DIREZIONE ASSISTENZA
CONTENTS
GENERAL VIEWS . . , . . . . . . . . . . . . . .OO-2
Dimensions and weights. . . . . . . . . . . OO-2
MODEL VARIATION . . . . . . . . . . . . . . . OO-3
IDENTIFICATION DATA . . . . . . . . . . . .OO-5
LIFTING POINTS AND
...G . TOWING . . . . . . . . . . . . . . . . u., . . . . . .OO-6
.-.
Pantograph jack . . . . . . . . . . . . . . . . . 00-6
Garage jack and safety stands. . . . . . . 00-7
Towing. . . . . . . . . . . . . . . . . . . . . . . , OO-7
SPECIAL SERVICE TOOLS., . . . . . . . . .OO-8
INSTRUCTIONS FOR PRE-DELIVERY
INSPECTION AND PERIODICAL
MAINTENANCE COUPONS. . . . ; . . . . . . OO-8
Pre-delivery . . . . . . . . . . . . . . u . . . . . 00-8
Checking level . . . . . . . . . . . . . . . . . . 00-8
Functional tests . . . . ; . . . . . . . . . . . . . 00-8
Cleaning and finishing inspection. . _ _ 00-8
Maintenance. . . , . . . . _ ........... 00-10
MAINTENANCE SCHEDULE. . . . . . . . . . 00-l 1
..
:,--FLUIDS AND LUBRICANTS CHART . . 00-19
*. RECCOMMENDED FUEL AND
LUBRICANTS . . . . . . . . . . . . . . . . . . . . -00-20
Fuel..........................OO-2 0
Fluids and lubricants . . . . . . . . . . . . . 00-21
APPROXIMATE REFILL CAPACITIES. 00-24
ENGINE MAINTENANCE . . . . . . . . . . .OO-24
Basic mechanical system . . . . . . . . . . 00-24
Ignition and fuel system. . . . . . . . . . . 00-28
Checking CO% . . . . . . . . . . . . . . . . . . OO-29
TROUBLE DIAGNOSIS AND
CORRECTIONS . . . . . . . . . . . . . . . . . . . .OO-32
CHASSIS AND BODY MA!NTENANCE. 00-39
Checking fuel and exhaust system . _ . 00-39
Clutch . . . . . . . . . . . . . . . . . . . . . . . . OO-39
Gearbox-differential . . . . . . . . . . . . . . 00-39
Assembly drive shaft . . . . . . . . . . . . . 00-39
Front axle and front suspension. . . . . 00-39
Rear axle and rear suspension. . . . . . . 00-40
Checking suspension heights . . . . . . . 00-40
Wheel alignment. . . . . . . . . . . . . . . . . 00-42
Brake system . . . . . . . . . . . . . . . . . . . OO-43
Steering system . . . . . . . . . . . . . . . . . 00-45
Body . . . . . . . . . . . . . . . . . . . . . . . ..OO-4 5
SERVICE DATA AND
SPECIFICATIONS. . . . . . . . . . . . . . . . . . OO-45
Engine maintenance . . . . . . . . . . . . . . .OO-45
Chassis and body maintenance. . . . . . 00-47
SPECIAL SERVICE TOOLS . . . . . . . . . :OO-48 .
May 1983
 COMPLETE CAR

GENERAL VIEWS

DIMENSIONS AND WEIGHTS .; . -

1
Model 1200 1350 1500
identification number 905.00 905.02 905.04 - 905.05
405.03 905.06 - 905.07

Wheelbase P m m ( i n ) 2 4 5 5 (96.651
Front Ca 1392 (54.8) -... IT
Track m m (in) .:
Rear CP 1359 (53.5)

Overall length LLI m m (in) 4015 (158.07)

Front Sa 800 (31.5)
Overhang mm (in)
Rear SP 760 (29.921

Overall width La m m (in) 1612 (63.46)

Height (unladen) H m m (in1 1305 (51.38)

Ground clearance m m (in) 121 (4.76)

Min. steering radius mm (in) 4700 (185.04)

Kerb weight kg (lb) 890 (1962.1)

Max. allowed aross weiaht ks (lb) 1 3 1 5 (2899)

Payload kg (lb) 425 (936.91

Front 725 (1598.31
Max. allowed axle gross weight kg (lb)
Rear 725 (1598.31

Max. towing gross weight kg (lb) 1000 (2204.6)

Front 2
Seating capacity
Rear \ \ 3

May 1 9 8 3
 COMPLETE CAR

MODEL VARIATION
(Except Switzerland, Sweden, Australia)

Body
Model 1200
I
5 -door saloon
1350
1500
WADRIFOGLIO

5 - door saloon
1500

-r
Drive Left qight Left Right Left Right Left Right

- on certification

Identification No. 905.02 905.03 905.04 905.OE 905.06 905.07

- on identification
label

- on identification
905 A - 905 Al 905 A2 905 A2
label
Type approval No.
- on intermediate
905 A00 905 Al 0 906 A20 905A20
bulkhead label

- on intermediate from from from

Serial NO.
bulkhead label 05.001 .OO 05.001 .OOl 0 5 . 0 0 1 .OOl

305.02 305.04
Type and serial No. from from
000.000.1 000.000.1

Tire dimensions 165170 SR 13 165170 SR 13 165170 SR 13

5Jx13H2 5Jx 13H2

Rim dimensions 5J x 13 H2 or Or

5 /2J x 13 CH 5 /ml x 13 CH

00-3 May 1983

 COMPLETE CAR

IDENTIFICATION DATA

IDENTIFICATION LABELS 5 - Door Saloon 1200 - .I350 - 1500

(Except Switzerland, Sweden, Australia)

Certification and identification label

(Identification No. and Type approval No.)
Intermediate bulkhead label-(Type approval
No. and serial No.)
Cylinder block label (Engine No.)
Lubrication data label (see Fluids and Lubricants
of each grouplllubrication data)
Paint label (This label indicates the product
used for the first paintl(Paint)

VEHICLE IDENTIFICATION (2) Serial number: progressively used as vehicle service identification
(AND SERVICE) DATA assigned by Production. number. This number consists of five
(3) Type approval number: not figure numbers, divided as follows:
VEHICLE IDENTIFICATION for service identification use; for 4a) Basic type number: it is assigned
CODES service purposes, use the type to all vehicles having a common
number which iS stamped on design concept (Ex.: 905: Saloon).
A) Chassis numbering identification label along with the 4b) Type variant number: it identi-
type approval number. fies, within the basic type, those
z A I? 9 0 5 A00 0 5 . 0 0 2 . 4 5 8 The following is an example of such vehicles that differ because of some
(I) (3) (2) label. variant that alters their features (Ex.:
905.02 5-door Saloon).
(1) Manufacturer identification let-
ters. (4) Identification number: to be

00-S May 1983

 COMPLETE CAR

B) Engine numbering
It consists of two sets of figures,
ALFA ROMEO AUTO SPA
II I II
namely:

305.00 00045 12
(I) (2)

(I) Type number: ir is assigned to

s all engines having common gen-
eral technical characteristics
(Ex.: 305.02: 1350 engine with
twin carburetor).
(2) S e r i a l n u m b e r : p r o g r e s s i v e l y
assigned by production.

LIFTING POINTS AND TOWING

PANTOGRAPH JACK

WARNING:
a. Never get under the vehicle
while it is supported only by the
iack. Always use safety stands to
support frame when you have to
work under the vehicle.
*,-+, - ? b. Place wheel chocks at both front
and back of the wheels diagonal-
ly opposite the jacks position.

Fit pantograph jack, supplied with

the vehicle, to safety points shown in
figure.

May 1983 00-B

 COMPLETE CAR

GARAGE JACK AND SAFETY STANDS

TOWING
WARNING:
Closely follow Motor Vehicle Fiegu- d. Set ignition key to GAR and
a. When raising vehicle with garage
lations r e g a r d i n g v e h i c l e t o w i n g . do not withdraw it from switch;
jack, be sure to support it with
otherwise antitheft device could
safety stands.
become engaged.
b. When jacking up the rear (front)
e. Release parking brake and set
of the vehicle, place chocks in CAUTION: gearshaft lever to neutral be-
front (in back) of the front
Use proper towing equipment to fore starting to tow the vehicle.
(rear) wheels. avoid possible damage to the f. Do not apply lateral forces to
vehicle. towing hook. Keep towing bar
Before towing, make sure that or similar devices always in
front and rear axes as well as line with the vehicle.
CAUTION:
steering system are in good g. Remember that when vehicle is
When raising the vehicle, always
working condition; contrarywise being towed, there is no vacuum
place a wooden block under vehicles
use a dolly. in servobrake; consequently,
lifting points.
If vehicle must be towed with its when braking, greater pressure
Position garage jack and safety stands
rear wheels raised, front wheels must be applied onto brake
in a safe manner under the points
m u s t b e p l a c e d o n a towing pedal.
shown in the figure.
dolly.

00-7 May 1983


SPECIAL SERVICE TOOLS
Special service tools play a very
important role in a vehicles majnte-
nance since they are essential to
ensure accurate, reliable and quick
service. To this effect, it must be
remembered that times taken rele-
vant to the various maintenance
operations are computed assuming
that said special tools are being used.
A l l special; s e r v i c e t o o l s , m a d e
INSTRUCTIONS FOR PRE-DELIVERY INSPECTION
AND PERIODICAL MAINTENANCE COUPONS
In this chapter are listed and
described all pre-delivery and main-
tenance operations required by
AI-FA 33 models.
As far as technical specifications
regarding each operation are con-
cerned, r e f e r t o e a c h s e c t i o n s
relevant Service Data and Specifica-
tions chapter.
PRE-DELIVERY
Pi-e-delivery inspection of a new
vehicle, prior to customer delivery,
consists in carrying out all checking
operations and tests hereafter
described in order to detect and thus
eliminate any damage or malfunc-
tion.
It goes without saying, however, that
when Dealer personnel picks-up the
vehicle should perform a visual check
in order to:
- make sure that vehicle is in
normal driving condition, espe-
cially as regards level of fluids
and controls in general
- detect any dents or scratcheson
body or other damage to the
vehicles interior (upholstery)
- make sure nothing is missing,
especially factory supplied ac-
cessories, spare tire and any
r parts that are to be fitted on
vehicle only prior to customer
delivery.
If checking operations show that
topping up -as foreseen by this text -
May 1983
COMPLETE CAR
expressly on the manufacturers
design, needed for overhauling, main-
tenance and repair of models are
listed and illustrated in this manual.
The identification number is deter-
mined by the relevant ordering part
number and consists of *a letter
followed by a five figure number
according to the following schedule:
is required, proceed accordingly;
such operation will be considered as
part of pre-delivery inspection. In
case damages or malfunctions other
than those herein described are
encountered, they will have to be
taken care of repair or adjust accord-
ing to current technical and adminis-
trative procedures. As each operation
is being carried out, the relevant card
must be filled out and then filed
together with the sold vehicles other
documents; also the pre-delivery
card included in the Instruction
Book supplied to the customer must
be duly filled out as demostration of
strictly execution of pre-delivery
checks.
CHECKING LEVEL
Coolant
- When engine is cold, check level
in expansion reservoir. If re-
quired, top up to specified max.
level.
Engine oil
- Check if level is up to MAX.
mark on dipstick (carry out this
operation after having parked
the vehicle on an even surface
and after the engine has been off
for a few minutes). If required,
top up with specified oil.
Gearbox and Differential oil
- Remove filler cap and check if
00-a ,
A.O.OOOO Special Service Tool
c.0.0000 Tester
u.0.0000 Reamer
Order of the listed tools by the
authorized workshop, must be per-
formed according to the usual
systems alretidy followed by each
Service - net.
oil level reaches the filler lower
edge. If required, top up with
specified oil and fit cap back.
Brake and clutch fluid
- Check if level in the reservoir is
up to max. mark. If required,
t o p up w i t h s p e c i f i e d f l u i d
remembering that tins must be
sealed and opened only when
ready to use..
Be sure to perform this opera-
tion with utmost care and
cleanliness.
Battery electrolyte
- Check and make sure electrolyte
covers the plate upper edge by 5
mm (0,2 in); contrarywise, top
up with distilled water.
Windshield washer fluid
- Check if relevant reservoir is full;
if required, top up with specified
solution.
Tire pressure
- Check tire pressure and, if
required, restore to specified
values. Use higher p.s.i. for spare
tire.
FUNCTIONAL TESTS
Engine starting and idling
- Check if engine starts properly.
When engine is warm, check
specified idle-rpm.

Engine controls
- Check and make sure starter
control knob works freely,
without sticking; further check
that when this knob is pushed
in, respective device is not at all
engaged on carburetor.
- Check accelerator pedal and
make sure it does not stick; also
check that when pedal is pushed
down all the way, throttle valve
is fully open.
Brake, clutch and gearbox controls
- With engine running, push brake
pedal and check if after the
initial stroke - it comes without
elasticity.
Also check if parking brake
control lever works properly.
- With engine running, push clutch
pedal down and make sure that
all gearbox speeds engage easily,
without sticking and noiselessly.
Tightening wheel screws
- Use a spanner and check if wheel
screws, are properly tightened.
Also check if screws, are in
compliance with vehicle and rim
type, as shown in the Spare Parts
Catalogue.
Dashboard instruments
- While starting up the engine,
check if all electrically con-
trolled instruments work proper-
ly (needles are moving): rpm
indicator, oil pressure gauge,
water temperature gauge, fuel
level indicator, and clock.
System circuits tightness
- Visually check circuits of follow-
ing systems for leaks or evidence
thereof: fuel, brake, clutch, and
engine cooling.
- Check engine, gearbox and dif-
ferential for evidence of oil
leaks.
Engine cooling electric fan
- Connect and short-circuit wires
of radiator thermal contact and
check if fan starts and works
properly.
Also make sure that wires are
properly and securely connected
to thermal contact.
COMPLETE CAR
Heating system
- Check proper working condition
of levers controlling heater and
outlets for admission of air into
the vehicle (open and close).
- Check if electric fan works
properly at different speeds and
if relevant warning light on the
board lights up.
Lights, signal, electrical accessory
equipment
- With ignition key set to M A R
check if lights outside and inside
the vehicle, as well as relevant
warning lights, go on: front
and rear parking lights, number
plate lights, direction indicators
and emergency flasher, stop
lights, high and low beam
headlights, headlights flasher,
reverse gear lights, rear fog lights
inside ceiling lamp (through
manual as well as door switch),
instrument cluster light.
- Check proper working condition
of following warning lights:
alternator, fuel reserve, oil pres-
sure, brake fluid level, parking
brake on, starter on, defroster
on, cooling water temperature.
- Check proper operation of horns
and cigarette lighter.
Windshield and rear window wiper
and washer
- After having installed wiper
blades, check if windshield wiper
works properly at both speeds as
well as it is set to intermittent
operation.
- Operate the windshield washer
and check if sprayer jets are
normal and properly directed
toward the windshields higher
section.
Locks, hinges, windows
- Check proper working condition
of all door locks (close, lock,
open from inside and outside).
Check in the same manner also
locks of engine and back door.
- Check door and bonnet hinges
for smooth noiseless operation.
- Check if windows can be opened
and closed all the way without
sticking and noiselessly.
00-9
Doors and bonnets
- Visually check all weather-
stripping for tight fit and make
sure they are not damaged, out
of shape or dirty.
-y See if doors and bonnets are
aligned and centered with rele-
vant openings.
Seats, seat belt and ac!essory equip-
ment
- After having removed relevant
protecting covers, inspect seats
checking if they slide freely on
tracks without sticking and
noiselessly. Also check proper
working condition of seat and
head-rest adjusting devices.
- Check if seat belts and relevant
retractors are in good working
condition.
- Check inside and outside
rear-view mirrors making sure
they swing easily and stay firmly
in place when set; also check
s n a p switch on m i r r o r f o r
day/night driving.
- Check maneuverability of sun-
visors, ashtrays, glove compart-
ment and any other accessory.
CLEANING AND
FINISHING
INSPECTION
Exterior cleaning
- If required, dewax the vehicle
using suitable products and
procedures; wash the vehicles
exterior with a solution of
water and shampoo, rinse it
thoroughly and dry it.
Finish up cleaning by removing
any stubborn spots by means of
suitable compounds.
Paint
- Visually and thoroughly check
all painted surfaces and remove
accidental or manufacturing
flaws, if any.
Exterior/Interior mouldings and fit-
tings
- Visually check all vehicles out-
May 1983

side parts: bumpers, mouldings,
grills, headlight rims, letters and
emblems making sure they are
securely fitted, and *have n o
spots or dents.
Verify all upholsteries (roof,
carpets, panels etc ..) removing
possible stains or scratches.
Factory issued accessory equipment
- Check if following items are in
their proper place in the vehicle:
tool kit, spare tire, jack, Instruc-
tion Book and Service Book.
May 1983
COMPLETE CAR
MAINTENANCE
Maintenance operations consist in
checking and restoring proper work-
ing condition of some parts of the
vehicle which are most likely to
become worn or out-of-adjustment as
a consequence o f t h e v e h i c l e s
normal use.
A list of various operations to be
performed at different intervals, as
shown in the chart that follows, is
included in the coupons of the
Service Book which accompanies
each vehicle.
00-10
Coupons will have to be stamped by
the Service Organisation Agency to
show that specified maintenance
operations have been carried out.
Just as for pre-delivery inspection,
should topping UP or change of fluids
and lubricants - as described in the
text - become necessary, they will be
considered as part of maintenance
o p e r a t i o n s . .In case damages or
malfunctions other than those listed
are encountered, they will be taken
care of repair of adjust according to
current technical and administrative
procedures.
 COMPLETE. CAR

MAINTENANCE SCHEDULE
(Except Switzerland, Sweden, Australia)

i= E E
- - - - -

X X X X X X X X X
- - - - - - -

X X X X X X X X X X
- - - - - - - - -
X X X X X X X X X
- - - - -

X X X X X X X X
- - - - - - - -

X X X X X X
- - - - - -

a= X X X X X

- - - -

0 ::
0 0
P 7
ri
7
5
6 $

00-11 M a y 1983
 COMPLETE CAR

(Except Switzerland, Sweden, Australia)

X X X X

X X

X X X X
-

X X X X

X X X X

X X X X X

0 0 0
7 r
i IO
8 b-l

May 1983 00-12

 COMPLETE CAR

MAINTENANCE SCHEDULE
(Swiss version)

Lu LL! tu tu u w w Lu Lu u w ul lu
N
- 5 5 E E
- - - - - - - - - - - -
X X X X X X X X X X X X X x
- - - - - - - - - - - - - -
X X X X X X X X X X X X X X

X X X X X X X X X X X X X X

X X X X X X X X X X X X X X

- - - - - - - - - -
X X X X X X X X X X X X X x

x X X X X X X X X X

- - - -

X X X x X X X
 COMPLETE CAR

(Swiss version)

2
0

5
K
w
8

z
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T

May 1983 00-14

 COMPLETE CAR

MAINTENANCE SCHEDULE
lSweden version)

- - -
X X X X X X X x
- - -
X X X X X X X X X X X X

- - - -

X X X X X X X X
- - -

X X X X X X X X
- - - -

X X X X X X X X X X

- - - -

X X X X X X
- -

0 0 R
7 v
P 8 L-4
s a 6

00-15 May 1983

 COMPLETE CAR

MAINTENANCE SCHEDULE
(Australia version)

X X X X X X X X

- - - - - -

X X

- - - - - -
X X X X X X X X
- - - - - -

X X

- - - - - -

X X X X X X X
- - - - - -
X X

- - - - -

X X X X X X X X
- - - - - -

x X

- - - - - -

x X X X X X X X
- - - - - -
X X

- - - - - -

X X X X

- - - - - -

+G

g
_m
0
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N W N

00-I 7 May 1983

 COMPLETE CAR

FLUIDS AND LUBRICANTS CHART

May 1983
 COMPLETE CAR

RECOMMENDED FUEL AND -LUBRICANTS

FUEL
To ensure proper engine operation,
use petrol with a 2 98 Octane Rating
(R.M.) and a G 1 1 s e n s i t i v i t y (I).

(1) Difference between Research Method

Oct%ne Rating and Motor Method Octane
Rating.
 COMPLETE CAR

FLUIDS AND LUBRICANTS

- -

::
c
.P
Y
.-&
.-I
P
!A
-

00-2 1 May 1983

 COMPLETE CAR

*
k
z

*
n

*
E
wa

May 1983
 COMPLETE CAR
i

APPROXIMATE REFILL CAPACITIES

APPROXIMATE REFILL CA P A C I T I E S I kg (lb) I 1 (Imp gal 1

FUEL TANK 50 (11)

FUEL RESERVE - 6.5 (I ,431

COOLANT - 7.3 (I ,611

With filter 3.6 (7.94)

ENGINE OIL SUMP
Without filter 3.15 (6.94)

GEARBOX-DIFFERENTIAL OIL
- IO2 (14F)
2.3 + 2.4 (5.1 + 5.3) -

1.8 (0.40)
CONCENTRATE ANTI FREEZE QUANTITY
DEPENDING ON TEMPERATURE
E - 2 0 C (-4F)
- 35C (-31F)

(4F)
- 2.6 (0.57)
3.65 (0.80)

ANTIFREEZE QUANTITY READY FOR USE - - 20C I - I 7.3 (1.61)

CAM SHAFT SUPPORT SUMPS 01 L Kg 0.250 (lb 0.55) FOR EACH

SUPPORT (REFILL TO BE C A R R I E D OUT IN CASE OF DISASSEMBLIES 0.5 (1.1)
ONLY-COMPLETELY DRY SUPPORTS

ENGINE MAINTENANCE
BASIC MECHANICAL
SYSTEM

CHECK AND POSSIBLE 2. Insert the key A . 5 0 1 9 3 i n t o

ADJUSTMENT OF VALVE proper hole on camshaft,
CLEARANCE 3. Further rotate crankshaft so that
camshaft hole is in line with the
Following operations must be per- adjusting screw on the cup.
formed while engine is cold. 4. Suitably rotate the cup involved
in the adjusting operation as well as
1. Disassemble spark plugs, remove the one next to it so that relevant
camshaft support cover and, by cavities will face each other.
means of a syringe, suck oil from 5. Introduce tool A.2.0278 for
tank. retaining of valve cups in order to
2. Using the feeler gauge C.6.0168 prevent rotation of cups during
check clearance between cam resting clearance adjustment (tool does not
radius and cup crown making sure it prevent axial sliding).
is within specified value.

Valve clearance (cold engine) In case clearance is not within the

Intake prescribed values, carry out adjust-
0.35 + 0.40 mm (0.014 + 0.016 in) ment operating as follows:
Exhaust 1. Rotate crankshaft till piston is in
0.45 + 0.50 mm (0.018 + 0.020 in) its compression stroke (valve closed).

May 1983 00-24

 COMPLETE CAR

1 Bolt 3 Screw
2 Bolt

Replacing timing belts with

engine on car
6. Interpose tool C.6.0168 between
tapper bucket upper part and cam 1 Mark on rear cover
REMOVAL 2 T - shaped reference mark
minimum radius and, by means of
wrench A.5.0193, operate until the
1. Disconnect electric fan wiring,
prescribed clearance is obtained. 6. Loosen idler pulleys lock
0
. loosen relevant screws 0 and
nuts 1 and then press idler
7 . For better security check clear- remove fan from radiator through
p u l l e y s @ so a s t o o v e r c o m e
ance after having removed previously lower channel 0.
tension load on belts. Tighten
inserted cup locking pin.
nuts 0 while in this position.
8. Repeat the procedure for each
valve of the two heads.
9. At the end of operation, restore
the tank oil level and reassemble
cover and spark plugs.

CHECKING, REPLACING
AND ADJUSTING DRIVE
BELTS

Alternator and water pump

control belt

Inspect belt for cracks or damage.

Replace it if necessary. Push on belt
longest section, located between
engine pulley and alternator pulley,
applying an 79 N (8 kg; 3.63 lb) load
and verify relevant deflection which
should be of 15 mm (0.59 in);
contrarywise proceed to adjust belt
tension as follows.
7. Loosen bolts
well as screws 8 1 and 0 as
3 that secure
alternator support bracket to the
engines front cover.
2. Move the alternator so as to
either stretch or slacken the belt and
then tighter&gain bolt 0.
3. Check again belt tension and
then tighten all previously loosened
bolts.
w2
1 Screw 2 Channel
2. Remove spark plugs, alternator
and water pump control belt.
3. Remove camshaft belts plastic
covers.
4. Remove camshaft support cov-
ers.
5. Remove timing plastic cover
located on cylinder block rear cover,
and rotate crankshaft till piston in
no. 1 cylinder is set in top dead
center on its combustion -stroke.
Such correct position is achieved
when the T-shaped reference
mark @ on flywheel is in line with
0.
the mark on rear cover 1
1 Lock nur 2 Idler pulley
7. Now remote first the right hand
cogged belt and then the left hand
belt from camshaft and crakshaft
pulleys.
ASSEMBLY
CAUTION:
Check again engine timing proceed-
ing as per step Sabove.
1. Rotate camshafts till reference
marks stamped on same are in line
with those stamped on relevant
support.

00-25 May 1983


2 . Key camshaft control belts. onto
crankshaft and camshaft pulleys
starting with the one of the left hand
cylinder head.
(1) Belt keying must take place
while belt pulling section (opposite
the idler pulleys) is fully stretched.
(2) Loosen idler pulleys lock nuts all
the way and then tighten them again.
(3) Let driving shaft rotate in the
functioning direction so as to allow
belt to set on pulleys.
(4) Set, one by one, the camshafts
to the neutral position, then unloos-
en nuts securing backstand, press a
few times on them and secure nuts to
the prescribed torque.
(5) Rotate crankshaft a few times in
its working direction so that belts
may take up their final position.
Rotate camshafts till they are in
neutral position: loosen idler pulleys
lock nuts pressing idler pulleys a few
times, and then tighten relevant nuts
according to specified torque.
Rotate crankshaft a few times in its
working direction thus allowing belts
to settle on pulleys, and then repeat
above described tension checking
operation while positioning cam-
shafts one at the time - with cups
disengaged.
@ : Tightening torque
Idler pulley lock nut
(cold engine)
37+46 N-m
(3.8 + 4.7 k g - m
27.49 + 33.98 ft-lb)
May 1983
COMPLETE CAR
3. Check again engine timing.
4. Fit back camshaft support cov-
ers, alternator and water pump
control belt, electric fan and spark
plugs.
5. Start engine and warm it up to
normal running temperature, then
remove again camshaft support cov-
ers. Working on one cylinder head at
the time, proceed as follows: bring
. A milky oil indicates the pres-
relevant camshaft in neutral position,
ence of cooling water.
loosen and then tighten again idler
Identify the cause and take
pulley lock nut thus giving the belt in
corrective measures.
its final tension load.
. An oil with extremely low
viscosity indicates dilution with
petrol.
@ : Tightening torque
Idler pulley lock nut
2 . Using an oil filter wrench,
(warm engine)
remove oil filter.
29+35 N - m
(3 + 3.6 k g - m
2 1 . 3 8 f 2 5 . 8 ft.lb)
6. Fit back camshaft support cov-
ers and timing belts covers.
CHANGING ENGINE OIL
ANQ REPLACING OIL
FILTER
1. With engine warm, remove oil
filler cap and oil pan drain plug 3. When engine oil is completely
letting oil drain completely into a drained, clean oil pan drain plug and
suitable container (wait at least 15 screw it back into place.
minutes). 4. Moisten the gasket of the new
oil filter and then install the filter
tightening it all the way.
5 . Refill engine with specified new
oil referring to LUBRICANTS &hart.
Check oil level with dipstick.
ENGINE OIL QUANTITY
1 kg 1 (lb)
Camshaft support sumps (*I 0.25 (0.55)
Engine oil sump 3.60 (7.94)
Sump capacity 3 . 1 5 (6.94)
Filter capacity 0 . 4 5 (1 .OO)
(*I Refill to be carried out, far each sump.
in case of disassembly only.
00-26
 COMPLETE CAR

6. Fit oil filler cap back and start
the engine letting it idle for about 2
minutes.
7. Now check following items for
any oil leaks: filter, pan, seal rings,
oil pressure transmitter, gaskets of
cylinder block and cylider head
covers, and cylinder head gaskets. If
necessary, tighten or replace items
that are not oil tight.
8. Turn the engine off and wait a
few minutes.
9. Take out dipstick and clean it;
fit dipstick back, take it out again
and check oil level making sure it
reaches the MAX reference mark.
CAUTION:
When checking oil level, park the car
on a level surFace.
COOLING SYSTEM
1 Coolant drain plugs
3. Fill cooling system with recom-
mended anti-incrustator following
relevant instructions for use.
Recommended anti-incrustator:
NALCO 1006
INTERPROIND Jal Auto
Stand. No. 3681-69955
4. Remove again drain plugs from
cylinder block bottom and let
anti-incrutiator drain completely.
5. Thoroughly flush the system
with running water.
6. Fit drain plugs back to cylinder
block and fill the radiator.
System refill
After having drained the cooling
system, refill it with the kind and
quantity of coolant as shown in
the following chart.
Sunimertime
Drinkable water I 7.3
(Imp Gal ) (1.61)
Refill radiator through relevant filler
according to following instructions:
1. Refill the system till max. level
mark in expansion reservoir is
reached.
2. Start the engine and warm it up
to normal running temperature thus
allowing the thermostat to open and
to expel any air that was left over in
the system.
3. When engine is cold, top up
cooling system till max. level mark in
expansion reservoir is reached.
4. Fit filler cap back and.tighten it.
Checking the system
1. Check coolant level in radiator
making sure it is within MAX and
MIN level marks.
2. Check hoses and unions for leaks
making sure they are not in any way
damaged.
3. Check filler cap making sure
relevant spring, gasket and valves are
in good working condition.
4. Test the electric fan as follows:
(1) Disconnect thermostat wires and
short-circuit them.
(2) Turn ignition key and check if
electric fan-starts up.
5. Check radiator as per instruc-
tions contained in Group 07 - Radia-
tor.
6. If top-up requires an abnormally
large amount of coolant, check entire
cooling system for leaks and elimi-
nate them.

System flushing Radiator cap pressure test

This operation should be performed 1. Fit union @ onto tester and
only if plain water is used as engine Minimum out- C - IO -20
then insert it on expansion reservoir
coolant in summertime. side temperature (S (14) (- 4)
cap.
Concentrated anti- 2. Apply pressure to the cap and
freeze Std. No. check tester to make sure that when
368 I-69956 I 1.8 2.6 3.65
specified pressure reading is reached,
1. While engine is cold, remove (Imp Gal ) (0.40 (0.57) (0.80)
the relief valve opens up.
radiator filler cap. Diluting drinkable
water 5.5 4.7 3.65
2. L o o s e n and remove drain (Imp Gal ! Il.211 (I .03) (0.80)
plugs 0, located on bottom of
Ready-to-use anti- Radiator filler cap relief pressure:
cylinder block, let coolant drain freeze Std. No. 68.6 kPa (0.69 bar;
completely and then fit plugs back 3681-69958 I 7.3
0 . 7 kg/cm; 9.96 p.s;i.l
on cylinder block bottom and (Imp Gal 1 (1.61)
tighten them.

00-27 May 1983


1 Tester 3 Filler cap
2 Union
Cooling system pressure test
1. Remove expansion reservoir cap.
2. Tighten tester onto expansion
reservoir filler.
3. Apply pressure to the cooling
system and check tester to make sure
that pressure remains within spec-
ified value.
Cooling system testing pressure:
107.9 kPa (I.08 bar;
1.1 kg/cm; 15.65 p.s.i.1
May 1983
COMPLETE CAR
CHECKING CYLINDER
COMPRESSION
When diagnostic poor engine perfor-
mance because power is not up to
normal, it is advisable to test cylinder
compression using relevant tester
(MOTOMETER) and according to
following procedure:
1. Start rhe engine and warm it up
t o n o r m a l running temperature.
2. Remove spark plugs.
3. Disconnect distributors high
voltage cable.
4. Apply compression tester onto
the seat of one spark plug.
5. _ Crank the engine briefly keeping
the accelerator pedal fully pressed so
that carburetor throttle valve is fully
open.
6. Verify that compression pressure
is above min. value (make sure there
are no leaks from testers union).
Min. compression pressure
1030 kPa (IO.3 bar;
10.5 kg/cm2 ; 149.34 p.s.i.1
7. Repeat the test to check com-
pression in other cylinders, being
careful to reset the tester each
time. Compare the readings and
make sure that max. difference
between the various cylinder pressure
measurements does not exceed speci-
fied value.
Max. compression difference
between cylinders
98 kPa (0.98 bar;
1 kg/cm; 14.22 p.s.i.1
If picked up values are not within
specified ones, look for the troubles
cause in poor tightness of the valves
00-28
or between cylinder liners and
pistons.
REPLACING AIR CLEANER
CARTRIDGE
I. Unfasten air cleaner cover retain-
ing spring clips 0.
2. Lift cover 0 and remove
cartridge.
3. Thoroughly clean cartridge by
blowing low pressure compressed air
from within.
If necessary, replace cartridge.
1 Cover
2 Air cleaner cover retaining spring clip
IGNITION AND FUEL
SYSTEM
CHECKING AND REPLACING
SPARK PLUGS
1. Disconnect spark plug wires with
relevant protecting boots.
2. Remove spark plugs with spark
plug wrench.
3. Clean electrodes and check insu-
lation for cracks and chips.
If electrodes are excessively worn,
replace the spark plugs.
S p a r k p l u g t y p e : L O D G E 2 5 HL
4. When replacing spark plugs, coat
plug thread with specified grease and
then fit them in relevant seat tighten-
ing them according to specified
torque.

Spark plug thread:
ISECO Grease: Molykote A - Std.
No.4500-18304
@ : Tightening torque
Spark plugs
25+34 N-m
(2.5+ 3.5 kg-m
18.08 + 25.31 ft.lb)
5. Connect spark plug wires and fit
back relevant protecting boots ac-
cording to following sequence: I - 3 -
2 - 4.
CHECKING IGNITION
WIRING
1. Visually check ignition wiring
for cracks, burns and loose terminals.
2. Measure resistance of high volt-
age cable by connecting an ohmme-
ter between the cables terminal and
the corresponding electrode on the
ignition coil.
COMPLETE CAR
CHECKING THE
DISTRIBUTOR
Visual check
1. Remove distributor cap and
rotor @ and check them for cracks
or chips.
2. Make sure that distributor cap
carbon is securely kept in place in its
seat by the relevant spring and that it
moves freely thus ensuring proper
constant adherence to distributor
rotor.
3. Apply a coating of engine oil to
felt inside rotor control shaft and a
coating of specified grease to cam.
.
P
oo-2 9
CHECKING CO%
CHECKING AND ADJUSTING
IGNITION TIMING,
IDLE-RPM AND COY..
I. Connect stroboscopic flash lamp
feed clamps to the battery and the
pickup to the high voltage cable of
cylinder no. 1.
2. Connect an electronic tachome-
ter to the engine by fitting feed
clamps to the ignition coils feeding
and the pickup to the coils high
voltage cable.
May 1983
 COMPLETE CAR

3. Remove the small plastic covet CHECKING AND ADJUSTING

located on the engine rear cover.
1 Advance hose
2 Ignition timing check hole
IDLE-RPM AND CO%
Preliminary inspection:
a. Clean or replace air cleaner.
b. Inspect ignition system making
sure following parts are in good
working condition: spark plugs,
cables, distributor cap, rotor
arm, (refer to: Group 05 - Igni-
tion System).
C. Check ignition timing.
d. Check adjustment of acceleratar
control (see: Group 04 - Accel-
erator Control).
CAUTION:
If during engine tune up there is no
extra cooling fan available, keep
checking indicator pump and the
water temperature gauge on dash-
board and immediately suspend
testing if temperature goes up,
meaning that engine is overheating.
Check idle-rpm and overall CO% as
follows:
1. Insert CO-tester probe @ into
the tail pipe 0.
2. Connect an electronic tachome-
ter to the engine.

4. Start the engine and warm it up

to normal running temperature.

5. Using the stroboscopic flash
lamp, check if - with engine running
at g 900 r.p.m. - the mark on the
engine rear cover is in line with the
fixed advance notch on flywheel.

Fixed advance
8% 1

6. Disconnect the vacuum advance

hose from distributor and verify that
when engine at 4500 r.p.m. the mark
on the engine rear cover is in line
with the max. advance notch on
flywheel.

Max. advance
36+ 1

7. If specified alignment does not

take place, loosen the distributor
retaining bolt and rotate distributor
either clockwise to retard or anti-
clockwise to advance.
8. Tighten the distributor retaining
bolt and check fixed and max.
advance to make sure they are
within specified values.
9. Fit the small plastic cover back
onto engine rear cover.
10. Fit vacuum advance hose back
onto distributor.
If above described adjustment does
not succeed in correcting max. 1 Tail pipe 2 CO-tester probe

advance, overhaul or replace the

distributor.

May 1983 00-30


3. Start the workshops gas ex-
hauster.
4. Srart the engine and warm it up
to normal running temperature.
5. Now check if engine rpm is
within specified value.
Idle-rpm
900 + 1000 r.p.m.
850 + 950 r.p.m. ( l )
(1 (for Switzerland, Sweden,
Australia)
6. If not within specified value,
adjust idle-r-pm just by turning
relevant idle-adjusting screw @
which makes it possible to change
rpm without changing CO percentage
(Carbon monoxide).
.. 7. Verify that CO percentage
picked up by tester corresponds to
specified value and that engine
runs smoothly.
Ajlowed CO %
< 3.5 % total
If not within specified value or in
case of engine tune up after engine
overhauling or after having cleaned
or replaced the carburetor, an
adjustment involving also mixture
metering screw @) and throttle
valve screw @) is required. In this
instance, proceed as follows:
(1) Remove seals from mixture
metering screw 0 and from throt-
tle valve screw 0.
(2) Tighten idling screw @ all the
way.
( 3 ) N o w act on throttle valve
screw 0 3 and on mixture metering
screw @ till following conditions are
present:
Rpm
850
8 0 0 (*)
C O %
0.5 + 1% total
() for Switzerland, Sweden,
Australia
(4) Loosen idling adjusting
screw @ till a 900 + 1000 rpm
(850 + 950 rpm for Switzerland,
COMPLETE CAR
Sweden, Australia) idling speed is
reached.
(5) Act on mixture metering
screw @ till the smoothest possible
engine running is obtained, while
keeping CO% within the prescribed
valves.
CO%
< 3.5% total
0 . 7 + 2 . 4 % (*)
() for Switzerland, Sweden, Aus-
tralia
(6) Fit back into place mixture
metering and throttle valve screw
seals,
(7) ff further optimizing of idle-rpm
is desired, just act on.relevant idling
adjusting screw 0.
1 Idling mixture metering screw
2 Idling adjusting screw
3 Throttle valve adjusting screw
EMISSION CONTROL
SYSTEM
Recycling of exhaust gas and oil
vapors, generating in the cylinder
block and then burned in the cylin-
ders, is achieved through a series of
blow-by hoses.
At any rpm, the vacuum created in
the carburetor is sufficient to convey
gas and vapors into intake duct and
from here into cylinders for final
combustion.
When engine is idling or running at
00-3 1
medium rpm, the vapors going up the
oil filler go through the flame trap
located in the hose @ connecting
oil filler to air cleaner; from here
then they go through the min. rpm
blow-by hose @ and, downstream
from throttle valve, are distributed
onto intake manifold @ _
Since when the accelerator is fully
depressed the vacuum generated by
the engine is not sufficient to com-
pletely suck exhaust gases solely
through the min. rpm hose, gases are
also conveyed inside air cleaner,
upstream from carburetor, by means
of the max. rpm blow-by hose 0.
CHECKING HOSES AND
UNIONS
1. Inspect hoses and unions to
make sure they are not in any way
damaged and that are no leaks.
2. Disconnect all hoses and clean
them blowing a jet of compressed air
through them.
Replace any damaged hose.
3. Remove flame trap located in
main blow-by hose near the oil filler;
wash it with suitable cleaner, blow it
with compressed air and, then fit
it into place.
Air cleaner
Max. rpm blow-by hose
Main blow-by hose
Oil filter
Min. rpm blow-by hose
Carburetor
Intake manifold
Cvlinder block
May 1 9 8 3
 COMPLETE CAR /

CLEANING CARBURETOR REPLACING FUEL FILTER

JETS
If necessary, clean carburetor jets
and blow-by hoses as follows:
a. Remove air cleaner, carburetor
cover, and then remove main jets
as well as idle jets.
Loosen hose clamps and remove the
b. Clean jets with compressed air
filter. Install a new filter paying
(do not use any metal tool) and
special attention to the fuel flowing
then fit them back onto carbure-
direction as indicated on filter body.
tor; also fit cover and air cleaner.
Tighten hose clamps.

TROUBLE DIAGNOSIS AND CORRECTIONS

Condition Probable cause Corrective action

CANNOT CRANK ENGINE l Dead battery Recharge and check recharge system
OR SLOW CRANKING
l Faulty battery Replace

l Oxidized battery terminals Clean terminals

l Loose wiring connections in Correct

starting circuit

l Faulty starter switch Replace

l Faulty starter Repair or replace

(Starting circuit trouble-shooting procedure)

Turn on starter while lights are on (set switch to ON).

If lights go off or dim considerably:
a. Check battery
b. Clean battery terminals

If lights stay bright and starter does not work:

a. Check wiring connection between battery and starter

b. Check starter switch
c. Check starter

ENGINE CRANKS NORMALLY BUT WILL NOT START

In most cases the trouble lies either in the ignition system or in the fuel system.

- Trouble in ignition system

- Trouble in fuel system
- Valves do not work properly
- Low compression

(Trouble-shooting procedure)
First of all check spark plugs as follows:
Disconnect high voltage cable from one spark plug and hold it about 10 mm (0.39 in) from any engine metal part
and let the starter run.

CAUTION
Above test must be performed with uttermost care.

