Propeller shaft imbalance. Remedy - balance propeller
shaft.
Sleeve yoke spline stuck. Remedy - replace sleeve yoke.
SPECIFICATIONS
Propeller Shaft Balance Specification
10.0 glcm at 3000 rpm. Low 'pot of propellershaft is marked

on the rear universal joint tlange.
Maximum runout of Propeller Shaft
0.50mm. Thiscanonly be measured accumtely un asuitable

propeller shaft jig, where the propeller shaft assembly is
correctly supported through iLS entire length.
Universal
I
Yoke
Lubricant
Front and Rear Universal Joints Lithium soap grease
TORQUE WRENCH
SPEC'S
Rear Universal joint flange/pinion
flange bolt ......................................................... 9-14Nm
UJ010
8.lnstall propeller shaft as pcr prior Section [INSTALLATION - PROPELLER SHAFf].
179
REAR AXLE
Subject
Page
Subject
Inspection ................................................................ 190

Differential Ca~ ....... _, .............................................. 190
Differential Side Gears and Pinion Gears ........... .. ... ... 190
Ring Gear and Pinion ... .... ................................. ........ 191
Bearings ......................... ... .............. ... ...................... 191
Differential Carrier .................. .............. .. ................. 191
GENERAL INFORMATION ...................... 181
Geneml Descri ption & Maintenance ............... ...........

RcarAxleldentification ............................................
Maintenance ...... .... ...................................................
Limited Slip Di ffcrcntial Precautions .........................
Lubrication .. .............................................................
Page
181
181
181
181
181
Assembly ................................................................. 191
Di fferential Case.......................................................
DiffcrentialBearingPre-LoadShirnSelection ............
Hypoid Pinion Positioning Shim Selection ................ ..
Pinion .... .. .................................................................
Pinion lnstallalion .....................................................
Differential Backlash Selling .......... ...... ... ......... .........
Ring Gear and Pinion Contact Pattem ............ .... .......
GENERAL MAINTENANCE ..................... 182
Check Rear Axle Lubricant Level ...........................

Rear Axle Shaft Hub Studs ....................................
Replacement.............................................................
Rear Axle Shan - Bearing andlor Seal ....................
Ren)oval ........ .......... ....... ............... ...........................
Replacement .................................... .........................
Installation .......................................................... .. ...
Limited Slip Differential .........................................
TorqucCheck ...........................................................
Pinion Oil Seal .........................................................
Replacement ............................ .................................
Pinjon Flange ...........................................................
Replacement(Using Old Oil Seal) .. .......... ........ ... ......
Replacement (Using NcwOil Seal) ............................
182
182
182
182
182
182
183
183
183
184
184
184
184
185
Limited Slip Differential ......................... 196
Dismantle ................................................................ 196

ltts()CCtion ................................................................ 197
Differential Case ............................................... ... ..... 197
Differenlial Side Gears and Pinion Gears ................... 197
Ring Gear and Pinion ................................................ 197
Beatings ................................................................... 197
Differential Carrier ................................................... 198
Assembly ................................................................. 198
MAJOR REPAIRS .................................... 187
Rear Axle Housing Assembly ..................................

Removal (sedan) ........ ............ ..... ..............................
Inslallation (sedan) ....................................................
Removal(wagon-utility) ..........................................
[nstallation(wagon-utility) ...... ..................................
Rear Axle Housing Assemhly ..................................
Dismantle ................................................................
Dismantle- DifrcrcnlialCase ....................................
191
192
192
193
193
194
195
187
187
187
187
188
General Problems ..................................................... 198

Problem Diagnosis Differential & Rear Axle
Bearing .................................................................... 199
188
188
190
SPECIFICATIONS ................................. 199

180
REAR AXLE
rear axle is COLD.
REAR AXLE
GENERAL INFORMATION
Axle
EF & EL Models are equipped with Borg Warner rear axle

a.semblies with a3.08 mtioand 183.8 mm ringgeardiameter
or with a 3.23/3.45 ratio and 189.9 mm ring gear dianleter.
They have either a two or four pinion type rear axle assembly.
A Limited Slip Differential, is also available.
Assembly
If servicing a vehicle fined with a Limited Slip Differential,

never run the engine with the transmission in gear and one
wheel raised. The driving force to the wheelan the ground
may cause Ihe vehicle to move.
Wheel balancers that are designed to usc on the vehicle are
not recommended for use on the rear wheels of vehicles
equipped with a Limited Slip Differential. One rear wheel
will drive if in contact with the ground when the opposite
wheel is raised.
This type of balancer may be used by removing the wheel
opposite to the one being balanced with the vehicle raised,
refit wheel nuts, reversed, to retain brake disc. Ensure that
safety stands are used to support the vehicle.
GENERAL DESCRIPTION &

MAINTENANCE
RearAudeIdentification
Rear axle assemblies can be identified by referring to the
identification lag anached to the rear axle housi ng cover. This
lag carries the part number for the rear axle assembly, final
drive ratio and the serial numberofthe axle assembly.
Lubrication
Identitication of rear axle assemblies fitted with production

option Spin Resistant Limited Slip Differential, fined with
the normal identification tag as well a. a lag fitted to the filler
plug stating that approved lubricant is only to be used.
MaintenanL"C
Rear Axle Breather.
The breather val ve should be checked regularly toensure that
the cover rotates freely and that the exhaust is not restricted,
broken or blocked by mud.
Axle Bearing.
The axle bearings are lubricated by the oil in the rear ax le
assembly and therefore require no periodic maintenance.
Differential Carrier Assemblies.
Check for lubricant leaILs at every maintenance service. If
there is evidence ofleakage, correct leak and add lubricant as
necessary.
Every 20,000 kms or 12 months, check to ensure that the
lubricant level is to the bottom of the fillerplughole when the
,
181
The lubricant level should becheckedevery20,oookrnsor 12

months when the unit is cold. Refer to checking rear axle
lubricant level section in this Chapter. At this temperature,
the lubricant should be level with the bonomofthc filler plug.
If necessary ,top lip differential tluid level with the approved
lubricant. Do not use any other types of lubricant in the
differential.
Ifan incorrect lubricant is accidentally used at any time, then
the rear axle should be drained and llushed out with the
specified lluid,drainedand refi lled with the correct lubricant,
thena road test shoilid be conducted.
REAR AXLE
GENERAL MAINTENANCE
CHECK REAR AXLE LUBRICANT LEVEL
1. Ensure vehicle is level.

2. Clean area around filler plug.
3. Remove filler plug.
4. The lubricanllevel is 10 be maintained at the bottom edge
of the filler plug hole. Top up the differential with specified
lubricant.
5. Inspect tiller plug fordamage. !fokay, refit in ax Ie housing
cover. If damaged, replace plug.
REAR AXLE SHAFT HUB STUDS
Replacement
1. Remove axle shaft assembly as described in Rear axle
shaft, Shaft andlor Seal section in this chapter.
2. Drive or press hub studs from axle shaft flange.
3. Dri veorpress hub smds into axle shaft flange, with support
around stud in either casco
4.lnstall axle shaft as described in Rear axle shaft, Shaft andl
or Seal seclion in this chapler.
axle assembly, measure bearingand

by mounting adial indicator so thatthe stylus is on the end of
the axle shaft. Ifend noat exceeds specitication, bearing
should be rcplaced.
Bearings should be settled by oscillating the shaft while
pressing in each direction on the axle flange while measuring
end t1oa!.
Axle bearing end f1oalspecification (axleshaftinstalll-d):
New bearing:
0.76 mm
Used bearing:
0.04 0.48 mm
REAR AXLE SHAFT - BEARING AND/OR

SEAL
To check for a failed bearing, conduct a road test.

!ffailure of the bearing is not obvious after removal of shaft
from vchiclc, the bearing should be washed.
Clean all the oil and dirt from inside the bearing. Re-oil with
a Iightengi ne oi I. then rotate the outerrace with an oscillating
motion while exerting a radial hand pressure.
Check for any rough or gritty feeling. Exarnmetheouterrace
track, rollers, cage and rib ring for any damage or wear.
Refer to "Problem Diagnosis" Seclion in this Chapter for
identification of bearing failures.
Check bearing for end float as outlined in Step 5 of the
Axle Retainer
---Plate
Wrench
following "removal" instructions.
Removal
1. Raise rear of vehicle and support rear axle assembly on
safety stands.
2. Remove wheel cover (steel wheels) or centre cap (alloy
wheels).
3. Mark relationship of wheel to axle flange. Remove road
wheel attaching nuts and remove wheel.
4. Remove brake calliper, and support it on a wire hook,
remove. Referto brake chapter, do notal low calliperto hang
by brake hose.
6. Remove 4 nange nuts on backing plate.

7. Remove rear axle, seal and bearing assembly from housing, using rear axle adaplor, logether with slide hammer.
Toassist in assembly, the retaining ring on the tapered roller
bearingiscemenledtothebearingcup.lnsomecasesthisring
may break awayduJing bearing removal operations, leaving
the bearing cup in the housing.
To remove bearing cup, use slide hammer together with
bearing cup remover.
Replacement
I. To remove bearing inner retainer, drill a5-7 nun hole into
retainer at right angles to axle shaft. Take care not drill
through retainer as dri II wi II damage axle shaft.
2. Then support axle and bearing in a vice. Then carefully
split retainer with a chisel across dri lied hole as shown.
3. Slide bearing outer retaining plate and oil sea toward axle
flange.
182
REAR AXLE
Rear
Axle
Hub
load to ensure the proper seating of all components.

12. Lubricate bearing with recommended axle lubricant.
Check that the bearinghasarninimum ofO.25 mmend float
and is free to rotate without binding.
Installation
1. Check that the oil drain in backing plate or flange is not
blocked by foreign matter.
2. Install axle shaft assembly, taking care to engage splines
of shaft with differential side gears. If necessary, lightly tap
endofaxleshaftuntil bearing is fully 'home' in axle housing.
Hole drilled into

bearing retainer
Axle
"'rlrl
4. Install special tool to axle shaft and press axle shaft from
bearing. Removeoi Iseal and retaining plate. Take care that
the beari ng is supponed on the inner race only, otherwise the
bearing may be damaged.
5. Check retaining plate for damage or distonion with a
straight edge. Replace plate if distoned.
6. Clean axle shaft (ensure that there is nodamage on bearing
seating surface or seal surface).
Reillr Axle
AS!lembly
D ies Turned Around

To Use For Stability
* On vehicles with Limited Slip Differential, do not rotate the

axle shaft until the opposite side axle shaft is installed.
Rotation of one axle shaft without the other shaft installed
will result in misalignment of the cone and the side gear
splines and prevent entry of the second shaft.
3. Inswll and torque 4 axle bearing retainer plate nuts,
drawing in oi I seal at the same time.
40 50 Nm.
Torque:
Bearing position
7. If old bearing is to be used, thoroughly clean bearing.

Lubricate it with light engine oil, then check for wear or
roughness as previously described. IF A NEW BEARING
IS GOING TO BE USED. DO NOT CLEAN OUT PRO
TECTIVE GREASE FROM ASSEMBL Y.
8. Install retaining plate and new oil seal on axle shaft. Install
seal so that spring loaded lip of the seal is towards the axle
bearing.
Ensure that the corrcct typcof seal for rear axle assemblies
with rear disc brakes is fitted.
Before installation of the seal, pack between the seal lips
with Lithium No.2 Grease.
9. Install bearing with radius on inner cone towards shoulder
on axle shaft.
If the old bearing is to be reinstalled, and the cup has pulled
away from the other race during removal, make sure that the
cup and mating faces on the bearing are thoroughlycIean and
frceofhard adhesive cement before assembly.
10. Install new bearing inner retainer on the axle shaft.
11. Usingspccial tool [4A5I orsimular], pressaxleshaft into
bearing.
Care must be taken to ensure that the bearing and retainer
arc guided on squarely during installation. Apply sufficient
Axle
- - - P l a te
4. Check axle bearing end Ooat. (Refer to Step 5 of

REMOV AL procedure.)
S.lnstall brake disc and calliper. Torgue calliper attaching
bolts.
Torque:
2231 Nm.
6. Install wheel and check lubricant level.
LIMITED SLIP DIFFERENTIAL
Torque Check
1. Place transmission in neutral with engine turned 'OFF'.
2. Jack up one rear wheel, then release par brake lever to fully
183
REAR AXLE
'OFF' position. Support axle housing on a safety stand.

3. Remove wheel cover (steel wheels) or centre cap (alloy
wheels).
4, Mark relationship of road wheel to axle flange. Remove
road wheel attaching nuts and remove wheel.
5. Remove calliper attaching bolts and remove calliper from
mounting, for disk brakes. (Refer to BRAKES Chapter in
this Manual.) Support calliper on a wire hook. 00 NOT
ALLOW CALLIPER TO HANG BY BRAKE HOSE.
Remove bmke disc.
6. Using a torque wrench in conjunction with adaptor and
torque wrench adaptor, rotate axle shaft in a forward direction.
If the unit is operating satisfactorily, a torque reading of
approximately 68 Nm should be obtained before axle shaft
turns.
If a torque reading of less than 68 Nm is obtained, remove
differential case and inspect case internal components and
repair a. necessary. (Refer to LIMITED SLIP DIFFERENTIAL Section in this Chapter.)
flange retaining nut, counting the amount ofturns to remove ..

5. Withdnlw pinion flange using special tool with nut and
screw. Place adnlin lnly beneath differential carrier housing.
6. Prise pinion oil seal from carrier bore using a universal seal
removing tool.
7. Lubricate new pinion oil seal lips with rear axle lubricant.
Lightly coat outside of seal shell with a nonhardening gasket
cement.
8. Start oil seal in differential carrier housing and drive seal
squarely into position using special tool. Seal fits flush to
0.25 mm below the carrier housing surface.
9. Ensure that pinion shaft is free from burrs and that flange
oil seal surface is free from damage.
10. Coat splines and seal surface of pinion flange with
differential gear lubricant, and install flange on pinion shaft
splines. ENSURE THAT CENTRE-PUNCH MARKS
ALIGN.
11. Install flange retaining nut and tighten nut the same
arnountofturns it took to remove, until centre-punch marks
align, then tighten nut carefully to a position nor more than SO
past aligned setting.
Adapter
Oifferential
Differential
Assembly
Torque
Wrench
Torque
Wrench
Axle
Flange
Vice
\,
7. Install brake disc and calliper. Torque calliper attaching

bolts.
Torque:
22 - 31 Nm.
8. Install road wheel.
* When installing the whcel, align the marks made prior to
removal .
9. Remove safety stand and lower vehicle.

10. Torque wheel nuts.
Torque:
100 - 125 Nm.
PINION OIL SEAL
Replacement
safety stands.
2. Disconnect propeller shaft from pinion flange. Refer to
"Propeller shaft and universal joints" Chapter in this
Manual.
3. Lightly centre punch al.ignment marks on the pinion flange
nut, pinion flange and pinion end so as to help in assembly.
4. Using a special tool, holding pinion flange and remove
Flange Holding
Tool
Cautioll: Should the retaining nut be over-tightened and the

pre-load exceeded, it will be necessary to remove the pinion
f rom the housing and install a 0.75 mm shim between the
:,pacer and the f ront pinion bearing. Under flO circum
stances must the retaining nut be backed offto decrease the
pre load setting. The collapsible spacer may only be reused
once.
12. Reconncct propellcr shaft rear universal joint flange to
pinion flange. Refer to PROPELLER SHAFf AND
UNIVERSAL JOINTS Chapter in this Manual.
13. Check lubricant level and top up if as necessary.
PINION FLANGE
Replacement [Using Old Oil Seal]

Due to production tolenlnces in the length of the pinion tJange,
it is essential that the following method be used when
installing a new pinion flange andlor pinion nut.
184
REAR AXLE
I. Remove axle shafts a~ per REMOVAL OF REAR

AXLE SHAFf, BEARING AND/OR SEAL Section in
rnis Chapter.
2. Disconnect propeller shaft from pinion flange. Refer to
PROPELLER SHAFf AND UNIVERSAL JOINTS
Chapter in this Manual.
Differential
Case
Tail Shaft
Retainer
Nuts
Flange
Universal
Joint
3. Check pinion and side bearing pre load before removing

pinion flange retaining nut. To check bearing pre-load:
(a) Fit a pulley to the pinion flange and attach a cord around
the pulley and to a spring scale.
(b) Start rotation of pulley and whilst in motion (approxi
mately 50 - 60 rpm) note reading on spring scale. To
determine pre-load on bearings, multiply the reading on the
spring scale by the radius of the pulley used.
EXAMPLE: !fthe pulley diameter is 152 mm, the radius is
76 mm which equals 0.076 m. The spring balance reading is
25N. Pre-load = 0.076 m x 25 N = 1.9 Nm.
4. Remove pinion flange retaining nut and pinion flange as per
REPLACEMENT OF PINION OIL SEAL Section of
this Chapter.
5. Ensure that pinion shaft thread is free from burrs. Then
coat splines with axle lubricant.
6.lnstall pinion flange and nut.
DO NOT, UNDER ANY CIRCUMSTANCES, USE

FORCE OR HAMMER DURING INSTALLATION
ONTO THE PINION SHAFT.
Caution: Should the retaining nut beover-tightenedalldthe
pre-load exceeded, ;t will be necessary /0 remove the pinion
from the Iwusing and install a 0.75 111m shim betweell the
collapsible >pacer and the front pinion bearing. Under 110
circumstances IIIUSt the retaining nut be backed off to
decrease the pre-load reading. The collapsible spacer lIIay
be re-used once.
7.lforiginal pinion oil seal has not been distUlbed, and is not
being replaced by a new seal. tighten nut gradually until end
play on pinion shaft is reduced to approximately 0.50 mm.
Attach a spring scale to pulley and check bearing pre-load.
Continue tightening nut whilealternalively turning pinion to
seat bearings until pre-load figure previously recorded (see
Step 3b) is reached. Then increa~e this original pre-load
reading by .11 to 34 Nm. FURTHER ROTATE THE
PINION AN EXTRA 30 - 40 TURNS AND RECHECK
THE PRE-LOAD TO ENSURE THAT NO CHANGE
HAS OCCURRED.
8. Reconnect propeller shaft rear uni versal joint flange. Refer
to PROPELLER SHAFf AND UNIVERSAL JOINTS
9.1nstall axleshaft assemblies. RefertoINSTALLA TJON
- REAR AXLE SHAFf, BEARING AND/OR SEAL
Section in this Chapter.
Axle
Shaft
Differential
Housing
Pinion
Shaft
Flange
Flange
Nut
The new flange is an interference fit on the pinion shaft

splines, and should be pulled into plate by tightening the
retammg nut.
10. Check axle lubricant level. Refer to CHECK REAR

AXLE LUBRICANT LEVEL Section in this Chapter.
Replacement (Using New Oil Seal)
1. Remove axle shafts as pcrREMOVAL - REAR AXLE
SHAFT BEARING AND/ORSEALSection in this Chapter.
2. Disconnect propeller shaft from the pinion flange. Refer
to PROPELLER SHAFf AND UNIVERSAL JOINTS
3. Check pinion and side bearing pre-load before removing
the pinion flange retaining nut. To check bearing pre-load:
(a) Fit a pulley to the pinion flange and attach a cord around
185
REAR AXLE
Differential
Housing - _......
Axle Shaft
Pinion
Seal ---
_ _ _~
Axle Bearings
Pinion Seal
Installing Tool
Axle Bearing Retaining Plale
~,,--
Ra034
------~~---
to a spnng
(b) Start rotation of pulley and whilst in motion (approximately 50 - 60 rpm), note reading on spring scale. To
determine pre-load on bemings, multiply the reading on the
spring scale by the radiu~ of the pulley used.
EXAMPLE: If the pulley diameter i~ 152 mm, the radius is
76 rnm, which = 0.076 m. n,e spring balance reading is 25
N. Pre-load = 0.076 m x 25 N = 1.9 Nm.
4. Remove pulley from pinion flange.
S. Hold flange with speeial tool [4A39/11 and slacken pinion
nange retaining nut until end play can be felt in the pinion
shaft.
6. Check oil seal and differential ~ide bearing pre-load using
a ~pri ng scale as outlined in Steps 3a and 3b descri bed above,
and record this meac;urement for later reference.
7. Remove pinion flange nut and pinion flangea~ previollsly

described.
Pinion
Flange
Pinion
Nut
FRA01B
12. Ensure that pinion shaft thread is free from burrs, then
coat splines of pinion flange with rear axle lubricant and
install nange on pinion shaft splines.
The new pinion !lange isan interference fiton the pinion shaft
splines and should be pulled into place by tightening the
retaining nut. Do not usc foreeor hanunertlle new flange on
to the pinion shaft.
13. Continue tightening retaining nut until end play on the
pinion shaft is reduced to approximately 0.50 mm.
14. Check new oi Iseal and differential pre-load using a spring
~cale as previously outlined in Steps 3a and 3b above. Record
reading for assembly reference.
15. Thepre-load reading fordifferential assembly obtained in
StepS above, is subtracted from pre-load reading obtained in
Step 14. The difference between these ligures represents
extra lip tension of new seal expressed as a Nm pre-load
figure. The difference between the pre-load readings obtained in Steps 5 and 14 mu~t be added to pre-load reading
obtained in Step 3b to obtain a total pre-load reading.
THEORETICAL EXAMPLE:
Step 14 New oil seal & beming pre1.47 Nm
load bearing
Step 5 Old oil seal & side bearing
1.02 Nm
pre-load reading
Subtract step 5 from step 14
0.45 Nm
Step 3b Complete Differential Assembly
1.47 Nm
The pre-load reading will therefore be
1.47 + 0.45 Nm
Which totals a pre-load reading of
1.92 Nm
Cautio,,: Should the retaining nut beaver-tightened alldthe
pre-load exceeded, it will be necessary to remove the pinion
from the housillg and illstall II 0.75 mm shim hetween the
spacer and the fr0111 pinion bearing. Under no circumstances IlUlst the retaining nut be backed offto decrease the
pre-/olldsettillg. The collapsible spacerlllayollly he reu.ved
8. Prise pinion oil seal from carrier bore using a suitable
ollce.
removing 1001.
16. Continue tightening retaining nut whi Ie alternately tuming pinion assembly to seat bearings unti Itotal pre-load figure
obtained in Step 15 (above) is achieved. Then increase this
pre-load reading by .11 to .34 Nm. Further rotate pinion an
extra 3 -4 turns and recheck pre-load toensure that no change
has occurred.
* It mustbe realised that the ligures in theexarnpleare purely
9. With rear axle lubricant, lubricate new pinion oil seal.

10. Lightly coat outside diameter of seal shell with a nonhardening ga... ketcement.
11. Using special tool, start new oil seal in differential carrier
housing and drive seal squarely into position.
186
REAR AXLE
9. Support rear axle housing under eenlTe with a floor jack.

10. Disconnect rear shock absorbers at lower mounting
points.
11. Remove rear stabilizer bar to axle housing mounting
bolts. Remove stabilizer bar to body mountings. Remove
stabilizer bar.
theoretical; in actual practice, the figures could differ greatly

and the figures obtained, when perfonning the various operations, are the ones to usc.
17. Reconnect propeller shaft rear universal joint flange to

pinion flange.
18. Install axle shaft a<semblies.
19. Check axle lubricant level.
(Sedan)
12. Disconnect parthard rod from axle housing mounting.
MAJOR REPAIRS
REAR AXLE HOUSING ASSEMBLY
Removal
1. Using a floor jack undercenlTeoftheaxle,jack up rear of
vehicle. Then place safety stands undertherearbody jacking
points.
2. Remove wheel cover (steel wheels) or centre cap (allow
wheels).
3. Mark position of wheels to axle flanges. Remove road
wheel attaching nul. and remove wheels.
4. Remove propeller shaft.
5. Set park brake in fully released position.
6. Disconnect park brake actuatorretum springs from actuator arms.
13. Lower axle housing on floor jack until rear suspension

springs and rubber insulators can be removed.
14. Remove upper and lower conlTOl arm to axle housing
attaching bolts and nuts.
15. Lower axle housing on jack and remove assembly from
underneath vehicle.
(Station Wagon - Utility)
16. Loweraxlehousing on floor jack until rear suspension is
hanging at its fulliength
17. Remove axle housing retaining 'U' bolts .
.---;---
Axle Housing
Assembty
/
7. Remove 2 bolts holding park brake cable brackets to rcar
disc brake assemblies. then disconnect cable from mounting
bracket.
8. Install a brake hose clamp. disconnect brake hose at axle
housing connection. Remove brake hose retaining clip.
Special
BrQ27
-/
Retainer
18. Lift axle housing with jack and remove a.sembly from
underneath vehicle.
lINaII
(Sedan)
The upperconlTol arm to axle housing attaching bolts must
be inserted in an inward direction.
Torque all bolts and nuts.
The conlTol arm attaChing bolts, nuts and panhard rod
mounting nut must be tightened with the vehicle at the
specified suspension height position.
Chcckand fill rearaxlecarriertoconect level with specified
187
REAR AXLE
lubricant.
Reconnect park brake levers and bleed brake hydmulic
system.
1. Place the axle on supports.
2. Connect the axle to the lower control arms and loosely
insl<~1 the allaching boll.
3. Locate the springs in the body, lower the body to compress
spnngs.
\, J
Retainer Plate
Torque
Wrench
4. Connect the parthard rod to the rear axle.

5. Install the shock absorber attaching bolts and nuts.
6. Install the upper rear control arms to the rear axle, nuts of
bolts to centre, do not torque nuts at this stage.
7. Support vehicle on axle housing Ccurb load position) and
torque all above mountings, install stabiliser bar.
Lower Control Arm Attaching Bolts
74 - 103
Upper Control Arm Attaching Bolts
74 -103
Stabilizer Bar Bracket Attaching Nuts
20
10
Stabilizer Bar Spacer Stud Nuts
Track Rod Attaching Nut to Axle Housing
74 - 103
Track Rod Attaching Bolt to Body Mounting 4 -103
Shock Absorber Upper Mounting Nut
35
74 - 103
Shock Absorber Lower Mounting Nut
(Station Wagon - Utility)
* The leaf spring to axle housing attaching 'U' bolts must be
inserted and tightened with the housing sitting on the aI igning
lug.
Torque all bolts and nuts.
Checklmd till rearaxlecaniertocorrect level with specitied
lubricant.
Reconnect park brake levers and bleed brake hydraulic
system.
1. Place the axle on supports.
2. Retit housing into vehicle
3.[nstall the rear axle bracket boltson both springs allaching
the axle housing and rear springs.
4. Lower jack and supports from rear axle housing.
5. Replace rear shock absorbers as described in rear suspension section.
6. Reconnect the hydraulic brake lines.

7. Connect the install stabiliser bar to the rear axle.
8.lnstall disk brake components:
a. [nstall calliper and bracket assemblies and brake lines,
install axle shafts.
b. Install splash shields.
c. Install discs, install calliper lower guide pins and nuts and
connect park hrake cable to the callipers and the brake
equaliser. Tighten to specification.
Brake Pipe Junction to Axle Housing Bolt 20-2SNm
Calliper Anchor Plate bolts
22-31 Nm
Dust Shield bolts
8-10.6 Nm
9,Align marks ondriveshaftand pinion flanges and connect
drive shaft. Tighten to specification.
Rear Universal Joint Flange to Pinion Flange 16-20Nm
10. Install rear wheels.
II. Tighten "U" bolts and lower shock absorber nuts to
specification.
Leaf Suspension "U" Bolt Nuts torque:
65 Nm
Lower Shock Absorber Nut torque:
20 Nm
12. With vehicle in curb load position fill the axle to the
bottom of the filler plug hole with the specified oil.
Rear Axle Lubricant:
Hypoid Gear Oil E.P. SAE 90
Rear Axle Lubricant Amount:
1.5 Litres
CAUTION: Premature gear fault may resultifspecified
lubricant is not used.
13. Lower vehicle and tighten the wheel nuts to specification
and check park brake adjustment.
101-108Nm
Wheel Nuts specified torque:
REAR AXLE HOUSING ASSEMBLY
Dismantle
1. Remove rear axle housing assembly as previously de-
scribed.
2. Clamp rear axle .sembly in a suitable holding fixture or
on work bench.
3. Drain lubricant from canier by removing rear cover.
4. Before dismantl ing differential assembly and dri ve pinion
hom axle housing, the following inspection should be done.
Inspections help find the cause of rear axle noise and
determine corrections needed.
Ca) Inspect the moving parts for chipped or scuffed surfaces.
Cb) Check torque of ring gear bolts, differential carrier
bearing cap bolts and pinion flange nul.
188
REAR AXLE
* Ring gear bolts have a left-hand thread.

(e) Rotate differential case through several turns whilst
having dial indicator set up (against back face of ring gear)

to measure ring gear runout.
Ring gear rear face run-out:
0.13 mm (max).
6. Mark bearing caps and adjacent sides of axle housing with

a daub of paint. This wil! aid the correct assembly of bearing
caps. Remove bearing cap boils and caps.
Paint Marks
Ring Gear
Dial Indicator
Bearing Cap
Bearing Cap
Identify the position of the bearing caps with paint

Ra016
Measuring Ring Gear Back Face Runout
Ra01 3
(d) With dial indicator set up as in (c). Push ring gear hard
one way, then hard the opposite way measuring side play.
Should be no side play present. Check there's no pinion end
play.
(e) Measure ring gear backlash at three equally spaced
positions using dial indicator.
Backlash:
0.10 - 0.18 mm (at the tightest point).
Blacklash
7. Install differential housing spreading tool and adaptors

[9255] to di fferential carrier housing.
Differential
Housing Spreader
a dial micrometer
Dial
Ring gear
to measure
carrierapproximatelyO.1 toO.2 mm and remove dial indicator, differential assembly, and spreading tool.
* Do not spread carrier more than 0.5 mm as damage will
occur.
9. Place left and right bearing cups with bearing caps to be

reinstalled in original location. Place shim with appropriate
cups.
IO.Install tool to hold pinion flange and remove pinion flange
(I) Noobvious faults found, check gear tooth contact pattern.
5. Remove axle shaft.
nul.
11.Instal! pinion flange removing special tool No. E9258B

ora soft face hammeron tIleearly productions only. Remove
pinion nange.
12. PlY pinion oil seal out of carrier bore using a suitable tool.
13. Remove pinion by tapping on front end with a soft faced
hammer. Then remove pinion front bearing from carrier
bore. Discard pinion bearing spacer.
Rear Axle
Assembly
Disc Turned Around

To Use As A Slide
Hammer
189
REAR AXLE
Differential
Differential
Housing
cups
using special tool [E9293Aj. [E9271] is used for installing
new bearing cups.
* It i, essential to only replace one bearing cup at a time, as
tool [E927 IJ relies on the remairting bearing cup a. a guide.
15. To removerearbearing from pinion, remove legs from the
ring of tool. Place ringon suitable press plates. Install pirtion
and adaptors into ring. Press pinion from bearing.
Dismantle- Ditl'ercntial Case
1. Before dismantling differential case, inspect differential
side bearings for any signs of damage.
Both side bearings and their cups are matched pairs. If
either bearing is to be replaced, its matching cup must also be
replaced.
2. If necessary, use special tool [EI673Ml1, adaptors
[E1673N 15] and stepped plug [E 167316B] to remove side
bearings from di fferential case. Discard side bearings once
they are removed.
3. Grip the differential case in a vice with soft jaws.
4. Remove ring gcar attaching bolts.
* Ring gear attaching boll, use a left hand thread and are
identified by an 'L' on the bolt head.
Assembly
Retaining
Bolts
Vice
FRA029
5. Remove differential case from vice.

6. Using soft faced hammer, remove ring gear from di fferen
tial case by hitting down on ring gear. Support ring gear

during this operation so that it does not strike bench top as it
comes free of case.
Donat useascrewdriverto pry between ring gear and case.
7. Drive out differential pirtion gear cross shaft and shon
shafl. retaining pins from differential case using a suitable
size pin punch and hammer.
8. Re-mount thedifferential casein vice withsoftjaws. Using
a brass drift and hammer, drive out pinion cross shaft from
di fferential case cover.
9. Rcmovedifferential case from vice. Using a brass dri ft and
hammer, separate two differential case halves by driving
against thrust block.
* Do not use a screwdriverto prise apart the differential case
halves,
10. Using a brass drift and hammer, drive out pinion gear
cross shaft from differential case.
11. Lift out pinion gears, l1,rust washers and thrust block from
differential ca.e. Remove differential side gears and thrust
washers from di fferential case halves.
Keep the gears with their respecti ve thrust washers in pairs
so that they may be reinstalled in their original position.
(continue steps 12 & 13 for four pinion differential)
12. For four pinion only drive out pinion gear short shaft
reLaining pins and shafts fmm differential case.
13. Lift out pinion gears. thrust washers and thrust block
from differential ca.e. Remove differential side gears and
thrust washers from differential case halves.
Inspection
All components should be thoroughly cleaned and dried,
then inspected.
A. Differential Case
Check case for general soundness and pay particular attention to the following poinL"
1. If di fferential case side bearings have been removed, check
case journals for damage and bearing seating surfaces are
free from dirt and burrs.
2. The ring gearspigot and mounting face should beclean and
3. The mating surfaces fordifferential case halves should be
clean and free from burrs.
4. The thrust surfaces for differential side gears and pinions
should be examined for excessive wear.
5. Thedifferential side gear journal bores should beclean and
free from scoring.
6. Thecase bores for differential pinion gearshaftsshould be
checked for "out of roundness".
B. Differential Side Gears and Pinion Gears
1. Examine all gear teeth forcmcks and hard contact marks.
2. The differential side gear splines should be checked for
excessive wear. Wear on splinescancontribute to excessive
driveline backlash.
3. Check differential side gear journals and back faces for
sconng.
190
REAR AXLE
4. Check fit of differential side gears in differential case cap

and cover. Wear on side gear hubs or in the case bores can
cause a "clunking" noise in rear axle a<sembly when vehicle
is driven at low speeds.
5. inspect differential pinion bores and thrust surfaces for
scoring. Also check differential pinion gear shafts are nOl
bent and that surfaces where pinions run are not worn or
scored.
6. Check thrust wa.hers, they should be free from cracks,
nicks and burrs. Excessive wear of thrust washers or pinion
gear thrust surfaces can a1socontribule toexcessivedri veline
backlash.
7. Check thrust block pinion gear shaft bores for "out of
roundness".
C. Ring Gear and Pinion

1. inspect gear teeth for scoring or damage. Scoring of gear
teeth is usuaUy caused by excessive shock loading, use of
incontct lubricant or insufficient "run in" before towing a
heavy load. Scored gears must be replaced.
2. The ring gear bore and back face should be clean and free
from burrs.
3. The rear bearing seating surface on the pinion should be
4. inspect pinion splines and flange splines for evidence of
wear.
S.lnspect thread and bearing journals of pinion.
6. If on ASSEMBLY. a new gear set is to be installed.
D. Bearings
Identification of bearing failures are described in Problem
Diagnosis.
1. Bearing cups should have an even wear pattern and must
be free from flaking or pining. Ensure that scating surfaces
are clean and free from burrs or raised metal.
2. Thebearing assemblies should feel smooth when turned in
their cups.
3. The ",sembly should be free from loose particles.
4. No cracks should be present in roller cages, and bores
should show noevidenceofnaking or pitting.
E. Differential Carrier
1. Check casting all over for general soundness.
2. Examine oil passages and ensure they are free from
obstructions and loose particles.
3. The bore for pinion oil seal should be free from burrs.
4. inspect rear cover face and bolt holes for damage.
5. Check rear cover seating surface.
Assembly
I. Apply differential oil to the differential gears, bearings,
thrust washers and differential pinion gear shaft.. with rear
axle lubricant before assembly.
2. Position differential side gears with their thrust washers
into differential case halves.
3. Using a soft faced hammer, install pinion gear cross shaft
and short shafts into differential ea..,just enough to allow a
191
pinion gear thrust washer to sit on the end of each shaft.

* Ensure retaining pin holes in differential case and pinion
gear shafts are in alignment and chamfered edge of holes in
shafts facing up.
4. Install one of the pi nion gear thrust wa,hcrs over inside end
of one of the shan shafts.
5. Position appropriate pinion gear next to thrust washer and
knock shortshafl in until itcomes through centre of the gear.
6. Carry out Steps 4 & 5 for second pinion gear shan shaft.
7. Install thrust block between 2 installed pinion gears.
Knock the 2 pinion gear short shafts into position ensuring
that retaining pin holes in the shafts line up with holes in
differential case.
8. Install pinion gear thrust wa.her and gear to cross shaft.
Knock cross shaft through gear and thrust block.
9. Install remaining pinion gear and thrust washer. Knock
cross shaft through pinion gear, ensuring that thrust washer
aligns with cross shaft. Knock cross shaft into differential
case until retaining pin hole in shaft aligns with hole in
differential case.
10. Install pinion gear cross shaft and short shaft retaining
pins. Ensure that ends of retaining pins protrude 6 mm from
differential ca~e cap to cover mating surface. This is
necessary so as to locate differential ca~e coverto ca.. cap.
11. Holding differential side gear in position through differential case cover bore. Push 2 differential case halves
together located on protruding retaining pins.
12. Place ring gear into position on differential case cap and
install ring gear attaching bolts.
Tail
Yoke
* For ea.. of a"embly, it may be necessary to heat the ring

gear on a hot plate until it is hot to touch, prior to installing
onto the differential ca.. cap.
On no account must a flame be used to heat the ring gear.
Also, use left-hand threaded guide pins to pilot the ring gear
over the differential case spigol.
13. Tighten ring gear attaching bolts evenly until gear face is
flu sh with differential case spigot. Torque bolts.
* Ring gear bolts have a left hand thread, identified by "I."
on bolt head.
Torque:
130 - 145 Nm.
ALTERNATIVE 1:
REAR AXLE
NOTE: If not installing new side bearings or adjusting ring

gear and pinion contact pattern:
(a) After satisfactory contact pattern is produced, clean ring
gear and pinion gear teeth and pour a liberal quantity of rear
axle lubricant onto gears and bearings.
(b) Tum gears to work lubricant into all surfaces.
(c) Fit rear cover and new gasket to carrier and torque cover
attaching boll,.
Torque:
23 - 3t Nm.
(d) Install rear axle assembly as per INSTALLATIONREAR AXLE HOUSING ASSEMBLY Section of this
Chapter.
ALTERNA TIVE 2:
NOTE: Ifinstalling new side bearings or adjusting ring gear
and pinion contact pattern:
If installing new side bearings, use special tool [E9277] to
press on side bearings to differential case journals.
B. Differential Bearing Pre-Load Shim Selection
1. With 2 differential bearing shims, place one against each
side bearing cup. With cups in position on bearings install
differential assembly in housing, without using the spreader.
2. With assembly positioned hard to one side of the carrier,
measure gap between shim and carrier with feeler gauges.
Rotate case making sure bearings are seated with feeler
gauges still in position. Check that the end Iloat has not
increased re-measuring clearance with feeler gauges again.
3. Remove case assembly, shims and bearing cups from the
housing.
4. To establish thickness of shims required:
(a) Measure total thickness of the 2 shims used in measuring
the end Iloat.
(b) Add the clearance measured by the feeler gauges.
(c) To apply the required pre-load to the bearings, add 0.15
mm for new bearings orO. I mm for used bearings.
5. Half thickness of the total value calculated in Step 4. then
locate a shim or number of shims that equal the halved
amoun~ there will be 2 lots needed.
6. Fit differential housing spreading tool and adaptors to
differential housing.
7. Using dial indicatortomeasurespreadofhousing. Spread
carrier approximately 0.25 mm. Remove dial indicator.
Housing Spreader
Undernocireumstances should the carrier be spread more

than 0.5 mm.
8. Place differential case, bearing cups and shims into
position, the COllect amount of shims on either side.
9. Remove spreading tool from housing ..
to. Fit bearing caps torqueing to correct tension.
Torque:
48 - 60 Nm.
11. Case assembly will need to be rotated several times to
ensure bearings are seated correctly.
12. Wrap a piece of string around differential case Flange and
check side bearing pre-load by pulling on end of string with
a spring balance. Spring balance reading must be within
specification.
Side bearing pre-load:
New bearings:
15 - 35 Nm,
Used bearings:
8 -18 Nm.
Check the preload
with a spring
scale and string.
Wrape string around
back of ring gear
Spring Scales
String
.....
---~-=~o~-..
o
o
o
13. Using spreading tool lE9255] to spread the carrier.

remove case assembly from carrier.
(a) If pre-load measured in Step 12 is within specification,
keep selected shims and bearing cups together ready for final
assembly.
(b) Should pre-load not be to specification, adjustments are
made by decreasing shim thickness for reducing pre-load or
increaSing the shim thickness to increase pre-load.
Service side bearing shims are available in 0.04 mm
thickness increments, from 4.60 mm to 5.60 mm.
A 0.04 mm alteration to total shim thickness will usually
bring the pre-load within specification.
14. Carry out Steps6-12 until thecoll ect pre-load is obtained.
C. Hypoid Pinion Positioning Shim Selection
The pi nion positioning shim is located between pinion rear
bearing cup and carrier.
If ring gear and pinion or the pinion rear bearing assembly
are replaced, pinion depth must be rechecked with pinion
192
REAR AXLE
setting gauge [E9300]. The gauge provides, in effect, a

nominal or 'zero' pinion as a gauging reference.
, If a new gear set is to be installed, ensure that the same
matching number appears on both the pinion and the ring
gear.
I.lnspect pinion bearing cups for nicks and burrs. Replace
if damaged by removing bearing cups using special tool
[E9293A]. Tool [E927 I] is used for installing new bearing
S. Mount arbor (pan of [E9300]) in canier assembly and fit

the side bearing caps. Tighten cap bolts lightly.
6. Check clearance between arbor and head ofdummy pinion
with feeler gauges. record thedimensions.
7. On the end of the pinion, there are etched marking figure
on the drive pinion installation. A zero marking (0) indicates
that shim size measured in Step 6 is correct size for this
canier/pinioncombination.
cups.
'ltisessential to only replace I bearingcupata time as tool
[E9271] relies on the remaining bearing cup as a guide.
2. Lubricate pinion front and rear bearings with rear axle
lubricant. Do not use engine or other oils, as a misleading
rotating torque can be obtained.
3. Install therear bearing onto dummy pinion [part ofE9300].
Install the dummy pinion into the canier housing. Fit front
bearing to dummy pinion and then install dummy pinion
thrust collar and nut.
'Ensure that the rear pinion bearing that will be used for final
assembly of the pinion is used on the dummy pinion.
4. Torque nut on end of dummy pinion.
Matching
Pinion
Numbers
FRA035
A positive marking, e.g., +3, means that a thickness

measurement equivalent to this numerical marking must be
subtmcted from shim size measured in Step 6 - refer to
followingchan.
* A negative marking, e.g., -3, means that a thickness
measurement equivalent to this numerical marking must be
added to the shim size measured in Step 6 - refer to the
following chan.
Testing
Pinion flange
Dummy pinion rotational torque:

New bearings:
1.7 - 2.8 Nm.
Used bearings:
0.8 - 1.4 Nm.
Rotate dummy pinion back and fonh during tightening to
ensure bearings settle.
'Pinion bearing pre-load is very important because it retai ns
the pinion in its COllect relationship to ring gear.
'Bearings that are installed with insufficientorno pre-load,
will, after a comparatively shon period of running, develop
end play, causing noisy operation on overrun and could be
responsible for scuffing of ring gear and pinion teeth.
'Bearings that have too much pre-load, may become pitted
or flaked and result in ultimate failure.
, It is therefore essential to ensure that bearings are preloaded to specified torque specification. Pinion bearing preload must be established before any attempt is made to
determine pinion positioning shim stack.
193
PinIon
Marking
Shim Thickness Required
-4
Add .10 mm to measurement of Step 6.
-3
Add .075 rom to measurement of Step 6.
-2
Add .050 mm to measurement of Step 6.
-I
Add .025 mm to mea'urement of Step 6.
o Size as measured in Step 6.
+I
Subtract .025 rom from measurement of Step 6.
+2
Subtract .050 mm from mea'urement of Step 6.
+3
Subtmct .075 rom from measurement of Step 6.
+4
Subtract .10 mm from measurement of Step 6.
* Pinion positioning shims are service in thicknessincrement'i
of 0.025 mm, from 0.2 rom to 0.75 rom.
8. Remove dummy pinion and arbor from canier.
D. Pinion Installation
t. Select pinion positioning shim stack asdetermined inStep
7 above.
2. Remove pinion rearbearingcup using special tool [E9293A].
3. Install pinion positioning shimls into pinion rear bearing
cup bore.
4. Install pinion rear bearing cup using special tool lE927 1J.
Ensure that cup is seated squarely in bore.
S. Press rear bearing inner race against the shoulder of the
pinion using special tool.
REAR AXLE
To avoid possible damage to the pinion gear teeth when

pressing the bearing on, ensure that the press plates are
perfect! y flat, free of burrs and foreign matter prior to
installing the bearing cone.
Locate bearing inner race squarely on the pinion and press
only on inner race surface.
Lubricate the bearing with rear axle lubricant.
6. Place the pinion in the carrier.
7. Lubricating front pinion bearing, then assemble new
collapsible pinion bearingspacer, fitting into housing, and fit
front bearing into position whilst supporting pinion head.
S. [nstall pinion flange and the original pinion flange retaining
nut.
9. Using special tool to hold pinion flange, gradually tighten
retaining nut while rotating pinion in both directions to seat
bearings.
Torque
Wrench
Flange
Flange Holding
Tool
FRA013
10. (a) Check bearing pre-load frequently by removing

nange holding tool and installing a pulley to pinion flange.
(b) Using a spring scale, measure rotational torque.
NutTorque:
New bearings with pinion oil seal installed: 1.6 -3.4 Nm.
Used bearings with pinion oil seal installed: O.S -1.7 Nm.
The torque figure iscalculatcd by mUltiplying the radiusof
the pulley by the spring balance reading.
Example: If the pulley diameter is 152 mm, the radius is 76
mm = 0.076 m. The spring balance reading is 25 N.
Therefore, the pre-load = 0.076 m x 25 N = 1.9 Nm.
Caution: Should the retaining nlll be over-tightened and
the removal of lhe differential, usually 0.1 to O.2mm

Use spreader on Banjo differentials
Differential
Dial Indicator
Housing Spreader
R.o14
tor.
Under no circumstances should the carrier be spread more
than 0.5 mm.
3. Place differential case assembly, with bearing cups and
pre-load shims selected previously in the carrier. (Refer to
DIFFERENTIAL BEARING AND PRE-LOAD SHIM
SELECTION Section of this Chapter.)
4. Remove spreading tool.
5. Fit bearing caps and torque to specs.
Torque:
55 Nm.
6. (a) Mount a dial indicator on carrier and check gear
backlash between the ringgearand pinion. Backlash should
be within specification.
(b) Check readingsat4equally spaced positions around ring
gear.
Position the dial indicator so that the indicator stylus is
perpendicular to the ring gear tooth and in tine with gear
rotation.
0.10 - O.IS rnm (at the tightest point).
Torque:
--
mlerometet
Dial micrometer
# Ring gear
pre-load exceeded. it will he necessary to remove the pinion
from the housing and install a 0.75 mm shim between the

collapsible spacer alld pinion front bearing. Ullder no
circumstances must the retaining nut be backed ojJ to
decrease the pre-load readillg.
E. DitTerentialBacklash Setting
1. Install differential housing spreading tool and adaptors
[E92RR] to differential carrier.
2. Fit dial indicator to measure spread of differential carrier.
SpreadcarrierapproximatelyO.25 mm. Remove dial indica-
7. (a) Ifbacklash is excessi ve, decrease size of shim on pinion

side of ring gear and increase gear side shim by the same
amount.
(b) Ifbacklash is insufficient, increasesizeofshim on pinion

side of ring gear and decrease ring gear side shim by same
amounl.
194
REAR AXLE
Gear Tooth Patterns: Throughly clean ring gear and pinion teeth. Paint
ring gear surfaces lightly and evenly with gear marking compound
c.
Heel contact
E.
B.
D.
Face contact
Toe contact
To correct: Increase thic kness of pinion

height adjusting washer In order to bring
drive pinion close to ring gear.
Flank contact
To correct: Reduce thickness of pinion
height adjusting washer In order to bring
drive pinion go away from ring gear.
A.
contact
Ra021
less Backlash
Decrease H
for more
backlash
left side
Increase (+)
Decrease (-)
Increase (+)
for less
for less
backlash
backlash
for more
backlash
right side
F. Ring Gear and Pinion Contact Pattern

1. Thoroughly clean ring gear and pinion teeth.
Z. Paint ring gearteeth lightly and evenly with gear marking
compound of a suitable consistency to produce a contact
pattern.
3. (a) Install backing plate assemblies and axles to the rear
axle housing and retit rear brake discs.
(b) Adjust park brake shoes until a torque of 80 Nm is
obtained at pinion flange.
4. Rotate pinion through several revolutions in both directions until a defmitecontact pattern is developed on ring gear.
Back off park brake shoe adjustment when completed.
S.lnspect contact pattern produced by above procedure.
'The largeendofthetooth is called the 'HEEL' and the small
end the 'TOE'.
* The top of the tooth which is above the pitch line is called
the ' FACE' while the area below the pitch line is called the
'FLANK'.
, The clearance between the pinion and ring gear teeth is
referred to as 'BACKLASH'.
The figure illustrates correct and incorrect contact patterns.

i) Contact pattern 'A' provides the ideal marking for
quietness and long life.
ii) If the pattern shows a toe contact 'B', it indicates not
enough backlash. To correct, move the ring gear away from
the pinion by increasing thesizeoftheshimon the pinion side
of the ring gear and decreasing the ring gear side shim by an
equal amount.
iii) IT the pattern shows a heel contact 'C' , it indicates too
much backlash. To correct, move the ring gear towards the
pinion by increasing the size of the shimon the ringgearside
and decreasing the size of the shim on the pinion side ofthe
ring gear by an equal amount.
* Make adjustment, increasing and decreasing shim thickness by 0.04 mm at a time. Check contact with gear marking
compound and continue adjustment until tooth contact appearsas in' A'. Backlash must remain within specified limits.
iv) To correct a pattern such as D', it will be necessary to
install a thicker pinion positioning shim as described under
HYPOIDPlNIONPOSmONINGSHIMSELECfION
Section in this Chapter. A 0.025 mm thicker shim is
recommended as a starti ng poi nt. Continued changes may be
necessary to obtain the correct setting.
195
REAR AXLE
v) lfthe pattern shows a flank contact 'E', it indicates that

the pinion is in too far. To correct, replace the pinion shim
with a 0.025 mm thinner shim and reoheck contact pattern.
iv) In making pinion position adjustments, be sure backlash
is correct before testing contact pattern. Moving the pinion
'lN' reduces backlash and moving pinion 'OUT' increases
backlash.
Ideal Contact:
DriveSide:
A central toe contact marking, lengthwise in position and
slightly low contact in the profile position.
Total length approximately 5/8 of the gear face width.
There should be clearance of about I mm between the
contact marking and the toe and along the top face angle line.
Coast Side:
* A centrally located marking, lengthwise in position and
slightly high in the profile position.
* Total length approximately 5/8 of the gear face width.
There should beclearance between the contact and the face
angle line of the gear.
Acceptable Heel Contacts:
DriveSide:
A central face contact marking, lengthwise in position, is
shown in figure. This represents the limit of acceptabiEty of
the contact marking towards the heel.
Marking should fade out at lea't 5 nun before heel end.
A central profile marking position is shown and is acceptable, although low contact marking is preferred.
Coa,tSide:
Thecentre of the contact marking is locatedat5/8 of the face
width from the toe and it does not approach the heel end by
less than 5 mm.
A high contact marking, a, shown in figure,is preferred for
coast side contacts which tend to be toward the heel.
* Acentml profi Ie marking position is acceptable, providing
the pinion face angleedge Iines do not appear low on the gear.
Acceptable Toe Contacts:
Drive Side:
* The contact markings begin almost at the toe end face and
extend in length by approximately half the face width.
* A sEghtly low contact marking is shown in figure. This is
preferable although a centmlly located profile position is
acceptable.
Coast Side:
The contact marking being almost at the toe end face and
may appear pointed as shown in figure. A square end is
equally acceptable.
* The total length of the contact marking is approximately II
2 of the face width.
* A high profile marking position is desirable, although a
central profile is acceptable.
6. (a) After satisfactory contact pattern is produced, clean
ring gear and pinion gear teeth and pour a liberal quantity of
rear axle lubricant onto gears and bearings.
(b) Tum gears to work lubricant into all surfaces.
7. Fit rear cover and new gasket to carrier and torque cover
attaching bolts.
Torque:
23 - 31 Nm.
8. Install rear axle assembly as per INSTALLATION REAR AXLE HOUSING ASSEMBLY
LIMITED SLIP DIFFERENTIAL
The overhaul procedures fora limited slip differential are the

same a, for standard differential. except for the differential
casing assembly internal components.
Dismantle
1. Before dismantling differential case. inspect differential
side bearings for any signs of damage.
* Both side bearings and their cups are matched parts. If
either bearing is to be replaced, its matching cup must also be
replaced.
2. (a) Ifreplacingsidebearings, use special tool [E1673H ISJ,
adaptors LE6673] and stepped plug LE1673C16] to remove
side bearings from dill. case.
(b) Discard side bearings once they are removed.
3. Grip differential case in a vice with soft jaws.
4. Remove ring gear attaching bolts.
* Ring gear attaching bolts use a left-hand thread and are
identified by an 'L' on the bolt head.
5, Remove differential case from vice.
6, Using a soft faced hanuner, remove ring gear from
differential case by hitting down on ring gear. Support ring
gear during this operation so that it does not strike bench top
as it comes free of casco
*Do not use a screwdriverto pry between ri ng gear and case.
7. Place differential case in a vice equipped with soft jaws.
8. Loosen and remove differential case cover bolts evenly.
Lift off differential case cover. If necessary, remove clutch
cone from cover(somelimes lhe cone will remain inside the
cover).
9. Remove the foUowi ng components in order fort wo pinion
differential:
Friction cone - shim - side gear - thrust block - thrust
springs - pinion shaft- pinion gears - thrust wa~hers - thrust
block - side gear - shim - friction cone.
that the el utch cones are not interchanged during

reassembling, mark the cone and corresponding side of the
differential case wilh a daub of paint.
*If shims are present, they must also be marked so that they
196
REAR AXLE
no
g w.ber
_ _ _ __
can be assembled into the correct case half.

10. Remove the following component' in order for four
pinion differential:
Small casing:
Thrust block - side gear - shim - friction cone.
Largecasing:
3 concentric thrust springs - spider (pinions and thrust
wa,he",still in place)- thrust block -side gear- shim - friction
cone.
'To ensure that the clutch cones are not interchanged duri ng
reassembling, mark the cone and corresponding side of the
differential case with a daub of paint.
'If shims are present, they must also be marked so that they
can be assembled into the correct case half.
, Keep the pinion gears with their respecti ve thrust washers
in sets so that they may be installed in their original position.
Inspection
, All components should be thoroughly cleaned and dried,
then inspected.
Check case for general soundness and pay particular attention to the following points:
Differential
Assembly
Bo~s
FRA044
1. Ifdifferential case side bearings have been removed, check

case journals for damage and bearing seating surfaces are
2. The ring gear spigot and mounting face should beclean and
free from dirt and bum.

3. The mating surfaces for differential case halves should be
4. The thrust surfaces for differential side gear,; and pinions
should beexamined for excessive wear.
S. Thedifferential side gear journal bores should beclean and
free from scoring.
6. The case bores for differential pinion gear shafts should be
checked for "out of roundness".
B. Differential Side Gears and Pinion Gears
1. Examine all gear teeth for cracks and hard contact marks.
2. The differential side gear splines should be checked for
excessive wear. Wear on splines can contribute to excessive
driveline backlash.
3. Check differential side gear journals and back faces for
sconng.
4. Check fit of differential side gear,; in differential case cap
and cover. Wear on side gear hubs or in the cs.. bores can
cause a "clunking" noise in rear axle assembly when vehicle
is driven at low speeds.
S. Inspect differential pinion bores and thrust surfaces for
scoring. Also check differential pinion gear shaft' are not
bent and that surfaces where pinions run are not worn or
scored.
6. Check thrust washe"" they should be free from cracks,
nicks and burrs. Excessive wear of thrust washers or pinion
gear thrust surfaces can also contribute toexcessivedriveline
backlash.
7. Check thrust block pinion gear shaft bores for "out of
roundness".
C. Ring Gear and Pinion

I. Inspect gear teeth for scoring or damage. Scoring of gear
teeth is usually caused by excessive shock loading, use of
incorrect lubricant or insufficient "run in" before towing a
heavy load. Scored gears must be replaced.
2. The ring gear bore and back face should be clean and free
from bum.
3. The rear bearing seating surface on the pinion should be
4. Inspect pinion splines and flange splines for evidence of
wear.
S. Inspect thread and bearing journals of pinion.
6. If on ASSEMBLY, a new gear set is to be installed.
D. Bearings
Identification of bearing failures are described in Problem
Diagnosis.
be free from flaking or pitting. Ensure that seating surfaces
2. Thebearing assemblies should feel smooth when turned in
their cups.
3. The assembly should be free fTOm loose particles.
4. No cracks should be present in roller cages, and bores
should show no evidence of flaking or pitting.
197
REAR AXLE
E. Differential Carrier
1. Check casting allover for general soundness.
2. Examine oil passages and ensure they are free from
obstructions and loose particles.
3. The bore for pinion oil seal should be free from bum;.
4. Inspect rear cover face and bolt holes for damage.
5. Check rear cover seating surface.
Assembly
1. All componenls are to be lubricated with the specified
lubricant to be used in the assembly.
2.lfshim thickness is required to be measured, place friction
cone tightly into casing and measure the distance from the
friction cone nat surface to the case face.
Dimensions:
29.34 to 29.51 = no shim needed
29.51 to 29.64 = O.13mm shim
29.64 to 29.77 = O.25mm shim
3. Clamp I axle shaft in a vice using soft jaws, allowing
approximately 75 mm to extend above vice jaws.
The axle shaft is used as a mounting tool to ensure COllect
side gear and clutch cone spline alignment.
Failure to follow thi s procedure will prevent installation of
the axle shafts at final assembly.
4. Place small di fferential case over axle shaft mounted in vice
with the interior upwards.
5. Replace the following components in order for two pinion
differential:
Friction cone - shim - side gear - thrust block - pinion
shaft - pinion gears - thrust washers - pinion shaft dowel pin
-thrust springs -thrust block -side gear- shim - frictioncone.
o Ensure cones are in there corresponding side of the
differential case
o U shims are present. they must also be fitted in there correct
sides.
6. Replace the following component' in order for four pinion
differential:
Friction cone - shim - side gear - Thrust block - pinion
spider (with gears and thrust wa,hers still filled) - 3 concentric thrust springs -thrust block - side gear - shim - friction
cone.
Ensure COnes are in there corresponding side of the

differential ca.e.
Olf shimsare present,they must also be fitted in there correct
sides.
* New pre-load ,pringsmustalways be installed on ASSEMBLY. DO NOT RE-USE OLD SPRINGS.
7. Install case cover onto ca'e cap.
Ensure that the cut out on each side of the ca," cover and
cap align.
8. Install 2 differential case caps to cover attaChing bolt' in
opposite bolt holes and tighten with finger.
9 .(a) Install other axle shaft through case cover, rotating axle
shaft to engagecl utch cone splines and then side gear splines.
(b) Leaveaxleshaft in this position. Install remainingcapto
cover attaching bolls and torque evenly.