May 1983 00-32

 COMPLETE CAR

Condition Probable cause Corrective action

Spark is good:

a. Check spark plug

b. Check ignition timing
C. Check fuel system
d. Check cylinder compression

Spark is not good:

Ignition system is out of order l Low or no current in primary Check primary circuit for loose or
circuit disconnected terminals

Verify that the electronic ignition unit

is properly functioning

l Rotor arm current leakage Clean or replace

l Faulty spark plugs Clean, adjust electrode gap or replace

l Improper ignition timing Adjust

l Faulty ignition coil Replace

l Cut-off in high voltage cable Replace

l Loose connection or cut-off Repair or replace

in primary circuit

Fuel system is out of order l Lack of fuel Refuel

l Dirty fuel filter Clean

l Dirty or clogged fuel pipes Clean

l Faulty fuel pump Replace

l Faulty carburetor choke Check and adjust

l Incorrect float level adjustment Adjust

l Improper idling Adjust

l Dirty or clogged carburetor jets Disassemble and clean

l Clogged fuel tank breather pipe Repair and clean

Low compression l Incorrect spark plug tightening Tighten to normal

l Incorrect valve clearance Adjust

l Compression leaks from valve Remove cylinder head and lap valves
seats

l Seized valve stem Replace valve and valve guide

00-33 May 1983

 COMPLETE CAR

Condition Probable cause Corrective action

High engine idling l Stiff accelerator cable and Check

linkage

l Incorrect idle adjustment Adjust

l Malfunctioning throttle valve Check

ENGINE POWER NOT UP TO NORMAL

Low compression Previously mentioned Previously mentioned

Ignition system out of order l Incorrect ignition timing Adjust

l Dirty or worn spark plugs Clean or replace

l Incorrect advance Adjust

Fuel system out of order Previously mentioned

Other b Faulty fuel pump Replace

I Clogged fuel pipes Clean

Air intake system out of l Clogged air cleaner Replace cartridge

order
l Air sucking around manifold Replace gasket
gasket or carburetor gasket

Overheating l Insufficient coolant Replenish

l Broken water pump drive belt Replace

l Faulty thermostat Replace

l Faulty water pump Replace

l . Clogged or leaky radiator Clean, repair or replace

l Faulty electric fan Replace

l Faulty thermal switch Replace

l Air in cooling system Restore proper cooling system

tightness

l Clogged jets (lean mixture) Overhaul carburetor

l Incorrect ignition timing Adjust

Overcooling l Faulty thermostat Replace

l Faulty thermal switch Replace

00-35 May 1983

 COMPLETE CAR

Condition Probable cause Corrective action

Other Petrol used has low octane rating Replace with petrol having specified
octane rating

Dragging brakes Adjust

1 Slipping clutch Adjust or replace

NOISY ENGINE (while driving)

Engine knocking b Overloaded engine Use proper gear in driving

I Knocking due to carbon deposit Disassemble cylinder head and remove

carbon deposit

I Knocking due to incorrect Adjust ignition timin,g

ignition timing

m Knocking due to improper petrol Use petrol having specified octane rating

. Preignition (due to wrong type Replace with specified type spark plugs
spark plugs)

Mechanical knocking

Crankshaft bearings knocking l Worn crankshaft bearings Replace bearings and either grind or
replace crankshaft. Check lubrication
This strong dull noise increases as system
engine is accelerated

Connecting rod bearings
knocking
l Worn connecting rod bearings Same as for above crankshaft bearings
This is a slightly higher-pitched
noise than the one caused by knock-
ing of crankshaft bearings and it
also increases as engine is acceler-
ated

Noisy pistons l Pistons and/or cylinder liners Overhaul the engine

are w( 2-r

This is a diffused metallic noise

which increases as rpm increase
and decreases when engine is warm

Noisy water pump l Play in rotor Replace water pump

l Improper adjustment of valve Adjust

clearance

l Excessive crankshaft end play Replace crankshaft axial bearings

May 1983 00-36

 COMPLETE CAR

Condition Probable cause Corrective action

ABNORMAL COMBUSTION
(backfire, self-ignition,
detonations)

Incorrect ignition l Incorrect ignition timing Adjust timing

l Wrong type spark plugs Replace with recommended type plugs

Fuel system out of order Previously mentioned Previously mentioned

Faulty cylinder heads l Incorrect valve clearance Adjust

l Excessive carbon deposit in Desassemble cylinder heads and remove

combustion chambers carbon deposit

l Damaged valve springs (backfire Replace

detonations)

EXCESSIVE OIL CONSUMPTION

Oil leaks l Loose oil drain plug Tighten it

l Loose oil pan screws Tighten or replace

l Worn or damaged oil pan gasket Replace gasket

l Worn or damaged cylinder block Replace gaskets and oil seal rings
and cylinder head gaskets and oil
seal rings

l Loose oil filter Tighten or replace, if necessary

l Loose oil pressure switch Tighten

l Dipstick does not fit tightly Replace dipstick

Excessive oil consumption l Worn cylinders and pistons Grind cylinders and replace pistons

l Improperly assembled piston Assemble properly

rings

l Worn piston rings Replace piston rings or, if required,

grind cylinders and replace pistons

l Worn piston rings and piston Replace pistons and rings

ring seats

l Worn valve guides and grommets Replace valve guides and grommets

l Worn valve sEems Replace valves

Other l Improper oil grade Replace with specified oil type

l Engine overheats Previously mentioned

00-37 May 1983

 COMPLETE CAR

Condition Probable cause Corrective action

EXCESSIVE FUEL CONSUMPTION

Engine power not up to Previously mentioned Previously mentioned

normal

Other l Idling too high Adjust idling

l Improper accelerator recovery Adjust

l Fuel leaks Repair or tighten fuel line unions

l Clogged air cleaner Replace cartridge

l Improperly adjusted carburetor Adjust

l Worn or damaged carburetor Replace gaskets

gaskets

OTHER PROBLEMS

Reduced oil pressure l Improper oil grade Replace with specified oil type

l Oil is missing Replenish with specified oil type

l Overheating Previously mentioned

0 Worn oil pump control valve Disassemble oil pump, repair or

replace it

l Worn oil pump Repair or replace

l Excessive play of sliding parts Disassemble and replace worn parts

l Clogged oil filter Replace cartridge

l Faulty oil pressure switch Replace

Excessive wear of sliding l Insufficient oil pressure Previously mentioned

parts
l Improper oil grade or contami- Replace with specified type oil and
nated oil replace cartridge

l Faulty air cleaner Replace cartridge

l Overheating or overcooling Previously mentioned

Seizing of sliding parts l Insufficient oil pressure Previously mentioned

l Insufficient clearances Adjust to specified values

l Overheating Previously mentioned

 COMPLETE CAR

CHASSIS AND BODY MAINTENANCE

CHECKING FUEL CLUTCH

AND EXHAUST
SYSTEM
1. Check fuel and exhaust systems,
especially at connections, making
sure there are no leaks.
2. Check condition of all fuel and
exhaust pipes replacing same if
required.
3. Tighten all loose connections.
CHECKING CLUTCH SYSTEM
Check clutch pump @ and clutch
control cylinder @ making sure
there are not oil leaks. If required,
tighten unions according to specified
torques or either overhaul or replace
faulty parts (Refer to: Group 12 -
Tightening Torques).
Make sure that clutch pump a n d
control cylinder boots are not in any
way damaged.

1 Oil supply plug 2 Oil drain plug

ASSEMBLY
DRIVE SHAFT
CHECKING DRIVE SHAFT
ASSEMBLY
Visually check drive shaft assembly
for wear or deformation of its
various components, making sure
protecting boots are not in any way
damaged or show grease leakage.
If necessary, replace damaged or
worn parts.

1 Clutch pump
2 Clutchcontrol cylinder FRONT AXLE AND
FRONT SUSPENSION
GEARBOX- CHECKING FRONT AXLE
DIFFERENTIAL AND SUSPENSION

CHECKING 2. Let oil drain completely (wait at 1. Block rear wheels with chocks
and raise front of vehicle fitting jack
GEARBOX-D1 FFERENTIAL least 15 minutes); clean drain
plug @ and tighten it. to proper lifting points (Refer to:
OIL LEVEL
3 . R e f i l l o i l p a n t h r o u g h SUPPIY Lifting Points and Towing).
Check oil level making sure it reaches 2. Check front suspension parts for
hole 0 with specified oil type and
filler lower edge; clean relevant cap wear or damage.
quantity. Refer to LUBRICANTS
and tighten it. Also check all bolts for proper
chart for recommended oil type.
tightening; refer to: Group 21 -
REPLACING Tightening Torques - for relevant
GEARBOX-DIFFERENTIAL Gearbox-Differential casing Oil tightening torques.
OIL wpacity Replace worn parts according to
1. While engine is warm, remove oil 2.3 + 2.4 kg (5.07 + 5.29 lb) relevant procedures described in
pan drain @ and supply 0 plugs. G r o u p 2 1 Front Suspension.

00-39 May 1983


3. Check shock absorbers for oil
leaks or damage.
4. Remove wheels.
5. Check brake pads for wear
(Refer to: G r o u p 22 - Front Disc
Brake).
REAR AXLE AND
REAR SUSPENSION
CHECKING REAR AXLE
AND SUSPENSION PARTS
1. Check rear axle and suspension
for loose, worn or damaged parts.
2. With vehicle in nominal driving
condition, i.e. with static load (Refer
to: Checking Suspension Heights),
tighten loose bolts according to
specified tightening torque. Refer to:
Group 25 Service Data and Specifi-
cations for relevant tightening
torques.
3. Replace worn parts according to
the relevant procedures described in
Group 25.
May 1983
COMPLETE CAR
ADJUSTING WHEEL
BEARING PRELOAD
After replacement or disassembly of
bearings, carry out adjustment oper-
ating as follows.
For wheel bearing replacement refer
to Group 25.
1. Tighten wheel bearing lock-nut
according to specified torque and at
the same time turn hub 4 + 5 times
in both directions to allow bearings
to settle.
@ : Tightening torque
Wheel bearing lock-nut
25 + 29 N-m
(2.5 + 3 k g - m
1 8 . 0 8 + 2 1 . 6 9 &lb)
2. Partially unscrew lock-nut a n d
hit the hub with a mallet to ensure
outer bearing settling against washer
and.nut.
3. t-land tighten the nut (moder-
ately, so as to obtain a less
t h a n 1 N.m; 0 . 1 kg.m; 0 . 7 2 ftalb -
torque).
4. Check and make sure axial play
is within specified value.
Bearing axial play
0 + 0.05 mm (0 + 0.002 in)
00-40
5. Caulk nut taking care to avoid
rotation in order not to alter clear-
ance play.
Apply specified grease quantity to
bearings in the suspension.
CHECKING
SUSPENSION
HEIGHTS
Be sure to perform following prelim-
inary operations:
a. Set up vehicle with all refill
liquids at max. level and with
spare wheel.
b. Check tire pressure; refer to
Wheels and Tires for specified
values.
c. Place car on lift.
Load weights on vehicle as
d.
shown in below figure.
e. Move vehicle up and down on
suspensions a few times.
Static load equivalent to three
passengers plus luggage
Passenger equivalent to
A i- 6 = 490 + 245 = 735 N
(50 + 25 = 75 k g )
(110 +55= 165 lb)
Luggage C = 490 N (50 kg; 1 IO lb)

FRONT SUSPENSION
HEIGHT
Check front wheel alignment picking
up specified K dimension which is
obtained by drawing two lines
parallel to floor plane respectively
passing through below defined
points 1 and 2.
Point 1:
it is the intersection between the
fidimension must be picked up for
both front right and front left
suspensions.
DIMENSION MEASUREMENT
1. Carry out measurement of
dimension relevant to step 1. making
use of the following tools and
COMPLETE CAR
plane passing on the base of the nut
connecting hub support to control
arm, and the straight line tangent to
the hub support.
Point 2:
axis of the bolt securing control arm
to chassis.
Front wheel alignment dimension
A=12+7mm
(0.47 4 0.28 i n )
setting the graded movable stem of
check tool to the complete backward
position (see following figure).
(I) Rule @ A-4.0146.
(2) T o o l for suspension height
check@ A.4.0149.
(3) Probe 0 A-4.0150.
00-41
1 Probe
2 Height check tool
3 Rule
2. Carry out measurement of
dimension relevant to step 2. making
u s e o f t h e f o l l o w i n g tools a n d
moving only graded stem of check
tool.
(1) Rule @ A.4.0146.
(2) T o o l for suspension height
c h e c k @ A.4.0149.
(3) Magnetic adapter @ A.4.0153.
1 Magnetic adapter
2 Tool for suspension height check
3 Rule
3. Directly read on graded scale
(located on movable stem of check
tool) rhe&height dimension value.
REAR SUSPENSION HEIGHT
(1) Check rear wheel alignmentby
measuring specified B dimension
which is the distance between the
two lines parallel to floor plane and
passing through below defined
points 1 and 2.
May 1983

Point 1:
Axis of bolt @ securing front rod
to wheel support.
Point 2:
Axis of bolt @ securing front rod
to body.
Car rear suspension height dimension
B = 23 * 7 mm (0.90 f 0.27 in)
Measurement of Bdimension must
be carried out both for right tie rod
and for left tie rod of rear suspen-
sion.
DIMENSION MEASUREMENT
1. Carry out measurement of
dimension relevant to point 1 and 2
making use of the following tools.
(1) Rule @ A.4.0146.
(2) T o o l f o r suspension heights
check @ A.4.0149.
(3) Magnetic adapter @ A.4.0206.
May 1983
COMPLETE CAR
1 Magnetic adapter 3 Rule
2 Check tool
Proceed as follows to carry out
dimension measurement relevant to
point 1; set graded movable stem of
check tool to the completely back-
ward position, then measure dimen-
sion relevant to point 2. by moving
only graded stem of tool.
2. Directly read on graded scale
(located on movable stem of check
tool) the value ofBheight dimen-
sion.
In case the read values differ from
the prescribed ones, replace springs.
WHEEL ALIGNMENT
CHECKING FRONT WHEEL
ALIGNMENT
Be sure to perform following prelim-
inary operations prior to checking
and, if necessary, adjust front wheel
angles.
a. Check tire pressure; refer to
Group 28 - Checking Tire
Conditions.
b. Set up vehicle with static load.
c. Pick up front wheel alignment&
dimension as well as rear wheel
alignment B dimension (Refer
to: Checking Suspension
Heights).
1. Toe-out
On aligned wheels, verify that
steering wheel racks are properly
centred. If necessary, w i t h d r a w
00-42
steering wheel and centre racks.
(1) Use suitable equipment and
measure toe-out making sure it is
within specified value.
Toe-out
H - M = +4flmm
(+0.157 f 0.04 in)
Front toe-out angle
a= IO
Wheel rim diameter
0 = 340 mm (13 in)
(2) If necessary, adjust toe-out as
follows:
- Loosen side rod lock-nut
- BY means of tool A-3.0156
disconnect vertical steering lever
ball joint (Refer to: Group
21 - Coil Springs and Shock
absorbers).
- Suitably turn ball joint still
specified toe-out is achieved.
Min. possible toe-out adjustment is
42 mm (0;08 in) on H - M difference
(variation corresponds to 1 turn
- 1 mm (0,039 in) thread lead - of
one ball joint) meaning that semi
toe-out value is equal to:
L = (l/2 M + 2 f 0,5) mm
(l/2 M + 0.08 f 0,020 in)
Orientate joint body @ located
on side rod @ so that, after
being connected to steering
8
lever 4 , the joints upper
level 1 is parallel to the levers
upper level 0.
Tighten lock-nut @ and then
tighten to specified torque the
nuts securing ball joint to
steering lever.
 COMPLETE CAR

@ : Tightening torque Camber angle

Nut securing side rod ball joint
p=O125
onto vertical steering lever
39+448 N - m
( 4 + 4.9 kgdm
2 8 . 9 2 + 3 5 . 4 3 ft.lb)

Camber and caster angles cannot be

adjusted.

4. Max steering angle

s = 33 30
BRAKE SYSTEM
CHECKING BRAKE FLUID
LEVEL

1 Joints upper level

2 Joint body
3 Steering levers upper level
4 Steering lever
5 Side rod
6 Lock nut

(3) Recheck toe-out value.

2. Camber angle
0 = 2015+ 30

CHECKING REAR- WHEEL

ALIGNMENT Check and make sure fluid level in
Rear angles cannot be adjusted. reservoir is not more than l/4 below
max. level. If fluid level is extremely
Toe-in angle low, check brake system for leaks.

a= O1 2 5
CHANGING BRAKE FLUID
1. Connect a hose to wheel
/+ I- _ bleeders and let brake fluid drain
a 1 a into a suitable container (refer
to: Group 22).

-4&
I I CAUTION:
Be extremely careful not to drop any
of the brake fluid on painted surfaces
since it is highly corrosive.

2. Refill system with new oil and

bleed all air from the system (refer
3. Caster angle
to: Group 22 - Brake System Bleed-
y= 1$30
ing).

00-43 May 1983

 COMPLETE CAR

(4) Maneuverability of control lever BODY

3. If required, c a r r y out travel
adjustment by operating on nut and
lock nut of adjustment fork located
under passenger compartment central
console.
4. Besides, verify the following:
(1) With control lever in the test
position also jaws must be at t-est.
(2) When operating control lever,
tables must slide freely.
(3) Indicator lamp must switch on
w i t h i n one click o f p a r k i n g b r a k e
control lever and switch off as soon
as control lever is at rest position.
must result to be easy and smooth
running and when control lever is
engaged hooking tooth must be into
its seat in the scroll gear without
difficulty.
STEERING SYSTEM
1. Check steering for sticking or
stiffness when turning wheels in bath
directions,
2. Rotate steering wheel clockwise
and anticlockwise checking steering
s y s t e m f o r e x c e s s i v e play. F o r
relevant adjustment refer to:
Group 23 - Checks and Inspections -
Rack Box and Guide Tube.
3 . T i g h t e n , w h e r e r e q u i r e d , all
steering system connecting points.
(Refer to: Group 23 - T i g h t e n i n g
torques).
4. Check condition of steering box
protecting boots and replace them if
necessary.
5 . C h e c k s t e e r i n g r o d bal1 a n d
flexible joints; replace them if worn.
LOCKS AND HINGES
1 . L u b r i c a t e h i n g e s a n d locks.
2. Adjust lock striker plates.
CHECKING SEAT BELTS
CAUTION:
. If seat belts have to be washed,
do not use chemical detergents
o r solvents since t h e y could
damage the buckles.
. After a serious accident involv-
ing belt stress, replace same even
if apparently it does not seem to
be damaged.
1. Check anchors making sure they
are not loose on mountings.
2. Check belts for wear.
3. Check proper working condition
of buckles and tongues,
4. Fasten seat belts and check if in
case of sudden movement they are
promptly locked. Contrarywise,
check retractors locking system.
If condition of any seat belt compo-
nent is questionable, replace the
entire belt assembly involved.

SERVICE DATA AND SPECIFICATIONS

ENGINE MAINTENANCE
TECHNICAL DATA - INSPECTION AND ADJUSTMENT
Engine
Engines
1200 I 1350 1500

Valve clearance (cold engine)

Intake m m (in) 0.35GO.40 (0.014+0.016)

Exhaust m m (in) 0 . 4 5 t 0 . 5 0 (0.018+0.020)

Alternator-pump belt tension

Force applied to belt N (kg, lb) 7 9 (8 ;3.63)
Deflection mm (in) 15 (0.59)

Cylinder compression

Min compression pressure kPa (bar , p.s.i. , kg/cm2) 1 0 3 0 (10.30,149.39;10.5)

Max compression difference

between cylinders kPa (bar, p.s.i., kg/cm2) 98 (0.98 ; 14.22 ; 1)

00-45 May 1 9 8 3
 COMPLETE CAR

CHASSIS AND BODY MAINTENANCE

TECHNICAL DATA - INSPECTION AND ADJUSTMENT

Axles and suspensions

Vehicle static loading arrangement (1) N kg, lb) A+6 =490 -1-245 =735 (50+25 =75)
(110 +55 =165)

c = 490 (SOT; (110)

Front wheel alignment mm (in) A =12 f7 (0.47 iO.28)

Rear wheel alignment mm (in) 8 =23+7 (0.90*0,27)

Front wheel toe-out (2) (3) mm (in) M - H =4*1 ( 0 . 1 5 7 f 0 . 0 4 )

Fronr wheel semi toc-out (21 (3) mm (in) L = (1/2 M +2 * 0.5) (l/Z M +0.08 *O.OZ)

Front toe-out angle a=io

Wheel rim diameter mm (in) 0 =340 (13.38)

Rear wheel toe-in a=oOk 25

Front wheel camber (3) p=-215&30

Rear wheel camber p=0&25

Front wheel caster (3) +y=1430

Max steering angle (3) 8 = 33 30

(1) Load vehicle, move it UP and down on suspensions a few times. Checking operations must be performed with vehicle fully set up
for driving.

(2) When turning a steering side rod joint by 360. M - H dimension changes by 2 mm (0.079 in).

(3) These values are referred to a vehicle in nominal driving condition, i. e. with static load

Brake system

Disc brake
Disc min. thickness m m (in) 9 (0.354)
Pad min. thickness m m (in) 7 (0.276)

Drum brake
Lining min. thickness m m (in) 0.5 (0.019)
Max drum inner diameter m m (in) 229.6 (9.04)

Parking brake
Lever stroke, when applying a pulling force of
= 98 N Il0 k g ) (22 lb) 2 notches

00-47 May 1983

 ENGINE MAIN MECHANICAL UNIT

.DRlVE UNIT REMOVAL AND INSTALLATION

REMOVAL

Drive u n i t s u p p o r t s

DETAIL A

040 c4s
(4.1 + 5
29.6 f 36.2)
DETAIL 6
DETAIL C

(kg.m
ftlb)

Drive unit central support

Central supporr to body fixing bolt
Rear support pin
Rear support to body fixing screws
Gearbox casing
Engine unit
Engine front support to crossmember fixing screw
Engine front support

Detail A Central support

Detail 6 Rear support
Detail C Front support

May 1983 01-2

 ENGINE MAIN MECHANICAL UNIT

Engine compartment - Electrlc w i r e s dlsconnectlons

Ignition inductor cable 10 Horn cables

ignition distributor 11 Electric fan supply cable
Cooling temperature transmitter cable 12 Windshield and rear window washers pump cables
Coil high voltage cable 13 Water temperature thermal contact cable
Tachometer and coil low voltage cables 14 Oil pressure manual contact cable
Alternator and alternator warning light supply cable 15 Starter supply cables
Head lamps cables 16 Energization cable
Electric fan thermal switch cables 17 Earth cable on engine cover
Foglamps cables

01-3 May 1983

 ENGINE MAIN MECHANICAL UNIT

E n g i n e c o m p a r t m e n t - Plplng r e l e a s e

1 Fuel pipe
2 Clutch oil supply pipe
3 Expansion tank plug
4 Air bleeder into crankcase
5 Sleeve for water return from radiator
6 Sleeve for water delivery to radiator
7 Servobrake vacuum pipe
6 Hot water to heater supply pipe
9 Heater warer return pipe

May 1983 01-4


During engine removal from car, it is
necessary to remove engine and
gearbox - differential as single
unit.
Put the vehicle on the auto lift and
engage first gear.
Great care is required when dealing
~~tY~~~~~ngine~
1. Operating from passenger com-
partment inside withdraw knob of
gearbox lever, then remove the
two lever bellows.
2. Remove the hood (refer to:
Group 56 - Hoods).
3. Working from inside the engine
compartment, disconnect the battery
earth cab le.
4. Disassemble the air filter as
follo\lvs:
(1) Disconnect the corrugated air
intake pipes from the air filter by
taking off the fixing clamps.
(2) Disconnect the blow-by pipes.
Then remove the filter (Refer to:
Group 04 Air Filter - Removal).
5. Disconnect accelerator and
starter controls as follows:
(1) Extract the retaining ring 0,
slip the return spring @ off its
clamps and take off the slotted
a d j u s t e r @ from the throttle
control lever.
(2) Release accelerator cable to-
gether with bracket @ unscrewing
the two securing screws located on
intake manifold.
(3) Disconnect hose and sheath of
starter control of operating on sheath
securing screw @ and on starter
control lever screw 0.
1
2
3
Bracket
screw
Screw
4
5
6
Spring
Retaining ring
Adjuster
May 1983
ENGINE MAIN MECHANICAL UNIT
6. With reference to the figure on after draining.
page 01-3 disconnect the following 9. Depending on what is to be
electric cables, preferably as indi- done, drain the oil from the oil sump
cated : - by removing the plug @ and, if
. earth cable @I, from the necessary, drain the oil from the
engine rear cover gearbox by removing the drain
. high voltage cable @, from the plug 0. Screw the plugs again after
coil draining.
. low voltage and tachometer
j cables @ from coil
. alternator and warning light
supply cable @, from the
alternator
l water temperature thermal con-
tact cable @, from the thermal
contact on the right hand head
. electric fan supply cable 0 ,
from the fan
. windshield and rear window
washers pump cables @ from
the pump
l starter motor supply I@ and
energization @ cables from
the starter motor
. oil pressure switch cable @ , 1 Gearbox oil drain plug
from manual contact on the rear 2 Engine oil drain plug
cover 3 Right head coolant drain plug
4 Left head coolant drain Plug
. electric fan thermal contact
cable @, from the thermal
10. Lower the vehicle and with
contact on radiator
reference to figure of page 01-4,
. fog lamp supply cables @,
disconnect the following pipes and
from fog lamp connectors
couplings, preferably as indicated:
l head lamp supply cables 0,
hot water to heater delivery
from the headlamps
pipe @, from the supply mani-
. horn supply cables @I , from
fold
the horns
water from heater return
. water temperature transmitter
pipe @, from the water pump
cable @ , from the transmitter
intake
on the intake manifold
delivery pipe @ to block from
l electronic ignition inductor
the water pump intake
cable a from distributor
water delivery coupling @, to
. remove ignition distributor
0
radiator
cap 2 together with spark plug
radiator water return coupl-
cables
ing 0, from the water pump
. oil level sensor cable, from level
intake
rod (for models fitted with
fuel inlet line 0, from supply
check control, only)
pump
clutch oil delivery hose 0,
CAUTION:
from pipe union (properly plug
Unfix the electrical cables from their
the hose)
clamps, separate them from the drive
servobrake vacuum intake
unit so as not to impede its removal.
pipe 0, from the suction mani-
7. Unscrew and remove the coolant fold.
expansion tank plug.
8. Raise the car and from beneath 11. Loosen bolt 0 securing engine
remove the right hand drain plug 3
under the cylinder block and drain
8
and then the left hand drain plug 4
central support @ to body.
off the coolant; screw the plugs again
01-6
 ENGINE MAIN MECHANICAL UNIT

INSTALLATION

1 Central support 6 Bolt securing gearbox rear support

2 Central support securing bolt 7 Exhaust pipe
3 Rear support 8 Engine cross member securing screw
4 Pin 9 Engine support cross member
5 Rear support securing screw 10 Front elastic support

CAUTION: 3. Remove the lifter and unloose illustration put the side rod @ in
Drive unit assembly must be per- the lower bolt @ securing the the support @ on the right side
formed in such a way that the gearbox to the rear support. rail @ then tighten, first,
gearbox rear support and the engine 4. Put the rod @ in the rear screw @, second, screw 0.
front support are not respectively support 0, positioning it on its
upwards a n d l o n g i t u d i n a l l y pre- body clamping points and screw up
loaded. 0.
the screws 5
5. Screw up the drive shafts to
Referring to preceding illustration, differential shafts joint screws in oil
follow as indicated. with the prescribed torque.
1. Raise the drive unit with the
column lifter used for disassembly
0: Tightening torque
until the centre support axis @ is at
Drive shafts to differential
about the halfway point of the
shafts connection screws
body slot and tighten the relevant
33 f 36 N-m
bolt-@, -+
(3.4 + 3.7 k g - m
Connect the left strut to the engine
24.58 + 26.75 ft-lb)
support cross member and fasten the
cross member in position to the body
with the screws @.
6. Assemble the exhaust pipe 0.
1 Right cylinder 4 Side rod
2. Fasten the front support @ in 7. Clamp the lower bolt @ secur- head 5 Screw
position to the cross member tighten- ing the rear support to the gearbox. 2 Right side rail 6 Screw
ing the correct screws. 8. With reference to the following 3 Support

May 1983 01-8


9. Complete the unit assemble
carrying out the disassembly opera-
tions in reverse order, with particular
attention to the following steps.
(I) By means of a spanner, tighten
to the prescribed indicative torque,
the union connecting hose to clutch
control pipe.
0: Tightening indicative torque
relevant to hose union to pipe.
15 + 19 N.m
(1.5 + 1.9 kg-m
10.84 + 13.78 ft.lb)
(2) Check The engine oil
c&responds to the MAX mark on the
dipstick, and the gearbox oil level
reaches the lower edge of the filler
hole. If necessary, top up with the
SEPARATION AND ASSEMBLY OF THE UNITS
SEPARATION
With the drive unit on the rotatory
stand fitted with suitable supporting
equipment, separate the engine unit
from the gearbox unit for the pur-
pose of replacement or overhaul of
the two units and of the clutch, as
follows:
1. Unscrew and take off the nuts
and washers @ from the starter
motor 0 securing screws 0
and remove the starter motor from
the engine unit.
1 Nut and washer 3 Starter motor
2 Screw
ENGINE MAIN MECHANICAL UNIT
prescribed oil: Summer
Engine oil Potable water
AGIP Sint 2000 lOW50
I P S u p e r M o t o r O i l lOW50 Winter
Antifreeze (See Unit 07 -
Gearbox oil differential: General Directives)
AGIP Fl Rotra HP SAE SOW90
IP Pontiax HD SOW90 (5) Adjust the accelerator cable (See
Unit 04 Accelerator Wire Adjust-
(3) Bleed the clutch hydraulic merit).
system (See Unit 12 - H y d r a u l i c (6) With the engine at running heat,
check its idling. For any tuning up
System Bleeding) and if necessary
top up the oil level to the MAX mark required, see Unit 00 Engine
Maintenance - Ignition and Feed
on the tank with the prescribed fluid
(AGIP Fl Brake Fluid Super HD or System.
level IP Auto Fluid FR).
(4) Top up the coolant with the
prescribed liquid.
ASSEMBLY
2. Remove the lower cover @ 1. Lubricate the direct drive shaft
protecting the engine flywheel after working seat with the prescribed
disassembling the screws and wash- grease (Grease Molykote paste G).
0
ers 2 securing the lower cover to 2. Perform assembly operations in
the engine rear cover and to the the reverse order to the separation,
gearbox. tightening connecting nuts and bolts
3. Unscrew and remove the remain- to the prescribed torque.
ing nuts and washers @ and com-
plete the separation of the two units. 0: Tightening torque
Nuts and bolts connecting the
Withdraw the thrust beating from its two units
support on the gearbox so as not to 39 + 48 N-m
(4 + 4.9 kg-m
28.92 + 35.43 ft.lb)
1 Lower cover 3 Nut and washer
2 Screw and washer
0 1 - Q M a y 1983
 ENGINE MAIN MECHANICAL UNIT

ENGINE DISASSEMBLY
@xl

May 1983
 ENGINE MAIN MECHANICAL UNIT

(6.7 + 7.4
48.4 + 53.5)

@ N.m
5.8 f 7.2)
(kwm
fr-lb)

1 Main bearings 13 Compression rings

2 Woodroff key 14 Oil scraper ring
3 Thrust half-ring 15 Oil pump
4 Oil pump gear 16 Oil sump
5 Bush 17 Engine oil drain plug
6 Seal ring 18 Main bearing caps
7 Rear cover 19 Piston
8 Oil plug 20 Connecting rod
9 Flywheel 21 Connecting rod bearings
10 Washer 22 Connecting rod cap
11 Lock ring 23 Crankshaft
12 Fin

May 1983 01-12

 ENGINE MAIN MECHANICAL UNIT

PRELIMINARIES 6. Unscrew and remove screws @

fixing union 0 to block, then
remove the union.
I. R e m o v e d r i v e u n i t f r o m c a r

according to procedures: Drive Unit

Removal and Installation.

2. Remove gearbox unit and clutch

unit from engine according to
procedures: Separation and As-
sembly of the units.

ENGINE UNIT
1 Vacuum advance pipe
2 Distributor securing nut
1. Sequentially remove following
1 Pipe union 2 Screws
parts:
- Oil filter @ u s i n g p r o p e r 4. Remove alternator. Remove carburettor
7.
spanner (1) Loosen securing bolts @ fixing (1) Unscrew the four nuts with
- Dipstick 0. alternator @ and remove driving securing washers carburettor to in-
- P r e s s u r e s w i t c h @ for mini- belt. take manifold.
mum oil pressure check (2) Complete bolts 0 removal and (2) Remove the accelerator cable
-- Thermal contact @ for water take out alternator @ _ return spring securing bracket, carbu-
temperature check from right (3) Unscrews screws @ and re- rettor, relevant gaskets and spacer.
cylinder head. move bracket @.

1 Bolts 3 Screws
2 Alternator 4 Bracket

5. Remove pipings.
8. Remove thermostat
(1) Loosen screws of clamps and (1) Unscrew screws 0, r e m o v e
1 Oil filter 3 Dipstick remove fuel supply pipe 0.
cover @ and thermostat.
2 Pressure switch 4 Thermal contact ( 2 ) L o o s e n s c r e w s @ of water
(2) Unscrew nuts 2 and remove
system coupling @ clamp @ and
thermostat housing8 1 from intake
remove coupling.
manifold @.
2. Remove sparking plugs using
proper box spanner.

3. Remove distributor assembly.

(1) Disconnect vacuum advance
pipe 0 from carburettor.
(2) Loosen distributor securing
nut 0 and withdraw distributor
from rear cover.

1 Thermostat 3 Screws
1 Fuel pipe 3 Coupling housing 4 Intake manifold
2 Clamp 2 Nuts 5 Cover

01-13 May 7983

 ENGINE MAIN MECHANICAL UNIT

9. Remove intake manifold (2) Unscrew right belt stretcher @

(1) Unscrew nuts 0, remove en-
gine lifting bracket @ and mani-
fold 0.
(2) Remove water temperature
transmitter from intake manifold.
securing nut and press on jockey
pulley @ to overcome belts tension
load; lock nut by fixing belt stretcher
in the loose belt position.

1 Belt stretcher 2 Spring

14.
14. Remove camshaft driving belts
rear covers.
15. Remove water pump assembly.
(1) Unscrew screws 1 with wash- . .
(I)
ers
ers securing
securing pulley
pulley
8 22 to
to water
water
pump hub and* remove pump driving
pulley.
1 Jockey pulley 2 Belt stretcher
1 Intake manifold 3 Nuts
2 Bracket

(3) Withdraw belt from pulley on

10. Remove fuel pump assembly
camshaft and on driving shaft,
(1) Unscrew nuts with washers se-
respectively.
curing fuel pump to block rear cov-
(4) Repeat procedure for left head
0
er 4 . camshaft driving belt.
(2) Remove pump 0, spacer 2
and pump control push rod 1 . 8

1 Screws 2 Pulley

(2) Unscrew screws @ securing

w a t e r p u m p @ to block and
remove pump with gasket.
12. Unscrew screws securing pulleys
16. Unscrew nut @ and remove
to camshafts preventing their rota-
right jockey pulley.
tion by toothed spanner A.5.0195,
1 Push rod 3 Pump then remove pulleys.
2 Spacer 4 Cover

11. Remove camshaft driving

toothed belts.
(I) Loosen securing screws and
remove two camshaft driving front
belts guards.

13. Unscrew securing nut and re-

move right belt stretcher @ and 1 Nut 3 Water pump
spring @ _ 2 screws

May 1983 01-14

 ENGINE MAIN MECHANICAL UNIT

17. Lock flywheel by tool A.2.0378. (2) Suck oil from camshaft supports (2) Withdraw upward pump from
18. Unscrew screws 0 and @, tanks with a suitable syringe. block.
remove guard @and engine front ( 3 ) U n s c r e w s c r e w s @ and @

0.
support 4 securing cylinder heads to block;
remove heads with relevant gaskets.
24. Remove block front cover.
( I ) Unscrew screws @ and nuts
with washers @ securing cover @
and remove cover with relevant
gasket.
(2) Remove front oil retaining
ring @ from cover by lever with a
screwdriver.
Replace ring at assembly.

1 Screw 3 Screw 1 Screws 2 Screws

2 Guard 4 Front support

19. Remove pulleys from crank- 22. Remove oil sump.

shaft. (1) Unscrew screws with wash-
(1) Unscrew nut 0. ers 0
1 securing oil sump to block.
(2) Sequentially remove washer @ (2) Remove oil sump and relevant
a n d s p a c e r 0, water pump a.nd seal gasket.
alternator driving pulley @, right (3) If required remove sealant marks
head camshaft drive toothed pul- on sump and block.
ley 0, spacer @, left head cam- 1 Screws 3 Block front cover
2 Nuts 4 Oil retaining ring
shaft drive toothed pulley @ and
pilot belt washer @.
25. Remove pistons and connecting
rods.
(1) Fit to flywheel a tool which
allows crankshaft rotation.

1 Screws 2 Oil sump

I N u t 5 Toothed pulley
2 Washer 6 Spacer
3 Spacer 7 Toothed pulley 23. Remove oil sump assembly.
4 Pulley 8 Washer (1) Unscrew screws with wash-
ers 0
1 securing oil pump @ to
20. Remove flywheel locking tool, block rear cover.
previously fitted.
21. Remove cylinder heads.
(1) Unscrew screws @ fixing COV-
0
ers 2 to camshaft supports; remove
covers with relevant gaskets.

(2) Turn crankshaft to permit access

to screws securing connecting rod
caps.
(3) Unscrew and remove screws @
and connecting rod caps 0.

1 Screws 2 Cover 1 Screws 2 Oil pump

01-15 May 1983


CYLINDER HEADS
1. Secure head to support stand
A.2.0195 connected to
A.2.0226 previously clamped in a
vice,
2. Unscrew screws 2 securing
c a m s h a f t r e a r c o v e8r 3 t o sup-
port 0; remove cover with seal
gasket.
3. Loosen and remove screws 4
with washers fixing camshaft support
to cylinder head; remove support
with relevant gasket.
A.2.0:7$$7=
1 Support 3 Cover
2 Screws 4 Screws
4. Remove cups @ from housing
on support, then camshaft @ with-
drawing from rear side.
ENGINE MAIN MECHANICAL UNIT
8. Acting on lever A.3.0324 com-
press springs and withdraw valve
stem totters using a screwdriver.
9. Sequentially remove upper caps,
outer and inner springs, boots from
intake valves, washers and lower
cups.
10. Repeat removal procedure for
each valve.
1 Camshaft 2 cups
5. W ithdraw front oil retaining ring
from its seat on camshaft support
using a screwdriver.
11. Withdraw yoke from head sup-
port tool and take out valves from
head lower side.
fork
CRANKSHAFT
1 . Clamp cranksahft in vice.
2. Secure puller A.3.0402 to shaft
0 6 . F i t t o o l s A . 3 . 0 3 2 1 , A.3.0324
a n d A.3.010316, used for valves
and withdraw rear guide bushing
from crankshaft.
removal, to head.
7. If not already done, insert valves n yA.3.0402
r e t a i n i n g y o k e 0 into cylinder
head support tool A.2.0195.
3. W ithdraw oil pump and distribu-
tor control gear by using proper plate
and press.
1 Yoke
0147 May 1983
 ENGINE MAIN MECHAN1CA.L UNIT

grinding, in order to ensure exact Engine

guide/seat perpendicularity as well Valve
12(N) 1 3 5 0 1 5 0 0
as proper valve working position.
38.875 + 38.9
Valve seat
(1.5305 + 1.5315)
outer
VALVE SEATS
diameter 33.375 + 33.4
1. Check valve seats for any scores, mm (in) (1.3140~1.3150)
cracks or burrs and make sure they
are properly fitted in their respective Diameter 38.8 + 38.825
recess on the cylinder head. of valve II .5276 + 1.5285)
2. If necessary, mount the head on Seat recess 33.3 + 33.325
tool A.2.0226 and regrind the valve mm (in) (1.3110+1.3120)
seats using the proper tool.
This operation may be performed as i. = intake valve
long as there is sufficient grinding e. = exhaustvalve
allowance that will permit eliminat-
ing the existing flaws while keeping 0
the specified profile; contrarywise, 1 Valve seat 3 Profile after max. 3. Oven preheat the head at 140C
valve seats will have to be replaced. 2 Original profile regrrdrng (284F).
For relevant procedure see para- 4. Fit new valve seats using the
graph: Valve Seat Replacement. (4) Having completed all machining, proper tool.
lap valve seats with proper tool.
(1) Regrind valve contact face till all Checking valve tightness
evidence of wear has been removed When replacing guides, after regrind-
and following taper is obtained : ing and lapping of seats, it is advis-
p = 90 t 90 30 able to test valve tightness - with
of dimension a on the 0 valves and sparkplugs duly mounted -
reference diameter. according to the following pro-
cedure:

0 Reference diameter: 1. Mount the head on tool

A.2.0226 and A.2.0195 previously
Intake = 37.3 mm (1.4685 in)
secured in a vice.
Exhaust = 31.9 mm (1.2559 in)
2. Fill the combustion chamber
a dimension at max. regrinding
cavity with gasoline.
limit:
3. Let some low-pressure air into
2.9 mm (0.1142 in)
the intake ducts and check for
presence of air bubbles in the gaso-
(2) Machine the valve seat upper
line.
face still the 6 reference diameter
position obtained through the pre-
vious operation is reached, attaining
the specified CL taper.

Taper of valve seat upper face

a=120

(3) Machine the seat inner face till

dimension b of the valve contact
face is restored, attaining the speci-
fied y taper.
Height of inner face:
Intake: b = 1.07 + 1.37 mm
(0.0421 + 0.0539 in)
Exhaust: b = 1.26 + 1.56 mm
( 0 . 0 4 9 6 + 0.0614 i n )
Taper of valve seat lower face:
I n t a k e : y = 50
Exhaust: y = 30
For seat lapping use the proper
lapping compound (SIPAL
AREXONS Carbosilicium for valves -
Std. no. 4100-31502).
Valve seat replacement
1. Remove worn valve seats using
the proper tool.
2. With a set of new valve seats
verify that dimensions shown in the
following table are complied with:
4. Follow the same procedure and
check tightness of the exhaust valves
by letting low pressure air into the
exhaust valve ducts.
5. Should there be some leaks,
ascertain that valves are properly
fitted in their seats and then repeat
above tightness tests; if the results
are negative, valve seats will need
relappin,g as indicated in paragraph:
Checks and Inspections - Cylinder
Heads and Valves - Valve Seats.

01-19 May 1983

 ENGINE MAIN MECHANICAL UNIT

SPRINGS cups nut is intact and that the cup

Visually check the springs for cracks
and make sure they are not out-of-
square if the evidenced flaws suggest
it, check the technical data of the
inner and outer springs and then with
a dynamometer verify that their
lenght under load falls within the
values shown in the following table:
425.32 + 452.76
(43.4 + 46.2 :
Load N 95.68 + 101.85)
has retained its original punching
position.
CAUTION:
Do not remove the valve clearance
adjusting screw from the cup.
VALVES
Check and make sure that valves do
not show any scores, burns or
evidence of sticking with their
corresponding cylinder head seats
(forming a step); if they do, replace
them.

(kg ; lb) 194.53 + 208.25

(19.85+21.25;
43.76 + 46.85)
I I CAMSHAFT SUPPORT
Length
0.
I I
25.25 (0.9941) 1. Visually check the seats of

i.
under
camshaft cups and journals for scores

1
load
23.25 (0.9153) and for any evidence of pitting or Diameter of camshaft bearings
mm (in)
abnormal wear. Front = 35.015 + 35.040 mm
0. = outer spring
(1) Reset reamer to testing di- (1.3785 + 1.3795 in)
i. = inner spring
mension. Centre = 46.500 + 46.525 mm
(I.8307 + 1.6317 in)
Rear = 47.000 + 47.025 mm
(1.8504 + 1.8514 in)

(3) Following the same procedure,

measure the diameter of the four cup
seats and determine the relevant
fitting play.

Diameter of cup seats

36.00 + 36.025 m m
(1.4173 + 1.4183 in)

Max. cup-to-seat play

0.1 mm (0.0039 in)

CUPS
Check that the outer surface of the
cups as well as the upper surface on
which cams work, show no scores, no
evidence of pitting or Abnormal wear.
Further verify that- calking of- the
CAMSHAFT
1. Carefully examine working sur-
faces of cams and of camshaft
journals making sure that there
are no scores, no evidence of seizure,
S overheating or abnormal wear.
2. With a micrometer measure the
diameter of camshaft journals.
(2) Measure the diameter of cam-
shaft bearings.