Torque:
35 - 45 Nm.
10. Remove axle shafts from differential case assembly.
Uthe shafts bind on the clutch Cone and side gear splines,
a light tap with a soft metal hammer may be necessary to
remove the axle shafts.
11. Place ring gear into position on differential case cap and
install ring gear attaching bolts.
Forease of assembly, it may be necessary, priorto installing
onto the differential case cap, to heat thering gearon hot plate
until it is hot to touch.
On no account must a flame be used to heat the ring gear.
Also, use left-hand threaded guide pins to pilot ring gear
over differential case spigot.
12.Tighten ring gear attaching bolts evenly until gear face is
flush with differential case spigot. Torque bolts.
Torque:
130 - 145 Nm.
o Ring gear attaching bolts use a left-hand thread and are
identified by an ' L' on the bolt head.
13. If installing new side bearings, press on side bearings to
differential case journals.
PROBLEM DIAGNOSIS
GENERAL PROBLEMS
'" Very often, rear axles are considered as noisy. when in
reality, the noise is emanating from some other source, such

as tyres, front wheel bearings, rear wheel bearings. transmission rear bearing (manual transmission). engine noises,
muffler roar, automatic transmission or power steering pump.
o All rear ax les have some slight humming noise. This will
vary with the type of body construction, load and tyre
pressure.
Noise which emanates from anyone of these can quite easily
be confused with a rear axle noise and unless a series of
el imination tesls are carried out to definitely conflJlTl the real
souree of the noise, rear axle assemblies may be (and often
are) dismantled unnecessarily.
Although not infallible, the following diagnosis guide will
a,~ist in locating and defining thedifferentcharacteristicsof
the components which could be responsible for a noise.
Road Test
Ensure that the axle lubricant is cOllect.
* Drive at low speed until thoroughly familiar with vehicle
noises, by which time the rear ax Ie should have warmed up.
Accelerate gradually from the lowest practical speed in top
gear to 100 krnlh, noting any noises and the speeds at which
they occur. Release the accelerator and without using the
brakes, allow the vehicle to lose speed.
o Next,allowthevehicletocoasttorest from lOOkmlh with
the transmission in neutral position. Any noises common to
earliertests may be eliminated as rear axle gear noise, as the
198
REAR AXLE
rear axle is not under load under these conditions.

Engine noise is gauged by gmdually accelemting the engine
with the vehicle at rest.
PROBLEM DIAGNOSIS - DIFFERENTIAL
AND REAR AXLE BEARING
Consider the following factors when diagnosing bearing

condition:
I. General condition of all parts during dismantling and
inspection.
2. Classify the type offailure.
3. Determine the cause.
4. Make all repairs following recommended procedures.
Problem: Abrasive roller wear!
Possible Cause:
Panem on races and rollers caused by fine abra<ives.
Remedy:
Clean all parts and housings.
Check seals and bearings and replace ifleaking, rough or
Problem: Cage wear!

PossibleCause:
Wear around outside diameter of cage and roller pockets
caused by abrasive materials and inefficient lubrication.
Remedies:
Replace bearings, check seals
Check for proper lubrication.
Problem: Misalignment!
Possible Cause:
Outer race misalignment duc to Foreign Object.
Remedies:
Clean related parts and replace bearing.
Make sure races arc properly seated.
Problem: Cracked inner race!
Possible Cause:
Racecrackedduc to improper lit, cocking, or poor bearing
scals.
Remedy:
Replace bearing and correct bearing seat.
Problem: Fatiguespalling!
Possible Cause:
Raking of surface metal resulting from fatigue.
Remedy:
* Replace bearing and clean all related parts.
Problem: Oiscolouring!
Possible Cause:
* Surface indentations in raceway caused by rollers either
under impact loading or vibration while the bearing is not
rotating.
Remedy:
Replace bearing ifrough or noisy.
Problem: Fatigue!
Possible Cause:
Corrosion set up by relative movement of parts with no
lubrication.
Remedies:
Replace bearing, clean related parts.
Check seals and check for proper lubrication .
Problem: Stain discoloration!
PossibleCause:
Discoloration can range from light brown to black caused
by incorrect lubrication or moisture.
Remedies:
* Re-use bearing if stains can be removed by light polishing
nOIsy.
Problem: Galling!
Possible Cause:
Metal smears on roller ends due to overheating lubricant
failure oroverload.
Remedy:
Replace bearing. check seals and check for proper lubrication.
Problem: Bentcage!
Possible Cause:
Cage damage duc to improper handling or tool use.
Remedy:
Replace bearing.
Problem: Abrasive step wear!
PossibleCausc:
Pattern on roller ends caused by fine abrasives.
Remedies:
Clean all parts and housing.
Check seals and bearings and replace if leaking, rough or
nOisy.
Problem: Etching!
PossibleCause:
Bearing surfaces appear grey (or greyish black) in colour
with related etching away of material usually at roller
spaclllg.
Remedy:
Replace bearings, check seals and chcck for proper lubrication.
Problem: Indentations!
PossibleCause:
Surface depressions on race and rollers caused by hard
particles of foreign materials.
Remedies:
Clean all parts and housing and check seals
Replace bearings if rough or noisy.
or if no evidence of over healing is observed.
* Check seals and related parts for damage.
SPECIFICATIONS
Rear Axle Assembly ........................ Borg Warner Series
Axle Type ................................................. Sern.i floating
Housing Type ................... Unitized Carrier Construction
Lubricant Conventional
199
REAR AXLE
Capacity .......... .......... ................. .......... ........... 1.65 litres

Type .... .................. ............ ........ .... ........ SAE 90 Hypoid
Lubricant Limited Slip
Capacity .., ....................................................... 1.651itres
Type ........................................................... SAE 90 EP
LubricantS Cylinder & 16HO
Capacity ........ .................... .............................. 1.65 litres
Type .......... ... ........ .................................. SAESOW- 140
Standard & L.S.D. Axles
Gear Type ...... ..... ..... ..... .... ... ..... .... ........ .... .. ........ Hypoid
Ratio: [Ratio is stamped on J.D. tag attached to rear coverl
DilJerential Gears
Type ........................................................ StraighlBevel
Axle Shaft
Type ............ ..... .... ....... ............ ............ ... .. Semi Floating
Bearing Type ........................................... Tapered Roller
Oil Seal ... ............. ........ . Spring Loaded Synthetic Rubber
Differential Pinion Gear
Bearing Type .......................... Adjustable Tapered Roller
Bearing Adjustment ...... ... .......... .... ..... CoJ\apsi ble Spacer
Bearing Pre-Load
New [wi oil seal] ........................................ 1.4-2.8 Nm
* New[w/ooilseall ...................................... 1.4-2.2 Nm
Usedfw/oilsealj ........... ............ ................ 0.7- 1.2Nm
Used lw/ooilseaIJ ..... ........ ..... .......... .. .... .... 0.7-1.1 Nm
Differential SideBcarings
Type ............ _.......................................... Tapered Roller
Adjustment ......................................................... .. Shints
Bearing Pre-Load
*New ..... ............. ......... "" ............... "" ...... I.O-2,SNm
* Used .... .......... ........ .............. ,.,.,., ............ , 0,5 - 1.4 Nnl
{Torque measured w/o axles or pinion installed}

Runoutspecifications
Case Assembly fw/o ring gearattachedJ ..... 0.5 mm (max)
Ring Gear Rear Face fwhen assembled onto ca<;e
assembly1 ........................ ........................ 0.13 mm (max)
Backlash .................. O. \ 3 - 0.18mm fat the tightest point}
L.8.D. PreLoad Specification ............................ 90 Nm
TORQUE SPEC'S
Nm
Differential Ring Gear Bolts (78 Model-LH

Thread) ........................................................... 130 - 145
Differential Bearing Cap Bolts ........................... 48 - 60
Rear Cover Bolts ............................................... 23 - 31
Breather ......... ..... ...... ................... ...,', ........... ",.20 - 35
Axle Bearing Outer Retainerto Housing Nuts .... ... 35 - 50
Track Arms to Body ............................................ 70 - SO
Track Arms to Pivot Link .................................... 70 - 80
Pivot Link to Axle Housing Cover .. ...................... 70 - 80
Suspension Anus to Axle Housing ........................ 70 - 80
Suspension Arms to Body .... ....... ... ...................... 70 - 80
Shock Absorberto Spring Plate Sedan ............... ... 70 - 80
Shock Absorber to Spring Plate Swagon. Ute &
Van ... ......... ....... ....... ........................................... 40-50
Disc Brake Calliper to Bracket pin nuts ................ 15 - 20
Disc Brake Splash Shield Screws ...... ........ ........... .. 8 - 10
Rear Propeller Shaft Universal Joint Flange to Pinion
Flange ................ ,.,.,", ...... ............ ... .. ............... ,' 55 - 65
Spring U bolts S'wagon, Ute Van .... .............. ....... 50 - 65
L.S.D. Case Cap to Cover Attaching Bolts .......... 30 - 40
Brake Pipe Junction to Axle Housing ........ ..... ..... .. 20 - 25
200
STEERING
SUbject
Page
Subject
Page
MINOR MAINTENANCE ................................ 202

Steering Gear Lubrication ........................................ 202
Fluid Contamination ....... .. ........................................ 202
Power Steering Pump Fluid Level ........................... 202
Adjustments ......................................................... 202
Replace Drive Belt and Adjust Belt Tension .. 202
Drive Belt Inspection ......................................... 202
Inspection ................................................................ 202
Power Steering Pump Pulley ............................ 207

Remove .. -- ................ .............. ........ ... .... .......... .... ... . 2fJl
InstalJ ....................................................................... W7
Power Steering Pump ......................................... 207
Remove ................................................................... 2fJ7
InsiaH ....................................................................... 200
Power Steering Pump Overhauling ................. 208
Visuallnspection ......... ...... ...... .. ..................... ......... 202
Clean and Inspect ........................................... ......... 208
Stages of Belt Wear ................................................ 202

Ignition Lock I Steering Column .................. 202
Remove ................................................................... 202
Install .... .. ................................................................. 202
Rack and Pinion Adjustments ...................... 203
Bleeding the System ............. ................................... 203
Power Steering Pump Hoses and Tubes ................. 203
Remove ................................................................. .. 203
Install ....................................................................... 203
Tie Rod Ball Joi nt .................................................... 203
Remove ............................................ ....................... 203
AssembJe ................................................................. 208
Install ....................................................................... 204

Bellows............................. ....................................... 204
Remove ................................................................... 204
Install ....................................................................... 2()4
MAJOR REPAIRS AND REBUILD ............... 204

Rack and Pinion Steering Gear ................................ 204
Steering Gear ........................ .................................. 204-
Dismantle ................................................................ 208
FORD Cll Power Steering Pump ................... 209

Power Steering Pumps Hoses and Tubes ........ 209
Remove ................................................................... 209
Install ....................................................................... 209
Power Steering Pump Pulley .............................. 209
Remove .............. ........................................ ............. 209
InstaU....................................................................... 209
Power Steering Pump ......................................... 209
Rernove ................................................................... 209
Install ....................................................................... 209
Power Steering Pump Overhauling ................... 210
Disrnantle .......................... .............. .. .. ............ .... .... 2 10
Clean and Inspect .................................................... 2 10
Assemble .......................................................... ....... 210
Clean and Inspect. ................................................... 205
STEERING COLUMN ....................................... 210

Steering Wheel ........................................................ 211
Steering Column Upper and Lower Cover .............. 211
Steering Column ...................................................... 211
Assembly ... .............................................................. 205

Rack & Pinion Steering Gear Mounting
POWER STEERING FLUID PRESSURE
Bushes .................................................................. 206
TEST ..................................................................... 212
Remove ................................................................... 2()6

Install ....................................................................... 2()6
PROBLEM DIAGNOSIS ................................... 212
Remove ................................................................... 2()4

Dismantle ................................................................ 204
SAGINAW Power Steering Pump ................... 207

Power Steering Pumps Hoses and Tubes .... 207
Remove ............. ........................................ .............. 2m
Installation ............................................................... 207
201
SPECIFICATIONS ............................................. 214

TORQUE SPECIFICATIONS ...................... 214
STEERING
Minor Maintenance
BELT ADJUSTMENTS
Steering Gear Lubrication

Rack and pinion steering assemblies have a semi-liquid
grease. which is included during the rack and pinion
assembly.
The rack and pinion assembly can not be checked during
a vehicle service.
Specified Lubricant:
Manual Steering:
Specified Amount:
6 & 8-Cy1. POWER STEERING REPI ",CE

DRIVE BELT and ADJUST BELTTENSION
1. Rotate the tensioner idler pulley relieving the tension on
the dri ve bel t.
Replace
Bett Marking
Belt Tensioner
Assembly
ESA MIC 75B

50 grams
Power Steering Fluid Contamination
New Belt
Marking
If the power steering fluid has been contaminated. the

power steering lines should be flushed and the steering
pump. rack and pinion gear must be removed. All must be
dismantled and thoroughly cleaned before assembly.
Co016
2. Remove the belt if belt is to be removed.

3. Install new drive belt (if applicable) on all pulleys.
4. Rotate tensioner idlerpulley. fit belt and release to apply
tension on bell.
Power Steering Pump Fluid Level
Power Steering Drive Belt Inspection
Visual Inspection
Condition ofthe belt is best judged by twisting the belt so
as to see the "V"surfaces or the ribs.
Stages of BeltWear:
2. MODERA TEL Y USED BELT: Few cracks; some
wear on surfaces. Replacement not required.

Check thc Iluid level in the reservoir by inspecting the capl
dip stick. If top-up of Iluid is needed add Iluid to the
"COLD" or "HOT" mark on the dip stick with the
specified Iluid. DON ' T OVERFILL.

4. FAILED BELT: Separation of belt material from
backing (chunking). Replace belt immediately.
Power sleenng fiuid

level reselVoir cop
and indicator
Hot
1-..,
Ignition Lock/Steering Column

Remove
1. Remove lower and upper steering column covers, then
disconnecteleclrical wiring loom.
2. Using punch orchiscl and hammer unscrew shear head
bolts by slowly working them anticlockwise.
3. When bolts are removed withdraw column lock assembly.
Cold Level
Install
1. Replace column lock assembly, ensuring it is in place
50021
Specified }'Iuid:
Dcxron II Power Steering Fluid
correctly.
2. Fit new shear bolts and tighten them until the heads
break off.
3. Connect electrical wiring loom and then replace lower
and upper steering column covers.
4. Check that steering lock will operate properly.
202
STEERING
RACK and PINION ADJUSTMENTS

The pinion bearings can not be adjusted. if adjustment is
need it is advised to replace the bearings. The rack pad
adjustments can be done in the vehicle.
4. Crank engine at idle and turn steering from lock to lock

to circulate the fluid. top up reservoir.
5. Repeating step 4 unti I the reservoir does not need fluid
added.
6. Check the fluid level and road test.
RackPadAdjusbnents
1. Steering must be positioned straight ahead before this
adjustment is attempted.
2. Release rack pad adjuster lock nut. backing it off two
turns. using tool No. 9326-7.
Power Steering Pump Hoses and Tubes
Remove
1. Remove the hoses from the steering rack and allow the
fluid to drain into container.
2. Disconnect and remove hoses and tubes from the
pump.
Install
1. Install the tubes to the steering rack.
Special Tool 93236-7
2. Install the fluid return hose and the pressure tube to the
pump.
3. Top up reservoir with power steering fluid and bleed
system as described above.
Rack Pad
Lock Nut
Tie Rod Ball Joint
Remove
1. Raise vehicle. remove split pins and loosen tie rod end
Adjust1ng Screw
retaining nut 114 of a tum and brake taper bond using a tie
rod removal clamp.
2. Loosen tie rod assembly lock nut.
SOl1
3. Rack adjuster screw is to be tightened to a tension of

10-12 Nm. then backit of2S"-30" using tool No. 9326-8 or
a nng spanner.
4. Hold the adjuster in position from step N03 tighten lock
nutt065 Nm. then cheekthatthe steering runs freely from
full lock to fuillock.
5. Ifthere is any tightness or binding present recheck rack
pad adjustment. otherwise rack should be pulled down and
inspected for damaged components.
Bleeding the System

After repairs are carried out the system must be bleed
of any air.
1. Reservoir must be filled to the cold level.
2. Jack front of vehicle up until front wheels are removed
from the ground. then place safety stands under vehicle.
3. Remove fuel pump relay andl or ignition relay I fuse to
prevent engine from starting.
Split
Pin
Nut
___ Spindle
TIe Rod
3. Remove lie rod end from steering arm, and unscrew tic
rod end from tie rod.
* Taking note of how many turns it takes to remove. for
use when installing the new one.
Tie Rod End
Assembly
Tie Rod
To Steering
Rack
Rod
Boot
203
Tie Rod End
Lock Nut
STEERING
Install
1. Screw tie rod end onto tie rod, the same amount ofturns
as the old one took to remove.
2. Install tie rod end in steering arm, tighten the nut, and
replace split pin the nut.
3. Tighten the tie rod assembly lock nut and lower the
vehicle.
4. Check the toe-in and toe out if needed adjust.
Bellows (Boots)
Remove
I.Lift front of vehicle and place on safety stands, remove
the tie-rod end (described above) and also remove tie rod
assembly lock nut.
Bellow C lip
3. Raise the vehicle and position it on safety stands.

Disconnect tie rod ends from steering arms spindles.
4. Remove steering rack retaining bolts, remove rack
from vehicle and place on a clean work bench.
Dismantle
1. Remove tie rod ends and rack boots as described.
2. Move the steering rack gear to full right lock, then
secure the exposed end of the rack in a vice using soft
grips. Remove the left hand tie rod. Forthe right hand side
tie rod repeat the same procedure.
SCrew Driver
Bellow Clip
Bellow
ROCk and
Pinion
3. Reposition rack assembly in vice holding the mounting

point, then remove valve housing dust boot and pressure
switch.
Split
2. Remove clips from the boots, then remove the boots
Pin
from the steering rack.

Install
1. Slide boots over steering rack, and install the bootclips.
2. Replace the locknut and tie rod end (dcscribed above).
Nut
J
.-;~) _
_ Spindle
MAJOR REPAIRS &

REBUILD
Rack & Pinion Steering Gear
* The steering gear must be removed from the
vehicle for maintenance.
Toe Rod
4. Disconnect and remove the pressure feed tubes, then

remove the bolts securing valve housing and remove
Note: The steering gear assembly //lust be cleaned

completely before any work is carried out in a clean
worki,,!: environment.
Special Tool 93236-7
Steering Gear
Remove
1. Disconnect the power steering lines from the steering
rack using a pipe spanner, allow nuid to drain into a
Rack Pod
Lock Nut
container, detach power steering sensor loom.
2. Remove boll out of steering shaft lower knuckle, loosen

top knuckle bolt and slide shaft upwards until its disconnected from steering rack.
204
STEERING
housing. ensure '0' rings have been removed.

S.Loosen rack pad lock nut using special tool No.9326-7.
6. Carefully drive seal and bearing from valve housing.
7. With steering rack on right lock remove lower pinion
bearing retaining screw I and nut.
B. Remove rack pad assembly from housing taking care,

using tool No. 9326-8.
9.Removepinionassembly from rack by winding out, then
remove tetlon seals from valve sleeve with out damaging
sleeve.
Do not dismantle any more of the pinion assembly,
10. Using tool No. 9326-2, remove pinion bearings and
seal.
11. From the left hand side housing, unscrew the rack
bearing retainer using tool No. 9326-1, being careful not to
cause any damage to the rack then remove the rack
assembly from the rack housing, the seal back up ring and
bearing will cause resistance when removing rack.
12. Remove rack bearing, piston, seal and retaining ring
from rack bar.
Early Production :
Remove left hand piston circlip before removing piston
then remove other circlip.
Late Production:
Piston will need twisting anticlockwise using tools No.
9326IA &9326-10 to release lock wire.
Rack and Pinion Housing
Socket Handle
and special tool
5016
13. Remove seals, '0' rings and tetlon rings from piston
and rack bearing, being careful not to damage the bearing
or seal diameters.
Adjuster
Piston Seal
Clean and Inspect.

1. Using suitable cleaning solvent wash parts and dry off
2. Throw all seals in bin, to be replaced with new ones.

Examine rubber boots for damage, if necessary replace.
3. Inspect bearings for signs of binding, damage and wear,
examine rack and pinion for wear or faulty teeth, rack pad,
bearing and seal.
4. Check rack housing internal diameters for scour marks
and damage.
5. Check rack pad for wear and damage, examine valve
housing and bearing, then valve sleeve for wear or
damage.
Assembly
1. Fit seals, '0' rings and tetlon rings to piston the inner
and outer diameters.
2. Using tool No.s 9326-5 & 9326-6 fit and press pinion
upper beating into housing, then fit pinion seal using tool
no. 9326-5, install pinion lower bearing using retainer
screw.
3. Fit the piston, seal and retaining ring onto the rack bar,
the seal spring loaded face is to be facing the left side of
the rack..
Early Production:
Fit tight hand piston circlip then piston then and other
circlip.
Late Production:
Piston wi ll need twisting clockwise using tools No. 9326I A &9326-10 to fit lock wire in groove, there should be
about 2mm pointing out when fully in place.
4, Fit tenon seal on tothevalvesleeve, then fit into tool No.
9007B, leaving illhere foratleast ten minutes to allow the
seals to compress to correct working size.
5. (a) Fit rack into housing from the left hand side teeth
first, first applying grease on teeth and auto fluid on the
seals.
(b) Make sure that the teeth of the rack are aligned with
the pinion bore.
(c) Fit rack seal to rack bearing, sealing edge towards the
bearing, and place assembly into housing, pressing into
place.
(d) Using tool No. 9326-1 install bearing retainer, tensioning
it to 60Nm.
Circlip
Rock ond Pinion Housing

Socket Handle
and special tool
Bearing
Seal
Piston
Retaining
Ring
"0" Ring
Rack
S016
5014
205
STEERING
6. Place SO grams of grease in pinion bore, then with rack

centred, fit pinion into housing, the pinion bolt clamp
groove is to be positionedat4S' from the rack shaft, facing
the back of the rack.
7. Rack pads, washers and springs can now be filled to the
housing, apply sealant on the adjuster screw or fit seal on
early production, remove screw and fit retainer to the
housing, with rack at left lock torque retaining nut to
SSNm.
8. With thread of adjuster screw coated with sealant
install and tension to 60Nm.
9. (a) Fit spigot rack housing '0' ring seal.
(b) Using tool No. 9326-3 & 9326-4 to fit valve housing
seal and then tool No. 9326-3 to fit bearing ensuring the
large flange is towards seal.
(c) Install valve sleeve into valve housing, then position
valve housing assembly on rack.
(d) Fit retaining bolts tensioning them to 6Nm.
10. (a) Place steering rack assembly in vice using soft
jaws and secure.
(b) Tum rack to full lock until rack bar is showing.
(c) Using tool No. 9326-10, fit tie rod to rack with tab
washer positioned in s lots and tension to IOONm.
(d) Repeat process to other end
II. Install oil transfer pipes with new '0' rings fitted,
tensioning fittings to ISNm, then fit pressure switch
tensioning to SNm.
12. Fit tie rod boots and adjust rack pads as described
above in this section.
3. Align spline grooves on steering pinion shaft and

steering knuckJe shaft, slide together until bOllomknuckle
bolt can be installed, once installed tighten bolt, then tighten
the top bolt.
Upper Clamp Nut Torque Specs:
40 - 60 Nm.
Lower Clamp Nut Torque Specs:
12 - 16 Nm,
Steering Rack
Bellow
Belk>w Retaining
Clip
@])I-o,o-_ToeRod End
lock Nut
4. Connect sensor loom, then power steering hoses and

tighten. Fill pump reservoir with specified fluid, and bleed
th e steering gear system as described in this chapter.
Specified Fluid: Dexron 11 Power Steering Fluid
5. Check and adjust if necessary the toe-in, tighten ball
joint lock nut to specification.
Tie Rod End Lock Nut Specified Torque:
70Nm
Tie Rod
Assembly
TIe Rod End

Assembly
SOlS
13. Install tic rod end ball joint lock nut and tie rod ball joint
to tie rod shaft.
14. Fit rack to vehicle and get wheel alignment.
Install
1. Place steering rack assembly in position on its mounts,
install and tighten the allaching bolts to specifi cati on.
Steering Gear - Sub-Frame Mounting Bolts Torque
Specification:
70 Nm.
2. Fit tie rod ball joints to steering arm spindles, install,
tighten nuts to specification and install split pins.
Tie Rod Ball Joint specified torque: 45 Nm
Centralize the steering rack with front wheels straight
ahead, then lower the vehicle from safety stands.
Rack & Pinion SteerIng Gear Mounting

Bushes
Remove
Support the housing in a press then press the bushes
from the rack housing.
Install
Press the new bushes into rack housing, apply soapy
waterto the bushes, this wi II help th e bushes press into the
hou,ing.
206
STEERING
Saginaw Power Steering

Pump
PowerSteering Pump Hosesand Tubes
Rem oval
1. Place drain tray under steering rack, and disconnect
hoses of rack and plug the hose fittings to prevent entry of
foreign material.
2. Drain tluid from power steering pump reservoir via
hoses.
3. Detach hoses from pump and remove from vehicle,

then plug the hose tittings to prevent entry of foreign
material.
Power Steering Pump Pulley

R em ove
1. Remove pump from the vehicle as described in this
chapter.
2. Draining the tluid from pump out the reservoir liller
hole.
3. Fit pulley removertool No. E9240B on the pulley hub,
place tool with pump litted into a vice and secure.
4. Hold power steering pump, rotating pulley remover nut
antic lockwise and use a puller to remove the pulley. Any
in and out pressure applied to pump shaft may cause
internal damage, remove tool.
Insta ll
1. Place pump pulley on powersteering pump, fit tool No.
E9239B, ensure the pulley is on the correct way.
2. Support pump, screw tool nut in a clockwise direction,
until pulley is !lush with the pump shaft, within 0.25 mm.
Any in and out pressure applied to pump shaft may cause
3. Remove tool from pump, install pump as described is
this chapter.
Power Steering Pump
Remove
l. Remove belt as described in this chapter.
2. Disconnect hoses from power steering pump and drain
tluid from pump into drain tray then plug hoses to prevent
entry of foreign matter.
3. Remove front bracket bolts from front of cylinder head,
undo rear mount to pump housing nul.
Installation
1. Remove plugs from rack and connect power steering
hoses to steering rack and remove drain tray.
2. Remove plugs from pump, then connect power steering
hoses to power steering pump, fill pump reservoir and
remove drain tray.
3. Bleed pump as described in this chapter.
Spanner _ _
High
Hose
'rt>
4. Remove pump from vehicle, placing it on clean work

bench.
Insta ll
1. Position pumpin rear mounting bracket titting nut. then
rep lace front mounting bracket to cylinder head bolts and
tighten.
Pump Mounting Bracket Bolts:
207
20-28Nm
STEERING
R r Bracket.,/'
Rnlnlng Nut
2. Fit hoses to pump and tighten .

3, Install the drive belt as described in this chapter.
* Make surc belt is correctly engaged on pulley ribs.
3. Fill power steering pump reservoir with fluid .
Fluid: Dexron II Power Steering Fluid
4. Follow bleeding procedure as described in this chapter.
Power Steering Pump Overhaul

Dismantle
1. Remove pump pulley if not removed. Also remove the
flow control valve assembly and mounting bolts from the
housing.
2. Place pump assembly in a bench vice.
3. Remove pump reservoir from pump by slightly twisting
to release the '0' rin g bond, then remove bolt and union
'0' ring seals.
4. End plate retaining ring should be positioned over pin
hole in housing, then using pin punch through hole pushing
retaining ring inwards to release from lip.
9. Remove pressure plate seal and shaft seal from housing

assembly, all seals will need replacing with new ones on
re-assembly.
lO.lnspect the shaft fordamage, if shaft is damaged it will
need replacing.
11. Remove the retainer snap ring from the rotor shaft
assembly, then remove rotor and thrust plate from shaft.
Clean and Inspect.
o Use a suitable cleaning solvent is used, also press ure
washer or hot wash can be used.
t. Clean all components of power steering pump.
2.Inspectcomponents for signs of wear, distortion, or any
other danlage that may be present.
3. Damaged components will need to be replaced.
Assemble
I. Install new shaft seal into housing make sure the seal
is seated properly, replace dowel pins.
2. Insert new pressure plate "0" ring into pump body. third
groove from the back.
all parts to be lubricated with transmission fluid
3. (a) Fit thrust plate to shaft with parted section facing
pulley end of shaft.
(b) Replace rotor on the shaft, countersunk end facing
thrust plate.
(c) Fit new shaft retainin g ring, tap the ring into position
with the help of a socket.
(d) Install this assembly into the pump bod y, fit the dowel
pins into the thrust plate.
4. Install pump ring (use two small holes)ontodowcl pins,
the arrow must face up.
Rotor Vane
Spring
~.
Flow
Control Valve
"\
Outlet
Fitting
~ .
"'"
S. Place screw driver underneath ring and twist ring out
of the housing, take care as the end plate is spring loaded.
6. Remove end plate, spring and "0" ring from pump
housing.
7. With pump removed from the vice, tipping it upside
down allowing the dowel pins and flow control valve to
drop out on to the bench.
*Service flow control valve as an assembly.
8. Tap pump shaft if necessary to remove shaft, cam ring,
vanes, rotor assembly and pressure plate.
.,~
-./
'
-.
S. Fit the pump vanes into the rotor grooves.

6. Replace the pressure plate, narrow slots fit onto dowel
pins, fit the spring onto the plate.
7. Install new end plate "0" ring, end plate and retaining
ring, using suitable clamp to compress.
8. Fit control valve and mounting bolt '0' rings into
position.
9. Fit the flow control spring and plunger into pump body.
lO.Install anew "0" ring seal, onto the housing lubricating
it with transmission fluid.
11.Install the reservoir onto the housing. pressing on the
reservoirto seat it into the pump assembly. Ensure that the
208
STEERING
union and stud seals are in the correct position.

Note: Apply transmission fluid to the sealing edges of the
reservoir before install ing.
12. Lubricate "0" ring seals to the union then install the
studs and the union assembly to the pump.
13. Install the pulley onto the shaft being careful not to
cause damage to shaft or pulley, then tighten pulley nut.
Ford C11 Power Steering

Pump
Power Steering Pump Hoses and Tubes
Removal (Flexible Line)
I. Lift vehicle and support with safety stands, place drain
tray under front of vehicle.
2. Remove lower front stone guard and disconnect power
steering lines, plugging the hose fittings on pump to prevent
entry offoreign material.
3. AJIow fluid to drain from power steering pump reservoir, then disconnect power steering lines at pump, plugging the hose fitlings on pump to prevent entry of foreign
material.
4. Remove fluid lines from the vehicle.
Installation (Flexible Line)
1. Replace fluid lines in vehicle.
2. Remove plugs from power steering pump reservoir,
then connect power steering lines at pump.
3. Remove plugs from lower fittings, connect power
steering lines at lower fittings, and replace lower front
stone guard.
4. Remove drain tray and safety stands from under front
of vehicle, then lower vehicle.
S. Bleed pump as described in this chapter.
Removal (Metal Tubes)
I. Lift vehicle and support with safety stands, place drain
tray under front of vehicle.
2. Remove lower front stone guard and disconnect power
steering lines.
3. Allow fluid to drain from power steering pump reservoir, plugging the hose filtings on pump to prevent entry of
foreign material.
4. Disconnect lines to power steering rack, plugging the
hose fittings on pump to prevent entry offoreign material.
S. Remove fluid lines from the vehicle.
Installation (Metal Tubes)
I. Replace fluid lines in vehicle.
2. Remove plugs from power steering rack, then connect
power steering lines to rack.
3. Remove plugs from lower fittings, connect power
steering lines at lower filtings, and replace lower front
stone guard.
4. Remove drain tray and safety stands from under front
209
of vehicle, then lower vehicle.

5. Bleed pump as described in this chapter.
Power Steering Pump Pulley

Remove
1. Remove pump from the vehicle as described in this
chapter.
2. Draining as much fluid possible frompuffipthrough the
fillertube.
3. Fit pulley puller tool on the pulley hub, place tool with
pump fitted into a vice and secure.
4. Hold power steering pump, rotating pulley remover nut
anticJockwise and remove the pulley. Any in and out
pressure applied to pump shaft may cause internal damage, remove tool.
Install
1. Place pump pulley on power steering pump, fit tool No.
E9239B, ensure the pulley is on the correct way.
2. Support pump, screw tool nut in a clockwise direction,
until pulley is flush with the pump shaft, within 0.25 mm.
Any in and out pressure applied to pump shaft may cause

3. Remove tool from pump, install pump as described is
this chapter.
Power Steering Pump
Remove
1. Release drive belt tensioner and remove the drive belt.
2. Disconnect pump hoses and drain nuid from pump into
a drain tray then plug the hoses and pumps to prevent entry
of foreign matter.
3. Remove the retaining nut and bolts securing the pump
to the bracket and remove pump from the vehicle.
Install
1. Position pump in mounting bracket, fit the attaching
bolts and partially tighten. Then install the fluid lines to the
pump and tighten hose clamps.
2. Install the drive belt and release tensioner.
* Make sure belt is correctly engaged on pulley ribs.
3. Tighten pump attaChing bolts and tension belt.
STEERING
Pump Attaching Bolts Torque:

20-28Nm
4. Fill power steering pump reservoir with fluid.
Fluid: Denon 11 Power Steering Fluid
S. Follow bleeding procedure as described in this chapter.
Power Steering Pump Overhaul
1. Clean work bench and tools.
2. Clean the pump assembly with solvent and/or pressure
washer. Draining as much fluid as possible from unit.
3. Do not use solvent on seals.
Dismantle
1. Remove pump pulley if not removed.
2. With pump assembly in vice remove the outlet and flow
control valve assembly. Remove the union "0" ring and
the Flow control valve seal and dispose of seals .
3. By twisting pump reservoir backwards and forwards to
break its seal it will then be able to be removed.
4. Using a suitable "C" clamp and support plates (D4P3044-A I "C" clamp, DSP-3733-A2 lower, DSP-3733A I upper), fit upper support plate to the pump cover and
the lower support plate over the pump shaft, fit assembly
into the clamp.
S. Tighten the clamp to release the pressure of the
retaining ring, there will not be a large amount of movement until the pump feel like it is bottoming out.
6 (a) End plate retaining ring should be positioned over pin
hole in housing, then using pin punch through hole pushing
retaining ring inwards to release from lip.
(b) Place screw driver underneath ring and twist ring out
of the housing, take care not to damage the housing,
remove the ring.
7. Loosen clamp to release pressure off the housing, then
remove pump cover.
S. Tap pump shaft if necessary to remove shaft, rotor
assembly, upper plate, and dowel pins.
9. Remove lowerplate by turning the housing upsidedown
and thumping into the palm of your hand or a flat piece of
board.
10. Lever shaft seal and retainer from housing.
I1.Disposeof all "0" rings and seals, replacing them with
new components on installation.
Clean and Inspect.
Use a suitable cleaning solvent is used, al so pressure
washer or hot wash can be used.
[. Clean all components of power steering pump.
2. Inspect components for signs of wear, distortion, or any
other damage that may be present.
3. Damaged components will need to be replaced.
Assemble
1. Install new shaft seal make sure the seal is seated
properly, replace dowel pins.
2. Place bellville spring into housing then fit lower plate
with seals fitted and facing front of the pump.
3. If rotor was removed from shaft.
(a) [nstall rotor on the spline end of the shaft.

(b) Fit new shaft retaining ring, tap the ring into position
with the help of a socket.
(c) Place cam over rotor and install springs and slippers,
grove facing outwards.
(d) Install this assembly into the pump body, fitthedowel
pins into the thrust plate.
4. Fit clamp and to assembly with adaptors to press lower
plate into housing until it bottoms out.
S. Fit the pump shaft rotor assembly into housing, aligning
the dowel pins and the notched section in the cam on the
opposite side of the pump to the square mounting lug.
6. Fit upper plate into position, aligning dowel pins and
notched sections.
7. Install new cover "0" ring, fit it into housing with
pressure channels lined up.
S. Using "C" clamp and support plates (D4P-3044-AI
clamp, DSP-3733-A2 lower, DSP-3733-AI upper), fit
upper support plate to the pump cover and the lower
support plate over the pump shaft, fit assembly into the
clamp.
9. Tighten clamp until retaining ring grove is clear of the
cover enough to fit ring.
10. Fit retaining ring ensuring that it is properly fitted into
the grove, release clamp and remove, place assembly into
vice.
11. Fit '0' ring to housing. Fit reservoir onto the housing,
pressing on the reservoir to seat it into the pump assembly.
Ensure that the control valve is correctly position.
Note: Apply transmission fluid to the sealing edges of the
reservoir before installing.
12. Fit "0" ring seal, control valve and outlet filling into
housing.
Outlet Fitting Torque Specification:
40Nm
13. Install the pulley onto the shaft being careful not to
cause damage to shaft or pulley, then tighten pulley nut.
STEERING COLUMN
Air Bag Assembly
Cautioll: Air bags call be harmful to persolls workillg

011 all air bag. Make sure the battery is discollllected.
If the vehicle has beell ill all accident the bag could
explode with very lillie illterference. Consult an expert
for further illformatioll, as extreme care must be
takell.
Disabling and Removal
I. Detach the negative ballcry terminal and allow the
vehicle to sit for at least one minute before continuing.
2. Withdraw the screw concealing plugs from the rear
steering wheel cover, then release the retaining screws.
3. Detach the clockspring connection to the air bag and lift
the air bag from the steering wheel.
210
STEERING
Installation and Activation

I. Connect the air bag clockspring connector, then carefully push the air bag assembly into place.
2. Fit the retaining screws and tension to specification,
then the battery can be reconnected.
3. Fit the screw cover plugs then check that the air bag
fault light does not come on.
Steering Wheel
Remove
1. Release the air bag assembly as previously described,
then remove the air bag assembly.
screws, then remove the cover.
2. Use a philips screw driver to remove the two screws

attaching the top cover to mounting brackets.
3. Remove the two mounting brackets nuts to the column,
lower the column (non height adjustable columns), and
lower into lowest position (adjustable columns).
4. Remove the top cover.
Install
1. Replace the top cover, then fit mounting screws.
2. Lift the column into position, and replace the two
mounting bracket nuts to the column, tighten to specification.
Steering Column nuts specified torque:
20 Nm
3. Replace the lower cover and two screws securing the
lower cover to the column.
2. Release the steering wheel retaining torques bolt.

3. Leave the bolt in place. then holding the steering wheel
on either side pull until it releases from the steering shaft.
4. Withdraw the bolt and steering wheel from the steering
column.
Install
1. Ensure steering is positioned straight ahead that fit the
steering wheel.
2. Install the retaining bolt, then tension to correct speci-
Steering Column
Remove
1. Detach the air bag assembly from the steering wheel.
2. Remove the lower cover from the steering column, then
disconnect
column
loom.
fications.
3. Fit the air bag assembly to the steering wheel as

previously described in this chapter.
Air Bag & Horn

Pad Assembly
Remove the upper universal joint to coupl ng ,

clamp bolt. and on column shift vehicles disconnect the
co ntroliinkage.
4. Remove the bolts securing the steering column lower
plate to the noor pan.
Steering Column Upper and Lower Cover

Remove
1. From the lower cover remove the two plastic retaining
211
STEERING
5. Remove the bolts securing the steering column bracket

then remove column from vehicle.
Install
1. Install steering column assembly to vehicle and slide
into position.
2. Replace the nuts securing the steering column to the
mounting bracket and the bolts securing the assembly to
the floor pan. tighten to specification.
Column to instrument panel nut torque: 20 Nm.
Column to floor pan nut torque specs:
14 Nm.
3. Connect column to universal coupling on rack to column
shaft. then connect shift linkage for column shift autos.
hydraulic circuit test, carefully check drive belt tension,

condition of driving pulley and fluid level.
The engine should be at normal operating temperature.
Front tyres at correct pressure. The engine must be
operating at idle RPM.
Connect a pressure gauge and valve (valve position
between pump and pressure gauge) assembly in the high
pressure hydraulic line between the pump and steering
gear. Remove the high pressure line at the steering pump,
install the valve then pressure gauge, reinstall the hose to
the pressure gauge.
Refill the power steering system with fluid to the correct
level.
Test 1 - Hydraulic Circuit Open
1. Engine idling over, valve open so fluid can run through
pressure gauge, turn the steering wheel so the steering is
fully turned.
2. Pressure should not be less than 6200 kPa, if it is check
for faulty components.
Test 2 - Hydraulic Circuit Closed
1. Engine idling over, valve open so fluid can run through
pressure gauge, turn the valve so it is closed for a second
ortwo,just long enough to read pressure then open valve
agam.
* Low pressure that is less than 6200 kPa.
- Check for faulty pump.
- Flow control valve stuck or inoperative.
* Pressure that is bet ween 6200 kPa and 6890 k Pa.
- Check for hoses that are blocked or kinked or faulty
steering gear.
Problem Diagnosis.
Problem: Hard Steering
* Tyres incorrectly inflated. Remedy- Inflate tyres to
8027
4. Reconnect column wiring at the multi-pin plugs and

replace the lower column cover and replace the steering
wheel tightening to specification.
Steering Wheel Nut torque specs:
50 Nm.
5. Fit the air bag assembly as previously describe in this
chapter.
correct pressure.
* Insufficient lubricant. Remedy-Lubricate suspension
and steering linkage.
* Excessive caster. Remedy-Check front wheel alignment.
* Steering system joints worn. Remedy-Replace steering

system joints.
* Lower arm ball joints worn. Remedy-Replace lower
arm ball joints.
* Steering column sticking. Remedy- Inspect steering
POWER STEERING FLUID

PRESSURE TESTS
column.
Test I provides a means of determining whether the

power steering system hydraulic parts are faulty. If test
I results in readings indicate faulty hydraulic operation,
test 2 wi II identify the faulty part. Before performing
Adjust or repair steering gear.

* Power steering belt loose. Remedy-Adjust belt.
Fluid level in reservoir low. Remedy-Check reservoir.
* Power Steering unit faulty. Check power steering unit.
* Rack and pinion out of adjustment or broken. Remedy-
212
STEERING
.....er Steering Unit Checks

oCheck fluid level on cap dip stick.
oLoose drive belt.
o Drivebelt slipping.
o High internal leakage.
0ln,ufficient pump pressure.
o Sticky flow control valve.
o Sleeringcolumn 10 rack & pinion connection may nol be
correcllyaligned.
If none of the above problems are found, carry alit a
pmsllre test as described in this Chapter, for other
possihle causes sllch as.
Control valve problems.
Pump pressure not as specified.
Sleering pump bypass of fluid.
* Loose drivc belt

* Drive belt slipping
* Drive belt badly worn
* Drive bclt has a glazed surface

Problem: Nolsefrom Power Steering Pump
* High back-pressure. Remedy - Blocked hose or faulty

rack and pinion.
* Scored pressure plate, thrust plale or rotor. Remedy Replace components.
* Extreme wear of pump ring and vanes. Remedy Replace components.
* Vanes not installed correctly. Remedy - Reinstall vanes.
Problem: Miscoloured PowerSteerlng Fluid
Problem: Poor Return

* Power steering fluid has air mixed with it. Remedy -
Tyres incorrectly inflated. Remedy-Inflate tyres to

correct pressure.
Insufficient lubricant. Remedy-Lubricate suspension
and sleering linkage.
Wheel alignmenl incorrect. Remedy-Check front wheel
alignment.
Sleering gear out of adjustment or broken. RemedyAdjust or repair steering gear.
Problem: ExcessIve Play
Front wheel bearing worn. Remedy-Replace front

wheel bearing.
Main shaft yoke or intermediate shafl yoke worn.
Remedy-Replace main shaft or inlermediate shaft.
Lower arm ball joints worn. Remedy-Replace lower
armballjoints.
Sleering system joints worn. Remedy-Replace steering
systemjoinls.
Rack and pinion oUi of adjustment or broken. RemedyAdjust or repair steering gear.
Problem: Abnorrrral NoIse!
Steering linkage loose. Remedy-Tighten steering linkage.

Sleering system joints worn. Remedy-Replacesteering
sy'temjoints.
Steering gear out of adjustment or broken. RcmcdyAdjust or repair steering gear.
'PowerSteering Pump Fluid Low. Remedy - Top up fluid
and check for fluid leakage.
Problem: DrlveBeltSqueal
213
Check pump for problem and repair.

Problem: SteerIng pump pressure not as
specified.
Possible Causcs & Remedies:
Pump has not been correctly assembled. Remedy Reassemble pump.

* Internal components of pump are extremely worn.
Remedy - Replace components.
* Control valve problems. Rcmedy - Repaircontrol valve.
* Pump
pressure not as specified. Remedy - Check and
.
reprur pump.
* Steering pump internal bypass offJuid. Remedy -check
and repair pump.
Leaking Pump Remedies
Check oi I level- if/eakage persists with the level correct
and cap lighl. replace the cap because of poor cap

ventilation.
* Replace drive shaft seal. Make cenain that drive shaft
is clean and frce of pitting in seal area.
* Replace reservoir O-ring seal.
Torque hose litling nut t040- 54Nm. Ifleakagepersists.
replace O-ring seal.
Torque oUllet litting 10 75 Nm. If leakage persists,
replace O-ring seal.
Torque hose litting nut to 48 Nm. If leakage persists.
rcplace conneclor and reface the tube flare. If nut threads
are damaged, replace nut.
* Replace O-rig seal.
STEERING
Specifications
STEERING GEAR
Steering Gear Type .. TRW Rack & pinion with integral
power cylinder & rotary valve mechanism - variable ratio.
Steering Ratio (on centre) ................................... 18.5:1
No. of Steering Wheel Turns Lock to Lock ............. 3.0
Allowable over full travel of rack .............. 2 N m (max)
POWER STEERING PUMP
Make ...... ........ ........................ ......... ................ Saginaw
Type .... .................. ........................ ..... .. .. Vane Impellor
Pressure at idle ............... .. .................... 6,200-6,890 kPa
Make .... .. ....... ................................................. FordC))
Type .. .................. ............................. ............. 100slipper
Pressure at idle ................. .................... 6,200-6,890 kPa
Lubrication
..... Hydraulic Dexron IT Automatic Transmi ssion Fluid
Drive Belt Tension:
New Belt ...................................... ... ... 8-9 mm @ LOON
U sed Belt ....................................... 10- 1 I mOl @ lOON
Belt is considered "used" after 10 minutes running
Caster
Except Tickford ................................................ 3-4 deg.
Tickford ................................................ .. ... .... .. 31/ 2 deg.
Camber
Except Tickford ................. ........................... -0.5-0 deg.
Tickford .................... ........... ....... .... ... .... ...... ... _11/4 deg.
Toe-in Specification (except Tickford)

Degrees .......... ...... ....... ............................... 0"()3' -00 13'
Linear ........................................................ -0.2-2.2 mrn
Specified Grease for Rack & Pinion Steering Gear
Unit ......................... EPI40 or SAE90
Torque Specifications
Steering Column
Steering Wheel ..... ................. ..... ........ .......... ....... ...... 50
Column Support Bracket to Pedal Bracket ............... 20
Toe Plate to Dash Panel ............................................ 14
Column clamp bolt ..................... ........ ..... .................. 5-8
Rack & Pinion Steering Gear
Steering Gear Attaching Bolts ................................... 70
Coupling Nuts ....................................................... 12-1 6
Tie Rod End to Steering Arms ................................ 100
Tie Rod Locknut ........................................................ 70
Tic Rod Stud Nut ....................................................... 45
Valve Housing Attaching Screws ................................ 6
Pressure Switch ........ .............................. .. ....... ......... 10
Pinion Bearing Nut ....... .. ........................................... 55
Pinion Bearing Screw ................................................ 60
Rack Bearing Screw .......................................... ....... 60
Rack Pad Locknut ..................................................... 65
Power Steering Pump

Pump to Mounting Bracket.. ...................................... 55
Idler Pulley Lock Nut ................................................ 40
Idler Pulley Brac ket to Block ..... ............................... 24
Resevoir to Pump ....... ............................................... 60
Bracket to Cylinder Head ............. ............................. 55
Pressure Hose Nut .................................................... 35
Return Hose Clamp ..................................................... 4
Discharge Fittings ........................................... .. ......... 70
214
FRONT SUSPENSION & AXLE
Subject
GENERAL DESCRIPTION
Page
216
Subject
Page
lnstallation ..................... .................. _. _..................... 220
Front Spring. Front Spring Scat & Bushing ........... 222

WHEEL ALIGNMENT .............................. 216
l>escription ............................... ........ ........................ 216
Removal ................................................................... 222

Installation ......... , ...................... ............................... 222
Caster ...................................................................... 216

Camber .......................... .. ..... ....... ............................ 216
Tre-Ln .................................................... .................. 216
WheelAlignmenlAdjustrnenl .................................... 216
Visuallnspection ..................................... .... ............. 216
Camber .................................................................... 216
Caster ...................................................................... 217
Tre-In ...................................................................... 217
Toe-In Adjustment ................. ................................... 217
Toe]n and Steering Wheel Adjustment .......... .. .......... 217
Replace Lower Control Arm Inner Pivot Bush ...... 222

Replacement ............................................................. 222
Front Spindle Ball Joint .......................................... 222
Inspeclion ................................................................. 222
Replacement ............................................................. 222
Lower Control Arm Strut Rod & Bush .................. 223
Replacement .................................... ..... .. .................. 223
Upper Control Arm ................................................ 223
Removal ................................................................... 223
BushReplacement .................................................... 223
Installalion ............................................................... 223
}"'ront Wheel AxJe (Spindle) ..................................... 224
Rernoval ................................................................... 224
Installation ................. ...... ........... .... ... ............ .......... 224
Front Shock A bsorher ............................................ 225
Renloval ................................................................... 225
Installation ....... ............................ ....... ........ ............. 225
MINOR MAINTENANCE .......................... 218
Wheel Bearings & Hub ............................................. 218

Removal ................................................................... 218
Inspect and Clean ..................................................... 218
PackBearings ........................................................... 218
lnstall ....................................................................... 219
Wheel Bearing AdjllStJnent ..................................... 219
Stabilizer Bar .......................................................... 219
Renloval ............................................... .................... 219
Installation ...................................... ...... ....... ............ 2 19
PROBLEM DIAGNOSIS ......................... 226

SPECIFICATIONS ................................... 228
MAJOR REPAIRS .................................... 220
Suspension Lower Arm ........................................... 220

Removal ................................................................... 220
215
FRONT
SUSPENSION
GENERAL DESCRIPTION
The front suspension, a McPherson strut type, incorporates
many features designed to ensure good ride characteristics,
combined with a high level of steering response and directional stability.
Each strut assembly houses adouble acting hydraulic damper
(shock absorber), which absorbs road unevenness, allowing
a smooth ride.
Production option "s PACK", is available as an option on all
sedan models, which has a modified suspension.
to be positive (+). When the wheels tilt inward at the top,

camber is said to be negative (-).
Toe-In
This refers to the turning in of the wheels. The actual amount
of toe-in is normally only a few millimetres. The purpose of
a toe specification is to ensure pardUel rolling of the wheels.
Excessive toe-in Orloe-out may increase tyre wear. A slight
amountofpositive toe-in, measured statically with the vehicle
at rest, is required to off-set the small deflections due to rolling
resistance and brake applications which tend to tum the
wheelsoutward.
WHEEL ALIGNMENT ADJUSTMENT
Some components of wheel alignmenls are set when the
vehicle is produced from factory and are not adjustable, the
adjustments that can not be altered are the King Pin Inclination, Caster and Camber.
Visual Inspection
It is necessary before any attempt is made to check camber,
casterortoe-in, carry out the following preliminary checks;
1. Check tyreand tyremountings. Always check camberand
toe-in at the mean run-out position on the tyre or rim.
2. Check and adjust tyre pressures to recommended values.
Tyre Pressure
Gauge
Tyre
Falcon Front
Suspension
Assembly
WHEEL ALIGNMENT
DESCRIPTION
Front wheel al ignment is the mechanics of adjusting all interrelated factors that affect steering; namely, caster, camber
and toe-in.
Caster
This refers to the ti Iting of the steering ax is either forward or
back ward from the vertical (when viewed from the side ofthe
vehicle). A backward tilt is said to be positive (+) and a
forward tilt is said to be negative (-).
Camber
When the wheels tilt outward at the top, the camber is said
3. Front wheel bearings should be correctly adjusted.

4. Lower control arm ball joint> and inner bushes should be
checked for wear.
5. Check steeri ng gear mounting bolts for tightness and tie rod
ball joints for wear.
6. The vehieleshould beat curb weight, fuel tank full (50kg
for station wagon, 46 kg for sedan) without driver, passengers or luggage, etc.).
7. Check for improperly operating front struts or rear shock
absorbers.
8. Check for loose or missing stabilizer bar or tension rod
attachments.
Camber
This is the angle that the top of the wheel leans in towards or
away from the vehicle, when the wheel leans inwards it is
negativecanlber.
The best setting for the camber is between -I" and (, the
216
difference between both sides should not exceed 3/4' varia-
Top view of wheels
tion.
Front of
vehicle
Camber angle
Positive
direction
A
Toe-In Is "A" minus "B"
Camber angle from front
1. Set steering gear and wheels in straight ahead position.

*Usteeringwheel is notin the right position itcan becorrecled
when doing the adjustments.
2. Loosen tie rod lock nuts, then clean and lubricate threads
that are still exposed.
3. Tum each tie rod as required until the correct toe-in is
obtained.
Duringtoe-in adjustment, ensure that steering wheel is held
in the straight ahead position, also both tie rods will need
adjusting equally to obtain the same reading on both sides.
If steering wheel is in need of movement adjust its central
position through the tie rods.
4, When the correct reading has been obtained tighten tie rod
lock nuts, with tie rods ends in alignment with their ball studs,
then tighten outer bellows clips securely, ensure boots are not
distorted.
S. Ensure that steering wheel isstill centralized, and road test
the vehicle.
FsOO7
Caster
This is the angle the wheel spindle leans towards either the
front or rear of the vehicle, the caster is positive when the
wheel leans towards the rear of the vehicle.
Side view of front of vehicle
Front of vehicle
Positive direction
F,006
Caster angle side view
Fs005
The best setting for the camber is between 3' and 4', the
difference between both sides should not exceed 1 variation.
Toe-In & Steering Wheel Adjustments
Toe-In
Toe-In & Out determines whether or not the front of the
Check the steering wheel position when the front wheels are
in the straight ahead position. Tfthe steering wheel is not in
vehicles wheels are pointing in towards each other or away

from each other. When checking Toe readings the steering
wheel must be centered before the vehicle is turned of and
must be started again if steering is to be move, as the power
steering switched off will havean effect on the measurements.
Toe-In Adjustment
Adjustment is achieved by winding the tie rods in orout ofthe
tie rod ends, thus increasing or decreasing their length and
thereby altering the toe-in setting.
its correct position, it can be corrected while toe-in is being
adjusted.
1. Clean and lubricate the exposed threads on the tie-rods.
Loosen the clip on the outer ends of the rack bellows and
ensure that the bellows are free on the tie-rods.
2. Hold the tie-rod and loosen the lock nut on each rod.
* Both rods have right hand threads.
3. Adjust toe-in. Tfthe steering wheel is in the correct position,
lengthen or shorten both rods equally to obtain correct toe-in.
FRONT of VEHICLE
Toe-in Adjustment
;,...._ _ 110 Rod
-_...c
LockNut _ __
spanner-=====~~
, , - - - Sail Joint
,/
Turn tie rod down
"
up to increase rod length
rod length
FS01 0 1
217
If the steering wheel is not in its correct position, make the
necessary rod adjustments to obtain the correct toe-in and

steering wheel spoke alignment.
4. When the toe-in and steering wheel spoke alignment are
both correct tighten the lock nut on each rod.
5. Position each tie-rod end ball joint at the centre of its
articulation and tighten the clips on the rack bellows.
6. Take care and slide the front disc off the axle hub.
7. Remove the bearing seal from inside bearing.
MINOR MAINTENANCE
FRONT WHEEL HUB, BEARINGS &
ADJUST
Remove
1. Jack the front wheel concerned up, remove
wheel trim, wheel nuts and wheel.
2. Remove the bearing dust cap, using a screw driverto lever
the cap off.
3. Remove the front brake calliper bracket attachi ng bolts, lift
the calliper off the disc and tic the calliper up. Do not leave
the calliper hanging by the brake f1 uid hose, as th is will cause
possible hose damage.
8. Remove the inside bearing.

9. If necessary remove the bearing cups from the disc by
tapping around the bearing cup with a brass drift and
hmnmer.
Inspect and Clean
be free from !laking or pitting. Ensure that seating surfaces
2. Bearing outer races should be a loose fit in brake disclhub.
3. Bearing inner cones should be free to revolve on the axle
stub.
4. Check wheel studs to ensure threads are not damaged, and
that boilS are pressed firmly into brake disclhub
4. Remove the wheel bearing nut split pin and nut.

5. Remove the wheel bearing washer and wheel bearing, if
there is some resistance with the bearing, hold the brake disc
in both hands and slightly wobble disc, this will case the
bearing and washer off the axle hub.
DISC
VVheel Studs
Assembly
Front wheel
bearing
5. The bearing assembly should feel smooth when turned in

the cup.
6. The assembly should be free from loose particles.
7. Wash bearing in a solvent solution and air.
8. After the bearing has been washed and airdried the bearing
should spin freely with no abrasive type noises.
Pack Bearings
New bearings may already be prepacked with grease.
1. Fill the palm of one hand with bearing grease.
218
Bearing Grease specified: High Temperature Grease

2. Take the bearing in the other hand and force the bearing
(largest diameter side) into the grease and the palm of your
hand, this will pack the grease into the bearing cage and
around the rollers.
specification.
Torque: .............................................................. 30 Nrn
7. Install the wheel and tighten the wheel nuts.
S. Spin wheel to check that the wheel spins freely.
9. Lower front wheel and tighten nuts
10. Remove jack stands and lower vehicle.
11. Torque road wheel attaching nuts to correct torque
specification.
Torque: ........................................................... 105 Nm.