May 1983 0 l-20


MAIN
AND CONNECTING
ROD BEARINGS
Thoroughly clean the main and
connecting rod bearings and visually
check them for scores as well as for
any evidence of seizure.
In case of excess wear, replace all
bearings. When fitting connecting rod
bearings to the crankshaft, be sure to
use matching parts, i.e. belonging to
the same size class; for this purpose
they are identified by same colour
dots on the side of the half-bearing
and on the relevant crank pin of the
shaft. Applicable dimensions and
tolerances are shown in: Service Data
and Specifications Connecting rod
bearings and Main bearings
charts.
PISTONS AND
CONNECTING RODS
1. Visually check pistons and con-
necting rods for cracks, scores and
evidence of excess wear.
2. Measure the play between the
rings and their seats in the piston.
For relevant dimensions and toler-
ances see: Service Data and Speci-
fications - Pistons and Piston
Rings charts.
3. Check piston diameter with a
May 1983
ENGINE MAIN MECHANICAL UNIT
micrometer. For relevant dimensions
and tolerances see: Service Data and
Specifications - Piston chart.
4. In case the connecting rod
piston assembly has been disassem-
bled, check the piston pin seats
on the connecting rod small end as
well as on the piston pin bosses for
excess wear.
5. Should parts not be replaced and Surface grinding must be performed
therefore used again, remember that in accordance with the roughness,
working surfaces - especially that of flatness and. parallelism tolerances
the piston pin seat on the piston - shown in the above chart.
must be totally free of any scores,
even the slightest one.
CYLINDER BLOCK
The piston pin must always be 1. Visually check cylinder block
replaced. for cracks or excess wear of sliding
surfaces.
2. Check cylinder walls surfaces for
roughness.
FLYWHEEL
Max. allowed roughness of cylinder
1. Verify that teeth of gear are not wall surface
in any way chipped or- show any 0.5 + 1 pm (20,10* + 39.10m6 in)
evidence of pitting; contrarywise,
replace the flywheel. 3. See to which size class the
2. Check the clutch driven plate cylinder walls refer to and then
contact surface on the flywheel for proceed to check them by measuring
any scores, chips or evidence of them. CylintJer walls are selected
overheating. Before doing so, how- according to their inner diameter and
ever, make sure that the contact are divided into five different classes:
surface has not been previously A, B, C, D, and E. The class iden-
ground and that the amount of tifying letters are stamped on the
material. available for removal is cylinder block upper surface next to
going to be sufficient for elimination each wall location.
of the existing flaws.
For this purpose, verify that dimen-
sion b shown in the chart is greater
than the min. specified limit and that
the removable stock will allow
surfacing as required.
Min. limit of dimension b
20.95 mm (0.8248 in)
01-22
 ENGINE MAIN MECHANICAL UNIT
Dimensions relevant to each class are
shown in: Service Data and Speci-
fications Cylinder block chart.
(1) Reset the reamer by means of a
micrometer.
(2) Measure the diameter at the
recommeded depth and then deter-
mine taper and out-of-round of
cylinders walls.
Cylinder wall max. taper:
A - B = 0.02 mm (0.00079 in)
Cylinder wall max. out-of-round:
X - Y = 0.02 mm (0.00079 in)
(3) Compare actual values D with
nominal ones C of each size class and
then determine the cylinders walls
max. wear.
Cylinder wall max. wear:
C - D = 0.04 mm (0.00157 in)
4. If the dimensions thus estab-
lished are not within tolerance,
cylinders walls must be rebored
keeping in mind that three different
oversize pistons are available as spare
parts; this means that the diameter of
walls will have to be in accordance
with the tolerances shown in: Service
Data and Specifications Cylinder
block chart.
(1) Mount main bearing caps on the
cylinder block and tighten screws as
specified in: Engine assembly -
Engine unit.
Then proceed to bore cylinder walls
so as to stay within the tolerances
shown in: Service Data and Speci-
fications - Cylinder block chart.
Lapping must be performed so that
tool marks cross each other at an
angle of 9CP + 1203
(2) If wear does not exceed the
specified limit but pistons and spring
rings need replacing because of some
flaws or damage, cylinders walls
will need at least to be lapped; in this
case measure the diameter of the
wails in order to identify the new
size class to which they belong
and that will have to be kept in mind
during piston fit operations, regar-
dless of the letter stamped on the
cylinder block. Should lapping cause
a size class change, cylinder wall will
no longer be identifiable through the
letter stamped on the cylinder block
which, therefore, must be erased in
order to avoid mistakes during future
operations_
01-23
PISTON - CYLINDER
WALL FIT
1. When original parts are involved,
they will be selected by matching
each cylinder wall identification
letter that is stamped on cylinder
block upper surface to the piston
that has the same letter stamped on
its head or a coloured dot painted on
the inside of its crown, according to
the following schedule:
Piston
Wall 8
identifying
Engine identifying
letter and
letter
colour
A - blue
1200
B - pink
1350 C - green
1500 D - yellow
E - w h i t e
If the letter stamped on the cylinder
block has been previously erased,
matching will take place according to
the identification letter stamped on
the piston that needs replacing; in
this instance, it is advisable to make a
double check and measure the
cylinder wall diameter.
2. When oversize walls are used,
they will be matched to the relevant
completely assembled pistons,
namely with compression rings and
oil scraper ring, which are available as
spare parts according to the follow-
ing oversize scale: G.2 - 0.4 - 0.6 mm
(0.0078 - 0.0157 - 0.0236 in).
May 1983

Cylinder wall to piston play
Standard 0.03 + 0.05 mm
(0.0012+ 0.0020 in)
Oversize 0.03 + 0.06 mm
(0.0012 + 0.0024 in)
2. Apply engine oil to piston pin,
to the connecting rod small end, and
to the piston pin supports.
3. Fit the connecting rodsmall end
between the piston pin supports
ensuring that holes are perfectly
aligned in order to allow proper
piston pin fit.
4. Fit the piston pin @ into the
piston @ and connecting rod 0,
and then lock it with two spring
rings 0.
a. PoSition pistons so that the
arrow stamped on their cr0w.n
points in the direction of engine
rotation, namely: upward for
the right head pistons and
downward for the left head
pistons.
b. Fit connecting rods in the
pistons so that the position of
matching identification numbers
and arrows corresponds to that
shown in the below Figure.
Connecting rod
Piston pin
Spring ring
Left head piston (No. 2 and 4)
Right head piston (No. 1 and 3)
With the help of a suitable
special pliers, fit piston rings in the
piston seat making sure that the
marking stamped on the flat surface
of the rings faces upwards.
MARKING
ENGINE MAIN MECHANICAL UNIT
-
CRANKSHAFT
1. Fit rear bushing and oil pump
drive gear on the crankshaft.
(1) Fit the crankshaft rear bush-
ing 0 by means of tool A.3.0450.
(2) Heat the oil pump and distribu-
tor drive gear to 150C (302F).
(3) Shrink the gear @ on the
crankshaft positioning it so that the
axis of the flywheel centering dowel
and the front surface of one of
the gears form the specified angle.
Positioning of crankshaft rear gear
a = 22+2~o
1 Bush 2 Pump drive gear
a
ENGINE UNIT
1. Fit crankshaft on cylinder block.
(1) Fit main bearings on relevant
main bearings supports and lubricate
01-25
them with oil. Select bearings accord-
ing to the diameter of crankshaft
journals.
(2) Fit thrust half-rings on the
relevant seat obtained in the third
main bearings support.
Make sure that these half-rings are
fitted with oil channels facing the
crankshaft shoulders.
(3) Place crankshaft on main bearing
supports.
2. Fit main bearing caps on cylin-
der block,
(1) Fit main bearings to main
bearing caps and lubricate them with
oil.
(2) Fit main bearing caps: front @
(see markings), centre @, and
rear 0, fitted with relevant bear-
ings, on cylinder block supports.
Coat supports with engine oil and
tighten oiled screws without fully
locking them.
(3) Tighten screws securing the main
bearing caps to the relevant cylinder
block supports in two or three
May 1983
 ENGINE MAIN MECHANICAL UNIT

successive steps, according to speci- block having the gauges indicating 4. Fit seal ring in the main oil
fied torque and sequence (from A finger touch the crankshaft parallel- gallery of the cylinder block rear
to F). wise to the shafts axis. cover.
(2) Using a screwdriver, move the
0: Tightening torque crankshaft along its axis and check
Caps to cylinder supports se- the gauges reading to ensure that
curing screws: g end play is within specified
6 6 + 73 N - m values.
(6.7 + 7.4 k g - m
46.4 + 53.5 ft-lb) Crankshaft end play
0.35 mm (0.0137 in)

5. Fit rear cover, with relevant

gasket, on t h e c y l i n d e r b l o c k .
(4) Subsequentially tighten screws Tighten all cover retaining screws
securing the main bearing caps to the according to specified torque.
cylinder block in two or three
successive steps, according to speci- @ : Tightening torque
fied torque and sequence (from A Rear cover retaining screws
to F). 19+24N-m
(1.9 + 2.4 k g - m
0: Tightening torque 13.7 + 17.4 ft.lb)
(3) If the shaft has not been pre-
Caps to cylinder block sup-
viously reground and therefore the
ports securing screws value established as per step above is
40+49 N - m greater than the specified value, it is
(4.1 + 5 kgam possible to regrind the shoulders of
29.6 + 36.2 ft.lb)
the rear journal till its c iength is
such that it will allow fitting of the
oversize thrust half-rings available as
spare parts.

Having completed tightening of all

screws, apply engine oil to t h e
supports and rotate the crankshaft
by hand. 6. Fit crankshaft oil seal ring using
tool A-3.0337.
3. Check crankshaft end play. Rear journal c length a. Apply engine oil to the rings
(1) Attach a centesimal dial gauge 2 8 . 7 6 4 + 28.804 m m . sealing lip, its external surface as
with magnetic base to the cylinder (1.1324 + 1.1340 in) well as to its working seat.

May 1983 01-26

 ENGINE MAIN MECHANICAL UNIT

13. Fit crankshaft front pulleys. 0: Tightening torque

(1) Key the below mentioned parts Screws securing water pump
according to the indicated sequence: 1 9 +24 Nam
the belt guide washer @, the left (I .9 + 2.4 kg-m
head camshaft drive toothed pul- 13.7 + 17.4 ft.lb)
ley 0, the spacer @, the right
head camshaft drive toothed pul-
ley 0, the water pump and alterna-
tor drive pulley @, the spacer 0,
and the washer 0.

10. Fit front cover, with proper

gasket, to cylinder block and tighten
screws and nuts according to speci-
fied torque.

0: Tightening torque 1 Nut 5 Toothed pulley

Front cover to cylinder block 2 Washer 6 Spacer 1 Gasket 3 Screw
retaining screws: 3 Spacer 7 Toothed pulley 2 Pump
19 + 24 N - m 4 Pulley 8 Washer

(1.9 + 2.4 kg-m 15. Fit cylinder heads.

13.7 + 17.4 ft.lb) (I) Turn crankshaft till the piston in
(2) After having suitably locked
flywheel rotation, tighten pulley No. 1 cylinder is set at Top Dead
11. Fit the engine front support @
retaining nut according to specified Center in the compression stroke;
and the pulleys lower guard @ to
torque. this correct positioning is further
the cover.
ensured by the 7 notch 0 on the
Tightening torque flywheel matching with the refer-
Pulleys to cylinder block re- ence 02 o n The r e a r c o v e r 0.
taining nut:
118 + 144 N-m
(12 + 14.7 kg-m
86.8 + 106.3 ft.lb)

1 Pulleys guard 2 Front support

12. Fit crankshaft oil seal front ring

using tool A.3.8338. Before doing so,
apply a coating of engine oil to the
rings sealing lip and work surface.

14. Fit the water pump.

(1) Fit new gasket @ on pump. 1 Notch 3 Cylinder block
2 Reference rear cover
(2) Fit pump 0, without pulley,
on cylinder block.
(3) Fit screws @ with washers and (2) Align the references shown on
tighten them to specified torque the camshaft rear journal and on the
value. support rear side panel.

May 1983 01-28

 ENGINE MAIN MECHANICAL UNIT
(3) Fit cylinder heads, with relevant
gaskets, o n t h e c y l i n d e r b l o c k .
By extremely careful during this
assembly operation in order to avoid
that opened valves, projecting above
the head surface, might strike the
Fylinder block surface and thus be
damaged.
(4) Position and then tighten the six
cylinder heads retaining screws @
in two or three successive steps,
according to the specified torque and
sequence (from A to F).
(5) Tighten screws @ securing the
camshaft support to the cylinder
heads.
0: Tightening torque
Head to cylinder block re-
taining screws:
81 + 87 Narn
(8.3 + 8.9 kg-m
60 + 64.4 ftdlb)
1 Head retaining screw
2 Camshaft support retaining screw
In case of in-car tightening, use
extension spanner A.5.0198 in accor-
dance with the following tightening
torques:
- for torque spanner with 300 mm
(11.811 in) lever arm:
57t62 N - m
(5.8 + 6.3 kg-m
41.9 + 45.6 Wb)
for torque spanner with 400 mm
(15.748 in) lever arm
62+67 N.m
(6.3 + 6.8 k&m
45.6 + 49.2 ft.lb)
16. Fit camshaft belts rear covers.
17. Fit belt tensioner assemblies on
the cylinder block pins according to
the following sequence: sup-
ports 0,
5 spring @, washers @ ( 2 ) V e r i f y t h a t t h e c r a n k s h a f t s
and washers 0. Lock belt jockey angular position corresponds to the
pulley assemblies with relevant Top Dead Center of cylinder No.1,
nuts 0 after having pre-loaded belt as previously mentioned for heads
jockey pulley in order to allow for assembly.
belt passage. (3) Rotate camshaft by means of
toothed spanner A.5.0195 till t h e
reference stamped on the supports
rear side panel is aligned with the one
stamped on the shafts rear journal.
(4) Key camshaft drive belts on the
crankshaft inner pulleys and on the
pulleys of both camshafts. Belt
keying must take place with the
belt pulling section, opposite the
jockey pulleys, fully stretched.
(5) Check that 5 clearance be-
t w e e n t h e camlhaft b e l t a n d t h e
profile of the engine front support
1 Nut 4 Spring
2 Washer 5 Support is not below the specified min. value;
3 Washer if it is, modify the profile of the
support till it meets the specified
value.
S min. clearance between camshaft
belt and engine from mounting
9 mm (0,3543 in)
Y-
18. Fit camshaft driving belts.
(1) Fit camshaft drive pulleys and
tighten the retaining screw to speci- (6) Completely loosen the belt
fied torque being careful, at the same jockey pulley lock nuts and then
time, to stop pulley rotation by tighten them again.
means of toothed spanner A.5.0195. (7) Turn the crankshaft a few times
in its working direction so that the
0: Tightening torque belts may take up their final po-
c Camshaft pulley retaining sition.
screw: (8) Act on the camshaft till cams are
6 3 + 70 Nam disengaged; loosen the belt jockey
(6.4 + 7.1 kg-m pulley lock nut and then retighten it
46.3 + 51.3 f&lb) according to specified torque.
01-29 M a y 1983

0: Tightening torque
Belt jockey pulley lock nut
(with cold engine)
37 f 46 N.m
(3.8 4 4.7 kgm
27.5 + 34 ftalb)
19. Fit oil pump.
(1) Turn crankshaft till piston No. 1
is at Top Dead Center in the com-
pression stroke, as mentioned for
heads reassembly.
(2) Turn the pump drive shaft so
that the next rotation, which Will
follow mating of the pump drive gear
with that on the crankshaft, will
position the distributor coupling
according to the specified p angle.
Apply a coating of engine oil to the
drive shaft.
Distributor coupling positioning
p = 22
1 Distributor coupling
(3) Fit the oil sump pump on rear
cover and tighten screws 0 accord-
ing to specified torque.
a: Tightening torque
Oil sump to rear cover re-
taining screws
IQ+24 Nhrn
(1.9 + 2.4 kg-m
13.7 + 17.4 ft+lb)
(4) Tighten retaining screws @
b e t w e e n p u m p body and support
according to specified torque.
May 1983
ENGINE MAIN MECHANICAL UNIT
0: Tightening torque
Pump body to support re-
taining screws:
8-I-10 N-m
(0.8 f 1 kgmm
5.8 + 7.2 ftblb)
1 Pump to rear cover retaining screws
2 Pump body to support retaining screw
1 Rotor arm 3 Distributor shaft
(5) Reassemble oil sump with prop- 2 Distributor lock -coupling
er gasket @ and tighten all re- nut
taining screws. Before doing SO,
21. Adjust clearance of intake and
evenly apply the specified cement to
the gasket (Cement Std. No. exhaust valves while engine is cold.
3522-00040 DOW CORNING The relevant procedure is described
Silastik 732 RTV). in Group 00 - Engine Maintenance.
Before applying the sealant, remove
all traces of old sealant and of oil Valve clearance (cold engine):
from all surfaces. Intake
0.35 4 0.40 mm
(0.0138 + 0.0157 in)
Exhaust
0.45 + 0.50 mm
(0.0177 + 0.0197 in)
22. Fill chambers of camshaft sup-
ports with engine oil.
Oil quantity required for fill-up
0.250 kg (0.5511 lb)
1 Oil sump 2 Gasket
in each chamber
20. Fit distributor on rear cover. 23. Fit support covers @ with
(I) Turn the distributors shaft so relevant gaskets 0.
that the rotor arm @ is positioned
on the reference mark stamped on
the distributors body.
The rotor arm 0 should point
toward the No. 1 cylinder. This
position corresponds to ignition in
No. 1 cylinder and to correct cou-
pling of the oil pump and distributor
shafts.
(2) If necessary, correct misalign-
ment of the rotor arm with the
reference mark stamped on the
distributors body by rotating the
latter and then tightening the lock
nut @ securing the distributor to
the cylinder block rear cover. 1 Cover 2 Gaskets
01-30

34. Assemble carburetor with spacer
and the interposed gaskets on intake
manifold studs.
0: Tightening torque
Carburetor nuts
19+24 N.m
(1.9 + 2.4 kg-m
13.7 + 17.4 ft.lb)
35. Perform following connections.
- Fuel supply pipe @ from fuel
pump to carburettor.
- Vacuum advance pipe @ from
carburettor and advance con-
troller located on distributor.
1 Advance pipe 2 Fuel supply pipe
36. Fit oil filter by manually tigh-
tening it and insert dipstick.
37. By means of adapter A.5.0115
fit spark plugs tightening them
according to specified torque.
May 1983
ENGINE MAIN MECHANICAL UNIT
(3) Key alternator and water pump
@I: Tightening torque
drive belt on relevant pulleys.
Spark plugs:
(4) Adjust belt tension according to
2 5 G34 N-m
specifiedvalue and then lock
(2.5 + 3.5 kg-m
bolts 0. For adjusting procedure
18.1 + 25.3 ft.lb)
refer to Group 00 - Engine Main-
tenance.
38. Secure cap to distributor body
with relevant springs, then connect
L o a d : 7 8 . 4 0 N (8 k g ) (
ignition cables between spark plugs
Arrow: 15 mm (0.5905 in)
and distributor cap, securing them to
relevant clamps.
Cables connection must take place
according to the ignition sequence of
cylinders.
1 Bolts 3 screws
2 Alternator 4 Bracket
40. Fill the engine with specified
engine oil (AGIP Sint 2000 lOW50
o r IP S u p e r M o t o r O i l lOW50).
Oil quantity required for fill-up
3.6 kg (7.93 lb)
39. Fit alternator and control belt.
(1) Secure bracket @ to engine
front-. cover and tightening the
0
relevant screws 3
(2) Position alternator on engine
support and tighten b o l t s 0
without fully locking them.
01-32
 ENGINE MAIN MECHANICAL UNIT

ENGINE LUBRICATION SYSTEM

DESCRIPT.ION

1 Bypass valve 4 Oil sump

2 Oil filter 5 Gear pump
cartridge 6 Pressure relief
3 Camshaft bear- valve
ing housing

-
The engine is pressure lubricated by
means of a gear pump. The pump is
mounted on the rear cover of the

? I. -4I M
engine and is actuated by a shaft
which is driven by a gear fitted to the

i F --, .I& ,
Oil pump -1 Oil filter cartridge
crankshaft.
The maximum oil pressure is ad-
justed by means of a proper valve
I I Oil strainer I I Block oil galleries I
fitted on the pump.
Oil is completely filtered in the
suction head by a strainer then by a
filter with cartridge placed on the oil
passage and provided with a bypass
safety valve, should the cartridge
become clogged.
The oil filter, on the engine rear
cover, has unions for the recircula-
tion of the oil vapours at minimum
and high running.
The insufficient oil pressure is
indicated on the combination meter
by means of a warning light con-

II I Connecting rod
half-bearings
nected to a manual contact inserted
on the main oil gallery of the block.

OIL PUMP
OIL PRESSURE CHECK
NOTE 1. Start engine and heat oil to 90C
(194F).
Oil passagi
2. Remove oil pressure checking
manual contact.
3. Fit gauge to manual. contact
- Return
hole.
)- BYpass passage
4. Start engine and record oil
pressure as shown on gauge.

01-33 May 1983

 ENGINE MAIN MECHANICAL UNIT

sembly Engine Unit.

Engine Oil pressme 3. Tighten screws @ securing
Engine speed kPa (bar, pump to engine rear cover then
r.p.m. kg/cm2 , psi) screws @ fastening pump body
to pump support to the specified
117.7 f274.6
torque value.
(1.18 f2.75,
1200 800
1.2+2.8,
0: Tightening torque
17.07 c-9.82)
Screws securing pump to en-
1350
gine rear cover
411 .E + 568.7
19+24 N-m
1500 (4.12+5.69,
(1.9 + 2.4 kg-m
4.2 +5.8 ,
13.7 + 17.4 ft.lb)
I 1 59.74 G82.49)

Screws fastening pump body to

pump support
5. Remove gauge and refit manual
Se-10 N-m
contact.
(0.8 + 1 kg-m
5.8 + 7.2 ft.lb)
If the oil pressure value is not within
the limits shown in table, the oil
pump is to be checked.
@-
1 Upper support 7 Screw
2 Driving gear 8 Strainer
3 Driven gear 9 Pump body
REMOVAL 4 Washer 10 Washer
Remove fuel pump from cover (see: 5 Washer 11 Spring
Engine Disassembly - Engine Unit). 6 Screw 12 Valve

1. Drain engine oil and remove oil

sump. If required, tap with a wooden
mallet on attachment side of sump to
block.
2. Unscrew screws @ and with-
draw pump from its seat.
DISASSEMBLY AND
ASSEMBLY
1. Unscrew screws @ securing
pump body to pump support.
2. Withdraw driven gear a
valve @ , spring @I and w a s h -
er @I.
3. Reassemble pump carrying out
the above procedure but in the
reverse sequence. Slightly tighten
screws @ without locking fully
home.
4. Manually rotate driving. shaft
checking for ,crawling and regular
CHECKS AND INSPECTIONS
1 Screw fastening pump to pump support
1. Check gears for wear, ensure 2 Screw securing pump
that--teeth are free from cutting or
chipping or that wear is regular and 4. Fill engine with th.e specified en-
not excessive on all the face length. gine oil (AGIP Sint 2000 lOW50 or
2. Check driven gear pin for IP Super Motor Oil lOW50).
indications of seituring and cutting.
3. Carry out same check as above OIL FILTER
for the pressure regulator valve, REPLACEMENT
additionally ensuring that it slides in
its seat on pump body without 1. Drain hot oil of engine from
crawling. If the spring of the pressure sump.
regulator valve is supposed to have 2. Remove filter using proper tool.
yielded, also considering the trouble
shown, replace valve.
4. Check that driving gear is
corredtly positioned on driving shaft
of oil pump and that crankshaft
driving gear has the pin regularly
fitted. .
5. Finally check working surfaces
of shaft and rear cover, of driving
cam of fuel push rod, and the at-
tachment point to the distributor for
cutting and signs of seizure.
3. Fit a new filter of the prescribed
INSTALLATION type. Manually screw in the filter.
1. Lubricate driving shaft with en- 4. Fill engine with prescribed en-
gine oil as per step 4. gine oil. After fitting new filter, let
2. Refit oil pump carrying out engine run for a few minutes and
procedure detailed in: Engine As- check for oil leakages.

M a y 1 9 8 3 01-34
 -ENGINE MAIN MECHANICAL UNIT

INSPECTION AND ADJUSTMENT

CAMSHAFT SYSTEM

U n i t : m m (in)

t 306.00 1200 I 305.02 1350 I 305.04 1500

RIGHT SUPPORT LEFT SUPPORT

Camshaft 531.364 531.364 531.364

I I
I make 0 . 3 5 f 0.40 (0.0138 + 0.0157)
Tappet clearance
Exhaust 0.45+0.50 ( 0 . 0 1 7 7 + 0 . 0 1 9 7 1

Value of the angle of timing Right support 23

marks on camshaft supports Left support 23

All values are with cold engine

CHECKING VALVE OPENING AND CLOSING ANGLES

Unit: mm (in)

Engine
1200 1350 1500
305.00 305.02 305.04

Valve clearance for checking m m (in) 0.7 (0.0276)

E Opening BTDC a 1zL

Closing ABDC b 48O

Valve clearance far checking m m (in) 0 . 7 (0.0276)

5
r Opening BTDC c 456
lz
C l o s i n g ABDC d P

(I 1 Crankshaft rotation ACW seen from flywheel side.

May 1983 01-36

 ENGINE MAIN MECHANICAL UNIT

CYLINDER BLOCK

Unit: mm (in)

Engine
inspection data
1200 1358 1500

Class A 8 0 . 0 0 t 8 0 . 0 1 ( 3 . 1 4 9 6 +3.1500) 84.00t84.01 (3.3071 -3.3075)

Class B 8 0 . 0 1 e80.02 (3.1500+3.1504) 8 4 . 0 1 + 84.02 (3.3075 f 3 . 3 0 7 9 1
Standard Class C 80.02 -80.03 (3.1504 + 3.1508) 84.02 G-84.03 (3.3079 4 3.3083)
Class D 80.03+80.04 (3.1508-3.1512) 8 4 . 0 3 + 84.04 (3.3083 f 3.3087)
Class E 80.04+80.05 (3.1512+3.15163 8 4 . 0 4 + 84.05 (3.3087 f 3.3091)
Cylinder bore a
1st 8 0 . 2 0 +-80.21 ( 3 . 1 5 7 5 +3.15791 8 4 . 2 0 + 84.21 ( 3 . 3 1 5 0 f 3 . 3 1 5 4 )
Oversize 2nd 80.40+80.41 (3.1654+3.1658) 8 4 . 4 0 + 84.41 (3.3229 f 3.3233)
3rd 80.60+80.61 (3.1733+3.1737) 8 4 . 6 0 + 8 4 . 6 1 ( 3 . 3 3 0 7 f 3 . 3 3 1 I)

Out-of-square between cylinder bore centreline

0.05 (0.00197)
and centreline of main bearings

Standard 0.01 (0.00041

Taper and out-of-round limit
Max 0.02 (0.0008)

Cylinder bore surface roughness o.5.10-3+l~10-3 ( 0 . 0 1 9 7 ~ 1 o-3 + 0.0394~10)

I

Cylinder bore grinding angle 9 0 + 1200

Front
63.663 G 63.673 (2.5064 + 2.5068)
Main bearing diameter b Rear

Central 63.673 -63.683 (2.5068 + 2.5072)

Width of rear main bearing support c 2 3 . 6 8 + 2 3 . 7 3 ( 0 . 9 3 2 3 + 0.9343)

01-37 IWay 7 9 8 3
 ENGINE MAIN MECHANICAL UNIT

PISTONS, COMPRESSION RINGS AND PINS

Pistons

u
-a

Ia

Unit: mm (in)

Engir
Inspection data
1200 1350 1500

Class A (Blua) 79.96 +79.97 (3.1480 + 3.1484) 83.96 f 83.97 (3.3055 + 3.3059)
Class B (Pink) 79.97 f79.98 (3.1484+3.1488) 83.97 f 83.98 (3.3059 + 3.3063)
Standard Class C (Green) 79.98+79.99 (3.1488-3.1492) 83.98 -83.99 (3.3063 + 3.3067)
Class 0 (Yellow) 79.99 + 80.00 (3.1492 e-3.14961 83.99 + 84.00 (3.3067 + 3.3071)
Piston diameter
Class E (White) 80.00 G-80.01 (3.1496 +3.1500) 84.00-84.01 (3.3071 f3.3075)
a (I)
1st 80.15+80.17-(3.1X5+3.1563) 84.15F84.17 (3.3130 t3.3138)
Oversize 2nd 80.35-80.37 (3.1634+3.1642) 84.35f84.37 (3.3209f3.3217)
3rd 80.55-80.57 (3.1713-3.1720) 84.55G64.57 (3.3287 -3.3296)

1.525 + 1.550
0.0600+0.0610)

1.525+1.545 (2)
First compression ring groove height c 1.525 + 1.545 (0.0600 + 0.0608)
0.0600+0.0608)
1.525e1.545
0.0600+0.0608)
(3)

1.775+1.800
0.0699 + 0.0709)

1.775 + 1.795 (2)

Second compression ring groove height d 1.775 + I.796 (0.0699 + 0.0707)
0.0699+0.0707~
1.775 + 1.795
0.0699-0.0707)
(3)

4.015+4.w0
(0.1581 -0.1590)

4.015 G-4.035 (2)

Oil scraper ring groove height c 4.015 e-4.035 (0.1581 +0.1589)
0.1581 +0.1589)
4.015 e4.035
(0.1581+ 0.1589:
(3)

Pin seat bore b 21.002+21.006 (0.8269+0.8270)

(1) To be measured to right angle to the piston pin at 17 mm (0.6693 in) from piston skirt
(2) Borg0 Piston
(3) Mondial Piston

May 1983 m-38

 ENGINE MAIN MECHANICAL UNIT

CONNECTING ROD AND CONNECTING ROD BEARINGS

Connecting rod

Unit: m m (in)

Engine
lnspecrion data
1200 1350 1500
I I

Small end bush bore diameter a 21.007 + 21.015 (0.8270 f 0.8274)

Big end bore diamater b 52.696 + 53.708 (2.0746 + 2.1145)

Connecting rod bearings Unit: mm (in)

Engine
Inspection data
12ctcl I 1350 I SO0

Blue 1.830 + 1.836

--e
Blue 1.831 + 1.835
(0.0721 +0.0722) T (0.0720 + 0.0722)
a Standard
Red 1.827 + 1.831 Red 1.8?6 + 1.832
(0.0719+0.0721) (0.0719 + 0.0721)

1.966 + 1.962 (0.0770 + 0.0772)

Connecting rod
2.083 + 2.089 (0.0820 + 0.0822)
bearing thickness
a 2.210+2.216 (0.0870+0.0872)

2.337 + 2.343 (0.0920 + 0.0922)

I 4th

M a y 1983 0 i-40
 ENGINE MAIN MECHANICAL UNIT

FLYWHEEL

Unit: mm (in)

Engine
Inspection data
1200 1350 1500

a 24.0 + 24.2 (0.9449 + 0.9528)

Regriding dimensions (I) b G 0.2 (0.0079)
c > 20.95 (0.8248)

Parallelism of the driven plate contact face compared

with flywheel-to-crankshaft support face (as read at 0.08 (0.0031)
a 100 mm radius)

Maximum out-of-flat of driven plate contact face 0.02 (0.0008,

Surface roughness of driven plate contact face 2.1 o-3 (0.0787~10)

(1) The depot of regrinding, dimension b, must be the same both on clutch driven plate contact face and on the face of the
register for the clutch cover, so that dimension a kept constant. Dimension c must not be lower than the specified limit.

01-41 May 1983

 ENGINE MAIN MECHANICAL UNIT

Unit: mm (in)

Engine
Inspection data
1200 1350 1500
I I

Max. misalignment between the centrelines of the two

0.25 (0.0098,
pairs of crankpins and the journals centreline
I

Max. out-of-square between thrust ring face and

0.03 (0.00121
main journals
I

Rear crankshaft bush diameter b 16.065 + 16.080 (0.6325 + 0.6331)

I

Fitment of rear crankshaft gear U

22 + 26O
(distributor/oil pump drive)

(.I ) Re-cutting equally spaced on both shoulders

Thrust rings

Unit: mm (in)
~ ~
Engine
Inspection data
1200 * 1350 I 1500

Standard 2.310 + 2.362 (0.0909 + 0.0930)

Thickness a
Oversize 2.437 t 2.489 (0.0959 + 0.0980)

Main -bearings

Unit: mm (in)

Engine
Inspection data 1200 1350 I 1500

Standard 1.832 t 1.841 (0.0721 + 0.0724)

Thickness a 1st 1.959 f 1.968 (0.0771 + 0.0775)

Oversize 2nd 2.086 t2.095 (0.0821 + 0.0825)
3rd 2.213 f 2.222 (0.0871 + 0.0875)
4th 2.34OG2.349 (0.0921 + 0.0925)

0 l-43 May 7983

 ENGINE MAIN MECHANICAL UNIT

CAMSHAFT SUPPORT, CAMSHAFT AND TAPPET BUCKET

Camshaft support

Unit: mm (in)

Engine
Inspection data
1200 1350 1500
1

Front 35.015 + 35.040 (I 3786 + 1.3795)

Bore of camshaft journal
Central 46.500+46.525 (1.8307+1.8317)
bearing diameter a
Rear 47.000 G-47.025 (1.8504+ 1.8514)

Seat tappet bucket diameter b 36.000 e36.025 (1.4173+ 1.4183)

Camshaft

Front Central Rear

Unit: mm (in)

I Enaine
Inspection data
t 1200 I 1350 I 1500

Intake
Cam height 8 . 5 (0.3346)
Exhaust

Front a 34.940 + 34.956 (I .3756 + 1.3762)

Camshaft journal diameter Central b 46.440 e46.456 (1.8283- 1.8290)

Rear c 46.940t46.956 (1.8480+ 1.8487)

Tappet bucket

Unit: mm (in)

Engine
Inspection data
1200 1350 1500

Diameter a 35.973 + 35.989 (1.4163 + 1.4169)

May 1 9 8 3 01-44
 ENGINE MAIN MECHANICAL UNIT

CYLINDER HEAD, VALVES AND SPRINGS

Cylinder head

Unit: mm (in)

Engine
Inspection data
1200 I 1350 I 1500

Valve guide seat diameter d 13.OOOf13.018 (0.5118+00.5125)

Standard 13.050 f 13.068 (0.5138- 0.5145)

Valve guide 0.0. a
Spare 13.064f13.082 (0.5143+0.5150)

Diameter of valve guide bore b 8.013f8.031 (0.3155+0.3162)

Valve guide protrusion e 9.8 + 10 (0.3858 4 0.3937)

Min. cylinder head thickness after resurfacing c 77.25 (3.04131 (1)

Max. error of parallelism between head surfaces 0.05 (0.00201

Max. out of flat 0.03 (0.0012)

Surface roughness 1.6.10-3 (0.0630.103)

..

(1) Resurfacing of cylinder head with hemispherical combustion chamber must be done on both banks of the same engine

Valves

Unit: mm (in)

Engine
1200 1350 1500
1

Intake 7.985t8.000 (0.3144-0.3150)

Valve stem diameter a
Exhaust 7.968+77.983 (0.3137 +0.3143)

Intake 38.00 + 38.20 (1.4961 + 1.5040)

Valve head diameter b
Exhaust 33.00+ 33.20 (1.2992 + 1.3071)
I ,

oi-45 May 1983

 ENGINE MAIN MECHANICAL UNIT

S p r i n g s

Engine
1200 I 1350 I
15w

Outer spring 25.25 (0.9941)

Length of valve spring with
mm (in)
valve open a Inner spring 23.25 (0.9154)

Outer spring 425.32 + 452.76 (43-4 + 46.2) (95.68 + 101.85)

Spring rating at
N (kg) (lb)
length a Inner spring 194.53+208.25 (19.85 t21.25) (43.76f46.85)

VALVE SEAT RECUTTING

recutting

Unit: mm (in)

Engine
1350 1500

Intake
Reference diametere 6 R
Exhaust

Cut limit of valve seat top surface a 2.9 (0.1142)

Intake 1.07 f 1.37 (0.9421 + 0.0539)

Cut limit of valve seat mating
surface b Exhaust 1.26 f 1.56 (0.0496 + 0.6614)

Valve seat top surface limit angle a 1200

I
-.
Valve seat mating surface limit angle p 9 0 + 9o 30

Intake 500
Valve seat inner face limit
angle y Exhaust 300

May 1983 01-46

 ENGINE MAIN MECHANICAL UNIT

FITMENT PLAYS OR INTERFERENCE FITS

Unit: mm (in)

Engine
Inspection data
1200 I 1 3 5 0 I 1500

Standard 0.03 4 0.05 (0.0012 + 0.0020)

Cylinder bore/piston play
Oversize 0.03 + 0.06 (0.0012 + 0.0024)

-First compression 0.035 + 0.067 0.035 + 0.067

ring (0.0014 + 0.0026) 0.035 + 0.067 2, (0.0014 f 0.0026)
(0.0014 + 0.0026 \

1
Second 0.035 + 0.067 (;;~4;;~;2,,l 0.036 + 0.067
Ring/groove end float compression ring (0.0074 + 0.0026) (0.0014 + 0.0026)
(f;;4y(;;26)@
* *

Oil scraper 0.025 + 0.057 (opdg;;*E4)(1) 0.025 + 0.057

ring (0.0010 + 0.00221 0.025 4 0.057 p) (0.0010 + 0.0022)
( 0 . 0 0 1 0 + 0.0022J

Maximum for
0.1 (0.0039)
each ring

Pin/small end play 0.007 + 0.019 (0.0003 + 0.0007)

Standard 0.002 f 0.010 (0.0001 + O.OOO4)

Pin/seat bore play
Maximum 0 . 0 1 8 (O.OOO7)

Front and rear 0.024 + 0.065 (0.0009 + 0.00261

Main bearing to- Central 0.034 + 0.075 (0.0013 + 0.0030)
journal play Maximum (with
0.1 (0.0039)
bearing in seat)

Red/Blue Red/Blue
0.034+ 0.662 0.032 + 0.064
Standard
Connecting rod bsaring- (0.0013 + 0.0024) (0.0013 + 0.0025)
to-crankpin play Maximum (with
0.090 (0.0035)
bearing in seat)

Standard 0.056 + 0.25 (0.0022 + 0.0098)

Crankshaft end float
Max 0.35 (0.0138)

End float of big end Standard 0.2 40.392 (0.0079 + 0.0164)

bearing Max 0.45 (0.0177)

Front 0.059 + 0.100 (0.0023 + 0.0039)

Radial clearance between
Central 0.044 + 0.085 (0.0017 + 0.0033)
camshaft and bearing
Rear 0.w + 0.085 (0.0017 + 0.0033)

Camshaft end float 0.10 + 0.33 (0.0039 + 0.0130)

0.011 + 0.052 (0.0004 + 0.0020)

0.1 (0.0039)

01-47 May 1983

 ENGINE MAIN MECHANICAL UNIT

Engine
Inspection data
1200 1350 1500
I

Standard 0.013 + 0.046 (0.0005 + 0.0018)

Max 0.07 (0.0027)

Valve stem-to
guide play
Standard 0 . 0 3 0 + 0.063 (0.0012 + 0.0025)

Max 0 . 0 9 (0.0035)

Valve guide-to-seat
interference fit
I Standard

Spare
0 . 0 3 2 + 0.068 (0.0013 + 0.0027)

0 . 0 4 6 + 0.082 (0.0018 + 0.0032)

I

(I) Borg0 Piston

(2) Mondial Piston

TEMPERATURES

Part Temperature

Oil pump/distributor drive gear for shrinking onto the crankshaft 150C (302F)

GENERAL SPECIFICATIONS
FLUIDS AND LUBRICANTS

Q-KY
Application TYPE
kg (lb)

Engine oil when full OIL AGIP SIN-T 2000 lOW50 3.15 (6.94)
Std.rd 3631-69352

Filter IP Super Motor Oil 1 OW50 0.45 (0.99)

Std.rd 3631-69353

Engine oil and filter routine maintenance 3.6 (7.94)

Camshaft supports chests (I) 0 . 2 5 0 (0.55) (2)

into each chest

(1) Applicable only in the case of supports dismantling

(2) This quantity relates to chests supply, completely drain, up to drain holes level

SEALING COMPOUNDS

Application Type Datwmination Q.w

Joint face, cylinder block-to41 sump CEMENT DOW CORNING: Silastick 732 RTV -

Std. no. 3522-00640

Plugs of water galleries in cylinder CEMENT LOCTITE 601 (green) - -

block and head Std. no. 3524-00011

(I 1 Before applying LOCTITE, remove all traces of old Loctite and degrease threads using trichlorethylene or chlorothene

May 1983 01-48

 ENGINE MAIN MECHAN1CA.L UNIT

(1) After having heated engine until intervention of radiator cooling electric fan, on cold engine, loosen, oil and tighten the six screw
securing heat to base by following the order shown in figure

(1) In the event of in-car tightening of head nuts with the aid of the extension A.5.0198 to be applied as shown, the torque
specifications are:
torque spanner having a 300 mm (I 1.84 in) lever arm N+m 57 f 62
kg.m 5.8 + 6.3
Ib.ft 41.9 + 45.6

torque spanner having a 400 mm (15.75 in) lever arm N*m 6 2 - 67

kg.m 6.3+ 6.8
Ib.ft 45.6 + 49.2

TROUBLE DIAGNOSIS AND CORRECTIONS

Condition Probable cause Corrective action

I. Noisy engine
Knocking of crankshaft and Excessive crankshaft end play Replace thrust bearing
bearing

Piston and connecting rod l Fit wrong Adjust

knocking
l Pin float Adjust

Camshaft knocking l Excessive valve play Adjust

l Tappet buckets wrong fit Replace

l Weakened valve spring Replace

Water pump knocking Improper shaft end play Replace water pump assembly

I I. Other mechanical trouble

Seized valve seat l Improper valve clearance Replace and adjust

l Weakened valve spring Replace

May 1983 01-50

 ENGINE MAIN MECHANICAL UNIT

Condition Probable cause Corrective action

Excessive!y worn cylinder l Worn fit surfaces Adjust or replace

and piston
l Poor oil quality User proper oil

l Dirty air cleaner Replace filter

l Too rich misture Adjust or replace carburettor

Faulty connecting rod l Shortage of engine oil Add or replace oil

Check oil level on daily basis

l Poor engine oil quality Use proper oil

l Worn or out-of-round crankpin Grind or replace

l Wrong connecting rod bearing-to- Replace

crankpin coupling

Faulty crankshaft bearing l Shortage of engine oil Add or replace oil

Check oil level on daily basis

l Poor engine oil quality Use proper oil

l Worn or out-of-round crankshaft Grind or replace

journal

l Wrong connecting rod bearing-to- Replace

crankpin coupling

Belt tensioner knocking Wrong belt stretching Restore stretch

Faulty timed Wear of oil pump control gear Replace

I I I. Lubrication
oil leakage l Loosen engine oil drain plug Tighten

l Oil leakage from sump gasket Replace gasket

l Oil leakage from camshaft Replace gasket

supports gasket

l Oil leakage from engine gaskets Replace gasket

and seal rings

l Oil leakage from oil filter gasket Screw in filter

Decreased of pressure l Dirty pression regulator valve Clean

l Poor-engine oil quality Replace

 ENGINE MAIN MECHANICAL UNIT

SPECIAL SE.RVICE TOOLS

Refer to
Tool number Tool nama
paw

A.2.0195 Base for cylinder head support 01-17

01-19
01-24

A.2.0226 Yoke for cylinder head support 01-17

01-19
01-24

A.2.0378 Tool for locking the flywheel 01-15

A-3.01 0316 Yoke to remove and refit valves 01-17

01-24

A.3.0311 Puller of valve guides 01-18

A.3.0312 Driver of intake valve guides 01-18

A.3.0314 Driver of timing gear cover Seal 01-24

A.3.0321 Support for removing and fitting 01-17

valves 01-24

A.3.0324 Lever for removing and refitting 01-17

the valves 01-24

May 1983 01-52

 FUEL SYSTEM

AIR CLEANER

1 Cover 6 Flame trap

2 Cartridge 7 Max. blow-by hose
3 Cool air intake sleeve 8 Air cleaner body
4 Hot air intake sleeve 9 Spring clip
5 Min. blow-by hose 10 Nut

REMOVAL 5. if necessary, remove flame from within; if necessary, replace it.

trap 6 0 from max. blow-by 2. Remove flame trap from blow-
Remove air cleaner body with hose@. by hose, wash both with specific
carriage cartridge as follows: 6. Loosen the four nuts @ products, then dry them with com-
I. U n f a s t e n the five spring securing air cleaner body to carbure- pressed air. Install flame trap into
clips @ that secure cover @ to air tor; remove air cleaner body. blow-by hose near oil filler.
c l e a n e r b o d y @; r e m o v e cover.
2. Remove cartridge 0.
CHECKS AND INSTALLATION
3. Disconnect coo I air intake
sleeve 3 as well as hot air intake IbJSPECTIONS Fit air cleaner, blow-by hoses and air
sleeve t.4
9. intake sleeves back together follow-
4. Disconnect blow-by hoses 0 1. Thoroughly clean cartridge by ing removal procedure in reverse
a d 0. blowing low pressure compressed air sequence.