12. Refit wheel cover/centre cap.
STABILIZER BAR
Removal
1. Raise front of vehicle and support on safety stands.
2. Position a suitable size open end spanner over flat in
stabi lizer bar spacer stud. Remove nut securing stabi lizer bar
spacer studs on each end of stabilizer bar. Remove lower
discs and bushes.
Fs033
3. Continue to pack the bearing with grease, turning the

complete bearing assembly between each packing action.
4.The beari ng is completely packed when grease is forced out
from around the rollers and cage, forthe full diameter of the
bearing.
Install
1. If the bearing cups were removed rrom the disc press new
bearing cups into position.
2. Install anew inner bearing and seal totheinsideofthedise
hub.
3. Slide the front disc onto the axle hub.
4. Install the packed bearing a.sembly onto the axle spline and
into the disc, install the bearing washer.
S.Install the wheel bearing nut loosely and adjust bearing as
described below.
Wheel Bearing Adjustment
Rotate the disc and tighten the wheel bearing nut to 20Nm.
Lom'en the nut 2 turns and then tighten the nut /() /2Nm so
asa new split pin can be installed, bend over end ofsplit pin.
3. Remove bolts securing support bracket to each side

member and rcmovestabilizerbar. Removesupport bmekets
and insulators from stabilizer bar.
installation
I.Assemble two insu lators and support bracket. to stabilizer
bar and bolt brackets to body.
The slot in each insulator should face the side member (cut
the insulator on the flat surface if necessary.
Bush_
& Ret,tur 80It
Shifter
Disc
Assembly
Wheel Bearing
6. Install bralkecaJliper and two bolts, apply loctite242 to the

bolts. Torque thecalliperanaching bolts to the call eet torque
219

Stabilizer Bar Support and Insulator
Stabilizer Bar
Shocker Strut
lower Retaining Bolt
,
,
(
,,I
/\.
Bar Bracket
Bar Insulator
.
/
Stabilizer Bar
Lower Control
Tension Bar
,
Fs0111
2. Install stabilizer barto spacer studs with bushes and discs

installed in the correct order. Torque anaching nuts on
stabilizer bar studs.
When tightening the spacer stud anaching nuts, ensure that
the spacer stud is stopped from rotating.
Stabilizer Bar Mounting Bracket to Under body ...... 20
Stabilizer Bar to Lower Control AI'Ul ....................... 20
3. Torque insulator support bracket to side member attaching
bolts.
MAJOR REPAIRS
SUSPENSION LOWER ARM
Removal
1. With front of vehicle raised and support on safety stands.
2. Remove wheel cover (steel wheels) or centre cap (allow
wheels).
3. Mark relationship of wheel to hublbrakc disc. Remove
road wheel anaching nuts and remove wheel.
4. Remove stabilizer bar link to lower arm retaining nut, on
both sides of the vehicle if needed and twist stabilizer bar up
clear of the lower arm ..
5. Disconnect bonom ball jOint and shock absorber lower
mounting boIt from lower arm.
Lower Ball Joint
6. Remove lower arm to sub rrame retaining bolt, and remove

arm from sub frame.
7. Loosen strut to lower control arm retaining nut and remove
arm from strut and vehicle.
Installation
1. Fit lower arm onto rear strut mount and then into the sub
frame, install subframe bolt and strut nut.
2. Install lower arm in position over ball joint stud, making
shore the lowershockermountis in position, then fit ball joint
retaining nut and shocker lower mount bolt, the ball joint
retaining nut can be tensioned.
Ball Joint Nut Torque ........................................ 8S Nrn
3. Install stabilizer bar, bush, disc and nut to lower arm .
Torquenu!.
When torqueing the spacer stud attaching nut, ensure that
the spacer stud is held from rotating.
220

FRONT SUSPENSION
Top Arm
Front Spring
......-
Shock
Ball Joint
Front Stabilizer Bar
_ _~_ _ Spindle
Assembly
Lower Control
Arm Strut
Front
Axle
Lower Control
Arm
Fs037
Ball Joint
(Behind Spindle)
lower Control
Arm Strut
Top Ball Joint
Jemmy Bar
Tie Rod
Bearing
Lower Conbol
221
Fs038
replace if needed.
Installation
1. With spring compressor on spring. spring insulator/top
mount refined, install spring onto shock absorber assembly.
2. Refit spring assembly onto shock absorber assembly, as
described in the Front Shock Absorber Replacement.
3. Shocker assembly can now be fitted into the vehicle as
described in FrontShock Absorber Replacement.
Torque ......................................................... 7 - 10 Nm.
4. Install wheel.
When installing the wheel, align the marks made prior to
removal.
5. Remove safely stands and lower vehicle.
6. Torque wheel attaching nuts.
Torque ................................................... 100 - 125 Nm.
7. Refit wheel cover/centre cap.

8. With vehicle lowered and sitting at normal travelling high
the bolts can be tensioned correctly.
Strut Nut Tension ............................................ 115 Nm
Shocker Lower Retainer Bolt Tension ............... 90 Nm
Sub-Frame Mount Bolt Tension ........................ 85 Nm
9. Check caster, camber and toe-in as described previously.
REPLACE LOWER CONTROL ARM INNER

PIVOT BUSH
Replacement
1. Remove control arm as per Removal of Lower Control
Arm Section in this Chapter.
2. Press bush from rear side of control arm.
3. install new bush, until nangeon outer sleeve is nush with
control arm.
* The bush can be installed with soapy water to assist
assembly. DO NOT LUBRlCATE.
4. Install control arm as per INSTALLAnON OF LOWER
CONTROL ARM Section in this Chapter.
FRONT SPRING, FRONT SPRING SEAT &

BUSHING
Removal
1. Remove spring assembly from vehide as described in
Front Shock Absorber Removal.
Strut Assembly
FRONT SPINDLE BALL JOINTS
Upper Aoun./....
& Retainer
Shocker
Inspection
The following procedure should be used when checking the
ball joint for wear.
1. Jack up vehicle under crossmember. to remove all load
from the ball joints.
2. Play from front wheel bearings must be removed before
testing the balljoints.
3. Hold the wheel at top and bonom, rocking the wheel back
and forth the movement ofthe ball joints can bechccked, there
should be no movement in the ball joint stud housing,
otherwise it should be replaced.
FS014
2 Remove spring assembly from shocker assembly as

previously described in Front Shock Absorber Removal.
Spring
Spring
---~~~~~~~~;l Tool
Compression
Checking Ball Joints

For Movement
Vehicle
Spring
Compression
Tool
'0
Front Strut
Fs0191
3. Carefully lift top spring insulator/top mount off spri ng
Wheel & Front

SuspensIon Assembly
Replacement
1. Remove front wheel spindle from vehide as described in
Front Wheel Axle Removal.
2. Balljoint retaining split pins will need to be removed from
the bottom face of the ball joint.
222
3. Ball joints then are able to be pressed from the spindle.

4. Once ball joints are removed refit new ones by pressing
them into place and fitting split pin into position.
5. Replace spindle into vehicle as described in Front Wheel
Axlelnstallation.
nut.
__
Stabilizer
Bar
LOWER CONTROL ARM STRUT ROD &

BUSH
Replacement
1. Remove control arm as per REMOVAL OF LOWER
CONTROL ARM Section in this Chapter.
2. Strut rod bushes should be removed by pushing out guide
pin, then the two sections of the bush from control arm.
Old lubrication must be thoroughly cleaned from inner
diameter of bush journal in control arm.
3. Install a new strut rod bush, by fitting two sections of the
bush into either side of the arm, and then inserting the guide
pin from the back of the arm.
Lubrication supplied with new bushes must be applied to the
bushes before installation.
4. Install lower control arm as per INSTALLA TION OF
LOWER CONTROL ARM Section in this Chapter.
UPPER CONTROL ARM
Removal
I. Jack up front of vehicle and place safety stands under side
framemembers.
2. Remove wheel cover (steel wheels) or centre cap (aJl
wheels).
3, Mark relationship of wheel to hublbrake disc. Remove
4.Remove brakecallipcr from spi ndle sitting it outofthe way,
also disconnect stabilizer bar from lower control arm.
5. Detach the upper ball joint from control arm. and allow
control arm to sit freely.
6.Undocontrol arm inner pivot to the spring tower securing
223
Lever
7. Remove control arm from the vehicle.

S. Disconnect pivot brackets from control arm by undoing
mounting nuts.
Bush Replacement
1. With control arm removed as described above bushes are
able to be replaced in the following manner.
2. Disconnect the pivot brackets from the control arm by
removing retaining bolts.
3. With pivot brackets removed from the control arm, the
bushes can now be removed as well.
4. Reassemble the bushes and pivot brackets to the control
ann.
5. Control arm is now able to be fitted as described below.

Installation
I. Fitcontrol arm pivots to control arms, leaving bolts loose.
2. Install upper control arm pivot mounts to spring tower and
install securing nuts. Do not fully tighten at this stage.
3. Fit upper ball joint to control arm , and tension retaining
nut.
Upper Ball Joint Nut .......................................... 55 Nm
4. Refit brakecallipertospindle and tension mounting bolts.

Calliper Mounting Bolts ..................................... 30 N m
5. Install wheel, aligning marks made priorto removal and
adjust front wheel bearing as previously described.
7. Bounce vehicle up and down several times to settle
suspensIon.
8. When suspension has settled the control arm inner pivot
bolt can be torqued.
Control allO pivot "bolt ...................................... 5S Nm.
FRONT WHEEL AXLE (SPINDLE)
Removal
1. Jack up front of vehicle and place safety stands under side
frame members.
2. Remove wheel cover (steel wheels) or centre cap (all
wheels).
3. Mark relationship of wheel to hublbrake disc. Remove
4. Remove tie rod ball joint nuts and tie rod from the .,de/
spindle arm.
9. Lowerthe lower control arm and remove the spindle/axle.

InstaJlation
Split
Pin
I. Install the spindle/axle onto the lower ball joint, lighten the
nut to specification and fit cotter pin.
Ban Joint Nut Specification ................................ 85 Nm
2. Lift lower control arm, fit the spindle/axle onto the upper
control arm ball join~ tighten the nut to specification and fit
cotter pin.
BalIJoint Nut Specification ................................ 55 Nm
3. Install hub and disc with bearings and seal fitted onto the
spindle/axle, then install nut and adjust as previously de
scribed in this chapter.
Nut
__ Spindle
Tie Rod
5. Remove two bolts attaching the brake calliperto the axle

spindle, remove the calliper and place where weight is not
hanging from brake hose.
,
I
Spindle
DISC Assembly
Lower ;ontrol
Arm
6. Remove the grease cap, nut retainer, nut, outer bearings,

hub and disc from spindle.
7. Loosen ball joints attaching nUL" and then brake tapered
bond between ball joint taper and spindle.
8. Detach nuts, then lift top control arm away from spindle,
and remove the spindle by lifting itoffthe lower ball joint.
4. Fit the brake calliper and retaining boIL', tighten the bolts
to specification, tighten upper bolt first.
Calliper AttachingBoltspecification ................. 30 Nm
5. Fit the connecting spindle arm to the tire rod joint, tighten
to specification, install cotter pin.
Tire Rod Ball Joint Specification ....................... 45 Nm
6. Install wheel, aligning marks made prior to removal and
adjust front wheel bearing as previously described.
8. Bounce vehicle up and down several times to settle
suspension.
224
FRONT SHOCK ABSORBER
Spring
Sprlng _ _ ___
Removal
1. With vehicle raise sitting on safety stands and wheels
Compression
,-J~ Tool
removed.
2.Remove brake calliper from spindle sitting itoutofthe way.
also disconnect stabilizer bar from lower control arm.
3. Detach the upper ball joint from control arm. and allow
control arm to sit freely.
Spring
Compression
Tool
Fs0191
7. Loosen and remove top shocker mount nut, then remove

top mount and spring as an assembly, placing to one side
carefully.
Spindle
Front Spring
4. Loosen lower shocker retaining bolt, then lift the bonnet

and remove shock assembly upper mounting bracket to
spring tower retaining nuts.
Absorber
(Change
Over
Unit)
*Top mount and spring only need removing in the easeofthe

shock absorber being replaced.
Installation
1. Hold new shock absorber in vice, and carefully place
spring and top shocker mount onto shock absorber, then
replace and tighten top shocker nul.
2. Release spring compressors until spring tension is released
onto top mount again.
3. Removeassembly from vice and install into vehicle, andfit
shocker lower mount bolt, bottom control arm may need to be
levered downwards.
4.lnstaJl and tension shock assembly upper mounting bracket
to spring tower retaining nuts.
Upper Shocker Mount Nuts .""" . ",,""""""",,. 40 Nm
remove
assembly from vehicle, bottom control arm may need to be
levereddownwards.
Strut Assembly
Shocker
Spring
Upper
& Retainer
FS014
6. Place shocker assembly into vice standing it upright, then

fit spring compressors and compress coi Ispring unti Itension
is released from the shocker top mount..
# Take care because the spring is under consUlerable
pressure, do not release suddenly as the spring can cause
severe body damage if allowed to release pressure sudtknly.
225
PROBLEM DIAGNOSIS
Testing Shock Absorbersl
Test shock absorber action as follows:

* This test procedure is not for gas pressurised shock
absorbers.
1. Clamp shock absorber by its bottom mount in a vice.
2. Slowly pump shock absorber up and down the full stroke
at least six times before checking it resistance.
3. Pump shock absorber by hand at various rates of speed and
obsetveresistance.
* When extending the shock absorber, the resistance should
be marginally greater than when collapsing the unit. The
resistance should be consistent throughout both strokes and
there should be no 'slack' spots.
* 'Slack' spots indicate either loss of oil (which is usually
visible on the outside- or valve not seating).
4.lt is normal to detect a hissing noise (orifice swish). The
following conditions are considered abnormal and reason for
replacement:
(a) A skip or lag at reversal ncar mid-stroke.
(b) A seize (except at either extreme end of travel).
(c) A noiscsuch asagruntorsqueal after completing one full
stroke in both directions.
(d) A clicking noise at fast reversal.
(c) Fluid leakage.
Shock Absorber Top

Mounting Brac;ket Bolts .nd Nuq
5. Attach upper ball joint to control arm. tensioning retaining

nut.
UppcrBaUJointNut ........................................ SSNm
General
6. Mount brake calliper back onto spindle, then connect
stabilizer barto lower control arm, tensioning nuts and bolts.
When diagnosing suspected front suspension problems, it

should beremembered that steering, wheels and tyresall have
an effect on front end performance. Refer to STEERING
and WHEELS AND TYRES Chapters.
Strut Diagnosis
* Test by quickly pushing up and down on the bumper bar
at the front comer of the vehicle.
* Inspect the struts for excessive fluid leakage.
Problem: Hard or heavy steering!
* Low or uneven tyre pressures.
* Steering gear or connections too tight or misaligned.
* Insuflicient lubricant in steering gear.

* Excessive caster.
Lowercontrol arms or tension rods bent. Remedy -Check

front wheel alignment. check alignment orcontrol arms and
tension rods.
* Excessive toc-in.
Calliper Retaining Bolts ..................................... 30 Nm
Stabilizer Bar Mounting Nut .............................. 20 Nm
7. Replace wheels and lower vehicle to ground.
Remedy - Check and adjust toe-in.
Problem: Excessive play or looseness In

steering!
* Steering gear or connections loose or worn.
RemedyAdjust steering gearorinstall new components as necessary.
226
Control ann ball joint loose or worn.

Front wheel bearings incorrectly adjusted orworn. Remedy
- Adjust bearings or replace as necessary.
Loose attachment of front suspension assembly to frame.
Remedy -Check and tighten front suspension attaching nuts.
Problem: Scuffed tyresl

* Toe-in incorrect.
* Tyres improperly inflated.
* Wheels or tyres out-of-true.

* Control arm ball joints worn. Remedy - Replace worn ball
Problem: Erratic steering on application

of brakesl
Excessive front bntkedise runout. Remedy - Machine front

brake discs.
'Oil soaked front brake pads. Remedy -Replace brake pads,
check and correct cause of oil leakage.
'Insufficient oruneven caster. Remedy -Check front wheel
alignment and adjust as necessary.
Steering knuckle bent. Remedy-Replace strut housing
'Excessive play in steering gear. Remedy- Adjuststeering
gear or replace worn components as necessary.
Problem: Vehicle pulls to one side!
Lower or uneven tyre pressures.

, Rear wheels not tracking with front wheels. RemedyCheckalignmentof rear wheels with front wheels and corrcct
fault, as necessary.
'Oil soaked front brake pads. Remedy - Replace brake pads,
check and correct cause of oil leakage.
*Toe-in incorrect.
Incorrect or uneven caster or camber. Remedy - Check
wheel alignment and adjust as necessary.
Rear axle assembly shifted. Remedy - Check attaching
bolts for looseness and control arm bushes for wear.
, Steering knuckle bent. Remedy - Replace front strut
housing.
Problem: Front or rear wheel tramp!
joints.
Uneven caster and camber. Remedy - Check front wheel
alignment, adjust as necessary.
Lower control armsortension rods bent. Remedy - Check
alignmentofcontrol arms and tension rods. Replacecomponents as necessary.
* Steering knuckle bent.
Remedy - Replace front strut
housing.
Problem: Cupped tyres!
Tyres improperly inflated.

* Wheels and tyres out ofbalance.
Dragging brakes. Remedy - Check for seizing of brake
callipers.
'Control arm ball joints worn, or incorrectly adjusted orworn
wheel bearings. Remedy - Replace ball joints or bearings,
adjust as required.
* Uncven caster. Remedy - Check wheel alignment and
adjust as necessary.
* Steering knuckle bent. Remedy - Replace front strut
housing.
Problem: Front wheel shimmy!
Steering connections incorrectly adjusted or worn.

* Control arm ball joint' or front wheel bearings loose or
wom.
Wheels and tyres out of balance.
* Wheels or tyres out-of-true.
* Incorrect or uneven caster or toe-in incorrect.
Wheels and tyres out of balance.

, Front struts or rear shock absorbers operating incorrectly
or unevenly, leaking fluid or inoperative. Remedy - Check
operation and replace component' as necessary.
Problem: Road shocksl
* Incorrect lyre pressures.
* Steering knuckle bent.
Remedy - Replace front strut
housing.
Problem: Car wanders!
* Steering gear or connections loose or worn.
* Steering gear or connections adjusted too tight.
* Steering gear incorrectly adjusted.
'Front struts or rear shock absorbers operating incorrectly

or unevenly, leaking fluid or inoperative. Remedy - Check
operation and replace components as necessary.
Compression or rebound rubbers missing.
Unbalanced wheels.
'Incorrect wheel alignment. Remedy - Adjust.
Remedy Test steering system for binding with front wheels off the
ground.
* Control ann ball joints worn.
Wheels toe-in too much to toe-out in straight ahead position.
Remedy - Adjusttoe-in to specification.
* Incorrect or uneven caster.

* Steering knuckle bent. Remedy - Rcplace front
housing.
227
strut
* Rear axle shifted.
TORQUE
SPECIFICATIONS
Remedy - Check attaching bolts for

looseness and control arm bushes for wear.
Loose attachment of front suspension assembly to frame.
Remedy - Check and tighten attaching nuts.
"Incorrect front wheel bearing adjustment.
Shock absorber upper attachment ................................ 40

Shock absorber to lower control arm ............................ 90
Lower control arm to boby .......................................... 85
Upper ann to bracket .................................................. 55
Upper arm bracket to body .......................................... 40
SPECIFICATIONS
Min
Max
Max DitIb/n
Wheels
+3
+4
LO
-0.50
0"
0.75
0"03'
0" 13'
linear
-0.2mm 2.2mm
Ki ng-Pin Angle relative to Spindle/ax Ie
Ca'ter
Camber
Toe-ino
Nm
Optimum
Road Wheel nut ........................................................ 150
+3.5
-0.25
0" 18'
3.0mm
7.5
Wheel Bearing adjusting nut ........................................ 30

Ball Joinlto Spindle/axle
Upper ...................................................... ................... 55
l....ower .................................................... _................... 85
Spring seat to lxxJy ..................................................... 40
Stabilizer Bar Mounting Bracket to Under body ........... 20
Stabilizer Bar to Lower Control Arm ........................... 20
Front Suspension Body Height Spacer Settings

Hole
Effective length
Sedans
Front C
178mm
Rear C
203mm
Front A
"s" Pack
141mm
Rear A
152mm
Ute, Van, Station Wagon:
Front B
158mm
Rear C
203mm
Front WheeL Bearing
Lubrication ........................ 34grams/hub ESA MIC 75B
Strut to Lower control ann ........................................ l L5
Strut to sub-frame ..................................................... 115

Brake caJiJ)er .............................................................. 30
Memo
228
REAR SUSPENSION
Subject
Page
MAINTENANCE ................................... 230
General InfOI Ilmtion ............................................... 230

Leaf Type SpringIBushes .......... ............. ............... .. 230
Removal .................................................... _.............. 230
InstalJation ............................................................... 230

Coil 'fype Spring ..................................................... 232
Removal ....... ................................................... ......... 232
Installation ................ .... .................. .. ....................... 232
L.ower Control Arlll!Bushes .................................... 233
ReOlOval .. .. .. ............................................................. 233
Instal1ation ............................................................... 233
Upper Control ArmlBushes .................................. 233
ReJOOvaJ ........................... ............................. ,.... ,.,.,.233
Installation ............................................................... 234

Shock Absorbers - Sedan ....................................... 234
Removal ............................................................... .... 234
Installation ............................................... ................ 234
Shock Ahsorbcrs- Utility/Station Wagon .............. 234
Removal ................................................................... 234
Installation ............................................................... 235
Track Rod & Bushes .............................................. 235
Removal ............................................. ...................... 235
Installation ....................................................... ........ 235
Rear Stabilizer Bar (Option) ................................... 235
RemovaJ ................................................................... 235
Installati on ............................................................... 235
229
Subject
Page
AUTOMATIC SELF LEVELLING ............. 236

Air Compressor ...................................................... 236
Removal ..... _............................................................. 236
Instal lation ..... ....... ....... ..... ...... ....... ............. ..... ..... ... 236
Dryer ...................................................................... 236
Removal ............................. _._................................... 236
Installation ............................................................... 236

Electronic Control Mooual ..................................... 236
Remove ...................... ...... ........................................ 236
Install .......................................... ............................. 237
Rear Air shock Absorber ........................................ 237
Renloval ................................................................... 237
Installation ..................................................... ....... ... 237
Nylon Air Line Repair ............................................ 1:37
Suspension Self Test ................................................ 238
REAR SUSPENSION
REAR
SUSPENSION
There are two main types of rear suspension used over the
series EA, EB, ED and associated Fairlane and LTD.
A conventional leaf spring type of rear suspension was used
on all Station Wagons, Utes and Vans.
All sedans utilize a coil spring type of rear suspension.
Various models used different coil spring tensions and these
different springs are identified by colour dots on the spring.
When replacing a spring it must be replaced by a spri ng ofthe
sametenSlOn.
'U'
Shock
Absorber
Bo~
Nuts
Retainer
Plate
RSOO2
5. Remove rear spring shack le bar nuts, bars and bushes .

Note:On the right hand side the two rearex haust mounts need
tobedisconnected.
6. Remove the front attaching bolt of the spring, remove the
spnng.
Installation
A self levelling suspension system was standard on some

luxury model vehicles and optional on others. This system usc
air adjustable rear shock absorbers. They are automatically
adjusted by aelectronicaJJy operated aircompressormounted
under the right hand side wheel arch (front fender) and is
operated by the electronic control module.
MAINTENANCE
1. Place the spring under the axle and fit the right shackle
assembly into the right hanger bracket and the end of the
spnng.
2. Install the shackle inner bush, shackle plate and locknuts
to linger tight only.
3. Install the front of the spring into the front hanger, fit bolt
& washer into hanger from the inboard side, fit locknuts to
linger tight only.
4. Lower the axle onto the spring, install the "U" bolts and
spring retaining plate under the spring and tighten the "u"
Torque:
60 Nm.
5. Replace lower end of shock absorber to the spring retaining
plate and tighten to specification.
GENERAL INFORMATION
Suspension systems should be checked for shock absorber

action, condition of suspension bushes, attaching bolts and
nuts, and an overall visual inspection of components for
defects. Periodic maimenance and adjustments are not required for the rear suspension components.
LEAF TYPE SPRINGS
Removal
1. Raise vehicle and support on safety stands under rcar
jacking poinL'\.
2 .Remove wheel covers where fitted then remove the wheels.
3. Disconnect the shock absorber at the rear spring.

4. Remove the "U" bolts from the spring and rear axle,
remove the spring retaining plate from beneath the spring.
Bushes
Spring
Retaining Plate
Retainer Nut
& Washer
Torque:
35 Nm.
6. Reconnect the two fC.1fexhaust bmckets on right hand side.
S. Torque all spring and shackle locknuts to specification.
230
REAR SUSPENSION
Leaf Spring Assembly
Shock Absorber
Hanger
Nut
Washer
Insulator
Insulator
Differential
Housing " - - - - :
Shock Absorber
Leaf Spring AssemtNy
Washer
Spring Retainer Plate

Nut Differential HO'''~''--~",
Absorber
.'
Shock _
Absorber
Cap
Coil Suspension Rear Suspension
Upper
Control
Arm
....1--W.Sh.,
Shock
Absorber
Top Housing
Lower
Control
Arm
Insulator
_Insulator
Shock
Absorber
Upper
Control
Arm
Shock
--Absorber
Lower
Control
Arm -_~
~~
::::lJ
Track Rod Assembly
Rs030
231
REAR SUSPENSION
Torquetospecification:
Rear spring to rearspring front hanger:
25 Nm
Rear spring to chassis:
70 - 115 Nm
9. Torque road wheel attaching nuts.
Torque:
100 - 125 Nm.
10. Refit wheel covers.
COIL TYPE SPRING
Installation
# After all the suspension has been assembled lower the

vehicle to the floor and torque suspension bolts and nuts.
1. Install the spring and insulators.
* Make sure the spring is correctly located in the spring seat,
i.e .. end of spring hard up to stop in the seat.
2. Raise the axle on jacks under the axle to its normal position
under the vehicle.
Removal
1. Raise vehicle and support on safety stands under rear

jacking points.
2. Remove wheel covers where fitted then remove wheels.
3. Place a jack underneath the axle and raise enough to take
the weight of the rear axle from the shock absorber. Remove
the bolts and nuts attaching the shock absorber lower mountings to the spring seat.
,'
Differential
Housing
Track
Assembly
Jack - - - '
Torque
Wrench
3. Fit the lower end of the rear shock absorber mountings to

the spring seat and tighten bolts to specification with vehicle
weight on axle,
Torque Shock Absorber mounting bolts: 7080Nm
4. Install the track bar to the rear axle and tighten, but not
specification at this stage,
5. Tighten all nuts attaching the upper and lower control arm
at this
but not to
4. Loosen the nuts at all of the rear suspension arm attaching

locations.
5. Remove the breather tube, breather and bolt from the rear
axle.
6.Install a brake hose clamp, disconnect the rear brake union.
7. Disconnect the track bar from the body at each end.
Differential
Housing -
Caliper
Mount
Control Arm
>rqule Wrench
& Socket
8. Remove the stabilizer bar from the rear axle.

9. Lower the axle.
10. Remove the spring and insulators.
6. Fit stabilizer bar (option) to rear axle

but not
to specification at this stage,
7. Replace the rear axle breather tube to the axle breather and
replace the breather bolt to the rear axle and rear brake union,
9. Tighten all suspension bolts and nuts to specification with
vehicle weight on suspension and differential.
232
REAR SUSPENSION
Torque Track Bar mounting bolts:

(EA 26 pre 5/90) ............................ 70 - 80
(XR8 and others) .......................... 74 - 103
Torque Suspension Lower Control Arm Nuts:
(EA 26 pre 5/90) ............................ 70 - 80
(XR8 and others) ......................... 74 - 103
Torque Suspension Upper Control Arm Nuts:
(EA 26 pre 5/90) ............. ............... 70 - 80
(XR8 and others) ........................ 74 - 103
Torque Stabilizer Bar clamp to rear axle: 15 - 20Nm
Torque Stabilizer Bar to mounting bracket 7 -14Nm
IO.Install brake union, remove brake hose clamp and bleed
brakes.
II. Torque road wheel attaching nuts.
Torque:
100 - 125 Nm.
Torque Suspertsion
Ann Nuts:
(EA 26 pre 5/90) ............................ 70 - 80
(XR8 and others) ......................... 74 - 103
Torque:
100 - 125 Nm.
LOWER CONTROL ARM I BUSHES
Removal
1. Raise vehicle and support on safety stands under rear
jacking points.
2. Remove wheel covers where titted then remove wheels.
3. Place ajack underneath the axle and raise enough to take
the weight of the rear axle from the shock absorber. Remove
UPPER CONTROL ARM I BUSHES

Removal
I. Raise vehicle and support on safety stands under rear
jacking points.
2. Remove wheel covers where fitted then remove wheels.
3. Place ajack underneath the axle and raise enough to take
the weight of the rear ax Ie from the shock absorber. Remove
4. Loosen the nuts at all of the rearsuspension arm attaching
locations.
5. Remove upper control arm to body mount attaching bolt
and nut. then remove control arm.
Ratchet _
& Socket
-----
""hide. _ _- - ;
Body -
4. Loosen the nuts at all of the rear suspension arm attaching
locations.
5. Remove lower control arm to body mount attaching bolt
and nut, then remove control arm.
Installation
i. Install the lower control arm to the rear axle and chassis.
2. Install all nuts attaching the lower control arm but do not
tighten to specitication at this stage.
vehicle weight on suspension and differential.
233
REAR SUSPENSION

1. Install the upper control arm to the rear axle and chassis.
2. Install all nuts attaching the upper control arm but do not
tighten to specification at this stage.
vehicle weight on suspension anddifferentia!.
Torque Suspension Upper Control Arm Nuts:
(EA 26 pre 5/90) ................... 70 . 80
(XR8 and others) ........................... 74 - 103
Torque:
100 -125 Nm.
5. Remove upper mounting lower bush and plate from shock

absorber.
Iustallation
1. Before installation, check shock absorber action and
inspect rubber bushes. replace where necessary.
2 Position the shock absorber through the spring seat

bracket, up so as the top of the shock absorber is in the correct
position.
SHOCK ABSORBERS-SEDAN
Removal
1. Open boot (rear compartment) and prise off shock absorber upper mounting cap cover.

safety stands.
3. Remove shock absorber upper mounting nut. upper plate
and bush.
3. Torquetheshockabsorbermountingnuts, with suspension

set at normal curb height.
Torque Shock Absorber mounting top nuts ........ 35
Torque Shock Absorber lower top nut.
(EA models) ................................ 70 - 80
(XR8 and EB models on) ............ 74 - 103
4. Install shock absorber upper mounting cap cover from
inside the boot.
5. Remove safety stands and lower rear of vehicle.
SHOCK ABSORBERS - UTILITY/STATION
WAGON
Removal
safety stands.
2. Open end gate and lift back the rear compartment floor
covenng.
4. Remove shock absorber lower mounting bolls and nuts!

nut, remove shock absorber via the spring seat bracket.
3.Removeshockabsorberuppermountingcoverscrewsand
remove cover.
4. Remove shock absorber upper mounting nut, plate and
Mounting
Plate
Differential
Assembly
Shock
Absorber
Retaining
Nut
234
Bushes
REAR SUSPENSION
bush.
5. Remove lower nut from shock absorber.
6. Pull shock absorber from lower mounting and remove.
Removeuppermountinglowerbushandplate;removelower
mounting bush from shock absorber.
loNallation
1. Before installation, check shock absorber action and
inspect rubber bushes. Replace where necessary.
2. Torque shock absorber mounting nuts with vehicle at floor
level.
Torque:
Shock Absorber Lower Mounting Nut:
35 Nm.
Shock Absorber Upper Mounting Nut:
35 Nm,
TRACK ROD & BUSHES
Removal
l, Raise rear of vehicle and support rear axle assembly on
safety stands.
2. Remove nut, washer and bolt from track rod side mil
housing mounting both left and right sides.
3. Remove track rod to axle housing nuts and washer.
1. Fit new bushes if necessary.

2. Install track rods, do nottighten until the vehicle is at curb
height.
3. Lower vehicle from safety stands.
4. Tighten track rod mounting bolt and nut to speci lied torque
at curb height.
Torque Track Rod bolts:
(EA 26 pre 5/90) ............................ 70 - 80
(XR8 and others) ........................... 74 - 103
REAR STABILIZER BAR (Option)
Removal
1, Remove nut securing stabilizer bar to body side rail
mounting bracket.
2. Remove spacer bolt washers and bushes at each end of
stabilizer bar.
3. Remove stabilizer bar bracket retaining bolts from axle
housing attachment points.
4. Remove stabilizer bar, brackets and insulators.
; zor
Bar Bush
Stabilizer
Bar
5. Inspect rubber insulators and bushes and replace where

necessary.
Installation
1. Inspect rubber insulators and bushes and replace where
necessary.
4. Remove track rod.

Installation
2. Install stabilizer bar, bmckcts and insulators.

3. Replace stabi lizer bar bracket retaining bolts to axle
housing attachment point'.
Stabilizer
Retaining
RS019
235
REAR SUSPENSION
Torque stabilizer bar bracket to axle housing retaining

bolt:
15 - 21 Nm.
4. Replace bolt, nut, washers and bushes securing stabilizer
bar to body side mil mounting bracket.
Torque stabilizer bar spacer stud attaching nuts:
7 - 14 Nm.
AUTOMATIC SELF
LEVELLING
Air Compressor
Removal
I. Disconnect the negative cable Ii-om the battery.
2.Remove the guard from around the compressor by removing the retaining screws and unciiping.
Rear Suspension
Pump Cover
Installation
1. Position the compressor assembly.
2. Replace the bolls securing the mounting bracket to the
compressor and the screws securing the bracket to the body.
Compressor to bracket bolts:
2.8 - 4.8 Nm
8.0 - 12.0 Nm
Bracket to vehicle screws:
3. Reconnect the electrical connections and the intake/exhaust tube.
4. Reconnect the air line to the dryer by pushing in .
5. Replace the guard around the compressor ensuring the
guard clips into position and replace screw(s).
Guard retaining screws:
3.5 - 5.5 Nm
6. Reconnect the negative cable to the battery.
Dryer
Oriver
3. Push in on the retainer for the airline to the dryer and

remove the air line.
4. Disconnect the electrical connections and the intake/
exhaust tube.
Removal
1. Remove compressor from the vehicle as described previously.
2. Remove the screw securing the dryer to the compressor,
then rotate the dryer clockwise to separate from compressor.
3. Remove the "0" ring seal and discard.
Installation
1. Install a new "O"ring seal on the dryer, then install dryer
to compressor and rolate anticlockwise to secure.
2.lnstallthe screw securing the dryer to the compressor and

tighten tospecification.
Dryer to Compressor screw:
3.5 - 5.5 Nm
3. Install compressorlO vehicle as described previously.
Electronic Control Module
5. Remove the screws securing the bracket to the body and

remove the boilS securing the mounting bracket to the
compressor.
6. Remove the compressor assembly.
Remove
i.From the banery disconnectlhe negative electrical connection.
2. Disconnect theeleetrical connection for the control module
attached to the floor pan above the rear suspension.
3. Disconnect the sensor connector link attached to the track
rod.
4.Remove the bolt securing the module and remove module

from vehicle.
install
236
REAR SUSPENSION
I.lnslall the module to the vehicle and tighten the retaining

bolito specification.
Modulemountingbolt:
8 - 12 Nm
2.Connectthe sensor connector link to the track rod. Sensor
connecting link to measure l06mm ball centre to ball centre
(98mm for TVE option)
3.Reconnecttheelectrical connection to the control module.
4.Connect the negative electrical connection to the battery.
Rear AIr Shock Absorber
Removal
I. Open boot (rear compartment) and prise off shock absorber upper mounting cap cover.
safety stands.
3. Disconnect the air line from the shock absorber.
position.
2. Torquetheshockabsorbermountingnuts, with suspension
set at normal curb heighl
Shock Absorber mounting top nuts .................... 35
Shock Absorber lower top nuts
(EA mooels) ................................ 70 - 80
(XR8 and EB models on) ............ 74 - 103
3. Reconnect the air lines to the shock absorbers and replace
the internal trim to the vehicle.
4. Remove shock absorber upper mounting nut, upper plate

and bush.
5. Remove shock absorber lower mounting boll' and nuts!
nut, remove shock absorber via the spring scat bracket.
6. Remove upper mounting lower bush and plate from shock
absorber.
cap cover
from inside the boot.
5. Remove safety stands and lower rear of vehicle.
Nylon Air Line Repair
If an air leak is found in the air line for the self levelling
suspension, the leak can ea.i Iy be repaired.

The line is cleaned around the leak area, then the line is cut
with a sharp knife. Rejoin the air line using a air line
connector.
lnstaIIation
L Position the shock absorber through the spring scat
bracke~ up so as the top of the shock absorber is in the correct
237
REAR SUSPENSION
Suspension Self Test
The suspension warning lamp located in the instrument panel

gives the diagnosis codes for the preliminary self test.
1. Frontdooropen, ignition ON, push the door courtesy light
button in and release very quickly (3 times per second).
OR
Ignition ON, tum interior lights on and off at dash very
quickly (3 times per second).
If the button is pressed fast enough the test will commence.
2. Once theselftest iscomplcted the warning lamp will flash
as described in the diagnosis table. The waming light flash is
b) A seize (except at either extreme end of travel).

c) A noise such 3' a grunt or squeal after completing one full
stroke in both directions.
d) A clicking noise at fast reversal.
e) Fluid leakage.
Self Test Diagnosis

See "Diagnostic Charts" chapter
TORQUE
SPECIFICATIONS
onceevery second.
PROBLEM DIAGNOSIS
Testing Shock Absorbers!
This test procedure is not for gas pressurised shock

absorbers.
1. Clamp shock absorber by its bottom mount in a vice.
2. Slowly pump shock absorber up and down the full stroke
al least six times before checking its resistance.
3. Pump shock absorber by hand at various rates of speed and
observe resistance.
When extending the shock absorber, the resistance shou Id

be marginally gneater than when collapsing the unit. The
resistance should beconsistent throughout both strokes and
there should be no 'slack' spots.
'Slack' spots indicate either loss ofoil or valve not seating.
4. It is normal to detect a hissing noise (orifice swish).
Replace shock absorber if listed conditions occur:
a) A skip or lag at reversal near mid-stroke.
Track Rod bolts .......... ,_ ...................................... 70 - 80

Stabilizer Bar clamp to rear axle ........................... 15 - 20
Stabilizer Barto mounting bracket.. ........................ 7 - 14
Shock absorberto upper mounting bracket ............ 30 - 35
Shock absorber upper mounting bracketto body ... 30 - 35
LcafSpringSuspcnsion
"U" bolts 50-65
Shock Absorber to spring relaining plale ................. 70-80
Front hanger to ~pring ............................................ 20-30
Rear hangerOOlt ........................... _........................ 55-65
Spring shackle bars to body & spring ..................... 30-35
Coil Spring Suspcnsion
Shock Absorber mounting top nuts .............................. 55
Shock Absorber lower top nuts ............................... 70-80
Upper Control Bar Front mounting nuts .................. 70-80
Lower Control Bar mounting nuts .......................... 70-80
Upper Control Bar mounting nuts ........................... 70-80
Memo
238
BRAKE SYSTEMS
Subject
Page
BRAKE SYSTEM .......................................... 24()
Description and Operation ................................. 240

ROUTINE MAINTENANCE ............................ 240
Hand Brake Cable ............................................. 240
Check and Adjust ... ........ ........... .... ....... .................. . 240
Adjustment .............................................................. 240

Park Brake Shoe Replacement ................ ...... .... ..... 240
Bleeding the Brake System ............................. 241
Bleeding ABS System ......................................... 241

Checking Brake Lines and Hoses .................. 241
Brake Pad Wear .................................................. 242

Brake Roughness ................................................ 242
Disc Brake Service Precautions ...................... . 242
Subject
Page
Dismantle 248
Inspection ................................ -. _............................ . 248
Assemble ........................... ...................................... 248
Installation ............................................................... 249
REAR BRAKE PAD REPLACEMENT .......... 249
Removal .................. .. .............................................. 249

Installation ............................................................ ... 249
REAR ROTOR .................................................... 249
Removal ....... ........................................................... 249
Repairs .................................................................... 249
Installation ............................................................... 249
Hydraulic System Failure Warning Switch ....... 242
HAND BRAKE ................................................... 249

Adjust Hand Cable .................................................. 249
Proportioning Valves .......................................... 242
Hand Brake Lever Assembly .................................. 249
MAJOR REPAIRS ............................................. 243

Master Cylinder ................................................. . 243
Remo ve .................................................................. . 243
Dismantle ................................................................ 243
Inspection ................................................................ 243
Remove ..... ............................................ ... .. ........ ..... 249

Install ........................... ......................................... ... 250
Adjust ..................... ........................................... ...... 250
ABS SYSTEM ............................................ 25()
Description of system .............................................. 250
Assernbly ................................................................. 244

install ....................................................................... 244
VACUUM BRAKE BOOSTER ........................ 244
On Vehicle Test ...................................................... 244
Removal .......................,., ...... ,.,............................... 244
Install ....................... ,.......... ,.......... ,......................... 245
FRONT BRAKE CALIPER .............................. 245
Remove ............ ,............ ,., ......,................................ 245
Dismantle ................................................................ 245
Inspection ................................................................ 245
Asscrnble ................................................................. 246
Lnstallation ........................... ,.............. ,.................... 246
FRONT ROTOR ................................................. 246
Removal ......,.. ..............................,... ,...................... 246
Repair ......................................... ,................ ,........... 247
Installation ............................................................... 247
FRONT BRAKE PAD REPLACEMENT ....... 247
Remove ................................................................... 247
Installation ............................................................... 247
REAR BRAKES CALIPER .............................. 248
Remove ........................ ,.......... ,....................... ' ......, 248
239
Removal of components ..........................................

H ydrau Iie Modu lator (pump) ...................................
Wheel Speed Sensor (front) ....................................
Wheel Speed Sen~or (rear) .....................................
250
250
251
25 1
ECU ....................................................... .... ............. 25 1

Front Tone Wheel ................................................... 251
Installation of components .......................................
H ydraul ie Modu lator (pu m p) ...................................
Wheel Speed Sen~or (front) ....................................
Wheel Speed Sensor (rear) .....................................
251
251
251
251
ECU ........................................................................ 251

Front Tone Whee l ................................................... 251
PROBLEM DIAGNOSIS AND TESTS .......... 252
SPECIFICATIONS ............................................. 252

TORQUE LIMITS .............................................. 252
BRAKE SYSTEMS
BRAKE SYSTEM
DESCRIP rION AND OPERATlON
The front and rear brakes use a calliper and disc style. and
for the service brake and the hand operated parking brake
via a lever and cable. uses drum brake style to apply a
clamping force on the in side of the rear discs.
The master cylinder has a twin back-up cylinder system
to prevent brake failure. The BClA duel master cylinder
is a compensating type featuring a "fast fill" system. The
primary and secondary pistons with the aid of the poppet
valve. operate a separate hydraulic system for the front
brakes and rear brakes. This has a safety benefit which
allows one set of brakes to continue to operate in case of
a failure with either front or rear brakes.
The master cylinder also incorporates the proportioning
valves and a brake failure warning lamp switch.
The master cylinder is assisted by the function of vacuum
operated brake booster. A signal diaphragm-type brake
booster is a self-contained vacuum-hydraulic braking unit
mounted on the engine side of the dash panel.
The brake booster is of the vacuum suspended type which
utilizes engine intake manifold vacuum and atmospheric
pressure for its power.
The booster unit is to be exchanged when it is inspected.
checked and found to be defective.
Some vehicles are also fitted with the Anti-lock Braking
System which has the function of preventing the brakes
from locking up by adjusting the brake fluid line pressure.
(Better Description in the ABS Section)
ROUTINE MAINTENANCE
HAND BRAKE CABLE
Check and Adjust
Place the tran smission in neutral.
Jack the rear of the vehicle and place on safety stands.
DO NOT START ENGINE.
Place safety blocks both sides of both front wheels.
Pull hand brake leverup until there is sufficient resistance
that the hand brake should be fu ll y functional (this should
be approximately 3-5 clicks from the fully off position).
VehICle
Body
Check back wheels for resistance. there should be enough

resistance that the wheels are impossi ble to turn by hand.
Release hand brake lever and check the back wheels for
resistance. there should not be any resistance.
Adjustment
1. With vehicle supported. withdraw the wheels.
2. Disconnect and raise the rear brake caliper from the
disc assembly and place to one side.
3. Release the disc rotor retaining screw. then withdraw
the rotor from the rear axle assembly.
Rear Disc
Assembfy
Inner Brake
Pad
Note: Turning rotor while pulling off will help in removal.

4. Release the park brake cables from the application
lever, then using vernier calipers, measure the distance
from brake shoe face to face.
S. The distance should read between 189.6-189.8 mm. if
distance is not within specifications adjust.
6. To adjust the distance turn the adjusting nut until desired
measurement is obtained.
7. Fit the disc rotor. bntke caliper and park brake cable.
then the wheel can be fitted.
8. Check park brake to ensure correct operation.
Park Brake Shoe Replacement
1. Support the vehicle. then withdraw the wheel, brake
caliper and rotor from the axle shaft.
2. Release the retaining screws on the hold-down springs,
then withdraw the shoe over the axle.
Disc Brake. _--:=---o.~
Assembly -
3. Detach the shoe from the actuation mechanism, ensur-
ing not to move the mechinisuffi.

4. Using a brush or vacuum clean the hand brake housing
240
BRAKE SYSTEMS
and assembly.
5. Screw the adjustment screw to the full adjustment
position and back a 1/4 turn (in notched nut), ensure the
adjuster screw and tappet slots are aligned.
6. Lowerthe shoe into position in the actuation assembly
slots, then fit the hold-down springs and ensure the shoe
is sitting on the backing plate pads.
7. Operate the park brake lever and check the function of
the assembly.
8. Adjust the shoes as previously described, then fit the
rolor, brake caliper and tyre.
9. Check the operation of the hand brake.
BLEEDING THE BRAKESVSTEM
Clean dust grease and foreign matter from the brake

bleeding valves on all four callipers.
Althe back left wheel prepare to start bleeding the brake
system. Always bleed the calliper with the longest length
of brake fluid pipe first, this to help ensure there are no air
traps in the brake pipe system.
Use a ring spanner on the bleeder valve, then connect a
dear plastic tube to the end of the bleeder valve, insert the
other end of the plastic bleeder hose into a clean container
halffilled with clean brake fluid.
Repeat above procedure (pumping the brakes) until all air

has been released from the back left brake bleeder valve.
Tighten the bleeder valve, remove the hose and spanner.
Repeat the bleeding procedure on the right rear wheel, left
front wheel then right front wheel.
Then repeat the pumping and bleeding procedure on the
left back wheel and right back wheel, this is to ensure the
pedal will not be spongy.
Check the level of the master cylinder.
Do not use the old brake fluid as a top up into the
master cylinder.
BLEEDINGABSSVSTEM
Ring
Spanner
The ABS Brake Syslem is bleed the same way as a

normal system is bleed, the only difference occurs when
bleeding the modulator.
CHECKING BRAKE LINES and HOSES
Raise the rear of vehicle, position on safety stands and

remove rear wheels. Inspect braking disc, linings and
calliper. Check all brake tube connection for possible
leaks and flexible hoses for deterioration. Install new
flexible hoses if required.
NB: Ensure hose is not twisted more than 15.
HOse - -- '
Tube must be submerged

in brake fluid
EInIk.
c.llper
Have an assistant press the brake pedal 3 or 4 times and

hold his foot on the pedal, this is pumping the brakes. After
your assistant has pumped the brakes, with his/her foot still
on the pedal, loosen the bleeder valve with the ring spanner
approximately half a tum. This will allow fluid and air to
passoutofthe bleeder valve through the bleeder hose into
the container with the brake fluid. When the assistants
foot on the brake pedal has travelled to the floor, tighten
the bleeder valve before the assistant allows the pedal to
rise from the floor, otherwise old fluid and air will be
sucked back into the brake system. Check the level of the
master cylinder and keep topping it up with fluid otherwise
air will enter the system.
241
_ _ FleXible Brake
Line
Caliper
Mounting Bracket
Br004
If a brake pad lining has worn to minimum specification,

replace both inboard and outboard pads. It is necessary
that both rear wheel sets be replaced whenever a respective brake pad is worn beyond specifications or damaged.
BRAKE SYSTEMS
BRAKEPADWFAR
lfvisual inspection doesn't adequately detennine condition of lining, a physical check is necessary. To check
amount of lining wear, remove brake pad assemblies.
Three thickness measurements with a micrometer should
be taken across the centre of each pad assembly; one
abrasion of the disc faces. Vehicles which stand unused

for periods of time in areas of high humidity or salt air may
incur rust on the disc which could cause a temporary brake
surge and roughness. Normally, however, thi ~ condition

should correct itself after a short period of usage. If rust
is severe enough, roughness will notelear up and the disc
must be resurfaced or replaced.
reading at each end and one in the centre.

0<a.1<. Pad
Micrometer
BRAKE ROUGHNESS
The most common cause of brake roughness (or chatter)
with disc brake is excessive disc face run-out. This is
easily checked withadial indicator. If measurement isout
of specification, disc must be re-surfaced or replaced.
Maximum Disc Runoutspccit1cation .... ...... ..... .. O. Illlm

Minimum Disc Thickness stamp on hub ........... 21.0mm
DISC BRAKE SERVICE PRECAUTIONS

Grease and any foreign material must be kept off calliper
assembly and surfaces of braking disc during service
procedures. The braking disc and calliper should be
handled, avoiding deformation of the disc and scratching
or nicking ofthc pad linings.
I f inspection reveals square sectioned calliper piston seal
is worn or damaged, it should be replaced immediately.
During removal and installation of a wheel and tyre
assembly, use care not to strike the calliper.
Before moving vehicle after brake service work, obtain a
finn brake pedal by using correct bleeding procedures.
Dragging the brakes (common result of left foot application on vehicles with automatic transmission) should be
avoided during vehicle operation.
As brake pad lining wears, reservoir level will godown. If
fluid has been added between relines, then re se rvoir
overflow may occur when piston is pushed back into new
lining position . Overflow can be avoided by removing a
small amounlofnuid from reservoir.
M icrometer
HYDRAULIC SYSTEM FAILUREWARNING

SWITCH
The hydraulic system warning switch located in the
master cylinder, is used to warn the vehicle operator that
one of the hydrauli c systems has failed .
Oisc - -_
CheCk run out of disc
Disc _.-
A failure in one circuit doesn't result in an entire brake

system failure.
-r.....-=
As pressure in onedrcuit fall s, the uneven pressure on the

spool valve forces the valve to move and contact switch
Micrometer
temlinal thus lighting the hrake amI failure warning lamp
on instrument cluster.
Brake
Rotor
Other less prevalent causes of roughness can be the use

of some type of nonstandard lining material and extreme
The warning lamp switch spool valve is sclfneutralising,

thus it is not necessary to remove the switch to allow the
valve to centralise .
The switch can be removed or replaced without fluid loss.
PROPORTIONING VALVES
Proportioning valves are fitted into the master cylinder.
Their purpose is to regulate the amount of fluid pressure
transmitted to the rear hydraulic circuits thus preventing
premature rear wheel "lockup" resulting in improved
braking and steering control under braking.
The valves contain a stepped piston working against a preloaded spring and poppet valve. This allows the front and
rear hydraulic pressure to increase at the same rate until
242
BRAKE SYSTEMS
ille piston overcomes the spring force. Attrus point the

piston will begin to move across to the poppet valve, thus
restricting the pressure increase to the rear brakes.
MAJOR REPAIRS
MASTER CYLINDER
# Each master cylinder has the bore size cast into the
master cylinder body on the upper front edge.
4. Withdraw the primary piston from the cylinder bore,
then the secondary piston and spring.
S. Release and withdraw the pressure differential switch
from the housing assembly.
6. Withdraw the proportioning valve assembly end plug
and seal, then tap the housing end on a piece of timber to
release the valve
--
Remove
1. Disconnect electrical connector from brake warning
switch.
2. Disconnect brake lines from master cylinder and plug
lines.
3. Remove nuts securing mastercylinderto brake booster
and remove master cylinder.
Do not move brake booster push rod. Do not press brake
pedal with master cylinder removed or reaction disc may
misalign in booster.
Dismantle
1. Release the reservoir securing screw and lift reservoir
clear of the cylinder assembly.
2. Face the reservoir ports down, then apply pressure to
the primary piston until the secondary piston securing pin
drops out.
Piston
Securing Pin
~,__ Secondary
Master Cylinder
Assembly
3. Release the fast fill valve using circlip pliers, valve will
fall from the assembly, then withdraw the '0' ring seal.
243
Master Cylinder
Assembly
Proportioning Valve
End Plug
NOTE: Do not use pliers to pull the valve from the

cylinder, do not disassemble the valve assembly as it is
serviced as a unit.
Clean and Inspect

1. Wash master cylinder body, reservoir and cap in clean
methylated spirits.
2. Wash all internal parts in brake fluid.
3. Check all recesses, openings and passages to ensure
they are open and free of foreign matter.
4. Place all parts on a clean surface.
S. Inspect the master cylinder bores for signs of etching,
pitting, scoring or rust. If in poor condition, replace the
cylinder. THIS CYLINDER IS NOT TO BE HONED.
6. When replacing cups, plastic retainers may be removed
by cutting with a sharp knife or razor blade, ensuring that
piston is not damaged in any way.
* Because special rubber compound is used, this master
cylinder MUST BE REPAIRED USING ONLY THE
GENUINE KIT. This kit includes new rubber components. Ensure all sections of the cylinder are repaired.
The operating pressures of the proportioning valve are
stamped on the front end of the cylinder and it is most
important thaI, should a cylinder need replacing, an iden-
BRAKE SYSTEMS
tical cylinder be used.

Assembly
1. Fit the proportioning valve assembly into the cylinder,
then the valve assembly end plug to retain the valve.
2. Fit pressure differential switch to housing assembly.
3. Fit the secondary piston spring and piston, then the
primary piston into the cylinder bore.
L Install master cylinder assembly on brake booster

taking care not to disturb brake booster push rod. Torque
master cylinder nuts.
Torque ........................................................ 13 - 14 Nm.
2. Unplug brake lines and master cylinder and securely
reconnect brake lines to master cylinder.
3. Reconnect electrical connector to brake warning switch.
4. Bleed brake system as previously described.
Master Cylinder
Reservoir - _ _
VACUUM BRAKE
BOOSTER
On Vehicle Test
Check the hydraulic brake system for leaks, top up
reservoir if required.
Primary Piston
Assembly
Master
linde'
Assembly
4. Fitthe fast fill valve '0' ring and val ve, then the circlip
to retain the valve in place.
S. Face the reservoir ports up, then apply pressure to the
primary piston until the secondary piston securing pin is
able to be droped into place.
6. Fit the reservoir, then secure with the retaining screw.
Master Cylinder _ _
Reservoir
Master Cylinder
Sore Assembly
Engine stopped, press the brake pedal down 5 to 6 times

this will utilise all vacuum available. Press the pedal down
and hold it down, start the engine.
To check if vacuum system is functioning properly, the
pedal will require less pressure as vacuum pressure builds
up. If there is no deference in pressure required to hold
pedal down then the vacuum system is not functioning.
Next step pull the vacuum hose from the booster valve.
Vacuum should be at engine end of the hose at idle.
Then operate engine for 10 seconds at fast idle. Stop
engine wait for 10 minutes, press the brake pedal down.
The pedal pressure required should be the same as when
the engine was operating. If the pedal requires quite a bit
of pressure (that the booster is not giving power assist
ancel, replace the brake booster.
Remove
Press the brake pedal down until all the vacuum is
relieved from the vacuum system.
I. Disconnect the master cylinder from the booster, with
brake lines connected, pull the master cylinder forward.
2. Pull the manifold vacuum hose from the booster check
valvefitting.
Tnstallation
3. In the cabin under dash panel, disconnect the booster

push rod from the brake pedal by removing a fine pin
retainer then remove push rod, spacer.
244
BRAKE SYSTEMS
2. Separate calliper housing from anchor plate and re-
4. Remove the brake booster rrom the fire wall attached

by rour nuts.
move brake pads.
Slldo_..
Rubber ,Boots
Br049
3. Withdraw slide sleeves and boots from anchor plate.

Separate boots.
Install
4. Place a block of clean wood between calliper piston and
I. Install the boosterto the fire wall. by sliding the push rod
and boot through the fire wall from the engine bay. use a
new gasket for the booster. Install the booster securing
nuts and tighten to specification.
Booster Securing Nuts Torque ............................ 30Nm
2. [nstall the spacer and booster push rod, to the brake
pedal, install retaining pin.
3. Install the vacuum hose to the booster fitting.
4, Install the master cylinder and tighten the securing nuts
tospeeification.
Master Cylinder Nuts Torque .............................. 30Nm
opposite legs on housing and apply air pressure at brake

hose inlet port to eject piston.
Brake
Caliper
Compressed
Blower
Block Of
Wood
BRAKE CALLIPER - FRONT

Remove
I. Raise vehicle and place on jack stands.
2. Mark position of road wheel relative to hub and remove
wheel.
3. Place a drain tray beneath calliper assembly.
4. Loosen and remove brake hose to calliper attaching
boll. Separate bolt from hose and discard scaling washers.
5. Remove two calliper attaching bolts and lift calliper
assembly out over disc.
Caution: Do not have YOllr fingers inside of calliper

when removing the piston by this method.
5. Remove rubber boot from bore.
6. Remove seal rrom bore, taking care nottodarnage bore
or seal locating groove.
7. Remove bleeder screw.
Clean and Tnspeet
1. Clean all metal parts thoroughly with methylated spirits.
Clean rubber parts with brake fluid only. Use clean, dry
compressed air to dry parts.
2. Examine bore and piston carefully for signs of damage,
abrasion, scuffing orcorrosion replace irnecessary.lrthe
bore is unserviceable, a new housing must be fitted.
Caliper
Piston
- - - Scoring
Dismantle
I. Remove calliper bolts and discard.
245
BRAKE SYSTEMS
3. Inspect slides sleeves for corrosion. Replace if corroded.