May 1983 04-2


IDLE COMPENSATOR
DEsCRlPTlON
The idle compensator actually con-
sists of a thermostat 0 that checks
the temperature of the engine intake
air and as a consequence either
opens or closes the throttle valve @
located in the air cleaners intake
duct. The throttle valve mixes the
cool air coming from outside with
that coming from the hot air intake,
located on the exhaust gas pipes
under the left side cylinder head, or
it works either fully closed or fully
open.
1 Thermostat
2 Hot air intake Sleeve
3 Cool air intake SieW@
4 Throttle valve
5 Air cleaner
CHECKS AND
INSPECTIONS
, 17.7 G29.4 KPa
CAUTION:
When disconnecting fuel system
hoses, use a container with safety lid
to collect the petrol that is left over
in the hoses.
FUEL PUMP DELIVERY
PRESSURE
1. Disconnect fuel delivery hose
from pump and from carburetor.
2. Replace same with a T-shaped
hose equipped with cutoff cocks.
3. Connect a pressure gauge to the
hoses free end.
4. Start engine up and with zero
delivery (cock on carburetor side is
closed), while keeping gauge at same
height as pump, verify that gauge
FUEL SYSTEM
CHECKS AND
I N S P E C T I O N S -
HOT AIR INTAKE CLOSING
TEMPERATURE
1. Warm up engine bringing it up to
steady running.
2. Turn engine off.
3. Remove air cleaner cover as well
as cartridge.
4 . Inset-t a thermometer next to the
thermostat inside the air cleaner.
5. When thermometer shows speci-
fied temperature, verify thermostat
commands, i.e. opening of throttle
valve thus fully closing the hot air
intake.
Hot air intake closing temperature
33+ 37C (91.4+ 98.6F)
COOL AIR INTAKE CLOSING
TEMPERATURE
1. With cold engine, remove air
cleaner cover as well as cartridge.
2. Insert a thermometer next to the
thermostat inside the air cleaner.
FUEL PUMP
reading is within specified values at
relevant engine rpm.
04-3
3. When thermometer shows speci-
fied temperature, verify thermostat
commands, i.e. closing of throttle
valve thus fully closing the cool air
intake.
Cool air intake closing temperature
28 + 32% (82.4 + 89BF)
THERMOSTAT
REPLACEMENT
1. Remove air cleaner from engine
(Refer to: Air Cleaner) _
2. Remove rivets securing air intake
to air cleaner body.
3. Replace air intake as well as
thermostat.
4. Connect air intake back to air
cleaner body by riveting it.
5. Fit air cleaner back to engine
(refer to: Air Cleaner).
FUEL PUMP PRESSURE
FISPA P u m p
(0.177 + 0.294 bar, at 5000 rpm
0.18 f 0.30 kg/cm2,
2.56 + 4.27 psi)
SAVARA Pump
17.7 + 29.4 KPa
(0.177 + 0.294 bar, at 6000 r-pm
0.18 + 0.30 kg/cm2 ,
2.56 + 4.27 psi)
5. If delivery pressure is not within
specified values, replace the pump.
6. Disconnect T-shaped hose and
restore normal operating conditions.
May 1983
 FUEL SYSTEM

CARBURETORS
W E B E R TWIN CARBURETOR

(Except Switzerland, Sweden, Australia.) q

- 32 DIR 51A/250 for 1200 model

- 32 DIR 81A/250 for 1350 model

- 32 DIR 71A/250 for 1500 model

* For 32 DIR 8IA/250 and 32 DIR i7pR50 only

May 1983 04-4

 FUEL SYSTEM

1 Carburetor cover including: 35 Safety washer 72 Bush for sealed idling cap
2 -Stud 36 Spring for loosen lever 73 Adjustment screw cap
3 Starting throttle 37 Secondary shaft securing nut 74 Idling mixture adjustment screw
4 Starting securing screw 38 Spring washer 75 Sealed idling cap
5 Starting shaft 39 Shim adjustment washer 76 Pump cover
6 Lever for starting shaft 40 Secondary throttle control lever 77 Pump cover securing screw
7 Corrugated washer 41 Sheath securing screw 78 Pump diaphragm
8 Starting shaft lever securing nut 42 Cap for secondar/ idling hole 79 Primary shaft return spring
9 Starting control tie rod 43 Throttle control lever 80 Pump filling spring
10 Tie rod split pin 44 Shim 81 Throttles securing screw
11 Tie rod washer 45 Loosen lever 82 Primary main shaft
12 Dust cover cap 46 Bush for loosen lever 82 Oversize primary main shaft
13 Dust cover plate 47 Secondary throttle adjustment screw 83 * Idling cut-off together with:
14 Carburetor cover gasket 48 Stop lever together with: 84 - Gasket
15 Primary auxiliary Venturi 49 - Bush for sealed idling cap 85 Conic seal needle
15 Secondary auxiliary Venturi 50 - Spring 86 Bush
16 Pump delivery valve 51 Adjustment screw 87 - Primary idling jet
17 Pump jet 52 Sealed cap for lever adjustment screw 88 Secondary main shaft
18 Pump jet gasket 53 Primary shaft return spring 88 Oversize secondary main shaft
19 Primary corrector jet 54 Shim adjustment washer 89 Throttle valve
19 Secondary corrector jet 55 Spring for adjustment screw of corrector idling 90 Secondary shaft return spring
20 Primary emulsioning tube 56 Adjustment screw for idling mixture corrector 91 Closing screw for pump discharge space
20 Secondary emulsioning tube 57 Gasket for de-flood device 92 Primary main jet
21 Carburetor body 58 Securing screw for de-flood device 92 Secondary main jet
22 Secondary idling jet 59 Economiser body including: 93 Float
23 Secondary idling jet carrier 60 Cap for adjustment screw 94 Float fulcrum pin
24 Shim adjustment washer 61 Spring washer 95 Needle valve
25 Lever return spring 62 - Diaphragm adjustment screw 96 Needle valve gasket
26 Fast idling regulation lever together.with: 63 - Device box 97 Filter inspection cap
27 - Nut 64 r Spring for diaphragm 98 Filter
28 - Adjustment screw 65 - Diaphragm 99 Tie rod spring
29 Bush for fast idling regulation lever 66 - Device cover 100 *Cut-off cbmp
30 Lever securing screw 67 - Cover securing screw 101 Economiser body control tie rod
31 Starting control lever together with: 68 Retaining ring 102 Eonomiser control lever
32 Cable securing screw 69 Retaining ring 103 Washer for cover securing screw
33 Bush for starting control lever 70 Washer for economiser body control lever 104 Carburetor cover securing screw
34 Shaft securing nut 71 Economiser control lever

* Only for 32 DIR 8 1 A/250 and 32 Dl R 7 I A/250

CHECKS AND INSPECTIONS

B e f o r e r e m o v i n g carburetor f r o m
engine, perform following checking
and adjusting operations:
--
1. Float leveling
Check f l o a t p o s i t i o n a s f o l l o w s :
(I) Remove the whole air filter (see
A i r C l e a n e r ) a n d disconnet t h e
gasoline feeding hose from float
chamber cover.
(2) Remove float chamber cov-
er 4 0,
(3) Make sure float @ is of the
weight prescribed in the technical
data, that no deformation is present
and that it freely rotates on its pin.
(4) If checked parts are defective,
replace them.
(5) Keep float chamber cover @ in
vertical position so as that float is
sli&tly in touch on needle valve,
w h i c h i s o f the s p r i n g - b o d y t y p e .
Using a gauge pin, check if float
distance from float chamber cover - 2. Needle valve tightness
with gasket @ firmly in qlace - is Needle valve tightness is checked by
within specified Qw value. means of a vacuum gauge. Keep float
chamber cover turned over and in
QW Dimension
horizontal position and then proceed
6.75 + 7.25 mm (0.266 + 0.285 in)
as follows:
(6) T o correct QW dimension, (1) Connect gauges plastic hose @
suitably bend float stopper 0. to petrol delivery pipe 0 on float
chamber cover.
(2) Load vacuum gauge air pump by
acting on cam @ ; as a consequence,
mercury will go up the graduated
scale.
(3) Wait for about then. seconds,
during which mercury will have to
remain steady, contraywise, replace
needle valve.
1 Float stopper 4 Float chamber
2 Float cuver
3 Gasket

04-5 May 7983


1 Petrol delivery 2 Connecting hose
Pipe 3 Cam
Remove carburetor from car in oder
to. carry out the following checks
(refer to: Group 01 Engine Disas-
sembly - Engine Unit).
1. Choke opening (air valve) by
economiser
To adjust choke 0 opening
proceed as follows:
(1) Fully engage choke by moving
starting control lever @ as shown in
relevant figure and at the same time
act on the economiser control
lever pushing it all the way back.
(2) Insert gauged point between
choke edge and duct making sure
dimension GWl is within specified
value.
GW, Dimension
5.5 + 6.5 mm (0216 + 0.256 in)
1 Ckoke air valve
2 Ckoke control lever
May 1983
FUEL SYSTEM
(3) In case the verified dimension
GW, is not within specified value,
remove cap and operate on travel
adjustment screw of economiser
diaphragm (see following figure).
(4) At the end of adjustment
operation, refit cap 0.
1 Cap 2 Economiser body
2. Throttle valve opening (gas
valve) with choke inserted.
To adjust throttle valve @ opening
proceed as follows:
(1) Fully engage choke by moving
starting control lever @ as shown in
relevant figure.
(2)-- Insert a gauged wire between
throttle valve edge and first body
duct making sure dimension G,,,,2
is within specified value.
GW2 Dimension
0.9 + 1 mm (0.035 + 0.039 in)
1 Throttle valve
2 Srarting confrol lever
04-6
(3) If GW2 dimension is not
within specified value,.loosen the nut
and operate on control lever adjust-
ment screw of throttle valve (see
next figure).
(4) Having completed adjusting op-
erations, tighten the nut.
1 Nut
3. Accelerator pump adjustment
Adjust accelerator pump as follows:
(1) Secure carburetor to support
C.4.0103 (fitted with gasket) of the
p u m p t e s t i n s t r u m e n t C.4.0101.
(2) Supply the carburetor with
petrol by connecting it to the tools
reservoir.
(3) Set the graduated measuring
tubes C.4.0105 under the foreseen
exhaust pipe -on support itself.
(4) Carry out twenty strokes corre-
sponding to as many complete
openings and closings of throttle
valve, operating on control lever 0.
(5) Check if volume of petrol
collected in the measuring tube
corresponds to specified VW value.
When pumping, briefly stop both in
throttle valve fully open and fully
closed positions.
Volume of petrol VW correspond-
ing to 20 strokes of pump control
lever:
VW = 17 + 20 -cm3
(1.03 f 1.22 cu.inJ
( 6 ) If VW value is not within
specified limit, check diaphragm of
acceleration pump and the pump
jet.
 FUEL SYSTEM

WEBER TWIN CARBURETOR

For Switzerland, Sweden, Australia.

Carry out checks and ajustments following the procedures performed for the WEBER twin carburetors, previously de-
scribed and referring to the tables provided in Technical Data and Specifications relevant to check dimensions.

WEBER TWIN CARBURETOR - EXPLODED VIEW

(it will be provided in the next issue)

May 1983 04-8

 FUEL SYSTEM

KEY

(it will be provided in the next issue)

04-9 May 1983


58 Central Venturi securing screw
59 Sheath securing screw
60 Air valve control iniermediate lever
61 Air valve control return lever
62 Bush
63 Air valve automatic opening control lever
64 Securing nut
65 Washer
CHECKS AND ADJUSTMENTS
Before removing carburetor from
engine, carry o u t the following
checks.
1. Check of float chamber hydrau-
lic level
For float chamber hydraulic level
check, operate as follows:
(I) Remove the whole air filter (see:
Air cleaner) and disconnect the fuel
feeding hose from float chamber
cover.
(2) Remove float chamber cover
(3) Make sure that float is of the
prescribed weight indicated in the
Technical Data, that no deformation
is present and that it freely rotates
around its pin.
(4) If checked parts are defective,
replace them.
(5) Verify that value of distance
A between fuel surface and float
chamber cover surface with assem-
bled gasket, is within specified value.
A = 21 + 23 mm (0.83 + 0.91 in)
FUEL SYSTEM
66 Sheath support 73 Air valve spring
67 Washer 74 Idling cut-off
68 Support securing screw 75 Air valve
69 Bush 76 Air valve control tie rod
70 Central Venturi 77 Air valve shaft assy
71 Economisier gasket 78 Air valve securing screw
72 Economisier assy 79 Stud
(6) To correct A dimension, re-
place washer located under needle
valve of properly bend float stopper.
(7) Reassembly carburetor cover, let
the engine executes a few rotations
then repeat check operations until
the prescribed dimension is obtained.
2. Needle valve tightness
To check needle valve tightness, see
Weber twin carburetor: Checks and
Inspections - Needle Valve Tightness.
1 Choke (air valve)
2 Starting control lever
(3) In case the verified dimension
GS. is not within specified valve
loosen lock-nut and operate on
diaphragm travel adjustment nut of
e c o n o m i s e r b o d y 0 (see next
figure).
(4) At end of adjustment, tighten
lock-nut.
Remove carburetor from car in order
to carry out the following checks
(see: Group 01 - Engine Disassemble
- Engine Unit).
1. Choke opening by economiser.
To adjust choke @ opening proceed
as follows:
(1) Fully engage choke by moving
starting control lever @ as shown in
relevant figure and at the same
time act on the economiser control
l e v e r pushing it all the way back.
(2) Insert gauged point between
choke edge and duct making sure
ti;;nsion GS, is within specified
GS, Dimension
4.5 + 4.75 mm (0.177 + 0.187 in) 1 Economiser body
04-11 May 1983

2. Throttle valve opening (gas
valve) with volet inserted.
To adjust throttle valve @ opening
proceed as folltiws:
(1) Fully engage choke as shown in
figure.
(2) Insert a gauged wire between
throttle valve edge and the first body
duct making sure dimension GS2
is within specified value.
GQ Dimension
0.9 + 1 mm (0.035 + 0.039 in)
1 Throttle valve
2 Starting control lever
( 3 ) I f GS2 dimension is not
within specified valve loose nut and
operate on control lever adjustment
screw of throttle valve (see next
figure) .
(4) Having completed adjusting op-
erations, tighten the nut.
ACCELERATOR CABLE ADJUSTMENT
1. Verify that throttle valve control
cable can freely slide inside sheath.
2. Verify that clearance between
clevis slot @ and pin @ on
carburetor throttle valve opening
shaft is within specified G1 limit.
Clevis slot to pin clearance
G, = 1 mm (0.039 in)
May 1983
FUEL SYSTEM
3. Accelerator pump adjustment @ : Tightening Torque
To check and adjust accelerator Carburetor retaining nuts
pump refer to: Weber Twin Carbure- 19 + 23.5 Narn
tor: Checks and Inspections - Accel- (1.9 f 2.4 k g - m
erator Pump). 13.74 + 17.35 ft.lb)
Volume of petrol VS correspond- OVERHAULING
ing to 20 strokes of pump control
lever: Carburetor should be overhauled
only if encountered defects cannot
be corrected neither through opera-
Twin carburetor Solex C32 EIES 45 tions. described in Checks and Inspec-
1 s t . b a r r e l cm3 8+ 10 tions above nor through cleaning of
(0.49 + 0.61) fuel filter, float chamber or jets.
(in)
2 n d b a r r e l cm3 s+ 10 When overhauling, keep following
(0.49-e 0.61) items in mind:
(in)
Total cm3 16+20
(0.97 + 1.22) a. Remove carburetor from engine
(in)
and disassemble it on bench.
Twin carburetor Solex C32 EIES 44
1 s t b a r r e l cm3 8+ 10 All disassembled parts must be
(in) (0.49 + 0.61) thoroughly cleaned.
2 n d b a r r e l cm3 9+11
(in) (0.55 + 0.67) b. Thoroughly and carefully check
Total cm3 17,: 21 most delicate parts such as
(in) (1.04 + 1.28) needle valve, throttle valve
Twin carburetor Solex C32 EIES 43 shafts, diaphragms, accelerator
pump and fuel filter.
1 s t b a r r e l cm3 8+10
C. Replace defective parts only
(in) (0.49 + 0.61)
with original ones and always
2 n d b a r r e l cm3 10+12
replace a I I gaskets.
(in) (0.61 + 0.77)
d. Use special care in cleaning jets
Total cm 18+22
so as not to damage relevant
(in) (1.10+1.34)
ratings; if possible blow them
with a jet of compressed air.
Fit carburetor back to engine (refer
to Group 01 - Engine Assembly - CAUTION:
Engine Unit) tightening relevant. Once carburetor has been over-
nuts according to specified torque hauled, it is advisable to perform
and performing idle adjustment (re- adjustments described in preceding
fer to: Group 00 - Engine Mainte- paragraph Checks and Inspections.
nance).
3. If required, adjust as follows:
(1) Loosen adjusting screws @
lock nut 0.
(2) Turn screw @ till specified
clearance is reached.
(3) Tighten,lock nut.
CAUTION:
To easy adjustment buck action of
return spring by manually partially
opening the throttle valve. 1 Adjusting screw 3 Pin
2 Lock nut 4 Clevis
04-12

REMOVAL
WARNING:
Before replacing any fuel line part,
carefully follow below instructions:
a. Make sure shop is equipped with
suitable safety equipment.
b. Disconnect battery ground ca-
ble.
c. Place petrol drained from tank
into a suitable container equip-
ped with a safety lid.
FUEL TANK UNIT
1. Remove filler cap from filler
hose and take out all petrol from
tank with the help of a suitable
w-w.
2. Loosen clamp @ and @
connecting fuel filling sleeve to tank
and connecting pipe to feeding hose.
3. Loosen and remove screw secur-
i n g g r o u n d c a b l e @) t o b o d y .
I Ground cable 3 Clamp
2 Clamp
4. support tank by means of
column lift and loosen screws secur-
ing the clamps supporting tank
to body.
5. Slowly lower column lift so as to
gain access to tank upper side.
6. Remove from float the electric
connections of warning lamp and
indicator of fuel level, then, operat-
ing from tank rear side, remove
breather pipe together with retaining
valve.
7. Remove tank and, if required
disassemble it.
FUEL SYSTEM
FUEL TANK FLOAT
Remove float of fuel tank operating
as follows:
1. S u p p o r t t a n k b y m e a n s o f
column lift and loosen screws secur-
ing the two clamps supporting
tank to body.
2. Slightly lower column lift SO
to gain access to float located on
tank upper side.
3. Disconnect from pipe union, on
float, the fuel delivery pipe @ and
remove electric connections @ of
warning lamp and fuel level indicator.
4. Loosen the six screws securing
float 0 to tank and remove float.
1 Float securing screw
2 Electric connections
3 Fuel delivery pipe
FUEL LINE
CAUTION:
Disconnect feedings pipes only if
absolutely necessary.
1. Remove filler cap and take out
all petrol from tank with the help of
a suitable pump.
2. Remove clamps from hose
unions; plug all hoses and pipes to
prevent dust or dirt from going
in during disassembly operations.
3. Free pipes from relevant holding
clamps on underbody.
04-15
CHECK VALVE
Remove check valve from supporting
clip on fuel tank.
as
1 Tank pipe side union
2 Outer side union
CHECKS AND
INSPECTIONS
T A N K
Check thank for flaws or any evi-
d e n c e o f warpage; i f n e c e s s a r y ,
replace it.
HOSES
Check hoses and make sure they are
not porous and show no evidence of
abnormal wear; replace hoses that are
not flawless.
PIPES
Check and make sure pipes are not
clogged, oxidized or dented.
CHECK VALVE
1. Blow in an air into the valve
located of fuel pipe side.
In doing so, one should notice some
resistance and some air should come
out of the outer union.
2. Now blow in an air jet into the
valve from outer side union.
The air jet should go right through
and come out of the fuel pipe side
union, without encountering any
resistance.
3. If check valve does not comply
with above, replace it.
INSTALLATION
Carefully fit all fuel line parts back
together following removal opera-
tions in reverse sequence and paying
special attention to below instruc-
tions.
May 1983
 FUEL SYSTEM

surfaces. 2. Do not twist or crush breather

CAUTION: c. Do not bend or twist
a. Carefully fit clamps back to line during installation.
unions without tightening them d. Start engine up and make sure
too much to avoid damaging the there are no leaks from connec-
hoses. tions.
b. Fit fuel delivery pipes securely
to relevant holding clamps on
underbody, making sure same
FUEL TANK UNIT
are properly fastened. 1. Fit tank back into car following
Failure to follow this caution removal operations in reverse se-
will result in damage to pipe quence.
pipes hoses after fitting; fasten them with
relevant clamps.
FLOAT
- *
Be sure to replace tne gasket each
time float is fitted back into tank.
CHECK VALVE
Be sure to fit check valve according
to proper working direction.

EXHAUST SYSTEM

1 Gasket 6 Bolt 11 Rear clamp

2 Nut 7 Front clamp 12 Rear muffler
3 Hot air intake 8 Central muffler 13 Support ring
4 Front manifolds 9 Support ring 14 Buffer
5 Nuts IO B o l t 15 Nut

CHECKS AND
INSPECTIONS
1. C h e c k m u f f l e r s a n d e x h a u s t
pipes making sure they are not in any
way damaged or cracked and show
no evidence of corrosion; contrary-
wise, replace them.
2. Thoroughly check supports ring
and do not hesitate to replace them
if they are cracked, porous or worn.
3. Check buffer on exhaust pipe
end.
4. Check surface of hot air intake
making sure there are no warps or
dents that could impair normal air
flow.
REMOVAL
a. Instructions hereafter described
have been compiled so as t o
allow separate removal of the
exhaust systems single compo-
nents.
b. Consequently, removal proce-
dure may be changed depending
on the operations purpose.
c. When removing the entire ex-
-haust system, it is advisable to
get someone to help you with
it.

May 1983 04-16


MANIFOLDS AND
MUFFLERS
Referring to the figure on page
04-16, proceed with removal as
follows:
1. Raise car on lift.
2. Remove rear muffler as follows:
(1) Loosen clamp 0 connecting
central element with rear one and
release this one from support retain-
ing rings @ .
(2) With a suitable hammer, lightly
and repeatedly strike all around the
muffler pipes connection area and
then alternately turn muffler @
clockwise and counterclockwise so
as to make separation easier.
(3) If necessary, use a plastic ham-
mer and lightly strike the muffler in
the direction of removal till rear
muffler comes off the central muf-
fler.
FUEL SYSTEM
3. Remove central muffler as fol-
lows:
(1) Remove rear muffler (refer to
item 2 above).
(2) Loosen clamps connecting cen-
tral element with front one and
disconnect central element from
support retaining rings @.
(3) With a suitable hammer, lightly
and repeatedly strike all around the
pipes connection area and then
alternately turn muffler @ clock-
wise and counterclockwise so as to
make separation easier.
(4) If necessary, use a plastic ham-
mer and lightly strike the muffler in
the direction of removal till central
muffler comes off front manifolds.
1 Sleeve 4 Clamp
4. Remove front manifolds as fol- 2 Hot air intake 5 Bolt
lows: 3 Screw 6 Nut
(1) Loosen clamp connecting front
element to central one and move it
from its seat. INSTALLATION
(2) Loosen the nut securing hot air
intake bracket to cylinder head and
Fit single parts back together follow-
withdraw the warm air intake sleeve.
ing removal operations in reverse
(3) Loosen nut @ securing mani-
sequence and paying close attention
f o l d .flanges t o c y l i n d e r h e a d s .
to below instructions:
(4) Remove manifolds @.
a. Always fit new gaskets between
manifbld flanges and cylinder
SUPPORT RINGS heads.
b. Having completed installation,
Verify integrity of support rings and
check and make sure that
replace them if necessary.
support rings move freely and
are free of undue stress; check
brackets making sure they have
HOT AIR INTAKE been properly secured.
C. While engine is running check all
1. Raise car on lift.
pipe connections for gas leaks
2 . W i t h d r a w s l e e v e @ from air
and the whole exhaust system
intake @ _
for unusual noises.
3. Loosen bolt @ connecting air
intake to manifolds and then remove
clamp @ thus separating the hot air
intake half shells.
4. Loosen nut @ securing support
lever to left head and remove hot air
intake.
04-17 Mav 1983
 FUEL SYSTEM

SERVICE DATA AND SPECIFICATIONS

TECHNICAL DATA

FUEL PUMP
-. FUEL TANK

-- I
Type
ALFA ROMEO
part No.
Brand
1200
305.00
Model
1350
305.02
1500
305.04
Overall capacity

Reserve
I
Imp. Gall 11

I
Imp. Gall
50

6.5
1.43

510.355 FISPA 4041 .Ol 4059.01

Mechanical 531.354 SAVARA 960.084.00

542.140 SAVARA 906.130.00

GENERAL SPECIFICATIONS

FLUIDS AND LUBRICANTS

Application TYPO Denomination Q.ty

Spacer on accelerator pedal rotation pin GREASE AGIP FI Grease 15

Standard 3671-69810

May 1983 04-18

 FUEL SYSTEM

$ .6-
s 5
T-r+
1
1

M a y 1983
 FUEL SYSTEM

6
LL

- P
5:

MN B
1.

- - - -

z 2
L

- -

R 8
L

- - -

* *
3 a 3

- -

:
E J
?
j

May 1983 04-20

 FUEL SYSTEM

INSPECTION AND ADJUSTMENT

FUEL PUMP WARM - COLD AIR AUTOMATIC MIXER

Fuel pump pressure Pump delivery

Warm air inlet complete closing

FISPA 17.7 i29.4 KPa engine temperature I warm

(0.177 + 0.294 bar) >33+37 9=
- thermostat temperature
(0.18 + 0.30 kg/cm2 ) I (>91.4+98.6F)
(2.56 +4.27 psi)
Cold air inlet complete closing
at 5000 rpm engine temperature cold
<28-32 93
SAVAR A 17.7 + 29.4 KPa thermostat temperature
(<82.4+89.6 F)
(0.177 GO.294 bar)
-
(0.18 - 0.30 kg/cm21
(2.56 f 4.27 psi)

ar 6000 rpm

ACCELARATOR CONTROL

Clearance between adjustment fork slot and throttle con-

trol shaft pin

Gl mm (in) 1 (0.039)

Clearance between throttle control lever and relevant

complete opening stop

G2 mm (in) 1 + 2 (0.039 f 0.079)

04-2 1 May 1983

 FUEL SYSTEM

p
R
In

May 1983 04-22

FUEL SYSTEM
 FUEL SYSTEM

TIGHTENING TORQUES
Unit
N-m kg.m ft-lb
Item

Carburerors retaining nuts

TROUBLE DIAGNOSIS AND CORRECTIONS

Condition Probable cause Corrective action

Fuel leakage l Needle valve is dirty or its seat is Thoroughly clean petrol filter and
loose on thread needle valve; tighten seat firmly: if
necessary, replace it with a new one
(original parts)
l Float sticks (hard on pin or sides) or Free the float and adjust its move-
is heavy ment: if necessary replace it (original
parts)

l Pipes improperly tightened or broken Tighten pipes and unions or replace

defective ones

l Gaskets are hard, worn or improperly Replace gaskets and tighten them
tightened properly
l Acceleration pump diaphragm is Replace diaphragm

l Fuel pump or pipes are overheated
l Fuel pump is mechanically defective
l Pipes, fuel filter or carburetor ducts
are clogged by foreign matter
l Fuel tank breather hose is clogged or
there is a water deposit on tank
bottom
Let bubbles out and try to eliminate
overheating causes
Overhaul pump replacing defective
components or replace the whole
pump
Thoroughly clean pipes, filter and
carburetor
Unclog breather hose and eliminate
water also from pipes and from car-
buretor float chamber

Cold starting is difficult or
impossible
I I
l Having verified that fuel level in float Restore proper fuel level in float
chamber is absolutely correct, pro- chamber
teed to check following possible
carburetor troubles.
l Starting control cable does not slide Repair or replace cable
freely, is broken, unhooked, etc.
l Choke sticks so that it tends to stay Free choke movement
either fully open or fully closed
l Starting jet, if any, is dirty or has Clean or replace jet
been tampered with

May 1983 04-24


Cold starting is difficult or
impossible (continue)
Excessive fuel consumption
Slow pickup especially when
in direct drive
Engine easily knocks, over-
heats or self-ignites
FUEL SYSTEM
Probable cause
Starting control valve, if any, is
sticky
Ignition and starting systems are out
of order
Carburation, ignition or compression
are defective, as also mentioned in
case of insufficient max speed
Air cleaner intake stopped in the warm
position
Twin carburetor goes into action too
early
Carburation, ignition or compression
are defective, as also mentioned in
case of insufficient max speed (pres-
ence of exhaust smoke is possible)
A c c e l e r a t i o n p u m p n o t .properly
adjusted or defective or pump circuit
of jet and valves is defective
Diffuser well is clogged or otherwise
defective
Carburation or ignition are defective,
as also mentioned in case of insuffi-
cient max speed
Octane rating of petrol used is too
low
Engine cooling system is defective
Excessive scaling of engine cylinders
Having also excluded any ignition
defect, engine compression will have
to be tested since there could be
leaks coming from piston rings,
valves or cylinder head gaskets
Engine compression is poor
04-25
Corrective action
Free valve movement so that it can
properly follow control cable
Overhaul ignition and starting
systems
Checking operations to be performed
same as previously mentioned
Replace thermostat located into
cleaner air intake
CAUTION:
Special attention should be paid
when checking fuel consumption
since speed load, road type as well as
driving habits play an important part
in establishing actual running fuel
consumption
Adjust relevant controls
Checking operations to be performed
same as previously mentioned
Overhaul pump and relevant circuits
Carefully overhaul air jet, diffuser
and relevant well making sure that
all components are properly rated
Checking operations to be performed
same as previously mentioned
Replace petrol in tank with a kind
having a higher octane rating
Check radiator, relevant thermostat
or shutter, if any, since the latter
could be improperly adjusted
Proceed to scale the engine
Check engine compression by means
of suitable gauge screwed onto spark
plug holes; overhaul or replace any
defective engine parts
Check compression and, if necessary,
overhaul the engine
May 1983

Condition
Improper engine idling or
progression phases
Power shortage (insufficient
max speed)
Exhaust system is unusually
or excessively noisy
May 1983
FUEL SYSTEM
Probable muse
l Inadequate fuel level in float cham-
ber or defective starter, ignition or
overall engine operation as previously
mentioned in connection with diffi-
cult cold starting
l Adjustment of idling adjusting screws
is incorrect
D Idling jet is dirty, loose or has been
tampered with
1 Progression holes or channels of
idling circuit are clogged or have
been tampered with
b Air leaks from fitting flanges or other
connections
b Throttle valve shaft has air leaks
from intakes
b Throttle valve or relevant controlling
parts are sticky
b Twin carburetors second throttle
valve does not work properly
I Inadequate fuel level in float cham-
ber or defective starting, ignition or
compression as previously mentioned
m Main jet, power jet, air adjusting
screw or diffuser are clogged, loose
or have been tampered with
b Fuel filter in tank or in carburetor
is clogged
b Air cleaner clogged
0 Throttle valve does not fully open
l Holes in manifolds
<
l Holes in pipes
l Gas leaks from loose connections
04-26
Corrective action
Perform same checks and repairs as
previously described
Carefully repeat all relevant adjust-
ments as per maintenance instruc-
tions
Check or replace idling jet
Check and thoroughly clean holes
and channels
Tighten as required and, if necessary,
replace relevant worn gaskets
Replace shaft and, if necessary, fit an
oversize shaft after having suitably
reamed relevant holes in the body
Free throttle valve
Overhaul and clean
Perform same checks and repairs as
previously described
Check, thoroughly clean or replace
defective parts
Clean the filter
Clean air cleaner and replace car-
tridge
Check throttle valve and relevant
controlling parts
Replace damaged parts
Replace damaged parts
Tighten properly as required
 FUEL SYSTEM

SPECIAL SERVICE. TOOLS

Refer to
Tool name
Tool number page

Carburetor pump EST 046

c.4.0101

c.4.0103 Twin carburetor support (to be used 04-6

with C.4.0101)

c.4.0105 Beaker for carburetor pump tests (to

be used with C.4.0101)

04-27 May 1983

 IGNITION, STARTING, CHARGING SYSTEM
CONTENTS
BATTERY . . . . . . . . . . . . . . . . . . . . . . . .05-2
STARTER . . . . . , . . . . . . . . . . . . . . . . . .05-4
Wiring diagram. . . . . . . . . . . . . . . . . .05-4
Disassembly . . . . . . . . . . . . . . . . . . . . 05-7
Checks and inspections . . . . . . . . . . . 05-l 0
Reassembly . . . . . . . . . . . . . . . . . . . .05-l 2
Test stand inspection . . . . . . . . . . . . . 05-I 2
Service data and specifications. . . . . . 05-l 2
Trouble diagnosis and corrections . . . 05-13
CHARGING . . . . . . . . . . . . . . . . . . . . . . .05-15
Wiring diagram. . . . . . . . . . . . . . . . . . 05-15
Disassembly . . . . . . . . . . . . . . . . . . . . 05-l 8
Checks and inspections . . . . . . . . . . .05-21
Reassembly . . . . . . . . . . . . . . . . . . . . . 05-24
Test stand inspection . . . . . . . . . . . . . 05-24
Service data and specifications. . . . . . 05-24
Trouble diagnosis and corrections . . . 05-25
TRANSISTORIZED IGNITION
WITHOUT CONTACTS. . . . . . . . . . . . . .05-26
Wiring diagram. . . . . . . . . . . . . . . . . . 05-26
Description . . . . . . . . . . . . . . . . . . . . 05-27
Checks and adjustments. . . . . . . . . . .05-28
Disassembly . . . . . . . . . . . . . . . . . . . . 05-31
Checks and inspections . . . . . . . . . . . 05-32
Reassembly . . . . . . . . . . . . . . . . . . . .05-33
Test stand inspections . . . . . . . . . . . . 05-33
Service data and inspections. . . . . . . . 05-33
Trouble diagnosis and corrections . . . 05-36
May 1983
 IGNITION, STARTING, CHARGING SYSTEM
WARNING:
a. Do not touch both the positive
and negative terminals of the
battery at the same time with
your bare hands.
b. In case of necessity use a I2-volt
booster battery with jumper
leads for starting the engine.
CHECKS
1. The container has no cracks in
it.
2. Verify that electrolyte level
covers electrodes of about 4 + 5 mm
(0.16 4 0.2 in).
3. The top of the battery is clean
and the terminals are not oxidized or
dirty.
4. The lead terminals are well
fastened on to the battery terminals
and make good contact.
CLEANING
1. Clean the top of the battery, its
terminals and the lead terminals with
a solution of sodium bicarbonate in
water.
2. Before reassembling terminals, it
is necessary to grease them with the
prescribed grease: Grease REINACH
E 10 Tat.
WARNING:
Do not let the cleaning fluid get into
the battery: it will react with the
electrolyte.
The electrolyte is acid and therefore
dangerous to eyes, hands and clothes.
SPECIFIC GRAVITY
1. Verify that electrolyte is at
correct level.
2. By means of a bulb hydrometer,
extract electrolyte from each cell and
check the specific gravity.
May 1983
BATTERY
Batteries left on the shelf or in cars
unused for long periods gradually
lose their charge. Therefor they need
to be charged up again when they are
to be used.
CHARGING
WARNING:
a. Remove the negative connection
before starting to charge the
battery.
b. Do not let the electrolyte heat
up above 45C (113F) during
charging.
3. Take the temperature t of the
electrolyte with a thermometer.
CAUTION:
4. Calculate the specific gravity at
a. Do not use naked flames near
25C (77F) f r o m t h e f o r m u l a
the battery while charging.
sg,, = sgt + 0.0007 (t - 25) (kg/dm3) b. First connect the battery to the
where: charger and then switch on the
= Specific gravity of electrolyte charger.
$gt
at PC
t = Electrolyte temperature CELLS TEST
Examples This test should be performed with
1. SElectrolyte s.g. at 15C ( 5 9 F ) : the correct electrolyte s.g.
1.290 kg/dm3 Measure the discharge voltage at the
s.g. at 25C (77F) will be: terminals of each cell.
sg*s = 1.290 + 0.0007 (15 -- 25) 1. Remove the plugs from the filler
= 1.283 kg/dm3 holes.
(35.51 Ib/cu in) 2. Put the test probes in two
adjacent holes (positive and negative)
2 . E l e c t r o l y t e s.g. at 35C (95F): as shown. The needle should flip over
1.275 kg/dm3 to the green zone (charged).
s.g. ar 25C ( 7 7 F ) w i l l b e : 3. Repeat for the other two pairs
of holes.
sg,, = 1.275 + 0.0007 (35 -- 25)
= 1.282 kg/dm3
(35.48 Ib/cu in)
5. Compare then the clensitycalcu-
lated at 25% (77F) with the value
prescribed for an efficient battery.
An efficient battery electrolyte spe-
cific gravity is
d = 1.28 * 0.01 kg/dm3 4. If the needle stops in the red
zone (low charge) at the same point
6. If necessary charge the battery. for each cell, charge the battery.
05-2
 IGNITION, STARTING, CHARGING SYSTEM

5. If the needle stops in the red
zone (low charge) but at quite
different points for the different
cells, put in another battery.
USING THE ELECTRONIC
BATTERY TESTER
(MOTOROLA)
Connect the positive instrument clip
to battery positive (+) and negative
to negative (-). Set battery voltage
s w i t c h @ to 12V. t e m p e r a t u r e
compensator @ to the estimated
battery temperature, and current
calibrator @ to the battery amps
according to type.
Voltage test
1. Switch selector 0 t o V O L T .
2. The reading on the VOLT scale
must be greater than 12.4 V.
3. If b a t t e r y v o l t a g e s h o w s l e s s Also check alternator belt tension
than 12.4V, charge the battery and (see: Group 00 Engine Mainte-
repeat the test. If the voltage again nance).
shows less than 12.4V. a celle may
be shortcircuited. Change the battery Starting test
for another one. 1. Set instrument selector switch to
VOLT.
Battery state 2. Take the ignition HT lead off
1. Set the instrument selector the coil.
switch to Cond. Batt.. 3. Start the engine and check the
2. The needle should flip over to needle does not drop below 9 V on
t h e G R E E N z o n e o n t h e RED- the Volt scale.
GREEN scale. 4. If it does, examine the starting
3. If it does not, put in another system (see: Starting).
battery.
Power test
1. Set instrument selector switch to
kW.
2. The needle should read be-
tween 2 and 4 kW on the kW scale.
3. If it does not, put in another
battery.

1 Selector switch
2 Temperature compensation
3 Battery voltage switch
4 Current calibration
Charge test
1. Set instrument selector switch to
VOLT.
2. Start the engine and let it idle
until the needle settles to its reading.
3. The reading should be be-
tween 13.6 and 15V.
4. If the reading is outside (above
or below) these limits, check the
alternator for defects, especially the
voltage regulator (see Charging -
Checks and Inspections).

SERVICE DATA AND SPECIFICATIONS

Technical Data

Car
1200 1350 - 1500 1500 Quadrifoglio
Battery

Voltage V 12

43 55
Capacity Ah 45 60

181 255
Discharge current A 185 275

Electrolyte s.g. kg/dm3 1.28 + 0.01

(lb/in 3 ) (35.43 5 0.27)

05-3 May 1983

 IGNITION, STARTING, CHARGING SYSTEM

General Specifications

FLUID AND LUBRICANTS

Application Type Denorninatioh Q-W

Battery terminals GREASE Grease REINACH: E 10 Tat -

Std. no. 3671 - 69812

STARTER
WIRING DIAGRAM

0
All

Al. Battery
Al I. Starter
Gl. Fuseholder box
ci85. Front service junction
El. Ignition switch

May 1983 05-4

 IGNITION, STARTING, CHARGING SYSTEM

BOSCH STARTER MOTOR

I
I
I

1 Dust coer 11 Fork

2 Retaining ring 12 Rubber block
3 Bush 13 Lamination
4 Commurator casing 14 Rotor
5 Brush holder I 6 Starting clutch
6 Brush spring 16 Snap ring
7 Excitation winding lug 17 Pinion stop ring
8 Brush 18 Drive housing
9 Yoke 19 Bush
IO Electromagnet

05-s May 1983

 IGNITION, STARTING, CHARGING SYSTEM

DUCELLIER STARTER MOTOR

1 Washer 11 Trunnion
2 Bush 12 Fork
3 Commutator casing 13 Screw
4 Brush holder 14 Rotor
5 Brush spring 15 Starting clutch
6 Brush 16 Snap ring
7 Yoke 17 Pinion stop ring
8 Electromagnet 18 Drive housing
9 Plate 19 Bush
10 Locator

May 1983 05-6

 IGNITION, STARTING, CHARGING SYSTEM

8. Unscrew the two screws 0

securing the electromagnet @ to
the drive housing @ and take out
the electromagnet.
9. Remove the rubber block @
with the lamination.
10. Unscrew the bolt @ serving as
clutch fork pivot.

I- Brush spring 2 Brush holder

6. Extract the two positive

J-h
brushes tJJ from the brush
holder @ and take off the brush
holder with the two negative
brushes 0
3 .

1 Electromagnet 3 Drive housing

screw 4 Rubber block
2 Electromagnet 5 Bolt

8
11. Withdraw the rotor 2 together
with the starting clutch 3 and the
forked lever 0.

1 Positive brushes 3 Negative brushes

2 Brush holder

1 Pinion stop ring 2 Snap ring

7. Unscrew the excitation winding

lug @ securing nut @ from the
electromagnet
14. Withdraw the starting clutch 0.
w i t h d r a w t h e iiri& ?mpy?
with excitation winding.

1 Fork 3 Clutch
2 Rotor

Hold the rotor in a vice with caps.

12. Free the pinion stop ring @
from the snap ring @ with a box
spanner.
13. With a pair of pliers remove the
snap ring @ from the rotor shaft
and slip off the pinion stop ring.

1 Electromagnet 3 Nut
2 Excitation 4 Yoke 1 Starting clutch
winding lug

May 1983 05-8

 IGNITION, STARTING, CHARGING SYSTEM

15. Unscrew the inductor wind- 4. Punch on the trunnion 6 for 0 8. Strip the rotor as for the Bosch
(see: Bosch Starter Motor, steps 12
ing 1 securing screw on the the fork on the pinion housing 0.
y o k e82 and extract the winding. and 13).

1 Lug 4 Rotor
2 Commutator 5 Pinion housing
casing 6 Trunnion
3 Brush holder

1 Inductor winding 2 Y o k e

16. If necessary, extract the bushes

5. Unscrew the nuts 2
remove the electromagnet 1 . 8 and

1 Nut 2 Fork

from the commutator casing and the

crive h o u s i n g w i t h t h e u s e o f a
punch. MARELLI STARTER MOTOR
Hold the starter motor in a capped
DUCELLIER STARTER
vice.
MOTOR
1. Unscrew the two screws @
Hold the motor in a vice with caps. securing the dust cover and take it
1. Hold the pinion firm with pliers off.
and unscrew the pinion adjusting 2. Unscrew the two nuts @ with
screw 0. Take out the screw and washers securing the commutator
the washers under it. casing 0 and remove it.

1 Electromagnet 2 Nuts

6. Hold the electromagnet in a vice

with caps. Use a screwdriver to keep
the electromagnet shaft from turning
and u n s c r e w t h e p i n i o n c l u t c h
fork @ clamping nut 0.
Remove the fork, spring and striker.
l 7. If necessary take the inductor
1 Washer 2 Screw clamping
winding out of the yoke (see: Bosch
Starter Motor, step 15.) and the 1 Commutator 3 Screws
2. Unscrew the two nuts clamping bushes from out of the commutator casing 4 Dust cover
the commutator casing @ and the casing and the drive housing. 2 Nut
stator yoke on the pinion housing on
to the stud bolts. Remove the CAUTION:
commutator casing with the brush When unscrewing nut 0, count the 3. Unscrew the electromagnet ex-
h o l d e r 0. exact number of threads to when it is citation winding lug nut and take the
3. Unscrew the excitation winding free so that it may be screwed up the yoke out of the starter motor con-
l u g @ fixing nut on the electro- s a m e a m o u n t i n re-assembly a n d taining the stator windings.
.mannet. Remove the stator and the correct fork adjustment had. 4. Extract the pivot cotter pin and

0
rotor 4 . take the starter engaging fork pivot.

05-9 May 1983

 IGNITION, STARTING, CHARGING SYSTEM

5. Remove the rotor electromagnet Rotor insulation test

assemblage and take the rotor to 1. Set the tester to c? x 1 scale.
pieces as for the Bosch starter 2. Put one prod on the commu-
motor (see: Bosch Starter Motor, tator and the other on the segment
steps IZ., 13. and 14.). pack or shaft.
3. There should be no sign of
current flow by the tester.

1 Commutator

4. If greater errors than these are

pound or if the commutator is badly
scored, put in a new rotor unless it
would seem enough to turn the rotor
and smooth it with a piece of cloth
1 Electromagnet 3 Fork for rotors.
2 Rotor 4 Clutch
Bosch and Marelli Starter Motors
Max turning depth on nominal
6. If necessary, take the field thickness 4. If the insulation is broken (short
winding out of the yoke (see: Bosch 0.25 mm (0.0098 in) circuit) put in another rotor.
starter motor. step 15) and the
bushes out of the commutator casing CAUTION:
Commutator continuity test
and out of the drive housing.
Repeat steps 2. and 3. for all the
1. Set the tester to the fi x 100
commutator segments.
scale.
2. Put the prods on the commu-
Rotor shortcircuit test on test
tator segments of the pack under
stand
test:
3. The test should show current 1. Position the rotor between the
flow. pole pieces of the rotor testing
apparatus and switch on.
CHECKS 2. Slowly rotate the rotor and rest
the steel blade on the rotor pack.
AND INSPECTIONS

Before making any electrical inspec-

tion thoroughly blow-clean the com-
ponents and especially the ends
of the winding with compressed air
and clean the commutator with a
cloth slightly wetted with petrol.

Commutator wear
1. Put the rotor on a lathe.
2. Place a magnetic-based centesi-
mal dial gauge on the lathe carriage 3. The blade will stick to the pack
with the gauge feeler in contact with in correspondence with the faulty
the commutator 0. lead cables if there is a short circuit.
3. Bosch and Marelli Starter Motors
If there is no electrical continuity,
Eccentricity should not be more than Excitation winding insulation
put in a new rotor.
the stated maximum. test

CAUTION: 1. Set the tester to the ax 1 scale.

Max permissible commutator 2. Put one prod on the lug of the
Repeat steps 2. and 3. for all the
eccentricity induction windings and the other
pairs of commutator segments.
b.06 mm (0.0024 in) prod on the yoke.

May 1 9 8 3 OS-IO
 IGNITION, STARTING, CHARGING SYSTEM

3. The tester should give no sign of 2. Put one prod on the brush 3. Eye check the pinion teeth.

current flow. holder plate and the other prod on a

positive brush holder.
3. The tester should give no sign of
current flow.
4. Repeat the test on the other
positive brush holder.

4. If the pinion does not work

properly or the teeth show excessive
signs of wear replace the starter
clutch.

Brush spring check

4. If insulation is broken, remove
the excitation winding from the yoke
and put another winding in its place
(see: Bosch Starter Motor, step 15).
Excitation winding continuity
test
I. Set the tester to the fi x 100
scale.
2. Put one prod on the induction
winding cable and the other prod on
the positive brush. (Repeat with the
other brush).
3. The tester should show current
flow.
5. If insulation is broken, put in
another brush holder plate.
Electromagnetic efficiency
check
carbon deposits and check that their
1. Shortcircuit the electromagnet
with the starter pin @ and connect
its positive pole @ to the positive
terminal of a battery.
2. Connect the batterys negative
t e r m i n a l t o the electromagnets
yoke 0.
1. Check that the brush springs
have not lost their elasticity and still
ensure good brush contact on the
commutator.
2. If necessary, put in new springs.
Brush wear inspection
C h e c k t h a t t h e stator a n d r o t o r
brushes are not chipped or dirty with
lengths are within the prescribed
limits.
Brush lengths (mid
Bosch 11 mm (0.433 in)
Ducellier 9 mm (0.354 in)
Marelli - m m (- i n )

Bush wear inspection

4. If continuity is broken in the
windings, remove the windings from
the yoke and put in others in their
p l a c e ( s e e : D i s a s s e m b l y Bosch
1 Yoke 3 Electromagnet 1. Check that the two bushes on
2 Pin positive pole
the front and rear rotor shaft bear-
3. The starter drive fork actuator ings are not excessively or unevenly
should trip. If it does not, put in worn. Side play between shaft and
another electromagnet. bush should lie within the limits.
Pinion efficiency check Shaft-bush clearance
1. Rotate the pinion clockwise as (0 bush 0 shaft) =

Starter Motor, step 15). shown in the figure. It should rotate 0.02+ 0.05 mm
freely. (0.00079 + 0.00197 in)
Positive brush holder insulation 2. Rotate the pinion counter-
test c l o c k w i s e , i.e. in the direction of 2. If wear is excessive, put in new

1. Set the tester to the ax 1 scale. meshing. It should lock. bushes (see: Disassembly Bosch

05-I 1 May 1983

 IGNITION, STARTING, CHARGING SYSTEM

Starter Motor, step 16). stand to correspond with the crown adjust the absorber current to the
wheel and connect up to the electri- value in the under-load test.
CAUTION: cal system. The torque should be that shown in
Make sure the bushes are assembled the technical particulars.
properly and the rotor shaft turns CAUTION: 2. Across-line test
easily and without play. The battery used in the test should (1) Apply the rated voltage to the
have a high enough capacity to avoid starter motor.
REASSEMBLY voltage variations. (2) Lock the crown wheel brake.
Follow the disassembly steps in the (3) Start up the starter motor and
opposite order and lubricate t h e take a quick reading. Current, voltage
following parts with the prescribed and torque should be those given in
grease. the technical particulars.
Surfaces in motion relative to the
starter motor 3 . T e s t w i t h e-m. s w i t c h o n t h e
. Commutator casing bush starter motor
. Drive housing bush (1) Remove the starter motor away
. Pinion gear from the crown wheel so that the
. Starting system sliding spiral pinion will not engage it.
coupling 1. Under-load test (2) Apply the rated voltage to the
. Electromagnet push rod (I) Apply the rated voltage to the starter motor. Switch on the starter
starter motor. Switch on the starter motor. The absorbed current should
TEST STAND so that the pinion turns the crown be that given in the technical data.
INSPECTION wheel and check for good working. (3) PICK-UP/CUT-IN voltage should
Put the starter motor on the test (2) Brake the crown wheel and be that given in the technical data.

SERVICE DATA AND SPECIFICATIONS

TECHNICAL DATA AND INSPECTION
Starter Motor

533.051 533.052 536.611

MARELLI
E95 0.9 kW
12 v

Voltage V

Min brush length mm (in)

Max commutator eccenrricity mm (in)

Shaft-bush side play mm (in)

Under-load test (pinion meshed with crown

wheel with torque dynamometer)

- Voltage V 10 10 9.8

-- Absorbed current A <230 <200 215

- Speed i-pm 3 1,450 3 1,450 1,800
- Torque N.m 5 5 5
(kg-m) (0.51 (0.5) (0.5)
(ft.1 b) (3.62) (3.62) (3.62)
.-
Across-line test (pinion meshed with
locked crown wheel)

- Voltage V 8 8 8
- Absorbed currant A G400 G380 400
- Torque N.m >lO.S 211 12
(kg.m) (21) PI.11 (1.2)
(ft.1 b) (2 7.231 I> 7.95) (8.68)

May 1 9 8 3 05-12
 IGNITION, STARTING, CHARGING SYSTEM

Starter Motor
533.051 533.052 536.611

BOSCH MARELLI
DUCELLIER
EF 12V 0.8 kW E95 - 0.9 kW
6246/C
0001211215 12v

N*cm 13+22 11317 15*3

Over running torque (kg.cm) (1.3+2.2) (I .l + 1.7) (I .5 * 0.3)
(in-lb) 11.13+ 1.91) (0.95 + 1.48) (1.30 ? 0.261

EM Switch on starter motor

- Max absorption current at rated
voltage A G4Q <40 55
- Min pickup voltage v 8 Gs 7

Pinion module 2.116 2.116 2.116

TROUBLE DIAGNOSIS AND CORRECTIONS

Condition Probable cause Corrective action

Starter motor does not turn
and no current flows
I Break in electric circuit between
battery and starter motor
m Break in electric circuit between
starter motor and starter switch
m Battery terminals dirty or loose
c.onnections
b Starter motor electromagnet or wind-
ing or is earthed
1 Excessively worn brushes not making
contact on the commutator
Locate and repair it Check battery
terminals and starter cable terminals.
Tighten up the securing screws
Locate and repair it. Check switch
contacts and replace if necessary
Clean the terminals and tighten up
the connections
Clean the moving and fixed contacts
of the switch when possible and
replace it if necessary
Replace the brushes with other origi-
nal ones after checking state of com-
muTator

Current flows but starter motor
does not turn, or turns slowly,
or starting does not take place
1 Rotor is rubbing against the pole
pieces or is being held between the
poles
1 Rotor shaft seized UP
) Field winding short circuited or
earthed
l Broken or earthed rotor
l Rotor short circuited
Replace the bearings if the bushes
are too worn. Check bearing align-
ment. Examine rotor shaft. See that
the poles are well located and se-
curely clamped into the yoke
Replace the rotor and the piece with
the seized-up bush
Take out rhe field coils and put in
new ones
Replace the rotor
Clean the carbon and copper dust
off-the commutator and brush hold-
ers and if necessary replace the
rotor

Starter motor turns but starting D Crown wheel teeth worn: pinion Replace starting ring gear
does not take place does not engage

05-13 May 1983

 IGNITION, STARTING, CHARGING SYSTEM
Condition
Starter motor turns but starting
does not take place
(continued)
Starter motor turns normally
but makes excessive or un-
usual noise
Starter motor does not develop
max power
Excessive brush wear
Sparking at the commutator
May 1983
Probable cause
l Wrong assembly: pinion engages only
partially
l Impurities in the coupling: Clutch
does not slide on rotor shaft
l Pinion engages ring gear properly
but the engine does not start
l Defective mechanical parts
. Foreign bodies have got into it
l Brush contact on commutator not
good
l Brushes do not slide freely in the
guides
l Ovalized commutator
l Mica projecting out of commutator
copper sections
l Brushes press excessively on com-
mutator
l Wrong brushes
l Electrical overload in general
l Slack brush springs
l Mica projecting from copper
05-14
Corrective action
Check concentricity and pinion-ring
gear distance
Clean and lubricate. If necessary
clean the coupling completely
Pinion free wheel defective and must
be replaced. Faulty clutch to over-
haul or replace. Electra-magnet not
working properly: repair or replace
Check bearings. Examine bushes and
if necessary replace bearings
Clean them out
Replace brushes or snug them by
running the motor on no-load for
some time. Check brush spring
loading and replace them if they have
lost their elasticity
Clean the brush-holder guides or
replace the brush holders if neces-
sary
Turn within in prescribed limits, re-
move mica and clean commutator
Remove mica and clean commutator
Check brush spring loadings for
prescribed values
Replace with others of prescribed
we
Overhaul the engine
Replace brush springs
Remove mica and clean the com-
mutator
. .
 IGNITION, STARTING, CHARGING SYSTEM

BOSCH ALTERNATOR

Distance piece 10 Rotor

Semipulleys 11 Regulator side bearing
Distance piece 12 Stator
Fan 13 Diode - holder plate
Stay bolt 14 Regulator mounting
Drive housing 15 Brush holder-voltage regulator
Control side bearing 16 Brush spring
Plate 17 Brush
Feather key

May 1983 05-16

 IGNITION, STARTING, CHARGING SYSTEM

MARELLI A L T E R N A T O R

'-1

.J

1 Pulley 7 Feather key 13 Brush holders

2 Cooling fan 8 Rotor 14 Rectifier bridge guard
3 Stay bolt 9 Bearing-regulator side 15 Excitation Tang
4 Distance piece 10 Stator 16 Positive terminal
5 Drive housing 11 Voltage regulator support 17 Insulating washer
6 Bearing retaining plate-control side 12 Diode rectifier bridge 18 Voltage regulator

DISASSEMBLY ;\ 2. Unscrew the two screws securing

t h e v o l t a g e r e g u l a t o r @ to its
mounting @ and take out the brush
CAUTION: holder regulator unit.
The following procedures are in-
tended for part replacement. If used
for component checking and inspec-
tion purposes, do not unsolder.

BOSCH ALTERNATOR
1. Hold the alternator pulleys 2
in a vice with caps, Release fan 81
and pulley to rotor shaft @ secur-
ing nut 0. Take off the nut,
the lock washer, the two semipulleys
with distance pieces and the fan with 1 Fan 3 Nut 1 Voltage regulator
washers and feather key. 2 Pulley 4 Shaft 2 Regulator mounting

May 1983 OS-18

 I G N I T I O N, ST A R T I N G , CHARGING SYSTEM

3. Hold the drive housing @ in a 9. Extract the bearing 0 on the

vice and unscrew the stay bolts drive housing end of the rotor
clamping the regulator mounting @ s h a f t @ with an extractor (see
to the housing 0. following figure) or a punch press
with half-plates.

CAUTION:
At reassemble use a new bearing if
the old one is worn or damaged and
put it on the press with the help of a
pipe which must rest only on the
inner ring of the bearing.

1 Drive housing 1 Stator

2 Regulator mounting 2 Diode holder plate

4. Remove the regulator mounting 7. Unscrew the screws 0 securing

by tapping it on its edge with a the diode holder plate to the regu-
plastic hammer as shown in the lator mounting and extract the diode
illustration. holder plate,

1 Bearing 2 Shaft

DUCELLIER A L T E R N A T O R +
1. Hold the alternator in a vice
with caps. Unscrew the screws 0

tor 38
a n d 2 securing the voltage regula-
to its mounting and extract
the voltage regulator.

1 Diode holder plate securing screws

5. Extract the rotor @ by tapping

8. Unscrew the two screws a
the rotor shaft @ on its end.with a retaining
securing the bearing
plastic hammer as shown in the plate @ to the drive housing and
I.. , illustration.
extract the bearing.

CAUTION :
At reassembly, use a new bearing if
the old one is worn or damaged.

1 Top screws 3 Voltage regulator

2 Side screws

1 Rotor 2 Rotor shaft 2. Unscrew the two screws 0

securing the brush holder @ and
the earthing plate @.
6 . U n s o l d e r t h e stator @ ( r o t o r ) 3. Unscrew the cable terminal
three-phase connections to the diode securing screw @ and take out the
holder plate 0. 1 Screws 2 Plate brush holder.

05-19 May 1983

 IGNITION, STARTING, CHARGING SYSTEM

7. Remove the regulator mounting IO. Extract the rotor @ by tapping

complete with stator and rectifier the end of the shaft with a plastic
bridge (the diode plate) by tapping it hammer as shown in the illustration.
on its edge with a plastic hammer.

1 Brush holder 3 screw

2 Screws 4 Plate

4. Unscrew the two diode cov-

take out the excita-
and take off the cover.
1 Rotor

8. Unsolder the stator three-phase

connections to the rectifier bridge 11. Unscrew the three screws secur-
tabs. ing the bearing retaining plate to the
drive housing and extract the bearing
(see: Bosch Alternator - step 6).
12. Take the bearing off the drive
housing side of the rotor shift (see:
Bosch Alternator - step 7).

1 Pin 3 Nuts
2 Cover
6. Unscrew the alternator charge
indicator pin 0 screw,
6. Unscrew the three alternator
pack assembly stud bolts nuts 0.
MARELLI ALTERNATOR
1. On a vice fitted with protective
jaws, secure pulley @ of alternator.
Loosen nut @ securing pulley and
fan @ to rotor shaft @; remove
nut, washer, pulley and fan together
with spacers and feather.
9. Hold the rotor in a vice with
caps. Unscrew the nut securing the
pulley @ and the fan @ -to the
rotor shaft. In order take off the nut,
the washer, the distance piece, the
pulley, the second distance piece and
the fan with washers and feather key.

1 Pulley 3 Fan
2 Nut 4 Shaft
1 Pulley 2 Fan
1 Pin 2 Nuts

May 1983 05-20

 IGNITION, STARTING, CHARGING SYSTEM
2. Disconnect voltage regulator
c o n n e c t o r s @ and @ of rectifier
bridge. Unscrew screw securing brush
holder 4
8 to voltage regulator
support 3 and withdraw it.
Voltage regulator
Rectifier bridge connector
Rest voltage regulator
Sliding brush holder
3. Unscrew tie rods @ assembling
control support @ to voltage
regulator support 0.
1 Tie rod 3 Voltage regulator
2 Control support support
4. Remove voltage regulator sup-
port by hammering on its edge by
means of a plastic hammer, as shown
in figure.
5. Withdraw rotor @ h a m m e r i n g
by means of a plastic hammer on
shaft @ of rotor itself, as shown in
figure.
2 Shaft
1 Rotor
6. Unscrew nut and screw of
rectifier bridge guard 0; withdraw
power pin @ and remove guard.
1 Guard 2 Pin
7. Unsolder connections of stator
t h r e e p h a s e s ro f i n n e d rectifier
bridge,
8. Withdraw rectifier bridge and
stator from voltage regulator sup-
port; then unscrew positive terminal
with relevant washer.
9. By means of an extractor (see:
Regulator Alternator Bosch) or a
OS-2 1
suitable press with plates and punch,
withdraw bearing on voltage regula-
tor support side from rotor shaft.
CAUTION:
On reassembly, use a new bearing (in
case bearing is damaged or worn) by
mounting it on press with the aid of
a tube which must face bearing
retaining ring.
10. On a vice fitted with protective
jaws, tighten control support 0.
11. By means of a drilling machine,
r e m o v e t h e n rivets @ securing
plate @ retaining bearing to control
support.
12. Withdraw bearing.
CAUTION:
On reassembly, use a new bearing, in
case the removed one is damaged or
worn.
1 Control support 3 Plate
2 Rivets
CHECKS
AtiD IWPECTIONS
CAUTION:
Before starting electrical checks
blow-clean all the components
thoroughly with compressed air.
1. Slip rings
(1) Inspect for wear,
(2) If the rings are scored, but not
badly, put the rotor. on a lathe and
rectify the rings with rotor cloth. If
the rings are badly scored, put in a
new rotor.
May 1983
 IGNITION, STARTING, CHARGING SYSTEM
2. Rotor winding continuity test
(1) Ser the tester to the AL x 1 scale.
(2) Put the prods on the slip rings.
(3) Winding resistance should be:
Bosch alternator 4 f 0.1 a
Marelli alternator 3.1 * 0.2 CL
Ducellier alternator 6.5 k 0.2 a
(4) If there is no electrical con-
tinuity, put in a new rotor.
3. Rotor insulation test
(1) Set the tester to the a x 1 scale.
(2) Put one prod on a slip ring and
the other prod on the rotor core.
(Repeat for the other slip ring).
(3.) The tester should show no sign
df current flow.
May 7983
(4) If the insulation is broken, put
in a new rotor.
4. Stator windings insulation test
(I) Set the tester to the a x 1 scale.
(2) Put one prod on the stator pack
and the other prod on the termi-
nals 0 of the first phase, then of
the second phase, and finally of the
third phase.
(3) The tester should show no sign
of current flow.
I Phase terminals
(4) If there is insufficient insulation,
put in a new sTator.
5. Stator windings continuity test
(1) Set the tester to the a x 100
scale.
(2) Test for electrical continuity
between: 1-2, 1-3, 2-3.
(3) In each case the tester should
show current flow.
05-22
(4) If there is no continuity in the
windings, put in a new stator.
6. Brush wear inspection
6- 1. Bosch Alternator
(1) The brushes in the voltage
regulator should not be chipped or
dirty with carbon deposits; their
lengths should be within the pre-
scribed limits.
Brush projection min.
5 mm (0.197 in)
(2) In case of excessive wear,
unsolders the brush cable as shown in
the illustration and put in new
brushes.
6-2. Ducellier Alternator and Mare//i
(I) The brushes in the brush holder
should not be chipped or dirty with
carbon deposits; their lengths should
be within the prescribed limits.
Brush length min.
Ducellier Alternator 6 mm (0.236 in)
Marelli Alternator 7 mm (0.275 in)
(2) In case if excessive brush wear,
put in new brushes: the one by
simply withdrawing i t f r o m its
seaT on the brush holder and the
other by withdrawing it after un-
screwing its securing screw.
DUCELLIER

7. Brush spring inspection
The brush springs should be stiff
enough to assure good brush contact
on the slip rings. If they are not, put
in a new voltage regulator unit.
8. Brush holder unit electrical
continuity inspection
(1) Set the tester to the 52 x 100
scale.
(2) Put one prod on one and then
on the other brush 0.
(3) Put the other prod on
terminal 0.
(4) The tester should show current
flow.
( 5 ) I f t h e r e i s n o eletrical conri-
nuity, check the brush holder and if
necessary put in new brushes and/or
brush holder.
1 Brushes 2 Terminal
DUCELLIER A N D MARELLI
c 9. Diodes inspection
9-1 Bosch Alternator
(I) Set the tester to zero on the fi x
1 scale.
(2) Put the prods on a diode termi-
nals.
Then either:
(2a) The tester shows no current flow
(infinite resistance).
Inverse current resistance
R =w
IGNITION, STARTING, CHARGING SYSTEM
Reverse the two prods The tester
should show the prescribed re-
sistance.
Direct current resistance
R = O+lOa
(2b)The rester shows current flow
and therefore the prescribed resis-
tance.
Reverse the prods and the tester
the shows no current flow (infinite
resistance).
CAUTION:
All excitation diodes must be tested
in this way.
1 Diode holder plate
(3) If the tester readings are not
those prescribed, put in a new diode
holder plate.
9-2. Ducellier Alternator and Marelli
Power diodes - Bridge direct rest
(1) Zero tester in the a x 1 range
scale.
(2) Carry out direct test of positive
bridge, by setting the tester negative
probe on positive heat sink of bridge
and the other probe, sequentially,
on each end of the three phases of
bridge. Check, on tesrer, that resis-
tance value for direct current is the
required one.
(3) Carry out direct test of negative
bridge, by setting the tester positive
probe on negative heat-sink of bridge
and the other -probe, sequentially,
on each end of the three phases of
bridge. Check on tester, that resis-
tance values is the required one.
05-23
Diode resistance in direct conduction
R = 0 -lOa
Power diodes - bridge inverted test
(I) Zero tester in the a x 100 range
scale.
(2) Carry out inverted-test of bridge
operating as per direct test, by
inverting (in sequence) probes be-
tween positive heat sink and the
three phases of bridge when testing
positive bridge.
Inverts (in sequence) probes between
negative heat sink and the three
phases when testing negative bridge.
(3) Verify on tester that current is
not present.
Diode resistance for inverted
conduction
R =mcL
1 Positive hear sink
2 Negative test sink
Energiration Diode Direct test
(1) Zero tester in the a x 1 range
scale.
(2) Connect tester negative probe
with output of energization diodes
(terminal D+) and second probe
(in sequence) with the three phases.
(3) Verify on tester, that resistance
values for direct current are the
required ones.
Diode R for direct current
R = 0+1os2
Energization Diodes Inverted test
(1) Zero rester in the ax 100 range
scale.
(2) Operate as per direct test by
inverting tester probes between out-
put of energization diodes (terminal
D+) and the three phases (in se-
quence). Verify,. on tester, that
current is not present.
May 1983
 IGNITION, STARTING, CHARGING SYSTEM

TEST 3. Let the alternator rotate at

STAND INSPECTION
3,000 rpm for an hour with rheostat
load to give a voltage of 13 + 14V.
1. Put the alternator on the test 4. Slow down the motor until the
stand and connect it to the stands current output is from 1 + 2 A and
electric motor. then disconnect load rheostats to get
2. Make the following electrical a voltage again of 13 + 14V. Take the
connections: current reading and the correspond-
(I) Terminal B+ to test stand ing rpm.
positive.
5. Keeping the voltage constant,
(2) Terminal B+- to the pilot light
vary the speed and the load rheostats
and to terminal D+.
and take current readings together
CAUTION : (3) Connection for test stand feet.
If the required resistance values are with the corresponding rpm at
not measured, replace rectifier different point up to max current
bridge. output.
6. The output current readings at
the various speeds should all be equal
REASSEMBLY to or greater than those reported in
Reassemble the alternator following the Technical Data.
the disassembly steps in the opposite
order, and taking care that:

CAUTION:
W h e n s o l d e r i n g t h e t h r e e stator
cables on to the diode holder plate
and, for the Bosch Alternator,
changing the brushes, the soldering
must be done as quickly as possible
so the diodes are not overheated. 1 Terminal B + 2 Terminal D +

SERVICE DATA AND SPECIFICATIONS

TECHNICAL DATA AND INSPECTIONS

Alternator
0.120.489.798 125 - 14V - 45A

Brush wear limit

Voltage regulator resistance 58+72 -

Diodes resistance i2 o-10 o-10 o-10

(I) Minimum readings when hot after 1 hours working at 5000 rpm with loading of 25 A

May 1983 05-24

 IGNITION, STARTING, CHARGING SYSTEM

T R O U B LE D I A G N O S I S ,AND CORRECTIONS
Before starting alternator troubleshooting, the battery should be fully charged (see: Battery)

Condition Probable cause Corrective action

Alternator does not charge l Slack belt Tension the belt

l Broken charging or earthing Check the circuit

circuit
l Faulty brushes Put in new brushes

l Excitation diodes short circuited Put in new diode holder plate

l Broken excitation circuit Check the circuit

l Broken rotor winding Put in new rotor

l Inefficient voltage regulator Put in new voltage regulator

l Stator winding earthed Put in new stator

Insufficient or irregular l Slack belt Tension the belt

output l Intermittent break in the Check the circuit
charging circuit
l Worn brushes Put in new brushes

l Inefficient voltage regulator Put in new voltage regulator

l An excitation diode disconnected Put in new diode - holder plate

or earthed
l Rotor partly short circuited Put in new rotor

l Stator disconnected, earthed or Put in new stator

partly short circuited

Excessive output Inefficient voltage regulator Put in new voltage regulator

Noisy alternator l Worn belt Put in new belt

l Loose pulley Tighten up the nut

l Poor bearings Put in new bearings

l An excitation diode short circuited Put in new diode-holder plate

l Loose alternator Tighten up the screws on the bracket

OS-25 May 1983

 IGNITION, STARTING, CHARGING SYSTEM

DESCRIPTION
The electronic ignition is an induc-
tive discharge transistorized system
without contacts, constituted by the
following components.
a. ignition distributor with mag
netic pulse generator A5 with
mechanic centrifugal spark
0 induction) at the winding ends of
advance and vacuum advance
calibrator.
b.
module.
0
Ignition coil A8 with electronic
C. Electronic module Nl
0
The ignition distributor with mag-
netic pulse generator differs from the
traditional type as, in the place of
contacts and of capacitor, it has a
m a g n e t i c p u l s e g e n e r a t o r (stator)
and, in the place of the cam, a
toothed timer (rotor).
High voltage distribution to spark
plugs is obtained by means of a rotor
arm and cap, The pulses are gener-
ated by a magnetic pulse generator
located into a variable air gap circuit.
During rotation of distributor shaft,
each time a tooth of the timer passes
in front of the fixed pole piece
expansion, a signal is generated (by
coil (pulse generator), with conse-
quent control of the electronic
module.
The electronic module, constituted
by a set of integrated circuits
mounted onto a ceramic support
enclosed into a proof container is, in
its turn, mounted together with coil,
onto an aluminium finned support
which also operates as heat dissi-
pator. Between the electronic mod-
ule and the support, it is interposed a
grease coat with thermal high con-
dutivity, with the purpose of ensur-
i n g heat maximum elimination and
stable performances.
Besides conducting or interdicting
the output transistor, the electronic
module has also the purpose of
processing the signal provided by the
magnetic pulse generator of distribu-
tor, conducting one linked with the
engine rotation revolution numbers.
It is thus obtained a control of the
coil charge current and of time
duration of conduction with genera-
tion of constant energy spark,
independently of engine speed and
battery voltage.
A coupling capacitor, secured to
m o d u l e r a d i a t o r and electrically
connected with coil terminal and
to ground, allows optimization of
primary voltage wave form on coil
and, consequently, higher perfor-
mances.

Gl. Fuseholder box A7. Timer (Rotor)

Bl. To ignition switch A5. Electronic distributor
Al 2. Spark plugs Nl. Electronic Module
Cl. To elecrronic tachometer AS. Ignition coil
A6. Magnetic pulse generator

OS-27 May 1983

 IGNITION, STARTING, CHARGING SYSTEM
CHECKS AND
ADJUSTMENTS
ON CARS
1. Check general rules
CAUTION:
Each check for presence of voltage or
current in electric connections, via
sparking, that is, ground discharging
the high-and low voltage points, must
be avoided unless they are required
special verifications expressely listed
with application of special devices.
Besides, the following operations
must be avoided:
. Connection interruption be-
tween tap of coil high voltage
and distributor, by discon-
necting the relevant cable (coil
side) when motor is running or
during starting phase.
. Ground connection of coil low
voltage terminal connected with
tachometer.
l Use of trouble diagnosis equip-
ments which allow the short-
circuit the low voltage signal,
between coil primary winding
and tachometer or not allowed.
WARNING:
Before powering the unit, make sure
that connectors of the electric
system are properly inserted and that
the module coil units is secured
to ground so as to ensure an effective
connection.
May 7983
WARNING:
Stroboscopic gun must always be
directly connected with battery
terminals.
2. System functioning verification
(I) With ignition key inserted (igni- (4) Verify that resistance internal to
tion switch closed) and engine still, rotor arm of ignition distributor
check, by means of voltmeter, that corresponds to the prescribed value.
the voltage on terminal 15 of coil
is equal to the battery voltage (12V).
(2) After carrying out the ignition Distributor Marelli Bosch
timing operation (for timing see: I I
Group 00 Ignition System and Rotor arm
i.2 5,000 1,000
Supply) check possible interruptions resistance I I
in the coil windings. To this purpose,
disconnect the tachometer cable and,
(5) Proceed as follows for system
with non-inserted ignition key, check general verification with ignition key
via ohmmeter, that resistance values not inserted, disconnect from a spark
of both primary and secondary plug the connection high voltage
windings are the prescribed ones. cable to distributor by setting the
free end at 5 mm (0.2 in) from
Coil Mardi Bosch engine body.
Primary
winding !a 0.72k.i 0% 0.7 - 1
Put on insulation gloves and start the
resistance
engine verifying that spark occur
Secondary
regularly between cable and ground.
winding 5-2
resistance
(3) With ignition key not inserted
(ignition switch open) verify func-
tioning of ignition distributor by
disconnecting the connector between
module coil unit and distributor
and checking via ohmmeter, that
resistance of pulse generator coil
corresponds to the prescribed value.
OS-28
 IGNITION, STARTING, CHARGING SYSTEM

BOSCH DISTRIBUTOR

1 Cap 11 Pulse generator securing screw

2 Rotor arm 12 Connector securing screw
3 Dust cover 13 Connector
4 Retaining ring 14 Spring securing screw
5 Timer 15 Spring
6 Retaining ring 16 Distributor body
7 Pulse generator (stator) 17 Advance regulator
8 Spring 18 Advance regulator
9 Retaining ring 19 Spring securing screw
10 Counterweight

05-29 May 1983

 IGNITION, STARTING, CHilRGING SYSTEM

MARELLI DISTRIBUTOR

1 Cap 7 Insulating support

2 Cap securing screw 8 Spring
3 Rotor arm securing screw 9 Counterweight
4 Rotor arm 10 Distributor body
5 Pulse generator securing screw 11 Advance regulator securing screw
6 Pulse generator (stator) 12 Advance regulator

May 1983 05-30

 IGNITION, STARTING, CHARGING SYSTEM

DISASSEMBLY

In the following are prqvided the

disassembly operations relevant to
ignition distributors, limited to the
part on which maintenance is carried
out.

BOSCH DISTRIBUTOR
Clamp distributor on a vice fitted
with protective jaws.
1. Remove cap 0 and withdraw
f i r s t t h e r o t o r a r m @ with rev
limiter and then the lubrication
felt.

The rev limiter is a centrifugal

located on the head of rotor arm
which interrupts the ignition dis-
tribution when the engine exceeds
6800 rpm. 1 Screw 2 Connector

2. Remove dust cover 0. 4. Remove cap securing springs @

after unscrewing the relevant 6. Lift inductive winding

0
ing stator to distributor
0
s c r e w s 2 T h e n u n s c r e w 1 secur-
body and
remove the advance regulator

screws 03 securing advance regu-

lator to distributor body.

1 Inductive winding
2 Advance ragulator
1 Cap 3 Dust cover 1 Stator securing screw
2 Rotor arm 2 Spring securing screw
3 Regulator securing screw
4 Spring

7. From distributor shaft, remove

3. Operating as per figure, remove
retaining ring of timer.
5. Operating on screw 0, remove
connector @ of distributor body.
in sequence the timer, retaining
ring 0 and inductive winding @
complete of stator and supporting
plate.

OS-3 1 May 1983

 IGNITION, STARTING, CHARGING S Y S T E M

1 Counterweights 4 Screws
2 Springs 5 Insulating
3 Pulse generator support

1 Cap 2 Securing screws

5. Unscrew the four screws secur-
1 Retaining ring 2 Inductive winding ing advance regulator to lower base
2. Unscrew screws 2 securing 0 of d i s t r i b u t o r b o d y , t h e n w i t h d r a w
rotor arm to body; then withdraw body from its seat by using as
0.
8. By means of a clamp, release
rotor arm 1 fulchrum the regulator shaft.
springs @ of counterweights 1 ,
then remove stop retaining rings8 3
and then withdraw counterweights.

CHECKS
AND INSPECtIONS

MARELLI DISTRIBUTOR
1 Counterweights 3 Retaining ring
2 Securing screws By m e a n s of a feeler gauge, v e r i f y
2 Springs 1 Rotor arm
that air gap between pulse genera-
tor @ and timer 0 corresponds
to the S prescribed value.
MARELLI DISTRIBUTOR 3 . W i t h d r a w s p r i n g s @ and re-
Clamp distributor on a vice fitted move counterweights 0. Air gap
with protective jaws. 4. Unscrew securing screws 4 , S = 0.4 + 0.5 mm (0.016 + 0.02 id
0
1. Unscrew screws 2 securing cap then remove pulse generator8 3
to distributor body; then withdraw (stator) a n d m a g n e t i c i n s u l a t i n g
cap (iJ. support 5 0.
May 1983 05-32
 IGNITION, STARTING, CHARGING SYSTEM

2. Counterweights advance
CAUTION:
(I) Carry out steps 1 and 2
Marelli Distributor
relevant to vacuum advance verifica-
Every time it is carried out a disas-
tion.
sembly or replacement operation of
(2) On vacuum spark advance con-
magnetic pulse generator, it is
trol disconnected from test bed
anyway required to reassemble the
vacuometer, r e a d , o n increasing
magnetic spacer of pulse generator
r.p.m., the automatic advance curve
support.
(see: Service Data and Specifi-
cations).
(3) If the particulars are not within
the prescribed values, carefully exam-
TEST ine the distributor and, particularly
STAND INSPECTIONS the counterweights and relevant
1. Vacuum advance return springs, timer, and pulse
(1) Mount the ignition distributor generator. Replace faulty the parts.
1 Timer 2 Pulse generator
on a test bed and carry out electric
connections.
(2) C a r r y o u t s p a r k r e s e t t i n g o n
goniometer disc of test bed by
REASSEMBLY rotating distributor manually or
For reassembly reverse the order of with the test bed motor without
disassembly and comply with the exceeding 50 r.p.m. speed.
following: (3) Carry out connection of vacuum
1. L u b r i c a t e the following com- pipe to vacuometer of test bed.
ponents by means of distributor (4) On increasing vacuum, read the
special grease. advance curve (see Service Data and
. Counterweights springs Specifications).
. Counterweights (5) If the read curve -is not within
2 . L u b r i c a t e f e l t of. d i s t r i b u t o r the prescribed deviations, replace the
shaft with few oil drops. vacuum advance device.

SERVICE DATA AND SPECIFICATIONS

TECHNICAL DATA AND INSPECTldNS

Ignition Distributor

Alfa Romeo Class 542.168 542.161

Type I
MARELLI
SM 802 AX
I
BOSCH
0.237.005.004

Firing order I-3-2-4

Pulse Generaxor Coil Resistance i-2 730 f 5% 1 1 0 0 1 0 %

Internal resistance of distributor 1 rotor arm A-L 5000 1000

Air gap mm 0.4 + 0.5

(in) (0.015 + 0.019)

ELECTRONIC MODULE

Suppl; voltage V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4+16

Maximum controllable current A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Radiator limit temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - 30 + + 185C (- 22 + * 365F)

05-33 M a y 1983
 IGNITION, STARTING, CHARGING SYSTEM

AUTOMATIC AND PNEUMATIC ADVANCE CURVES

800 5"45' 3O45'

1700 13"45' 11015'

1800 140 120

2500 13O II0

3000 12"15' lO"15'

338 7"30' 5"30'

I

May 1983 OS-34

 IGNITION, STARTING, CHARGING SYSTEM

IGNITION COIL

AHa Romeo Class 542.167 542.162

MARELLI BOSCH
Type
BAE 207B 0.221.6C10.002

Primary winding resistance s-2 o-72,* lO.Vo 0.75 1

Sawndary winding resistance n 7900f10% 6700 + 9600

SPARK PLUGS

Alfa Romeo Class 535.420

Type LODGE 25 HL

FLUID AND LUBRICANTS

Application Type Demmination Q.W

Spark plug thread OIL ISECO Molykote A

Standard 4500 - 18304

TIGHTENING TORQUES

Unit
N.m kg.m ft.1 b
Item

Spark plugs in IS-EC0 oil: Molykote A 25+34 2.5 + 3.5 18.08 + 25.31

05-35 May 1983

 ENGINE COOLING SYSTEM

,CONTENTS

COOLING SYSTEM . . . . . . . . . . . . . . . 07-2 ELECTRIC FAN CONTROL

General description . . . . . . . . . . . . . 07-2 THERMAL CONTACT . . . . . . . . , . . . . 07-6
Removal . . . . . . . . . . . . . . . . . . . . . 07-3 Removal and installation q I , . . . . . . 07-6
Hydraulic system leak test. . . . . . . . 07-3 Checks and inspections . . . d _ . I . . . 07-6
WATER PUMP . . . . . . . . . . . . . . . . . . . 07-3 HEADER TANK PRESSURIZED
Checks and inspections . . . . . . . . . . 07-4 PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . 07-6
Installation . . . . . . . . . . . . . . . . . . . 07-4 Leak test . . . . . . . . . . . . . . . . . . . . . 07-6
THERMOSTAT . . . . . . . . . . . . . . . . . . . 07-4 SERVICE DATA AND
Removal . . . . . . . . . . . . . . . . . . . . . 07-4 SPECIFICATIONS . . . . . . . . . . . . . . . . 07-6
Checks and inspections . . . . . . . . . . 07-4 Inspection and adjustment . . . . . . . 07-7
Installation . . . . . . . . . . . . . . . . . . . 07-5 Tightening torques . . . . . . . . . . . . . 07-8
RAD I AT0 R . . . . . . . . . . . . . . . . . . . . . 07-5 TROUBLE DIAGNOSIS AND
Removal and installation . . . . . . . . . 07-5 CORRECTIONS . . . . . . . . 1.. . . . . . . . 07-8
Leak test . . . . . . . . . . . . . . . . . . . . . 07-6

May 1983
 ENGINE COOLING SYSTEM

COOLING SYSTEM

GENERAL DESCRIPTION

1 Electric fan
2 Thermostat
3 Radiator
4 Electric fan thermal contact
5 Cooling drain plugs
6 Centrifugal pump
7 Header tank
8 Cooling temperature transmitter
9 Heater
IO Cooling temperature warning light thermal contact
11 Cooling temperature indicator
12 Cooling temperature warning light
13 Cooling water level sensor for check control
(I 500 Quadrifoglio model)
14 Cooling water minimum level warning light
(1500 Quadrifoglio model)

May 1983 07-2

 ENGINE COOLING SYSTEM

CHECKS AND INSTALLATION pulley. For the timing and belt

INSPECTIONS
The water pump cannot be over-
hauled and in case of failure must: be
replaced.
1. Check pump body and impeller
for indications of wide oxidation and
corrosion; if any, replace pump.
2. Verify that there is no excessive
play in the rotation and axial move-
ment of impeller.
1. Fit water pump with new
relevant gasket to block and tighten
securing screws to specified torque
value.
: Tightening torque
Screws securing water pump
19+24 N-m
(1.9 + 2.4 kg-m
13.74 + 17.35 ft.lb)
2. Check correct timing of engine
and key camshaft belt on camshaft
keying procedure refer to: Group 00
- Engine Maintenance.
3. Refit front cover of camshaft
belt, pulley, alternator, pump and
alternator driving belt, in reverse
order of removal.
4. Stretch pump-alternator driving
belt.
For the stretching procedure of belt
refer to: -Group 00 - Engine Mainte-
nance.
5. At end of pump installation,
pour the coolant and letting the
engine run for a few minutes check
against coolant leakages.

REMOVAL
1. Drain coolant up to the lower
level of thermostat housing.
2. Detach coupling @ connecting
thermostat cover to radiator.
3. Screw out screws @ and
remove cover
gasket @ _
0 3 with relevant
4. Withdraw thermostat @ from
Imousing @ .
THERMOSTAT
CHECKS AND
INSPECTlOONS
Thermostat should be checked in
accordance with the following pro-
cedure:
1. Fit thermostat @ to suitable
test equipment.
2. Fill container with water and
switch on equipment to heat water.
3. Check that, when thermostat
opens, temperature value read on
thermometer @ dial indicator is
84 + 88C (183.2 + 190.4F).
4. Additionally check that thermo-
stat is fully open at 98C (208.4F)
and valve travel greater than 7 mm
(0.28 in).
If above values are not met, thermo- 1 Thermometer 2 Thermostat
stat must be replaced.

1 Coupling 5 Washer
2 Clamp 6 Thermostat
3 Cover 7 Gasket
4 Screw 8 Housing

May 1983 07-4

 ENGINE COOLING SYSTEM

LEAK TEST
I. Remove radiator from car (Refer
to: Radiator Removal and Installa-
tion).
2. Close radiator outlet and inlet
unions.
3. lmmerge radiator in a tank
previously filled with water and
check for possible leakages inflating
compressed air through radiator
breather pipe until a pressure of
98.1 + 107.9 kPa; (0.9 + 1.0 bar;
1 + 1 .I kg/cm2 ; 14.22 + 15.64 psi) is
reached.
4. If leakages are found, clean area
to be soldered by a wire brush and
deoxidate by baked hydrochloric
acid (zinc chloride).
5. Solder the leaking area.,
6. Test again radiator for leakages
as described above and then refinish
radiator with black synthetic enamel.
In case of leakages from radiator
fitted with side tanks (with gaskets),
replace the radiator.
7. Refit radiator to car (Refer to:
Radiator - Removal and Installation).
Fill with coolant and check for
leakages.

ELECTRIC FAN CONTROL THERMAL CONTACT

REMO-VAL AND CHECKS AND

INSTALLATION INSPECTIONS

1. Drain coolant. Check thermal contact according to

2. Disconnect thermal contact ca-
bles.
3. Unscrew thermal contact from
radiator.
4. Installation is carried out in
reverse order of removal.
5. At the end of installation
procedure, fill the circuit with
coolant and let the engine rotates
until coolant reaches the temperature
of 88 + 92C (190.4 + 197.6F) a n d
verify that electric fan inserts.
the following procedure:
1. Fit thermal contact @ to the
test equipment used for thermostat
test.
2. Fill container with coolant and
switch on equipment to heat water.
3. When warning light 0 illumi-
nates, verify that temperature shown
on thermometer dial indicator corre-
sponds to the thermal contact setting
value 88 + 92C (190.4+ 197.6F).
1 Warning light 2 Thermal contact

HEADER TANK PRESSURIZED P L U G

LEAK TEST

1. Screw fitting @ to test equip-

ment and insert on header tank
pressurited plug.
2. Act on tool to increase pressure
and check on dial indicator that
blowoff valve opens at the required
setting pressure.

Pressurited plug setting pressure

69.6 kPa; (0.69 bar;
0.7 kg/cm ; 9.95 psi) 1 Pipe fitting 2 Pressurized plug

May 1983 07-6

 ENGINE COOLING SYSTEM

SERVICE DATA AND SPECIFICATIONS

INSPECTION AND ELECTRIC FAN
CAUTION:
Electric fan intervention
ADJUSTMENT temperature 88 - 92C
Produit harmful to the paint. Avoid
contact with painted parts.
(190.4+ 197.6F)
BELT TENSIONING
Load to be applied: 78.4 N
COOLING SYSTEM SCALES
(8 kg REMOVER
17.64 lb) GENERAL
NALCO: 1006
Resultant arrow mm
SPECIFICATIONS INTERPOIND: Jal Auto Cat.
105.6 in)
3681-69955

THERMOSTAT COOLANT
TEMPERATURE Summer
- Start of opening 84 + 88C
(183.2 + 190.4F) Water I 7.3
Imp. Gall 1.61
- End of opening 986
(2084F) Winter
- Bulb travel >7
Min. tempera-
(> 0.28 :;
tu re T -10 -20 -35
OF (14) i-4) 1-31 I
RADIATOR
Antifreeze cat.
Radiator leak control
3661-69956 I 1.8 2.6 3.65
pressure 1 0 7 . 9 kPa
(Imp. gall) (0.391 (0.57: 10.80)
(1.0 bar;
1 .I kg/cm2; Water I 5.5 4.7 3.65
15.64 psi) (Imp. gall) (I .2) (I .03 IO.801

Antifreeze ready
PRESSURIZED PLUG for use cat.
Pressurized @lug setting 3681-69958 I - 7.3
pressure 68.6 kPa (Imp. gall) - (1.61
(0.69 bar;
0 . 7 kg/cm;
9.95 Psi)

SEALING AND FIXING COMPOUNDS

Application TYW Denomination Q.W

Sealing compound for cooling &tern Sealing powder AREXONS Cat. 3522-00101 7.3 g
0.20 (az)

ALUMASEAL can be used as an alternative.

Of-7 May 1983

 ENGINE -COOLING SYSTEM

TIGHTENING TORQUES

ft*lb

Cooling.temperature transmitter on feeding manifold 33441 3.4 f 4.2 24.58 + 30.37

Water pump securing Screws 19 +24 1.9 + 2.4 13.74 + 17.35

TROUBLE DIAGNOSIS AND CORRECTIONS

Condition Probable cause Corrective action

Water leakage b Radiator damaged Repair or replace

m Leaks in system couplings Repair

I Loose or broken clamps Tighten or replace

I Leakages from thermostat Replace gasket or thermostat

0 Damaged cylinder head gasket Replace. Check engine oil for contami-
nation

* Loose cylinder head tightening Restore correct tightening

screws

Poor circulation l Pipes obstructed Check pipes and clean system

l Insufficient coolant Top up

l inoperative water pump Replace

l Water pump and alternator driving Adjust

belt loosen

Corrosion and scales Periodically change coolant at intervals

recommended.
Follow instructions for use shown on
packaging.

Overheating l Inoperative thermostat Replace

l Dirty and scaled radiator Clean pipes flushing with the specified
descaling compound. Follow instructions
for use shown on packaging.

l Ignition out-of-phase Retime

l Poor lubrication Restore oil level

l Faulty water pump Replace

l Insufficient coolant Restore coolant level and check system

for leaks

May 1983 07-8

 CLUTCH

DESCRIPTION

This is a hydraulic controlled, dry,
singledisc clutch provided with a
thrust bearing @ which is always
in contact with pressure plate
spring @ . Diaphragm spring @
pressure engaged driven plate. Dis-
engagement is obtained by a ped-
al @, operated through a master
c y l i n d e r0
7 which transmits fluid
pressure increase to operating cylin-
der @ piston.
The latter operates on the with-
drawal lever @ by a push rod @,
moves thrust bearing (self centering)
and wins diaphragm spring action.
By means of gaskets performing on
cylinder, piston takes up possible
slacks and therefore driven plate
wear recovery is automatic.