4. Blow through port in bleed screw with compressed air.
Assemble
1. Lubricate cylinder bore and piston with specified brake
fluid . (ESW FM 6C2)
2. Fit new seal into inner groove of bore. Ensure seal is
not twisted and is fully seated in groove.
3. Install piston boot over end of piston.
4. Position piston into calliper housing, seating boot into
grove in calliper bore. Ensure boot flange is squarely and
firmly seated in groove.
Installation
1. Ensure anchor plate mounting surfaces are clean.
2. Press inner brake pad by hand to ensure piston is
bottomed in bore.
3. Position calliper assembly over disc, insert anchor plate
retaining bolts. Torque bolts.
Calliper Anchor Bolt Torque ............................... 30Nm
4. Reconnect brake hose using new sealing washers.
Torque attaching bolt.
'1
Caliper Piston
Dust Boot
Brake Hose
Retaining Bo'::-~"':
-::-.:..!
Brake Hose to Calliper Torque ........................... 30 Nrn

5. Bleed brake system as previously described.
6. Depress brake pedal several times to bring pads into
position against disc.
7. Install road wheel(s) and lower vehicle.
Brake
Caliper
5. Push piston squarely into bore by hand until fully seated.
Torque .............................................................. 140 Nm
Ensure piston boot seated in piston/cailiperboregrooves.
8. Check level of fluid in master cylinder.
Brake
Cahper
Caliper
Piston
Brtl26
Front Rotor
Removal
1. Remove the calliper assembly as described above.
There is no need to disconnect the brake hose, if the
calliper docs not to be pulled down. Place the call iperto a
side, tie with stri ng or support on wire hook to front
suspension, so thecalliper is not supported on brake hose.
2. Remove the front bearing grease cap. Remove the
bearing lock nut split pin, lock nut, adjusting nut, and flat
washer from the spindle. Remove the front wheel
bearing assembly. Remove the hub and rotor from the
spindle.
6. Lubricate slide sleeves with silicone type grease (Dow

Corning No. 44).
7. Reinstall slide sleeves in calliper housing using new
calliper housing to sleeve bolts. Use an open end spanner
to hold hex section of gu ide pin when tightening bolts.
Slide Sleeve Bolts Torque ... ................................ 30 Nm
* Do not reuse old bolts.
8. Install new guide pin boots.
9. Assemble calliper housing and anchor plate together.
Ensure guide pin boots are correctly located in guide pin
and anchor plate grooves.
10. Install bleed screw, then brake pads as previously
described.
Spindle
OISC As sembly
246
BRAKE SYSTEMS
the master cylinder reservoir. Do not remove the brake

line or completely empty the reservoir or it will be necessary to bleed the hydraulic system. Discard the brake
fluid.
Brake fluid must be removed, this will prevent the
reservoir overflowing when the calliper piston is
forced in while replacing pad.
2. Remove the wheels. Work on only one brake at atime.
Pad assemblies must always be replaced as sets either
Repairs
The only repairs that can be done is the rotor can be
machined, if disc is machined and width is under specifications the disc will need to be replaced.
The linished braking surfaces of the rotor must be flat and
parallel within O.08mm, overall thickness across braking
surfaces after machining must not be less than specified
muumum.
Front Disc Side Surface min . thickness .............. 3.2mrn
Front Disc minimum thickness spec ................. 22.0mm
front or rear.
3. Remove the two mounting bolts which hold thecalliper

to the calliper frame, lift the calliper away from the disc
and calliper frame. It is not necessary to disconnect the
brake hose at the calliper for pad replacement, only for
call iper overhauling.
Vernier
Calipers
--
Front Disc
Assembly
# If the rotor is to be machined the bearing must be

removed, otherwise they will become contaminated with
machined particles of metal.
Installation
1. Install the rotor on the spindle. Install the front wheel
bearing assembly plus washer, bearing nut, lock nut and
split pin.
Adjust the front wheel bearing as described in the "Front
Suspension" chapter.
2. Replace the front bearing grease cap
4. Lift the brake pads out of the calliper.

Installation
'Connect brake hose ifit was disconnected during calliper
removal.
1. Push piston into thecalliperbore, by hand ifthecaUiper
has been overhauled, or by using a suitable uG" clamp.
This is necessary to obtain enough clearance for the new
pads and the calliper to fit over the rotor.
2. Locate the inboard pad in calliper first.
Front wheel
bearing cover
3. Replace the calliper assembly on the axleas previously

described.
Front Brake Pad Replacement
Remove
1. Remove one half of the fluid from the front section of
247
3. Slide the outboard pad into the calliper.

4. Position calliper correctly over rotor and slide straight
Brake Systems
into position until calliper head bolt holes align with their
respective holes on the calliper frame.
5. Install both calliper mounting bolts and torque to
specification.
Front Brake Calliper Mounting Bolts torque ........ 30Nm
6. Replenish the brake fluid in the master cylinder. Pump
the brake pedal several times to position the shoe and pad
assemblies.
7. Check for leakage of fluid at all connections under
pedal pressure. Check fluid level, install wheel and tighten
wheel nuts, tighten nuts to specification .
Wheel Nut specified torque ............................... I40Nm
8. Road test the vehicle and make several light stops to
seat the linings.
BRAKE CALIPER-REAR
Remove
1. Withdraw the wheel from the vehicle, then release the
two caliper mounting bracket mounting bolts.
2. Withdraw the caliper from the rotor, then release the
brake pads from the caliper assembly.
Disc
3. Withdraw slide sleeves and boots from anchor plate.

Separate boots.
4. Place a block of clean wood between calliper piston and
opposite legs on housing and apply air pressure at brake
hose inlet port to eject piston.
Caution: Do not have your fingers inside oj calliper
when removing the piston by thi., method.
5. Remove rubber boot from bore.
6. Remove seal from bore, taking care not to damage bore
or seal locating groove.
7. Remove bleeder screw.
Inspection
1. Wash all components of the calliper assembly in clean
warm water to disperse the brake fluid.
2. Dry components with air blower or clean rag, ensuring
all passage ways are clean and clear of blockages.
3. Once dried inspect all components for any wear and
damage (scuffing, corrosion, pitting, scoring), if any is
present the component will need replacing.
Assemble
1. Lubricate cylinder bore and piston with specified brake
fluid. (ESW FM 6C2)
2. Fit new seal into inner groove of bore. Ensure seal is
not twisted and is
seated in
Rotor Assembly
NOTE: For caliper rebuild release the brake hose before

withdrawing the caliper from the rotor.
Dismantle
1. Remove calliper bolts and discard.
2. Separate calliper housing from anchor plate and re
move brake pads.
Caliper
Assembty
Br<l36
Rear Disc
3. Install piston boot over end of piston.

4. Position piston into calliper housing, seating boot into
grove in calliper bore. Ensure boot flange is squarely and
firmly seated in groove.
S.Push piston squarely into bore by hand until fully seated.
Ensure piston boot is fully seated in piston and calliper bore
Rotor Assembly
grooves.
Caliper
248
BRAKE SYSTEMS
6. Lubricate slide sleeves with silicone type grease (Dow

Coming No. 44).
7. Reinstall slide sleeves in calliper housing using new
calliper housing to sleeve bolts. Use an open end spanner
to hold hex section of guide pin when tightening bolts.
Slide Sleeve Bolts Torque ..... .................. ......... ... 30 Nm
Do not reuse old bolts.
8. Lnstall new guide pin boots.
9. Assemble calliper housing and anchor plate together.
Ensure guide pin boots are correctly located in guide pin
and anchor plate grooves.
10. Install bleed screw, then brake pads as previously
described.
Installation
1. Fitthe brake pads to the caliper assembly, then position
over the rotor.
the
4. Press the caliper piston back into the housing, umil it

bottoms out.
S. Fit the new brake pads to the caliper assembly.
6. Position the caliper over the rotor, ensuring that the
brake pads are correctly fitted.
7. Fit thecaliperassembly retaining bolts, then the wheel.
8. Lightly pump the brake pedal several times to push the
brake pads against the rotor, then road test the vehicle.
Rear Rotor
Removal
1. Remove calliper as described in brake pad replacement
(removal), previously in this chapter.
2. Remove rotor retaining screw and withdraw rotor from
axle flange.
Repairs
The only repairs that can be done is the ro tor can be
machined. if disc is machined and width is under specifi
cations the disc will need to be replaced .
Thefinished braking surfaces of the rotor must be flat and
parallel within 0.05mm, overall thickness across braking
surfaces after machining must not be less than specified

nummum.
Rear Disc minimum thickness spec ............ ...... 12.Omm

Installation
1. Replace machined rotor over axle flange ensuring that
the retaining screw is aligned.
==-..
Disc Brake. __
Assembly -
, ii-
NOTE: Reconnect the brake hose to the caliper, if

disconnected during removal.
2. Fit the caliper assembly retaining bolts, then the wheel.
NOTE: Bleed the brake if brake hose was disconnected
during removal.
Rear Brake Pads Replacement
l. Withdraw the wheel from the vehicle, then release the
two caliper mounting bracket mounting bolts.
2. Withdraw the caliper from the rotor, then release the
brake pads from the caLiper assembly.
3. Release the reservour lid and seal from the brake
cylinder reservour.
e ... ".
2. Replacecalliper as described in brake pad replacement

(i nstallation) previously in this chapter.
- -.....
HAND BRAKE
Hand Brake Lever Assembly
Remove
1. Release the hand brake cables from the rear brake
assemblies, withdraw the dust boot from the assembly.
2. Release the adjusting nut from the hand brake cable,
this allows the cable to slide through the lever assembly.
3. Release the three bolts retaining the lever assembly to
the floor.
249
BRAKE SYSTEMS
There are two different ABS braking system designs that

are used on the EF & EL, both systems operate in the
&
Nut
same manner.
ASS Brake Fluid _ _- ;

Supply & Outlet
-~
lever
~~ .....,
4. Lift the lever assembly from its mounting position,

carefully sliding the cable out of the assembly.
Install
1. Fit the hand brake cable to the lever assembly, then
lower the lever assembly into place, ensuring that the
cable is slid right through.
2. Start the adjusternut on the end of the hand brake cable,
then retain the lever assembly with the three retaining
bolts.
3. Attach the hand brake cables to the rear brake
assemblies, then adjust the hand brake cable.
4. Fit the dust cover boot to the hand brake lever

assembly.
Adjust
1. Adjust the rear brake shoes as previously described.
2. Raise the hand brake levertwo notches, then adjuslthe
hand brake cable adjuster until there is minimum drag on
the rear wheels.
3. Pull hand brake on another five notches and check that
there is resistance at the rear wheels.
ABSSYSTEM
Description of System
The Anti-lock Braking System is designed to provide safer
braking performance on all road surfaces and conditions.
The design of the system is to prevent any of the vehicles
wheels from locking up under heavy braking situations or
where there is a slippery surface on one part of the road.
The vehicles brake arc monitored by speed sensors on

each wheel, the speed sensors sends a signal to the
Electronic Control Unit on the speed of the wheels. In the
case of one wheel moving slower than the others the
Electronic Control Unit will send a signal to the Modulator
Assembly, which will then alter the brake fluid pressure to
the appropriate wheel until it is travelling at the same speed
as the other wheels.
The ECU receives information from both the speed
sensors and the brake pedal switch, this information is then
processed to enable a signal to be sent to the modulator
assembly as to which brakes need the nuid pressure
adjusted.
The operation of the system increases braking perfoonance and stabi lity, which in tum allows the driver of the
vehicle maintain maximum steering conlroi over the vehicle under extreme braking.
Removal of Components
Hydraulic Modulator (Pump)
1. Pump is located under the left front wheel arch, in front
of wheel.
2. Remove pumps plastic cover, clean around all fittings.
250
BRAKE SYSTEMS
Stub Axte_~~~~~
Assembly
.__, __-::::;:-__ DiSC Rotor
""", --
Assembly
Vehicle
Body
Front Tone Wheel

1. Remove disc hub assembly from vehicle, do not
8.018
3. With ignition switched off loosen the brake lines and

disconnect the electrical connector plug from the pump.
4. Remove mounting nuts and brake pipes. slowly withdraw the pump from the vehicle ensuring not to get the
brake lines caught.
Wheel Speed Sensor (Front)
1. Remove loom from chassis rail and wire from loom.

2. Remove sensor retaining bolt and unclip from bracket.
3. Remove sensor from vehicle.
Wheel Speed Sensor (Rear)
1. Remove loom floor sealing grommet, pull loom down
and disconnect from main loom.
2. Disconnect sensor wire from mounting points on rear
suspensIOn.
3. Remove retaining bolt and withdraw sensor from
vehicle.
ECU
1. Located above steering column, remove retaining nuts.
2. Remove connecting plug from ECU and withdraw unit
from vehicle.
251
damage speed sensor.
2. Push out two wheel studs to remove tone wheel and

discard the tone wheel.
3. Replace wheel studs ensuring that they arc seated
properly.
Installation of Components
Hydraulic Modulator
1. Place pump into position, refit brake pipes loosely.
2. Refit retainer nuts making sure that insulators, spacers
and washers are in place.
3. Tension retaining nuts and brake pipes to specification.
4. Fit wiring connector and bleed braking system as
described in brake bleeding section.
S. Refit pump plastic cover.
Wheel Speed Sensor (Front)
1. Place sensor in position, fit retainer bolt and clip wiring
into the retainer bracket.
2. ReconneCl sensor wiring into loom and re-fasten to
chassis.
Wheel Speed Sensor (Rear)
1. Install sensor into position, replacing retainer bolt and
retain wiring in position.
2. Connect sensor wiring to loom and refit sealing grommet into floor.
ECU
1. Connect wiring loom to ECU and install into place.
2. Fit retaining nuts and torque to specifications .
Front Tone Wheel
1. Using tool No. #E-9355, place hub and tone wheel in
position.
2. Place guide and nut in position, then screw down by
hand.
3. Using a spanner tighten until guide has bottomed out on
the hub.
4. Remove tool and fit hub back into position on stub.
BRAKE SYSTEMS
Problem Diagnosis and

Tests
Preliminary Tests
Fluid Level
Check the nuid level in the brake master cylinder reservoirs before performing the test procedures.
If necessary, top up the master cylinder reservoirs to the
level indicated on the side of the reservoir.
Brake Pedal Clearance Check
The brake system is designed to permit full Slroke of the
master cylinder when the brake pedal is fully depressed.
There is no need for brake pedal clearance adjustment.
With the brake master cylinder outlet lines disconnected
and the brake pedal fully depressed, the centre of the top
surface of the brake pedal pad should be 25mm from the
noor surface.
If the pedal height is below specilication make the necessary repam.
Hydraulic System Test
Turn the engine off and exhaust all vacuum from the
booster system by depressing the brake pedal several
times, before performing this test.
Depress the brake pedal and hold it in the applied position.
If the pedal gradually falls away underthis pressure, the
hydraulic system is leaking. Check all tubing, hoses, and
connections for leaks.
If the brake pedal movement is spongy, bleed the hydraulic
system to remove air from the brake system.
SPECIFICATIONS
BRAKE BOOSTER
Vacuum diaphragm .......................................... 230 mm
MASTER CYLINDER
Make .................................................... PBR Duel Line
Main Bore Diameter .................................... 23.81 mm
Fast Fill Bore Diameter ................................ 31.75 mm
Stoke ............................................ ................... 36.0 mm
Split
Sedan ............................................ .................... 58.5 0/0
Wagon ............................... ... ............................. 41.5%
Disphlcement
pnmary ... ............................................................. 6.2 cc
secondary ...................................................... ...... 8.9 cc
Calliper (Front)
Makc ..................................... ......... BCIA . AD' caliper
Type ............................................. Single Piston Calliper
Bore Diameter. ................................................ 60.3 mm
Calliper (Rear)
Make ................... ........................... BClA 'AD' caliper
Type ... ..... ..................................... SinglePiston Calliper
DISC (Front)
Type ........................................... Cast Iron - Ventilated
Diameter (Standard) ........................................ . 286 mm
Thickness (New) ................................................ 25 mm
Max. Runout ........................................ ...... .. ... . 0.08 mm

Min. Thickness Refaced (overall) ................... 22.0 mm
DISC (Rear)
Type .................................................... Cast Iron - Solid
Diameter .......................................................... 299 mm
Thickness (New) .......................................... ... 10.5 mm
Max Runout ..................................................... 0.05 mm
Min. Thickness Refaced (overall) ..................... 8.5 mm
DISC PADS
Material ............................................................. BM709
LiningWearLimit ............................................. 1.0mm
ABS SYSTEM
Front Tone Wheel Run-out ................................ 0.4 mm
System and Motor Dropout .................................. 8.7 V
Fuse ....................................................................... 30A
Warning Lamp ..................................................... 1.2 W
Current Draw - motor (cont) ................................. 50 A
Front Wheel Sensor Resistance ...... 1.65 +1- 0.2 klohms
Rear Wheel Sensor Resistance ........ 2.2 +1- 0.4 klohms
TORQUE LIMITS
Nm
Master Cylinder to Booster ............................ ........... 30

Booster to Fire Wall .............................................. .... 30
Brake Tube Nuts ....................................................... 12
Brake Hose to Calliper ....................................... .... ... 30
Guide Pin Bolts (Standard) ............... .............. .......... . 30
Rear Calliper Anchor Retaining Bolts ....... .. ............. 45
Guide Pin Bolts (Rear) .............................................. 30
Brake Line ............................................................. 8- t 1
Hand Brake Cable to Backing plate ...... .. .......... ... 12-16
Hand Brake Equalizer Adjuster Nuts ................... 12-16
Stop Light Warning Switch ............................ ..... 1.5-3.0
Hand Brake Lever Mounting Nuts ....................... 12-16
Cable Bracket Nuts ......... ....................... .................. 5-8
Reservoir Attaching Nut ........................................ 5-5.5
Wheel Speed Sensor ................................................. 13
ECU Mounting nuts .................. ................................. 20
60 Pin Connector to ABS ECU .......................... 3.4-5.0
Bore Diameter ............................................... 44.45 mm
252
EXHAUST SYSTEM
Description
Page
Catalytic Converter
--....
Exhaust
GENERAL DESCRIPTION ...................... 253
-6 Cylinder .............................................................. 253

-V8 ................................................... ,...................... 253
Catalytic Convener ................................................... 253
PROBLEM DIAGNOSIS ...................................... 254

Exhaust Diagram V8 Vehicles ................................... 255
Exhaust Diagram 6 Cyl. Vehicles .............................. 257
Exhaust
PIpe
Catalytic
ExOO71
GENERAL DESCRIPTION - 6 Cylinder
Six cylinder engines are fitted with a single pipe exhaust

system, the engine exhaust mani fold is connected to the
catalytic convener, which then is connected to the mufflerand
resonator assembly. The rearmumeris then connected to the
resonator assembly by an pipe intermediate pipe. The tail pipe
then runs from the rear muffler to the rear of the vehicle.
There is specific tailpipe forsedan. utility and station wagon
applications.
The exhaust system is supponed by a rubber insulator at the
rear end of the mumer and at the rear of the tailpipe.
GENERAL DESCRIPTION -
va
Gas
Stainless Steel Outer Shell
Ceramic monlith
with platinum rhodium
palladium
EX0021
Exhaust Gas
Nitrogen & Water
intcmal componcnl'i consistofaceramic
Models with V8 engines consist of two pipe and catalytic

convener assemblies joined by a 'Y' pipe, followed by the
muffler assembly and finally a rear mumer and tailpipe
assembly.
CATALYTIC CONVERTER
Alarge percentage of the cat.1lytic conveners manufactured

in Australia are exponed for use on many foreign vehicles.
Catalytic conveners and mumers look very similar. Except
a catalytic convener when opemting properly will conven
carbon monoxide and hydrocarbons, that is exhaust gas into
carbon dioxide which is a harmless gas that is present in our
enVlfOnment.
Theoutsideconsists ofa stainless steel housing, the convener
253
small holes to allow the exhaust gasses to flow through. The

convener housing ha~ gauze packed in between the housing
and the honeycombed ce ....unic monolith.
Unleaded petrol will give a black tailpipe instead of the
traditional light grey exhaust that is expected with leaded
petrol..
SERVICE NOTES
When installing any exhaust system component, care must be

taken to install each component in correct order.
Incorrect assembly ofexhaustsystem components can often
bethecauseofmttlesand 'booms' due to incorrect alignment
or clearance from body or suspension pans .
When installing the exhaust system, ensure that the correct
EXHAUST SYSTEM
Problem: Internal rattling In mufflerl
Pipe
Exhaust Pipe
:/
Dislodgedturningtubesandlorbafflesinmuffler. Remedy
- Replace muffler.
Catalytic converter monolith has crumbled and pieces
blown into muffler. Remedy - Replace catalytic converter
assembly and affected muffler.
TORQUE WRENCH
SPECIFICATIONS
EA Falcon & NA-DA Fairlane/LTO
assembly, installation, tightening sequence and clearance for

the system involved are observed. Genemll y speaking, fit the
components closest to the engine first, and work your way
back to the rear of the vehicle.
When exhaust system service work is required, refer to
illustrations for necessary information and proper al ignment
and arrangement of each component position.
Use exhaust sealer on pipe ends to ensure a properscal which
will not leak exhaust gases.
PROBLEM DIAGNOSIS
Problem: Leaking exhaust gases!
Possihle Causes and Remedies:

* Leaksatpipejoints. Remedy- Torque U-boltnutsandjoilll
bolts.
* Damaged or improperly installed converter gaskets. Remedy - Replace gasket as necessary.
* Burned or rusted-out exhaust pipe or muffler. RemedyReplace component as necessary.
Problem: Exhaust nolsesl

* Leaksatmanifoldorpipeconnections. Remedies- Torque
clamps at leaking connections, or replace gasket.
* Burned or blown-out pipe or muffler. Remedy - Replace
pipe/mume .. assembly as necessary.
* Exhaust manifold cracked or broken. Remedy - Replace
manifold.
* Leak between manifold and cylinder head. RemedyTorque manifold to cylinder head studs.
Nm
Engine front pipe flange toexhaust mani fold flange attaching

stud and nuts .............................................................. 50
Converter pipe to muffler pipe flange inner nut ............. 55

Converter pipe to murner pipe flange outer nut ............. 25
Muffler to outlet pipe assembly clamp ......................... 30
Mounting Bracket screws ............................................ 10
EB-ED Falcon & NC-DC Falrlane/LTO
Nm
Engine front pipe flange to exhaust mani fold flange attaching

nute:; " ......................................... _, ............................... 25
Engine front pipe nange to exhaust manifold !lange attaching
stud ......................... .................................. .. ............... 27
Converter pipe to muffler pipe flange nuts .................... 27
Converter pipe to muffler pipe flange outer nut ........ .. ... 27
Mufflerto outlet pipe assembly clamp ......................... 27
Mounting Bracket screws ............................................ 27
8 Cylinder Vehicles
Nm
Engine front pipe nange to exhaust mani fold !lange attaching

nute; ............................................................................ 25
Engine front pipe flange to exhaust manifold flange attaching
stud ............ .............. .... ... ........... ......... ......... ..... .... .... . 30
Converter pipe to muffler 'Y' cross over nuts ............... 30

Support to 'Y' cross over nuts ..................................... 25
'Y' cross ovcr to muffler pipe flange outcr nut ............. 30
Mufflerto outlet pipe assembly clamp ......................... 30
Mounling Bracket screws ............................................ )0
Problem: Loss of engine power,

hesitation, surging, bad fuel economy,
stalling I hard startlngl

* Clogged catalytic converter (may result from serious
engine malfunction or wrong fuel). Remedy - Replace
catalytic con verter.
* Crushed pipework. Remedy - Replace pipework.
254
EXHAUST SYSTEM
Headers
Catilitic Converter
Assembly
Gasket
'Y' Exhaust Pipe
Brackets
Gasket
Ex001
8 Cylinder Exhaust System ( Front Section)
Front Muffler
Assembly
Rear Muffler
Assembly
Gasket
Mount _____.....:=_,
Support
Brackets
'---Rubber
Rubber
Ex003
8 Cylinder Exhaust System ( Rear Section Sedan)
255
EXHAUST SYSTEM
Rear Muffler
& Outlet Pipe Assembly
EF XR8 Exhaust
System
Heat Sheild
Rear
Hangers
Left Hand
Muffler Assembly
Sheild
'H' Jundion
Pipe
Overaxle
Assembly
Center Mufner
Hangers
Right Hand
Muffler Assembly
Muffler
Gaskets
Ex010
8 Cylindel'" Exhaust System

Fairlane I LTD
Rear Muffler & Outlet
PIpe Assembly ::.::.:..::.:_
Center Muffler
Inlet Pipe
Rear Mutrler
Hanger
EngIne Pipe
Exhaust
TIps
Flange
Center Muffler
Assembty
Ex011
Center Muffler
Front Support
Center Mulner
Rubber
Center Muffler
Front Hanger
Hange,-..
Front Hanger
Center Muffler
Rear Support
Center Muffler
Bracket
Nut
E,0Q5
ExOO6
256
Hanger
EXHAUST SYSTEM
8 Cylinder Exhaust
Fairlane I LTD
Center Muffler &

Inlet Pipes
Exhaust Tips
-Inlet
Rear Mumer &
Outlet Pipe
Ex013
Rear Muffler
Assemblies
Gasket
Catilitic Converter &

Engine Pipe Assembly
.....-----..,~
Centre Muffler
I
Sedan
Support
Bracket
6 Cylinder Exhaust System
ExOO2
6 Cylinder Exhaust System

Fairlane I LTD
Rear Muffler & Outlet
Pipe
Assem~
__
Engine Pipe
Flange
Rear Muffler
Hanger
Exhaust
Tips
Sheild
Center Muffler
Assembly
Ex011
257
FUEL TANK & E.F.I. FUEL PUMP
Subject
Page
GENERAL INFORMATION ...................... 258

Fuel Pump ... .... .... ........ .... ........... .... ............. ......... .... 258
FillerNeck ................ ...... .. ... .... ... ........................ _.... 258

Fuel rnlet ....................................... ........................... 258
SERVICE OPERATIONS ......................... 259
Fuel Tank (Sedan) ................................................... 259

Removal ......... ,., ........................ .... ...... ..................... 259
Installation ................................... ................... ......... 259

Fuel Tank (Stntion Wagon) ................................... 260
Removal ................................................................... 2OO
Tn~tallation ............................................................... 26()
Fucl Gnuge Tank Unit ............................................. 260
Renloval ................................................................... 26()
Installation ...... ......... ......... ....................................... 261
Fuel Filtcr ................................................................ 261
Fuel Purnp(lnl~ank) ............................................... 261
Removal .... ..... .......... ....... ................................... ...... 261
Installation ................ .................. ............................. 262
SPECIFICA l 'JONS ................................................ 262
TORQUE WRENCH SPECIFICATIONS ........... 262
GENERAL INFORMATION
On sedan models, the standard fuel tank is 681itres capacity

on Fainnont, Ghia, Fairlane and LTD (and V8 engine
models) an 80 litre tank is used.
Vans and Utilities have a 68-litre capacity fuel tank.
Station Wagons have a 72 litre capacity fuel tank.
The optional 85-litre capacity long range fuel tank is available only for sedans.
Fuel tanks are supported into a metal plate or frame for
support. With the fuel fillerneck attached to the body panei.
Sedan fuel tanks are fitted with a single in-tank fuel feed
pump.
FUEL PUMP
The fucl pumps are electronic, located in the fuel tank and
pressllrise the fuel system. The fucl pump will often run for
approximately 8- 10 seconds after the engine is turned off.
The 6 cylinder and V8 fuel pump for MPEFI and SEFI
systems deliveries a minimum pressure of 250kPa with a
volume of240cc per 10 ,econds, with theXR6delivery ata
minimum pressureof300kPa with a volumeof280cc per 10
seconds.
The 6 cyJinder EFI system deliveries a mini mum pressure of
IOOkPa with a volume of24Occ per 10 seconds.
Sendef Urn!
...,
"""'"
Ancmbty
FUEL FILLER NECK
L"""'"
To help prevent the fuel tank being fi lied widlleaded petrol,

the fuel filler neck has a bui Itin restrictor and denector.
The opening in the restrictor will only admit the smaller
unleaded petrol nozzlespoutand must be fully inserted toby
ass the denector.
Attempted refuelling witha leaded petrol nozzle or failureto
fully insert the unleaded petrol nozzle will result in petrol
splashing back out of the filler neck.
FUEL INLET
S'1'0 F....I Tank
The fuel filler cap is a "screw on" type with a (clicking)
258
FUEL TANK & E.F.t. FUEL PUMP
Piece Broken
sealing
Ring
Sender Unit
Cover Plate
Retaining
Screws
FiOO5
7. Suppon fuel tank with suitable jack.

Locate a block of wood between the jack and tank to prevent
feature to lock. When installing the cap, screw iton until a

cbcksound is heard, which indicates thecapis properly titted.
Should a replacement cap be required, use only the cap
specified for FalconIFairlaneetc. models. Useof an incorrect
cap can cause malfunction of the emission control system.
damage to tank.
8. Remove the bolts and nut securing the fuel tank straps to
the body, and lower tanlc
SERVICE OPERATIONS
FUEL TANK - Sedan
Removal
1. Drain the tank
Beware of distoning the fuel filler pipe deflector, with
syphon hose.
2. Open rear companment, remove the floor covering then
Unit
Cover Plate
~etaining
Screws
compartment.
Before removing the tank, lower tank slightly so that the

vent hoses that are routed through the side frame can be
disconnected from the tank.
Installation
#To assist when installing the filler neck through neck seal,
lubricate upper end of filler tube with petroleum jelly.
I. Install the fuel tank straps, bolts and nuts to the body, and
lift tank into position.
2. Support fuel tank with suitable jack and block of wood ..
3. Connect electrical connectors to fuel gauge tank unit, then
the fuel tank to canister vapour hose from vapourpipeat front
of tank.
4. Connect tank vent hoses at fillerneckand check for kinks
in hoses and replace if necessary.
5. Connect the fuel line between the fuel gauge tank unit and
the fuel feed pipe, then the fuel return line from the tank
conncc110n.
connectton.

kinks in hoses and replace if necessary.
S. Disconnectelectrical connectors from fuel gauge tank unit,
at front of tank.
6.Remove the rearbumper bar assembly as described in body
chapter.
6. Lift tank fully into position and tighten supporting strap

bolts and nuts.
Strap Bolts Torque:
3S Nm.
7. Open rearcomp'" anent, replace the senderunitcoverplate
to the floor of the rear companment, replace the floor
covenng.
259
8.Replace the rear bumper barassembly as described in body

chapter.
9. Tum ignition on and check for fuel leaks.
FUEL TANK - Station Wagon
Removal
1. Drain the tank

* Beware of distorting the fuel filler pipe den ector. with
syphon hose.
2. Open reartai Igate. remove the floor covering then remove
the spare wheel cover and wheel.
3. Disconnect the fuel line between the fuel gauge tank. unit
and the fuel feed pipe. then the fuel return line from the tank
connection.

kinks in hoses and replace ifnecessary.
4. Connect the fuel line between the fuel gauge tank unitand
the fuel feed pipe. then the fuel return line from the tank
connection.
5. Replace the sender unit cover plate to the tloor of the rear
compartment, replace the floorcovering.
FUEL GAUGE TANK UNIT
Removal
1. Open rear compartment. remove the noor covering then

remove the sender unit cover plate from the noorofthe rear
compartment.
5. Disconnectelectrical connectors from fuel gauge tank unit.

at front of tank.
Tank
Cove<
6.Remove the screws securing the fuel tank to the tloorpan,
hen carefully lift the fuel tank from the vehicle.
Inslallation
I.Lift the fuel tanktothevehicle. replace the screws securing
the fuel tank to the noor pan. Torque attaching screws.
TankSecuringScrews:
11 Nm.
2. Connect electrical connectors from fuel gauge tank unit.
at front of tank.
3. Connect tank vent hoses at tiller neck and check for kinlu;
in hoses and replace if necessary.

connection.
Check the Filter is installed with

the fuel flowing through the filter the correct direcrion.
3. Clean around the sender unit assembly, then remove the

band clamp and unserew the retaining ring.
Fitter
Fuel
-Tank
Filter Bracket
Fu015
FUEL PUMP [IN TANK]
4.Remove the senderunitJpump assembly from the fuel tank,

Installation
Removal
compartment.
Fuel Pump
Float Level
Fuel Pump
Assembly
FuOtt
# Ensure strainer is timl1y attached to the fuel pump inlet
fitting.
l.Instal l the senderunitJpumpassemblytothe fuel tank, then
replace the lock ring to the tanlc
2. Check electrical connections and connector retainer and
make sure pulsator seals engage pump outlet fitting firmly.
and the fuel feed pipe. then the fuel return linefrom the tank
connection.
connectIOn.
4. Replace the sender unit cover plate to the floorofthe rear

compartment, replace the floor covering.
FUEL FILTER
All models have a filter at fuel pick-up in the tank as well as

a serviceable tilter in the fuel line between the fuel tank and
engine. The straineris under the vehicle attached to the floor
pan and towards the rear of the vehicle.
261
3. Clean around the sender unit assembly. then remove the
band clamp and unscrew the retaining ring.

4. Remove the sender unit/pump assembly from the fuel tank,
SPECIFICATIONS
Fuel Tank Capacity
Sedan ....... ........................................................ 68 Litres
Fuel Pump
Fuel Pump
Assembly
Station Wagon .................................................. 72 Litres

Vans and Utility ...................... .......................... 68 Litres
Electric Fuel Pump (6 & 8 cylinder)
Delivery ............................... 240 cc in 10 sec @ 275 kPa
(I6HO) ... ............................ .. 280 cc in 10 sec @ 300 kPa
Idle pressure ...................................................... 225 kPa
(l6HO) .............................................................. 250 kPa
Stationary engine ............................................... 275 kPa
(l6HO) .............................................................. 300 kPa
Pressuredrop(min) ............................ ........ IO%in 10 sec
Pump 100m resistance ...................................... < I Dohms
Fu011
Installation
# Ensure strainer is tirmly attached to the fuel pump inlet
fitling
1. Install the sender unit/pump assembly from the fuel tank,
2. Connect the fuel line between the fuel gauge tank unit and
the fuel feed pipe, then the fuel return line to the tank
connection.
TORQUE SPECIFICATION
Description
Nm
Fuel Tank Straps Sedan ............... ............................... 35
Fuel Tank Screws wagon ............................................ II
Fuel Pipe Hose Clamps ........................................ 0.5-3.0
Fuel Gauge Tank Unit Mounting Bolls ................. 2.0-3.5
# Check electrical connections and connector retainer and

make sure pulsator seals engage pump outlet fitling linnly
3. Replace the sender unit cover plate to the floor of the rear
compartment, replace the f1oorcovering.
Filler
. / Sender Unit
and Pump
Assembly
Location
Sedan Fuel Tank
262
WHEELS AND TYRES
GENERAL INFORMATION.
Tyres should be routinely checked for wear, there are special

patterns that appear when the tyre tread is low as shown
opposite. Also the depth of tread can be checked with a tyre
tread depth gauge.
The tyres fitted as original equipment have been selected for
safety, handling and comfort characteristics. Therefore when
replacing any tyres it must be noted that a tyre of a lesser
rating must not be used.
Wheel and tyre specifications are displayed on a decal fitted
on the rcar section of the right side front door .
When installing a wheel ensure that as the road wheel

attaching nuts are gradually tightened in the order shown.
Tighten Wheel Nuts in order shown
Inflation Pressure
Tyre innation pressures should be checked with the tyres

cold. Never reduce tyre pressure when the tyres are hot.
Wh002
Wheel Nut Specified Torque: ................... 100-125 Nm.

Tyre rotation as shown will help correct uneven tyre wear, it
isalso recommended that the wheels arc balanced althe time
of tyre rotation.
Tyre Pressure
Gauge
lyre
Four wheel rotation
Five wheel rotation

Wh001
Low
Pressure
Low tyre pressure is a common fault affecting tyre life.
While driving in normal conditions a tyre flexes as it rolls
along the road and this nexing in tum generates heat. If the
tyre is correctly inflated this heat build-up is not detrimental
to the tyre. However an under innated tyre nexes far more
than normal resu Iti ng in greater heat generation. Underthese
conditions the temperature ofthe tyre can rise to a point where
263
WHEELS AND TYRES
one side of the tyre wearing faster than the other.

pressure
is to low
will result in
on the edges of
the lyre
Camber angle
the mbbercompounds that bind the tyre together arc softened

and weakened. In extreme conditions this may result in the
tread separating from theca.ing onhe plies separating from
eachother.
Under inflation also reduces tyre life by causing excessive
wear on the tyre edges.
Overloading has the same effect as under inflation causing
excessive tyre flexing and subsequent heat generation.
Tyre damage and wear is accelerated if the vehicle is dri ven
at high speed orin an overloaded condition.
High Tyre Pressure
High tyre inflation pressure can result in danlage to the casing
and furtheneduces tyre life by causing excessi ve wear at the
centre of the tyre tread.
Positive
direction
Camber angle from front
FsOO7
Wheel camber is adjustable, the setting may alter as a result

of damage to the front end. In this event the damaged
components must be replaced, and camber adjusted as
described in Front SuspenSion chapter ..
Wheel Balance.
Wheels out of balance can result in cupped or spotted wear

around the tyrecircumference. Usually an out ofbalance tyre
will vibration through the steering wheel when driving on
smooth surfaces.
Pressure that is
high will result
in wear of the
i the centre
of the lyre.
Shock Absorbers
Very high inflation pressure exens increased strain on the

casing which subsequently reduces resistance to impact
shocks. Since the tyretread is stretched tight, tread cracks can
rapidly develop and the tread is likely to crack.
Wheel Alignment
Faulty or worn shock absorbers can also result in cupped or

spotted wear. Faulty shock absorbers should be replaced in
pam.
It should be noted that in addition to the foregoing factors,
driving habits, road conditions and the terrain overwhich the
vehicle is operated will have a direct bearing on tyre life.
Toe-In
Tyres and Tyre Pressure
Front of
vehicle
Tyro specifications and tyre inflation pressure for each

particular vehicle is on a decal located on surface of the
drivers side door which faces the centre pillar.
Tyre Specification
Trye Pressure Decal.
A
Toe-In Is "A" minus "6"
Toe-in setting is an imponant factor in tyre life. Excessive

toe-in results in tapered or feathered wearon the outside edge
of the tyre while excessive toe-out has the same resulton the
inside edge. Under these conditions the tyre is dragged along
the road instead of rolling freely .
Check Front Suspension chapter for specifications and the
correct procedure for adjusting toe-in.
Camber
Excessive wheel cambereitherpositiveornegative, results in
TORQUE WRENCH SPECIFICATIONS
Nm
Steel Wheel- Attaching Nuts ..................................... 125

AlloyWheel-AttachingNuts .................................... 100
264
WINDSCREEN WIPERS & WASHERS
Subject
Page
[)escription ............................................................... 265

Wiper Ann ............................................................... 265
Windshield Wiper Motor and Linkage ....................... 265
Replace Wiper Blades ............................................... 266
Wiper Blade Insert Assembly (with Metal Backing) ... 266
Wiper Blade (Rubber Insert only) .............................. 266
Checking Wiper Arm to Windscreen Alignment ......... 266
Windshield Washer ................................................... 267
Washer Nozzle Adjustment ....................................... 267
Rear Window Wiper Motor ....................................... 267
Installation
1. Install the wiper onto the wiper arm.
2. Slide the wiper onto the arm end.
3. Install wiper arm assembly onto spline so that the blade is
positioned as shown on windshield. Forrearwindow wiper,
position blade as shown in diagram.
4. Install nut and tighten to torque specification.
Wiper Anu Nut Torque Specificatiou ................ 20 Nm
5. Push trim cap into place.
WINDSCREEN WIPER ARM LINKAGE AND
MOTOR
Removal
1. Li ft and push back the nultri mcover. Remove the attaching
nut for the wiper arm.
2. Remove wiper arm by Ii fting arm then turn and pulli ng arm
off pivot.
3. Remove body mesh panel as described in 'Body' in this
DESCRIPTION
manual.
The wiper motor is a two speed type and incorporates a

parking switch which is activated when wipers are switched
off.
4. Remove wiring loom connectors and earth wire attached to

the wiper motor.
5. Remove the wiper motor attaching screws and motor.
The windscreen washer boule is located in the engine com-
partment underthe bonnet. The washer pump, a centrifugal

type driven by a motor is mounted in the washer bottle.
Control switches for high speed, low speed, intermittent
operation and the windscreen washers are mounted on a talk
lever on the left hand side of the steering colunm.
WIPER ARM
Removal
1. Lift and push back the nut trim cover. Remove the attaching
2.Remove wiper arm by lifting arm then turn and pulling arm
off pivot.
3. Remove wiper blade from arm.
Slide the wiper away from the arm.
265
6. Disconnect the wiper motor from the linkage by releasing
the ball socket.
Wiper insert rubbers deteriorate as a result of environmental

conditions, such as atmospheric pollution and road grime,
temperature extremes and natural ageing of rubber. It is
therefore recommended that wiper inserts are replaced every
twelve months.
Wiper Blade Insert Assembly (With metal
backing)
Retaining Clip
Wiper Arm
Is Attached To
Wiper Blade
Assembly
;
eE
7. Remove the screws securing the wiper linkage at drivers

and passengers side.
8. Carefully remove linkage from vehicle.
Wiper Blade
Assembfy
Installation
1. Install wiper linkage into position then install and tighten
retaining screws.
2. Install wiper motor and attaching screws.
Wiper Motor Assembly Screws 7-10 Nm

3. Replace ball jOint securing the wiper motor assembly and
wiper ann pivot shafts.
WO07
I. Lift the blade away from the windscreen as far as it will go,
so the wiper arm is held into position by it, own spring
tension.
2. Remove the retaining clip from the wiper and slide the old
blade assembly out from the arm.
3. Slide the wiper insert assembly into position, install the
metal retainingclip.
Wiper Blade (Rubber insert only)
Wiper Arm
Assembly "-
".;. Retaining
.. Clip
Earth Strap
Retaining Screw
Wiper Motor
Assembly
Earth Strap
Assembly
4. Replace waterdenectormesh as described in . Body' n
manual.
S. Replace wiper anns a. described above.
REPLACE WIPER BLADES
Wiper Blade
Arm End
Plug
woos
I.Lift the blade away from the windscreen as far as the blade
will go, so the wiper arm is held into position by its own spring
tension.
2. Remove the wiper from the arm. Unclip the wiper away
from the arm.
3. Remove the retaining clip from the end of the wiper.
4. Pull the rubber away from the wiper arm (retaining clip
end) and slide the old blade rubber out from the other end of
the wiper.
S.Slide the new rubber wiper insert into position from the end
of the retaining clip, instal! the metal retaining clip.
6. Instal! the wiperonto the wiper arm. Clip the wiperontothe
arm.
Wiper Blade
I
Remove Plastic Plug
CHECKING WIPER ARM TO WINDSCREEN

ALIGNMENT
This check should be performed if wiper inserts are in good
266
opemtingcondition.
1. Operate wipers and then, by turning ignition switch off,
position wipers at approx imatcly 3<1' into thearcof the wiper.
WASHER NOZZLE ADJUSTMENT
1. Check washer fluid spray pattern is as shown below.

2. If adjustment is necessary use a metal wire or pin 1.0mm
or less in diameter inserted in nozzle tube.
3. if insufficient washer fluid is supplied check system for
clogged, bent or crushed hoses.
Windscreen Washer shouki
spray a pattern as shown
30 Degrees
,,
,
mml,
"
. ........
': .... 30 :
'
. . .' .
'
..... . .....
. .......,
''':'~
'
-~.- ._\
".' .
~ ; ...
Normal
Stoping
Position
,,~
2. Remove wiper blade and check that end of wiper arm is

square to windscreen.
3.lf arm is not square, gently twist end of arm to achieve
correct alignment.
4. Refit wiper blades.
5. Tum ignition switch on and allow wiper arms to return to
normal position.
WINDSHIELD WASHER
The windshield washer components are located as shown in

photo on this page.
Don't operate w her motor for more than 20 seconds
continuously or when washer bottle is empty as motor or
pump could be diilllaged.
Washer Liquid
Fill washer unit with either water or water and a small anlOunt
ofdetcrgent, this will help remove road grim such asoil and
insects.
Note: Do 1101 use to much detergent as this will obscure
vision on the windscreen.
Blocked Washer Nozzle

Ifthe nozzles become blocked remove the hose from the back
of the washernozzle and use air pressure to blow the foreign
matter from the nozzle. Reconnect the hose to the nozzleand
test washer unit.
I
300 mm .
\NOlI
REAR WINDOW WIPER MOTOR
Remove
I. Li fL and push back the nut trim cover. Remove theaLLaching
2. Remove wiperarm by liftingarm then tum and pullingarm
off pivot.
3. Remove the internal tail gate trim panel and then No. plate
lightasscmbly.
4. Disconnect re.rcompm tment harness connector and earth
strap.
5. Remove the wiper motor attaching nuts and pull the
assembly out of the tail gate.
Install
I. Install wiper motor. Torque motor attaching bolts to

specification.
Wiper Motor Attaching Bolts ............................ 11 Nm
2. Reconnect the wiring harness to the wiper motor.
3. Replace No. plate light assembly and end gate trim panel,
Electrical Loom
Connector
Wiper Arm
Motor
Washer
Jet
LQOiil
ensure thaL the panellits in the correct manner.
4. Replace cap, hexagon nut, cap washer and spacer to the

wiper shaft housing.
5. Replace wiper arm to wiper arm drive. Torque wiper arm
pivot nut to specification.
Wiper Arlll Pivot Nut .......................................... 6 Nm
267
BODY
Subject
Page
GENERALlNFORMATION ................................... 268

FLOOR PAN / CHASSIS ....................................... 269
DASHIINSTRUMENTPANEL ............................... 271
REAR COMPARTMENT (BOOT) LID & TAlL
GA"rn ." ................................................... ," ........ " ... 273
FRONT and REAR DOOR ASSEMBLIES .............. 278
STATIONARY GLASS ........................................... 285
SEATS & SEAT BELT ASSEMBLIES ................... 288
HEADLINING & TRIM .......................................... 294
PAINT & EXTERIOR ORNAMENTATION .......... 295
FRONT SHEET METAL ........................................ 297
RADlATORGRTLLE .............................................. 299
BUM PER BARS ..................................................... 300
results in a lightweight body which will not bend, buckle or

vibrale with nomJally accepted road use, and minor impact.
Afler a collision it's advisable to check the body alignment.
The reinforced box sections of the front lower structure and
strut mountings in the fender splash shields ahead of the fire
wall the ones that will most likel y to be damaged. These areas
in front of the r. re wall carry the front suspension, suppon the
engine and the fronl body panels.
The box sections of the body should also be inspected as Ihese
sections suppon the doors and help in providing protection to
GENERAL
INFORMATION
The body incorporates a noor pan frame as the basic
construction. The body doesn't have a frame but it's assembled by spot welding panels together. This construction
80185
the driver and passenger in case of a collision. The door

pi liars, si lis and roof rai Is provide added strength to tloorpan
and the general body components.
If replacing body panels it is advisable thaI these panels be
perfect! y aligned, if they can nol be panel beaten or repaired
so they align it is advisable that the panels be replaced with
an other panel eitherneworsecondhand in very good repair.
As these panels help give strength 10 the vehicle body.
268
BODY
FLOOR PAN I
CHASSIS
Subject
FLOOR PAN I CHASSIS ALIGNMENT
Body alignment may bechecked accurately by the following

method:
Page
FLOOR PAN I CHASSIS ALIGNMENT __

269
CENTRE CONSOLE .............................................. 269
Removal ._ ............................ _.................................... 269
Installation ............................................................... 270
FLOOR CARPET - INTERNAL ........ ... ................... 270
RernovaJ ............................ _............ _......................... 270
Installation ...................................................... _........ 270
CARPET - BOOT - REAR COMPARTMENT ... ..... 270
CARPET - SIW AGON ......... ........................ ....... 270
Removal ..... .............................................................. 270
Installation ............................................................... 270
SIDE KICK PANEL ................................................ 271
ReOlOval .............. _... ................... ...................... ........ 271
Installation ............................................................... 271
u u _____ u
Measure vehicle and compare with di mensions shown.

Compare the dimensions made on both sides of vehicle. All
dimensions must be measured at the weldedjoints ofthe body
to ensure unifonn measurements or from the centre of holes
if measuring from a hole in the body or floor pan I chassis.
Having correct underbody alignment is essential, as any
misalignment of the underbody can adversely effect suspension, fitmentof doors, engine hood, tail gateorrearcompartmentlid. Theunderbodyshouldbealignedtowithin 1.0mm
of dimensions specified as illustrated.
In preparing for an underbody alignment check, place the
vehicle on a level surface with the weigbt of the body
supported at wheel locations.
CENTRE CONSOLE
Removal
L Disconnect the battery earth cable.
2_ Unscrew the gear shift knob on manual transmissions, "T"
Bar for automatic transmissions.
3. Lift the cover for the shift lever, then disconnect the
ecconomy switch for automatic vehicles and remove the
screw securing the console from under the cover.
4. In front of the shirt lever remove the mat covering, then
remove the two retaining screws.
269
BODY
FLOOR CARPET - INTERNAL
iog the two retaining screws, then remove the mat from the
base of the console bin and remove two retaini
Removal
1. Disconnect the battery ground cable.
2. Remove the transmission console as described above.
3. Remove the front scat assemblies and rear seat cushion
assembly. As shown in "Seat" section.
4.Lift the covers and remove bolts securing seat belt buckle
a"cmblics to transmission tUlmel and the outcr front seat belt
lower attachment bolts.
5. Lift carpet taking care not to damage carpet as sealant will
need to be worked free.
Installation
1. Use asuitablesealantto tix insulation into place. carefully
replace carpet.
2. Replace seat belt anchoring bolts to specified torque.
Seat Belt Anchoring Bolts Torque:
30 Nm.
3. Install seat assemblics.
4. Install centre console if one was fined.
5. Connect earth cable.
CARPET - BOOT - REAR COMPARTMENT
6. The two screws on either side at the rearoftheeonsoleand

the two at the front of the console are to be removed.
7. Disconnectany electrical connections that may be present
for accessories and hand brake then Ii ft console from vehicle.
InstaJlation
Note: Ensure to remove the rear air vent from the centre
console before installation.
I. Install the console into position and connect any electrical
connections that are present.
2. Ensure the console is correctly positioned and insert the
Removal and installation of the carpet assembly involves

removing the plastic carpet retaining trim, which is held by
pull out and push in clips. The lifting of the fTOnt and rear of
the carpet during removal and the correct location of the
carpet edges and the firm pressing down on the CaJ pet at the
Velcro tape locations during installation. Take care of the
plastic caJ'pet retaining trim, which is held by pull out and
push in clips.
CARPET - Station Wagon Back Section
nine retaining screws.
3. Install the cover mats, economy switch, cover for the shift
lever, and replace the gear shift knob or ''T'' bar.
4. Replace and connect the power window switch where
fined.
5. Connect the banery earth cable.
6. Install rear air vent by pressing in until retaining clips
engage.
Centre Con.ole Rear AJr Vents
Remove
Lift the carpet from the vehicle by gently lifting the edges of
the ClUpet towards the centre.
lnstalIation
Lay CaJ pet out in the correct position and fit CaJ pet to floor.
Making sure the carpet fits neatly up against all edges.
270
BODY
SIDE KICK PANEL
GLOVE COMPARTMENT (Glove Box)
Removal
Removal
Remove the clips and studs securing the tri m assembl y to the
side panel under the dash.
Installation
Fit panel into position and install twist clips.
DASHI
INSTRUMENT
PANEL
Open the glove compartment lift the glove box attaching

hinge, orwith the blade of a screwdriver located between the
head of the hinge pin, prise the pin, lift the compartment and
remove.
Installation
Position the glove compartment door into position and refit
the hinge pins. Ensure ule glove compartment door fits
eOllectly.
FUSE and RELAY COMPARTMENT COVER
Removal
Assembly
Subject
Page
GLOVE COMPARTMENT (Glove box) ................. 27 1

Rel1lOval ............................ _................ _..................... 271
Installation .... ............. ................. ................... .......... 271
FUSE & RELA Y COMPARTMENT COVER ......... 271

RelllOve ...................................... , ............................. 27 1
Installat.ion .................................................. ,_ ........... 27 1

CENTRE RADIO FACIA & ESCUTCHEON .......... 27 1
ReOlOvaJ ................................................................... 27 1
Installation ............................... ,., ............................. 272
DASH PANEL ASSEMBLy ........................... .. ...... 272
Rel110vaJ ................ ............... .................................... 272
Installation ............................................................... 272
INSTRUMENT CLUSTER SURROUND ............... 272
Removal ........................................ ........................... 272
Installation ................................... , ........................... 273
HEATER & AIR CONDITIONING CONTROLS ... 273
Rel11OvaJ ............ ,.,..... ............................................... 273
Installation ........................................ ....................... 273
AUTO CLfMATE CONTROL ................................ 273
ReTllOvaJ .. ,..... ...... ... .................................................. 273
Installation .... ........................................................... 273
271
To remove hold handle opening, pull out then lower cover to

release retaining lugs and remove.
Installation
To replace secure upper lugs into position then clip lower
section of cover into position.
CENTRE RADIO FACIA & ESTCHEON
Removal
1. Remove the a~htray, then remove the two lower retaining
screws.
2. Remove the centre facia a~sembly by lifting out at the base

releasing the upper retaining clips, then fully remove facia.
BODY
1ru>1aIIation
Instrument
Assembly
Dash Assembly
1. Insert facia clipping the top into position then install and
tighten the two lower retaining screws.
2. Install ashtray into position.
InstaUation
*Earthwires mustbefittedatthecentrethetopmounting
point
1. Place instrument panel assembly into vehicle. At the rear
of instrument panel connect all applicable wiring connectors.
2. Locate theend bracket (left hand side) overside bracket and
rotate instrument panel into position, temporally install instrument panel screws and connect other wiring loom connectors, vacuum tubes and heater control cable.
3. Install the upper instrument panel earth lead, then install
dash panel floor pan bolts and tighten retaining screws.
4. Install the steering column and connect wiring looms.
5. Install right and left hand side cowl trim panels.
6. Install the hood catch release handle and glove box.
7. Install the extension panel reconnecting sun load sensor if
DASHPANELASSEMBLY
Removal
I. Detach the battery. Take out the ashtray, two radio facia
retaining screws, pull the panel rearward at the base and lift
from the upper attaching points.
2. Remove centre console as descri bed previousl y.
3. Remove right and left hand side cowl trim panels.
4. Disconnect the engine hood release cable from the instrument panel retainer.
5. Take out the glove compmunent and disconnect heater
control cable, except on climatic control.
fitted.
sun load sensor if climatic control is fined.

7.lfapplicable, detach tlle radio speakers wiring. Removethe
steering column attaching nuts and allow the column to drop
down, unclip the steering column wiring connectors. Remove
instrument panel earth, connection bolt (centre).
8. Unscrew instrument panel to floor pan retaining bolts and
top retaining screws, support panel and unclip all wiring
connectors. Near the left footwell duct detach radio antenna
connector.
9. Take the instrument panel assembly out.
8. Install centre console as perviously described.

9. Install radio surround bezel, connect cigar lighter wiring
and install ashtray.
10. Check that instrument panel switches etc function correctly.
INSTRUMENT CLUSTER SURROUND
Removal
1. Disconncct the banery ground cable.

2. Remove the centre radio facia as described previously.
3. Remove the screws attaching the instrument cluster surround to the dash panel.
272
BODY
4. Partially remove the instrument surround facia then disconnect any switches which are connected such a~ boot
release, fuel door release and read demist switches.
5. Fully remove surround from instrument panel.
ImtalIation
1. Refit the surround and connect the wire connections to the
switches.
3. Release the control panel retaining screws from the

assembly, then detach the wiring and vacuum connectors.
4. Withdraw the control switch assembly.
Install
1. Position the control switch assembly.
2. Attach the wiring and vacuum connectors to the control
panel, then fit the retaining screws to the assembly,.
3. Fit and secure the instrument cluster panel, attaching the
wiring to the switches.
4. Connect the cigarette lighter wiring as panel is being fitted,
to the dash assembly.
5 .Secure radio trim panel fitting the retaitting screws behind
the ash tray, then fit the ash tray into the dash.
Dash Assembly
~
6. Check the operation ofthe cuntrul switches.

AUTOMATIC CLIMATE CONTROL PANEL
Removal & Installation
tighten the retaining screws.

3. Install the centre radio facia as described previously.
4, Connect the earth cable.
Remove for automatic climate control is the same procedure

as described in the heater chapter and previously is this
chapter.
If damage is detected the assembly will require replacing, as
it is a non-repairable unit.
Heater & Air Conditioning Controls
Remove.
1. Withdraw the ash tray from the dash, then the radio trim
panel by releasing the retaining screws from behind the ash
Imy.
2. Detach cigarette lighter wiring
a~
panel is being withdmwn, then release and withdraw the instrument cluster
panel, detaching the wiring from the switches.
REAR
COMPARTMENT
(BOOT) LID &
TAILGATE
Subject
Page
Rear compartment lid Gas Prop - Sedan ... _................ 274

Rear compartment lid Hinge - Sedan .......................... 274
Lock cylinder -Boot Lid .......................................... _274
Lock assembly - Rear compartment lid - Sedan ......... 275
Lock striker - Boot Lid .............................................. 275
273
BODY
Weatherstrip - Replacement - Boot Lid ...................... 275

Boot Light Assembly .......... _............................ ......... 276
Boot Light Switch ..................................................... 276
Gas strut -Tail Gate-Station Wagon ........................... 276
Tail Gate Assembly - Station Wagon ......................... 276
Lock Assembly - Tail Gate - Station Wagon .............. 277
Lock Striker Tail Gate-Station Wagon ...................... . 277
Tail Gate Weatherstrip Assembly - Station Wagon ... 277
BootSolenoid Assembly - Sedan ............................... 277
Tail Gate Solenoid Assembly - Wagon ...................... 278
REAR COMPARTMENT (BOOT) LID GAS
PROP-SEDAN
Installation
t. Install gas prop into position reconnect and then install the
rear seat comer bolster.
2. Re-engage the ga~ strut, then replace the retaining clip to
the groove in the gas prop.
REAR COMPARTMENT LID HINGE - Sedan
Removal
1. Lift and prop the boot lid open.
2. Lift the boot and mark the hinge position with a pencil or
felt pen, this will help when installing the boot to its correct
position.
Removal
1. Lift and prop the boot lid open.
2. Remove the retaining clip from the groove in the gas prop
mounting stud, then disengage the prop by sliding sideways.
Mark hmge
location for_--alUgnment
Hlnge _ __

3. Remove the retaining clip from the groove in the gas prop
mounting stud, then disengage the prop by sliding sideways.
4.Remove the hinge to lid attaching nuts, from the head of the
hinge pivot pin bend the lock tab down and then remove pivot
3 .Remove the comer bolster for the rear seat, then disconnect
the ga~ prop from floor pan and remove.
Mark hinge
location for _ _-j~
aUignment
Hinge _ __

Ga. prop """
274
BODY
pin and hinge.

Installation
1.lnstaIl the hinge to the hinge bracket then install the pivot
pin and bend over the lock tab.
2. Attach lid to hinge using alignment marks, then install the
gas prop into the mounting pin and secure with retaining cI ip.
3. Gently close rear compm Uloent lid and check for on even
gap around boot lid. Ifalignment iSCOllect carefully open rear
compartment and tighten hinge nuts.
Adjust
Elongated holes in the rear compartment lid provide forward
and rearward adjustment of the lid. Vertical height adjust
mentat the hinge area of the lid can be achieved by elongated
hinge bolt holes in the mounting bracket.
: Following any adjustment of the rear compartment lid, it
is essential that the Iid lock striker engages correctl y with the
lid lock. Adjust the strikerto ensure positive engagement of
the lock and to achieve correct alignment between the rear
compartment lid and adjacent panels.
1. Install the latch assembly in position and fit the two

retaining screws, reconnect remote cable and electrical connections.
2. Fit the lock and extension assembly and install theretainer.
3. Install trim panel to inside of rear compartment lid .
LOCK STRIKER-BOOT LID
Removal
1. Lift the boot and remove the lowertrim panel from around
striker.
LOCK CYLINDER-BOOT LID
Removal
1. Remove trim panel from inside of the boot lid.
2.Disconnect the lock cylinder connecting rod and compress
the lock cylinder retainer tangs.
1 From within the rear compartment, remove the lock
cylinder, as illustrated.
Installation
1. Fit the lock cylinder and refit the connecting cable.
Boot Lock
Release Cabfe
the striker position

or felt pen, this will
help when installing the striker to its correct position.
3. Remove the screws attaching the lock strikeno therearend
inner panel, removing the striker.
Installation
1. Refit the attaching screws fi nger tight, adjust the striker to
the pencil or felt pen marks. during removal and tighten the
bolts.
2. Following any adjustment of the striker or rear com partmentlid, it is essenlial that the lid lock correctly engages the
striker.
3.lnstalilhe trim panel back overthe striker mounting.
Assembly
Retaining Clip
2. While supporting the cylinder fit the retainer tangs.

3. [nstall trim panel to inside of rear compartment lid.
LOCK ASSEMBLY-REAR COMPARTMENT
(BOOT) LID-SEDAN
Removal
1.Removethe inner trim panel from the insideofthe boot lid.
2. With tile rear compartment lid mised. remove the two lock
assembly altachi ng screws, disconnect the remote cable and
electrical connections.
3. Remove lock assembly.
InstaIIation
WEATHERSTRIP REPLACEMENT - BOOT

LID
The one piece rear compartment lid opening weatherstrip is

a rubber 'U' section fitted with an integral retaining system.
It lits linnlyoverthe upturned flangeoftllerearcompartment
openmg.
275
BODY
GAS STRUT - TAIL GATE-STATION
WAGON
Replace
Using a thin bladed screwdriver localed under the strut baB
pi vot spring, with the tail gate supported in the raised position,
prise thespringopen. This will allow the strut to be pulled off
the ball pivot. Replacement is by a push lit.
..
Rear compartment
seal lip
When installing the weatherstrip assembly . locate the longer

side of the 'U' section on theout.ideoftherearcompanmenl
opening upturned flange.
BOOT LIGHT ASSEMBLY
Removal
1. With the rear compartment lid mised and using the blade
of a screwdriver located belween the lamp lens and rear
compartmenl inner panel, carefully prise the lamp assembly
out of the lamp aperture.
2. Removing the light assembly. disengage the electrical
connector.
Light Assembly
TAIL GATE ASSEMBLY-STATION WAGON
Removal
1. With the tai Igale supported. remove the lowerconnections
of the ga. strut assemblies. and disconnect the electric
connections.
3. Mark the location of the hinges to body to assist in

alignmenton assembly.
4. Then with the aid of an a"istanl, remove the hinge 10 door
nuls, remove Ihe tail gate assembly.
5 .From the head of the hinge pi vol pin bend the lock tab down
and then remove pivot pin and hinge.
1nstaIiation
Installation
1. Relit the tight a"embly and connect the wi ring connector.
2. Reconnect the battery earth cable.
BOOT LIGHT SWITCH
Removal
1. With the bool tid raised. remove the screws securing the
switch assembly to the centre of the rear panel ncar the lock
striker.
2. Disengage the electrical connector and remove the switch
a.sembly.
InstaUation
1. Replace the switch assembly. lit the screws to hold the
switch.
2. Reconnect the electrical wire connector.
3. Reconnect the battery earth cable.
80039
1. Install the hinge 10 the hinge bracket then install the pi vOl
pin and bend over the lock tab.

2. With the aid of an assistanl. reinstall the hinge nuts. while
holding the lail gate assembly in place.
3. Reconnect the electric connections, with the tail gale
supported. iiI the lower connections of the ga. Strul assem
blies.
4. Ensuring that the tail gate lock correctly engages the lock
striker bolt. If necessary, adjusl the striker bolt to ensure
correct engagement with the lail gate lock and also to ensure
correct alignment between the tail gate and adjacent body
276
BODY
panels.
lnstaJIation
1. Replace the lock assembly, refit the screws and nuts, then
tighten.
2. Replace thecentre light assembly and secure with retaining
screws then replace inner trim panel.
LOCK ASSEMBLY - TAIL GATE - STATION

WAGON
Removal
l. Remove the tail gate inner trim.
LOCK STRIKER - TAIL GATE - STATION

WAGON
The tail gate lock striker plate is secured by 2 bolts in the lower
member of the tail gate opening. These 2 bolts provide the

lock striker with horizontal, forward, rearward and side to
side adjustment.
WEATHERSTRIP ASSEMBLY - TAIL GATE
OPENING - STATION WAGON
Tail Gate
Tnm
--.s;:;::
:---,-L
screws
gate centre lamp
assembly, four on inside tailgate skin - one from exterior of
tail gate in the centre of the light assembly behind number
plate. Then remove the lamp assembly and disconnect electrical connections.
Weather
80042
The one piece tail gate opening weatherstrip is a rubber 'U'

section fitted with an integral retaining system. It fits firmly
over the upturned flange of the tail gate opening.
NOTE: When installing the weatherstrip assembly, locate
the longer side of the 'U' section on the outside of the tail gate
opening upturned flange.
RELEASE SWITCH - BOOT LID LOCK
Removal
3, From within the tail gate, remove the screws securing the
latch mechanism, then disengage the lock connecting rod.
Boot Latch
Release Solenoid
Attachmg
Nuts
~--
1. Remove the instrument panel facia as described previously.

2. Disconnect the electrical conneclions from the rear of the
switch.
3. Depress lhe locking tabs on the switch and push oUloffacia
assembly.
4. Remove the latch assembly.
277
BODY
Front Door Exterior Handle .. .. .. ............ .. .................. 280

Rear Door Exterior Handle .......................... .......... .. . 281
Remote Lock Interior Handle & Rod .. ...... .. ......... .. ... . 281
Door Lock Cy Ii ndcr ... .............. ........ ........ ... ....... .. ... .. 281
Install
1. Refit switch to facia panel by pressing in until clips secure
switch, then reconnect electrical connections.
2. Install the instrument panel facia as described previously.
Front 000" Window .................................. ..... .. ........ . 282
Rear Door Window ... ....... ....................... ..... .. .. .. ....... 282

Rear Door Fixed Window Glass - Sedan ............ ........ 283
Front Door Window Regulator ....................... .. ....... .. 283
Rear Door Window Regulator ................................ .. 284
Front & Rear Door Weatherstrip ...... ......................... 284
Pillar & Floor Side Panel Moulding .......... ................. 284
Door Belt Weatherstrip & Moulding .. ........................ 285
Exterior Rear View Mirror - Electric Operation ......... 285
SOLENOID ASSEMBLY - TAIL GATE LOCK
Removal
1. With the rear tail gate raised, remove the inner trim panel
and centre light assembly.
DESCRIPTION
Doors consist of a pressed inner door panel and an outer panel
which is spot welded and folded on to the inner panel. The
inner panel incOlporates a strengthened section to protect
passengers from a possible collision.
Double arm scissor type window regulators attached to the
glass lifterchanncls and door inner panels operate the front
and rear door sliding windows.
Electric motors for operating the front and rear sliding
windows are standard equipment on Ghia, Fairlane and LTD
models, and optional on Falcon models.
Lift bar exterior door handles operate the fork type door locks
in conjunction with door lock striker bolts.
A key locking system is used to operate all locks on the
vehicle. A snib button operates the door locks internally.
Electricdoor lock actuators operate the door locks on central
locking.
Doorweatherstrips incorporate plastic clips which retain the
weatherstrip in holes located around the outer lower edge of
the door inner panel. The upper section of the weatherstrip
is retained in a channel which is an integral part of the rolled
section upper door frarne.
Tail Gate _-.-;;;::;::

Trim
2.Remove the tai Igate latch mechanism retaining screws and

operating rods, then disconnect the electrical connection and
remove assembly from tail gate.
3. Remove the screw securing the solenoid to the rear

compartment lid, disconnect the electrical connector, remove
thesolenoid.
Inslallation
1. Refit solenoid and the retaining screw which secure the
solenoid to the reartai Igate, connect the electrical connector.
2. Install the latch assembly, tighten retaining screws and
connect the electrical connections and operating rods.
3. Install the centre light assembly, tighten retaining screws
and connect electrical connections.
4. Install interior trim panel to tail gate.
FRONT & REAR

DOOR
ASSEMBLIES
MAINTENANCE
FRONT & REAR DOORS
Subject
Page
MA.IN1'ENANCE _....... ............ ............................ .... 278

Front and Rear Doors ...... .......... ..... ............ .............. 278
I...A>ck Striker .. .... .................................................. .. ... 279
Door Window Regulator Handle ............................... 279

Door Inner Trim Panel ... ... ... ..... ............ ................... . 279
Front DoorLockAssembly ................................. ...... 280
Rear Door Latch Assembly ....................................... 280
Removal
1.0n doors fined with electrically operated sliding window
regUlators andlorelectricdoor locks, it is necessary to remove
the trim assembly, then disconnect the door electrical harness.
Z.Remove the bolts for the door check link, then remove the
upper and lower hinge pin lock screws.
3. Lift door from hinges and remove from vehicle.
4. If hinges are damaged remove the bolts securing lower
section of hinge to door.
bNallation
278
BODY
Hinge pin _ _
lock screw
Door
\ ,
-
Striker Retaining
Bolts
I
1. Install the door onto the hinges and install hinge pin lock
screw, tighten the hingeatwching bolts iflooscned after door
is aligned.
spaces between the suiker assembly and body pillar to

achieve cOllect engagement of the suiker to the lock.
If a replacement door is being filled, it is sound practise to
remove the door lock suikcr assembly and allow thedoorto
hang freeon the hinges. Set the hinges as necessary to achieve
correct alignment and uniform margins, then reinstall the
suiker and adjust.
DOOR WINDOW REGULATOR HANDLE
Removal
Using a phi Ilips head screw dri vcr remove the screw from the
centre of the handle, then lift hand from spline.
Installation
Press the handle onto the regulator spline, then install and
tighten the retaining screw.
DOOR INNER TRIM PANEL
2. Replace the bolts for the door check link, then reconnect
electrical connections and replace trim if necessary.
Adjust
Attention should be gi ven to uniform margins amI alignment
between the door and surrounding parts when door adjustmentf\ are being carried oul.
Removal
1. Use a phillips screw dri vcr to remove the window regulator
as previously described if fined.
2. Use multigrips& rag to pull off, the push in door lock knob.
3. Remove the screws securing the mirrorrrim panel to door
frame .
Uniform margins and alignment of front and rear doors in

relation to the body opening can be achieved by selling the
appropriate door hinge.
Adjust hinges in conjunction with adjustment to lock striker
to achieve an acceptable doorclosing effort with correct door
lock to strikerengagcmenl.
LOCK STRIKER
Remove Or Adjust
1. Mark the striker position with a pencil or felt pen, this will
help when installing the striker to its correct position.
2. Loosen or remove the two bolts securi ng suiker assembly.
Installation
Align the suiker assembly so that the bridge of the striker
locates centrally in the lock fork as the door is being closed.
Securely tighten the suiker assembly.
Correct engagement can be achieved by vertical or horimnral
adjustment of the door lock suiker assembly. Add or delete
279
screws
5. Remove the screws sccuring the doortrim.

6. Carefully lift the trim from the door inner panel.
Installation
1. Carefully position thedooruim on to the door ensuring it
is aI igncd COli eclly, then install and tighten the ui m retaining
BODY
screws.
2. Once the door trim is in position fit the attachments back,
such a. window regulator handle, door handle and screw on
mouldings.
FRONT DOOR LOCK ASSEMBLY
Removal
I. Remove the door window regulator handle, door pull
handle and door innertrim panel. Then carefully peel off the
waler deflector from the door inner panel.
2. Remove the antidamper shield
~~
S. Replace the water shield, inner door trim, arm rest, door
handle and window regulator handle.
REAR DOOR LATCH ASSEMBLY
Removal
1. Remove the trim panel from the rear quaner glass, then
remove the door window regulator handle, door pull handle
and door inner trim panel as previously described.
2. Detach the door latch and remote lock bellcmnk from the
pivot and detach the rod.
3. Remove the door water shield and nuts retaining the outer
door handle, disconnect the handle from the door panel and
disconnect the door latch rod.
4. Remove the latch retaining screws, detach the remote latch
operating rod and remove latch from door.
~~-
3. Disconnect thedoor lock cy Iinder control rod and external

door handle control rod.
4. Remove the bolt from the lower section of the rear gla.s
guide channel.
S. Remove the lock assembly attaching screws and remove
the lock assembly from the door.
lock Assembly
Retaining Scr8YIS
lock Assemt>t/
'11
I
Installation
1. Place latch into door panel, connect the latch remote
operating rod. Install the retaining screws.
2. Connect the latch rod to outer door handle, position handle
to door panel and install retuning nuts.
3. Install lock bellcrank and refit the door water shield.
4. Replace the inner door trim, arm rest, door handle and
window regulator handle.
FRONT DOOR EXTERIOR HANDLE
Removal
1. Wind window glass up.
2. Remove the door mirror inside lri m, innerdoor handle and
External Door Handle
Installation
Lubricate frictional surfaces of the lock assembly with
lithium grease.
I. Install the lock assembly to the door, tighten the attaching
screws.
2. Replace the bolt to the lowerscction ofthe rear glass guide
channel.
3. Connect the door lock cylinder control rod and external
door handle control rod and install the anti-tamper shield.
4. Connect bellcmnk to the lock a.sembly.
280
BODY
window regulator wi nder handle.

3.Remove screws securingdoortrim then lifttrim from door.
Carefully peel off the water deflector from the inner door.
4. Remove the two nuts attaching the exterior door handle.
5. Pull the door handle slightly away from the door, uncliping
the latch rod as removing.
IffitaIIation
1. Feed top section of door handle into door handle opening

and reconnect rods.
2. Fit the attaching nuts to the door handle from inside
the inner door.
REAR DOOR EXTERIOR HANDLE
Removal
1. Remove the trim panel from the rear quarter glass, then
remove the inner door handle and wi ndow winder handle.
2.Removescrews securing door trim then lift trim from door.
3. Disconnect the outer door handle rod from the door latch
asscmblyrods.
4. Remove the (2) attaching nuts to the outer door handle.
InstaJIation
I. Feed top section of door handle into door handle opening
then reconnect rods.
2. Fit the attaching screws to the door handle from inside
the inner door.
4. Replace trim panel to rear quarter glass.
plastic lugs to screw heads.

DOOR LOCK CYLINDER
Removal
1. Wind up the door window.

2. Remove the remote mirror interiortrim, inner door handle
and window winder handle.
3. Remove screws securing door trim then lift trim from door.
Then carefully peel off the water deflector from thedoor inner
panel.
INNER DOOR HANDLE

Removal
1. Pull theplasticlugs from the retaining screws, then remove

the screw securing the inner handle to the door.
Door Trim
--------"
4. Remove the two nuts retaining the door handle.

S. Remove door handle from door panel, uncliping the latch
rod as removing, disconnect rod from lock cylinder barrel.
6. Pull the retainer for the door lock barrel forward to
disengage, then remove lock barrel.
,
2. Pull the handle from thc door trim disengaging the remote
control rod from the door handle while removing.
bNaJlation
l. Replace remote control door handlea~sembly to innerdoor
trim engaging the control rod.
lReplace the retaining screws securing the handle and fit the
281
Door Lode Barrel
Installation
1. Install the lock barrel into position and secure with retainer,
then reconnect control rod.
BODY
2. Feed top section of door handle into door handle opening

and reconnect rods.
3. Fit the attaching nuts to the door handle from inside
the inner door.
Front Door _
80065
bolts at lower edge of holes in camerplate. To control glass

position in rear glass channel pull glass rearward.
5. Tighten retaining bolts.
6. Check that the window runs up and down in runs.
IMPORTANT: Powdered graphite applied into the lock
cylinder via the key is the only lubricant recommended for
lock cy Ii nde",.
REAR DOOR WINDOW

Removal
FRONT DOOR WINDOW

Removal
1. Remove trim panel for rear quarter glass, then remove the
door pull handle and door inner trim panel as described
previously ,then carefully peel off the watcrdencctor from the
1. Remove door pull handle and door inner trim panel as

described previously, then carefully peel offthe waterdenec
tor from the door inner panel.
2. Raise the glass so that the retaining bolts for the glass
channel are accessible, then remove bolts.
door inner panel .
2. Detach the door latch remote lock bell crank from the pivot
and disconnect the rod.
3. Temporary install the window winder. wind up window
until the glass channel bolts are seen at the access holes in the
inner panel, suppon glass and remove bolts.
>
Gla retain r boIto
3. Temporary install window winder, lowerlhe glass,lift the

glass the glass from the window channel and remove from
window opening on oUl,ide of vehicle.
Installation
1. Lowerthe glass into the door, front edge ofwindow in first.
2. Position the glass into the door and push back to original
position to fit into window channel.
3. Wind window until the glass channel is visible through the
inner panel access holes. Assemble glass loosely to the
regulator.
4. To ensure alignment push glass downwards of retaining
4. Take the rear glass run retain bolts out. Remove the
window from the inside of the door frame.
Installation
1. Place the glass into the door from the inside, move the gla,s
forward and lower into the glass channel.
2. Install the glass run bolts. Raise the window and fit the
gla.s loosely in the regulator.
3. To control position in rear glass channel pull the glass
rearward and tighten retaining bolts.
4. Check the gla.s moves freely in the glass channel over the
282
BODY
full length of travel.

' ---
Rear Door Fixed Window Glass - Sedan
Removal
1. Remove the outer beldine weatherstrip from the rear door,
thenremovetheglassoutermouldingforthereardoorquarter
glass.
2.Using a sharp blade cut the uretherane around the perimeter
of the glass.
Window regulator
assembly
3. Remove the quarter glass from the door.

Installation
1. Install the glass into position following the windscreen
installation method.
2. Replace the glass outer moulding to the rear door quarter
glass, then install the beltline weatherstrip.
FRONT DOOR WINDOW REGULATOR
Removal
1. Remove door pull handle and door inner trim panel as
described previous Iy, then canefully peel off the waterdetlector from the door inner panel.
2. Temporary install window winder, wind the gla.s up so
that the bolts forthe gla.s channel are accessible, then remove
bolts.
3. Drill out pop rivets and remove the two nuts and bolts
securing the window negulator and cam to the door inner
panel then remove the regulator assembly through the aperture in the door inner panel.
---,
#
283
Installation
1. Ensure that the surfaces of the window regu lator assembly
and associated parts are lubricated with lithium grease.
2. Aligning the attaching holes in the assembly with the
corresponding holes in the door inner panel, locate the
regulator assembly inside the door. Attach the regulator
assembly to door using nuts and bolts, then install regulator
to the panel, do not use rivets, drill larger holes, use bolts.
3. Lower gla.s into the door, front edge of window in first
from the outside, then position the glass into the door and push
back to original position to fit into window channel.
4. Temporary install window winder, wind the glass upuntil
the glass channel is visible through the inner panel access
holcs. Assemble glass loosely to the regulator.
5. To ensure alignment, push glass downwards into carrier
plate. To position in rear glass channel pull glass rearward.
Tighten retaining bolts.
6. Check that the window operates satisfactory.
BODY
REAR DOOR WINDOW REGULATOR
Removal
1. Remove trim panel for rearquaner glass, then remove the

door pull handle and door inner trim panel a~ described
previous Iy, then carefully peel offthe waterdetlector from the
door inner panel.
2. Detach the door latch remote lock bell crank from the pivot
and disconnect the rod.
3. Temporary install window winder, wind the glass up until
the glass channel retaining bolts are accessible through the
holes in thedoorinnerp,mel. support glass and remove bolts.
4. Take the rear gla~s run retain bolts out. Remove the
window fTom the inside of the door frame.
Rear Door
Rear glass
panel.
1n>1allation
1. Ensure that the frictional surfaces of the window regulator
assembly anda"ociated pans are adequately lubricated with
lithiumgrease.
2. Aligning the attaching holes in the assembly with the
corresponding holes in the door inner panel, locate the
regulator a.sembly inside the door.
3. Attach the regulator assembly to the door using retaining
bolts.
4. Do not usc ri vel~ to replace the winding mechanism dti II the
holes larger and use bolts and nuts.
S. Place the glass into the door fTom the inside, move the glass
forward and lower into the glass channel.
6. Install the glass channel boIL~ . Wind the regulator up and
loosely fit the glass.
7. To fit the glass securely pull the glass rearward intochannel
and tighten retaining bolts.
8. Check the glass moves up and down satisfactorily.
FRONT & REAR DOOR WEATHERSTRIP
Removal
run retalntng bolts
S. Drill out the rivets securing the regulator assembly to the

door inncr pane then remove the bolts secuting the assembly
Removing the weatherstrip from the door by carefully prising

from the door.
I
; DrIll out Pop Rive.
Door seal
:t
lnstalIation
Replace the weatherstrip, pushing the retaining lug, on the
weatherstrip into the door.
PILLAR & FLOOR SIDE PANEL MOULDING
Removal
to the door panel.

6. Remove assembly through the aperture in the door inner
1. Prise the weatherstrip from around the front and rear doors
overlapping the trim.
2. Remove the screws attaching the sill cover trim and trim
from front and rear door openings.
3. Remove the moulding with front and rear doors open and
the front seat back rest fully declined.
lnstalIation
1. Slide the moulding into place, replace weatherstrip to help
284
BODY
STATIONARY
GLASS
secure the trim.

2. Install the sill cover plates and tighten the screws.
DOOR BELT WEATHERSTRIP-MOULDING
Removal
With the window fully lowered and using a wide bladed screw
driver, carefully prise the rear end of the weatherstrip and
moulding up off the door, working towards the front of the
door, removing the assembly.
Locate door belt weatherstrip and moulding assembly over

the top of the door outer panel, then using the palm of your
hand, firmly tap the assembly down, over door upper flange.
Exterior Rear View MIrror - Electrical
Removal
1. Remove the screws securing mirror trim panel
frame.
to
door
Subject
Page
GENERAL INFORMA nON ................................... 285

Windscreen ............................................................... 285
Glass Preparation ..................................................... 286
BodyOpeningPreparation ........................................ 286
GlassFitment Using Sealant Adhesive ....................... 286
Install Windscreen Components ................................. 286
Rear Window Sedan ......... ........................................ 286
Glass and Body Preparation ...................................... 287
Rear Quarter Window Assembly - Sedan ................... 287
Rear Quarter Window - Station Wagon ..................... 287
Tail Gate Window - Station Wagon ........................... 287
Water Leak Sealing .................................................. 288
Interior Mirror ............. _............................................ 288
GENERAL INFORMATION
The windscreen is a laminated type of glass which has a
plastic lamination between two layers of safety glass. If
struck hard enough it will crack into a large section enabling
the driver to stop the vehicle safely.
WINDSCREEN
Removal
1. Disconnect the windsheild wiperarms and internal mirror
from the vehicle.
2. Unscrew the grille panel then withdraw it from the vehicle.
3. Pull the windseal from the windscreen side moulding
panels, to allow excess to the moulding retaini ng screws, then
unscrew and withdraw the mOUldings.
Mirror Trim Panel

Securing .
retaining screws.
3. Remove mirror assembly from vehicle.
Installation
1. Install the mirror and tighten the three retaining screws.
2.Reconnect electrical connections, replace inner trim panel .
3. Replace control knob on drivers side and test operation.
4. Pry the top moulding from the windscreen, pulling it from
the vehicle, bottom moulding is not removed until the wind-
285
BODY
screen is removed from the vehicle, although the lockingclip

will still need to be removed from the moulding, this can be
done using a screw driver.
Pull up
before applying the urethane.

3. A bead of urethane 3mm diameter is to be run around the
body nangeoverthe primed area.
remove
Top
Moulding
5. Using a nat blade cutti ng tool cut the sealer keeping the tool
hard against the windscreen, the sealer must be cut all the way
around to ensure it will be ea,y to lift from the vehicle.
6. Apply suction cups to windscreen and withdraw the
windscreen from the vehicle.
GLASS PREPARATION
I. Degrea,e gla" bonding surface 25 mm around perimeter

of glass. using urethane cleaning solvent.
NB: Remove the solvent immediately after application.

2. Apply a thin coating of glass primer around glass on
bonding surface. Allow to dry for 10-15 minutes.
of glass
Glass
GLASS FITMENT USING SEALANT

ADHESIVE
1. Using a hand or automatic applicator, apply a smooth

continuous beadofurethanelsilicon adhesive, such as Sikallex
255 ore<luivalent, between the centre and outer edge, on top
of original urethane and around entire perimeter of the body
opening. The urethane bead should be a minimum of3mm
in diameter.
NOTE: The placement of cartridges adjacent to a source of
warmth will a.sist the flow of urethane when using a hand
applicator.
2. Install the windshield, push the windscreen upwards until
the top moulding is hard against the roof. Press windshield
firmly into position and check that the bottom moulding is on
the spacers, then place the slide locks into position.
3. Check effectiveness of sealing from inside of the vehicle.
Should any gaps in the sealing exist, apply additional urethane
on the outside to fIll these gaps. Using a flat bladed tool,
smooth the surface of the urethane around the edge on the
outside of the windshield to ensure effective sealing.
4. Fit the remaining components in reverse order to removal.
INSTALL WINDSCREEN COMPONENTS
80074
NB: The primed surface must not be touched, if this occurs

it must be primed again.
3. Fit the upper and lower windscreen mouldings to the
screen.
BODY OPENING PREPARATION
1. Clean the body nange and any remaining adhesive until a

smooth flat surface is obtained then clean with solvent and
allow to dry.
2. Apply body primer over body flange to give a total
"blacked-out" appearance. Allow to dry for 30 minutes
Install the following by reversing removal procedure.

- Windscreen side mOUldings.
- Interior rear vision mirror
- Windscreen wiper arms.
- Grille panel
REAR WINDOW SEDAN
Removal
1. Disconnect rear window defogger wiring.
2. Remove rear pillar finishing panels from the vehicle.
3. Remove the remaining mouldings, to allow the urethane to
be cut from the inside.
4. Cut the urethane as describe in the windscreen removal.
5. Place the suction caps on the screen and then remove itfrom
the vehicle.
286
BODY
GLASS AND BODY PREPARATION
Procedure is same as windscreen section.

GLASS FlTMENT
Inner Trim - - -
1. Glass bonding is carried out using procedure detailed in

Windscreen section.
2.lnstall following by reversing removal procedure:
- Rear pillar mouldings
- Rear pillar fini sh panel
3. Connect rear window defogger wiring.
REAR QUARTER WINDOW ASSEMBL YSEDAN
Fairlane and LTDsedans havearearquarterwindow titted.

Removal
1. Detach the rear quarter window inner trim panel to allow
access to the window.
2. Using a flat blade cutting tool cut the scaler keeping the tool
hard against the window. the sealer must be cut all the way
around to ensure it will be easy to lift from the vehicle.
3. Apply suction cups to window and withdraw from the
vehicle.
Installation
1. For installation referto the windscreen installation procedures.
2. Rear glass upper moulding is gently pulled upwards to

disconnect from gla".
3. Using a nat blade cutting tool cut the sealer keeping the tool
hard against the rear quarter window. the sealer musl be cui
all the way around to ensure it will be ea.y to lift from the
vehicle.
4. Apply suction cups to rear quarter window and withdraw
the rear quarter window from the vehicle.
NOTE: It is not necessary to remove all traces of original
urethane. However. anyoriginaJ urethancrcmainingmustbe
smooth and firm.
Installation
For installation refer to the windscreen installation procedures.
* Install the rear quarter glass rear moulding. Install pillar
trim panel.
TAIL GATE WINDOW-STATION WAGON
Removal
1. Disconnect battery ground cable and tail gate window
wiper arm and blade assembly and electrical demistconnectors.
2. Detach rear screen side mouldings, then withdraw the

upper and lower moulding strips.
Stabon Wagon Tall Gate
2. Replace the rear quarter window into place lining up the

locating pins and retainers.
3.Push therearquarterwindow firmly into place. and ensure
it is secure.
i Attaching Screws
(Rear Window Side Trim)
REAR QUARTER WINDOW-STATION

WAGON
Removal
1. Detach the pillar trim panels and the rear quarter glass
lower and rear mouldings.
3. Using a flat blade cutting tool cutthesealerkeeping the tool

hard againsttherearscreen, the sealer must becutall the way
around to ensure it will bceasy to lift from the vehicle.
4. Apply suction cups to rear screen and withdraw the rear
287
BODY
screen from the vehicle.

NOTE: It is not necessary to remove all traces of original
urethane. However, any original urethane remaining must be
smooth and firm.
Installation
See "Windscreen Install" for installation procedure.
WATER LEAK SEALING
1. Apply a strong solution of detergent and water around the
edge of the window glass
2. From the inside of the vehicle, appl yair pressure of around
IOpsi (69kPa).
3. Bubbles will form on the outside of the windshield,
indicating the location of the leak.
4. If the suspect leak area is not obvious. commence the
testing across the top and down the sides until the leak location
has been determined.
S. Refer to preceding instructions, remove the windshield
moulding, covering the leak location then, if silicon is uscd,
thoroughly dry out the repair area with compressed air.
If urethane is being used, it is only necessary to removedust,
foreign matter, etc. Water activates the curing process of
urethane.
Using a blade, work fresh urethane or silicon in and around
the leak area.
6. Leak test the repair, if urethane has been used, using the
bubble leak test or a non pressurized water test.
Ifsilicon is used. allow a minimum ofone ( 1) hour to permit
the silicon to skin and adhere to the originaillrethane prior
to testing the repair.
Should the leak persist, apply additional urethane/silicon
until the leak has been corrected.
INTERIOR MIRROR
Replace
As illustrated remove grub screw lift mirror from mounting
plate, place new mirror into position and tighten grub screw.
Installation
To install a mirror onto a new windscreen.
I. Windscreens are now marked with the location for the
internal rear view mirror base plate.
vertical line and the top of the plate is at the horizontal line.
3. Attach mirror to mounting plate and screw in grub screw.
SEAT & SEAT

BELT
ASSEMBLIES
Subject
Page
SER VICE OPERATTONS ..................... ............ ... .. . 288

Front Bucket Seat Assembly .......................... ........... 288
Front Seat Forward & Back Adjust Track ................. 289
Front Recliner ........................................................... 289
Front Seat Head Restraint Assembly .... ...................... 289
Front Bench Seat Assembly ....................................... 289
Front Seat Cushion Cover .......................... ... ......... ... 290
Rear Seat Cushion and Back Assemblies - Sedan ....... 290

Rear Seat Annrest ................................... ................. 290
Rear Seat Assembly - SlWagon ................................. 291
Rear Seat Side Bolster Assembly .............. ............ ..... 291
Rear Seat Back Latch - Station Wagon ..... ..... ............ 291
Front Seat Belt Retractor & Buckle Assembly ........... 292
Rear Seat Belt Retractor Assembly ..... ....................... 293
Centre Seat Belt Retractor Assembly ......................... 293
Electrically Operated Seats ........................................ 293
Generdllnformation ........... ........... .... .. ..... ......... ... ... .. 293
Seal Track ................................................................ 293
Motor & Drive Cables ... ... .......... ........ ...... ....... ..... .... 294
Seat Switch ............ .................................................. 294
SERVICE OPERATIONS
FRONT BUCKET SEAT ASSEMBLY
Removal
1. Remove the bolts securing the frontendandrearend of the
seat adjuster to floor from inside the car.
Seat
Front Windscreen
Seat Track Front

Retaining Bolt
2. From inside of the vehicle stick the mounting plate to the

glass, tiling care that the mounting plate is in line with the
288
BODY
2.Remove the seat from the vehiclc, then place seat a"embly
on a clean protected surface.
FRONT SEAT HEAD RESTRAINT

ASSEMBLY
Installation
Front seat head restraints are retained by a press - release

knob locatcd in sleeves which are secured to the seat frame.
I.lnstall the scat assembly al igning the bolt holes, then tighten
the scat attaching bolts to speci fication.
Seat Retaining Bolts:
35 Nm,
Head Rest
Release Clip
FRONT SEAT FORWARD & BACK ADJUST

TRACK
Removal
1. Press in the release knob to release the head restraint.
2. Remove the head restraint from the seat back.
Instal1ation
Place the headrestmint into position above the seat, and push
the legs of the restraint down into the seat.
Removal
1. Remove thc front seat assembly then place the assembly
face down on a clean protected surfaces.
2. Remove the bolts sccuring the adjustment tmcks.
FRONT BENCH SEAT ASSEMBLY
Removal
I. Remove bolls from the back of the seat tracks.
Installation
1. Replace the adjustment tracks, tighten bolts to 25Nm.

2, Install the fTont seat assembly and tighten the attaching
35Nm
FRONT SEAT BACK ASSEMBLY
Removal
1. Remove the front seat assembly then place the assembly
face down on a clean protected surfaces.
2. Remove the recliner knob (pull off), trim panels by
releasing retainers.
Note: Dri vcrs seat the two height adjustment handles need to
be remove, by opening clips at back of handles.
3. From either side of the seat remove the two bolts securing
the back to the base.
4. On all models except GLi unctip the cover flap from the seat
base.
2.Slideseat back on seat tracks, remove front attaching bolts.
Seat
Installation
1. If required reclip cover flap into position and install seat

back, then tighten the retaining bolts to 25 Nm.
2. Replace the side trim panels, rectiner handle and hcight
adjustment handle.
3. Install the front seat assembly and tighten the seat attaching
35 Nm.
289
Seat Track Froo'

Retaining Bolt
3. Remove seat assembly from vehicle and remove seat from

scat tracks.
BODY
Installation
1. Inslall scalia seal trdcks.
2. Replace seat inlo vehicle and install bolts to 50Nm.
FRONT SEAT CUSHION COVER
Removal
I. Remove the seal and seat track a"embly as previously
described.
Falcon Bucket
Seat
Removal
l. Push with knees from edge of seal cushion down and
rearwards to disengage a.sembly retainer from brackets

attached to the floor, remove and place cushion on a clean
protected surface.
2. Fold down each scelion of the rear seal back tllen remove
clips securing carpet to rear seat backs.
3. From the seat back hinge remove the upper bolt for each
segment, then lift frame from the vehicle, then place frame
a.sembly on a clean protected surface.
Release handle
2. Remove the screws allaching the seal track to Ihe seaL

3. Remove the hog rings altaching the seat cushion coverto
lhe seat frame and remove the cushion cover.
Installation
I.Centre thecoveron the seal franleand evenly pull the cover
over the frame and fix the cover to the frame with the hog
nngs.
2. Rcplacethe seal onto the seal tracks with anachingscrews.
3. Install seat to the vehicle and fix with attaching nuts.
REAR SEAT CUSHION AND BACK
ASSEMBLIES-SEDAN
Installation
1. Fil seat back into position in vehicle and secure the seat
latch.
2. Install the hinge bolt 10 each segment and tighten to
specification.
Sea! Back Hinge Bol!Specification: 11 Nm.
3. Fit the cushion section into place with the back of the
cushion in under the back section.
4. Push down hard on the front of the cushion and force back,
this will clip the seat frame under the seat bracket and force
the cushion back further under the back section.
REAR SEAT ARMREST
Removal
1, Remove the rear seat assembly, then remove the seal cover
from the fmmc near the armrest frame.
290
BODY
l Remove screws securing rear seat armrest to rear seat

frame and lift armrest assembly from seat opening.
3. Remove plastic covcr panel.
Installation
1. Fit plastic cover panel. then fit armrest to seat frame and
tighten screws.
l Fit seat cover back over seat fnune then install seat
assembly into vehicle.
REAR SEAT ASSEMBLY - Station Wagon
Removal
I. Push with knees front edge of seat cushion down and
rearwards to disengage seal retainer from brackets attached
to the floor, remove and place cushion on a clean surface.
4. From the seat back hinge remove the upper bolt for each
segment, then lift frame from the vehicle, then place frame
assembly on a clean protected surface.
Installation
I. Fit scat back into position in vehicle and secure the seat
latch.
2. Install the hinge bolt to each segment and tighten to
specification.
Seat Back Hinge Bolt Specification: 25 Nm.
3.Fit floor extension panel into position and tightenretaining
bolts.
Floor Extension Panel Bolts:
25Nm.
4. Fit the cushion section into place with the back of the
cushion in under the back section.
5. Pushdown hard on the front of the cushion and force back,
lhis will clip the seat frame undcrthc scal brackcl and force
the cushion back further under the back section.
REAR SEAT SIDE BOLSTERS
Remove
I. Remove the rear scat assembly as described previously.
2. Remove the bolster back locking pin, thcn removc the lower
retaining bolt.
2. Fold down each section of the rear scat back then remove
clips securing carpet to rear seat backs.
3. Remove bolster from vehicle.
panel bolts and fold back to

access seat hinges.
Install
1. Replace bolster into position in the vchicle and lighten
lower bolt to specification.
Bolster Lower Mounting Bolt:
10 Nm
2.Replace the locking pin. then install the rearseata.sembly
as described previously.
REAR SEAT BACK LATCH
Removal
I. Remove the seat back from the vehicle as previously
described.
2. Remove the latch cover lhen remove the seat cover and
foam padding.
291
BODY
Remove cover by
pulling down from frame
to illustrations then remove bolt and upper attachment.

2. Remove cover from bolt securing seat belt lower attachment to floor pan, then remove bolt and seat belt lower
attachment.
,
3. Remove latcMock from eitherside ofthe seat back and the
connecting rods from the lever to the latcMock.
4. Remove the latch assembly and knob.
,.:------Rod to release button
latch mechanism
Installation
1. Connect the latch a~sembly with connecting rod and knob.
2. Install the connecting rods from the leverto the latcMock.
Install the latcMock to either side of the seat back.
3. Install the seat cove rand foam padding, then the latch
cover.
4. Install the rear seat assembly as previously described.
FRONT SEAT BELT RETRACTOR AND
BUCKLE ASSEMBLY
Removal
1. Remove sash guide cover from bolt securing upper seat belt
attachment to centre pillar, with front seat fully forward, refer
Spanner
belt upper
mounting bolt
3. Remove sections of front and reardoor windlacing and seal

adjacent to centre pillar lower trim. Remove pillar trim
retainers, carefully remove centre pillar trim.
4. Remove two bolts securing front seat belt retractor to
centre pillar, removing retractor.
---
Installation
When installing bolts ensure that the lower bolt threads are
sealed with non hardening sealer and that all seat belt
attaching bolts are torque to specification.
1. Install bolt securing frontseat belt retractor to centre pillar.
RetractorBoItSpecification: 20 Nm
2. Replace centre pillar trim. Replace sections of front and
rear door windlacing and seal adjacent to centre pi liar lower
trim. Replace pillar trim retainers.
3. Replace boltand seat belt lower attachment. Replacecover
to bolt securing seat belt lower attachment to floor.
Lower Mounting BoltSpecilication: 30 Nm
4. Replace sash guide cover to bolt securing upper seat belt
attachment to centre pillar.
Upper Mounting BoltSpecilication: 30 Nm
292
BODY
1. Remove the snap in scrivet from the retractor cover, then
REAR SEAT BELT RETRACTOR

ASSEMBLY - SEDAN & STATION WAGON
remove the cover.
Removal
1. Remove rear seat cushion assembly, then remove the rear
quarter trim panels,
2. Remove sash guide cover from bolt securing upper seat belt
attachment to rear pillar, then remove bolt and upper anach-
2. Remove the bolt sceuri ng the belt retractor assembly then

remove the assembly.
Install
1. Install the retractor assembly into position and tighten
retaining bolt.
2. Replace cover and secure with snap in scrivit.
ment.
Bear seat belt
upper mounting bon
ELECTRICALLY
OPERATED SEATS
GENERAL INFORMATION
Motor fitted to the electrically operated seats will drive in

forward and reverse, and has a switch and housing, the
motors operate worm dri ve assemblies and four flexibledri ve
cables. The motors arc positioned front/central mounted on
a moving frame fortheback and forth travel,ceniial mounted
on a moving frame forthe front tilt, rear for the rear tilt. The
motor and drive assembly are serviced as assemblies. The
nexibledrive cables and switch are separate units.
The front motor is powered to provide horizontal drive.
Pinions at each end of the cross-shaft mesh in a frame on the
lower track section, this frame moves backwards and forwards.
Thecentre and rear motorsdri ve the vertical movement ofthe
seat. The centre and rear drive units are activated in unerson
when the vertical drive is in operation. They operate worm
wheels and drive gears on the left track assembly at the front
and rear. The movement is lIansferred viacross-shafts at the
back and rear to levers at the front and rear of the right track,
the left track is also fitted with the levers.
The mid mounted motorconlrOls the front vertical movement
gear and the rear tilt switch operates the rear motor which
3, Remove bolts securing rear seat belt lower attachments,

check diagram if including lap type seat belts, to floor pan.
Removing the bolt securing rear seat belt retractor assembly
to quarter inner panel, remove retractor assembly.
1 ,.
eeK
retaining
turns the rear vertical movement wonn gear .
SEAT TRACK
Ensure that bolt threads have sealer.

J. Replace bolts securing rear seat belt lower attachments to
floor pan. Replace the bolt securing rear seat belt relIactor
assembly to quarter inner panel
2. Replace sash guide cover to bolt securing upper seat belt
attachment to rear pillar and upper attachment.
3. Replace rear seat cushion assembly and rear quarter trim
panels.
Retractor BoltSpccification:
30Nm
Seat belt attaching bolts torque:
30Nm
CENTRE REAR SEAT BELT RETRACTOR
ASSEMBLY
Removal
Removal
1. Remove bolts and seat assembly from the noor pan,
remove the bolt attaching the seat belt. Detach the wiring
connector under the seat. Withdraw the seat from vehicle.
2. Withdraw the bolts attaching the track assembly to the seat
frame and remove.
Installation
1. Install the track assembly on the seat frame.
2. Install the four track attaching bolts and tighten, Front
IONm Rear 20Nm.
Measure between the lIack base channels and adjust by
turning the 'J' nut at the right front comer, the distance from
track to track at the front is the same as that at the rear.
3. Join the switch wiring loom under the seat.
293
BODY
4.Install the seat assembly in the vehicleand connect wiring

loom. Install the seat belt to seat frame and tighten 27-34Nm.
5. Connect the battery earth cable.
6. Test the operation of the seat.
NOTE: Clean handsareessential when working on the body
Intenortnm.
SERVICE OPERATIONS
MOTOR AND DRIVE CABLES

Removal
1. Take the seat and track assembly out of the vehicle.

Remove the two motor assembly screws on right track.
2. Detach the drive cable clamps on the left hand track, detach
the motor drive cables from seat.
3. Separate the motor and remove drive cables.
Installation
1. Replace the cables and tighten the bracket to the motor.
2. Replace the motor and cable assembly on the right track
with two screws.
HEADLINING ASSEMBLY
Removal
1. Move both front seat backs to the reclining position.

2. Remove the interior rear view mirror, sun visors, assist
grips and interior lights.
3. Remove the windscreen header moulding, rear window
header moulding side rai I mouldings and roof pillar mouldmgs.
3. Situate front cable in strap and attach the three cables to

drive unit on the left hand track. Tighten the cable retaining
clamps.
4. Place the seat and track assembly in the vehicle.
5. Test the operation of the seat.
SEAT SWITCH
Removal
1. Pull off the recliner knob.
Securing screws
2. Remove the seat side trim held by two screws on the scat
frame.
3. Dctach wiring connector from wiring loom.
Installation
1. Place the new switch and wiring assembly onto the scat
frame.
2. Rcplace the side valence panel, recliner knob and the
replace and tighten the valence retaining screws.
3. Test the operation of the seat and switch.
Installation
I.Position hood lining intovehiclethroughrear, then position
the front of the moulding to the sun visor mounting holes.
2. While retaining the front in position secure lining over the
interior lamp cutout.
3 .Secure the headl ining by inserting the fastener buttons into
position.
HEADLINING
ANDTRIM
Subject
4. On station wagons remove the centre roof moulding.

5. On sedans release and fold down the rear scat back rest.
6. Remove the fasteners securing the headlining, then remove
lining through rear of vehicle.
Hood lining fasten ...

(&ocate<:! around entire
Page
e~8
SERVICEOPERATlONS ....................................... 294

HEADLINING ASSEMBLy ................................... 294
Removal ........................................................... ........ 294
Installation ........... ..... ............ ................................... 294
Hood Iming
MOULDING ASSEMBLY, QUARTER WINDOW IN

NER TRIM - SEDAN ...... ........................................ 295
Removal ..................... .. ................ ,........................... 295
rnstallation ................ .. ............................................. 295
REAR PARCEL SHELF TRIM - SEDAN ............... 295
Relnoval ..... ............... ....... .. ...................................... 295
I.nstallation ......... .. ... .. ............................................... 295
80126
294
of lining)
BODY
4. Install the finish mouldings into position, then install the

assist handles, interior lights and sun visors.
5. Clean the headlining of any marks that occurred during
installation.
2. From inside the rear compartment, carefully tap up and out

the fasteners securing the trim and retainer strip, to the rear
parcel shelf then remove the trim. Trim is also glued in place.
Installation
MOULDING ASSEMBLY, QUARTER
WINDOW INNER TRIM - SEDAN
Removal
I. Remove the rear seat cushion ,md back assemblies and the
rear seat belt upper attachment.

2. Remove the section of the finishing lace adjacent to the
leading edge of the quarter window inner trim moulding
assembly, then using a wide bladed screwdriver located
between the quarter inner panel and inner trim moulding,
adjacent to the trim fasteners, carefully prise the trim moulding away from the quarter inner panel.
1. Carefully fit the pareel self trim moulding to the shelf panel,
with trim fasteners.

2. Replace the rear seat cushion and back assemblies as
previouslydescribed.
TOP TRIM between DOORS
Removal
J. Remove the screw as indicated.
2. Remove the seat beillopanchorpoinl, pull trim away from

panel.
Installation
Disengage seat belt from guide and remove inner trim
moulding.
l. Carefully fit the trim moulding to the centre pillar.

2. Rcplace the screw and seat bell top anchor point.
Installation
PAINT &
EXTERIOR
ORNAMENTATION
I. Carefully fit the trim moulding to the quaner inner panel,

with trim fasteners.
2. Replace the rear scat cushion and back assemblies as

previously dcscribed .
REAR PARCEL SHELF TRIM - SEDAN
Removal
I. Remove rear seat cushion and back assemblies.
Subject
Page
BODYMAlNTENANCE ........................................ 295

External Paint ................................................ ...... ..... 295
Cleaning ................................................................... 296

ExtetiorOmamentation .................. ........................... 296
MouldingClipReplaccment ............................. ......... 297
AdhesiveBonded Emblems ....................................... 297
A ir Scoop Assemblies ............... ......... ..... ....... ........... 297
BODY MAINTENANCE
EXTERNAL PAINT
Acrylic Enamel Paints
This range of painL< have a harder surface, and hold a higher
295
BODY
gloss surface for metalliccolours than the ordinary enamels,

provided the paint surface is maintained. This enamel also
has the property of good smoothness.
Below are repair guide lines for acrylic enamel paints:
Polishing Paint:
Minorpaint runs, scratches, dry over spray and orange peel
can be eradicated by machine or hand polishing or by both
sanding and polishing without the necessity of repainting. If
repairing this type of defect lreat the entire panel as, spot
repairs will leave a blemish appearance and should be
attempted only in area< that do not have large areas of pai nt.
When polishing follow the guide lines.
Lightly sanding using 1200 wet and dry paper with water or
soapy water as a lubricant removing the defect. Usi ng a brush
apply medium cutting polishing compound to the painted
surface. Use a polisher or drill and polishing wheel and
woollen pad, polish the entire panel, do not hold the polisher
in the one position as this will leave cut marks in the paint
surface. Change woollen pad, then with a clean lambs wool
pad buff the entire panel.
Acrylic enamel paints needa light polishing to improve their
gloss, as age and weathering can remove the lustre from the
paint surface.
Painting Panels:
Airdry acrylic lacquer is more durable than airdryenanlels.
Vehicles painted with either conventional airdrying temperature.low temperature bake enanlels or acrylic lacquers, can
repair with acrylic enamels. When repairing metallic paint
colours, a good colour match can be achieved with acrylic
lacquer. Aftertherepaired panel has been painted, polish the
new and old surfaces to obtain a n even paint surface.
Remove wax, polish or grease with No. 600 wet and dry
paper thoroughly rub down the original finish. If trims and
mouldings arc not removed, make sure paint surface neartrim
and mOUldings, is thoroughly rubbed back to provide adhesion of new paint. Areas sanded to the base metal must nO!
be left untreated, otherwise a fdm ofrust wi II develop on metal
surfaces.
If panels have been damaged, the paint should be removed,
the damaged section panel beaten to the correct shape. Body
filler and puny are applied, then the repaired section sanded
back with coarse paper such as No 120 wet and dry paper to
to body
'Cew~h 000"" paper.
A feather appearance will develop as the correct
Jevel of the putty surface meets the original paint and
body surface.
--
start with. Then use No 360 or 420 wet and dry paper before
moving to No 600 wet and dry paper to obtain a good finish.
After sanding, apply a pri mer to any bare metal that has been
exposed. Sand the primer surfaces with No. 800 wet and dry
paper with water before applying paint. The lacquer or
enamel used should be thinned with thinners as recommended
by the supplier of the paint.
spray Painting
Spray the paint at an
25cm , over lap each
from the panel of 18cm to

to obtain an even finish
CLEANING
Regular maintenance throughout the life of a car, is recommended to help the appearance of paint surface and the
general appearance of the vehicle. The following steps are
suggested as a guide for regular body maintenance:
1. Wash the car, chamoisdryexteriorand vacuum the interior
thoroughly.
2. Inspectopenings for water leaks and seal wherenecessary.
Repair all loose weatherstrips which are useable.
3. Replace any door or boot lid weatherstrips which are
damaged. Weatherstripping can he protected with silicon
polish.
4. Replace all cracked. chipped and dcfective light surfaces
tmd windows.
5. The windshield wiper rubbers must be inspected regularly
and replaced iffaulry.
6. Clean the seal<, door trim panels and headlining.
Exterior Cleaning
Wash the car regularly with warm water and car wash
detergent, then chamic dry. Do not dust or wipe the paint
surface when it is dry because it will rubdustanddirtintothe
paint surface and scratch the paint surface.
Help the vehicle paint surface by regularly washing. The
vehicle paint surface should be polished every 12 months.
EXTERIOR ORNAMENTATION
Screws, clips, fa~teners, retainers, bushes, nuts and contact
adhesive are used to secure the various exterior mOUldings,
badges, emblems, etc, as illustrated. When removing or

installing exterior mOUldings, the following care should be
exercised:
a) Finishes adjacent to the moulding should be covered with
masking tape to prevenl damage.
b) Holes in body panels for screws, bolts, clips, etc; that could
pennit water entry into the body must be adequately sealed
296
BODY
with non hardening sealer or presealed screws, nuts or clips.

The body side mouldings are secured to the front fender
and front and rear doors with double sided adhesivetape
and urethane adhesive.
MOULDING CLIP REPLACEMENT
Drill a small hole in the panel next to the original weld stud
location. Insen a self-sealing screw through original cli p and
into outer panel, or replace damaged weld stud with 5Olfsealing screw-type weld stud.
ADHESIVE BONDED NAMEPLATES AND
EMBLEMS
EL XR SERIES AIR SCOOP ASSEMBLY
Remove
I.Raise the bonnet then remove the five retaining screws and
backing plate from underside of air scoop.
2. Lower bonnet and lift air scoop assembly from bonnet.
lnstaU
1. Position the air scoop into place in bonnet then while

holding air scoop in position raise bonnet.
2.lnstall the backing plate, tighten the five retaining screws,
then lower bonnet and check air scoop is aligned correctly.
FRONT SHEET
METAL
Subject
Page
Service Operations ................................. 297
Removal
parts is more easily achieved
the use
of heal lamps positioned adjacenllo the pan to be removed.
CAUTION: Ensure that the heat lamps are not too close or
the heat 100 intense to adversely effect paint finish.
It is essential when installing theseadhesi ve bonded pans that
the panel to which the pan is to beapplied is thoroughly clean
and thaI the panel temperature is at least 21 degrees Celsius.
EF XR SERIES AIR SCOOP ASSEMBLY
Air Scoop Retaining Botta
Front Fender Assembly ............................................. 297

Bonnet ......................................................... ............. 298
Bonnet L..atch ............................................................ 298
Bonnet Lock Secondary Catch or Striker ................... 298
Engine Bonnel Relea~eCableAssembly ..................... 298
Panels that are attached to the front consist of bonnet, front
fenderand frontend panel. Thebonnetassembly is hingedat
the rearand is supponedin the open position by a gas plunger
attached to the engine inner skin panel. The bonnet lock
release lever mounted beneath the righl hand side of the
instrumentpanel,controlsthebonnetlockreleascspring. The
bonnet, when released from the locked position,engages ina
secondary safety catch which can be released by inserting
fingers beneath the leadingedgeofthe bonnet.
SERVICE OPERATIONS
-
FRONT FENDER ASSEMBLY
Removal
Remove
I. Raise the bonnet then remove the four retaining screws
from underside of air scoop.
2. Lnwer bonnet and lift air scoop assembly from bonnet.
Irt.1aU
I. Position the air scoop into place in bonnet then while
holding air scoop in position raise bonnet.
2.lnstall and tighten the four retaining screws, then lower
bonnet and check air scoop is aligned correctly.
297
BODY
I. Remove the front bumper bar assembly.

2. Remove the front fender liners.
3. If necessary remove radio antenna. The manual antenna
is removed by detaching the nut at the upper end of the
assembly.
4.Removebolt and washer assemblies and bolts securingthe
rear of the fenderto the front end assembly.
---'----
Bonnet _____........
Screw driver
Gas
Bonnet
80134
2. Penci Imark around the hinges on the bonnet, then remove

the bolts securing the bonnet to the hinges as shown in
diagram.
Mark hinge
positk>n with a felt pen
before loosening bolts
S. Remove the screw and washer assemblies securing the

lower and upper pan of the fender to the front end assembly
and the engi ne inner skirt panel, removi ng the fender.
80180
3. Remove the assembly.

Installation
I.Position the bonnet into position aligning the pencil mark,
with the hinges.
2.lnstali the hinge to bonnet retaining bolts.
3. Install and bonnet props into position and replace the
retaining clips, then adjust and tighten hinge retaining bolts.
Installation
1. Place the front fender into position insert tlle screw and
washer a"emblies to secure the lower and upper part of the
fender then the rear section of the fender.
2. Do not tighten the screws until the fender has been aligned
so that it tits into the correct position with the other body
panels.
BONNET
Removal
1. With the bonnet raised and supported, discoooect the
bonnet props by removing the retaining clips from the ball
Adjust
When adjusting the bonnet and assembly. uniform spacing

and alignment between the bonnet and adjacent pmts is
important.
Sioned holes in the hingearms provide horizontal adjusnnen~
whilst floating anchor nuts mounted inside the bonnet inner
panel, provide vertical adjustment for the rear end of the
bonnet.
Verticaladjustmelll for the front end ofthe boooet is achieved
by adjustment of the pilot pin and bonnet lock nut in
conjunction with theboooet buffers located on the front ofthe
bonnel i nncr panel.
retainers.
BONNET LATCH
Remove or Adjust
Raise and support the bonnet assembly, then remove the

splash shei Id moulding. Slacken off the bonnet latch screws.
298
BODY
RADIATOR
GRILLE
Remove the release cable from the latch and remove the
screws and latch. To adjust move the lock assembly to align
with the suiker.
Subject
Page
Falcon Radiator Grille .............................................. 299

Fairmont RadiatorGrilie ........................................... 299
FairlaneILTD Radiator Grille .................................... 300
Installation
Reconnect the release cable to the latch. Align the latch with
the lock striker and tighten the latch screws.
BONNET RELEASE CABLE ASSEMBLY
Bonnet Release
Cable
Removal
Raise and support the bonnet assembly. Remove radiator
front shroud. Depress the hood lock release spring and
disengage the nipple at the front end of the release cable from
the release spring. Disengage cli ps securing cable assembl y
to front end panel assembly and right hand engine skirt panel.
From inside the vehicle, disconnect the cable, bracket and
lever assembly from the right hand shroud panel, lower
rearwards, then pull the complete assembly into the vehicle.
Installation
From inside the feed thecable through the fIre wall. Install the
cable, bracket and lever assembly to the right hand shroud
panel.
Raise and support the bonnet assembly. Remove radiator
front shroud. Depress the hood lock release spring and
engage the nipple at the front end of the release cable to the
relea'>Cspring. Engageclipssecuringcableassemblytofront
end panel assembly and right hand engine skirt panel.
EL FALCON RADIATOR GRILLE
Remove
With engine hood raised, remove the two retaining clips and
remove grille from vehicle.
Disassembly ofG rille
From the back of the assembly remove the three retaining
screws and separate grille assembly.
Assembly of Grille
Install pla<tic centre bar to grille and tighten the three
retaining screws.
Install
Install radiator grille into position and secure with retaining
clips.
FAIRMONT & GHIA RADIATOR GRILLE
Remove
With engine hood raised, remove the nuts securing the
radiator pille to the bonnet. Carefully remove the pille
a<sembly.
Disassembly of Grille - EF only
Prise of the centre badge, then remove the screw and remove
inscrt from surround.
Assembly of Grille - EF only
Install insert into surround and press into position until clips
engage then install retaining screw and badge.
Install
Install radiator grille into position, then tighten the retaining

screws to specification.
RadiatorGrilleScrews:
1.8 - 2.6 Nm.
Retaining Clips
299
BODY
FAIRLANE & LTD RADIATOR GRILLE
Remove
With engine hood raised, remove the nuts securing the
mdiator grille to the bonnet. Carefully remove the grille
assembly.
Install
Install radiator grille into position, then tighten the retaining
nuts to specification.
0.9 - 1.5 Nm.
Radiator Grille Nuts:
BUMPER BARS
Subject
3. Remove front bumper bar assembly by sliding fOlWard.