(1.5 + 1.9
10.8 4 13.7)

(!$I15 + 23
(1.5 + 2.4
10.8 + 17.41

1 Clutch disc
2 Bleeder screw
3 Operating cylinder
4 Control push rod
5 Flexible hose
6 Brake and clutch hydraulic system reservoir
J Clutch master cylinder
8 Pedal
9 Clutch withdrawal lever
10 Diaphragm spring
11 Direct drive shaft
12 Thrust bearing support
13 Self centering thrust bearing
14 Clutch cover
15 Pressure plate
16 Flywheel
17 Bush

May i983 12-2

 CLUTCH

HYDRAULIC CONTROL UNIT

CLUTCH PEDAL CHECKS AND INSPECTIONS DISASSEMBLY
1. Inspect pedal and pedal pad for 1. Remove boot @, remove stop-
REMOVAL
deformation or damage. per ring 0, then remove push rod
1. Operating from the interior 2. Inspect bushes of clutch pedal, with fork 0, gaskets @ and 0,
compartment, remove stopper pin and spacer for excessive wear or p i s t o n @, washer and
@
ring @, and remove pin @ discon- seizing. spring @ .
necting pedal @ Tram master cyl- 3. Inspect return spring for fatigue 2. Reniove c o n n e c t i o n and
0
inder control fork 0 and return or damage. gasket @ .
spring.
INSTALLATION
Install clutch pedal on car in reverse
order of removal and apply grease to
bushes of clutch pedal and to master
cylinder fork connection pin (AGIP
Fl Grease 15).

CLUTCH MASTER
CYLINDER
REMOVAL
1. Remove filler plug 0 o n
reservoir 0, relevant gasket and 1 Master cylinder 7 Fork
filter then, with a syringe, drain 2 Stopper ring 8 Washer
1 Fork 3 Pedal 3 Gasket 9 Spring
enough fluid to make level fall below
2 Pin 4 Stopper ring 4 Piston 10 Gasket
connection to master cylinder @. 5 Gasket 11 Connection
2. Disconnect SUPPlY flexible 6 Boot
2. Operating from the engine room, hose @ from master cylinder.
remove pedal pin stopper spring @ 3. Loosen connection and discon-
and relevant nect rigid pipe @ from master CHECKS AND INSPECTIONS
washer. Unscrew
screw @ securing the bracket @ cylinder.
for sheath stopper of accelerator 4. Operating from inside the car,
control cable, in order to be able to remove stopper ring, remove pin and
CAUTION:
withdraw pedal pin enough to disconnect cylinder control fork
To clean or wash all parts of master
recuperate the clutch pedal from the from pedal (see: Clutch P e d a l -
cylinder, recommended clean brake
interior compartment. Removal).
fluid must be used. Never use mineral
5. Unscrew screws 0 fixing
oils or gasoline and kerosene to avoid
master cylinder to pedal assy and
damaging rubber parts.
then remove master cylinder.

1. Check cylinder bore and piston

for score or rust and if found replace.
2. Check cylinder bore and piston
for wear. If the clearance between
cylinder bore and piston exceeds
specified value, replace piston
assembly or master cylinder as-
sembly.
3. Check condition of boot and
replace it if damaged.
1 Stopper spring 3 Screw 4. Check all recesses, openings and
2 Bracket 1 Plug 5 Connection internal passages to ensure that they
2 Flexible pipe 6 Rigid pipe are clean and free from foreign
3. Remove the two plastic bushes 3 Screws 7 Reservoir
matter.
from pedal. 4 Master cvlinder

12-3 May 1983

 CLUTCH

ASSEMBLY DISASSEMBLY
1. Lubricate sliding part surfaces. 1. Remove filler plug on supply
2. Install piston assembly to cylin- reservoir, together with gasket and
der body. filter, and by means of a syringe
3. Make sure that master cylinder drain enough fluid to make level fall
operates normally. below connection to master cylinder.
4. Make sure that piston can move 2. Remove flexible hose connecting
maximum stroke smoothly. reservoir and clutch master cylinder
and remove pipe.
INSTALLATION 3. Loosen the rigid and flexible
pipes connections, connecting master
1. Install clutch master cylinder in
cylinder and clutch operating cylin-
reserve order of disassembly. Push rod 6 Cylinder body
Boot 7 Bleeder screw der and remove pipes.
2. Top up oil to correct level in
reservoir. Gasket 8 Gasket
Spring 9 Piston INSTALLATION
3. Bleed air out of hydraulic Ring
system (Refer to: Hydraulic System 1. Install clutch line in the reverse
Bleeding). order of disassembly.
CHECKS AND INSPECTIONS 2. Top up oil in reservoir to correct
@ : Tightening torque level.
Visually inspect all disassembled
Clutch hydraulic piping con- 3. Bleed air out of hydraulic
parts and replace parts which are
nections system. (Refer to: Hydraulic System
worn or damaged.
15+18 Narn Bleeding).
(1.5 + 1.9 kg-m CAUTION:
10.8 + 13.7 ft-lb) To clean or wash all parts of operat- HYDRAULIC SYSTEM
BLEEDING
ing cylinder, recommended clean
CLUTCH OPERATING brake fluid must be used. Never

CYLINDER use mineral oils or gasoline and

REMOVAL
1. Remove operating cylinder con-
trol hose, then remove clutch operat-
ing cylinder lock ring @ from its
seat on engine back cover 0.
2. Remove operating cylinder.
kerosene. It will ruin the rubber parts
The clutch and brake hydraulic
system must be bled whenever
of the hydraulic system.
hydraulic system has been discon-
nected or air has entered it.
1. Check cylinder bore and piston
Refer to figure on page 12-2 (see:
for score or rust.
Description) and observe the follow-
2. Check cylinder wear, spring
ing procedure.
efficiency and integrity of seal rings.
3. Check whether bleeder hole is
clean. CAUTION:
a. Do not re-use brake fluid
ASSEMBLY drained during bleeding oper-
Assemble clutch operating cylinder ation.
in reverse order of disassembly. b. Exercise care to prevent splash-
ing of brake fluid on painted
INSTALLATION areas as it will damage the
paint.
Assemble clutch operating cylinder
c. During bleeding operation fluid
in its seat on engine back cover
level in reservoir must be kept
together with retainer ring.
above min. mark.

1 Lock ring
2 Clutch operating cylinder HYDRAULIC SYSTEM
3 Back cover
P IPIN G 1. Remove clutch and brake hy-
draulic system reservoir plug and top
DISASSEMBLY
CHECKS AND INSPECTIONS up with recommended brake fluid
1. Remove push rod @ with (ATE S or AGIP Fl B r a k e
b o o t 0, p i s t o n @) a n d p i s t o n Visually inspect clutch lines for
Fluid Super HD corresponding to
spring @ from operating cylin- evidence of its integrity. Replace
Alfa Romeo Part No. 3681.69905).
der 0. damaged parts. If leakage occurs at
2. Remove bleeder screw pro-
2. Remove push rod from boot. joints due to loosening, retighten
tection b o o t @ o n O p e r a t i n g
3 . R e m o v e b l e e d e r s c r e w 0. and if necessary replace damaged
cylinder 0; install a hose on same
parts.

May 1983 12-4

 * CLUTCH

2. Check with a sliding gauge @

for even wear of both facings a n d
whether clutch disc thickness is not
near to specified limit. Replace
disc if necessary.
Wear limit for disc thickness
6.5 mm (0.26 in)

& 1 LA.2.0378
A.4.0144 A

1 Flywheel 3 Clutch cover

2 Cover fixing screws
1 Clutch cover
2 Pressure plate working surface 1 Sliding gauge
3 Diaphragm spring
3. Check fit of clutch disc hub @
6. R e m o v e c o v e r @ and c l u t c h
on direct drive shaft @ for smooth
disc 0. Flywheel
sliding or excessive backlash. If
Check flywheel friction surface @ necessary replace clutch disc.
for overheating, uneven wear, scor-
ing, or removal of material. If neces-
sary, disassemble flywheel and grind
both working surface and clutch
cover support plane.

Grinding limit value on planes

0.2 mm (0.01 in)

1 Clutch disc 2 Clutch cover

1 Clutch disc 3 Clutch disc hub
2 Direct drive shaft

CHECKS AND INSPECTIONS INSTALLATION

Wash all disassembled parts except
clutch with suitable cleaning solvent
to remove dirt and grease before
making inspection and adjustment.
Clutch cover
Check pressure plate working sur-
face @ for overheating marks,
uneven wear, scoring and material
removal.
Replace clutch cover if necessary.
1 Engine flywheel
2 Pressure plare support plane
3 Working surface
Clutch disc
Inspect clutch disc for burn or oily
facings, loose rivets and broken
torsional springs.
1. In case of clutch abnormalities
due to oil leakage at crankshaft or
direct drive shaft oil seal, replace
both clutch disc and seals.
1. If the two oil seals on crankshaft
and on direct drive shaft have been
removed when c l u t c h u n i t w a s
disassembled, i n s t a l l two new oil
seals (Refer to: Group 01 Engine
Assembly - Crankshaft and Group 13
5Speed M a n u a l G e a r b o x S h a f t s
and Gears).
2. Install flywheel if removed in
disassembling clutch unit (Refer to:
Group 01 - Engine Assembly).
Be sure to keep clutch disc, flywheel
and pressure plate facings clean and
dry.
3. Set clutch disc and clutch cover
on flywheel.

May 1983 12-6

 CLUTCH

SERVICE DATA AND SPECIFICATIONS

GENERAL SPECIFICATIONS
FLUIDS AND LUBRICANTS

1 Thrust bearing 2 Bush

Application TVP~ Denomination

Thrust bearing working seat @ GREASE - AGIP Fl Grease 33 FD

Std. N . 367 I-69833134

- IP Autogrease FD
Std. N . 367 I-69833134

- ISECO Molykote BR2

Std. N. 3671-69841

End crankshaft bush @ GREASE ISECO Molykote Paste G -

Std. N. 3671-69840

Clutch pedal-cylinder control fork GREASE AGIP Fl Grease 15 -

connection pin Std. N. 3671-69810

Clutch pedal hub

Clutch hydraulic system supply FLUID - ATE S - S t d . N . 3681-69905

- AGIP Fl Brake Fluid Super HD
Std. N. 3681-69905
- IP Auto Fluid FR
Std. N. 3681-69905

INSPECTIONS AND ADJUSTMENTS

FLYWHEEL AND CLUTCH COVER

Grinding limit values on working surfaces . . . . . . . . . . . . . . . . . . . . . _ . . . . . _ . , . . . _ . . _ _ . . 0.2 mm (0.01 in)

CLUTCH DISC

Disc thickness atwear limit . . . . _ _ _ . _ . . . . . . . . _ . . . . _ . . . . . . _ . . . _ . . . . . . . . . . . . _ 6.5 mm (0.26 in)

May 1983 12-8

 CLUTCH

TIGHTENING TORQUES

N.m kg*m fz-lb

Clutch caver to angine flywheel unit securing 15 + 23 1.5 + 2.4 10.8 + 17.4
screws

Gearbox unit to engine resr caver securing 39 + 47 4 + 4.9 28.9 + 35.4

bons and nuts

Hvdraulic system pipe fitting securing nuts 15 + 18 1.5 + 1.9 10.8 + 13.7

TROUBLE DIAGNOSIS AND CORRECTIONS

Condition Probable cause Corrective action

Clutch slip Some trouble symptoms may also be attributable to engine problems. First
determine whether engine or clutch is causing the problem.
Symptoms:

- Car Will not respond to T O test for slipping proceed as follows:

engine speed during accel-
- engage parking brake
eration
- disengage clutch and shift gears into 4th
- lnsufficient car speed
- increase engine speed and gradually release clutch pedal; if car does not
- Lack of power during uphill move and engine does not stop, clutch is slipping
driving
l Clutch facing excessively worn Replace clutch disc
- Increasing of fuel con-
l Clutch facing wet with oil or grease Replace clutch disc (replace enginel
sumption
gearbox oil seals) if faulty

l Diaphragm spring weak or damaged Replace pressure plate

l Flywheel or pressure plate warped Repair per replace flywheel or clutch

caver

l Impurities in master cylinder, piston Clean cylinder or replace faulty parts

does not return to start position

Clutch does not disengage well T O test for dragging clutch proceed as follows:

- disengage clutch and shift gears into Reverse

- shift gears into Neutral, then gradually increase engine speed

- after a short interval, shift gears into Reverse

If noise is heard while gears are being shifted, clutch is dragging

l Clutch disc hub splines or rusted Clean or replace clutch disc

12-Q May 1983

 CLUTCH

Condition Probable cause Corrective action

l Flywheel and/or pressure plate Repair or replace flywheel and/or

faciw worn or warsed clutch caver

l Engine supports not efficient Inspect and/or replace engine supports

SPECIAL SERVICE TOOLS

Refer to
Tool number Tool name
page

A.2.0378 Tool for locking the flywheel

A.4.0144 Clutch disc aligning bar

12-l 1 May 1983

 GEARBOX

CONTENTS

5 - SPEED MANUAL GEARBOX.. . . . 13-2 Checks and inspections . _ . _ . . . . . . 13-25

Description . . . . . . . . . . . . . . . . . . . 13-5 Assembly . . . . . . . . . . . . . . . . . . . . . 13-25
Rear support . _ , . . . . . , . . . . . . . . . 13-5 SERVICE DATA AND
Rods and forks . . . . . . . . . . . . . . . . 13-6 SPECIFICATIONS . . . . . . . . . . . . . . . . 13-26
Shafts and gears . . . . _ . . . . . I . . . . . 13-10 Technical data . . . . . . . . . . . . . . . . . 13-26
Differential carriers . . . . . _ . , . . , . _ 13-19 General specifications . . . . . . . . . . . 13-26
Crown gear and pinion . . . . . . . . . . 13-22 Inspection and adjustment _ _ . _ _ _ _ 13-28
Differential casing . . . . . _ . e . . _ . _ . 13-22 Tightening torques . . . . . . . . . . . . . 13-30
Gearbox - differential casing . . . . . . 13-24 TROUBLE DIAGNOSIS AND .
GEARBOX OUTER LINKAGE.. . . . . . 13-25 CORRECTIONS . _ , . _ . . . . _ . . . . _ _ . _ 13-31
Disassembly . . . . . . . . . . . . . . . . . . . . 13-25 SPECIAL SERVICE TOOLS n. . . . . . . . 13-33

May 1983
 GEARBOX

S-SPEED MANUAL GEARBOX

Gearbox-differentlsl unit and r e a r s u p p o r t

13.74 + 17.36)
b
21

(4 + 4.9
28.92 + 35.43)

-.,Y . ,.C
~19 + 24
(1.9 + 2.4
13.74 + 17.36)

@ N.m
(kg-m
ft4b)

1 Pin 17 Flexible bush

2 Gearbox casing 18 Oit seal ring
3 Bushing 19 Bracket
4 Central support 20 Bushing
5 Oil plug 21 Flexible support
6 Speedometer sensor 22 Reverse gear switch
7 Spring ring 23 Gasket
8 Dowel 24 Plug
9 Rear caver 25 D r a i n plug
10 Valve 26 Oil sump
11 PIUJ 27 Gasket
12 Plate 28 Bushing
13 Pin 29 Oil seal ring
14 Flexible support 3 0 Support
15 Rear support 31 Lock ring
16

May 1 9 8 3 13-2
 G EARBOX

S h a f t e , geara a n d differen~ial c a e i n g
@ 220.5 + 245
(22.5 + 25
162.70 + 180.771

QI 69 + 8 5
(7 + a.7
50.61 + 62.91)

67 + 74
(6.8 f 7.5
/
49.17 + 54.23)

@ N+m
(kg-m
ft4b)
1 Direct drive shaft 14 R.G. driven gear 27 3rd speed driven gear
2 Spring 15 Bushing 28 4th speed driven gear
3 Bushing 16 1 st speed driven gear 29 Shim
4 P i n 17 Retainer 30 Bearing
5 Bearing 18 Guide sector 31 5th speed driven gear
6 Reverse gear shaft 19 Locking sector 32 Nut
7 Reverse gear 20 Synchronizing ring 33 Bearing
8 Primary shaft 21 Lock ring 34 Shim
9 longue 22 Sleeve 35 Pinion
10 Bearing 23 HUb 36 Bearing
11 Lock ring 24 Fietainer 37 Differential casing
12 5th speed driving gear 25 2nd speed drive gear 38 Bearing
13 Oil deflector 26 Shouldered ring 39 Crown gear

13-3 May 1983

 GEARBOX

Roda and forks

@ 25 + 2 6
(2.5 - 2.7 T N*m
0
18.07 + 19.52) (kg-m
ftdb)

1 Lever 11 Sth-speed R.G. rod

2 Main selector rod 12 Plug
3 Guide pin 13 Ealls
4 3rdAth speed rod 14 R.G. fork
5 Interlock plunger 15 Bushing
6 1 sr-2nd speed rod 16 5th.speed - R.G. rod
7 Interlock plunger 17 1st.2nd speed control fark
8 Detent hall 18 3rd4th speed control fork
9 5th speed control fork 19 Selector lever
10 Ist-2nd speed lever 20 Spring pin

May 1 9 8 3 13-4
 GEARBOX

DESCRIPTION Installation of vehicle 3. After installing drive unit on

In case of assembly of groups and vehicle fil1 up with prescribed oil
The gearbox has five forward and installation on vehicle proceed as ( A G I P F I R o t r a M P S A E 8OWQO
one r e v e r s e gear. All g e a r s h a v e follows or IP Pontiax HD 8OWQO), oil should
synchromesh except reverse gear. 1. Assemble gearbox differential be fed in slowly till the level reaches
AII gears are in constant mesh and unit and engine unit (refer to. the lower rim of filler hole, check for
have helical teeth. Reverse gear teeth Group OI Separation and Assembly oil level and fit in plug.
are straight tut. The gears are oper- of the Units).
ated by means of a floor-type gear 2. Assemble drive unit on vehicle
lever connected to the selector shafts (refer to. Group 01 Drive Unit -
b y means o f a remote l i n k a g e . Removal and Installation).
Connection of rear support to
gearbox casing is obtained through a
couple of elastic s u p p o r t s w h i c h REAR SUPPORT
reduce to a minimum the trans-
DISASSEMBLY suitable stand provided with bracket
mission of vibrations to the speed
Set gearbox-differential unit on and proceed as follows:
control lever.
Differential and gearbox form a
single assembly. Crown gear-pinion
couple is of the hypoid type and
has a ratio of QI35 or 11139.

TRANSMISSION RATIOS

I Crown gear and

Gearbox pinion ratio
Gear
ratio 9135 11139

Overall ratio

1 1:3.750 1:14,580 lA3.293

2 1: 2.050 1: 7.970 1: 7.267
3- I~I.387 1: 5.392 1: 4.916
4- 1: 1.027 2: 3.992 1: 3.640
5 1: 0.825 1: 3.207 1: 2.924 1 . R e m o v e remote I i n k a g e 1 re- 2. Dissassemble gearbox outer link-
RM 1:3.091 1:12.017 1:10.957 taining clip @ from lever 83 and age from rear support (see. Gearbox
remove i-cd. Outer Linkage - Disassembly).
Remove washers @ and bush 0. 3. Disconnect drive unit rear sup-
port from flexible supports 0
and @ which connect it to gearbox-
differential casing @ by unscrewing
REMOVAL AND 0
the two screws 3 .
INSTALLATION

Removal from vehicle

Should the whole drive unit be
removed from the vehicle and the
two units be thereafter separated,
proceed as follows;
1. Remove drive unit from vehicle
(refer to: Group 01 - D r i v e U n i t
Removal and Installation).
2. Separate gearboxdifferential
unit from engine unit (refer to:
Group OI - Separation and Assembly 1 Upper flexible support
1 Remote linkage 4 Washers 2 Gearbox-differential casing
of the Units).
2 Bush 5 Retaining clip 3 Screws
3 Lever 4 Lower flexible support
5 Rear support

13-S May 1983

 GEARBOX

4. Remove pin @ inserted into ASSEMBLY 3. Unscrew screw @ and remove

flexible support @ and remove the
flexible support itself from rear
support should its replacement be
required.
1. Reassemble end flexible support plate @ securing oil bleeder valve
on rear support, the pair of flexible to gearbox casing caver and remove
supports on rear caver, then the rear valve plug @ and valve aitself.
support itself following the reverse
order for disassembly and using the
same tools previously used. .
2. Reassemble the outer Iinkage of
gearbox on rear support (refer to:
Gearbox Outer Linkage - Assembly).

RODS AND FORKS

1 Pin 2 Flexible support
DISASSEMBLY
5. Unscrew screws connecting flex- 1. Remove spring pin securing lever
ible supports @ and @ to rear to main selector rod 0 and remove
caver of gearbox casing 0. lever.
Remove flexible supports.

1 Valve plug 3 Plate

2 Screw. 4 Valve

1 Rear caver 3 Lower flexible

4. Unscrew and remove screws @
2 Upper flexible support
support
f i x i n g r e a r caver @ to g e a r b o x
1 Main selector rod 2 Lever casing @ . Use a plastic hammer fo
loosen caver and remove it together
with seal gasket @.

CAUTION: 2. Unscrew reverse gear light

earbox casing is made of aluminium switch 0 and remove it together
alloy. with relevant washer from rear cov-
Handle with maximum tare to avoid
damaging it.
0
er 2 .

CHECKS AND INSPECTIONS

1. Clean metal parts of rear support
with solvent a n d check f o r i t s in-
tegrity.
2. Check amount of leverage articu-
lation wear.
3 . Check o n i n t e g r i t y o f r u b b e r
1 Screws 3 Gearbox casing
bushings, and replace worn or
1 Switch 2. Rear caver 2 Rear caver 4 Seal gasket
damaged ones.

May 1983 13-6

 GEARBOX

5. Remove main selector rod 2

seal r i n g @ f r o m r e a r caver 1 8
S h o u l d removal of seal r i n g t a k e
place while gearbox is fully assem-
bled (on stand or vehicle), special
tool A.3.0429 must be used.

A.3.Q42g7
r-i-l 10. Remove main selector rod 4
and recover selector 0, spring 8 3
and lever 0.

1 R e a r caver 3 Seal r i n g
2 Main selector rod

1 Screw
5. Remove guide pin @ for main 2 1st and 2nd speed rod
s e l e c t o r r o d @ return spring 1 3 Screw
7. U n s c r e w a n d r e m o v e screws8 4 4 3rd and 4th speed control fork
5 1st and 2nd speed lever
with relevant fixing washers from oil
6 Screw
sump; remove oil sump @ together 7 1st and 2nd speed control fork 1 Selector 3 Spring
with relevanr gasket. 2 Lever 4 Main selector rod

11. Engage 5th speed and remove

9. Use tool A.3.0322 to remove the
following spring pins:
- Pin @ securing reverse gear and
5th speed lever on rod @
securing safety lever on
securing selector lever
on rod 0.
5th speed and reverse gear rod @
lock r i n g @ place on central
support 0.
Unscrew and remove the two halls
securing plug @ then remove the
halls themselves.

1 Return spring 4 Sci-ews

2 Guide pin 5 Oil sump
3 Main selector rod

8. Unscrew screw 0 securing 1st

a n d 2 n d sseed control fork 13) o n
r e l e v a n t r o d @ a n d serez 6
securing 1st and 2nd - speed lever 5 .
Remove lever @ from gearbox
8 1 Speed selector lever pin

casing. Loose and remove screw 3 0 2 Main selector rod

3 Reverse gear and 5th speed lever pin 1 Central support 4 5th speed and
fixing 3rd and 4th speed control 4 Reverse gear and 5th speed rod 2 Lock r i n g reverse gear rod
fork @ on relevant rod. 5 Safety lever pin 3 Securing plug

13-7 May 1983

 GEARBOX

12. Remove 5th speed and reverse
gear rod @ together with 5th speed
c o n t r o l f o r k @ and sleeve 0.
1 5rh speed and 3 5th speed control
reverse gear rod fork
2 Sleeve
13. Use a driftpin @ to remove 3rd
and 4th speed rod 2 and recover
its relevant fork 8 1 from syn-
chronizer sleeve. Proceed as above
for removal of 1st and 2nd speed
r o d @ t o g e t h e r w i t h f o r k @.
14. Remove the following compo-
nents from the seats on the rear
support of gearbox casing:
- The three detent halls @ from
the three rods
- The two interlock plungers 3
after unscrewing screw 4
which give access to a channel
8 into assembly seat of 3rd and 4th
w h i c h cari b e inspected b y a
screwdriver able to move the
interlock plungers considered.
ASSEMBLY
1. Set the corresponding 1st.2nd
and 3rd-4th speed control forks on
relevant synchronirer sleeve.
2 . Insert d u m m y r o d . A . 3 . 0 3 0 3
speed rod. Assemble through hole on
dummy rod a new spring with
relevant detent hall, after greasing,
t h e n b y means of the driver tool
A.3.0309 insert: and compress t h e m
SO as to be able to move backward
rool rod to keep them into position.
3. Insert relevant rod into gearbox
casing seat pushing at the same time
tool rod. Complete assembly of rod
b y i n t r o d u c i n g i t i n t o t h e small
hub of the fork and by aligning the
hole on the latter with the slot on
the rod.

1 Spring 3 Interlock plungers

2 Detent halls 4 Screw

1 3rd and 4th speed control fork
2 3rd and 4th speed rod
3 Driftpin
4 1st and 2nd speed control fork
5 1st and 2nd speed rod
The withdrawal 3rd and 4th speed
rods and 1st and 2nd speed rods
proceeds, as the millings appear,
respectively circular and rectangular
shaped, in correspondence with the
rear support of the gearbox, it is
n e c e s s a r y t o rotate t h e r o d s t o
prevent the halls from getting in-
serted into the millings themselves,
preventing thus the withdrawal from
being completed.
During removal o f s p e e d r o d s ,
depending upon the operation to be
carried out, i t may b e useful t o
keep in their seats detent halls and
interlock plungers: u s e f o r t h i s 4. Grease and assemble the two
purpose tool A.3.0303. interlock plungers in the horizontal
seats on the gearbox casing using
guide tool A.3.0304 and driver tool
CHECKS AND INSPECTIONS A-3.0309.
Wash parts carefully before operating
on them. Superficial faults, wear and
efficiency of certain organs cari be
better detected. A.3.0304 - ,A.3.0309
1. Inspect whether speed control
forks are not excessively worn or
warped.
2. Inspect w h e t h e r rods a r e n o t
warped.
3. Inspect w h e t h e r s l o t s o n r o d s
bear any nickings.
4. I nspect whether detent halls and
interlock plungers bear any nickings
or seizing marks.

May 1983 13-8


5. Grease and assemble spring and
1st~2nd speed rod detent hall, using
tools A.3.0304 and A.3.0309. Grease
a n d insert relevant bal1 into radial
hole on rod. Insert then rod itself
into its seat on the gearbox casing,
paying attention to the reciprocal
position of milling and of detent hall,
and make it pass through the small
hub of relevant fork.
6. Use relevant securing plug to
close interlock plunger hole.
7. Grease and use tools A.3.0303
and A-3.0309 to assemble spring and
5th speed and reverse gear rod
detent hall.
Insert then rod 0, together with
5 t h s p e e d c o n t r o l f o r k 0, i n t o
small hubs of 5th speed and reverse
gear lever @ and into reverse gear
control fork @ together with
relevant sliding sleeve.
1 5tb speed and reverse gear lever
2 5th speed and reversa gear rod
3 5th speed control fork
4 Reverse gear control fork
8 . A l i g n a x e s o f holes a n d insert
spring pin of 5th speed and reverse
gear lever by means of tool
A.3.0322.
Insert the two halls into their seats
on central support of gearbox casing
GEARBOX
together with relevant spring, then
lock securing plug and unscrew it by
one quarter of a rotation.
M o u n t lock ring of 5th speed and
reverse gear rod on the end of the
rod itself, on the differential side.
9. Assemble partially main selector
rod, by introducing it from the rear
side of the gearbox casing, insert it
then into the selector lever, into the
spring and into the lever. Complete
then introduction of rod.
Align axes of lever holes with the
c o r r e s p o n d i n g ones on rod and
mount spring pins using tool
A.3.0322.
The speed selector lever pin @
must be shim fitted while the other
lever% p i n @ must be fitted as a
striker on the edges of the pin
itself, with the excess portion of the
pin protruding on the selectors side.
2 Pin
1 Pin
10. Fit the guide pin for the main
selector rod return spring.
11. Position the 1st2nd speed le-
v e r @ on the relevant rod 0.
Turn rod @ SO that specified S
clearance is established between le-
ver @ and rod 0.
13-9
Screw
Ist-2nd speed rod
6th speed and R.G. rod
R.G fork
3rdAth speed rod
Selector
Main selector rod
1 st-2nd speed lever
S clearance between 1st2nd speed
lever and 3rd-4th speed rod
1.4 + 1.9 mm (0.055 + 0.075 in)
12. Align rhe holes and then fit rhe
retaining screw 0. Tighten it
according to specified torque.
0: Tightening torque
Screw securing 1st2nd speed
selector lever to rod:
25326 N-m
(2.5 + 2.7 kgm
18.07+ 19.52 ftalb)
13. For gear synchronizing center
Ist-2nd and 3rd-4th speed control
forks - in that order - on toothed
rings with the help of a gauge; now
fit retaining screws and tighten them
according to specified torque.
CAUTION:
Prior to tightening, thoroughly clean
the retaining screw thread with
OMNIFIT surface-active agent and
t h e n coat it with OMNIFIT 150 H
cernent
0: Tightening torque
Screw securing fork to 1st2nd
and 3rd - 4th speed rod.
2 1 f 23 N-m
(2.1+ 2.3 kgm
15.10 f 16.63 Wb)
May 1983

Check working condition of spring-
plunger-rod assembly making sure
that speed selection is smooth and
that speeds do not jump out of their
position and become disengaged.
14. Fit oil sump, with a new gasket,
on the gearbox casing and tighten
relevant screws.
15. Position rear caver, with a new
gasket, on both gearbox casing
centering seats; fit the oil bleeder
valve with relevant retaining plate,
and then tighten all screws.
16. Apply a coating of ISECO
Molykote BR2 grease to the main
selector rod ,seal ring as well as to
its work seat on the rod.
U s i n g 1001 A . 3 . 0 2 9 4 , fit the seal
ring on the rod.
1 Main selector rod
17. Fit the relevant lever on the
main selector rod and then, using a
punch, fit the retaining pin.
18. Fit reverse gear switch on rear
caver.
May 1 9 8 3
GEARBOX
0: Tightening torque
R.G. switch to gearbox casing
40+49 N-m
(4 + 4.9 kg-m
2 8 . 9 2 + 3 5 . 4 3 ft-lb)
TESTING
Check working condition of spring-
plunger-rod assembly making sure
that speed selection is smooth and
that speeds do not jump out of their
position and become disengaged.
1 5th speed gear 3 Nur
2 Hub
/
SHAFTS AND GEARS
DISASSEMBLY .
Pinion shaf-t gears
1. Remove rods and forks (refer to:
5. Remove differential casing (Re-
Rods and Forks - D i s a s s e m b l y ) .
fer to: Group 17 - Differential
2. Acting on relevant sleeves, en-
Differential Casing).
gage two speeds in order to prevent
6. Slowly push pinion shaft toward
pinion from turning.
the differential casing and remove all
3 . W i t h a p u n c h , e l i m i n a t e all
caulking from the gear train to parts making u p the train on the
pinion locking nut 0. pinion (I~L, 2nd, 3rd and 4th
4. With spanner A-5.0196, loosen speeds), being careful to mark the
sequence and the position of gear
the nu-t and remove the hub 0, the
5th speed gear 0 with relevant bushings to be later followed during
synchroniting unit, and the bushing. reassembly.
1 Pinion 3 Direct drive shaft
2 Primary shaft
13-10
 GEARBOX

CAUTION:
If friction between the pinion and
the inner race of the rear taper roller
bearing hinders withdrawal of the
pinion shaft, use tool A.3,0296.

r A-3.0296
- - l -

1 Pinion shaft 3 Pinion shaft

front bearing 4 Pinion
2 Adjusting washer

7 . R e m o v e t h e pinion 0, w i t h
relevant taper roller bearing @ and
adjusting washer 0, from the
gearbox-differential casing.
9. Using tools A.3.0296 and
A.3.0297, remove the pinion front
bearing outer race from the gearbox-
differential casing.
Synchronizing units
R e m o v e t h e lock r i n g @ a n d
then remove in sequence: the syn-
chronizer ring 0, the guide sec-
ror 0, the locking sectoi-@, and
the retainers @.

1 Lock rini 4 Locking sector

2 Synchronizer ring 5 Gear
1 Taper roller 2 Adjusting washer
bearing
3 Guide secfor 6 Retainer
3 Pinion

The 1 st speed synchronizing unit has

only one retaiher.
8. With tool A.3.i)296 remove the
rear bearing outer race from the
gearbox-differential casing.
10. With the help of a press and of Direct drive shaft
plates A-3.0306, remove the front 1. Remove the lock ring 0 of the
b e a r i n g @ inner race and the clutch drive thrust bearing support
adjusting washer @ from the pinion
and then remove the support 0.
shaft 0.

13-l 1 May 7983

 GEARBOX

d--- - cl
1 R.G. shaft retaining screw

-3 lo2

1 Lock ring
2 Thrust bearing support 1 Pin retaining 3 Joint
spring ring 4 Spring ring
2 Direct drive shaft 5 Pin
2. Remove the direct drive shaft oil
seal ring located on the front of the
gearbox casing. 4. Having removed the direct drive
shaft, if necessaryL remove the direct
drive shaft bush with the help of tool
A.3.0291. This tool removes also
T O remove oil seal ring, with the oil seal ring.
mounted unit, operate as per figure
making use of tool A.3.0452.

2 Reverse gear 4 R.G. control fork

3 R.G. shaft

Primary shaft
1 . F i t lock t o o l A . 2 . 0 3 0 0 a t t h e
end of the primary shaft @ in order
to prevent it from turning.

3; R e m o v e t h e s p r i n g ring 0
retaining the pin @ connecting the
direct drive shaft @ to the
joint 0.
Remove the pin in question and pull
out t h e d i r e c t d r i v e s h a f t . N o w Reverse gear shaft
remove the spring ring @ retaininq
1. Loosen a n d r e m o v e t h e R-G.
the pin that connects the primary
shaft to the joint; remove this latter
shaft @ r e t a i n i n q screw 1 and 0
then remove the shaft, with relevant
pin and pull out the joint from the
q q e a r @ and R . G . fork @
primary shaft. on gearbox-
its l o c a t i o n
differential casing. 1 Primary shaft

May 1 9 8 3 13-12
 GEARBOX

9. Fit tool A.3.0296 on the

2. Loosen the screw securing the
gearbox-differential casing and then
primat-y shaft to its rear bearing and
fit the A-3.0492 end piece.
remove the oil deflector.
Carefully tighten the screws securing
3. Using tool A.3.0495 remove the
tool A . 3 . 0 2 9 6 to t h e gearbox-
5th speed driving gear 0.
differential casing to avoid damaging
the casings threads.
10. With the above mentioned tool,
push the primary shaft toward the
differential casing.

1 Bal1 bearing 2 Lock r i n g

7 . F i t pinion 0 back i n t o t h e
gearbox-differential casing.
8. Fit rear bearing on pinion
shaft 0, together with the first
section (fork shaped) o f tool
A-3.0490, at the location of the 4th
1 5th speed driving gear
speed driving gear. Now fit the
s e c o n d s e c t i o n o f tool A.3.0490
locking it on the pinion, by means of
4. Pull out the tongue securing the the relevant nut, at: the location of
5th speed driving gear to the primary the 5th speed driven gear.
shaft.
remove the A.3.0490
5. Loosen and Now remove the front floating
7 P
screw 5
8 securing
shaft 3 front: floating bearing @.
the primary bearing from the primary shaft.
11. Remove the 4th speed driving
gear and relevant tongue.

1 Bearing lock ring 4 Front bearing

2 Fiear bearing 5 Bearing retaining
3 Primai-y s h a f t screw

1 Pinion

6. Remove lock ring @ from rear

bearing 0. 1 4th speed driving gear

13-13 May 1983


12. Keeping tool A.3.0296 in place,
remove pinion shaft with all the part?
that are fitted on it; now totally
remove tool A.3.0490.
13. Completely screw the tool
A.3.0296 and insert tools A.3.0491
and A.3.0500 on its nut thread.
Unscrew tool A.3.0296 and remove
primary shaft rear bearing from its
seat, then separate it from the tool.
A.3.0491
A.3.0500
14. Remove the primary shaft @
from the gearboxdifferential casing
passing through the Seat of the rear
bearing.
1 Primary shaft 2 3rd speed gear
CHECKS AND INSPECTIONS
T h o r o u g h l y w a s h all p a r t s a n d
visually check them with extreme
tare for any surface flaws.
May 1983
GEARBOX
Gears and splines ASSEMBLY
1. Check that teeth contact pattern
of primary shaft and bevel pinion Primary shaft
gears extends to the entire working 1. First fit on the primary shaft the
surface. Unevenly worn gears or gears longue for keying of the 4th speed
with broken teeth must be replaced driving gear.
making sure that relevant mating 2. Fit the shaft in its seat on the
gears have not been damaged. gearbox-differential casing and then
Follow the same checking procedure fit the 4th speed gear on the shaft.
for splines of primary shaft, direct 3. Lock the primary shafts front
d r i v e s h a f t , a n d o f t h e pinion. end with tool A.2.0300 (refer to:
2 . Also c h e c k t h a t a b o v e men- Primary Shaft - Disassembly).
tioned toothing as well as the groove 4. Fit tool A.3.0300 on the pri-
on the synchronizing ring do not mary shafts rear end using it to key
show any scores, evidence of pitting the 4th speed gear.
or excessive wear. Replace all parts
that are not flawless.
Bushings
Check pinion bushings for excessive
wear making sure that working
surfaces in contact with gears do not
s h o w any scratches or evidence of
pitting. Replace all parts that are not
flawless.
Synchronizing unit A.3.0300 1 w
Check sliding surfaces for scores and
make sure that sleeves slide smoothly
5. Using tools A.3.0491 and
on relevant hubs; check synchroniz-
A.3.0296, fit rear bal1 bearing on
ing rings for excess wear.
primary shaft.
Carefully t i g h t e n screws o f t o o l
Bearings A.3.0296 on the gearbox casing to
avoid damaging the casings threads.
1. Carefully inspect all bearings by
slowly rotating them: no vibrations,
noise or sticking should be noticed if
bearings are in good working con- A.3.0491-
dition.
2. Check surface of all rings and
rotating parts making sure there are
no scores, marks or roughness due to
friction of foreign matter. Replace all
parts that are not flawless.
Reverse gear shaft
If any of the parts making up the
r e v e r s e g e a r s h a f t assembly a r e
defective or damaged, replace them
with new ones available as spare
parts.
1 Bal1 bearing
13-14
 GEARBOX

6. With the help of suitable plyers
fit the lock ring in its seat on tha
primary shafts rear bearing support.
Make sure the lock ring is properly
lodged in its seat.
7. Keeping the primary shaft
locked by means o f t o o l A . 2 . 0 3 0 0 ,
fit tool A.3.0300 on same s h a f t s
rear end; center the shaft in the rear
bal1 bearing.
Fit primat-y shaft on rear bearing.
8. Fit roller bearing on the primary
shafts front end being careful to
align the hole of the bearings outer
race with the corresponding hale
in the gearbox-differential casing. Fit
securing screw into the hole in the
gearbox-differential casing.
Fit securing screw into the hole and
fully tighten it.
Having completed primary shaft
assembly, check and make sure it
turns freely on the bearings, without
sticking.
outer races and then fit them on the
gearbox casing, using the same tools
u s e d during d i s a s s e m b l y ( T o o l
A.3.0296 for the rear bearing race,
and tool A.3.0296 - together with
tool A.3.0297 - for the front bearing
race).
CAUTION:
T a k e special tare during a s s e m b l y
making sure that bearing races are
exactly flat against casing surface.
2. Fit the proper shim, selected in
advance, on the pinion shaft (refer
to: Adjustments - How to determine
pinion height).
Using a press and tool A.3.0307, fit
the taper roller bearing inner race on
the pinion shaft.
3 . I f p r e v i o u s l y disassembled f o r
overhaul purposes, reassemble syn-
chronizing units (refer to: Synchro-
nizing units).
4. Apply the prescribed engine oil
to outer surface of bushings and then
fit them on gears according to their
relevant position at time of disas-
sembly thus restoring the original
working surface pattern.
5. Partially insert bevel pinion into
the gearbox casing and then fit all
parts making up the train, while
slowly p u s h i n g t h e pinion in till
is reaches its final position. During
this operation be sure to follow the
sequence and positioning show in the
relevant figure, paying special atten-
t i o n to the R.G. driven gear @
and to the 4th speed shoulder
washer 0.
Fit standard shim A.4.0141 @
(9.60 mm (0.378 in) thick) and the
inner race of the rear taper roller
bearing @, making sure that it fits
flat against the shoulder washer.

9. Fit on primary shaft the longue

for keying of the 5th speed driving
gear.
10. With tool A,3.0300 fit the 5th
speed gear in its seat on the primary
shaft by the gearbox casings outer
rear side.
11. Fit oil deflector in its seat on the
5th speed gear and tighten the
primary shaft retaining screw, with-
out fully locking it. .

Reverse gear shaft

1. Fit reverse gear shaft, with
relevant sliding gear and driving fork
into its seat o n g e a r b o x c a s i n g .
2. Tighten to specified torque the
screw securing the R.G. shaft to the
gearbox casing.

0: Tightening torque
R.C. shaft to gearbox casing
retaining screw
19-24 N-m
(1.9+ 2.4 kg-m
13.74 + 17.36 ft-lb)

Pinion shaft gears

1 Reverse gear 4 Rear taper roller
1. Coat with grease (AGIP FI
2 4th speed bearing
Grease 33 FD) the outer surface of shoulder 5 Lock nut
t h e pinion t a p e r r o l l e r b e a r i n g s 3 Standard shim

13-15 May 1983

 GEARBOX

In case of friction between the It is advisable net to exchange the

bearings inner race and the pinion, parts belonging to the different
use tools A.3.0300, A.3.0301 for synchronizing units.
easier fitting.

6. Fit the bushing and the hub of

the 5th speed driven gear and then
tighten by hand the pinion gear train
lock nut.
7. E n g a g e t w o g e a r s a n d t h e n
tighten the nut according to specified
torque, without caulking.

0: Tightening torque
Pinion gear train to pinion
shaft lock nut
2 2 0 . 5 + 245 N - m
(22.5 + 25 k g - m k.4.0142
162.70+ 1 8 0 . 7 7 ft-lb)
3. Fit rear taper roller bearing inner
0
race 2 and relevant lock nut onto
dummy pinion 0.

1 Gear 5 Locking sector

2 Retainer 6 Synchronizing
3 Guide sector ring
4 Retainer 7 Lock ring

2. Now follow the same procedure

for the 1st speed gear reme.mbering,
however, that in this case rhere is
o n l y one retainer (refer to: Disas- 1 D u m m y pinion
sembly - Synchronizing units): 2 Taper roller bearing inner race

4. Tighten the nut according to

8 . N o w Select t h e s h i m f o r f i n a l
fitting (refer to: How to determine
Pinion Shaft Taper Roller Bearing
Pre-load).
Synchronizing units
1. As far as 2nd, 3rd, 4th and 5th
s p e e d g e a r s a r e concerned fit re-
tainers @ @ and on gear
body 0 placing locking sector @
and guide sector @ between them.
Fit synchronizing ring @ on re-
tainers and sectors and then lock into
alace all aarts w i t h r e l e v a n t lock
ring 0.
ADJUSTMENTS specified rolling torque using coupl-
ing tool A.2.0274, 1 dm. dia. sheave
How to determine pinion height 6.5.0124 and weight C.2.0037.
CAUTION: 0: Dummy pinion rolling torque
Use only metric system in order to a. For original bearings being
avoid confusion in computations. used again:
3 + 6 N.dm
T O d e t e r m i n e pinion h e i g h t , n d (0.3 + 0.6 kg-dm
therefore shim thickness, proceed as 0.217 + 0.434 ft-lb)
follows:
1. Fit inner race of the pinion shaft b. For replacement bearings
front taper roller bearing on dummy (new)
pinion A.4.0142. 12+ 14 Nqdm
2. Insert dummy pinion in gearbox (1.2 + 1.5 kg-dm
casing. 0 . 8 6 7 + 1.085 f t - l b )

May 1 9 8 3 13-16
 GEARBOX

0: Tightening torque
A.2.0274 Screws securing tool C.6.0162
A.4.0142 to gearbox-differential casing:
C.5.0124 40+49 N-m
1 (4 + 4.9 kgmm
28.92 + 35.43 f-t-lb)

1 Front taper roller bearing inner race

2 Rear taper roller bearing inner race

5. Turn dummy pinion a few times

in both directions to allow bearings 11. Determine as follows the S
to settle. thickness of the shim that is to be
6 . F i t a centesimal dia1 g a u g e t o f i t t e d b e h i n d t h e pinion h e a d :
bracket A . 4 . 0 1 3 6 a n d r e s e t i t b y
Ll + L2
means of reference gauge C.6.0161. s = - (k C)
2

8. Place the differential carrier,

w i t h dia1 g a u g e , o n t h e h e a d o f 12. Among the various shims avail-
dummy pinion and then take reading able as spare parts, Select the one
of Ll value. with thickness nearest to the value
determined as per above instructions.