Dismantle
1.Place the front bumper bar assembly facedown on a clean
protected surface.
2 Remove the support beam inner bmckets and support
assemblies from the centre bumper bar facia assembly.
Page
FRONT BUMPER BAR .......................................... 300
Remove .................................................................... 300

Dismantle ............ ...... ............. ....... ..... ............... ..... .. 300
Assemble .................................................................. 300
lnstaJl ....................................................................... 300
REAR BUMPER BAR ASSEMBLY-SEDAN ........ 300

Rell10ve ................................... " ........................... .... 300
InstalJ .................................................................... ' .. 301

REAR BUMPER BAR ASSEMBLY - S'WAGON .. 30 I
Remove .................................................................... 30 I
Install ....................................................................... 301
SERVICE OPERATIONS
FRONT BUMPER BAR - ALL
Remove
1. Remove the front splash sheild from under front fender,
then raise the bonnet and remove the protective cover.
Assemble
1. Place the front bumper bar assembly face down on a clean
protected surface.
2. Replace the support inner bmckets and support assemblies.
InstaII
1. Slide front bumper bar assembly into position.
2. With front bumper bar assembly supported install mounting nuts to side rail.
3. Replace the bumper cover to fender retaining screws, then
install protecti ve cover and splash shei ld.
Rear Bumper Bar Assembly - Sedan
Remove
1. Remove bumper bar outer side retaining screws and
bumper retaining screws from under wheel arch.
2 With the bumper bar fully supported, remove bolts
securing rear bumper bar assembly to rear end of vehicle.
Bolts removed from inside boot.
3. Remove rear bumper bar assembly by sliding back and
disconnect licence plate light.
2.Remove the four bumpercoverto fender retaining screws,
then remove the nut securing the front bumper arms to side
rail.
300
BODY
Station
Wagon
Rear
Bumper
Install
I. Install rear bumper bar assembly into position, push-into
side brackets and reconnect licence plate lite.
2. With the bumper bar fully supported, replace bolts securing rear bumper bar assembly to rear end of vehicle.
3. Replace bumper bar outer side retaining screws and
bumper screws inside rear wheel arches then tighten main
retaining bolts to specification.
BumperMountingBoltSpecifimtions:
25 Nm
REAR BUMPER BAR ASSEMBLY STATION WAGON
Two
Mounting
Boks
Ei1her
Side
3. Remove bumper bar end retaining screws.

4. Remove rear bumper bar assembly.
Install
1. Install rear bumper bar assembly by sliding into position.
2. With the bumper bar fully supported, replace boIls securing rear bumper bar assembly to rear end of vehicle.
3. Replace bumper bar outer side retaining screws then
tighten main retaining bolts to specification.
Bumper Mounting BoltSpecifications:
19-25 Nm.
4. Replace rubber grommets in bolt holes.
Remove
1. Lift tail gate of vehicle, and remove rubber grommets.
2 With the bumper bar fully supported, remove bolts
securing rear bumper bar assembly to rear end of vehicle.
Memo
301
HEATING, AIR CONDITIONING &

AUTOMATIC CLIMATE CONTROL
Subject
Page
Subject
HEATING .............................................................. 303

CONTROL AND SWITCH ASSEMBLy ............ 303
ReITlOve .................................................................... 303
Install ....................................................................... 303

FAN MOTOR ASSEMBLy .................................. 304
RertlOve .................................................................... 3M
Instal ........................................................................ 304
RESISTOR ............................................................. 304
RerTlOve ............................................. ....................... 304
install ....................................................................... 304
FOOTWELL DUCTS ............................................ 3()S
ReJ110Ve ................................... ................................. 305
InstaJl ....................................................................... 305
WINDSCREEN DEMlST DUCTS ........................ 305
RclTlOVC ................................... . . ........... . . . . . . . . ..... . . . . . .. 305
rn~talt .................................. ................... .................. 3()S
HEATER ASSEMBLy .. ......... ............ ... ... ............ 305
R Clll0VC ........... . ..... . . . . . . . . . . ...... . . . . . ....... ... . . . . . . . ....... . . . . . 305
Insta.11 ....................................................................... 305
BLEEDING AIR FROM HEATER CORE .......... 306
HEATER CORE AND PIPE ............................... 306
Remove .................................................................... 3()6
lnstaJi ....................................................................... 3()6
HEATER WATER VALVE ASSEMBLY ............ 306
Remove ., ........,.,.......... ,..............,..............,.............. 3()6
Install .... .........,.......................,..............,... ,.............. 3M

VACUUM TANK ................................................... 306
RenlOve ........ ................ .............. ,............................. 3{)6
Install ., ... ......... ..... ,........ ,., ...... ..... .... ......................... 3()6
PROBLEM SOLVING AND DIAGNOSIS ......... 307
AIR CONDITIONING .......................................... 309
GENERAL INFORMATION ................................ 309
REFRIGERANT CIRCUIT .................................. 3()9
SERVICE OPERATIONS ..................................... 309
COMPRESSOR DRIVE BELT ............................ 309
COMPRESSOR OIL REPLACEMENT .............. 309
Compressor Inspection Procedures ............................ 309
l...cak Test .............................. ,............ ,.,., ................. 3{)9
CompressorSmoolhnessTesl .................................... 310
Clutch Test .. ,.,., .... ,.,.,.,., .... ,.... ........,...................... ,.. 3 10
Noise,,, ....... ,,"" ......... " ....... ,,""" ......... " ....... "" ........ 310
COMPRESSOR ASSEMBLy ............................... 310
Removal ................... ,............................................... 3 10
Installation ........ ........... ............................................ 3 10
HEATER CASE ASSEMBLy .............................. 310
Rcrnoval ................................. """" .... ,.. "" ....... """" 3 10

Installation .......................................................... ,.... 3] 1
Page
EVAPORATOR &lOR HEATER CORE ............. 311

ReITlOval ............................................................... .... 311
Installation ....................................' ....... ,...... ......... ... 3 II
THERMOSTAT ASSEMBLY .............................. 311

RerTlOval .................................................... ............... 311
Installation ............................................................... 312

THERMOSTATIC EXPANSION VALVE .......... 312
Removal ................................................................... 312
Install ....................................................................... 312
CONDENSER ........................................................ 312
Removal ................................................................... 312
Installation ............................................................... 312
RECEIVER I DRYER (ACCUMULA TOR) ......... 312
RemovaJ ................................................................... 312
Installation ............................................................... 313
PROBLEM SOLVING & DIAGNOSIS ............... 313
AUTOMATIC CLIMATIC CONTROL .............. 314
DESCRIPTION and CONTROL .......................... 314
CONTROL PANEL ASSEMBLy ......................... 314
RerTlOval ................................... ................................ 314
Bulb Replacement ..................................................... 314
Install ........... ,., ......................................................... 314

AMBIENT TEMPERATURE SENSOR ............... 314
Remove ........,........ ,......,., ......,.......... ,....................... 314
Install ............. ........ ......................,.. ............... ... ,.. ,... 314
COOLANT TEMPERATURE SENSOR ............. 314
Remove and Install .................................................. 314
SUNLOAD SENSOR ............................................. 315
ReOlOve .,., ................................................................ 315
Install ...................................... ,., .... ,., ...... , .... , ....... ,... 315
CABIN TEMPERA TURE SENSOR ..................... 315
Remove and Install ................................................. 315
EV APORA TOR TEMPERATURE SENSOR ...... 315
Remove ........,...... ,., ....,., ....,...,......,., ...... ,....,....,........ 315
Install ...........,.. ......................................................... 315

FAN SPEED CONTROLLER ............................... 315
Remove .,.............,.................................................... 315
Install .................................................... ,., .. ,., .. ,." .. ".3 ]5

VACUUM CONTROL SOLENOIDS ................... 315
Remove .............................,.... ................ ............. ,.... 315
Install ......................... ,.............................,....... ,....... 316
BLEND DOOR MOTOR ...................................... 316
Rcrnove ......................,...... ,...................................... 316
Install ......................................... ,...... ,., .... , ...... ......... 316
CABIN AIR SNIFFER MOTOR ........................... 316
Rcrnove .............................,., ......,...... ,......,.... ,.......... 316
Install .................................................. ,..,.. ..... .......... 316
302
HEA T & AIR CONDITIONING
Air Flow Diagram
H020.
HEATING
Heater and Air Conditioner Controls
# See "Body" chapter also.
Dash Facia Retaining

Radio
Remove.
\. Withdraw the ash tray from the dash, then the radio trim
panel by releasing the retaining screws from behind the ash
tray.
2. Detach cigarette lighter wiring as panel is being withdrawn, then release and withdraw the instrument cluster
panel, detaching the wiring from the switches.
3. Release the contrul panel retaining screws from the
assembly, then detach the wiring and vacuum connectors.
4. Withdraw the control switch assembly.

Install
1. Position the control switch assembly.
2. Attach the wiring and vacuum connectors to the control
panel, then fit the retaining screws to the assembly,.
3. Fit and secure the instrument cluster panel, attaching the
wiring to the switches.
303
6. Remove the fan motor by removing the three screws

attaching the motor to the case. Take care when removing or
replacing the wires rrom between the heater case.
Install
Fan Assembly
4.Connectthecigarette lightcrwiring as panel is being fitted,

to the dash assembly.
5.Secureradio trim panel fitting the retaining screws behind
the ash tray, then tit the ash tray into the dash.
6, Check the operation of the control switches.
H012
FAN MOTOR ASSEMBLY
Remove
1, Remove the glovcbox and centre console as described in the
body chapter.
2, Remove the instrument panel and move backforacccss to
heater assembly as described in the body chapter.
3. Label wiring connectors and vacuum fitting to assist in
assembly. Detach the fan motor wiring connectors and detach
the hoses from the vacuum motor on the footwell. To help
removal of the motor connector. Bend the single resistor
tenninaldownwards.
4, Detach the footwell duct by removing the screws, the nuts
and washers and detach the duct from the clip retaining the
forward edge of the duct.
1. Pull the wires paslthe seal between fire wall and the heater
box, tie fine wire or string to the wiring connectors
2. Install the fan motor to heater. Push the fan onto the fan
motor shaft and install the retaining clip.
3. Connect fan wiring no need to straighten the single
temlinal.
4.lnstall the passenger footwell duct to heater box, install
retaining clip, washers and nuts and screws.
5. Connect the vacuum hoses. Replace the instrument panel
and the console.
6. Replace the glovebox and centre console as described in
body chapter.
7. Check operation of heater and fan assembly.
RESISTOR
Removal
J. Removethe glove box and the wiring loom connector from
the resistor.
2. Bend the single tenninal down to allow the connector to be

removed. Remove the resistor attached by screws.
5. Remove the fan retaining clip from the fan shaft and pull
the fan off the fan motor shaft.
Location for resistor

electrical connection
Install
1. Replace the resistor, screws and wiring loom, no need tonO(

straighten the terminal.
304
2. Replace the glove box and attachment screws.
J. Replace the duct into position then replace and tighten the
retaining screw.
Rctainingnuttorquespecification .................. 5 - 8 Nm.

2. Replace the dash extension panel.
FOOTWELL DUCTS
HEATER ASSEMBLY
# Remove dash as described in "Body" chapler
Remove
1. Drain sufficient coolant from the radiator so as coolant wi II
not now into the vehicle.
2. Remove the instrument panel as described in the instrument
chapter.
3. Disconnect the hoses from the inlet and outlet heater core
pipes and vacuum line to the water valve assembly.
# Remove dash as described in "Body" chapter

1. Remove the glovebox and centre console as described in the
body chapter.
2. Remove the instrument panel and move back for access to
heater assembly as described in the body chapter.
3. Remove vacuum hoses from duct then remove and the duct
by removing two nuls and screw.
linter Core Hose

~Pipes
Ho wtth Heater
Cor4Iot valve
ImtaIl
I. Install the passenger footwell duct to heater box, install
retaining clip, washers and nuts and screws.

2. Connect the vacuum hoses. Replace the instrument panel
and the console.
3. Replace the glovebox and centre console as described in
body chapter.
4. Disconnectelectrical wiring connectors.

5. From within the engine compartrnent, remove the live (5)
nuts securing the heaterca,e to the dash panel.
WINDSCREEN DEMIST DUCT
Remove
l.Remove the dash extension panel as described in the body
chapter.
2. Remove the screws from either end and the centre of the
duel
6. From within the vehicle, remove the heater assembly from

the dash panel.
1nstaIl
J. Place the heater assembly into position on the dash panel
3. Remove the duct from vehicle.

Install
and secure with the live washers and nuts.

2. Connect all vacuum hoses.
3. Install the instrument panel as described in the instrument
chapter.
4. Connect the water hoses and top up radiator with coolant.
305
5. Bleed the heater system of any air locks, as described later

on.
6. Check the operation of the heater.
line from the water valve assembly.

2. Remove the water valve ."embly.
BLEEDING AIR FROM HEATER CORE
1. Placeacontainerunderthe hose outlet connection at water

pump.
HeatwCore Hose
~Pipes
..10 I. wllto Heater

Valve
eor..d
2. Disconnect the outlet hose at the water pump, block off the
connection at the water pump, trapped airshould be allowed
to escape. When a steady now of coolant comes from the
hose, connect the hose tighten clamps.
3. Top up coolant from container.
Install
1. Install the heater water valve assembly.
2. Replace the heater hoses and clamps. Replace vacuum line
to the heater water valve assembly.
3. Tighten hose clamps. start engine check for water leaks.
VACUUM RESERVOIR
HEATER CORE AND PIPE
Remove
Remove the heater assembly as described previously, then
separate the heater box and remove the heater core from the
heating assembly.
Remove
1. Remove wheel liner.
2. From undertherearofthe right hand side front wheel arch,
disconnect the vacuum line connection and remove the screw
securing the vacuum reservoir. Remove the vacuum tank by
unhooking from panel tabs.
Heater Core
H026
Install
Install the heater core into the heater casing, then join the
heater box together and replace into vehicle as described
previously.
lnstaJJ
1. Replace the vacuum tank by hooking it into the two panel

tabs under the rear of the right hand side front wheel arch.
Replace the screw securing the vacuum reservoireonncctthe
vacuum line connection.
2. Replace wheel liner.
HEATER WATER VALVE ASSEMBLY
Remove
1. Loosen hose clamps, remove the heater hoses and vacuum
306
PROBLEM SOLVING AND

DIAGNOSIS
Problem: No cooling or warm airl
Possible Causes:
Coolant leak in heating system.
Fan does not operate:
(a) Heater cireuit fuse blown.
(b) Heater water valve faulty.
(c) Temperature control resistor faulty.
(d) Heater relay faulty.
(e) Fan motor faulty.
(f) Wiring faulty .
Problem: Cool air comes out
intermittently!
Possible Causes:
Magnetic clutch slipping.
Expansion valve faulty.
Wiring connection faulty.
Excessive moisture in the system.
HEATING TROUBLE DIAGNOSIS GUIDE
Condition - No or low volume Heat or

Demlst
CA USE: Radiator coolant low.
ACTION: Top-upcoohmt, check cooling and heating system for leaks.
CAUSE: Engine overheating and displacing coolant.
ACTION: Check for blocked radiator, loose drive belt,
faulty thermostat, water pump not operating due to impeller
damage.
CAUSE: Damaged of faulty water pump drive belt.
ACTION: Replace belt if cracked, glazed or badly worn,
adjust belt tension.
CA USE: ThemlOstal.
ACTION: Check thermostat as described in "Cooling'
chapter.
CAUSE: Heater water valve not operating.
ACTION: check vacuum to heater water valve, replace if
required.
CAUSE: Vacuum not available to close water valve.
ACTION: Check vacuum system (turquoise hose), repair if
necessary.
CA USE:Blocked heater core.
ACfION: Check correct coolant is in cooling system,
different coolant mixtures can causing blocking of cooling
system or heater core,
CAUSE: Control cables.
ACTION: Check operation of cable.
CAUSE: Vacuums hoses.
ACfION: Check all hoses arc connected, not blocked by
307
sharp bends or twists or jammed between two objects and

blocking offvacuum.
Operate controls with engine idling to see if control knobs
operate.
CAUSE: Vacuum units not functioning.
ACTION: Check operation of vacuum units with a vacuum
pump and hose.*O ....mge vacuum line needs tbeengine to
be at operating.
Turquoise and black vacuum lines have many connections.
CAUSE: Radiator or heater hoses blocked, collapsed, soft.
ACTION: Fit new hoses to replace affected hoses.
CAUSE: Air inlet blocked.
A CTI 0 N:Checkgrille in frontof windscreen for leaves and
general rubbish.
CAUSE: Fan not operating.
ACTION: Check fan fuse and relay, replace if necessary.
Wiring to fan faulty or shorted, find fault and correct. Fan
motor burnt out, replace fan.
Condition - Heater gives hot air only.
CAUSE: Radiator coolant low.
ACTION: Top-up coolant, check cooling and he.1ting system for leaks.
CAUSE: Engineoverheating.
ACTION: Check for blocked radiator, loose water pump
drive belt, faulty thermostat, water pump not operating due
to impeller damage.
CAUSE: Damaged of faulty water pump drive belt.
ACTION: Replace belt if cracked, glazed or badly worn,
adjust belt tension.
CA USE: Thermostat.
ACTION: Check thermostat as described in "Cooling'
chapter.
CA USE: Blocked radiator core.
ACTION:Checkcollectcoolantineoolingsystem,different
coolant mixtures can cause blOCking of cooling system.
CA USE: Control cables.
ACTION: Check operation of cable.
CAUSE: Vacuums hoses.
ACTION: Check all hoses are connected, not blocked by
sharp bends or twists or jammed between two objects and
blocking off vacuum. Operate controls witll engine idling to
see if control knobs operate.
CAUSE: Vacuum unil' not functioning.
ACTION: Check operation of vacuum units with a vacuum
pump and hose. *Ol"dnge vacuum line n~'Cds the engine to
be at operating.
Turquoise and black vacuum lines havc many connections.
CAUSE: Radiator hoses blocked, collapsed, soft.
ACTION: Fit new hoses to replace affected hoses.
CAUSE: Heater water valve not operating.
ACTION: check vacuum to heater water valve, replace if
required.
CA USE: Vacuum not available to close water valve.
ACTION: Check vacuum system (turquoise hose), repair if

necessary.
FAN ROTATING TEST
Tum on fan at switch, if a hum is heard but no air flow, the
fan could be is loose on fan motor shaft.
FAN CONTROL SWITCH TEST
Replace with a switch that is known to work.
HEATER CORE BLOCKED TEST
Tum heater control switch to hot, loosen and remove heater

outlet hose (hose going to water pump). Start engine, see if
water flows from heater hose, if not, heater core is blocked.
HEATER WATER CONTROL VALVE TESTS
Disconnect the vacuum hose, see if the heater valve leverwiU
move freely backwards and forwards, if notrepairorreplace
heater valve.
Disconnect vacuum hose, attach vacuum testing pump to
heater val ve, operate pump, see if heater control valve works.
Attach a flow pressure vacuum gauge to heater valve hose,
start engine and operate heater control in cabin, note pressure
gauge reading. Ifthere is no variation on gauge vacuum hose
must be blocked or have a faulty connection.
HEATER CONTROL SWITCH
A vacuum switch is operated locause a vacuum at the water
valve vacuum motor, this in tum operates the water valve.

The crank arm attached to the temperature control knob is
operated by a plunger in the heater switch.
VACUUM TESTS
At each vacuum motor test the movementofthe plungershaft

and crank arm see if they move freely backwards and
forwards, if not repair or replace vacuum motor.
Di~connect vacuum hose, attach vacuum testing pump to
heater val ve, operate pump, see if the vacuum motor works.
Attach a flow pressure vacuum gauge to vacuum hose, start
engine and operate control switches in cabin, note pressure
gauge reading. If there is no variation on gauge, vacuum
system hose must be blocked or have a faulty connection.
Trace back to find fault and COllect.
308
AIR
CONDITIONING
tensioner. Inspection of the tension marks located on the

assembly is the only means of checking the belt tension.
GENERAL INFORMATION
The following information provides basic service operations
for the air conditioning system, including tlle eomprcssor.
REFRIGERANT CIRCUIT
The refrigerant circuit (illustratcd) incorporates the followingmajorcomponents.

Acompressor, evaporator, accumulator and a condenser.
Theengine RPM is higheron airconditioned models so as not
to drop to low at idle during system operation. When the
ignition is turned off and the air conditioning ha~ been
operating, a faint sound of liquid tlowing for 30-60 seconds
maybe heard. This is the refrigerant in the system continuing
to flow until high side and low side pressures equalize.
COMPRESSOR OIL REPLACEMENT
Sanden TRV 105 Compressor:

If the oil drained from the compressor measures less than
II Oml replace II Oml of new oil in thereplacementcompressoc.
Refrigerant .......................... __ Refrigerant Type R-I34a
DOllot replace more thallllOml oIllewoil even ijmore thon
II0ml was removed/rom the compressor.
COMPRESSOR INSPECTION
PROCEDURES
SERVICE OPERATIONS
LEAK TEST
Seeping oi Idoes not necessan Iy indicate leaki ng refrigerant,
look forthe following problems:
Shaft seal area seeping oil. Leak test see area between clutch
and compressor.
Oil around finings.
Oil around crack in compressor housing.
* Always clean away all oil, grease, etc and blow away
COMPRESSOR DRIVE BELT TENSION

AND ADJUSTMENT
Inspect dri ve beltcondiLion.
COMPRESSOR DRIVE BELT TENSION
The brive belt is tensioned automaticly by the spring loaded
Receiver De-Hydrator
Compressor
Condenser
Binary Switch
SWitch
t
High Pressure
Expansion Valve
Low pressure liquid

Low pressure vapour
High pressure liquid
High pressure vapour
309
residual refrigerant before starting detection procedures.

Referto system orsupplier manuals forthe proper techniques
to be used for 'ELECIRONIC' Leak Detectors.
When using 'Electronic' - shop type detectors (detectors with
a minimum leak mte of 14-28 cc per year); in the seal area,
set the instrument 114 to 113 range above maximum sensitivity. For leak testing all other portions of the compressor - set
the detector at maximum sensitivity. 'Soap Bubble' - Any
bubbles, on any portion of the compressor indicate a leak
requmng reparr.
COMPRESSOR SMOOTHNESS TEST
1. Discharge the system.
2. Disengage clutch.
3. Rotate front plate by hand.
fIXing points - replace andlortorque bolts to specifications.

4. Loose or wobbling engine crankshaft pulley - repair or
replace.
5. Genemtor bearing noisy - replace.
6. Water pump bearing noisy - replace.
7. Engine valves sticking or burnt - repair or replace.
8. Timing chain noisy - replace.
9. Loose engine mounting bolts - re-torque.
to. Low refrigerant charge. Low charge can be detennined
by low suction pressure together with low head pressure.
11. Oil level - insufficient oil can cause unusual noise.
COMPRESSOR ASSEMBLY
Removal
2. Discharge system.
3. Removecompressordrive belt.
4. Disconnect hoses from compressor.
4. While rotating, if severe rough spots or 'catches' are felt,

repair or replace the compressor.
CLUTCH TEST
1. Check for continuity of with an ohm meter on field coil if

it is broken, replace the coil or repair broken wire if it can be
found.
2.Chcckcurrentdmw and volwge, correct specifications are:
Amperuge Range ................. 3.5 to 4.2 amps at 12 volts.
Note the following symptoms and remedies.
A very high amperage reading - The field coil has a short.
No arnperagecontinuity - the field coil has break in wiring.
Tfthe reading is intermittent or poor system earth, this causes
a lowervoltageat the clutch. This will cause clutch slip which
may be diagnosed as belt slip. Check for tight fit of coil
retai ni ng ci rclip. Check to determine proper system ground.
Replace field coil if open or short circuit is found.
3. Suspected Bearing Noise - Carry out the following:
Removebelt. Disengageclutch. Rotaterotorpulley by hand.
Listen for bearing noise. Feel for hard or nat areas. If
excessive, rcpairorrepiace compressor.
* All compressors have operating noise, this should not be
mistaken for a t~lulty compressor.
NOISE: Check for:
1. Loose bell.
2. Broken bracket andlor compressor body mounting replace broken componenl.
3. Missing, broken or loose bolts at compressor and engine
CAUTION:Cap or plug disconncctedconnectors on pipes

and on compressor immediately to prevent absorption of
moisture from the atmosphere into the system.
5. Disconnectelectrical conneclOrthen remove theanaching
bolts securing the compressor to the mounting bracket removing the compressor.
Installation
1. Install thecompressorto the mounting bracket and torque
mounting bolts to 37-56Nm.
3. lnstal I hoses to compressor. Removecap from hose fitting,
install new '0' ring seals after lubricating them with refrig
emnt oil, then torque hose connections.
4. Adjust the drive belt as outlined earlier.
5. Connect battery earth.
6. Charge the system as outlined in earlier in this in this
section.
7. Start engine and test operation or compressor.
HEATER CASE ASSEMBLY
# See Body Chapter and Healer section of this chapter.

Removal
2. Discharge the system (as previously described in this
310
5. Charge the system and reconnect the battery terminal.
section) and fTom within the engine compartment, Temove

wateTdeflectoT and disconnect the refrigerant inlet and outlet
pipe connector.
'Capopen connections to prevent moisture and dirt entry into
system.
3. Remove the Instrument panel as previously described in
this chapter.
4. Disconnect the vacuum hoses from the heateT I air
conditioner, disconnect the wiring connection to resistor as
described earlier.
5. Disconnect the vacuum lines from the heateT wateT valve
undeT the bonnet.
EVAPORATOR or HEATER CORE
Removal
2. Discharge the system (as previously described in this
section) and from within the engine compartment, remove
wateTdeflectoT and disconnect the refrigerant inlet and outlet
pipe connector.
*Capopen connections to prevent moisture and dirt entry into
system.
3. Remove the instrument panel as previously described in
this chapter.
4. Remove the heateTcaseussembly as described previously.
5. Separate the two halves of the heateT case assembly, then
remove the probe fOT the AlC thermostat from the case.
6. From the case remove the two screws securing the core
6.Removethepa,sengeTfootwellductuspreviouslyde~ribed.
assembly and remove core from casc.
7. From the engine bay Temove the five nuts secuTing the
heateT case assembly to fire wall from undeT bonnet.
H027
Installation
1. Install the heateT assembly into the cabin and up against the
firewall undeT the dash assembly, then from the engine bay
replace and tighten the five nuts securing the heater case
assembly.
2.Replace the passenger side foot well duct, then reconnect
the vacuum lines to the heateT wateT valve undeTthe bonnet.
3. Connect the vacuum hoses to heateT assembly and also
connect the electrical connection to the resistor.
4. Replace the Instrument panel as previously described in
this chapter.
311
Installation
1. Install the COTe into the case assembly and tighten the two
retaining screws, then replace theAlC thermostat probe.
2. Assemble the two halves of the heateTcase, use silastic to
seal the lower edge of the ca'e and then replace into vehicle
a,described pTeviously.
3.lnsta11 the Instrument panel as pTeviously described in this
chapter.
4. From within the engine compartment, replace the water
deflector and Teconnect the Tefrigerant inlet and outlet pipe
connector. ChaTge the system.
5. Connect the battery ground cable.
THERMOSTAT ASSEMBLY
Removal
1. Disconnectbattery ground cable. Remove the dash assembly as previously described.
2. Remove electrical connections.
3. Carefully remove the SCTews securing the thermostat to the
heater evaporator COTe Temove the .,sembly.
Installation
1. If the evaporator core fins are damaged or bent use blade
or sm,1l1 screwdriver. During installation of the thermostat
make sure the capillary tube is not caught on the heater box.
2. Install thermostat and anaching screws.
3. Install dash assembly as previously described.
4. Start engine and test run air conditioner.
THERMOSTATIC EXPANSION VALVE (TX)
CA UTION: Caporplugall disconnectedconnectolli immediately to prevent absorption of moisture from the atmosphere into the system.
3. Remove the bolts/nuts securing the condenser assembly to
the radiatorside suppon brackets and remove assembly from
the vehicle.
Installation
# During installation useanew '0' ring, dipped in refrigerant
oil, on all connections. Evacuate, leak test, charge and
conduct functional test on the system.
1. Securing the condenser assembly to the radiator side
suppon brackets, replace the bolts/nuts.
2. Connect the inlet and outlet refrigerant pipeconnectolli to
the side of the condenser, use new "0" rings
3. Replace the front bumper bar.
4. Recharge the air conditioner refrigerant system.
RECEIVER I DRYER (ACCUMULATOR)
Removal
1. Discharge the system.
2. Disconnect the in let and outlet refrigerant pi pe connectors
on the accumulator.
3.Remove the two recei ver dryer retaining nuts and remove
recciver/dryerassembly.
Removal
2. Discharge the air conditioner refrigerant system.
3. From one side of the TX valve remove the flange head
screw, tube bracket and tubes.
4. From the other side of the TX valve remove the 2 screws,
tube bracket and tubes.
Install
1. Assemble the tubes into place and secure with brackets.
2. Evacuate. leak test. charge and conduct functional test on
the system.
CONDENSER
Removal
I. Discharge the air conditioner refrigerant system.
2. Remove the front bumper bar. Disconnect the inlet and
outletrefrigerantpipeconnectollionthesideofthecondenser.
CAUTION: Cap orplug all disconnected connectors inunediately to prevent absorption of moisture from the atmosphere into the system.
* If the accumulator is left opm to the atmosphere for any
time longer thall it takes to cap, the accumulator should be

replaced.
312
Installation
#During installation useanew '0' ring, dipped in refrigerant
oil, on all connections. Evacuate, leak test, charge and
conduct functional test on the system.
1. Securing the receiver/dryer, replace the bolts.
2. Connect the inlet and outlet refrigerant pipe connectors to
the side of the condenscr, use new "0" rings
3. Recharge the air conditioner refrigerant system.
PROBLEM SOLVING AND

DIAGNOSIS
Quick Cooling Test
The procedure can be used to detennine whether or not the
system has the proper charge of refrigerant (providing ambienttemperatureisabove21 degrees Celsius). Thischeckcan
be made in a manerof minutes, simplifying system diagnosis
by pinpointing the problem to the amount of charge in the
system or by eliminating this possibility from the overall
check-out.
1. Engine must be warm.
2. Hood and body doors must be open.
3. Selector control set at VENT.
4. Temperature control at COLD.
5. Fan switch on 4.
6. Normal engine idle.
7. Check the temperature (place your hand on pipe etc) of
evaporator inlet pipe and accumulator surface with compressorengaged.
a) BOTH SAME TEMPERATURE AND SOME DEGREE COOLER THAN AMBIENT-Normal condition:
check for other problems.
b) INLET PIPE COOLER THAN ACCUMULATOR
SURFACE-low refrigerant charge. Add slight amounts
(200gms) of refrigerant UNTrL BOTH feel the same temperature allow stabilization time between additions (approx
four minutes). Then add 400gms additional refrigerant.
c) INLET PIPE HAS FROST ACCUMULATION-accumulation surface warmer. Proceed as in step (b) above.
AIR CONDITIONING
TROUBLE DIAGNOSIS
GUIDE
Problem: No cooling or warm air!
Possible Causes:
Magnetic clutch does not engage:
(a) NC fuse blown.
(b) Magnetic clutch faulty.
(c) NC switch faulty.
(d) Temperature control resistor faulty.
(e) Thermostat faulty.
(I) NC compressor faulty.
(g) Wiring or ground faulty.

(h) Refrigerantempty.
(i) Heater relay faulty.
(j) Pressure switch faulty.
Compressor does not rotate properly:
(a) Drive belt loose or broken.
(b) Compressor faulty.
Expansion valve faulty .
Leak in system.
* Fusible plug on receiver blown or clogged screen.
* Blower does not operate:
(a) Heater circuit breaker blown.
(b) NC switch faulty.
(c) Temperature control resistor faulty.
(d) Heater relay faulty.
(e) Blower motor faulty.
(I) Wiring faulty.
Problem: Cool air comes out intenninently!
Possible Causes:
Magnetic clutch slipping.
Expansion valve faulty.
Wiring connection faulty.
* Excessive moisture in the system.
Problem: Limited amount of cool air at high speed!
Possible Causes:
* Thermostat faulty.
NC amplifier faulty.
Problem: Cool air comes out only at high speed!
Possible Causes:
Condenser clogged.
* Compressor I'au Ity.
* Insufficient or too much refrigerant.
Problem: Insumcientcooling!
Possible Causes:
* Condenser clogged.
* Magnetic clutch faulty.
Compressor faulty.
* Expansion valve faulty.
* Thermistor faulty.
* NC amplifier faulty.
* Insufficient or too much relrigerant.
* Air or excessive compressoroii in system.
* Receiverclogged.
Problem: Insufficient velocity of cool air!
Possible Causes:
* Evaporator clogged or frosted.
* Air leakage from cooling unit or air duct.
Air inlet blocked.
Blower motor faulty.
313
AUTOMATIC
CLIMATE
CONTROL
AMBIENT TEMPERATURE SENSOR

The two components may
be parallel. not at an angle.
As seen in next photograph.
DESCRIPTION & OPERATION
Automatic Climate Control option is a standard fining on

Fainnont Ghia, Fairlane and LTO models.
H026
Remove
The ambient airtemperaturesensor is located in the radiator
airdenector.
To withdraw the sensor, release the retaini ng bolt from within
the den ector, then withdraw the sensor from between the
bumper bar and radiator, disconnect the wiring connector as
the scm,or is withdrawn.
lnstaIl
Fit the sensor in the reverse procedure to removal.
ENGINE COOLANT TEMPERATURE

SENSOR
The control unit automatically controls the cabin temperature, the vehicle operator adjusts the temperature to the
comfort level desired and the control system automatically
adjusts to hold the temperature constant.
There area number or sensors fitted throughout the vehicle,
these sensors gi ve readi ngs of the tempemture so the control
unit can adjust to compensate for any temperature change.
The Automalic temperature setting can be adjusted bet ween
16"C and 32"C. The automatic temperature control can also
be overridden and used as a manual control unit similar to a
standard vehicle. The manual controls for the air now are
located behind a panel at the bottom of the control panel, the
panel is opened by pushing it in and releasing.
The control pad also contains a ambient button, which gives
the temperature reading of the outside temperature, the
ambient sensor is located in the front of the vehicle either on
the radiator upper panel or the radiator upper panel support
depending on the model.
CONTROL PANEL ASSEMBLY

Removal & Installation
Remove for automatic climate control is the same procedure
as described in the heater chapter previously is this chapter.
If damage is detected the a~sembly will require replacing, a~
it is a non-repairable unit.
Bleeder
Plug
Remove
Open the bonnet on the vehicle disconnect the electrical
connections from the sensor and unscrew the sensor from the
water outlet housing.
Install
Apply teflon tap to the sensor thread, then screw the sensor
into position in thewateroutlet housing. Reconnectelectrical
connection.
314
SUN LOAD SENSOR
Remove
1. Remove the screws securing the instrument panel pad
extension, partially remove extension then disconnect sensor
electrical connection and remove extension.
2.Remove the two screws securing the sensor to theextension
Evaporator Case Hole ...................................... 38 mm.

4.lnsert thespecial tool through thecuthole, then disconnect
the sensor and retainer.
S.From the hole remove the sensor and retainer then separate
the retainer from the sensor.
6. Disconnect the sensor wiring and remove the sensor and
wiring from the evaporator case.
Install
1. Install the wiring and sensor assembly into the evaporator
case and reconnect the wiring connections.
2. With the sensor pulled through the hole install the retainer
5mm from the globe, then using the special tool install the
retainer as shown in diagram.
3.1 n the hole cut into the evaporator case install a sealing plug
then install the glove box surround, cowl panel trim and glove
box.
FAN SPEED CONTROLLER
Fan Speed Controler
panel.
1nstall
I. Replace the sensor to the extension panel, tighten the two
retaining screws then position the extension panel intoposition connecting theelecirical connection.
2. Ensure the extension panel is sitting in correct position,
replace and tighten the retaining screws.
CABIN TEMPERATURE SENSOR
Remove & Install
The cabin temp sensor is a non-repairable component, and is

located in the control panel assembly. The control panel
assembly will need to be replaced to rectify the problem.
H029
EVAPORATOR TEMPERATURE SENSOR

Remove
I. Remove the glove box as described in the body chapter.
2.Removethecowl panelirim from the left hand sideandalso
remove the glove box surround a~ described in the body
chapter.
3.1n the location shown in the below diagram cut a hole in the
evaporator case to a dimension speci fied.
Remove
1. Remove the glovebox compartment, left side cowl trim
panel and the left side lower dash panel forremoval instructions refer to the appropriate section in the body chapter.
2.Disconnect the electrical connections from the control ler,
then remove the retaining screws.
3. Remove the fan speed controller from the heater case.
Install
1.Replace the fan speed controllcr to the heater case, replace
and tighten the retaining screws.
2. Reconnect the electrical connections for the controller.
3.Replace the lower leti sidedash panel, cowlirim panel and
glovebox as described in body chapter.
VACUUM CONTROL SOLENOIDS
Remove
1. Remove the glovebox compartment. left side cowlirim
panel and the left side lower dash panel for removal instructions refer to the appropriate section in the body chapter.
315
2. Disconnect theelcctrical connections and vacuum hamess.

3 .Remove the screws securing the vacuum control solenoids
and remove the solenoids.
2.lnstall and tighten the retaining screws then reconnect the

3.lnstall the heater case and instrument panel.
CABIN AIR SNIFFER MOTOR
Install
1. Replace the vacuum control solenoids then replace and
tighten the retaining screws.
2. Reconnect the electrical connections and vacuum hamess.
3. Replace the glovebox compartment, left side cowl trim
panel and the left side lower dash panel for installation
instructions refer to the appropriate section in the body
chapter.
BLEND DOOR MOTOR
Remove
1.Referto the body chapter for instructions for removing the
instrument panel, and remove.
2. Rcfcr to the heating or air conditioning section of this

chapter for removal instructions of the heater case and
remove case.
3. Disconnect the electrical conncction to the motor then
remove the retaining screws for the motor.
4. Remove blend door motor from vehicle.
Install
I.lnstall the motorinto position ensuring the blend door lever
and motor lever are aligned.
Remove
1. Remove the radio power antenna I Economy switch from
the left side of the steering column and boot I fuel fillercap
from the right sideofthe steering colwon then remove theone
screw either side in the switch locations (These screws go into
the instrument cluster panel).
2. Remove the three upper shroud retaining screws then
remove the shroud.
3. Remove screws securi ng the radio shroud, then release the
lower retaining lugs and remove the shroud panel.
4. Remove the climatic control unit, 4 screws.
S. Remove radio surround trim, as previously described.
6. Remove the centre trim held by two screws at top and two
screws in behind radio trim.
7 .Removethe two retaining screws securing the motor, then
disconnect the electrical connections.

8. Remove motor from vehicle.
Install
1.lnstall cabin air sniffer motor into vehicle and reconnect the
2. Install and tighten the two motor retaining screws then
replace the cabin temperature sensor as described in air
conditioning section of thi s chapter.
3. Replace the centre trim held by two screws attop and two
screws in behind radio trim.
4. Replace radio surround trim, as previously described.
S. Replace the climatic control unit, 4 screws.
6. Remove place the radio shroud by placing the lower
retaining lugs and two screws.
7. Replace shroud and three upper shroud retaining screws.
8. Replace the screw either side of the steering column at
switch locations. Replace the radio power antennal economy
switch from the leftsideofthe steering column and boot I fuel
filler cap from the right side of the steering column.
316
INSTRUMENTS, RADIO - TAPE

PLAYER & HORN
Subject
Page
Subject
Instrument Clusters ................................................ 318

General Infonnation .................................................. 318
ServiceOpcralions .................................................... 318
Instrtunent Cluster .................................................. 318
Remove ... ............. .......... .......................................... 318
Dismantle -GLi ........................................................ 319

Dismantle -SlPack ................................................... 319
Dismantle - Fairmont, Fairlane & LTO .... .... .............. 3 19
Assemble -GLi ........................................................ 319
Assemble - SlPack .................................................... 319
Assemble-Fainnont, Fairlane & LTO ........................ 320
Install ....................................................................... 320
Head Light Switch .................................................. 320
Remove .................................................................... 320
Install ... ..................... ............................................... 320
Trip Computer - Fainllont, Fairlane & LTD, ......... 320
Remove .................................................................... 320
Install .. .. ..... ................. ............. ............ ..... ............... 321
Radio - Stereo System ............................................. 321
Radio Cassette Unit - Falcon ................................... 321
Remove .................................................................... 321
Install ....................................................................... 321
Radio Cassette Unit - Ghia, Fairlane & LTD ......... 321
Remove ....... ............. ........... .... ......... ...... ............... ... 321
Install ....................................................................... 321
Remote Control Unit ............................................... 321
ReDlOve .................................................................... 321
Install ....................................................................... 321
Amplifier ................................................................. 322
Remove .................................................................... 322
Install ....................................................................... 322
Compact Disc Player Or Sub Woofer ..................... 322
Remove ................................. .. ................................. 322
Install ....................................................................... 322
Front Door Speakers ............................................... 322
Rernove .................................................................... 322
Install ....................................................................... 322
FrontSpeakers ........................................................ 322
Remove .................................................................... 322
Page
Install ....................................................................... 322

Rear Speakers ......................................................... 323
Reroove .................................................. ....... ........... 323
Install ............................... ........................................ 323
Rear Speakers - S/Wagon ....................................... 323
ReJTl()ve .. ...................... ............... .......... ................... 323
Install .... .... ....... ....... ........ ....... .... ..... ..... ......... ..... ..... . 323
Manual Antenna ...................................................... 323
RetllOve ................................................................. ... 323
Install ....................................................................... 323
Power Antenna ........................................................ 323
Reloove ........................ ......... ..... ............... .. ............. 323
Install .................................. ....... ....... ..... .. ............... . 324
Sender Units ............................................................ 324
Vehicle Speed Sender .............................................. 324
Remove .................................................................... 324
Install ........................... ............................................ 324
Coolant Temperature Sender .................................. 324
Remove ............. ....... ..... .. ........ ....... .......................... 324
Insta11 ....................................................................... 324
Oil Pressure Switch ................................................. 324
Remove ...... ..... ......... ..... .... ... ..... ....... ....... ....... ....... .. 324
lnsta11 ...................................................................... . 324
Fuel Gauge Sender ................................................. . 325
Remove ................................................................... 325
Install .......... ......... ..... .................... ..... ..... ... ..... ... ..... . 325
Centre COflS()Ie Switches ....................................... .. 325
Remove ................................................................. .. 325
Install ...................................................................... . 326
Break Failure Switch .... ... .... ............ ..... ....... .......... .. . 326
Hom Assembly ...................................................... . 326
Remove ......................... ......... ..... ............ ..... ....... .... . 326
Test .......................................................... ................ 326
Hom Actuator ....................................................... . 326
Remove .............................. ..... ....................... ..... ... .. 326
Install ...................................................................... . 326
317
SJM!CificatiollS .......................................................... 326
INSTRUMENT. RADIO - TAPE PLA YER & SWITCHES
Instrument Clusters & Trip

Computer
Instrument Clusters
Some or the models are fitted with analogue instruments

including the speedometer. TheGLi Falcon instrumentcluster has a speedometer/odometer and trip meter, fuel level and
coolanttempemtures gauges. The cI uster also incorporates a
warning lamp bar below the instruments.
Trip Computer
The tripcomputeris fitted to all FairmontGhia, Fairlaneand

LTO vehicles, the trip computer contains the time, day &
date.
It also provides the driver with details of instant fuel consumption per I OOkm,Avemgefuelconsumption per lOOkm,
Average speed travelled and the expected range in kilometres
offuel remaining.
GLi Falcon Instrument Cluster
IcOO'
Optional Futura and Fairmont cluster assemblies include a

tachometer, Volt Meter and Oi I Pressure Gauges.
General Information
There are two switch cl usters mounted on the steering wheel

column. These switches are lUrrting indicator switchlheadlight dimmer and windscreen wiper and wa<her. AIso where
fitted the cruise control switches are mounted ofrthe steering
wheel.
Futura Option & Fairmont Instrument Cluster
SERVICE OPERATIONS
Fairmont Ghia, Fairlane and LTD instrument cluster has a
tachometer plus a trip computer, and also a car out line
warning system.
INSTRUMENT CLUSTER
Remove
1.From the instrument panel remove the ashtray and the radio
racia plate.
Fairlane and LTD
318
INSTRUMENT, RADIO - TAPE PLA YER & SWITCHES
2. Remove the instrument cluster facia from the instrument

panel.
L.J
the electrical connectors for the instruments. It is therefore

important that the screws and contact surfaces are clean and
free of grease and only the correct brass washers are installed
on all locations. Failure to do so will result in a circuitry
breakdown.
Lflhe Printed Circuit Board (PCB) is damaged, replaccthe
PCB unit.
* Do not touch dial faces.
Dismantle- Futura & Fairmont
I.Remove the tripmetershaftknob by twisting, then from the
back of the assembly remove the screws.
2.Remove Ihe mask and lens assembly by releasing the four
clips on the lower face.
3. From the back of the cluster remove the fou,"crews, then
unplug the small electrical connector.
4. From the front of the cluster remove the warning jewel
mask, then carefully remove the spcedometerfrom the cluster
3. Remove the two upper and two lower retaining screws

from the instrument cluster and partially remove cluster.
housing.
S. From the back of the cluster assembly remove the three
screws.
6.From the front of the cluster assembly remove the tachomeler.

7. From the back of the cluster assembly remove the four
screws/nuts, then withdraw the gauge assembly.
8. Separate the voltmeter and temperature gauges from the
circuil board.
4. Disconnect electrical wiring harness and remove instrument cluster from vehicle.
Dismantle - GLi Falcon

1.
9. From thc back of the cluster assembly remove the four

screwslnuts, then withdraw the gauge assembly.
1O.Rcmovcthetwonuts from between thetwocireuit boards,
then separate the fuel and oil gauges from the circuit board.
I1.From thcbackoftheclustcrassemblyremovethc screws.
12. Remove the warning lanlp circuit board from the cluster
2.Remove the mask and lens assembly by releasing the four

3. From the back of the cluster remove the four screws. then
4. From the front of the cluster remove the warning jewel
mask, then carefully remove the spcedometerfrom the cluster
housing.
5. From the back of cluster assembly remove the three screws.
6.From the front ofthecl usterassembly remove the temperaturegauge.
7. From the back of the cluster assembly remove the three
screws/nuts.
8. From the front of the cluster assembly remove the fuel
gauge.
9.From the back of the cluster assembly remove the screws.
10. Remove the circuit board from the cluster housing.
Assemble - Futura & Fairmont

Assembling is the reverse of the disassembly procedure
taking note of the following:
Some of the screws securing the instruments to the case are
free of grease and only the correct bmss washers arc installed
breakdown.
* If the Printed Circuit Board (PCB) is damaged, replace the
PCB unit.
* Do noltouch dial faces.
Assemble - GLi Falcon

Assembling is the reverse of the disassembly procedure
Dismantle - Fairmont Ghia, Fairlane & LTD

I.Remove the tripmetershaft knob by twisting, then from the
back of the assembly remove the screws.
2.Remove the mask and lens assembly by releasing the four
319
housing.
13.From the back ofthe cluster assembly remove tlle screws.

3. From the back of the cluster a"embly remove the three
lnferia LIght/Dimmer
Knob
screws.
4. From the front of the cluster assembly remove tachometer.

S. From the back of the cluster remove the six screws, then
6. From the front of the cluster remove the speedometer/
outline module from the cluster housing.
7 .From the back of the cluster assembly remove the screws.
9. From the back of the cluster assembly remove the four
screws then from the front of the cluster housing withdraw the
gaugeassembly.
2. Unscrew the ring nut securing the switch to the instrument

panel then remove the ring nut and the switch shroud.
3. Remove the switch from the instrument panel and disconnect the electrical connection.
Assemble - Fairmont Chia, Fairlane & LTD
Assembling is the reverse of the disa"embly procedure

frecof grease and only the correct brass washers are installed
breakdown.
!fthe Printed Circuit Board (PCB) is damaged, replace the
PCB unit.
Do not touch dial faces.
Install
1, Partially instal I instrumentcluster and reconnect electrical
wiring harness.
2.Fully install the instrumentclusterintoposition and tighten
the four retaining screws.
3.lnstall the instrument cluster facia to the instrument panel.
Install
l.Connectelectrical connectors to switches.
2. Replace the switch into position then install the shroud into
place.
3 .lnstall and tighten the retaining lockring to secure the light
switch to the instrument panel then press on the inner and
outer switches.
4. Test operation of lights.
TRIP COMPUTER - Fairmont Ghia, Falrlane
& LTD.
Remove
I.From the instrument panel remove the ashtray ,md theradio

facia plate.
2. Remove the instrument cluster facia from the instrument
panel.
4. To the instrument panel install the radio facia plate ,md

ashtray.
HEADLIGHT SWITCH
Remove
1. Hold the main switch knob and carefully pull knob from the
switch assembly, then remove the outer control switch by
pullingoff.
320
INSTRUMENT, RADIO TAPE PLA YER & SWITCHES
LDisconnect!heelecnical connections for!he nip computer

men remove nip computer from facia.
Inslall
Install
1. Connect electrical connectors and antenna connector to

rear of radio/cassette. Install mdio/cassene.
2. Install the two mounting screws to !he bracket.
3.Replacethetopof!hecentrefaciaensuringtabsaresecured
then replace the lower retaining screws.
4. Test radio/cassette unit.
I. Install the tripcomputerto the facia assembly and recon

nect the elecnical connections.
2.1nstall the instrumcntcluster facia to !he instrument panel.
3. To the instrument panel install the radio facia plate and
ashtray.
RADIO CASSETTE UNIT - Fairmont Ghia,

Fairlane & LTD. (HI range systems)
RADIO - STEREO SYSTEM

There are three main levels of radio/stereo systems fitted to
the vehicles. Thc standard Low range system, !he Mid range
system and Hi range system. The different models are tined
with different level systems with the ba.ic Falcon having Low
rangesystcm through to LTD having Hi range system.
RADIO CASSETTE UNIT - Falcon &
Remove
Remove
I. Remove !he centre facia assembly by removing !he two
lower retaining screws then lift up bottom offacia, releasing
me upper tabs, !hen remove facia.
2. Remove !he two mounting screws from the bracket.
3. Pull radio/ca.sette unit out sufficient! y to access elecnical
connectors at rear of radio/cassette unit.
4. Disconnect elecnical connectors and antenna connector
from rear of radio/cassette.
S. Remove radio/cassene.
321
1. Remove !he centre facia assembly by removing the two

lowcrrctaining screws then lift up bollomoffacia, releasing
the upper tabs, then remove facia.
2. Remove the twO mounting screws from the bracket.
3. Pull radio/cassene unit out sufficiently to access electrical
connectors at rear of radio/cassette unit.
4. Disconnect elecnical connectors and antenna connector
from rear of radio/ca.sene.
5. Remove radio/casselle.
Install
1. Connect electrical connectors and antenna connector to

rcar of radio/casscttc. Install radio/cassette.
2. Install !he two mounting screws to !he bracket.
3.Replace the top of theeentre facia ensuring tabs are secured
!hen replace the lowerretaining screws.
4. Test radio/cassene unit.
INSTRUMENT, RADIO TAPE PLA YER & SWITCHES

AMPLIFIER
Remove
I.Open therearcompru tnl"ntand remove the inner trim panel
from the right hand side rear quarter panel.
2. Remove the screw securing the bottom of the amplifier
bracket 10 the compartment floor.
4. Remove the four nuts securing the unit to the underside of

the rear parcel shelf panel and remove unit from vehicle.
Install
1.Install the compact disc player or sub woofer into position
and tighten the four retaining nuts.
2.Reconnect the electrical connections, then replace the rear
parcel shelf as described in body chapter.
3. Install the rear side speakers into the parcel shelf.
4. Test operation of compact disc player or sub woofer.
FRONT DOOR SPEAKERS
Remove
1. Remove the door trim panel as described in the body
chapter.
2. Remove the gasket for the speaker.
3. Using a drill, drill out the four rivets retaining the speaker
to the inner door panel.
Rivots
3. Carefully using a drill, drill out the rivets securing the

mounting bracket to the rear quarter panel.
4. Disconnectthe electrical connection and removeampli fier
and bracket from vehicle.
S. Remove screws securing the amplifier to mounting bracket
and remove brdcket.
Install
1. Replace the amplifier into the mounting brackct and tighten
Front . - Speaker
retaining screws.
2 Reconnect the electrical connections and replace the

amplifier and bracket into position.
3.Secure the mounting bracket into position using new rivets,
then replace and tighten the lower retaining screw to floor.
4. Replace the rear quarter inner trim panel.
4. Disconnect elcctrical connector and remove speaker.

Install
i.lnstaH the speaker into position and reconnect the electrical
COMPACT DISC PLAYER or SUB WOOFER
2. Using ri vets secure the speakerto the inner door panel and
replace the speaker gasket.
3. Install the door trim panel as described in body chapter.
Remove
1. From the rear parcel shelf remove the two side speakers.
2.Remove the rear parcel shelf as described in body chapter.
3.Disconnect thecleetrical connections for the compact disc
player or sub woofer.
"}
connectlons.
FRONT SPEAKERS
Remove
I. Remove screw securing the extension panel fortheinstru
ment panel, then lift the extension panel.
...... Attaching Nuts
322
2.Disconnect the electrical connection forthe sunload sensor

and remove the extension panel.
3. Remove screws securing the speaker.
4. Pull speaker up to access electrical connector.
5. Disconnect electrical connector and remove speaker.
'!!ShU
I. Replace the speakers into position and reconnect the
2. Replace the screws securing the speakers into position.
3. Connect the electrical connection for the sunload sensor
and replace the extension panel.
4. Install the screws securing the extension panel to the
instrument panel.
4. Remove the speaker assembly from vehicle.

Install
1. Replace the speaker assembly into the vehicle and secure

by riveting into position.
2. Reconnect wiring harness connectors.
3. Replace the rear trim panel to the rear mil gate.
MANUAL ANTENNA
Manual Antenna
REAR SPEAKERS - Sedan
Remove
I. Tag and disconnect wiring harness connectors.
2. Remove speaker retaining nuts and remove speakers.
Rear Speaker
In026
Remove
1. Disconnect antenna cable from cable connecting link
located behind the side trim kick panel.
2. Remove tabs/nuts/screws securing fender inner liner and
remove inner liner.
3. Push antenna down to fully closed position.

4. Disconnect earth lead tenninal by removing retaining
screw.
Install
I. Install speakers into position and tighten retaining nuts.
2. Reconnect wiring harness connectors.

REAR SPEAKERS - S'Wagon
Remove
I. From the rear mil gale remove the trim panel.
2. Tag and disconnect wiring harness connectors.
3. Using a drill, drill out the rivets securing the speaker
mounting bracket to the tail gate.
5. Support antenna and remove the nut attaching antenna

bracket to panel.
6. Remove antenna cable grommet from panel.
7. Withdraw antenna down through bezel and remove,
complete with cable and grommet, refer to diagram.
InstaIlation
Insmllation is the reverse of the removal procedure.
1. Ensure antenna cable is routed correctly.
2. Apply sealant around lower mounting bracket to provide
water tight seaJ.
POWER ANTENNA
Removal
1. Set antenna to fully retracted position.
2. Disconnect antenna cable from cable connecting link.
3. Disconnect leads from main wiring harness and antenna
connector plug, refer to diagram.
4. Remove nuts/screws securing fender inner liner and
remove inner liner.
5. Remove antenna support bracket attaching nut, refer Lo
djagmm .
6. Removeantenna cablc grommet from panel and disconnect

earth lead.
7. Withdraw antenna down through bezel and remove,
complete with cables and grommet.
323
INSTRUMENT, RADIO TAPE PLAYER & SWITCHES
Installation
1. Push the sender unit into position in the transmission, then
tighten the retaining bolt.
2. Reconnect the electrical connections.
Power Antenna
COOLANT TEMPERATURE SENDER

Removal
I. On 8 cylinder engines remove the intake manifold cover.

2. Disconnect electrical connector from temperature gauge
sender unit.
3. Unscrew and remove temperature gauge sender unit. Note

that some coolant will discharge.
Wire
Power Wire and
Connection
--.....
Mounting
/Bracket
Antenna Lead
In040
Installation
Installation is the reverse of the removal procedure taking
note of the following:
1. Ensure cables are routed correctly, refer to diagram.
2. Apply sealant and lower mounting bracket bolt hole to
provide water tight seal.
Installation
1. Screw in the new temperature gauge sender unit.
2 Reconnect electrical connector to temperature gauge
sender unit.
3. On 8 cylinder engines replace the intake manifold cover.
OIL PRESSURE SWITCH
Removal
SENDER UNITS
Oil Pressure Swftch
VEHICLE SPEED SENDER

Removal
Oil Pressure Gauge

Type Unit
~
L Disconnect electrical connector from senderunit.

2. Unscrew the retaining bolt and pull the sender unit out of
the transmission.
Vehicle
Speed
Sender
Unit
Wiring Loom
and Connector
In042
Disconnect electrical connector from oil pressure switch,

Unscrew switch to remove.
InstaJlation
Install unit, tighten and fit electrical connection.
Sender Unit
Attaching
Bracket I
In041
324
FUEL GAUGE SENDER
Removal
Toremove the fuel gauge tank sender unit, the fuel tank does
not have to be emptied below half full.
1. With plastic fuel tanks, loosen the mountingstraps so that
when the fuel gauge sender unit is removed the tank does not
distort thereby making it impossible to replace the new unit.
2,Remove the cover from the floorpan allowing access to the
top of the tank.
6. Remove gauge senderunit and seal, lifting the fuel pump

and tilter from swirl pot, then immediately replace the
retaining lock ring to the tank.
* Care should be exercised during removal of the unit from
the tank, so as not to damage the ftlter or the float amI and
float.
Fuel
.... Tahk
Fuel
Tank
Cover-
.--
..,..
-.-~
""-
l,ioe>
3. Disconnect the sending unit wire from the mounting flange

and the fuel pump wires at the connection (not at flange).
4. Disconnect fuel line and vapour line from the unit.
5. Remove the clamp forthe band then remove the retaining
ring by unscrewing with special tool.
Fuel Sender Un~ Retaining

Ring Release Tool
For Dimensions
See Following Diagram
IcOOO
Fuel Sender Retaining Ring Tool Dimentions
CENTRE CONSOLE SWITCHES

_ _ _0.5 Inm
./
.sq.u ....
Removal
1. Unscrew the gear shift knob on manual transmissions, 'T'
Bar
2t4mm
Installation
I. Clean mating surfaces of sender unit and tank.
2. Install new seal to sender unit.
3. Replace gauge senderunit, positioning the fuel pump and
filter into the swirl pot.
4. Install and tighten the retaining ring by unscrewing with
special tool.
S, Tighten sender unit retaining ring to specification.
Early Model Retaining Ring 40 Nm.
Late Models tighten till the lugs contact the body of the
fuel tank.
6, [nstall the clamp and tighten to specification.
Band Clamp ........................................................ 3 Nm.
7. Reconnect fuel line and vapour line to the unit.
8.Reconnectthe sending unit wire to the mounting f1angeand
the fuel pump wires at the connection.
9 .Replace the cover to the floorpan allowing access to the top
of the tank.
10. With plastic fuel tanks, tighten fuel tank mountingstraps
if necessary, fill tank with fuel and check for leaks around
sender unit.
Bar for automatic transmissions.
I
"""I eo mm
2. Lift the cover forthe shift lever, then remove the two screws
securing the switch panel.
mm
132mm
IcOOOa
325
Install
1. Install hom.
2. Tighten bolt to specified torque.
Horn Mounting Bolt Torque Specification .... 20-27 Nm
3. Install front bumper assembly a. previously described.

HORN ACTUATOR
The hom actuator is located in thecentreofthe steering wheel.

To sound the hom the centre of the steering wheel is pushed
in towards the steering column.
Remove
remove
electrical connections and remove switch assembly from

console.
Install
I.Reconnect the electrical connections for the switch assembly. then install switch assembly into centre console.
2. Install and tighten the two retaining screws fortheswitch
assembly.
3.1 nstall the cover for the shi ft lever. and replace the gear shift
knob or "1" bar.
BRAKE FAILURE SWITCH
Forbmke fai lure waming switch information. refeno 'Brakes'

in this manual.
HORN ASSEMBLY
Remove
Remove the hom pad which isa push in fit. sometimes it may
not pull off ea,ily. Insert a small screw driver in around the
edge of the hom pad and lightly lever it out. Li ft the pad from
the steering wheel disconnecting the electrical connections.
Install
Holding the pad near the steering wheel connect the electrical
connections.
Replace the hom pad which is a push in fit. it is a neat fit.
SPECIFICATIONS
Lamp Bulbs
Base Type
Rating (Watt)
Instrument and switch ............. 3 - 4 (depending on model)

All warning bulbs ......................................................... 3
Cigar light illumination ........ ..... ... ....... .......................... 2
1. Remove front bumper assembly as previously described.

2. Disconnect electrical connector(s) from hom(s). Unserew
attaching bolt and remove horn(s).
Retaining Botts
Current Draw Test
I. Remove hom.
2. Connect a 0-1 0 amp ammeter in series with the hom and
3. Check the current draw of the hom. the ammeter should
register between 5-7.2 amps.
Note: If reading is outside specifications replace hom.
326
BODY ELECTRONICS MODULE

&SMARTLOCK
Subject
Page
* remote entery
* central door lock switch
Body Electronics Module ........................................ 327

Description & Operation ........................................... 327
Component Location .................... ............................. 327
Component Replacement ........................................... 327
Smartlock & Keyless Entry System 328
Description and Operation ........................................ 328
Programing and System Overrides ............................. 329
Component Replacement ........................................... 329
* diagnostic adilities
* battery saver (EL only)
MidSeries Additions
* dome lamp delay
* windscreen wash
* power window operation (key off)
* speed sensitive intermittent wipe (ELonly)
High Series Additions
* antenna
Servicing and Diagnosis .............. ........ .. ..... ............... 329
- direction control
- height
* cluster
- LCD illumination
-graphics illumination
- brightness for day/night
The BEM fitted to the EF & EL arc of two diffcrent
Body Electronics Module

(BEM)
The Body Electronics Module (BEM) is a control unit for a
variety of different electrical components throughout the
vehicle, this includes the smart lock system.
constnlctions, they are both mounted in the same position and

arc removed in the same manner, they are located behind the
instrument cluster finishing panel, on the left side of the
sleeringcoJumn.
The low and mid series modules have two wiring loom
connectors and the high series has three wiring loom conneclors.
Replacement
1. Release the instrument cluster finishing panel and detach
the wiring loom from the module.
,J
I~ ,
The components controled by the BEM for the different
series vehicles is listed below.
Low Series Operations
*wiper control after wash
*dome lamp operation (door unlock)
* dome lamp (door open)
*automatic relock
*tailgate lock/unlock
*boot unlock
*doorlock/unlock
intermittent wipe
*heated backlight
327
2. Loosen the module retaining screws and allow the module

to be withdrawn from the vehicle.
3. Fit and retain the module into position, then reconnect the
wiring loom and replace the instrument finishing panel.
BODY ELECTRONICS MODULE & SMART LOCK
Smart Lock & Keyless

Entry System
Description & Operation
The 'Smart Lock' system design is two function combined

to provide the added security of an engine immobilization
system, as well as remote entry to the vehicle through the
operators keypad. This enables the doors and boot/tad
gate to be unlocked via the remote keypad to provide easy
access for the operator,
The immobilization system over rides a numberof di fferent operating systems or the vehicle.
Components
Smart Lock components:Control Module
Keypads (up to 4)
Boot/tailgate release
Dash warning light
Central locking system
SmartLock linked components:Starting system
Central locking system
Boot/tai Igate release
Hazard lights
Dome light control (high series)
Vehicles ECU
SmartLock Warning Light
The warning light is positioned in the lower left comerofthe

dash. It is used to indicate the systems state of operation, and
provides code information when system fault is detected,
described later in diagnosis.
Electronic Ignition Lock
__ Smartlock
Ignition
receivers the determine the position of the ignition lock and

correct installation, when it's turned to the start position the
ignition lock transmits threccodes from theE' PROM, which
are received by the SmartLock module.
Remote Entry System & Keypads
Vehicle Doors
Button
Immobilization System
The SmartLock Module acts in conjunction with the

electronic ignition lock. The electronic ignition lock has
stored codes incorporated in an E'PROM. With ignition in
the on position the SmartLock module requests three
codes to be provided from ignition lock, when two correct
codes are given the immobilization system is disengage.
The SmartLock module is also linked to the ECU to
overrides the fuel injectors, these also need the correct
eodes to return to normal operation to prevent the vehicle
from being hot wired.
SmartLock Module
The module is a combination of, printed circuit board,

microprocessor, keypads and E' PROM code storer. The
E' PROM is not a power reliant component, so codes are not
lost when battery problems arise.
When the vehicle ignition system is switched to the off
positiontheSmartLockmoduleautomaticallypreformsaself
check. The following time the vehicles ignition is turned on
any problems will be displayed by the SmartLock warning
light, described later in diagnosis.
The module is located next to the steering column, underthe
dash on the left hand side.
SMLOO2
Remote entry allows the vehicle operator easy access to

unlock and lock the all vehicle's doors at one time without
using the key, it also operates the interior light on the high
series when unlocking.
The operator uses a keypad which transmits a code to the
SmartLock module, this operates thedoor lock regulators, It
will not operate while the ignition is in the on position. The
SmartLock is able to be programmed for up to four keypads.
The keypads battery has a life of approximately 12 months.
The boot/tailgate release/un lock is also operated from the key
pad, although the tailgate is unable to be relocked by the
keypad, the key will need to be used. When the key pad IS
operated the hazard lights will nash to indicate the operation
of the SmartLock system.
Central Door Lock/Unlock & BooVTailgate
Switches
The central door lock/unlock button located on the left dash

panel enables all of the doors to be operated from within the
vehicle. The boot switch located on the right dash panel
328
BODY ELECTRONICS MODULE & SMART LOCK
releases the lock, on the slwagons located in the same position

unlocks and locks the rear tail gate.
....,.....
The boot/tailgate button also is able to enter the SmartLock

module to a learn mode, this is used when entering anew code
from a keypad, described later in this section,
SmartLock Operation Modes
Nonnal Operation Mode

Codes will be veritied and the warning light will stay on for
a period of 3 seconds then switch off and remain off, the
vehicle can be started.
Anned Operation Mode
In the armed mode with the key out of the ignition the warning
light will stay on for 0.1 seconds then switch off for 1.1
seconds, this will keep repeating unti Ithe ignition is switched
on again. The SmartLock module is waiting for a keypad
signal.
Inunobilized State
The system will enter this mode if the SmartLock module
receives two or more wrong codes with ignition switched to
run. The engine will not start or tum over in this state, if
during transferring the codes there was a corruption the
vehicle should start on the second try. The following procedurecan be followed ifproblem still persists.
need to be repeated.
Normal Mode Down loading
When changing the SmartLock module or electronic lock
assembly, the codes will need to be down loaded before the
vehicle will return to normal operations. Use the following
procedures :(a) With all accessories switched off, tum the ignition to the
on position and leave for30mins until the door locks operate
through two cycles and the SmartLock light goes out.
(b) Switch the ignition to off and leave for 30sec, then check
for normal operation by starting the vehicle.
Keypad Down Loading
To down load keypad codes when adding new keypads or if
the SmartLock system has had components changed and the
old keypad codes need to be down loaded, use the following
procedure.
(a) With vehicle switched off tum the ignition key to accessories, then press boot release button (mounted in the dash)
three times quickly to place SmartLockmodule in learn mode.
(b) Operate oneof the buttons on each of the keypads that are
being used on the vehicle, each time a code is entered the door
locks will operate two times to confirm new entered code.
(c) Once all keypads have been entered into the system, exit
the learn mode by switching the ignition to the off or on
position, then check the function of the keypads.
Component Replacement
Ignition Lock Assembly

I. Withdmwthesteeringeolumncovers, then using pin punch
and hammer, work the shear head bolts from the ignition lock
assembly.
2. Withdraw the lock from thesteeringcolullUl and detach the
wiring loom from the assembly , Conncctthe new assemblies
wiring loom.
3. Fit the lock assembly to the steering column installing new

shear head bolts, tighten until the heads brake off.
4. Fit the steering column shrouds into position, tllCll follow
the Normal down loading mode procedures.
SmartLockModuie
I. Withdraw the hand brake assembly cover from the vehicle
and detach the modules wiring loom.
2. Withdraw the retaining bolt and module from above the
hand brake assembly on the centre finishing panel, then refit
Programming And System Overrides
Starting I n Immobilized State

A1laccessoriesswitched to the of position and the ignition in
the on position, the immobilization code will be !lashing.
Leave the ignition on for 30 mins, this will allow the
SmartLock module to re-Iearn the codes for the system.
When the operation is complete, a positive response is the
door locks will run through two operations and the vehicle
will operate normally. A negative response will be the
waming light is constantly bedisplayed or stay off, the vehicle
will still be able to be started.
Note :-(a) Electronic lock faulty the vehicles ignition is able
to be switched totheoffposition forno longer than 30sec and
restart without having to wait for another 30mins.
(b) The courtesy lamp fuse removed the vehicle will still not
be able to be started and the starter motor wi II not tum over.
(c) SmartLock module failure the engine will start immediately from the on position, but not if tumed back to the
accessories or off position. If switched to either of these
positions the Starting An Immobilized Vehicle operation will
the new module in reverse and retain in place.
3. Fitthe hand brake assembly coverthen follow the Normal

down loading mode procedures.
Servicing And Diagnosis
Reading Error Codes

Once repair have been finished the ignition will need to be
switched off then to on and off again to operate the selftest
mode. Ifproblems still arise the system will display the most
important code only. System code chart listed below.
329
LIGHTS, SWITCHES & BATTERY

SYSTEMS
Subject
Page
Subject
Page
Battery .................................................................... 331
Install ....................................................................... 335
General Tnfonnation ................................................. . 331

Periodic Maintenance ................................................ 33 I
Testing Battery Elcctrolyte(Acid) .............................. 33 I
Usingthc Hydrometer ............................................... 33 I
Test Result Indications .............................................. 33 I
Rear Lamp Assembly - Station Wagon ................... 335
Replace .......................................................... .. ........ 335

Remove ... ....... ....... ...... ..... ... ....... ................ ....... ... .... 336
Install ....................................................................... 336
Rear Lamp Assembly - Utility & Van ..................... 336
Replace .................................................. ,'" .............. 336
Battery Charging .................................................. ... 332

Fast Charging ............................... " ......................... 332
Slow Charging ......................................................... 332
Li~I1t.~
Interior Dome Lamp ............................................... 336

Replace .........,.,', ...................... ".,"",., ............. ,",.," 336
Centre Reading Lanlps ........................................... 336
Repl ace ,.,"",.,"", ................. " .................................. 336
Rear Readin~ Lamps ............................................. 337
................................................................... 33~
HeadlightGlobeReplacement ............ ........ ............... 332

Replace .................................................................... 33~
Adjust Headlight Pattern ........................................... 332
Replace .. ,.,",., ................................................ ,......... 337

Console Rear Courtesy Lamp ................................. 337
Replace ..... ,., ............................................................ 337
Fronl Footwell Courtesy I.amp ............................... 337
Replace ................................................... ,.. .... ,......... 337
RearCompartmenlLamp ...................................... 337
Replace ................ ,................................................... 337
AdjuslJnent .,.,., ............... ,.................................. ....... 333

Parking Lamp Bulb ................................................ 333
Replace .................................................................... 333
Front Turn Signal Lamp Bulb ................................ 333
Replace .................................................................... 333
HeadlampAssemhly ............................................... 333
Remove ..................................... " ................. , ........... 333
Install ...................... , ....................... ,., ... ............... ... . 333
Ignit.ion Lock Light ................................................. 337

Replace .... ,...... ,.................. ,., ............................... .... 337
Headlamp Assemhly - XR Series ............................ 333
Gear Seleclor Light - Column Auto ........................ 337

Replace ,.,., ..,.,.,., ............... ... ,................................... 337
Gear Selector Light - Floor Shift Auto ................... 338
Replace .. ,...................................................... ........... 338
Renlove .................. "...................... """ ......... ",, ...... . 333

1nstall ...... ,..................... ,....... ..................... ... ........... 334
Front Turningindicator Light Asscmbly ................ 334
Rcmove .................................................. .................. 334
Install .................. ...... ............ " ............................ " ... 334

Licence Plale I~amp -Sedan/Fairlanc/LTO ............. 334
Replace .................................................................... 334
Licence Plate Lamp - Station Wagon ...................... 334
Replace .............................................. ............. ......... 334
Back-up, Stop and Tail and Turn Signal Lamp GlobeFaJcon ...................................................................... 334
Replace .................................................... ................ 334
Rear Lamp Assembly - Sedan ................................. 335
RerTl()ve ............................... ... .................................. 335
Install .............. ........ ................ ................................. 335
Back-up, Stop and Tail and Turn Signal Lamp Globe.FairlaneIL.TD .......................................................... 335
Replace ............... ...... ........... ... ................................. 335
Rear Lamp Assembly - Fairlane & LTD ................ 335
RCTTlOve .................................................................... 335
Install ................... .................... ................................ 335
Boot Lid Mounted ................................................... 335
ReITlOve ............... ................. .................................... 335
Internal Glove Box Ligl1t ........................................ 338

Replace ... ....................... ...............................,.......... 338
lnteria Lamp Switch ............................................... 338
Stop Lamp Switch ................................................... 338
Replace ....... ..................... ........................................ 338
Back-up Lanlp Switcl1 ............................................ 338
Headlamp and Turn Signal Control Lever ............. 338
RelllOve ....... ........ ....... ...... ........................................ 338
Install ........ ..................... .......................................... 338

WindscrL'en Wiper & Washer Switch ................... 338
Remove ................................... " ............................. " 338

InstaJl ....................................................................... 339
Head lJght Switches ............................................... 339
Renlove .................................................................... 339
Install .... ...... .......... ........... ........... ...... .. ..... ................ 339
Turn Signal and Hv.ard Flasher Unit ..................... 339
Replace .......... ... .... .............. ......... .. .......................... 339

Instrument Cluster and Warning Lamp ................. 339
BulbS.,eci.fications .................................................. 339
330
LIGHTS SWITCHES & BA TTERY SYSTEMS
BATTERY
Slon.

GENERAL INFORMATION
Battery acid is highJy corrosive which may on contact, cause

personal injury or damage paint surfaces. Anyspillage must
be immediately diluted and flushed away with clean water.
Thebatteryelectrolyte shouJdbe maintained at recommended
level by topping up with dislilled water.
Clean the battery terminal and the insideofthe cable terminal
using a suitable tool.
PERIODIC MAINTENANCE
1. Protect paint finish using suitable covers.

2. Disconnect battery cables at battery (negative fIISt).
3. Remove battery hold down clamp andremove battery from
vehicle.
4. inspect battery carrier for acid damage. If necessary
remove corrosion by using a solution of bicarbonate of soda
in warm water and scrubbing area with a stiff brush, taking
care to avoid spreading corrosion residue, and flush area with
clean water. Damaged areas should be repainted to avoid
further corrosion.
5. Clean battcry cover by same method.
Do not allow any cleaning solution or water to enter battery
cells as this will dilute electrolyte.
6. Check battery cables for damage and fraying and replace
if necessary.
7. Clean Battery tenninals. If necessary remove corrosion by
using a solution of bicarbonate of soda in warm water and
scrubbing area with a stitf brush, taking care to avoid
spreading corrosion residue, and flush area with clean water.
A hydrometershouJd be used to determine the specific gravity

ofbattery electrolyte. The reading obtained indicates amount
of unused sulphuric acid remaining in electrolyte and stateof
charge of battery.
The reading obtained will vary in relation to the temperature
gravity rises.
1. Liquid level of battery cell should be at normal height and
electrolyte should be thoroughly ntixed with any battery
times to bring temperature of hydrometer float to that of the
acid in the cell.
3. Drawsufficientelectrolyte into hydrometer barrel with the
pressure bulb fully expanded to lift float so that it does not
position.
_ - - - - - - -HYdrometer
_ - - - - Battery

Electrolyte specific gravity
Battery Charge Level.
1.240 to 1.260
100%
1.2 I0 to 1.240
75%
1.180 to 1.210
50%
Below 1.130
Completely discharged.
A battery should be charged if the specific gravity is less than
1.210.
lfthere is more than 0.25 specific gravity variation between
If battery charge is low and battery is serviceable. check
altemator operation and all electrical connections.
8. Check battery case, cover and vents for damage.

9. Install battery and hold down clamp. Do not over tighten
hold down clamp as thi s could crack case.
10. Connect battery cables and tighten to specifications.
Ensure battery polarity is not reversed.
II. Coat terminals with light ntineral grease to avoid corro-
331
BATTERY CHARGING

gas mixture Jonns beneath the cover oj each cell.
* Do not smoke near batteries on charge or which have
recently been charged.
* Do not break live circuit atterminals of batteries on charge.
A spark will occur where the live circuit is broken. Keep all
open flames away from battery.
NB: Fast charging will provide sufficient charge after onc
LIGHTS
HEADLIGHT GLOBE REPLACEMENT
Replacement
1. Remove dust cap from rear of head lamp assembly.
FAST CHARGING
Fast charging a battery in the vehicle is not recommended,

however if this procedure is uscd it is most importantthat the
battery isdisconnected.
NB: A battery will be irretrievably damaged if following
precautions are not taken.
1. Battery clectrolyte temperature must NEVER exceed
45"C.
If this temperature is reached, battery should be cooled by
reducing charging rate or remove battery from circuit.
2. As batteries approach full charge electrolyte in each cell
will begin to gas or bubble. Excessive gassing must not be
allowed.
3. Do not fast charge longer than one hour. lfbatterydoes not
show a significant change in specific graviry after one hour
of "FAST' charge, the slow charge method should be used.
2. Disconncctelcctrical connection pull outlarnp socket from

reflector, by releasing retaining clip.
3. Remove bulb from retainer then replace bulb with one of
same wattage.
SLOW CHARGING
Many discharged batteries can be brought back to good

condition by slow charging; especially batteries that are
sulphated. Battery should be tested with a hydrometer and
a record kept of the readings taken at regular intervals
throughout the charge. When a cell has a specific gravity
reading that is 0.25 or more below other cells, that cell is
faulty and battery should be replaced.
Safe slow charging rates can be calculated by allowing one
ampere per positive plate per cell i.e. 4 amperes for a 9 plate
battery and 5 amperes for an 11 plate battery.
The average time required to charge a battery by the low
charge method at normal rates is from 12 to 16 hours,
however. when a battery continues to show an increase in
specific graviry, battery charge should be continued even if it
takes 24 hours or more. Watch the temperature of batteries
carefully and if tempemture of anyone of them reaches43"C,
lower the charging rate.
Battery will be fully charged when it is gassing freely and
when there is no further rise in specific gravity after three
successive readings taken at hourly intervals. Make sure
hydrometerreadings are corrected fortempemture.
Many batteries can be brought back to a useful condition by
slowchargingathalfthenormalchargingratefrom60to 100
hours. This long charging cycle is necessary to reconvert
crystalline lead sulphate in to active materials.
4. Install socket, dust cap and check lamp operation.

CA UTION: Never touch bulb with bare hands while they
are illumin1lted, or immediately after turning them off.
Never hold halogen bulb with bare hands, dirty gloves, etc.,
or premature bulb Jailure will occur. IJthe glass surface is
dirty, be sure /0 clean it with alcohol, and install after air
drying thoroughly.
ADJUST HEADLIGHT PATTERN
Always adjust headlight pattern according to the state laws

and regulations.
Before adjusting headlight take note of the following procedure:
1. Ensure tyres are inflated correctly.
2, Clean headlight lenses.

3, Check the vehicle is positioned on a level floor.
4. Bounce vehicle to ensure vehicle is at normal height.
5. Place sufficient weight in vehicle to simulate full load
conditions (I litre of fuel = 0.72 kg).
332
ADJUSTMENT
Adjusting screws are located at rearofheadlight assembly in
enginecompartment under bonnet.
Adjustas follows:
OUTER LlGHT
Adjust vertically and horizontally by turning screw.
lNNERLlGHT
Adjust vertically and horizontally by turning screw.
USlNG A WALL
1. Manufacture an aiming target on a light coloured wall.
2. With vehicle up against wall, align vehiclecenlre line with
centre line of screen.
3. With vehicle up against wall, mark head light height and
centre of light lense on wall.
4. Place vehicle 3.5 meters in front of screen ensuring the
vehicle is aligned with vehicle centre line mark on screen.
5. Switch headlights onto low beam and aim outer lights.
a) Adjust inboard adjuster to achieve correct venical beam
height.
b) Adjust outboard adjuster to centralize beam.
6. Switch headlights onto high beam, mask outer lights and
aim inner lights.
a) Adjust inboard adjuster to achieve cOllect vertical beam
height
b) Adjust outboard adjuster to centralize beam.
2. Remove bulb from bayonet type socket and replace.

3. Install socket and test operation.
HEADLAMPASSEMBLY
Remove
1. Depress locking tab on headlamp wiring harness connectors and separate connectors from the headlight assembly.
2. Remove screws securing lampassembly to front end panel.
PARKING LAMP BULB

Replace
1. Remove dust cap from rear of headlamp assembly.
2. Disconnect electrical connection pull out park lamp socket

from reflector, by releasing retaining clip.
3. Remove bulb from retainer then replace bulb with one of
same wattage.
4. Install socket, dust cap and check parking lamp operation.
ImtaU
Installation is the reverse of removal procedures noting the
following points:
I.Ensure the locating peg on the outside of the light is seated
properly and the locating pads are against the flange of the
front fender.
2. Tighten the headlamp assembly mounting screws.
3. Check operation ofheadJamp and tum signal lamps.
4. Check headlamp aim.
FRONT TURN SIGNAL LAMP BULB
HEADLAMP ASSEMBLY - XR Series
Replace
1. Twist to release bulb socket from behind tum signal lamp
aso;embly.
Remove
1. Withdraw the front bumper bar from the vehicle.
2. Detach the head light wiring loom from the head light
a<;.<embly.
3. Release the head light assembly mounting bracket from the
vehicle chassis and withdraw the assembly from the vehicle.
333
lnstaU
I. Fit the head light assembly to the vehicles chassis and
secure with the retaining bolts.

2. Fit the bumper barto position and secure tensioning bolts
to correct torque.
3. Attach the head light wiring loom to the headlight assembly.
4. Check the operation of the lights.
FRONT TURNING INDICATOR LIGHT
ASSEMBLY
Remove
lLift bonnet to gain access to the front bumperto body trim
panel and release the retaining clips.
check the operation of the light.

LICENCE PLATE LAMP - Station Wagon
Bulb Replacement
I. Remove the number plate then remove the centre screw
securing lampassembly.
2. Open rear compartment and remove the rear trim panel.
3. Remove the remaining securing screws for the lamp
assembly and remove the lamp a.sembly from the vehicle.
2. Remove retaining screws which holds the light in place.
3. Slide the light assembly from the front fender.
4. Remove the wiring connector from the light.
Install
1. Connect the wiring connector.
2. Slide the light into place.
3. Fasten the light retaining screws into place.
Tall Gat. _ - - - Trim
--
with one
5. Install lamp assembly into vehicle and replace the four
inner retaining screws.
6. Replace rear trim panel and replace the outer centre
retaining screw.
7. Replace the number plate into position and then check lamp
operation.
4. Test operation of light and close bonnet.
BACK-UP, STOP, TAIL AND TURN SIGNAL

LAMP GLOBE - Falcon Sedan
LICENCE PLATE LAMP

- Sedans - Fairlane & LTD.
Rcplac-e
I. Release the two retaining screws from the rearlight assembly, then lift the light assembly from the vehicle.
2. Depress tab securing bulb holder and remove bulb holder.
3. Insert new bulb into holder and refit holder into rear lamp
housing.
4. Check lamp operation.
Replace
1. Lift the number plate light assembly from the rear bumper
bar using a tin screw driver.
2. Withdraw the globe holder from the assembly, by twisting
the holder and withdrawing.
3. Remove the globe and change for a new one, then refit the
globe holder to the assembly.
4. Push the assembly back into the rear bumper bar, then
334
REAR LAMP ASSEMBL V - Falcon Sedan
Remove
L Open rear compartment and disconnect the tail light
electrical connection, then press the rubber gromet through.
2. Remove the two rear light assembly retaining screws and
partially remove light a"embly in the outward side direction.
3. Depress tabs securing bu Ib holder and remove bulb holder.
4. Fully remove light a"embly from rear of verucle.
5. Check condition of rubber seal and replace as necessary.
3. Depress bulb and rotate to remove from socket.

4. Insert new bulb into socket and refit socket into rear lamp
housing.

REVERSE LAMP ASSEMBL V - Falrlane &
LTD.
Remove
t. From inside boot, remove the trim panel from the inside of
the boot lid.
Install
Installation is reverse of removal procedures, noting the

following points:
I. Tighten lamp housing screws.
STOP, TAIL AND TURN SIGNAL LAMP
GLOBES - fairlane & LTD.
Replace
I. From inside the rear compartment remove eitherthe rear
comer trim panels or the boot lid inner trim panel.
2. From inside boot, release the light assembl y retaining nut,
then withdraw the two outer retaining screws, pull the light
assembly from the vehicle.
~=-----:-:
2. Depress tabs sccuring bul b holder and remove bulb holder.

3. Remove the nine nuts securing lamp housing to rear end
panel and remove lamp housing.
4. Check coodition of rubber seal and replace a< necessary.
Install
following points:
1. Tighten lamp housing nuts.
REAR LAMP ASSEMBL V-Station Wagon
Globe Repla~'emen(
1. From rear compartment, remove the trim panels from the
rear quart,ers.
2. Twist the bulb holders to remove the holders from the rear
of the light assembly.
3. Remove bulb and replace with one of same wanage.
4. Install bulb holders and replace trim panel into position .
5. Check rear lamp operation.
Remove
335
--r
Tnm
light
Assembly

Install
Installation of the rear lamp a<sembly is the reverse of
removal procedures.
Check rear lamp operation.
INTERIOR DOME LAMPS
Replace globe
1. Unclip the lens from the light by slightly squa.hing the lens
and pulling off.
Vehicles Hood _-:'~----'~
Lining
1. From rearcompartmcnt, remove the trim panels from the

rear quarters.
2. Twistthe bulb holders to remove the holders fTom the rear
of the light assembly.
3. Remove the three nuts securing lamp housing to rear end
panel and remove lamp housing.
4. Check condition of rubber seal and replace a' necessary.
Install
followingpoinl':
1. Tighten lamp housing nuts.
2. Check rear lamp opemlion.
REAR LAMP ASSEMBLY - Utility & Van.
Replace
1. Remove four screws retaining lamp housing to rear end
panel, and remove lamp housing.
2 .Remove bulb sockets by depressing lever and turning bulb
socket.
3. Depress bulb and rotate to remove from socket.
4. Insert new bulb into socket and install socket into lamp
housing
S. Replace light assembly
2. Remove the globe and replace with one of same wattage.

3. Replace lens by pushing in, ensuring the lens clips into
position properly.
CENTRE READING LAMPS - Fairmont
Ghia, Falrlane & LTD.
Replace globe
1. Unclipthe lens from the light by slightly squashing the lens
and pulling off.
2. Remove the globe by twi sti ng and replace with one of same
wattage.
Nole: Use a cloth to remove the bulb to preventtouchif/g the
globe.
3. Replace lens by pushing in, ensuring the lens clips into
position properly.
336

Vehicles Hood _ _ _ _ _ _ _ _
'
Dash
-:--'!r--"::::::j~::'
Assembly
2. Replace globe with one of same wattage.

3. Install bulb holder into position and twist to lock.
REAR READING LAMPS - Fairmont Ghia,

Fairlane & LTD.
Replace globe
I. Unclip the lamp from the mounting plate.
2.Remove the globe and replace with one of <arne wattage.
Note: Use a cloth Ia remove the bulb Ia prevent lauching the
globe.
3.Replace light assembly to the mounting plate, ensuring the
lens clips into position properly.
REAR COMPARTMENT LAMP
Replace globe
1.Carefully use a small flat blade screwdriver, prise the light
assembly from the body panel in the rear compartment.
2. Remove the globe and replace with one of same wattage.
3. Replace the light assembly into position, ensuring it is
secured correctly.
CONSOLE REAR COURTESY LAMPS Fairmont Ghla, Falrlane & LTD.
IGNITION LOCK LIGHT
Replaceglobe
I.From therearoftheconsoleremove the fi I lcrpanel orwhere
fitted remove the remote control facia.
2. Twist the bulb holder and remove from the console then
replace the bulb with one of same wattage.
3. Replace bulb holder into position twisting to lock into
position.
4. Replace the rear filler panel or remote control facia.
Replace globe
1. Remove the lower shroud cover from the steeringcolumn
a. described in the steering chapter.
2. Remove the bulb holder which is retained by a "c" clip.
3. Remove the bulb from the holder and replace with one of
same wattage.
4.Install bulb holder and thenreplacesteeringcolumn lower
shroud panel as described in steering chapter.
FRONT FOOTWELL COURTESY LIGHT Fairmont Ghia, Fairlane & LTD.
GEAR SELECTOR LIGHT - Column Auto.
RepIace globe
I.From the lower instrument panel twist the bulb holder and
remove.
337
Replace globe
1. Remove the upper and lower shrouds from the steering
column as described in steering chapter.
2. Remove bulb and replace with one of same wattage.
3. Replace upper and lower shroud covers as described in
steering chapter.
GEAR SELECTOR LIGHT - Floor shift Auto
Replace globe
I.Remove the control cover from the centre of the console by
carefully prising out.
2. Remove the bulb holder and remove the bulb from the bulb
holder.
3. Install new bulb of same wattage into bulb holder.
4. Install bulb holder and replace the control cover into
position.
Disconnect the wiring connector at the switch, unscrew the

switch from the bracket and remove.
To install the switch screw the switch into position, and adjust
the switch sothe pedal will activate the switchafterthe pedal
free travel has been taken up.
Reconnect the wiring connector.
Test stop light operation.
BACK-UP LAMP SWITCH
ManWli Transmission
GLOVE BOX INTERNAL LIGHT & SWITCH
Replace globe
I. Gently and carefully prise the switch and globe assembly
from the front ofthe glove box.
2 Remove the light bulb from the switch assembly and
replace with one of same wattage.
3. Install light switch assembly into glove box assembly.
INTERIOR LAMP SWITCH
The back-up lampswitch for vehicles equipped with manual

transmission is nonadjustable. The diagram illustrates the
position of the switch on the transmission.
Automatic Transmission
The back-up lampswitch (incorporated with the neutral start
switch) for vehicles equipped with automatic transmission, is
located at the selector lever. Referto ' Automatic Transmission' in this manual.
This photograph illustrates the installation of tile interior

lamp switch, fitted on all doors, on all models.
STOP LAMP SWITCH
Replace
The switch is located under the dash on the brake pedal
mounting bracket
HEADLAMP AND TURN SIGNAL CONTROL

LEVER
Remove
I. Remove steering wheel, steeringcolurnn lower and upper
covers. Refer to 'Steering Chapter' in this manual.
2. Disconnect the two electrical connections then release the
clamp at the rear of the switch assembly.
3. Remove the switch ""embly from the rear steering
column.
lnstall
I. Install contfolleverand switch assembly into position and
tighten retainingciamp.
2. Reconnect the two electrical connectors.
3. Replace steering column upper and lower covers and the
steering wheel. Referto Steering in this manual.
4. Test operation of wipers and washers.
WINDSCREEN WIPER & WASHER SWITCH
Remove
I. Remove steering wheel. steering column lower and upper
338
LIGHTS SWITCHES & SA TTERY SYSTEMS
INSTRUMENT CLUSTER AND WARNING

LAMP CLUSTER ILLUMINATION
covers. Refer to 'Steering Chapter' in this manual.

2,Disconnect the two electrical connections then release the
clamp at the rear of the switch assembly.
3, Remove the switch assembly from the rear steering
column.
Instrument illumination and warning lamp bulbs are a push

fit into sockets which twist.
Imtall
SPECIFICATIONS
1. Install control lever and switch assembly into posi tion and
tighten retaining clamp.
2. Reconnect the two electrical connectors.
3. Replace steering column upper and lower covers and the
steering wheel. Refer to 'Steering' in this manual.
4. Test operation of wipers and washers.
HEADLIGHT SWITCH
Remove
l.Hold the main switch knob and carefully pull knob from the
switch assembly, then remove the outer control switch by
pulling off.
2. Unscrew the ring nut securing the switch to the instrument
panel the remove the ring nut and the switch shroud.
3.Remove the switch from the instrument panel and disconnect the electrical connection.
Install
I,Connect electrical connectors to switches.
2. Replace the switch into position then install the shroud into
place.
3.lnstalland tighten the retaining lock ring to secure the light
switch to the instrument panel then press on the inner and
outer switches.
4. Test operation of lights.
BULB SPECIFICATIONS
Watt
Headlamps
Falcon - H4/Hi/Lo beam ........................................ 60/55
FairlanefLTO
- H Jllow beam ............................................................ 55
- HIlHi beam .............................................................. 55
Driving lamp - Falcon - H3 ......................................... 55
Parking (Front) ........................... ........ .......................... 5
Turn Signal ................................................................ 21
Reverse I...amp ............................................................ 21
Stop and Tail Lamp ................................................. 2115
High Mount Stop Lamp .............................................. 21
Number Plale Lamp ...................................................... 5
Luggage Compartment ................................................ 10
Interior dome lamps .................................................... 10
Interior map lamp ......................................................... 5
Rear passanger lamp ..................................................... 5
Glove Box. .................................................................... 4
Tmnsmission shi fler ...................................................... 2
InstnunentPanel
Falcon GL .......................................................... 3 @ 1.2
Falcon ..s.. Pack & Fairmont ............................. .4 @ 1.2
Fairmont Ghia, Fairlane & LTO .......................... 4 @ 3.0
Warning Lamps
lamps on, low radiator, low oil ...................................... 3
high beam, low fuel, high temp ...................................... 3
park brake, brake fail, LH & RH turn ............................ 3
Low washer, check suspention ....................................... 3
Alternator ..................................................................... 2
Speedometer light .................................. Xenon bulb 5 W
Door ajar warning .................................. Xenon bulb 5 W
TURN SIGNAL AND HAZARD FLASHER

UNIT
Replace
The location and installation of the turn signal and hawrd
flasher unit.
Access to the flasher unit is gained by turning the fasteners
(on the instrument panel right hand lower trim) 90 degrees to
release the trim , then remove the trim.
339
ELECTRICAL WIRING & FUSES ETC
Subject
Page
Subject
Fuses ................... .. ................................. .. ......... .. ....... 340

Relays .............. ................ .. .... .. .......................... .. ....... 341
Circuit Breaker ............................................. .............. 341
Fusible Links .................... ............................ .............. 341
Wi ri ng Hrunesses ..... ...... ..... .. ... .... .. ... ...... ... .. .............. 341
Key to Electrical Oiagmms ....... .. .... ..... ... ..... ... .. .... .. .... 341
Wiring Diagrams ...................................... 342
Starting & Charb~ng System - EF ( I) ..... ... .. ................ 342

Starting & Charging System - EL ( I) ... .. .... .. ....... .... ... 343
6 CyL Fuellnj. - Ignition System - EF (2) ... ... ....... .... .. 344
6 CyL Fuel Inj . - Ignition Systcm - EL (2) ... ...... .. ... ... .. 346
V8 Fuel Inj . - Ignition System (3) ......... ... ........ .... .. .. ... 348
Falcon Exterior Lighting - EF (4) ....... .. ...................... 350
Falcon Exterior Lighting - EL (4) ............................... 351
FairianeILTO Exterior Lighting - EF (4) .................... 352
FairlaneILTO Exterior Lighting - EL (4) ...... ... ... .. ...... 353
Falcon Tum/Hazard Lights (6) ................................... 354
Hanl (7) .............. .. ..................... ................................. 355
Falcon StoplReverse Lights - EF (8) .. ....... .................. 356
Falcon StoplReverse Lights - EF (8) ... ........................ 357
FairlaneILTO Stop/Reverse Lights (8) ........................ 358
Fairl'meILTO TumJI-Iaz.1fd Lights (6) ...... ................ .. 359
GLiIFutura Instrument Cluster (9) .............................. 360
FmtlFmt GhiaIXR Instrument Cluster (9) .. ... ... ... ... ..... 361
FairlaneILTO Instrument Cluster (9) ... ................ ... .. .. 362
GLiIFuturaIXR Interior Lighting - EF (5) .. .... .. ... ... ... .. 363
GLilFuturalXR Interior Lighting - EL (5) .. ... ...... ...... .. 364
FmtlFmt Ghia/FairlaneILTO Interior Lighting (5) ...... 365
Rear Demister ( 10) ................................. .................... 366
Wiper Washer System (ll ) ... .. ............ ...... ... .. .... .. .... .. . 367
Heater & Air Conditioning (12) ... ............. ...... .... ... ... .. 368
Automatic Climate Control - EF (12) ... .... .. ................. 369
Automatic Climate Control - EL (12) .. ....................... 370
Audio System Low & Mid Series (13) ........................ 371
Page
Audio Premium Sound System (13) .... ... ......... .... ...... .. 372
Mobile Phone Conector - EL (14) ..... ...... ... ..... ... ......... 373
Power Door LockslSmartlock - EF (15) .. ..... ...... .... .... 374
Power Door LockslSmartlock - EL ( 15) ....... ... ....... .... 375
Power Windows (16) .......................................... ........ 376
Electric Mirrors & Cig. Lighter (17) ... ..... ................... 377
Fmt GhiaiFairl,melLTO Power Seats (1 8) ..... ... ........ .. 378
Clock (19) ... ....... ..... ... .................. .. ..... ....... ................ 379
Trip Computer (19) ... ... ..... .. ... ... ................ ... ..... ..... .... 380
Cruise Control System (20) .............. .. ............. .. ......... 38 I
FairlaneILTO Self Leveling Suspension (2 1) ... ........... 382
6 CyL Electronic Auto Trans (22) ............................... 383
V8 Electronic Auto Trans - EF (22) ... ......................... 384
V8 Electronic Auto Trans - EL (22) ........................... 385
ABS Antilock Bmkes - EF (23) .................... .. ............ 386
ABS Antilock Bmkes - EL (23) .... .... .. ..... ... ... ..... ..... ... 387
Air Bag (24) ............................................................... 388
Engine Cooling Fans - EF (25) ................................... 389
Engine Cooling Fans - EL (25) ....................... ..... ....... 390
FUSES
The fuse p,mel is situated in front of the dri vers seat, to the
right of the steering column, in the instrument panel lower
right hand side, cover a,sembly.
Access is gained by lifting the panel door by the handle and
pulling outwards. Fuses are multi coloured to easily identify
the fuse capacity, the fusc capacity is also printed on the fuse.
Fuses are identified with a label showing which circuit they
belong to, a, an example "wipers". A 25 amp circuit breaker
is also located in the fuse panel, this is an over load protection
device for the headlights.
Inspection of fuses is achieved by removing the suspected
fuse and examine the element in the fuse for a break.
Always replace blown fuses with filse, of the same mting, if
340
anotherfusefailureoccurs, thecircuit must be checked to find

the rault, once the fault has been COllected replace the fuse,
with the COllect rating.
Additional fuses are located at the radio/sound system, this is
an inline secondary fuse located at the sound system elecoical
connections.
RELAYS
There are three relay panels located through the vehicle the
fi"t relay panel is combined with the fuse panel.

As shown previously.
The second is located under the bonnet in the engine bay
behind the banery.
While the third is situated under the lower right panel to the
left of the steering column.
FUSIBLE LINKS
There are four fusible links connected to the chassis and

engine elecoical wiring system. These fusible links protect
against short circuit damage to elecoical equipment and
elecoical harnesses, the first link is located near the brake
booster at the break out connection of the wiring loom.
The remaining three are connected to the positive wiring from
the banery, there is two heavy fuses and one light fuse.
Fusible Link
Function
1
HEGO sensor.
2& 3
Instruments, lighting and a1tematorl
regulator circuitry.
4
E.F.I. systems.
WIRING HARNESSES
CIRCUIT BREAKER
The headlight circuit breaker situated in the fuse panel is a

built protection device for over loading of the headlight
circuit, the circuit breaker will automatically reset.
There are a number of different wiring harnesses fitted to the

vehicles, depending on the body series and model, the Fairmont
Ghia, Fairlane and LTO body series have a large number of
ancillary harnesses.
Key To E
Diagrams
1"-" - "-" - " -"--,

.
I
Component Boxes
EL Vehicles on~
L .. _.. _.. _ .. _ .. _ .. ~
,------,
Component Boxes
All Vehicles nollllal
L _____ J
Wires
All Vehicles noJlllal
Wires
EL Vehicles on~
Wire Colors
All Vehicles only
Wire Colors
EL Vehicles on~
Color Oefinrtion
Wiring (main coIor~ine colour)
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341
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390
DIANOSTIC CHARTS
Subject
Subject
Page
J>age
ABS Brake Charts ................................................. 392

EF Model Ve hicles Codes ........................................ 392
EIM odel Ve hicles Code s ......................................... 393
Pin Connector C hart ....................... .. ... .................... 394
Kn oc k Senso r C heck ............... ................ ..... ..... ..... .. 40 I

Sync hroni zer C hec k ................................................. 40 1
Coi I Pac k C hec k ..... ......... ..... ....... ....... ....... .... ...... .... 402
No Self Test C odes Report ....................... ..... ... ....... 403
Rear Suspension Self Leveling .............................. 395

Suspension Diag nostic C hart s ... .... .... ..... .. ...... ....... .. 395
Self Tes t Diagnosis ............................. ..... ... ... ...... .... 395
Engine Charts ........................................................ 403

Engine Diagnostircodes (EF o nly) .......................... 403
Engine Di agnostircodes (EL only) .......................... 406
EEC V Pin Tesl C harls EF 6Cyl ..... ........................ 409
EEC V Pin Test Charts EL 6Cy I. ............................ 41 1
Transmission Diagnostics ...................................... 397

BTR 93/97 LE Transmi ssio n Diagonsis ... .. ... ..... ...... 397
TCM Singal Levels 97LE ... ............. .... .................... 397
TCM Singal Level s 93 LE ... ............ .... ............ ......... 397
Situation Codes ....... ...................... ..... ........ ............. 398
Solenoid Shi fl Sequence 93LE ................................. 398
Solenoid Logic & SIalic Gear Slales 93LE ....... ...... . 398
Solenoid Ope ration During Gearshifts 93LE ... ..... ... 39 8
Solenoid Logic & Stalic Gear Slates 97LE ... .. ......... 399
Solenoid Operation During Gearshi flS 97LE ........... 399
EEC V Pin Test Charts 8Cyl all .. ........................... .413

AUI O Trans. Temp Links .. .... .......... ......................... 41 5
AutomaticClimateControl ................................... 41 5
Auto Climate Control SelfTesl ........... ....... ..... ... ..... 415
AulO Climate Control Functional Test ...... ..... ..... ..... 41 6
Auto C limate Conlrol Diagnostic Test ..................... 41 7
Air Bag Diagnostics ............................................... 41 8

Air Bag Trouble Codes EF only .... .......................... 418
Air Bag Trouble Codes EL .. .. ... .... ..... .......... ..... .... ... 419
Ignition Diagnostics ............................................... 400

ECU SelfTest Codes ........... .................................. .. 400
Crankshaft Posilion Sensor Check ..................... ...... 40 I
391
DIAGNOSTIC CHARTS
ABS BRAKES DIAGNOSTIC CODES

(EF Models)
Code checks to be conducted using:
T2100CAM Tester and T2100CAMAD2 Adaptor.
Extract 2 digit fault codes
Fault code memory clear
Wiggle tests for intermittent faults
T2100SAM Tester and T2100ABSBM Adaptor.

Extract 2 & 4 digit fault codes
Apply 'On Demand' fault checks
Individual wheel speed sensor readings
DIAGNOSTIC TROUBLE CODE CHART
2 Digits 4 Digits Problem

12
No codesstored
0000
19
9342
ECU fault.
Right front valve fault.
22
5210
Left front valve fault.
24
5194
26
5242
Rear valve fault.
5145
Right front wheel speed
31
sensor continuity fault.
32
Right rear wheel speed
5165
5155
Left front wheel speed
33
Left rear wheel speed
34
5175
41
5259
Right front wheel sensor
fault.
42
5260
Right rear wheel sensor

fault.
Description
System Ok
Internal fault in ECU.
Solinoid fault in modulator.
Sensor open circuit.
Sensor, wiring or ECU fault.
Sensor signal incorrect for vehicle
conditions. Sensor, wiring or ECU
fault. Tone wheel missing or fitted
incorrect, sensor fallen out.
Required Action
Replace ECU & retest.
Replace modulator & retest.
Preform test I.
Preform test I.
Preform test 1.
Preform test I.
Preform test 2.
Preform test 2.
incorrect, sensor faBen out.
43
5258
Left front wheel sensor

fault.
44
5261
Left rear wheel sensor

fault.
61
63
5095
2014
69
6969
Pump motor fault.

Valve relay or supply
voltage fault.
Voltage fault.
78
5229
ABS operation error.

ECU or modulator fault.
ECU or modulator fault.
Preform test 2.
Preform test 2.
Preform test 3.
Preform test 4.
Check power wiring for

ECU detected low voltage supply.
faults & retest.
Alternator, battery. wiring
or ECU fault.
Road conditions caused incompatable Preform test 5.
wheel speed signals, extrem road
conditions. Erase codes & road test.
392
DIAGNOSTIC CHARTS
ABS MODULE 15 PIN CONNECTOR CHART

PinNo.
Operation
I
ABS Lamp 1 STO
STI
2
Not used
3
Left front sensor + V E
4
Left rear sensor -VE
5
Right rear sensor -VE
6
7
Right rear sensor +VE
Right frant sensar + VE
8
Brake lamp switch
9
Natused
10
Not used
II
Left front sensar -VE
12
Left rear sensar + VE
13
Right front sensor -VE
14
15
Not used
ABS MODULE 15 PIN CONNECTOR CHART
PinNo.
Operation
Ignition power.
I
ABS fuse power.
2
Ground.
3
ABS lamp.
4
Readings
Lamp on : <2.5 V to ground. Lamp off: >9.5 V
>9.5 V
Ignition off: 1.2 +1- 0.2 klohm to pin 12
Ignition orf: 2.2 +1- 0.4 k/ohm to pin 13
Brake on: >9.5 V.
Brake off: <2.0 V
----------------------Ignition off: 1.2 +1- 0.2 klahm to pin 4

-----------Readings
Ignition on : >9.5 V
Ignitian on: >9.5 V
< 0.5 V with reference to battery negati ve
Ignition on : <2.5 V.
Ignition off: >9.5 V
ABS BRAKES DIAGNOSTIC CODES

(EL Models)
Code checks to be conducted using:
T2100CAM Tester and T2100CAMAD2 Adaptor.
Extract 2 digit fault codes
DIAGNOSTIC TROUBLE CODE CHART

2 Digits 4 Digits Problem
No codes stored
12
0000
9342
ECU fault.
19
Right front inlet val ve fault.
22
5214
5194
Right front outlet valve fault.
23
Left front inlet valve fault.
24
5198
5194
Left front outlet valve fault.
25
Rear inlet valve fault.
26
5250
Rear outlet valve fault.
27
5242
31
5145
Right front wheel speed
Right rear wheel speed
32
5165
5155
Left front wheel speed
33
T2100SAM Tester and T2100ABSBM Adaptor.

Extract 2 & 4 digit fault codes
Wiggle tesls for intermittent faults
Apply 'On Demand' fault checks
Individual wheel speed sensor readings
Description
System Ok
Internal fault in ECU.
Solinaid fault in modulator.
Salinaid fault in modulator.

Sensor. wiring or ECU fault.
393
Required Action
---------Preform test 4.
Preform test 1.
Preform test 1.
Preform test I.
Preform test l.
Preform test 1.
Preform test I.
Preform test 2.
Preform test 2.
Preform test 2.
DIAGNOSTIC CHARTS
2 Digits
34
41
4 Digits
5175
5148
Problem
Left rear wheel speed
Right front wheel sensor
fault.
Required Action
Preform test 2.
Description

Preform test 3.
42
5168
Right rear wheel sensor

fault.

Preform test 3.

43
5158
Left front wheel sensor

fault.
44
5178
Left rear wheel sensor

fault.

Preform test 3.
Preform test 3.

61
63
5095
5266
69
9318
Pump motor fault.

Valve relay or supply
voltage fault.
Voltage fault.
78
5222
Wheel sensor signal error.
ECU, wiring or modulator fault.

ECU, wiring or modulator fault.
Preform test 4.
Preform test 4.
ECU detected low voltage supply.

Alternator, battery, wiring
or ECU fault.
Speed sensor signal wrong for
Preform test 4.
Preform test 3.
vehicle coodi tions.

79
9484
Brake light switch fault.
------
No codes.
Fault in brake light circuit. Switch,

switch wiring, taillight ortaillight
wiring fault.
Wiring loom, ABS warning light or
modulator fault.
Preform test 4.
Check for open
circuits. Recurring
change modulator.
Retest system.
ASS MODULE 31 PIN CONNECTOR CHART

Pin No, Operation
Circuit No.
524
I
Right rear +VE
Right rear -VE
2
523
----Not used
3
Right front -VE
516
4
Right Front + VE
514
5
Left front -VE
522
6
Left front + VE
521
7
519
Leti rear -VE
8
Left rear +VE
518
9
Not used
10
571
Self test input/output
II
12
Not used
Not used
13
10
Brake light input
14
Ignition power (ECU relay) 140
15
57
Ground monitoring
16
Valve relay power
537
17
Readings
Ignition off: 2.2 +/- 0.4 klohms ton pin 2
Ignition off: 2.2 +/- 0.4 klohms ton pin I
Ignition
Ignition
Ignition
Ignition
Ignition
Ignition
off:
off:
off:
off:
off:
off:
1.65 +/- 0.2 klohms ton pin 5

----------
---------Brake off: <2.0 V

Brake on: >9.5 V
<0.5 with refeence to battery negative
394
DIAGNOSTIC CHARTS
Pin No.
18
19
20
21
2231
Operation
Valve relay power
Ground (ECU relay)
Not used
ABS light
Not used
Circuit No.
537
-----
Readings
<0.5 with referance to battery negative
-----
----------
991
Ignition on : <2.5 V
-----
----------
Ignition off: >9.5 V
Automatic Self Leveling Suspention Codes

Diagnostics Chart
Trouble Codes
Light Off
One Light Flash
Causes
Warning light power supply.
Warning light globe.
Connection between hight control unit
and warning light faulty.
Height sensors power supply damaged.
height sensor.
Compressor operation faulty.
Height sensor link.
Leak from shockers or air lines.
Circuit ground for height sensor.
Power supply for height sensor.
Compressor relay.
Compressor.
Two Light Aashes
Exhaust valve operation fault.

Height sensor indicates vehicle is to
high and can not lower.
Height sensor link.
Exhaust vent solenoid.
Exhaust vent filter.

Height sensor unit.
Three Light Flashes
Height sensor fault or the control

module.
Four Light Flashes

Light Continuously
llluminated
System passes diagnostic check.

Control unit problem.
Solutions
Apply test No I.
Chech and replace gloge.
Check the harness and warning light circuit
with ohmmeter.
Apply test No 4.
Apply test No 3.
Apply test No I.
Check adjustment and attachment.
Check system using soapy water solution.
Check between ECU and body for continuity.
Apply tests No 3 & 4.
Fit wire from earth and ECU pin 3. the relay
should engage and pump opperate.
Check compressor voltage supply, 10V or more.
Check compressor ground between compressor
connector pin No 2 and earth.
Fit wire from ECU pin No 3 and earth, the compressor
power supply should be I OV or more.
Ensure all doors on the vehicle are closed.

check link adjustment and attachment.
Check compressor connector pin No 4 for voltage,
should read IOV or more.
Fit wire from ECU pin No 6 to earth. the solenoid
should activate and click.
From under battery tray withdraw the intake/exhaust
filter and ensure they are clean.
Check ECU connector pin No 7 voltage, IOV or more
when vehicles doors closed and zero with doors open.
Check ECU pin No 1 to ground continuity.
Check ECU pin No 1 to ground continuity.

Check ECU pin No I to ground continuity.
395
DIAGNOSTIC CHARTS
Automatic Self Leveling Suspention

System Test Charts
System Test Chart No 1
Test Step
la = Check Vehicle Load.
*Check vehicle for over loading in both the
boot and passanger compartment, if
nesseccary unload.
*Was the vehicle overloaded.
Result
Action Taken to Resolve
Yes
Perform a system operational check.
No
Check the trim height.
Result
Yes
Light circuit checks out OK.
No
Check warning light globe and instrument

panel fuse.
Result
Yes
Height sensor to ignition are OK.

Go to 3b.
No
Repair the short in the circuit between

the module and the ignition.
Repeat 3a.
Yes
Ignition to module checks OK.

Go to 4.
Repair the short or open circuit.
Check instrument panel fuse.
Repair low voltage due to a faulty connector
low battery, etc.
Repeat 3b.

Test Step
2a = Power Monitor Light. Ignition On.
*Earth test light clip on the module
retaining screw.
*Detatch loom connector from the module.
'Place test light to the No 8 pin of the harness.
*Did the warning light switch on.

Test Step
3a = Check Ignition Circuit, Ign. Off.
'Set volt meter for 12 volts.
'Connect the voltmeters negative lead to
the module retaining screw.
'Detatch loom connector from the module.
*Is the voltage reading zero.
3b = Check Ignition Circuit, IKn. On.

'Tum ignition switch to the on position.
*Connect the voltmeter as in the previous task.
*ls voltage reading greater than 10 volts.
No

Test Step
4a = Check Battery Circuit
'Set ignition to the off position.
'Use voltmeter set to 12 volts.
'Connect the negative lead to the module

retalmng
screw.
'Detatch loom connector from the module.

*ls voltage reading 10 volts and steady.
396
Result
Yes
Battery circuit OK.
No
Service low voltage fault within thecircuit.