~ A.4.0136 C.6.0162
7 Example:

Ll = 0 . 8 6
L2 = 0 . 8 8
c = 0.13

L, + L2 0.86W.88
s z!z- - (IC) = - (0.13)
2 2

0.86
(1) + 0.88
1.74

1.74:2=
(2) 0.67

0.67
(3) - 0.13
Computed shim
s = 0.74
thickness

Selected shim
thicknesr S = 0.75 m m

7. Fit crown a x i s r e f e r e n c e t o o l 9. Repeat above operation by fit-

t i n g tool C.6.0162 into the Seat o f Shim thickness thus determined in
C.6.0162 into the differential carrier
the opposite side differential carrier t h i s one e n s u r i n g c o r r e c t pinion
Seat; tighten, in bias sequence and
and take reading of L, v a l u e . height since readings have been taken
according to specfied torque, the
10. Read dimension C (plus o r w i t h pinion in its actual o p e r a t i n g
four screws securing it to the gearbox-
minus) etched on pinion. position.
differential casing.

13-17 May 1983

 GEARBOX

How to determine pre-load of
pinion &aft taper roller
bearings
CAUTION:
Use only metric system in order to
avoid confusion in computations.
After having fitted all various parts as
described in paragraph Reassembly -
Pinion Shaft: Gears, item no. 5,
measure pinion end play by carefully
following the procedure described
hereafter:
1. Fit bracket A.2.0242 to gearbox
casing with the interposed spacers
A-2.0234 and then a centesimal dial
gauge to the bracket.
roller bearings pre-loading:
S = 9.60 - G - 0.10
whereas 0.10 is a play-correcting
factor for taper roller bearing pre-
loading.
- - F - J -
1 Pinion 3 Rear bearing
2 Front bearing
Select the shim with thickness
nearest to the value determined as
per above instructions keeping in
mind, however, that max. allowed
tolerance is * 0.02 mm and that
thicknesses available as spare parts
have a 0.05 mm variation step.
various parts do not rotate.
6. Fit the shim selected as per
above computation; now fit the
bearing inner race, all the parts
making up the 5th speed driven gear
set and lastly the nut.
7. Tighten the nut to specified
torque.
0: Tightening torque
Pinion shaft gear train locking
nut
220 + 245 N-m
( 2 2 . 5 + 25 k g - m
162.70,+ 1 8 0 . 7 7 ft.lb)
8. Coat all gears of primary and
pinion shafts with specified gearbox-
differential type oil (AGIP FI Rotra
-
MP SAE 8OW90 or IP Pontiax HD
8OW90).
Turn pinion shaft a few times in both
rotating directions to allow bearings
to settle.
9. Fit coupling tool A.2.0274, the
1 dm rad. sheave C.!%O124, and The
C.2.0037 weight to the pinion shaft
nut.
A.2.0274 -

Example:

Standard shim
thickness = 9.60
G = 0.37
Play -correcting factor = 0.m
S =9.60-G-0.10
Properly tighten the screws securing = 9.60 - 0.37 - 0.10

bracket A.2.0242 to the gearbox 9.60

casing in order to avoid damaging (I)
- 0.37
casing threads. 9.23

9.23
2. Turn pinion @ a few times in (2)
0 . 1 0
-
both directions to allow bearings @
9.13
and @ to settle. Push pinion by
Computed shim
hand in one direction and reset the C-2.0037
thickness S = 9.13
dial gauge.
3. Move pinion in the opposite Tolerance = 0.02
direction and take reading of G Dimensional variation
play on dial gauge. steps of available spare 6
shims = 0.05
In case of subsequent end-play Selected shim
readings, it is necessan/ to rotate thickness S = 9.15 mm
again the pinion in both directions to 10. Check that weight descends
allow bearings to settle. 5. Loosen and remove the nut as normally without stopping and with-
well as the hub, rhe bushing, the out pulling the disc too fast.
4. Determine as follows the rear bearing inner race, and the standard Check that in such condition rolling
shim S thickness for pinion taper shim making sure that the trains torque is as specified.

May 1983 13-18


0: Rolling torque of pinion with
gear train.
a. For original bearings being
used again
4 + 7 N-dm
(0.40 + 0.70 kg-dm
0.289 + 0.506 ft.lb)
b. For replacement bearings
hew)
1 3 + 1 6 N-dm
(1.3+ 1.6 kg-dm
0.939 + 1.157 ft.lb)
In case of rolling torque values
greater or lower than specified ones,
correct them by fitting a rear shim
either 0.05 mm thinner or thicker
than the one previously fitted.
In this instance, rechecking of rolling
torque is required.
11. Caulk the nut with punch and
hammer.
12. First prevent shafts from rotat-
ing by engaging two speeds and then
tighten the screw securing the oil
deflector to the primary shaft
according to specified torque.
0: Tightening torque
Oil deflector retaining screw
69; 8 5 N-m
(7 + 8.7 kg-m
50.61 + 62.91 ft.lb)
Direct drive shaft
1. If previously disassembled, fit
direct drive shaft bushing @ to
gearbox casing using tool A.3.0308.
GEARBOX
1 Bushing
2. Fit bushing on primary shaft
making sure that holes for sub-
4
sequent pin fitting are aligned; fit
A.3.0453 1
the pin and a new retaining spring
ring.
3. Insert direct drive shaft into its
seat and connect it to the bushing by
fitting the pin and a new retaining
CAUTION:
spring ring.
Cover direct drive shaft splines with
tape.
Make sure that retaining spring rings
are properly lodged in their respec-
5. Fit the clutch drive thrust
tive seats so as to prevent pins from
bearing support and secure it to its
dropping out.
seat on the differential casing by
means of the relevant lock ring.
4. After having applied grease
( I S E C O : M o l y k o t e BR2) t o i t s
Make sure that lock ring is correctly
sealing lip and to its work seat on
lodged; check that its tongues are
the shaft, fit a new oil seal ring on
facing the sleeve seat and thus
the direct drive shaft with the help of
pressing it on the casing.
tool A.3.0323. During this operation
be careful not to damage the sealing
TESTING
lip of coupling splines.
Check that hubs and synchronizing
Use tool A.3.0453 to assemble oil rings are in perfect working condi-
seal ring on direct .drive shaft, on tion and that engagement of gears is
assembled unit. noiseless and easy.
DIFFERENTIAL CARRIERS
1 Taper roller 6 Shim
bearing 7 Seal ring
2 Phonic wheel 8 Carrier
3 King nut 9 Seal ring
4 Lock ring 10 Differential shaft
5 Ball bearing
13-19
 GEARBOX

6 . Using tool A.3.0299, remove the

DISASSEMBLY differential carrier taper roller bear-
ing outer race.
IMPORTANT:
The following procedure refers to the
right hand differential carrier.
Difference between left differential
support and right one is only con-
stituted by absence of phonic wheel
in the left differential support

1. Loosen and remove oil sump Taper roller bearing outer race
retaining screws with relevant Phonic wheel
washers, now remove the sump and Ring nut
Spring ring
the seal gasket.
Bearing
2. Loosen and remove the
Oil seal ring

8
screws 1 securing the differential. Seal ring 7. Remove the bearing lock ring
carrier 2 to the gearbox casing Differential carrier from its seat in the differential
Partially pull back the carrier and Differential shaft carrier.
remove the two shims 0, being
4. Lock differential carrier in a vice
careful to mark the relevant position
and remove the ring nut securing the
to be later followed during reas-
differential carrier on the bearing and
sembly. Now completely disassemble
phonic wheel using tool A.3.0298.
differential carrier.

8. Now with tool A.3.0302, re-

5. With The help of a press and of move the ball bearing from the
plates A.3.0295, remove differential differential carrier.
s h a f t @ f r o m t h e c a r r i e r 0.
Remove the oil seal ring.

1 screw 3 Shim
2 Differential carrier

3. Remove seal ring 0 from

1 Differential shaft
differential carrier @.

Following the same procedure, disas-
semble the left hand differential
carrier.
9. In case of malfunction of speed
indicator device, remove sensor @
from gearbox after removing retain-
ing spring @ and replace it.
1 Spring ring 2 Sensor
CHECKS AND INSPECTIONS
Having thoroughly washed all parts,
perform following checking ope-
rations:
1. Carefully inspect all bearings
while slowly r o t a t i n g t h e m : n o
vibrations, noise or sticking should
be noticed if bearings are in good
working condition.
2. Check the surface of all rings
and rotating parts making sure that
there are no scores, marks or rough-
ness due to friction of foreign
matter.
If surfaces of rings and of rotating
parts show scores, evidence of
abnormal wear, pitting or over-
heating, replace them without hesi-
tation.
3. Check that contact surface of
differential shafts splines extends to
the entire working surface; if any of
the teeth is chipped or show evidence
of abnormal wear, replace shafts
making sure that relevant mating
parts have not been damaged.
ASSEMBLY
Referring to the right hand differ-
GEARBOX
-.I -.
ential carrier, proceed as follows:
1. Apply gearbox oil to the oil seal
ring outer surface and fit it into its
seat on the differential carrier using Ff
tool A.3.0430.
CAUTION:
L-.-J 1X.3.0292
Make sure the crowfoot on the oil
seal ring points in the direction of
the differential shaft rotation.
T T
i.- .-i
A.3.0430
5. Apply grease (ISECO Molykote
R BR2) to the oil seal ring inner surface
and to its seat on the differential
shaft. With tool A-3.0293 and the
help of a press and a rest plate, fit
now the differential shaft.
2. With tool A-3.0302 and the help
of a press, fit the differential shaft
bearing into the carrier.
IL. I
.-.I
t?? 6 . A p p l y g e a r b o x o i l (AGIP Fl
A-3.0302
Rotra MP SAE 8OW90 or IP Pontiax
HO 8OW90) to the mating surfaces
on differential shaft of the bearing
retaining ring nut. Make sure to fit a
new ring nut.
7. On differential shaft install first
ring, nut and then phonic wheel,
using. tool A.3.0293 together with a
press and a rest plate.
8. After having applied a coating of
gearbox oil, fit the small seal ring in
the carriers groove.
3. Fit the differential shaft bearing 9. Fit the right hand differential
lock ring. carrier in its seat on the gearbox
4. Using tool A-3.0292 fit the taper casing
roller bearing outer race into the
carrier.
13-21 May 1983
 GEARBOX

Following fhe same procedure, reas-
semble the left hand differential
carrier.
IO. Fit oil sump with relevant
sealing gasket.
scribed in paragraph Differential
Casing - Assembly, fit crown gear
to differential casing.
2. Fit differential casing back to
gearbox casing.
3. With tool A.3.0287 remove
inner races of taper roller bearings
from the differential casing.

CROWN GEAR
AND PINION
DISASSEMBLY
Crown gear
1. Remove differential carriers
from the gearbox-differential casing
(refer to: Differential Carriers
- Disassembly).
2. Remove differential casing from
the gearboxdifferential casing (refer
to: Differential casing - Disassembly).
3. Loosen and remove the screws
securing the crown gear to the
differential casing and then remove
the crown gear.
Pinion
1. Remove gears from pinion shaft
and then withdraw the shaft from its
seat in the gearbox-differential cas-
ing, with relevant bearings (refer to:
Shafts and Gears).
CHECKS AND INSPECTIONS
Having thoroughly washed all parts,
proceed as follows:
1. Slowly rotate bearings checking
them for vibrations, noise or sticking.
2. Check surface of all rotating
parts and of roiling tracks for scores
or any evidence of abnormal wear,
pitting or overheating; in the affir-
mative, replace the parts involved.
3. Make sure that contact pattern
of bevel pinion teeth extends to their
entire working surface. If any of the
teeth are nicked, replace the pinion
and make sure the crown gear has
not been damaged as a consequence.
Check both toothings for scores
and any evidence of pitting or excess
wear.
ASSEMBLY
Crown gear
1. Following the procedure de-
Pinion
Position the pinion into its seat in
the gearboxdifferential casing and fit
bearings and gears (refer to: Shafts
and Gears).
TESTING
A.3.0287 1 1
Verify back-lash between crown gear
and pinion in four diametrically
opposite positions. Irregular back-
lash, with excessive differences be-
tween the measured points, is an
indication of crown gear deformation
with consequent flatness error
between gearbox casing/crown gear
place and differential casing plane.
Make sure the differential works
properly and is completely noiseless.
Incorrect assembly ofcrown gear and
pinion or worn taper roller bearings
could be the cause of the trouble.
4. Loosen and remove the screws
DIFFERENTIAL and washers securing the crown gear
CASING to the differential casing.
Now remove the crown gear.
DISASSEMBLY
1. Remove left and right hand
differential carriers (refer to: Dif-
ferential Carriers - Disassembly). CHECKS AND INSPECTIONS
2. Remove differential casing from Having thoroughly washed all parts,
gearbox-casing, perform the followingchecking
operations:
1. Slowly rotate bearings checking
them for vibrations, noise or sticking.
2. Check the surface of all rotating
parts and of all rolling tracks for
scores and any evidence of abnormal
wear, pitting or overheating; in the
affirmative, replace the parts in-
volved.
3. Visually check gears, both plane-
tary and side gears, making sure that
there are no scores or evidence of
pitting, that contact pattern extends
to their entire working surface and
further that mating is noiseless and
smooth.
If necessary, replace the whole
1 Differential 3 Crown gear
differential casing; in this case also
casing 4 Taper roller
2 Retaining screw bearing replace taper roller bearings.

May 1983 13-22


CAUTION:.
Use only metric system in order to
avoid confusion in computations.
5. Compute, as shown below, the
average value Hm of the four
measurements picked-up as per item
4 above and determine the thickness
of B shims that will have to be
fitted behind the crown gear side
carrier for pre-loading of taper roller
bearings.
B = Hm - 0.20
whereas 0.20 is correcting factor for
bearing pre-loading.
Example of computation of the four
picked-up measurements:
HI = 1 . 8 8 H,= 1 . 9 4 ;
Hg= 1.90 e Ha= 1 . 9 6
B = Hm -0.20 =
1.88+1.94+1.90+1.96
= - 0.20 =
4 values, proceed as hereafter de-
= 1.92 - 0.20 = 1.72 mm
6. Considering that max. allowed
tolerance is -I- 0.02 mm and that
shims available as spare parts have a
thickness variation step of 0.05 mm
select the thickness nearest to the
computed value (in the above in-
stance one would select the 1.70 mm
thickness).
7. Fit selected shims behind the
crown gear side carrier and tighten
retaining screws to specified torque
(refer to: Step 2).
Crown gear to pinion backlash
Adjust crown gear to pinion backlash
following the procedure hereafter
described.
1. Rotate pinion and crown gear to
allow relevant bearings to settle and
then use tool A.2.0243 to lock the
pinion.
Properly tighten screws of tool
A.2.0243 on gearbox casing.
2. Fit a centesimal dial gauge to a
magnetic base and place the gauges
indicating finger on the outer edge of
a crown gear tooth at right angles
with the tooths side.
May 1983
GEARBOX
lash and if now within specified
values, repeat above adjusting opera-
tions.
When refitting previously disas-
sembled parts (carriers, differential
casing, bearings and crown gear), it is
essential that also same A and B
shims are used - or at least new ones
of same thickness - and that they are
placed back exactly where they were
located at time of disassembly.
3. Rorate crown sear as far as
backlash will allow and read the
value shown on dial gauge.
4. Repeat the above reading on
four different points of the crown GEARBOX-
war, equally distant o n e f r o m DIFFERENTIAL
the other. CASING
Each of the four measured values DISASSEMBLY
must fall within the range of 0.05 to 1. Remove rear support (Refer to:
0 . 1 0 m m (2*10- + 4-10m3 i n ) . Rear Support - Disassembly).
2. Remove the clutch control fork
If backlash does not fall within these and then withdraw the thrust bearing
from the direct drive shaft (Refer to:
scribed, remembering that total shim G r o u p 12).
thickness (A + B) between differen- 3. With the help of a punch,
tial carriers and gearbox casing must remove the clutch control fork
remain constant otherwise it would retaining pin.
cause bearings pre-load to change:
- in case backlash is below speci-
fied value, move crown g e a r
away from the pinion by de-
creasing thickness of A shims
and equally increasing that of B
shims.
- in case backlash is above speci-
fied value, move crown gear
closer to the pinion by increas-
ing thickness of A shims and
decreasing that of B shims by
the same extent.
When correcting shim thickness it
should be remembered that in order
to change dial gauge reading (min.
distance between crown gear and
pinion teeth) by 0.01 mm (0.4.10-3 4. Remove differential carriers
in), one must move a thickness of (Refer to: Differential Carriers -
0 . 0 1 5 m m (0.59-10-3 i n ) f r d m Disassembly).
one side to the other. 5. Remove differential casing with
crown gear (Refer to: Differential
Having completed fitting of shims, Casing - Disassembly).
tighten retaining screws to specified 6 . R e m o v e rods and forks (Refer
torque (Refer to: Adjustments - How to: Rods and Forks - Disassembly).
to Determine Pre-load of Differential 7. Remove shafts and gears (Refer
Casing Bearings). Double check back- to: Shafts and Gears - Disassembly).
13-24

CHECKS AND INSPECTIONS
1. Thoroughly clean casing with
solvent and check it for scores, nicks
or evidence of pitting.
2. Check the casings mating sur-
faces making sure there are no nicks,
no evidence of roughness nor or old
sealants.
3. Check that the clutch for
retaining pin is not in any way
damaged.
ASSEMBLY
1. Fit shafts and gears (Refer to:
GEARBOX OUTER LINKAGE
DISASSEMBLY
1. Loosen and remove the nut with
washer @ as well as the screw 0
securing the main selector rod @ to
the gearbox lever 0; then remove
the spacer @ and the two bush-
ings 0.
1 Gearbox lever 5 Rear support
2 Spacer 6 Main selector rod
3 Bushing
4 Nut with washer
7 Retaining screw
2. Loosen and remove the gearbox
lever guide @ retaining screws with
washers 0; now remove the guide,
the boot aand the bushing 0
located at levers end.
1 Boot 3 Bushing
4 Guide
2 Screws with
washers
GEARBOX
Shafts and Gears Assembly).
2. Fit differential casing (Refer to:
Differential Casing -Assembly).
3. Fit differential carriers (Refer
to: Differential Carriers - Assembly).
4. Fit rods and forks. Thoroughly
clean rear cover and oil sump mating
surfaces; fit new gaskets with speci-
fied sealants and then fit cover
and sump (Refer to: Rods and Forks
- Assembly).
5. Fit clutch control fork retaining
pin.
6. Fit the clutch control fork and
3. Loosen and remove the nut
and the screw @ securing
gearbox lever support 0 to
flexible bush @I ocated on the
extensions; now remove side wash-
0
ers 3 as well as the spacer 0.
1 Support 5 Spacer
2 Nut 6 kasher
3 Washer 7 Screw
4 Flexible bush
4. Remove rear support (Refer to:
5-Speed M a n u a l G e a r b o x - R e a r
Support).
6. Lastly remove the flexible bush
with the help of following tools: a
press, a plate, a base and punch tool.
13-25
then fit thrust bearing on direct drive
shaft (Refer to: Group 12).
7. Fit rear support (Refer to: Rear
Support - Assembly).
@ CHECKS
the AND INSPECTIONS
the
1. Thoroughly clean outer linkage
rear
metal parts with solvent and make
sure they are in good condition.
2. Check linkage articulated joints
for excess wear.
3. Make sure boot is in perfect
condition; i f d a m a g e d o r w o r n ,
replace it.
ASSEMB.LY
1. Fit rear support (Refer to:
5-Speed M a n u a l G e a r b o x - R e a r
Support).
2. Apply grease (AGIP Fl G r e a s e
15 or SHELL Retinax G) to the
spacer 0 on the speed selector
lever to main selector rod connec-
tion 40 and to the spacer 0
securing the fork to the flexible bush
on the gearbox cover.
Apply 5 g (0.176 oz) of same grease
to the speed selector lever guide 0.
3. Go on to fit all gearbox outer
linkage following disassembly pro-
cedure in reverse sequence.
1 Spacer 3 Spacer
2 Guide 4 Main selector rod
May 1983
 GEARBOX

SERVICE DATA AND SPECIFICATIONS

TECHNICAL DATA

Differential ratio

Gearbox Speed selector Gearbox 9135 lll39

Speed
differential lever positions ratio Gearbox- Speed Gearbox- Speed
differential at 1000 r.p.m. differential at 1000 r.p.m.
overall ratio Km/h (mi/h) overall ratio Km/h (mi/h)

1 1 : 3.750 1 : 14,580 7.08 (4.39) 1 : 13.293 7.77 (4.81)

2 1 : 2.050 1 : 7.970 12.96 (8.05) 1 : 7.267 14.21 (8.81)
3 i : I.387 1 : 5.392 19.15 (11.89) 1 : 4.916 21 .Ol (13.05)
4 1 : 1.027 1 : 3.992 25.87 (16.07) 1 : 3.640 28.37 (17.63)
5 1 : 0.825 1 : 3.207 32.20 (20.0) 1 : 2.924 35.23 (21.89)
R.G. 1 : 3.091 1 : 12.017 8.59 (5.34) 1 : 10.957 9.42 (5.86)

Engine 1200 1200 1500

1350 1350
1500

GENERAL SPECIFICATIONS

FLUIDS AND LUBRICANTS

APP. Application Name Qw

Type
0.

Inner surface of:

- Seal ring of main selector rod GREASE ISECO Molykote BR2 -
- Seal ring of priman/ shaft Std. No. 367159941
1 - Seal ring of differential shaft
- Seal lip and work seat on shaft

Outer surface of:

- Seal rings OIL See item 5

May 1983 13-26

 GEARBOX

APP.
0.
Application Type Name Q.W

Outer races of differential casing and pinion GREASE - AGIP: Fl Grease33 FD

2
taper roller bearings Std. No. 3671 69833

Mating surfaces of:

3 - Ring nut securing bearing to differential OIL See item 5
shaft

Outer surface of:

- Spacer on main selector rod to speed GREASE - AGIP: Fl Grease 15
4 selector lever connection - SHELL: Retinax G
- Spacer for lever to fork fitting Std. No. 3671-69811

Speed selector lever guide 5 g (0.176 otj

Fill-up of gearbox-differential casing OIL - AGIP: Fl Rotra MP SAE 8OW90 2,300 kg

5 - IP: Pontiax H.D 8OW90 +O,lOO kg
Std. No. 363169408 5.07 lb + 0.22 lb)

Outer surface of differential carriers and

6 relevant seats on gearbox casing OIL See item 5 -
Bushings for bevel pinion driven gears

Outer surface of:

- Gearbox rear flexible support GREASE - UNION CARBIDE CHEMICAL
- Flexible support for speed selector COMPANY:
lever upper joint Ucon lubricant 50 HE-5100
- MI LLOIL: slipping agent for
rubber sections
Std. No. 4500-I 7502

Outer surface of:

- Fin for gearbox rear flexible support GREASE - SPCA: spagraph
- ISECO: Ergon Rubber Grease no. 3 -
Std. No. 367169816

SEALANTS AND SURFACE-FIXING AGENTS

Application Type Name Q.ty

Lower screws securing differential carriers CEMENT DOW CORNING: Silastic RTV732
to gearbox casing Std. No. 3522-00040

13-27 May 1983

 GEARBOX

Application Type Name Q.W

- Screws securing forks to speed selector CEMENT Omnifit 150 H

rods Std. No. 352400023

N.B. For surface cleaning use: SURFACE Omnifit - Std. No. 3514-90003 -
FIXING
AGENT

- Inner surface of bore for oil plug on CEMENT DIRING: Heldite

gearbox casing Std. No. 3522-00015

INSPECTION AND ADJUSTMENT

REAR SUPPORT RODS AND FORI<S

fl positioning of gearbox rear flexible support 1. 5 clearance between 3rd-4th speed rod 0 and
lst-2nd speed selector lever @

S mm 1.4 + 1.9
P degree 90 4 2
(in) (5.5. 10.*+7.4 IO-*)

2. End play between fork and synchronising unit

sleeves

Clearance mm 0 250 + 0.375

(in1 (9.8 1 O-3 - 1 . 5 1 O-*1

ROLLING TORQUES

I tern N*dm

Dummy pinion

- Original bearings being used again 3 2.6

0.3 + 0.6 0.217 + 0.434

- Replacement bearings (new) 12 + 15 1.2 f 1.5 0.867 + 1.085

Pinion with gear train

- Original bearings being used again 4 2- 7 0.4 + 0.7 0.289 + 0.506

- Replacement bearings (new) 13 - 1 6 1.3 + 1.6 0.939 + 1.157

May 1983 13-28

 GEARBOX

DIFF-ERENTIAL CASING PINION

Thickness 3 of shims B for pre-loading of differential 1. Thickness 3 of shims for setting of pinion height
casing taper roller bearings

s = H (avg.) - 0 . 2 0

H = clearance between gearbbx casing

and flange of L.H. differential carrier C = value engroved ou pinion

0.20 = corrective value for bearing preloading Ll, L2 = crown gear shaft deviation values

Thickness Part No. Thickness Part No.

mm (in) m m (in)

1.00 (0.04) 1.55 (0.062) 101452 101463 0.75 (0.W) 101430

1.05 (0.042) 1.60 (0.064) 101453 101464 0.80 (0.032) 101431
1.10 (0.044) 1.65 (0.066) 101454 101465 0.85 fO.034) 101432
1.15 (0.046) 1.70 (0.068) 101455 101466 0.90 (0.036) 101433
1.20 (0.048) 1.75 (0.07) 101456 101467 0.95 (0.038) 101434
1.25 (0.05) 1.80 (0.072) 101457 101468 1.00 (0.04) 101435
1.30 (0.052) 1.85 (0.074) 101458 101469 1.05 (0042) 101436
1.35 (0.064) 1.90 (0.076) 101459 101470 1.10 (0.044) 101437
1.40 (0.066) 1.95 (0.078) 101460 101471 1 .I5 (0.046) 101438
1.45 (0.058, 2.00 (0.08) 101461 101472 1.20 (0.048) 101439
1.50 (0.06) 101462 1.25 (0.051 101440
 GEARBOX

2. Thickness S of shims for pre-loading of pinion 3. Pinion to crown gear backlash

taper roller bearings

S = 9.60 - G - 0.10

9.60 = sample washer thickness

Backlash mm 0 . 0 5 + 0.10
G = clearance measured by gauge (in) (Zrlo-3 + 4q0-3)

0.10 = corrective value

Thickness Part No.

mm (in)

4.10 (0.164) 700165

4.15 (0.166) 700166
4.26 (0.170) 700167
4.35 (0.174) 700168
4.45 (0.178) 700169
4.55 (0.182) 700170
4.65 (0.186) 700171
4.75 (0.190) 700172
4.80 (0.192) 700173
I

TIGHTENING TORQUES

Unit
N*m kg-m ft-lb
Item

LEVER AND FORKS

Screw securing 1st - 2nd speed selector

to rod 25 + 26 2.5 + 2.7 18.07 + 19.52
Screws securing forks to speed control
rods 21 + 23 2.1 - 2.3 15.10 + 16.63
Screws securing pin for R.G. sliding gear 19 + 24 1.9 + 2.4 13.74 + 17.36

SHAFTS AND GEARS

Primary shaft outer bearing retaining

screw 69 f 85 7 + 8.7 50.61 + 62.91
Bevel pinion gear train retaining ring nut 220 f245 22.5 + 25 162.70 + 180.77

May 1983 13-30


Trouble
Noisy both during acceleration
and deceleration (drive shaft
assy already checked)
Transmission is noisy when in
curve, both with speed engaged
or when in neutral (drive shaft
assy already checked)
Transmission is noisy when in
neutral (vehicle is not moving)
Transmission is noisy when in
reverse gear
Engagement/disengagement of
speed is not easy
Speeds become disengaged
May 1983
G-EARBOX
Probable cause Corrective action
l Differential gears are worn or Replace gears
damaged
l Excess play of hypoid gears Check and replace, if necessary
l Crown gear securing screws are Tighten
loose
l Bevel pinion shim is worn or Replace shim
damaged
l Pinion shaft retaining nut is loose Check gearbox components and
then tighten the nut
l Excess play in gear train Adjust gear train
l Teeth of planetary and side gears Replace differential casing
are worn, damaged or show evi-
dence of pitting
l Irregular variations of driving Adjust engine idling
torque
l Not enough oil Fill up to correct level
l Reverse gears are worn or damaged Replace defective parts
First of all it should be established if the trouble is caused by the gearbox or by
the control system. If the clutch still transmits torque when the pedal is pushed-
down, it means that it is not disengaged. Verify if the clutch properly couples
(pedal is released) and uncouples (pedal is pushed-down) the engine to the gear-
box casing. If clutch is not faulty, the trouble originates either from the gearbox
or from the control system.
l Bushing on outer speed selector Replace bushing
lever is worn
l Gearbox outer linkage needs adjust- Check linkage, joints and controls
ing and/or lubrication of joints is
insufficient
l Stroke of outer linkage parts is not Check the system and, if necessary,
sufficient due to excess play repair or replace worn parts
l Not enough oil in gearbox-differ- Fill-up to correct level
ential casing
l Synchronizing units are faulty Refer to Synchronizing unit is faulty
l Inner controls are deformed or Repair or replace defective parts
worn
l Sleeves and gears are worn or Replace worn parts
defective
l Excess end-play of the gear that Verify adjustment of gear train
becomes disengaged (Noisy both
during acceleration and deceler-
ation)
13-32
 GEARBOX

Trouble Probable cause Corrective action

Speed selection is poor l Bushing on outer speed selector Replace bushing

lever is worn
l Plungers are worn or damaged teplace plungers
l Springs can no longer be used due Ieplace springs
to fatigue or because they are
broken
l Rod millings are worn or deformed Replace rods
l Selector fork and/or levers are ?eplace the selector and/or the levers
worn or damaged

Synchronizing unit is faulty l Sleeve and gear front toothing are 3eplace defective parts
or grinds worn or damaged
l Distance between gear and sleeve 3eplace defective parts
front toothing is incorrect
l Synchronizing ring is worn Replace
l Sleeve splines are worn or damaged Replace

Reverse gear light do not light l Switch of R.G. light is faulty Replace the switch
up when R.G. is engaged

Speed selector lever vibrates l Lever return spring is out of order

and is noisy due to fatigue
l Bushing on outer speed selector Replace faulty parts
lever is faulty
l Refer to other items concerning
noisy gearbox

Seizure, pitting or breakage
l Oil level is below normal or oil is
not of the specified type
l Incorrect clearances (not enough)
l Bearing and gear adjustments are
incorrect
l Excessive torque or improper use
of clutch
l Retaining screws are loose
Replace faulty parts and use
specified oil
Adjust clearances and replace
faulty parts
Replace faulty parts
Replace faulty parts and tighten
screws to specified torque

SPECIAL SERVICE TOOLS

Refer to
Tool number Tool name
paw

0 A.2.0234 Spacer for locking

1 of1 intermediate ~ 13-18
flange (ta be used with A.2.0242)

13-33 May 1983

 GEARBOX

Tool number Refer to

Tool name
page

A.2.0242 Support of dial gauge to read pinion 13-18

spacer thickness (to be used with A.2.0234)

A.2.0243 Tool for locking pinion 13-24

A.2.0274 Adapter of sheave for checking 13-16

pinion bearing pm-load 13-18

A.2.0300 Tool for locking mainshaft (to be 13-12

used with A.3.0300) 13-14
13-15

A.3.0287 Adjustable span puller for differential 13-22

carnier bearing cones

A-3.0291 Puller of bush shim and oil seal from 13-12

mainshaft and gearshift rod

A-3.0292 Driver of differential bearing cups 13-21

CL-

A.3.0293 Driver of bearing and phonic wheel 13-21

retainer onto differential spindle

A.3.0294 Driver of oil seal onto gear shift rod 13-10

(with assembled unit)

-.

May 1983 13-34

 GEARBOX

Refer to
Tool number Tool name
paw

A.3.0295 Plate for whith drawal of differential 13-20

spindle

A.3.0296 Puller / driver of rear pinion bearing 13-11

cup and puller of pinion shaft and 13-13
13-14
mainshaft
13-15

A.30297 Puller I driver of front pinion bearing 13-11

cup (use with A.3.0296) 13-15

A.3.0298 Puller of speedometer pinion and 13-20

ring nut from shaft

A.3.0299 Puller of differential bearing outer races 13-20

A.3.0300 Driver of mainshaft and 5th speed 13-15

driver gear 13-16

A.3.0301 Driver of pinion 13-16

A.3.0302 Puller I driver of drive flange bearing 13-20

13-21

A.3.0303 Guide for fitting striking rod balls of 13-8

3rd. 4th and rev. striking rods (use 13-9
with A.3.0309)

13-35 May 1983

 GEARBOX

Refer to
Tool number Tool name
page
-

A.3.0430 Driver of output shaft seal 13-21

A.3.0452 Puller of drive spindle seal (with unit 13-12

assembled)

A.3.0453 Driver of drive spindle seal 13-19

($-$D

A.3.0490 Puller of 4th - speed gear from 13-73

mainshaft (to be used with 13-14
A.3.0296 and A.3.0492)

A.3.0491 Puller / driver of rear mainshaft 13-14

bearing (to be used with A.3.0296)

A.39492 Auxiliary shaft for removing 4th-speed 13-13

gear from mainshaft [to be used with
A.3.0296 and A.3.0490)

A.3.0495 Puller of 5th _ speed drive gear 13-13

A.3.0500 Tool for removing rear mainshaft 13-14

bearing (to be used with A.3.0296
and A.3.0491)

A.4.0136 Support of dial gauge for pinion 13-17

setting (to be used with C-6.01 61)

13-37 May 1983

 GEARBOX

Refer to
Tool number Tool name
paw

c.5.0124 Sheave for checking differential bearing 13-16

pm-load (to be used with A.2.0274 and 13-17
C.2.00371 . . . . . ..I 13-18

C.6.0161 Reference gauge for pinion setting (to 13-17

be used with A.4.0136)

C.6.0162 Tool for checking pinion setting (to be 13-17

used with A.4.0136)

13-39 May 1983

 DIFFERENTIAL AND DRIVE SHAFT ASSEMBLY

CONTENTS

DIFFERENTIAL . . . . . . . . . . . . . . . . . 17-2 Installation . . . . . . . . . . . . . . . . . . . 17-5

Crown gear and pinion . . . . . . . . . . 17-2 SERVICE DATA AND
Differential casing . . . . . . . . . . . . . . 17-2 SPECIFICATIONS . . . . . . . . . . . . . . . . 17-6
DRIVE SHAFT ASSEMBLY . . . . . . . . . 17-2 General specifications . . . . . . . . . . . 17-6
Removal . . . . . . . . . . . . . . . . . . . . . 17-3 Tightening torques . . . . . . . . . . . . . 17-6
Disassembly . . . . . . . . . . . . . . . . . . . . 17-3 TROUBLE DIAGNOSIS AND
Checks and inspections . . . . . . . . . . 17-4 CORRECTIONS . . . . . . . . . . . . . . . . . . 17-6
Assembly . . . . . . . . . . . . . . . . . . . . . 17-4 SPECIAL SERVICE TOOLS . . . . . . . . . 17-6

May 1983
 DIFFERENTIAL AND DRIVE SHAFT ASSEMBLY

DIFFERENTIAL
CROWN GEAR DIFFERENTIAL
AND PINION CASING

For crown gear and pinion over- Fey differential casing overhauling
hauling procedure refer to: Group 13 procedure refer to: Group 13
- 5-Speed Manual Gearbox - Crown 5Speed M a n u a l G e a r b o x Differ-
Gear and Pinion. ential Casing.

DRIVE SHAFT ASSEMBLY

fl/ %A\ 24.58 + 26.75)

1 Shaft
2 Wheel nut
3 Washer
4 Drive shaft
5 Washers
6 Stopper ring
7 inner race
8 Cage
9 Ball
10 Clamp
11 Boot
12 Clamp
13 Clamp
14 Boot
15 Clamp
16 Inner cover
17 Seal ring
18 Outer ring
19 Inner race
20 Cage
21 Ball @ N*m
2 2 Stopper ring A Outer joint
Ikgmm
23 Outer cover B Inner joint
ftdb)
24 Plate

May 1983 17-2

 DIFFERENTIAL AND DRIVE SHAFT ASSEMBLY

ASSEMBLY
Reassemble joints being careful to fit
parts back into their original posi-
tion, as marked at time of disas-
sembly, and following the procedure
hereafter described.

OUTER JOINT (A)

1. Thoroughly coat with grease
(Molykote VN 2461 C or Optimol
Olistamoly 2 L N 584) the cage, the
Outer cover 4 Inner cover
inner race and the steel balls; pack
Outer ring 5 Plate
Plates retaining 6 Boot the joints recess with 40 g (1.41 oz)
screws of the same type grease.
1 Inner race 3 Outer ring 2. Fit boot on shaft being extreme-
2 Cage ly careful not to damage it in any
Mark outer ring, cage and joints
way along the splines; to this effect
inner race with a reference line to
splines should be covered with tape.
ensure proper positioning when as-
3. Fit lock ring to groove on joints
sembling.
inner race. Make sure lock ring i s
j 6. Use pliers to remove lock ring.
properly and securely lodged in its
Seat on the shaft.
4. Following disassembly proce-
dure in reverse sequence, now fit the
inner race and the cage.
Inner race should be fitted SO that its
face, on which lock ring was previ-
ously fitted, faces to outside of the
joint.
5. Fit steel balls as shown in the
7. Now remove the. constant-speed
CHECKS figure.
joint from the shaft with the help of
a press, two half-plates, a punch and AND INSPECTIONS
a base.
1. Using suitable equipment,
thoroughly clean all joint parts. CAUTION:
2. Check working surfaces and bails Do not exchange this joints steel
for scores or any evidence of wear balls with those of the inner joint as
due to friction of foreign matter; theirdiameter is different.
replace the joint, if necessary.
Remember that broken boots will
cause loss of lubricant and will also
allow foreign matter to enter which,
in turn, will cause faulty operation of
the constant-speed joints; usually this
problem is easily detected during
testing.
3. Make sure that play in both
joints is not too much since excessive
8. Slip boot off the shaft and play is the cause of noise during
remove inner cover from the joint. sudden torque reversal; this is evi-
9. Remove both seal rings from the denced by a knocking sound which is
joints outer ring. easily detected during testing.
10. Remove steel balls from the Should disassembly by required, it is
joint and then disassemble the joint advisable to replace the joint protect-
into its different components: outer ing boots as well as the seal rings on
ring 0, cage 0, and inner the constant-speed joint on gearbox-
race 1 0. differential side.

May 1983 17-4

 DIFFERENTIAL AND DRIVE SHAFT ASSEMBLY
6. Fit washers on shaft, wheel side,
according to numbering marked at
time of disassembly. Now fit the
constant-speed joint with the help of
a press, of two half-plates and of tool
A.3.0605.
7. Finish up lubricating by packing
joint with 40 g (1.41 02) more of the
above mentioned grease and make
sure that balls are completely sur-
rounded by grease.
8. Fit boot on joint; fit new clamps
and tighten them using suitable pliers
being careful not to damage the boot
in doing so.
INNER JOINT (B)
Thoroughly coat with grease (Moly-
kote 2461 C or Optimal Olistamoly 2
I- N 584) the cage, the inner race and
the steel balls; pack the joints recess
with 40 g (1.41 02) of the same type
grease.
1. Fit boot on shaft being extreme-
ly careful not to damage it in any
way along the splines; to this effect
splines should be covered with tape.
2. Following disassembly proce-
dure in reverse sequence, now fit the
inner race and the cage.
3. Fit steel balls as shown in the
figure and verify that the joint works
properly.
CAUTION:
Do not exchange this joints steel
balls with those of the outer joint as
their diameter is different.
4. Fit inner cover to the joint and
then fit the latter on the shaft with
the help of a press, of two half-
plates, of a base and a punch.
5. Pack joint with 40 g (1.41 02)
more of the above mentioned grease
and make sure that balls are
completely surrounded by grease.
6. Fit both seal rings on the joints
outer ring.
17-S
7. Fit lock ring following disas-
sembly procedure in reverse se-
quence.
8. Fit the boot; fit new clamps and
tighten them using suitable pliers
being careful not to damage the boot
in doing so.
9. Fit the three plates to the inner
cover, insert relevant screws and
washers, and lastly fit the outer cover
onto the six screws.
INSTALLATION
1. Insert shaft into wheel hub.
2. Connect shaft to differential
drive shaft and lock securing screws
to specified torque.
@ : Tightening torque
33 -F 36 N-m
(3.4 + 3.7 kg-m
24.56 f 26.75 ft-lb)
3. By means of a new nut, secure
wheel hub to shaft. Tighten nut to
specified torque, then caulk it.
0: Tightening torque
226 + 275 Ndrn
(23+ 28 kg-m
166.30 + 202.46 ft.lb)
May 1983
 DIFFERENTIAL AND DRIVE SHAFT ASSEMBLY

SERVICE DATA AND SPECIFICATIONS

GENERAL SPECIF~ICATIONS
FLUIDS AND LUBRICANTS

Application TVP~ Denomination Q.ty

Drive shaft assembly constant-speed GREASE Molykote VN 2461 C 8Q 9

joints (for each joint) or Optimal Olistamoly 2 LN 584 (2.82 oz)
Std. No. 3671-69843

Split grease quantity between the two

sides of each joint;s crown of steel balls

TIGHTENING TORQUES

N.m

Screws securing (in oil), with outer spacer, drive 33 + 36 3.4 + 3.7 24.58 + 26.75
shaft assembly to differential shaft

Nuts securing drive shaft assembly to wheel hub 226 + 275 23 f 28 166.30 + 202.46

TROUBLE DIAGNOSIS AND CORRECTIONS

Condition Probable cause Corrective action

Necking during sudden torque l Too much play between seats and Replace the joint
reversal steel balls

l No r enough lubricating grease and Smear with grease and replace boots
leakage from the boots

SPECIAL SERVICE TOOLS

Refer to
Tool number Tool name
we

A.3.0605 Base for withdrawal and fitmend of drive

shaft from constant speed joint.

May 1983 17-6

 FRONT SUSPENSION

CONTENTS

DESCRIPTION . . . . . . . . . . . . . . . . . . . 21-2 SERVICE DATA AND

FRONT WHEELS HUB . . . . . . . . . . . . . 21-3 SPECIFICATIONS . . . . . . . . . . n . . . . . 21-9
Removal . . . . . . . . . . . . . . . . . . . . . 21-4 Technical data . . . . . . . . . . . . . . . . . 21-9
Disassembly. . . . . . . . . . . . . . . . . . . 21-4 General specifications _ . . . . . . . . . . 21-10
Checks and inspections . . . . . . . . . . 21-5 Checks and inspections _ . . . . . . . . . 21-10
Assembly . . . . . . . . . . . . . . . . . . . . . 21-5 Tightening torques . . . . . . . . . . . . . 21-11
Installation ................... 21-6 TROUBLE DIAGNOSIS AND
FRONT SUSPENSION . . . . . . . . . . . . . 21-6 CORRECTIONS . . . . . . . . . . . . . . _ _ . . 21-l 1
Coil spring and shock absorber . . . . 21-6 SPECIAL. SERVICE TOOLS . . . . . . . . . 21-13
Transverse and semi-trailing link . . . 21-8

Refer to Group 00 - Chassis and Body Maintenance

for:

l Checking Suspension Height

l Wheel Alignment

May 1983
 FRONT SUSPENSION

DESCRIPTION

1 Coil spring IO Wheel cover

2 Steering lever 11 Bearing
3 Strut 12 Hub nut
4 JOIre boot 13 Wheel hub
5 Shaft 14 Wheel screw
6 Semi-trailing link 15 Brake disc
7 Transverse link 16 Dust cover
8 Ball joint 17 Rim
9 Hub support

May 1983 21-2

 FRONT SUSPENSION

5. Withdraw bearing from hub

support by means of press puller -
A.3.0302 and two plates. I

- A.3.0330

6. Reclamp hub in vice and using a

suitable tool withdraw bearing inner
race.
1 Hub support 2 Hub

1 Hub support 2 Bearing

5. Lubricate seal ring outer surface

with prescribed oil (AGIP Fl Rotra
HP SAE 8OW90 or IP Pontiax HD
2. Clamp hub support in vice pro- 8OW90) and fit ring it its seat on hub
vided with jaws, fit a new ring and support by means of tool A.3.0330.
using octagonal spanner A.5.0239
screw ring nut into its seat on sup-
port, tightening it to the specified
torque.
3. Caulk ring nut edge.