Repeat 4a.
DIAGNOSTIC CHARTS
rCM Normal Sillnal Levels 97LE only

Pin No. Situation
1
A
B
B
2
A + Diagnostics off.
A + Diagnostics on.
B + Diagnostics off.
B + Diagnostics on.
3
A
A+Economy
4
A + Performance
5
C
6
A + Engine Running
7
A
B
C
8
C
9
C
10
C
11
B
12
B
B
13
14
A + Performance Mode
A + Economy Mode
16
A + Zero Throttle
A + Full Throttle
B
B
18
A
19
A + Vehicle Speed
20
*2
21
B
22
B
23
24
25
A
B
26
B
27
B
28
B
29
A
B
30
A
A
Test Result
Pin 5 Voltage
Resistance Earth
Pin 5 Resistance
Voltage to Earth
Voltage to Earth
Pin 8 Resistance
Pin 8 Resistance
Voltage to Earth
Voltage to Earth
Voltage to Earth
Pin 21 Resistance
Voltage to Earth
Voltage to Earth
Pin 29 Resistance
Pin 21 Resistance
Pin 21 Resistance
Pin 21 Resistance
Pin 21 Resistance
Pin 21 Resistance
Pin 21 Resistance
Pin 21 Resistance
Pin 21 Voltage
Pin21 Voltage
Pin 9 Voltage
Pin 9 Voltage
Pin 9 Resistance
Pin 25 Resistance
Voltage to Earth
Voltage to Earth
Pin 8 Voltage
Resistance to Earth
Resistance to Earth
Voltage to Earth
Pin 9 Resistance
Pin 2 I Resistance
Pin 2 I Resistance
Pin 2 I Resistance
Current in Line (amps)
Pin 7 Resistance
Voltage to Earth
Pin 21 Voltage
ECU Normal SiIrnal ! .evels (Integrated Module 93LE)

Pin No. Situation
Test Result
71
A
Voltage to Earth
96
B
Resistance to Earth
79
A Economy Mode
Voltage to Earth
79
A Normal Mode
Voltage to Earth
397
Min.
0.25
1.0Mohm
57.00hm
4.80
0.00
l.00hm
Oohm
*1
0.0
10.0
O.Oohm
*1
0.20
3.00hm
l.70hm
O.Oohm
O.Oohm
O.Oohm
23.00hm
23.00hm
23.00hm
0.00
10.0
0.53
3.74
O.Oohm
O.Oohm
*1
0.00 * I
Max.
4.70
15.5Kohm
5.20
0.20
l.00hm
0.2
14.0
J.Oohm
1.60
6.00hm
l.700hm
1.00hm
1.00hm
1.00hm
45.00hm
45.00hm
45.00hm
2.00
J.OI
4.88
5.0Kohm
5.0Kohm
9.00
O.OOohm
O.OOohm
0.01 ohm
O.Olohm
4.50
3.2Kohm
23.00hm
23.00hm
23.00hm
0.10
3.00hm
11.3
11.3
4.80
4.800hm
45.00hm
45.00hm
45.00hm
0.30
6.00hm
14.0
14.0
Min.
10.0
23.00hm
0.00
10.00
Max.
14.0
45.00hm
2.00
14.00
DIAGNOSTIC CHARTS
Pin No.
94
29
29
64
Situation
B
A Normal Mode
A Economy Mode
B Normal Mode
B Economy Mode
A
64
53
81
37
B
B
A
B
C
AWOT
ACT
BWOT
BCT
B
B
B
91
89
27
1
28
Test Result
Resistance to Earth
Resi stance to Earth
Voltage to Earth
Resistance to Earth
Resistance to Earth
Voltage to Pin 91 M I
M2
M3
D
N
R
P
Resistance to Pin 91 M I
M2
M3
D
N
R
P
Resistance to Earth
Pin 71/97 Resistance
Pin 91 Voltage
Pin 91 Resistance
Resistance to Earth
Pin91 Voltage
Pin 91 Voltage
Pin 91 Resistance
Pin 46 Resistance
Resistance to Earth
Resistance to Earth
Resistance to Earth
Min.
Max.
23.00hm
45.00hm
0.00
0.20
1.0Mohm
O.Oohm
1.00hm
1.0Mohm
0.9
1.10
1.90
2.40
2.90
3.40
3.90
1.0Kohm
1.8Kohm
3.0Kohm
4.5Kohm
6.8Kohm
1O.6Kohm
18.6Kohm
23.00hm
3.00hm
0.25
57.00hm
0.00
3.70
0.50
3.0Kohm
500.00hm
23.00hm
23.00hm
23.00hm
2.10
2.60
3.10
3.60
4.10
1.4Kohm
2.2Kohm
3.4Kohm
4.9Kohm
7.2Kohm
11.2Kohm
19.0Kohm
45.00hm
6.00hm
4.80
15.5Kohm
1.00
4.80
1.20
5.0Kohm
1.2Kohm
45.00hm
45.00hm
45.00hm
Situation Code
A = PCMlTCM disconnected from vehicle loom, measurement is at the pin on the loom and ignition on.
PCMITCM disconnected from vehicle loom, measurement is at the pin on the loom ..
B PCMlTCM disconnected from vehicle loom, measurement is at the pin on the PCMlTCM.
C *\ -Use an Oscilloscope to observe Periodic Pulse waveform
Use standard diagnosis procedure for test.
*2 -
Solenoid Shifting Sequence
931 ,E: Solenoid Loeic for Static Gear Condition

Gear
SI
SZ
1st
ON
ON
2nd
OFF
ON
3rd
OFF
OFF
4th
ON
OFF
93LE: Solenoid Operation purine Gearshifts
Gearshift
To Initiate Shift Typical S5 Current Ramp
1-2
SIOff
920 rnA to 700 rnA
S40N
398
Condition for Gearshift

S40FF
DIAGNOSTIC CHARTS
Gearshift
1-3
4-3 KD
To Initiate Shift
SIOFF
S20FF
S30N
S40N
S20FF
S30N
S40FF
S20FF
S30N
S40N
S10N
S20FF
S30N
SION
S40N
S40N
4-2 KD
S30N
1-4
2-3
2-4
3-4
900 rnA to 700 rnA

S30FF
S40FF
900 rnA to 650 rnA
S3 OFF
S40FF
730 rnA to 550 rnA
S3 OFF
S40FF
Typical S5 Current Ramp
S30N
880 rnA to 700 rnA
850 rnA to 610 rnA
S40FF
700 rnA
S10FF
S40FF
S10FF
S20N
S3 OFF
S20N
S3 OFF
S40FF
S40FF
to
920 rnA
600 rnA to 900 rnA

4-1 KD
3-2 KD
@ 20 kph
@ 60kph
@ 100 kph
3-1 KD
2-1 KD
S30N
S40N
S20N
S40N
950 rnA to 1000 rnA
450 rnA to 250 rnA

600 rnA to 460 rnA
800 rnA to 680 mA
S30N
S40N
800 rnA to 1000 rnA
S40N
800 rnA
CONY. CLUTCH
ON
S70N
OFF
KD =Power On For Kickdown
to
1000 rnA
650 rnA to 400 rnA

500 rnA to 1000 mA
SION
S20N
S3 OFF
S40FF
SION
S40FF
S7 OFF
97LE: Solenoid LOl:ic at Static Gear Condition

Gear
Sl
S1
1st
ON
ON
2nd
OFF
ON
3rd
OFF
OFF
4th
ON
OFF
97LE: Solenoid Function While In Gearshifts
Gearshift
To Initiate Shift Typical S5 Current Ramp
1-2
S10ff
900 rnA to 650 rnA
S40N
1-3
SJ OFF
S2 OFF
850 rnA to 600 rnA
S3 ON
399

S40FF
S3 OFF
S40FF
DIAGNOSTIC CHARTS
Gearshift
To Initiate Shift
4-3 KD
S40N
S2 OFF
S30N
S40N
S20FF
S30N
S40N
SION
S20FF
S30N
SION
S40N
S40N
4-2 KD
S30N
1-4
2-3
2-4
3-4
Typical SS Current Ramp
870 mA to 650 rnA
S3 OFF
S40FF
700 mA to 500 rnA
S3 OFF
S40FF
S30N
880 mA to 700 mA
800 mA to 600 mA
S40FF
700 mA to 900 mA
SIOFF
S40FF
SIOFF
S20N
S3 OFF
S20N
S3 OFF
S40FF
S40FF
600 mA to 950 mA
4-1 KD
S30N
S40N
900 mA to 1000 mA
3-2KD
@ 20kph
60 kph
@ 100 kph
3-1 KD
@
2- 1 KD
S20N
S40N
600 mA to 450 mA
550 mA to 400 mA
800 mA to 650 mA
S30N
S40N
770 mA to 1000 mA
S40N
750 mA to 1000 mA
CONY. CLUTCH
S70N
ON
OFF
KD = Power On Kickdown
650 mA to 350 mA
400 mA to 1000 mA
SION
S20N
S3 OFF
S40FF
SION
S40FF
S7 OFF
IGNITION SYSTEM DIAGNOSTIC CODES

EEC V Self Test Codes
EDIS related error codes
211
214
215/216/2171226
227
232
No codes reported
Will not self test
Action to Take
apply test I
apply test 3
apply test 4
apply test 2
change EEC Y module, retest
apply test 5
check power and earth connections, check ST!, STO, SIGRTN
wiring, retest, problem still not fixed replace EEC Y module.
400
DIAGNOSTIC CHARTS
Checking Crankshaft Position Sensor

Test Steps
la
*Is the sensor fitted correctly?
Result
Yes
No
Ib
Ie
Id
Ie
Yes
'Disconnect EEC V module and

fit breakout box.
*Check sensor continuity using ohmmeter.
*Is the reading between 300-4000hms?
*Reconnectthe EEC V module leaving
break-out box fitted.
*KOEO, measure the voltage between:
CKP (+ve) (pin 21) to earth
CKP (-ve) (pin 22) to earth
'Arc the readings within 1-2 volts?
'Connect the EEC V module and measure
the AC voltage:
Engine cranking CKP(+ve) to CKP(-ve)
expected reading 0.5-1.5 volts
Engine running CKP( +ve) to CKP(-ve)
expected reading 2-5 volts
*00 the reading come within specifications?
'Ignition off, check CKP(+ve) to CKP( -vel
for any shorts in module.
*Does a short exist?
No
Yes
No
Yes
No
Checking Knock Sensor

Test Steps
2a
*Is the sensor fitted correctly?
2c
2d
2e
Result
Action
Continue to 2b.
Repair and retest.
Continue to 2c.
Yes
No
Yes
No
No
No
Replace the sensor then retest.
Result
Action
Continue to 3b.
Repair and retest.
Continue to 3c.
Inspect supply wiring for open
circuit, repair and retest.
Yes
No
*Disconnectsensor.
*Inspect synchronizer supply voltage.
*Is the supply at ignition voltage?
Yes
No
401
Continue to 2d.
Inspect signal return wire connector,
repair and retest.
Continue to 2e.
Inspect signal return wire connector,
repair and retest.
Yes
Checking Synchronizer
Test Steps
3a
*Is connector fitted correctly?
3b
Continue to Ie.
Inspect the tone wheel and sensor for
signs of damage.
Repair and repeat test.
Fit a new module.

Yes
*Ignition on, engine off measure DC voltage

between pins 57 and 91.
'Is reading between 2.5-3.5 volts.
*Disconnectsensor.
*Meansure resistance, signal return (pin91)
at EEC V to sensor connector earth pin.
*Is the resistance < 1ohm?
*Disconnect sensor.
*Meansure continuity between sensor signal
pin and EEC V KS (57).
*Is the resistance <Iohm?
*Check the base timing with STI earthed
during fault code transfer from KOER self-test.
'Is bsae timing at Odeg +/- 2deg?
Continue to Id.
Check the circuit for any shorts, if non
detectable replace the EEC V module.
Yes
No
2b
Action
Continue to lb.
Conti nue to Ie.
Check wiring and sensor.
DIAGNOSTIC CHARTS
Test Steps
Result
Action
3c
Yes
Continue to 3d.
Check signal return wiring for bad
'Sensordisconnected, check resistance from

signal return connector to EEC V s ignal
No
return pin.
*18 the resistance < lohm?
3d
connections, repair and retest.
'Sensordisconnected, checkconlinuity of
signal wire to EEC V pin 85 (CMP).
*Is resistance < lohm ?
Yes
*Reconnectscnsor.
No
Replace synchronizer, then retest.
Test Steps
Result
Action
4a
Yes
Continue to 4b.
No
Repair and retest.
Yes
Continue to 4c.
Check for open circuit in coil power
3e
No
Continue to 3e.
Check CMP wiring for bad connection ,
repair and retest.
*Turning engine over, inspect signal output,

expected output (ie: I cycle per 2 engine
revelutions).
*Expected:
Idle frequency:
4Hz (@500rpm)
8Hz(@IOOOrpm)
Voltage:
low state: < 2.0V
high state: > 2.0V
*Ensure signal rising edge is between 5deg
BTDC and 45deg ATDC of cy Ii nder.
*Is the singal correct?
Checking Coil Pack
4b
Is coil connector filled correctly?

'Check coil pack power supply.
*Is supply at ignition voltage?
No

4c
Yes
Detatch EEC V module and fit the

breakout box.
No
Continue to 4e.
Continue to 4d.
*Rcsistance to be measured between:
4d
4e
4f
4g
CD (A) pin 26 and CD (B) pin 52

CD (A) pin 26 and CD (C) pin 78
CD (B) pin 52 and CD (C) pin 78
* Are the reading < 30hm?
*Check three coil driver wires from the
EEC V module to coil pack for their resistance.
'Are the results < lohm?
*Check the resistance between coi I pack
pin 4 (VPWR) and the other three pins.
Arc the results < lohm?
'Detatch EEC V module and fit the
*Key on, measure DC voltage from:
CDA (EEC V pin 26) to earth
COB (EEC V pin 52) to earth
CDC (EEC V pin 78) to earth
'Are the readings within I volt ofVPWR?
'With EEC V module connected repeat 4f.
Are the readings within I volt of VPWR?
Yes
No
Continue to 4e.
Inspect coil driver wires for open

Yes
No
Yes
No
Yes
No
402
Continue to 4f.
Fit new coil pack, retesl.
Continue to 4g.
Inspect coil pack wiring for
open/short circuits, retest.
Continue to 4h.
Fit new EEC V module, retest system.
DIAGNOSTIC CHARTS
Test Steps
4h
*Enginerunning, measure AC voltagefrom:
CDA (EEC V pin 26) to earth
COB (EEC V pin 52) to earth
CDC (EEC V pin 78) to earth
*Are the readings between 1-2 volts?
4i
*Check regular spark duration while
cranking, (using dummy plug).
*Is there a regular spark?
(one spark per plug per revolution)
Result
Yes
No
Action
Continue to 4i.
Fit new EEC V module, retest system.
No
Inspect plugs, HT leads etc,

retest system.
Result
Yes
No
Action
Continue to Sa.
Perform tests 1 and 4.
No
Fit new harmonic balancer and

tone wheel, retest.
No Self Test Error Codes Reported

Test Steps
5a
*Is there a regular sparking during cranking
(using dummy plug).
*Is there a regular spark?
(one spark per plug per revolution)
5b
'Check the base timing with STI earthed
during fault code transfer from KOER self-test.
'Is bsae timing at Odeg +/- 2deg?
EEC V ELECTRONIC ENGINE MANAGEMENT

DIAGNOSTIC CODES
Engine Diagnostic Codes (EF Only)
Description
Code
Name
II1
Pass
No codes for this sort of test.
IAT value is to low, possible cause short to
IAT short to
112
ground.
ground or faulty sensor.
IAT value to high, possible cause short to
113
IAT short to
B+ or Vref.
Vref or B+ or faulty sensor.
IAT sensor out
TAT value is out of range or erratic,
114
possible cause sensor going out of spec.
of calibration.
116
ECT sensor out ECT value is out of range or erratic,
of calibration.
ECT value is to low, possible cause short to
ECT short to
ll7
ground.
ECT value to high, possible cause short to
118
ECT short to
B+ or Vref.
Throttle position sensor out of range, possible
121
TP sensor out
cause sensor going out of spec.
of calibration.
122
TP short to
TP value is to low, possible cause short to
ground.
123
TP short to
TP value is to high, possible cause short to
B+ or Vref.
MAP sensor out MAP sensor prodcing frequency out of normal
126
of calibration.
range or no frequency.
EEC didn't see MAP(l6) or MAF(V8) value change
NoMAPIMAF
129
change in goose. when engne was goosed in ER test.
1571184 MAF short to
MAF voltage to high, possible cause short to
ground.
403
16 V8 KOEO ER CONT
*** ***
*** *** ***
***
*** *** ***
***
*** ***
*** **. .**
***
*** *** ***
***
** ** **
**
** ** *
**
* ** *.*
.*.
*** *** ***
***
***
***
** **
.**
*** ***
**.
***
DIAGNOSTIC CHARTS
Code
1581185
159
167
172
173
176
177
21 I
214
215
216
217
226
227
232
327
328
332
334
335
411
412
452
511
512
513
Name
MAF short to
B+orVrcf
MAF sensor out
calicration .
No TPcharge
.
10 goose.
System always
lean H02S(2).
System always
rich H02S(2).
System always
lean H02S(2).
System always
rich H02S(2).
PIP erratic
during idle test.
CMP sensor
input faided
EDIS coil A
failed.
EDIS coil B
failed.
ED IS coil C
failed.
Unknown ESID
coil failure.
Knock sensor
failure
EDIS CPU
failed.
EGR shorted to
ground.
EGR valve
position too low.
EGR valve not
working.
EGR valve
position too high.
EGR sensor out
of calibration.
ISC - low idle
fail.
ISC - high idle
fail.
Speedo signal
fault.
Internal EEC
fault.
Internal EEC
fault.
Battery voltage
too low.
Description
MAF voltage to low, possible cause short to
MAF sensor out of normal range, possible
EEC didn't see throttle position sensor valve change
when engine was goosed in self test.
Engine running lean, posible cause faulty sensor
cold sensor, exhaust manifold leak.
Engine running rich, posible cause faulty sensor
PIP signal out of range, possible cause CKP
sensor or internal EDIS failure.
CMP signal out of nonnal range, possible cause
faulty CMP sensor or wiring.
Coil A failed to fire, possible cause faulty coil

or wlflng.
Coil B failed to fire, possible cause faulty coil
orwlrmg.
Coil C failed to fire, possible cause faulty coil

orwmng.
CMP failure, one EDIS coil failed to fire, coil
was not identified by EEC.
Knock sensor failed to provide signal when
in normal HInge.
Internal EEC fault, EDIS CPU failed.
EGR voltage to low, caused by short to
Valve position low , possible cause
val ve closed.
Valve position does not change during the ER test,
possible vacuum leak in control system.
Valve position to high, possible cause fully
open valve.
Voltage out of normal range, sensor not
calibrated within specifications.
ISC has no control over low idle speed during
engmerunnmg tests.
ISC has no control over high idle speed during
engine running tests.
Intennil1ent or missing speedo signal.
16 V8 KOEOER CONT
'" '"
'"
**' '**
*.* V8
*** .,*
***
*** ***
'** *,*
*'* '**
*--
-*.
**-
***
-**
----.-.
-,---
***
--*
-"
*
***
-"
***
'"
"-
*** ***
*"
,***,
*.* .**
,.* .**
'** **'
'"
'*'
*" "*
*** *"
404
V8
***
EEC module faulty .

Internal battery power voltage to low, internal
EEC fault or low system voltage.
**'
***
"*
*" '" "*
EEC module faulty .
"*
*"
*" ***
'"
***
***
,-,
'"
DIAGNOSTIC CHARTS
Code
521
Name
PSP railed open.
522
NOS - A/C on.
523
AC blower fan
sensor fault.
LPG enabled.
524
538
578
628
634
636
636
637
691
692
693
694
695
696
697
777
778
783
784
785
786
787
788
Operator did not

do goose.
Battery voltage
too low.
Trans mode
switch fault.
Gear selector
sensor fault.
Trans oil temp
fault.
Trans temp link
stuck low.
Trans temp link
stuck high.
Trans solenoid I
fault.
Trans solenoid 2
fault.
Trans solenoid 3
fault.
Trans solenoid 4
fault.
Trans solenoid 5
fault.
Trans solenoid 6
fault.
Trans solenoid 7
fault.
RIH side cooling
fan not operating.
UH side cooling
fan not operating.
Serial link output
check fail.
EGRoutput
check fail.
CANPoutput
check fail
PIL output
check fail.
Fuel pump
output check fail.
ACCoutput
check fail.
16 V8 KOEO ER CONT
Description
Steering needed to be turned 112 turn during ER
test, possible causes faulty or disconnected
switch, or not turned far enough during test.
KOEO test, trans in P or N, A/C turned
to the off position.
EEC received no AlC blower fan signal, cause
open circuit, blowen fuse (high), short to B+ (low).
LPG is selected, no system faults are
indicated,
Operator required to quickly open the throttle
fully during ER test.
Internal voltage too low for proper tams operation,
causes EEC fault or low internal voltage.
Mode selector intermittent operation, causes faulty
switch or wiring problems.
Gear selector switch signal too high/low, are
not between normal values.
Trans temp signal incorrect, cause open circuit,
short to ground or B+.
Link between EEC and 97LE module near ground,
causes short to ground, or fault in modules.
Link between EEC and 97LE module near B+ or Vref,
causes short to B+ or Vref, or fault in modules.
EEC cannot control solenoid, cause open circuit,
Fan motor not drawing current from battery
when EEC switches it on.
Link is faulty, cause open circuit or short
to B+ or ground.
EGR output faulty, cause open circuit or short
to B+ or ground.
CANP output faulty, cause open circuit or short
to B+ or ground.
Indicator light output faulty, cause open
circuit or short to B+ or ground.
Fuel pump output faulty, cause open
A/C control relay faulty, cause open
405
".

*.* ***
***
***
***
*** ***
***
*,*
*** ***
***
***
***
***
*** ***
***
***
,.,
'"
***
***
.**
.**
**'
,**
***
***
*.,
,,*
'"
".
*** *** ***
'"
*" *,*
**' *** **,
'"
"*
*.* *"
".
** ** *
,*,
'"
'"
'** **.
DIAGNOSTIC CHARTS
Code
789
791
792
793
794
795
837
838
839
844
845
998
Name
RCO output
check fail.
FCI output
check fail.
FC2 output
check fail.
FC3 output
check fail.
FC4 output
check fail.
BBMoutput
ckeck fail.
Evap sensor
short to earth.
Evap sensor
short to B+N ref.
Evapsensor
out of calibration.
Vehicle
Immobilised.
VehicleImmobil
plant mode.
ER test error.
Description
Recirculation over-ride output faulty, cause
open circuit, short to ground orB+.
Elector drive fan I faulty, cause open circuit,
short to ground orB+.
Elector drive fan 2 faulty, cause open circuit,
Broad band manifold output faulty, cause
open circuit, short to ground or B+.
Evap sensor voltage too low, cause short
to ground or faulty sensor.
Evap sensor voltage too high, cause short
Evap sensor voltage out of range, cause
sensor going out of specs.
EEC not receiving enable code from BEM,
cause open circuit, short to ground or B+.
Tmmobilization system in plant mode, BEM
trained on electronic lock assembly.
One or more major sensors are faulty, continue
KOER test to determine problem.
Engine Diagnostic Codes (EL Only)

Qescription
Code
Name
No codes for this sort of test.
III
Pass
IAT value is to low, possible cause short to
IAT
112
IAT value to high, possible cause short to
IAT short to
113
B+or Vref.
TAT sensor out
IAT value is out of range or erratic,
114
of calibration.
116
ECT sensor out ECT value is out of range or erratic,
of calibration.
ECT value is to low, possible cause short to
ECT short to
117
ground.
ECT value to high, possible cause short to
ECT short to
118
B+ or Vref.
Throttle position sensor out of range, possible
TP sensor out
121
of calibration.
TP value is to low, possible cause short to
122
TP short to
ground.
TP value is to high, possible cause short to
123
TP short to
B+ or Vref.
MAP sensor out MAP sensor prodcing frequency out of normal
126
range or no frequency.
of calibration.
EEC didn't see MAP(16) or MAF(V8) value change
129
NoMAPIMAF
change in goose. when engne was goosed in ER test.
157
MAF short to
ground.
406
If! Yl! KOEO ER CONT
".
".

,

.,.
"*
If! V8
ER CONT
.*
DIAGNOSTIC CHARTS
521
Name
MAFshort to
B+orVref
MAF sensor out
calicration.
No TP charge
In goose.
System always
lean H02S(I).
System always
rich H02S( I).
System always
lean H02S(2).
System always
rich H02S(2).
PIP erratic
during idle test.
Knock sensor
failure
EG R shorted to
ground.
EGR valve
position too low.
EGR valve not
working.
EGR valvc
position too high.
EGR sensor out
of calibration.
ISC - low idle
fai I.
ISC - high idle
fail.
Speedosignal
fault.
Internal EEC
fault.
Internal EEC
fault.
Battery voltage
too low .
PSP failed open.
522
NOS -NCon.
523
AC blower fan
sensor fault.
LPG enabled.
Code
158
159
167
172
173
176
177
211
277
327
328
332
334
335
411
412
452
511
512
513
524
538
539
Operator did not

dogoose.
TP signal
nOISy.
Description
MAF sensor out of normal range, possible
EEC didn't see throttle position sensor valve change
when engine was goosed in self test.
cold engine, MAP hose off, fuel sysetm.
cold engine, MAP hose off, fuel sysetm.
PIP signal out of range, EEC saw accelernation
or decelleration too fast.
Knock sensor failed to provide signal when
in Donna] range.
EGR voltage to low, caused by short to
Valve position low, possible cause
valvcclosed.
Valve position does not change during the ER test,
possible vacuum leak in control system.
Valve position to high, possible cause fully
open valve.
Voltage out of nonna] range, sensor nal
calibrated within specifications.
ISC has no control over low idle speed during
ISC has no control over high idle speed during
Intermittent or missing speedo signal.
-_.
16 YH KOEO ER CONT
407
._.
V8
V8
**.
._,
--,
._, '"
-_.
._,
-_. ._.**
.., -,.
-_.
*-, --,
'"
._,
_..
*** ***
***
-_.
--*** ***
***
*** ***
_.-
*** ***
EEC module faulty .

Internal battery power voltage to low, internal
EEC fault or low system voltage.
Stecring nccded to be turned 112 turn during ER
test, possible causes faulty or disconnected
switch, or not turned far enough during test.
KOEO test, trans in P or N, A/C turned
to the off position.
EEC received no A/C blower fan signal, cause
open circuit, shon to B+.
LPG is selected, no system faults are
indicated,
Operator required to quickly open the throttle
fully during ER test.
TP varing excessively, cause return signal
shorting to ground .
* **
* '**
EEC module faulty .
._. _
-_.
---
--'**
*** *** ***

***
***
***
--- --* -**

***
*** ***
***
* '**
,.,
*.-
DIAGNOSTIC CHARTS
Code
578
628
634
636
636
637
69 1
692
693
694
695
696
697
777
778
781
782
783
784
785
786
787
788
789
791
792
Name
Battery vo ltage
too low.
Trans mode
switch fault.
Gear selector
sensor fault .
Trans oil temp
fault.
Trans temp link
stuck low.
Trans temp link
stuck high.
Trans solenoid I
fault.
Trans solenoid 2
fault.
Trans solenoid 3
fault.
Trans solenoid 4
fault.
Trans solenoid 5
fault.
Trans solenoid 6
fault.
Trans solenoid 7
fault.
RlH side cooling
fan not operating.
lJH side cooling
fan not operating.
GSO output
check.
ACR output
check.
Serial link output
check fail.
EGR output
check fail.
CANPoutput
checkfail
ElL output
check fail.
Fuel pump
output check fail.
GCOoutput
check fail.
RCO output
checkfail.
FC! output
check fail.
FC2 output
check fail.
Description
Internal voltage too low for proper tarns operatio n,
causes EEC fault or low internal voltage.
Mode selector intermittent operation, causes faulty
switch or wiring problems.
Gear selector switch signal too high/low, are
not between normal values.
Trans temp signal incorrect, cause open circuit,
Link between EEC and 97LE module near ground,
causes short to ground, or fault in modules.
Link between EEC and 97LE module near B+ or vref,
causes short to B+ or vref, or fault in modules.
Fan motor not drawing CUITent from battery
EEC cannot control solenoid, cause open
Link is faulty, cause open circuit or short
to B+ or ground.
EGR output faulty , cause open circuit or short
to B+ or ground.
CANP output faulty, cause open circuit or short
to B+ or ground.
Indicator light output faulty , cause open
Fuel pump output faulty, cause open
Recirculation over-ride output faulty, cause
open circuit, short to ground or8+.
Elector drive fan I faulty, cause open circuit,
408
,--
Y8 KOEOER CONT
,-,
**-
--- ,-._- '**

'"
--,
.*.
**.
*,*
*_.
,-._,
-_.
".
.**
.*.
--,
_.,
,--
,-,
,-,
'**
._- --- ._
.*-
---"
*-,
--- -" ,**

,_. _
.-. ._,,*
--,
----- '" '"
'*' *'* *-*
,.,
_.- ---
,-- -"
,,*
"* ** *
DIAGNOSTIC CHARTS
Code
795
796
837
838
839
844
845
998
Name
BBMoutput
ckcck fail.
SSPS output
check fail.
Evap sensor
short to earth.
Evap sensor
short to B+lYref.
Evap sensor
out of calibration.
Vehicle
Immobilised.
Vehicle Immobil
plant mode.
ER test error.
Description
Broad band manifold output faulty, cause
open circuit, short to ground or B+.
Speed sensitive PIS faulty. cause
open circuit. short to ground or B+.
Evap sensor voltage too low , cause short
Evap sensor voltage too high, cause short
Evap sensor voltage out of range, cause
sensor going out of specs.
EEC not receiving enable code from BEM,
cause open circuit, short to ground or B+.
Immobilization system in plant mode. BEM
trained on electronic lock assembly.
One or more major sensors are faulty, continue
KOER test to determine problem.
16 V8 KOEO ER CONT
***
***
*** *** ***
*** *** ***
**.
*** *** ***
***
*** *** ***

*** *** ***
*** *** ***
***
***
EEC V ELECTRONIC ENGINE MANAGEMENT

PIN TEST CHART
EF 6 Cylinder Pin Test Chart
Descript
Pin
Abreviation Number Description
SOL.2
I
Gear select solenoid 2 (sol-2)
STO
2
Self test output
EEl
Electronic engine immobi lization
3
H02S.GND
4
HEGOground
CCE
10
Compressor clutch engaged
Yoltage
K.O.E.O.
12
12
0-12 signal
0
0
FC!
17
Electric drive fan I
12
BBM
20
Broad band manifold
12
CKP+VE
CKP-VE
PWRGND
CSEGND
CD(A)
SOL.!
SOL.4
NIE
21
22
24
25
26
27
28
29
Crankshaft position sensor positive

Crankshaft position sensor negative
Power ground
Case ground
Coil dri ver A'
Gear select solenoid 1 (sol-I)
Pattern select 1 (norm/econ)
1.5
1.5
AEAT
PSPS
30
31
A/C evapor air temp

PIS pressure switch
MAP
H02S
34
35
Manifold absolute pressure sensor

Heated exhaust gas oxygen sensor
409
0
0
12
12
0
9-12 normal
oeconomy
1.5-2.0 @ 2()<>C
0
2500-3000 rpm
Voltal:C
En!:ine Idle
12-14.5
12-14.5
0-12 signal
0
12-14.5 NCon
o NCoff
12-14.5 relay I off
orelay I on
oup to 3800rpm
12- 14.5 over 3800rpm
1.5
1.5
0
0
12-14.5
0
9-14.5 normal
oeconomy
1.5-2.0 @ 20"C
o no PIS load
10-12 PIS load
2000 rpm
0.8V at start for40-60sec
0.1-0.8V normal ron
DIAGNOSTIC CHARTS
Descript
Abreviation
TOT
ECT
Pin
Number Description
Transmission oil temp
37
Engine coolant temp sensor
38
Voltaee
Voltaee
K.O.E.O.
Eneincldle
3.6 @ 20"C
1.0-3.6 @ normal
3.1 @ 20"C
2.2 @ 40"C
0.5 @ 100"C
3.9 @ O"C
2.2 @ 40"C
3.1 @ 20"C
< 1.0v (NC off)
12-14.5(A/C low series)
0-6 (NC high series)
@ 25 Hz freq.
12
12.14.5 relay 2 off
orelay 2 on
0-12 pulse wave
0-12 square wave
12-14.5 relay 4 off
12
orelay on
IAT
39
Intake air temp sensor
ACC
41
A/C clutch
FC2
42
Electric drive fan 2
DOL
43
45
46
Data output link

Tacho
Electric fan 4
51
52
53
55
57
58
64
Power ground
Coil driver 'B'
Multiplex control so lenoid I (sol 3)
Keep alive power
Knock sensor
Vehicle speed sensor
Trans range/neutral drive switch
66
0-10 square wave

Auto Trans
P : 3.8-4.2
R : 3.3-3.7
N : 2.8-3.2
0: 2.3-2.7
3 : 1.8-2.2
2: 1.3-1.7
I : 0.8-1.2
Manual Trans
Neut : 0-0.1
In gear: 5
12
12
12
RPM
FC4
PWRGND
CD(2)
SOU
KAPWR
KS
VSS
TRINDS
12
12
12-14.5
3
0-10 Square wave
As per KOEO
STI
CANP
FC3
67
68
Self test input

Canister purge
ACR
69
NC relay (W AC)
12 (A/C off)
VPWR
IN!
IN)
71
73
74
IN}
75
12
12
12
12
PWRGND
PWRGND
CD(C)
EIL
FP
SOL.5
ISC
CMP
76
Vehicle power
Injector 5
Injector 3
Injector I
Power ground
Power ground
Coil driver 'C'
Economy indicator lamp
Fuel pump
Variable pressure solenoid (sol 5)
Idle speed control
Cylinder identi fication (cam position)
77
78
79
80
81
83
85
410
o
o
12-14.5
12-14.5
12-14.5 (NC off)
(NC on)
12-14.5 (relay 3 oft)
o (relay 3 on)
12-14.5
14
14
14
o
o
12
> I O(norm.),O(econ.) > 10(norm.),0(econ.)
>1 (pump on)
12 (pump off)
10-14
10-14
12
8-1 I (load dependant)
< lor>8 (depending on position in cylinder)
DIAGNOSTIC CHARTS
Descript
Ahreviation
BFS
TP
Pin
Npmber DescriptiQJI
Blowerfanspeed
86
89
Throttle position sensor
VREF
SIGRTN
FSS
90
91
92
Voltage reference
Signal return
Fuel select (LPG)
RCO
SOL.6
93
Recirculation override
Power solenoid control (soI.6)
Gas shut off (LPG)
GSO
SOL.7
VPWR
INJ.6
INJ.4
lNJ.2
PWRGND
Desrript
Abreviation
KAPWR
VSS
EEl
KEYPWR
ECT
FSS
94
95
96
97
99
100
101
103
Voltal:e
K.O.E.O.
Low Series
high - 12
off - 0
High Series
high - I
off - 12
Voltaec
Eneine Idle
Asper KOEO
0.7+1-0.15
Asper KOEO
(closed throttle)
4.0-4.5
5
Power solenoid control (sol. 7)

Vehicle power
injeclor6
Injector 4
Injector 2
Power ground
Pin
Number Description
1
Keep alive power
3
4
Electronic engine immobilization
Key power
5
7
Fuel select (LPG)
8
ACC
10
NCclutch
SOL.7
ElL
GCO
11
12
13
Lock up solenoid (soI.7)

Economy indicator lamp
Gas cut off solenoid (LPG)
SOL.6
BBM
14
15
Power solenoid control (501.6)

Broadband manifold
lGNGND
STO
CSEGND
ISC
16
17
20
21
Ignition ground
Self test oUlput
Case ground
Idle speed control
411
>9.0 (petrol mode/noLPG)

o (LPG)
12(fresh), l.O(recirc) 14.0(fresh), l.O(recirc)
12
12 (LPG off)
(LPG on)
o
0
12
12
12
12
12-14.5
14
14
14
Voltaec
Voltaec
K.O.E.O.
EneineJdIe
12-14.5
12
0-10 square wave
0-10 Square wave
0-12 signal
0-12 signal
12
12-14.5
3.1 @ 200C
>9.0 (petrol modeinoLPG)
(LPG)
2.2 @ 40' C
0.5 @ lOO' C
< l.Ov (NC off)
<l.Ov (NC off)
I 2-14.5(NC on)
12-14.5(NC on)
0
0
> lO(norm.),O(econ.) > lO(norm.),O(econ.)
OvGAS
OvGAS
12v NO GAS
12vNOGAS
12
12
up to 3800rpm
12-14.5 over 3800rpm
0
0
12-14.5
12
0
0
8-11 (load dependant)
12
DIAGNOSTIC CHARTS
Descript
Abreviation
FP
KS
JAT
VREF
NfE
PSPS
Pin
Number Description
22
23
25
26
27
28
Voltaee
K.O.E.O.
Fuel pump
Knock sensor
Voltage reference
Pattern select I (norm/eeon)
12 (pump oft)
3
3.9 @ O"C
5
9-12 normal
economy
0
PIS pressure switch
H02S
29
Heated exhaust gas oxygen sensor
TRINDS
30
Trans rangelneutral drive switch
Auto Trans
P : 3.8-4.2
R : 3.3-3.7
N : 2.8-3.2
D: 2.3-2.7
3 : 1.8-2.2
2 : 1.3-1.7
I : 0.8-1.2
Voltag:e
EneineIdlc
> I (pump on)
3
2.2 @ 40"C
5
9-14.5 normal
Oeconomy
o no PIS load
12-12 PIS load
0.1-0.8V normal run
As per KOEO
Manual Trans
CANP
GSO
31
32
Canister purge
Gas shut off (LPG)
FC2
33
Neut : 0-0.1
In gear: 5
12
12 (LPG off)
(LPG on)
12
DOL
SOL.3
SPOUT
VPWR
SOL.5
SSPS
PWRGND
CCE
34
35
36
37
38
39
40
41
Data output link

Multiplex control solenoid I (sol 3)
Spark out
Vehicle power
Variable pressure solenoid (sol 5)
Speed sensitive power steering
Power ground
0-12 pulse wave

0
12
12
10-14
12
0
0
TOT
AEAT
BFS
42
43
44
Transmission oil temp

A/C evapor air temp
Blower fan speed
MAP
SIGRTN
TP
45
46
47
Manifold absolute pressure sensor

Signal return
STI
H02S.GND
SOLI
SOL.2
FCI
48
49
51
52
53
Self test input

HEGOground
Gear select solenoid I (sol-I)
Electric dri ve ran I
3.6 @ 20"C
1.5-2.0 @ 20"C
high - 12
off - 0
155-160 Hz
0
0.7 +1- 0.15
(closed throttle)
4.0-4.5 (WOT)
12
0
12
12
12
412
8.0-10.0
12 (LPG oft)
o (LPG on)
12.14.5 relay 2 off
o relay 2 on
0-12 pulse wave
0
6-7 avg.
12- 14.5
10-14
0-12 pulse wave
0
12-14.5 AlCon
A/C off
1.0-3.6 @ normal
1.5-2.0 @ 20"C
Asper KOBO
100-105 Hz
0
As per KOEO
12-14.5
0
12-14.5
12-14.5
12-14.5 relay I off
o relay I on
DIAGNOSTIC CHARTS
Descript
Abreviation
ACR
SOLA
PIP
VPWR
INJBANKI
INJBANK2
PWRGND
Pin
Number
54
55
56
57
58
59
60
8 Cylinder PIn Test

Descript
Pin
Abreviation Number
STO
2
EEl
3
H02S.GND
4
CCE
10
Voltage
K.Q.E.Q.
12 (AiC off)
AlC relay (WAC)

Profile ignition Pickup
Vehicle power
Injector 1,3,5
Injector 2, 4, 6
Power ground
0
0-12
12
12
12
0
Voltage
Engine Idle
12-14.5 (AiC off)
o(AiC on)
0
6vavg.
12-14.5
14
14
0
Chart
Self test output

Electronic engine immobilization
HEGOground
Voltage
K,Q,E,Q,
12
0- I 2 signal
0
0
FCI
17
Electric drive fan I (EL models)
12
FC2
17
Electric drive fan 2 (EL models)
12
IGNGND
PWRGND
CSEGND
AEAT
TTL
H02S(I)
23
24
25
30
34
35
Ignition ground
Power ground
Case ground
AlC evapor air temp
Trans temp link
Heated exhaust gas oxygen sensor I
0
0
0
1.5-2.0 @ 20"C
MAFRTN
ECT
36
38
Mass air flow sensor return

IAT
39
ACC
41
A/Cclutch
FC2
42
Electric drive fan 2 (EF models)
0-0.1
3.1 @ 20"C
2.2 @ 100"C
3.9 @ O"C
3.1 @ 20"C
<I .Ov (AiC off)
12-14.5(AlC on)
12
SSPS
42
DOL
RPM
FC4
43
45
46
Speed sensitive power steering

(ELmodels)
Data output link
Taoch
0-12 pulse wave
EVR
IDM
47
48
EGR vacuum regulator

Ignition diagnoctics monitor
12
12
PIP
SPOUT
PWRGND
KAPWR
49
50
51
55
Profile ignition Pickup

Spark out
Power ground
Keep ali ve power
0
12
413
12
12
Voltage
Engine Idle
12-14.5
0- 12 signal
0
12-14.5 AlCon
o AlC off
12-14.5 relay I off
orelay I on
12.14.5 relay 2 off
orelay 2 on
0
0
0
1.5-2.0 @ 20"C
See Following Table
0.1-0.8V normal run
0-0.1
0.5 @ IOO"C
2.2 @ 40"C
< 1.0v (AiC off)
12-14.5(AlC on)
12.14.5 relay 2 off
o relay 2 on
0-12 pulse wave
0-12 pulse wave
0- I 2 square wave
12.14.5 relay 2 off
o relay 2 on
8-12 (during operation)
9-12 (reduces at higher
speeds)
0- I 2 square wave
0-12 square wave
0
12-14.5
DIAGNOSTIC CHARTS
Descript
A breviation
VSS
H02S(2)
TR
EVP
Pin
Number Description
58
61
Heated exhaust gas oxygen sensor2
Trans range
64
65
EGR valve positions
Volyu:e
K.O.E.O.
010 square wave
As H02S(I) pin 35
Auto Trans
P : 3.8-4.2
R : 3.3-3.7
N : 2.8-3.2
D : 2.3-2.7
3 : 1.8-2.2
2 : 1.3-1.7
I : 0.8-1.2
Manual Trans
Neut: 0-0.1
In gear: 5
0.4
VoIYII:e
Enl:ine Idle
0-10 Square wave
Asper KOEO
%EGR
STI
CANP
FC3
66
67
68
Self test input

Canister purge
12
12
12
FCI
68
Electric drive fan I (EL models)
12
ACR
69
NC relay (WAC)
12 (NC off)
VPWR
lNJBANK7
INJBANK5
INJBANK3
INJ BANKI
PWRGND
PWRGND
FP
ISC
BFS
71
80
83
86
Vehicle power
Injector 7
Injector 5
Injector 3
Injector 1
Power ground
Power ground
Fuel pump
Idle speed control
Blower fan speed
MAF
88
Mass air flow sensor
12
12
12
12
12
0
0
12 (pump off)
12
high - 12
off - 0
0
TP
89
72
73
74
75
76
77
0.7 +/- 0.15

(closed throttle)
4.0-4.5 (WOT)
414
Voltage
0.40
0 .75
1.10
1.45
1.80
2. 15
2.50
2.85
3.20
3.55
3.90
10
20
30
40
50
60
70
80
90
100
12-14.5
8.0-10.0
12. 14.5 relay 2 off
orelay 2 on
12.14.5 relay 2 off
orelay 2 on
12-14.5 (NCoff)
o (NC on)
12-14.5
14
14
14
14
0
0
>1 (pump on)
8-11 (load dependant)
As per KOEO
Eng Con MAFsigV
Idle
0.60
32kph
1.10
46kph
1.70
2.10
96kph
As per KOEO
DIAGNOSTIC CHARTS
Descript
Abreviation
VREF
SIGRTN
RCO
VPWR
INJBANK8
INJ BANK6
INJBANK4
INJ BANK2
PWRGND
Pin
Voltaee
K.O.E.O.
5
0
12.0 (fresh)
1.0 (recirc)
12
12
12
12
12
0
Nwnber Description
Vol tage reference
90
91
Signal return
93
Recirculation override
Vehicle power
Injector 8
Injector 6
Injector 4
Tnjector2
Power ground
57
72
73
74
75
76
Trans Temp Links

Trans State
Limphomemode
Thermistor fault
Temp < 105"C
I05'C < temp < 120'C
120'C < temp < 135"C
Temp < 135'C
Idle Speed Min required

750
750
o
675
712
750
Voltaee
Eneineldle
5
0
14.0 (fresh)
1.0 (recirc)
12- 14.5
14
14
14
14
0
Communtcation I ,ink Freq.

12 volts
volts
10 Hz
20Hz
30Hz
40Hz

SELF TEST
Press MODE, and OFF Simultaneously - Wait 30 seconds
ERROR
CONDITION
DESCRIPTION
CODE
DETECTED
EI
Electronic Control
Faulty Electronic
Control Unit
Unit
E2
Blend Door Servo
Movement of blend
Unit
door out of range
DEFAULT
VALUE
RAM air to
screen
Poor temperature
modulation
COMMENT
Replace Unit
Check if motor
disconnected, door
movement obstructed
or incorrect wiring
E3
E4
E5
Cabin Sensor
Solar Sensor
Ambiant Sensor
E6
Evaporator
Temperature Sensor
E7
Engine
Temperature Sensor
E8
EEC V Communicating
Line Fault
Set point directly

controls thermal
control valve
Nosunload
Open circuit
Short circuit
Open circuit
Open ci rcu it between
sensor & EEC V
module
Short circuit between
sensor & EEC V
module
Faulty Line
415
Check fordisconnected
cabin sensor
Check for short in wiring
compensation
or sensor
Assumes arnbiant
is 20'C
NC clutch does
not engage
Check for disconnected
Assumeshot
engine ie. 93'C
Check for short in wiring
All values from

EEC V set at
default valve of l'e
Check EEC V
sensor
Check fordisconnected
sensor
sensor
communication line
toACC
DIAGNOSTIC CHARTS

FUNCTIONAL TEST
Note: This test process is designed to identify failures which are not solved under the SelfTes!.
FUNCTIONAL INSTRUCTIONS
RESULT
ACTION
TEST
I
* Start the engine.
* Set control to 22'C
, Control unit powers

* Go to 2.
up.
* Control unit doesn't light up. * Refer to diagnostic test G.
Fan on low speed.
* Go to 3.
, Refer to diagnostic test C.
Fan off.
, Refer to diagnostic test D.
Fan high speed.
, Go to 4.
* Wann air is
discharged from floor
ducts.
Cool air is discharged.
, Refer to diagnostic test A.
* Cold air is discharged
'Go to 5.
from face ducts.
* Air is not cold.
* Refer to diagnostic test B.
* Air is discharged from
* Go to 6.
setting.
demist nozzle onto screen
Press demist button.
& fresh/recirc door is in

fresh position.
* Air is not discharged
Press the auto button.

* Set control to 30"C setting.
* Verify that fan starts on
low speed.
Warm engine to normal
operating temperature.
* Set control to 18C

setting.
from the demist nozzle.

* Fresh/recife door is not
in fresh position.
10
diagnosis"
Refer to "vacuum system
diagnosis"
'Got07.
, Press auto button.
* Fresh/recife. door is
* Press recife button.
in the recife. position.

* Fresh/recife. door is
in the fresh position.
Air is discharged
from face outlets.
* Air is not discharged
from face outlets.
* Air is discharged
from appropriate outlets.
Air is not discharged
From appropriate outlets.
* Fan goes to low speed.
* Fan doesn't go to low
speed.
Refer to diagnostic tests

C&D.
* Fan goes to high speed
'Gotol!.
, Set to face mode.
* Repeat 7 for facelfloor

floor/screen & floor modes.
* Refer to "vacuum system

* Press the manual fan
speed override.
* Adjust to low speed.
* Ramp the fan override
to high speed.
ie. until H is displayed.
diagnosis"
Go to 8.
* Refer to "vacuum system

diagnosis"
* Go to 9.
diagnosis"
Go to 9.
NB: A click should be

heard from fan speed
controller between speeds 9
& 10 or H as high fan relay
is activated.
11
* Fan does not go to high
, Refer to diagnostic test C.
speed.
The word Auto appears
in the display.
System check completed.
416
DIAGNOSTIC CHARTS
AUTOMATIC CLIMATE CONTROL DIAGNOSTIC TEST

Note: The AAC system diagnosis test are designed to identify causes of system malfunctions.
DIAGNOSTIC
TEST
A
SYMPTOM
POSSIBLE CAUSE
* Cool discharge air
* Heater malfunction.
when system is set to

AUTO/30"C.
* Blend door not in

maximum heat position.
* Cabin sensor is shorted.
* Wann discharge air
Clutch malfunction
when system is set to

AUTOI1S"C.
TESTIREPATR
PROCEDURE
* Check ifhot water valve is
open. If not, refer to "vacuum

system diagnosis"
* Refer to "blend door actuator
motordiagnosis"
* Check resistance across sensor
terminals. Change if shorted.
* Check circuit.
* Check compressor clutch is
operational.
* Remove glove box door.

Disconnectcompressorclutch
* No fan.
* High fan only.
* Fan won't go to high

speed.
* AlC is on continually.
* Control head digits

and LEOs do not light up.
electrical connector.
* Light should illuminate with
ignition on and AUTO/IS"C
setting indicating that fault is in
loom to compressor or clutch
solenoid.
Iflight doesn't illuminate trace
circuit back to control unit and if
OK change control unit.
* Blend door not in
* Refer to "blend door actuator
motor diagnosis"
maximum cold position.
* Low refrigerant level.
* Diagnosis as described in part??
* Faulty wiring.
* Check circuit.
* Faulty fan controller.
* Change fan controller.
* Faulty fan motor.
* Change fan motor.
* Faulty control unit.
* Change control unit.
* Faulty wiring.
* Check circuit.
* Faulty wiring.
* Check circuit.
* Short circuit in
evaporalor sensor.
terminals. Change sensor if
shorted.
* Faulty wiring.
* Check circuit.
* Replace fuse.
* Fuse.
* Ignition circuit.
* Check circuit.
* Check circuit.
* Illumination circuit.
* fIIumination dimming circuit. * Check circuit.
* Ground circuit.
* Check circuit.
417
DIAGNOSTIC CHARTS
DIAGNOSTIC
TEST
H
SYMPTOM
PossmLE CAUSE
* System stays in cold
Engine sensor open circuit.
engine lockout air to screen

low fan speed when engine
has reached normal operating
TESTLREPAIR
PROCEDURE
Check sensor is connected.
Check circuit.
* Check sensor resistance
- should be less than 5 kOhm.
temperature.
* System does not control
* Cabin sensor hose not
* Inspect and repair. Refer to
temperature.
connected to sensor or air
diagnostic procedures.
hose.
* Cabin vacuum engine line
* I nspect and repair. Refer to
sensor obstructed or not
installed properly.
* Cabin sensor hose kinked
or damaged.
* Vacuum line disconnected.
Inspect and repair. Refer to

* Check vacuum cOIUlections from

vacuum solenoid pack and or
engine vacuum port.
System runs hot during

hi gh sun load conditions.
* Sun load sensor open
* Check if sensor is connected.
circuit.
* Check sensor is not covered.
*Check sensor function. Referto

* System over cools at
normal comfort settings.
*. Ambient
sensor short
.
ClfCUIt.
* Check circuit.
* Check circuit.
terminals. Change sensor if
shorted.
AIR BAG DIAGNOSTIC TROUBLE

CODES - EF MODELS
PRIORITY CODE
No Lamp.
Highest
Continuous
Lamp.
12
13
14
21
22
23
24
32
33
34
35
41
42
44
45
52
COMPONENTIFAULTDESCRll'TION
Inoperative indicator circuit.
Fault code timed out, diagnostic monitor disconnected or inoperative, or no ignition
voltage to diagnostic monitor.
Low battery voltage.
Air bag ci rcuit shorted to ground or crash sensor resistance to ground.
Crash sensor circuit shorted to ground.
Diagnostic monitor not mounted to vehicle properly.
Sating sensor output circuit shorted to battery voltage.
Memory clear circuit failure.
System disarm failure or internal diagnostic monitor fault.
Air bag circuit low resistance or open circuit.
Resistor high resistance or open circuit.
Air bag circuit low resistance or shorted.
Resistor shorted or low resistance.
Dash crash sensor feed/return circuit open.
Front crash sensor feed/return circuit open.
Dash crash sensor not mounted to vehicle properly.
Front crash sensor not mounted to vehicle properly.
Intermittent or repaired low battery voltage.
418
DIAGNOSTIC CHARTS
PRIORITY CODE
53
72
73
74
75
81
82
84
85
COMPONENTIFAULTDESCRIPTION
Imermillent or repaired air bag circuit shorted to ground or crash sensor resistor to
ground.
Intermittent or repaired crash sensor circuit shorted to ground.
lmermillentor repaired diagnostic monitor not mounted to vehicle properly.
Intermittent or repaired safing sensor output circuit shorted to battery voltage.
Intermittent or repaired memory clear circuit failure.
Intermittent or repaired system disarm failure or internal diagnostic monitor fault.
Intermittent or repaired air bag circuit high resistance to open circuit.
Intermittent or repaired resistor high resistance or open circuit.
Intermittent or repaired air bag circuit low resistance or shorted.
Intermittent or repaired resistor shorted or low resistance.
Intermittent or repaired dash crash sensor feed/return circuit open.
Intermittent or repaired front crash sensor feed/return circuit open.
Intermittent or repaired dash crash sensor not mounted to vehicle properly.
Intermittent or repaired front crash sensor not mounted to vehicle properly.
Continuous
flash - no
code.
Tone.
Both crash sensors disconnected.

Lamp inoperative and some other fault exists.
54
61
62
63
64
Lowest
AIR BAG DIAGNOSTIC TROUBLE

CODES - EL MODELS
DTC
LFC
COMPONENTIF AULTDESCRIPTION
B 1869
No Lamp.
Inoperative indicatorcircuit.
Fault code timed out, diagnostic monitor disconnected or inoperative, or no ignition
voltage to diagnostic monitor.
Low ballery voltage.
Air bag circuit shorted to ground or crash sensor resistance to ground.
Crash sensor circuit shorted to ground.
Diagnostic monitor not mounted to vehicle properly.
Safing sensor output circuit shorted to battery voltage.
Memory clear circuit failure.
System disarm failure or internal diagnostic monitor fault.
internal microprocessor fault. (set during on demand self test only).
Driver Air Bag circuit high resistance or open circuit.
Passenger Air Bag (where fitted) or Resistor (where no passenger air bag fitted)
High resistance or open circuit.
Driver Air Bag circuit low resistance or shorted.
Passenger Air Bag (where fitted) or Resistor (where no passenger air bag fitted)
Shorted or low resistance.
Dash crash sensor feed/return circuit open.
Front crash sensor feed/return circuit open.
Dash crash sensor not mounted to vehicle properly.
Front crash sensor not mounted to vehicle properly.
Intermittent or repaired low battery voltage.
Intermittent or repaired air bag circuit shorted to ground or crash sensor resistor to
ground.
Intermittent or repaired crash sensor circuit shorted to ground.
Continuous
B
B
B
B
B
B
B
B
B
B
1867
1913
1914
1921
1922
1923
1924
1342
1932
1933
Lamp.
12
13
14
21
22
23
24
24
32
33
B 1934
B 1935
34
35
B
B
B
B
B
B
1941
1942
1944
1945
1952
1913
41
42
44
45
52
53
B 1914
54
419
Updates I Corrections Falcon EFIEL
Updates I Corrections Falcon EF/EL

Timing chain marks: Page 31 /32
/---~
Sprocket~
\
Timing Mark Aligned
Camshaft
3 Degrees Above
Rocker Cover Rai!
Timing
Chain ............
Idler S haft Sprocket
Timing Marks On
Crankshaft
Sprocl!.et
Sprockets Aligned
Automatic Transmission Band

Adjustment: Page 138
Front Band
1. From the transmission case measure the protrusion
ofthc front servo push rod.
2. To the front servo apply area (8 I outer); apply air
pressure at 6501700 kPa.
3. Measure the travel of the push rod.
4. Subtract 3mm /Tom travel to determine shim size.
5. Release air.
6. Install the shim between the ease abutment face and
the anchor strut flange. Install shim by hand pressing
on until a click is heard which indicates shim is clipped
home correctly.
Note: Do no/force or hammer shims into position.
7. Rc-check push rod travel is within specification.
Push Rod Travel:
3rnrn +/- O.25rnrn
Rear Band
1. Using a set of vernier calipers measure the distance
/Tom the rear servo piston to the inner face of
transmission case (distance A).
2. To the rear servo apply area (B2 outer); apply air
pressure at 6501700 kPa.
3. Measure the travel of the piston.
4. Subtract 3. 75mm /Tom travel, then divide the
remainder by 2.5 to determine shim size.
5. Release air.
6. Install the shim between the case abutment face and
the anchor strut flange. Install shim by hand pressing
on until a click is heard which indicates shim is clipped
home correctly.
Note: Do notforce or hammer shims inlo position.
7. Re-check push rod travel is within specitication.
Push Rod Travel:
3.75mm +/-O.625mm
En~iflC
I
61 Outcr
FRO:<OT BAND ADJ UHMEr'-'T
420

Ef El WSM

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INDEX

EP.F5 - FALCON I FAIRLANE - 1994 to 1998 - EF EL - Automotive Repair Manual

Automatic Climate Control ............................... .. .. ............ _........................................................................ .............. 314

GENERAL INFORMATION -- MODEL IDENTIFICATION

GENERAL INFORMA TION

GENERAL INFORMATION -- Model Identifiacation (C'td)

Body Type Sedan

PAINT COLOUR AND CODE

TRIM TYPE, COLOUR AND CODE

ENGINE TUNE-UP & MAINTENANCE

Check Oil Level

BeltAdjustment (idlerpulley) ...................................... 10

Removal .. ........ ............ .................... .......................... . 12

Belt Tension ............................................................... 10

PROBLEM DIAGNOSIS ...................................... 14

ENGINE TUNE UP & MAINTENANCE

ENGINE TUNE-UP &

Engine Oil Dip Stick

6 Cylinder MPEFI Engine

The recommended oil quality should be used, as vehicles

* The oil filter should be changed every 10,000 Kilometres

2. Replace the clips on the air filter housing.

ENGINE TUNE-UP & MAINTENANCE

excessively damaged, dirty oroily.

to cross thread the compression tester into the head.

6. Crank the engine over several times on the starter motor

Inspection of High Tension Lead.

and record the highest test.

starter motor. This would be expected from an engine in good

Resistance: 25k ohms f lead

Spark plug lead

REPLACE DRIVE BELTandADJUSTBELT

High Tension Leads

Use a screw in type of compression tester gauge, as these

Stages of Belt Wear:

1. NEW BELT: Cracks or chunks.

---'----the spark plugs and

Drive belt must be checked often to ensure that it is still in

give the most accurate

Incorrectly adjusted drive belts will cause belt squeal and

Aluminium heads are quite soft, so care must be taken not

ENGINE TUNE-UP & MAINTENANCE

Coolant Specification: e.g_

Belt's that have operated for 10-15 minutes are treated as a

The vehicles havea self adjusting idJerpulley setup on them,

1_ Fit3/S" dri ve socket bar to idler pulley mount bracket, and

Slot For Socket

INSPECTVALVECI EA.R ANCE

Top-up or refill of Coolant

Six cylinder and VS's have non adjustable rocker arm

ENGINE TUNE-UP & MAINTENANCE

TESTING BATTERY ELECTROLYTE (ACID)

WARNING: When batteries are being charged explosive

A hydrometer should be used to detennine the specific

recently been charged.

Specific gravity of 1.26 indicates

SPARK PLUG INSPECTION-6 cylinder & V8

1. Clean and Inspect Spark Plugs.

USING THE HYDROMETER

Bend the outer electrode carefully

V8 Correct electrode gap:

3. Spark plug type.

1.210 to 1.24() ...................................................... 75%