@ : Tightening torque
Bearing ring nut
226 + 225 N-m
(23 + 27 kg-m
116.3 + 195.2 ft-lb)

CHECKS
AND INSPECTIONS
l . Carefully clean hub and hub
support and visually check surfaces
for damage. Replace damaged parts,
if required.
2. Replace, at any rate, bearing
assembly, ring nut and seal ring.

ASSEMBLY
6. Clamp hub support in vice
1. Fit new bearing @ to hub 4. Insert support 0 into relevant
provided with jaws and fit dust cover
support @ by means of press, tool hub @ using press, tool A.3.0330
and brake disc.
A-3.0330 and stand A.3.0415. and plate.

21-5 May 1983

 FRONT SUSPENSION

INSTALLATION Nut securing semi-trailing link (2) Connect shaft to differential

1. Reinstall hub-hub support as-
sembly in the reverse order of
removal and tighten following parts
to the specified torque values:
@ : Tightening torques
Nuts securing vertical guide to
bdy
12+ 1 5 N-m
(I,2 f I,5 kgpm
El,84 + 11 ft.lb)
Screws securing hub support to
strut braket
39-48 N - m
(4 + 4.9 kg-m
28.9 f 35.43 ft.lb)
ball joint to hub support drive shaft by locking the six secur-
39-48 N - m ing screws to the designed torque.
(4s4.9 kg-m (3) By means of a NW nut, secure
29.9 + 35.43 ft.lb) shaft to wheel hub. Tighten nut to
designed torque and caulk it.
2. Refit caliper to hub support.
@ : Tightening torques
@t Tightening torque Screws securing drive shaft to
Screw fixing caliper on hub differential shaft
support 33+36 N - m
59 G-74 N - m (3.4 + 3.7 kg-m
(6 + 7.5 kg-m 24.58 + 26.75 ft.lb)
43.4 + 54.2 ft.lb)
Nut securing wheel hub to
3. Refit shaft, by doeing as fol- shaft
lows: 2 2 6 + 275 N-m
(1) Insert splined end into wheel (23 + 28 kg-m
hub. 116.3 + 202.5 ft.lb)

FRONT SUSPENSION
COIL SPRING AND SHOCK ABSORBER

39.05 + 62.91) 28.9 f 35.43)

39.05 + 62.91k

I

.lj

@ N-m
(kg-m
ftlb)
39.05 + 62.91)
1 Washer 10 Lower washer 19 Strut bracket
2 Upper washer 11 Rubber bound bumper 20 Flexible bush
3 Rubber support 12 Lower cap 21 Semi-trailing link
4 Complementary retainer 13 Lower retainer 22 Ball joint
5 Retainer 14 Thrust bearing 23 Flexible bush
6 Rubber seat 15 Bearing washer 24 Transverse link
7 Upper cap 16 Seal ring 25 Flexible bush
8 Boot 17 Strut
9 Spring 18 Steering lever

May 1983 21-6

 FRONT SUSPENSION

REMOVAL 6. Hold strut properly, then loosen A.2.0251

1. Place car on lift, block rear and unscrew the four screws 0 7
wheels, jack up front of vehicle, then securing strut bracket to hub sup-
support it by stands placed in adja- port.
cent position to jacking points (refer
to: Group 00 - Lifting Points and
Towing).
2. Remove four screws and wheel.
3. Unscrew nut securing ball pin of
steering track rod @ to lever @ of
strut 0.
4 . U s i n g A . 3 . 0 1 5 6 puller with-
draw upwards pin of steering track
r o d @ to lever @ of strut 0.
1 Securing nut 2 Tool nut

3. Withdraw following parts (refer

1 Screw
1 Strut 3 Ball joint
2 Strut lever 4 Steering track rod
5. Operating withing engine com-
partment, loosen and remove four DISASSEMBLY
nuts @ securing strut to body 0. Clamp strut in vice and carry out
disassembly as follows:
1. Hook spring bytool A.2.0251
and screw two nuts @ of tool so as
to progressively compress spring until
-upper cap is released.
to figure of page 21-6 1: washer 0,
upper -washer 01 rubber sup-
p o r t 0, c o m p l e m e n t a r y r e t a i n -
e r @, lower washer 0, w i t h
b o o t @, s p r i n g r u b b e r seat @
with relevant retainer 5 0 and
cap 0, rubber bound bumper 0 ,
spring @ with relevant lower
cap @ secured to compression
tool.
If required, gradually release spring
from tool, then separate spring from
lower cap.
Then remove lever retainer 13 0
from spring lower cap.
4. Referring to the following fig-
ure, dismantle cap retainer 0 to
following parts, taking care in
numbering them and mark direction
to be kept during assembly: roller
thrust bearing @ , bearing wash-
er @ and lower seal ring @ .
Mark lower capas SO as to identify
them during assembly.

WARNING:
Compress spring as minimum as
possible so as to allow upper cap
rotation with relevant gasket and
retainer.
When compressing spring, ensure that
tool is always hooked firmly to
spring and lower cap.

2. Unscrew shock absorber securing

1 Lower retainer 3 Bearing washer
nut @ as shown on following
2 Thrust bearing 4 Seal ring
1 Body 2 Nut figure.

21-7 May 1983


CHECKS AND INSPECTIONS
Clean all the components.
.;- Self-lubricating bush
j..
Check self-lubricating bushes embod-
;..;,,,ied in strut lower cap retainers for
: signs of excessive wear which are
showed by metallic dust appearing
,,- onbush working surface.
Shock absorber
If required verified setting data re-
levant to shock absorber built-in
strut. (Refer to Service Data and
Specifications-Checks and Inspec-
tions).
Replace shock absorber in case they
are removed because of inefficiency
or oil leakages are detected.
Springs
Visually check springs for anomalous
,
signs.
Rubber parts
Replace rubber parts if deformed,
damaged or aged.
ASSEMBLY
1. Lubricate seal ring and thrust
bearing of spring lower cap 0
retainer with grease (AGIP Fl Grease
33 FD, IP Atitogrease FD).
Refit all parts of retainer to strut
complying with direction and order
marked during disassembly.
2. If previously removed, refit tool
A.2.0251 to spring @ and lower
cap @ with tool clamped in vice;
compress spring so that subsequent
assembly procedure can be carried
out.
A.2.0251
1 2 8 . 9 + 3 5 . 4 3 ft.lb)
ro
1 Lower cap 2 Spring
May 1983
FRONT SUSPENSION
Refit remaining parts of strut .as- 2. Remove wheel from the opera-
sembly complying with sequence tive side.
shown on figure. 3. Loosen and remove shaft secur-
ing nut (wheel side).
4. Detach constant-speed joint
from differential drive shaft by
loosening the six securing screws
and remove shaft.
5. Remove nut securing semi-trail-
ing link ball joint pin @ to hub
support and withdraw pin using tool
A.3.0157.
6. Loosen bolt @ securing trans-
verse link @ to engine cross mem-
ber @ and bolt @ securing to
semi-trailing link @ , then with-
draw the removing transverse link.
7. Loosen bolt @ securing semi-
trailing link to body and remove the
link.
Spring lower and upper caps should
be those corresponding with the-side
.(righthand .or l&hand) to which
strut is installed.
INSTALLATION
1, Install strut in the reverse order
of removal and tighten following
parts to the specified torque:
@ : Tightening torque
Screw securing hub support to 1 Cross member 5 Bolt
strut bracket 2 Bolt 6 Semi-trailing link
3 Transverse link 7 Bolt
39t48 N - m
4 Fin
(4 + 4.9 kg-m
28.9: 35.43 ft-lb)
8. If required, after checking flex-
Nut securing strut to body
ible joints: remove flexible joints
12+ 15 N-m from semi-trailing links and trans-
(I,2 + I,5 kg-m verse jinks by means of proper tool.
8,84 + 11 ft.lb)
Nut, steering tie rod ball joint
on bracket lever
39 + 48 N-m
(4 + 4.9 kg-m
TRANSVERSE AND
SEMI-TRAILING LINK
REMOVAL
1. Place car on lift. Support front
of vehicle on stands sited in adjacent
-position to jacking points and block
rear wheels by hand brake.
21-8
 FRONT SUSPENSION

CHECKS AND INSPECTIONS @ : Tightening torque

Clean all the components
1. Visually check semi-trailing links
and front transverse links for blows,
deformations, oxidation, cracks.
2. Examine condition of flexible
bushes in semi-trailing and transverse
link knuckles.
3. Check that semi-trailing link ball
joint pivots free from crawlings or
with notable slack in its seat.
Avoid flexible joints coming into
contact with oil or grease.
INSTALLATION
1. If previously removed, it flexible
joints, inserting them from the
chamfered side, to semi-trailing link
and front transverse link.
Screw securing semi-trailing
CAUTION: link ball joint pin to wheel
To ease joints installation, lubricate support
outer surface with the fluid pre- 39+448 N-m
scribed for rubber parts fitting to (4 + 4.9 kg-m
metallic seats (MILLOIL Slider for 28.9 4 35.43 ftdlb)
rubber sections; UNION CARBIDE
CHEMICALS COMPANY Ucon Lu- Screw securing transverse and
bricant 50 HB - 5100). semi-trailing links
53+ 8 5 N-m
( 5 . 4 + 8 . 7 kgm
2. Install transverse links and semi-
39.05 + 62.91 ftlb)
trailing links to body in reverse order
of removal and torque-tighten screw
3. Refit drive shaft (see: Front
securing semi-trailing link ball joint
pin to wheel support to the specified Wheels Hub - Assembly).
values.
Tighten fixing points of semitrailing
and transverse link flexible joints to
specified torque with car having its
nominal height (see: Car Height).

SERVICE DATA AND SPECIFICATIONS

TECHNICAL DATA

COIL SPRING SHOCK ABSORBER

Wire diameter mm (in) 13.6 (0.535) Shock absorber type hydraulic

Coil diameter mm (in) 160 (6.299) Piston rod diameter mm (in) 20 (0.787)
Free length mm (in) 293 (I 1.535) Stroke mm (in) 148.5 (5.846)
Stiffness N/mm 24.5
Wmml (2.51
(lb/in) (140)
 FRONT SUSPENSION

GENERAL SPECIFICATIONS

FLUIDS AND LUBRICANTS

Application TYPe Denomination Q.W

I I

Seal ring and spring lower cap retainer GREASE AGIP Fl Grease 33 FD -
thrust bearing IP Autogrease FD
Norm. 3671-69833134

Hub support seal ring outer surface FLUID AGIP Fl ROTRA HP SAE 8OW90
IP Pontiax HD 8OW90
Norm. 3631-69408

Outer surface of the semitrailing link FLUID MILL01 L: Slider for rubber sections -
and front link silent block UNION CARBIDE CHEMICALS COMPANY
Ucon Lubricant 50 HB-5100
Norm. 1500-l 7502

CHECKS AND INSPECTIONS

DATA OF SHOCK ABSORBERS SETTING

SHOCK ABSORBER I LEFT RIGHT

I I

Alfa Romeo Part Number 542.353 I 542.352

Compression N (kg) (lb) 1 0 7 . 9 + 1 8 6 . 4 (11 + 19) (24.25+ 4 1 . 8 9 )

Low speed
Expansion N (kg) (lb) 215.X + 3 1 3 . 9 ( 2 2 + 3 2 ) ( 4 8 . 5 + 70.55)

Compression N (kg) (lb) 421.83559.2 (43 + 5 7 1 ( 9 4 . 8 + 1 2 5 . 7 )

High speed
Expansion N {kg) (lb) 1128.15G1324.3 (115 + 135) ( 2 5 3 . 5 + 2 9 7 . 6 )

NOTE: The shock absorbers are integrated in the strut tubes

May 1983 21-10

 FRONT SUSPENSION

Trouble Probable cause Corrective action

Steering wheel shocks,
vibrations or shimmying
(cont.)
l Excessive play in steering linkage Check and replace if required
Tighten
l Loose screws securing steering
box
l Unserviceable shock absorber or Tighten or replace
loose securing points

Vehicle drifts or wanders Drifting becomes evident when vehicle is running on a flat surface with hands
off steering wheel. Reference should also be made to: Group 25 - Trouble
Diagnosis and Corrections

l Worn or faulty tire Replace

Steering wheel excessive play
l Improper tire air pressure and/or Adjust and/or tighten
loose wheel nuts
l Difference in height between right Replace tire with thinnest tread
and left tire tread
l Asymmetric suspension height Restore
l Incorrect steering geometry Restore
l Brake dragging Check and restore working conditions
l Worn suspension linkage flexible Replace worn components
bush
l Connection steering-suspension Replace faulty components
faulty
l Pinion-rack mating incorrectly Adjust
adjusted
l Worn steering components Replace worn components
l Loose steering box securing Tighten
screws

Noise l Improper tire air pressure Adjust

l Damaged and worn ball pin or Replace or lubricate
steering parts; or lack in lubri-
cation
l Loose steering or suspension Tighten
linkage
l Faulty shock absorber Replace
l Faulty wheel bearing Replace
l Faulty suspension linkage bush Replace
l Damaged coil springs Replace
l Loose shock absorber securing nut Tighten

Tires squeal when taking l Improper tire air pressure Adjust

a curve l Incorrect steering geometry Restore
l Incorrect driving Avoid incorrect driving

Abnormal tires wear l Refer to: Group 28-Wheels and Wheels and tires
(or uneven) Tires

May 1983 21-12

 FRONT SUSPENSION

Trouble Probable cause Corrective action

Stiff steering wheel l Improper tire air pressure Adjust

l Excessively worn tire Replace
l Pinion-rack mating incorrectly Adjust
adjusted

After these preliminary operations, if trouble persists, check and operate as

follows.
Jack up front of vehicle and support on safety stands. Separate strut knuckled
arm from track rod and move steering wheel.
a) If steering wheel is light to move, check and locate cause of trouble in steer-
ing linkage, suspension or front axle
b) If steering wheel is hard to move, check and locate cause of trouble in steer-
ing box or steering column.

Improper steering boxlubrication Lubricate

or/and oil contamination (b)
Improper steering linkage lubri- Correctly lubricate, replace grease
cation, grease contamination or or worn parts
abnormal steering wheel wear (a)
Worn or seized ball pin (a) Replace
Deformed steering linkage (a) Replace
Incorrect steering geometry (a) Restore
1

SPECIAL SERVICE TOOLS

Refer to
Tool number Tool name
I page

A.2.0251 Tool for compressing and retaining spring

A.3.0156 Puller of upper pin from stub axle

A.3.0157 Puller of wheel hub support lower joint

pin

21-13 May 1983

 FRONT SUSPENSION

Refer to
Tool number Tool name
Page

A30302 Puller/driver of cup of front hub 21-5

bearings

A.3.0330 Driver of seal and bearing of front hubs 0 \ 21-5

I
(to be used with A.3.0415)
\

IO
21-5
A.3.0415 Base of withdrawal fitment (to be used
with driver A.3.0330)

cl

21-5
A.5.0239 Wrench for bearing front hub nuts

May 1983 21-14

 FRONT AND REAR BRAKES

CONTENTS

DESCRIPTION . . . . . . . . . . . . . . . . . . . 22-2 Control lever . . . . . . . . . . . . . . . . . . 22-17

Brake system bleeding . . . . . . . . . . . 22-3 Control cables . . . . . . . . . . . . . . . . . 22-18
Pedal assembly . . . . . . . . . . . . . . . . 22-4 SERVICE DATA AND
Brake master cylinder . . . . . . . . . . . 22-6 SPECIFICATIONS . . . . . . . . . . . . . . . . 22-l 9
Hydraulic system piping . . . . . . . . . 22-8 General specifications . . . . . . . . . . . 22-19
Brake pressure regulator valve . . . . . 22-8 Inspection and adjustment . . . . . . . 22-20
Servobrake . . . . . . . . . . . . . . . . . . . 22-9 Tightening torques . . . . . . . . . . . . . 22-21
Vacuum system . . . . . . . . . . . . . . . . 22-l 0 TROUBLE DIAGNOSIS AND
Front disc brake . . . . . . . . . . . . . . . 22-10 CORRECTIONS . . . . . . . . . . . . . . . . . . 22-22
Rear drum brake . . . . . . . . . . . . . . . 22-15 SPECIAL SERVICE TOOLS . . . . . . . . . 22-26
PARKING BRAKE . . . . . . . . . . . . . . . . 22-17

Refer to Group 00 - Chassis and Body Maintenance

for:
l Brake System

Mav 1 9 8 3
 FRONT AND REAR BRAKES

SERVICE BRAKE

the pedal all the way down; now

BRAKE
SYSTEM BLEEDING
Bleed brakes following the procedure
described hereafter and being careful
to perform the following:
a. Check that during bleeding the
fluid level in the reservoir does
not go below the MIN level.
tighten the bleeders.
It is up to the operator whether to
carry out the operation by operating
at the same time or separately on the
fire bleeder screws.
you feel a direct action on the fluid
CAUTION:
During bleeding operation always
keep the level of fluid in reservoir
above the Ml N level.
(3) Remove hoses from bleeders and
fit relevant caps.
5. Press brake pedal all the way
down and check whether; immediate-
ly after the pedals initial free travel,
without elasticity, if not so, repeat
bleeding operation.
6. Restore fluid level in the reser-
voir and close it with relevant cap.

b. Do not reuse the oil drained

during bleeding operation.
c. Work with extreme care in order
to avoid damaging painted sur-
faces through contact with the
fluid.

1. Place car on a lift.

2. If required, refill reservoir with
specified fluid (ATE S or AGIP Fl
Brake Fluid Super DE or IP Auto
Fluid FR).
3. Remove dust covers from bleed-
ers located on calipers or on wheel
cylinders.
4. Carry out bleeding operations
closely following the instructions
described hereafter.
(1) Fit a small hose to the bleeder of
each front brake caliper, of each rear
wheel cylinder, and of bleed screw of
brake pressure regulator. Place the
hose other end into a transparent
container previously partially filled
with specified brake fluid.
(2) Loosen the above mentioned
bleeders and press a few times the
brake pedal all the way down,
releasing it very slowly and waiting a
few moments in between pressings.
Repeat this operation till the fluid
coming out of the hoses is free of air
bubbles and then press once more

22-3 May 1983

 FRONT AND REAR BRAKES

PEDAL ASSEMBLY

@ N-m
(kg-m
ft-lb)

1 Retainer 7 Bull ring 13 Brake pedal

2 Washer 8 Spacer 14 Bull ring
3 Gasket 9 Accelerator pedal 15 Spring
4 Pedal assy bracket 10 Bolt 16 Spacer
5 Stop light switch 11 Plastic bush 17 Clutch pedal
6 Pin 12 Pin

DISASSEMBLY b. Passenger compartment

Carry out removal of pedal assembly 1. Separate from accelerator pedal
operating as follows: the control cable @ and release
electric connection @ of the stop
a. Engine seat light switch.
1. Disconnect electrical wiring @ 2. By removing retaining rings,
of brake fluid level warning light and return springs and connecting pins
with a syringe take out all brake and disconnect the brake and clutch
clutch fluid from reservoir @ pedals from control forks @
2. Unscrew unions @ connecting a n d @ o f t h e r e l e v a n t master
the four pipes that start out from the cylinders.
brake master cylinder 0. F r o m 3. By unscrewing the four securing
clutch master cylinder @ remove nuts 0, separate from pedal
the pipe @ and the hose @ con- assembly the servobrake - braker
necting it to the reservoir. master cylinder unit.
3. From servobrake remove the 4. By unscrewing the two securing
sleeve 90 connected to the vacuum b o l t s @ remove clutch master
intake pipe. cylinder from pedal assembly.
4. R e m o v e s c r e w
@ securing 5. Unscrew the six nuts (set in
sheath clamp plate of the accelerator evidence by figure) securing pedal
control cab le. assembly to body and remove
1 Hose 5 Brake master pedal assembly from engine seat.
2 Clutch master cylinder 6. Remove, if necessary, the acce-
cylinder 6 Brake liquid tank lerator pedal from hinge to pedal
3 Pipe 7 Electric cables
assembly support by unscrewing
4 Pipe unions 8 Screw
9 Sleeve bolt @.

May 1983 22-4

 FRONT AND REAR BRAKES

CHECKS AND INSPECTION 4. Lubricate end of accelerator

cable before connecting it to pedal.
1. Verify condition of pedals, of
Then, after securing the sheath clamp
pedal assembly and gasket.
plate to pedal assembly, adjust its
2. Check against presence of ex
travel (see: Group 04 - Accelerator
cessive wear and mesh in bushes, pin
Control Adjustment).
and spacer.
5. Tighten to the prescribed torque
3. Check against presence of yield
the unions of brake master cylinder
in return springs.
pipes and the union of clutch master
4. If necessary, remove and replace
cylinder pipe.
the stop light switch.

0: Tightening torques
Unions of brake master cylin-
REASSEMBLY der pipes
For pedal assembly, reassembly, 8+10 N - m
reverse the order of disassembly and (0.8+ 1 kgam
apply a coat of the prescribed 5.78 + 7.23 ft.lb)
grease (AGIP Fl Grease 15) to the
1 Electric 5 Clutch master parts subject to sliding and to return Union of clutch master cylin-
connection cylinder fork springs. der pipe
2 Cable 6 Brake master 15 + 1 9 N - m
3 Nut cylinder fork (1.5+ 1.9 kg-m
4 Bolt
10.85 + 13.74 ft-lb)
INSTALLATION
1. Reinstall pedal assembly to body 6. Fill the brake and clutch oil tank
by reversing order of removal and up to maximum level.
complying with the following. 7. Carry out bleeding of brake
DISASSEMBLY
(1) Replace, if required, the gasket hydraulic system (see: Brake System
Disassemble pedal assembly operat- between pedal assembly and body. Bleeding) and of clutch (see: Group
ing as follows: (2) Tighten, to the prescribed 12 Hydraulic Control Sub-assembly
1. Remove retainer @ of pedals torque, t h e n u t s secuging p e d a l Hydraulic System Bleeding).
pin @ and washer @ . assembly to body.
2. Withdraw Pin and recover ped-
a l s @ a n d 0, a n d s p a c e r @. 0: Tightening torque of pedal
3. Remove plastic bushes @ from assembly nuts
pedals. 9+15 N-m
( 0 . 9 5 1.5 k g - m
6.51 + 10.85 ft.lb)

(3) Lubricate forks connecting both

brake and clutch pedals to the
relevant master cylinders, with AGIP
Fl G R E A S E 1 5 ; t h e n riconnect
them.
2. Reconnect to pedal assembly the
servobrake together with brake mas-
ter cylinder and then clutch master
cylinder.
3. If previously removed, reconnect
accelerator pedal after lubricating
spacer. Make sure that accelerator
pedal can freely rotate after tight-
ening securing nut to the prescribed
torque.

1 Retainer 5 Pedal 0: Tightening torque

2 Washer 6 Spacer St10 N - m
3 Pin 7 Pedal
(0.8 f 1 kg-m
4 Bush
5 . 7 8 + 7.23 f t - l b )

22-5 May 1983

 FRONT AND REAR BRAKES

BRAKE MASTER CYLINDER

N-m
(h-m
*lb)

1 Level indicator 12 Gasket 23 Washer

2 Reservoir 13 Tab washer 24 Spring
3 Union 14 Lock ring 25 Support disc
4 Seal ring 15 End washer 26 Return spring
5 Spring 16 Gasket 27 Setscrew
6 Support disc 17 Washer 28 Washer
7 Spring 18 H shaped gasket 29 Master cylinder body
8 Washer 19 Bush 30 Filter
9 Gasket 20 Push rod piston 31 Gasket
10 Space sleeve 21 Space sleeve 32 Cap
11 Intermediate piston 22 Gasket

May 1983 22-6

 FRONT AND REAR BRAKES

b. Tighten to the prescribed torque
two new nuts securing brake
master cylinder to servobrake.
(T): Tightening torque
Brake master cylinder nuts to
servobrake
BENDITALIA
12+ 1 5 N-m
(1.2+ 1 . 5 kgmm
8.68 + 10.85 ft4b)
ATE
21 + 28 N-m
(2.1 + 2.9 kg.m
15.2 + 21 ft4b)
c. Pipes must be connected to
master cylinder and tightened to
the indicative prescribed torque.
@ : Tightening torque
Unions securing pipes to brake
master cylinder
8-10 N - m
(0.8 + 1 kgmm
5.78 + 7.23 ft.lb)
d: Fill reservoir up to proper level
using only specified fluid (ATE
S o r AGIP Fl B r a k e F l u i d
Super ED, or IP Auto Fluid FR).
2. Bleed brake system (Refer to:
Brake System Bleeding) and, if
required, also clutch system (Refer
to: Group 12 Subgroup Hydraulic
Control - Hydraulic System
Bleeding).
syringe in order to suck the 3. Loosen and remove bolt @
liquid of brake clutch tank. connecting the Panhard rod @ to
b. A S piping is removed, remember body and loosen the equalizer
to plug up the ends in order to securing bolt @.
avoid foreign matter from en-
tering.
. To remove pipes, loosen unions
on both ends.
. To remove hoses, unscrew
unions collecting pipes-to hoses
and remove them. Then, discon-
nect hose on the other side.
c. At the end of installation on car,
both front and rear flexible
cables must not result to be
kink. For their check, take as
reference the writing with the
relevant manufacturer mark
located on end of pipes, or the
light coloured band (for front
cables) located along pipe itself.
d. Having completed installation of
1 Unions 5 Bolt
piping, fill up brake fluid reser- 6 Bolt
2 Fork
voir to proper level and bleed 3 Spring 7 screws
the brakes (Refer to: Brake 4 Panhard rod
System Bleeding).
4 . L o w e r Panhard bar in order to
Tightening torques
easy spring @ withdrawing from
Hose unions of brake hydraulic
pin 0, and from rubber ring @
system
located on rod itself. Remove spring
IO+ 1 5 N - m
by withdrawing i t f r o m equaliz-
(1 + 1.5 kgmm
7.23 + 10.85 ft-lb)
er 0 4
5. If necessary, remove bolt @
and equaliter.
Pipe unions of brake hydraulic
system
8+10 N - m
(O-S+ 1 kg-m
5.78 + 7.23 ft.lb)

HYDRAULIC 1 Spring 4 Equalizer

2 Ring
SYSTEM PIPING 5 Bolt
BRAKE PRESSURE 3 Pin

CHECKS AND INSPECTIONS REGULATOR VALVE

Thoroughly check all brake system
piping (pipes and hoses) making sure
they are not out of shape or cracked
and that outer surfaces of pipes do
not show any evidence of oxidation.
Replace parts that are not flawless.
REMOVAL AND
INSTALLATION
CAUTION:
a. In case of removal or reinstal-
lation of brake pipings, use a
REMOVAL
1. Unscrew the three unions 1 of 0
the brake pressure regulator pipes,
taking care to close, by means of
caps, the two feeding pipes of brake
pressure regulator, in o r d e r t o
prevent tank emptying.
2. Remove from body, the brake
pressure regulator valve by unscrew-
ing the two securing screws @ and
removing f o r k @ f r o m c o n t r o l
spring 0.
CAUTION:
Do not disassemble components of
the brake pressure regulator.
INSTALLATION
1. Reinstall to body the brake
pressure regulator valve by tightening
bolts to the prescribed torque:
15 + 24 N.m ( 1 . 5 + 2 . 4 kg.m)
( 1 0 . 8 5 + 1 7 . 3 5 ft.lb) a n d ( i f pre-

May 1983 22-8

 FRONT AND REAR BRAKES

INSTALLATION 2. Remove non-return valve (iJ so that the crawfoot in the above
after having removti relevant figure points towards the intake
1. On bank, reconnect master cyl-
clips 0, manifold _
inder to servobrake tightening secur-
ing nuts to the prescribed torque
(see: Brake Master Cylinder - Instal-
lation).
2. For reinstallation on car of the
whole unit, reverse order of removal
and comply with the following.
(1) Tighten unions of pipes to the A Intake manifold side (black)
prescribed torque: IO + 14 N.m B Servobrake side (white)
(1 + 1,4 kg-m) (7.23 + 10.84 ft.lb).
(2) Lubricate connecting pin with
prescribed grease (AGIP Fl GREASE
15); then reconnect fork to brake
pedal.
(3) Restore level of brake fluid; then
carry out bleeding (see: Brake Valve 2 Clips
System Bleeding).
3. Check valve thoroughly making
sure it works properly, meaning that
VACUUM SYSTEM it allows air flow only in the direc-
1. Visually check hoses making tion shown by crawfoot.
sure they are in no way damaged or
clogged; also make sure clips are all 4. When fitting non-return valve
properly tightened. back to hose, be careful to position it

FRONT
DISC BRAKE
DBA CALIPER

@ 59 + 73
(6 + 7.5
43.38 + 54.23)

(0.2 f 0.35
1.45 + 2.53) b

1 Caliper setting 7 Dust cover

@ N.m
clip 8 Piston
(kg+m
2 Caliper support 9 Seal ring
ftilb)
3 Pad 10 Floating caliper
4 Pad retaining 11 Bleeder
clip 12 Bracket
5 Retainers 13 Washer
6 Plate 14 Screw

May 1983 22-10


Pad replacement
I. Lift cars front end positioning it
on safety stands (Refer to: Group 00
- Lifting Points and Towing).
2. Using suitable pliers remove
retainers @ from setting plates 0
as shown in the figure below.
1 Plares 2 Retainers
3. With the help of a punch, push
p l a t e s 0 and @ a n d t a k e them
out.
Plates are not interchangeable.
1 Upper plate 3 Floating caliper
2 Lower plate
4. Press floating caliper so as to
push it toward the lower groove and
then remove it from the support.
1 Caliper support 2 Floating caliper
FRONT AND REAR BRAKES
5. Remove both pads, each with
relevant dowel pin 0, and then
remove pins from pads,
-1
1 Fad dowel pin
CAUTION:
When pads are off, do not push brake
pedal in order to avoid piston from
being ejected from its seat on float-
ing caliper. When replacing pads use
only original spare parts and replace
them on both calipers.
Pad assembly must be carried out by
p o s i t i o n i n g t h e crawfoot i n t h e
forward rotation direction of the
brake disc.
6. Clean pads seats on caliper with
alcohol.
CAUTION:
Do not lubricate in any way either
the pads resting seats on calipers nor
pad dowel pins.
7. Fit dowel pins on pads and then
fit same into relevant seat.
8. Push piston towards its position
into floating caliper.
CAUTION:
To avoid overflow of brake fluid
when the piston is pushed back, it is
advisable to suck some of the fluid
from the reservoir by means a
syringe.
9. Now fit the floating caliper and
both setting plates.
CAUTION:
Do not lubricate setting plates.
10. Fit relevant retainer on each
plate,
22-11
11. Restore proper brake fluid level
in reservoir (ATE S or AGIP Fl
Brake Fluid Super ED or IP Auto
Fluid FR).
CAUTION:
To restore correct braking, push
brake pedal all the way down a few
times.
Caliper unit
REMOVAL
Remove caliper unit as follows:
1. By means of a syringe, suck
brake fluid from feed tank.
2. Disconnect brake fluid hose 0.
3. Loosen and remove the two
screws @ securing caliper unit to
hub support and then remove the
whole caliper unit.
CAUTION:
In case of caliper unit replacement,
make sure that on front axle are
mounted calipers of the same type
only.
1 Securing screws 2 Hose
INSTALLATION
Fit back caliper unit as follows:
1. Fit caliper unit and bracket for
brake fluid hose and then tighten
relevant retaining screws to specified
torque.
0: Tightening torque
Caliper retaining screws
59+73 N-m
(6 + 7.5 kg-m
43.8 f 54.23 ft-lb)
May 1983

2. Connect brake fluid hose (Refer
to: Hydraulic System Piping).
3. Fill brake fluid reservoir up to
max. level (ATE S or AGIP F 1
Brake Fluid Super ED or IP Auto
Fluid FR).
4. Bleed brake system (Refer to:
Brake System Bleeding).
Floating caliper
DISASSEMBLY
If required, carry out disassembly of
brake caliper operating as follows:
1. Empty brake fluid reservoir with
a syringe.
2. Disconnect brake fluid hose.
3. Remove floating caliper (Refer
to: Pad Replacement) and close it in
a vice equipped with protecting jaws.
4. Remove dust cover @ and then
use a jet of compressed air to remove
brake piston @ from cylinder.
5. Remove seal ring @ from its
seat on cylinder.
1 Floating caliper 3 Piston
2 Dust cover 4 Seal ring
May 1983
FRONT AND REAR BRAKES
CHECKS AND INSPECTIONS
Thoroughly wash all parts in alcohol
and dry them with a jet of com-
pressed air.
CAUTION:
Do not use metal tools and deter-
gents containing mineral oil.
Floating caliper body
1. Check cylinder surface for
cracks, evidence of excessive wear
and presence of rust or foreign
matter.
2. T o r e m o v e rust or foreign
matter, clean the surface with a very
fine emery cloth.
3. In case of more severe damage
replace floating caliper body.
4. Check bleeder and make sure it
is in good working condition.
Piston
Check piston outer surface for
cracks, evidence of excessive wear,
deterioration and presence of rust
or foreign matter. In case just one of
above flaws is present, replace the
piston or the whole floating caliper.
CAUTION:
Do not clean piston surface with
emery cloth but go on and replace it.
Seal ring and boot
Replace seal ring and booteach time
they are disassembled.
Caliper support
Check element good condition and
replace it if necessary.
Clips
Make sure they are not damaged or
abnormally worn; replace them if
necessary.
INSTALLATION
If previously disassembled, carry out
reassembly of floating caliper operat-
ing as follows:
1. G r e a s e c y l i n d e r , p i s t o n a n d
sealing ring applying a coat of rhe
prescribed brake grease (Grease ATE
Bremsrylinder Paste or DBA Grease);
fit seal ring on cylinder and then
insert control piston.
22-12
2. Lubricate boot inner surface
with the above mentioned grease,
and fit it into its seat.
3. Fit floating caliper on relevant
support (Refer to: Pad Replace-
ment).
4. Connect oil pipe back to floating
caliper and tighten relevant union to
specified torque; fill reservoir up
with specified brake fluid (ATE S
or AGIP Fl Brake Fluid Super ED or
IP Auto Fluid FR).
0: Tightening torque
Brake pipe to caliper union
IO+14 N-m
(1 + 1.5 kg-m
7.23 f 10.84 ft.lb)
5. Bleed brakes (Refer to: Brake
System Bleeding).
CAUTION:
At the end of installation on car,
make sure that hose are not kink.
Brake disc
REMOVAL AND INSTALLATION
1. Remove from hub support, the
whole brake caliper without discon-
necting it from hose (see: Group 21 -
Front Wheel Hub).
2. Remove brake disc from hub
support after having removed the
dowel pin.
3. Install disc and caliper following
removal procedure in reverse se-
quence.
CHECKS AND INSPECTIONS
1. Thoroughly clean brake discs
and check that working surfaces are
not deeply scored or porous. Replace
or machine them if necessary.
2. Should machining of disc work-
ing surfaces be required, keep in
mind the following:
(1) Always machine both surfaces of
each disc, removing the same amount
of material from each surface.
(2) Machining must be performed
according to tolerances indicated in
the Service Data and Specifications
Section - Checks and Adjustments.

Pad replacement
1. Lift cars front end positioning it
on safety stands (Refer to: Group 00
- Lifting Points and Towing).
2. Using a suitable punch, push pad
d o w e l p i n s @ as shown, in the
figure that follows:
1 Pins
3. Remove, in sequence: the lower
pin, the cross spring plate 0, and
the upper pin.
1 Cross spring plate
4. With suitable pliers, remove the
pad on cylinders side.
5. With a plastic hammer, strike
floating caliper on cylinders side
thus removing the other pad.
1 Pad on cylinders side
2 Brake disc
May 1983
FRONT AND REAR BRAKES
1. Empty brake fluid reservoir with
CAUTION: a syringe.
When pads are off, do not push brake 2. Disconnect brake fluid hose.
pedal in order to avoid piston from 3. Remove pads (Refer to: Pad
being ejected from its seat on float- Replacement).
ing caliper. When replacing pads use 4. With a plastic hammer, strike
only original spare parts and replace floating caliper @ till it comes off
them on both calipers. from its support @ _
Pad assembly shall be carried out by
positioning crawfoot towards the
forward rotation direction of brake
disc.
6. Clean pads seats on caliper with
alcohol.
CAUTION:
Do not lubricate in any way the
pads retaining seats on calipers.
7. Push piston back into floating
caliper.
CAUTION:
1 Floating caliper 2 Caliper support
To avoid overflow of brake fluid
when the piston is pushed back, it is
5. Fit caliper on a vice equipped
advisable to withdraw some of the
with protecting jaws and remove the
fluid from the reservoir with a
dust covers @ lock ring 0 as well
syringe.
as the boot.
6. Use a jet of compressed air to
8. Fit pads into their relevant seat
remove brake piston @ from
and then complete assembly by
cylinder on floating caliper body
fitting, in sequence: the first dowel
a
pin, the cross spring plate, and the
7. Remove seal ring @ from its
second dowel pin.
seat on cylinder.
9. Restore proper brake fluid in
reservoir (ATE S o r -AGIP Fl
Brake Fluid Super ED or IP Auto
Fluid FR).
CAUTION:
To restore correct braking, push
brake pedal all the way down a few
times.
Caliper unit
1 Lock ring 4 Seal ring
REMOVAL AND INSTALLATION 2 Oust cowr 5 Floating caliper
Removal and installation procedures 3 Piston
of ATE calipers are like those of
DBA calipers (Refer to: DBA Caliper
CHECKS AND INSPECTIONS
Removal and Installation).
For checks and inspections of ATE
Floating caliper calipers, refer to: DBA caliper -
Checks and Inspections.
DISASSEMBLY
INSTALLATION
If required, carry out disassembly of
floating caliper, operating as follows. If previously disassembled, carry out
2 2 - 1 4
 FRONT AND REAR BRAKES

assembly of floating caliper, operat- 7. Proceed and complete the as-

ing as follows. sembly fitting the pads and securing
1. Apply a coating of the pre- them by means of relevant dowel
scribed brake grease to cylinder, pins (Refer to: Pad Replacement).
piston and seal ring; fit seal ring on 6. Fill reservoir up with specified
cylinder and then insert control b r a k e f l u i d ( A T E 5 or AGIP Fl
piston. Brake Fluid Super ED or IP Auto
2. Lubricate boot inner surface Fluid FRI.
with the mentioned brake grease; 9. Bleed brakes (Refer to: Brake
then secure it with relevant lock ring. System Bleeding).

Make sure boot and relevant lock CAUTION:

ring are properly fitted. 6. If the step on the piston does
n o t m a t c h t h e square calipers
diagonal, r o t a t e t h e p i s t o n w i t h
3. Fit floating caliper on relevant suitable pliers till the position
support. required by the square caliper is
4. Connect oil pipe back to floating reached.
caliper.
At the end of installation on car,
make sure that hose are not kink.
Brake disc
For all operations concerning brake
discs refer to: DBA Caliper Brake
Disc.

0: Tightening torque
Brake pipe to caliper union
IO+ 14 N-m
(1 + 1.5 kg-m
7.23 + 10.84 ftelb)

5. Using a square caliper with a 2@

angle, v e r i f y t h a t b r a k e c o n t r o l
piston is properly positioned.

REAR DRUM BRAKE

@ N-m
(kg-m
ft.lb)
1 Bleeder cap
2 Bleeder
3 Dust cover
4 Piston 14 Vibration -damping spring
5 Seal ring Vibration - damping spring stop
6 Spring
7 Cylinder body
8 Knuckle pin securing plate
9 Jaw driving plate 19 Adjustment lever
10 Jaw return spring 20 Jaw
11 Spring 21 Shoe holder disc

22-15 May 7983

 FRONT AND REAR BRAKES

JAW REPLACEMENT 6. Disassemble, (if required) the c. On installed drum, adjust dis-
adjustement device, operating as tance between jaw-drum b y

Removal follows: repeatedly operating on brake

(1) Remove retain spring 0, Then pedal.
I. Remove wheel and brake drum
from jaw, withdraw pin @ together d. Adjust travel of parking brake
together with hub (see: Group 25
with spring @ and lever @ of the control lever (see: Group 00
Rear Hub).
adjustment device. Chassis and Body Maimenance).
2. Operating from passenger com-
(2) Remove seal ring @ and
partment, loosen cormol cables of CYLINDER FOR JAW
separate from jaw the swinging le-
parking brake, b y o p e r a t i n g o n OPENING CONTROL
ver 0
1 of the adjustment device.
adjustment nut and lock-nut.
3. Operating from wheel side, re- Removal
The removed seal rings must anyway
lease control cable end @ f r o m
be replaced during reassembly. 1. Remove jaws (see: Jaw Re-
lever @ and release it from fair-
placement - Removal).
lead 0, 2. Disconnect The oil delivery pip-
4. By means of a suitable clamp
ing to j a w o p e n i n g c y l i n d e r , b y
release, in the following order: shoe
operating on union 0, as shown in
upper return spring 0, shoe lower
figure.
return spring @. Remove then the
3. Unscrew and remove the two
jaw vibration _ damping springs 0.
screws @ securing cylinder to brake
holder disc; then remove cylinder.

1 Swinging lever 4 Pin

2 Spring 5 Retain spring
3 Lever 6 Seal ring

7. If previously disassembled, reas-

semble the adjustment device after
1 Screws 2 Union
1 Upper spring 4 Control cable end lubricating the following contact
2 Lever 5 Fairlead surfaces:
,3 Vibration 6 Lower spring . Swinging lever nut and adjust- Disassembly
damping spring
ment device lever nut.
1. Remove dust covers @ f r o m
. Contact surfaces between
cylinder body @, then, pitk up the
adjustment device and swinging
jaw opening control pistons 0,
5. Remove the two jaws from lever.
t o g e t h e r w i t h g a s k e t 0, w h i c h
brake holder disc and if required,
a r e e j e c t e d b y s p r i n g 0; t h e n
separate them, after releasing Installation
withdraw spring itself.
spring 0 from jaw jointing
To correctly position the new jaws 2. Remove bleeder protection
square 0.
on brake holder disc, operate by cap @ and remove bleeder.
reversing o r d e r o f r e m o v a l a n d
coupling with the following:
a. L u b r i c a t e w i t h b r a k e g r e a s e
contact surfaces between the
under mentioned components.
jaws and opening control cyl-
inder.
toothed surfaces of the jaw
adjustment device.
gears of the jaw return springs.
b. On installed jaws, before assem- 5 Spring
1 Dust cover
blying drum, set the adjustment 2 Piston 6 Bleeder
device lever so as to maximum 3 Gasket 7 Cap
1 Spring 2 Square reduce opening of jaws. 4 Cylinder body

May 1983 22-16

 FRONT AND REAR BRAKES

placed between support and body. pin @ c o n n e c t i n g l e v e r @to REINSTALLATION

adjusting fork @ , withdraw pin
with washers from fork and separate
this one from the lever.
2. Unscrew bolt @ securing the
lever to its relevant support @ and
separate the two components.
3 . W i t h d r a w b u s h @ and h a n -
dle @ from lever, remove pin
1 Lever 4 Lock nut
stopper cotter @ on which ratchet
2 Screws 5 Bracket gear paw1 @ rotates and withdraw
3 Nut the pin from its seat.
4. Separate from lever the whole
block of ratchet gear control with
DISASSEMBLY p u s h b u t t o n 0, spring @, stop-
With reference to the following p e r 0, r o d @ a n d pawl 0.
exploded view remove the control 5. If necessary, remove switch of
lever operating as follows. the parking brake indicator from
1. Withdraw cotter pin from brake support.
6 . 5 1 + 10.84)
To reinstall control lever with
support, reverse the order of removal
and complying with the following:
1. Apply a coat of specified grease
(AGIP Fl Grease 15 or S H E L L
R e t i n a x Gll) t o s u r f a c e s w h e r e
cables slide in the incovered section
and to fork adjusting screw.
2. Carry out parking brake adjusT-
ment (see: Group 00 Chassis and
Body Maintenance).
CONTROL CABLES
REMOVAL
1. Operating from the driver s
compartment remove rear console
and, by operating lock nut and
nut of adjustment fork loosen
control cables and withdraw them
from equalizer.
2. Remove rear wheel and drum
together with hub (see: Group 25 -
Rear Hub - Removal).
3. Operating on wheel side release
control cable end @ from lever @
and free it from f a i r - l e a d @.
Release control ,cable from brake
shoe holder 0, withdraw it from
this last and remove it after releasing
it from the underbody clamps.

1 Handle 9 Bush
2 Lever 10 Sector gear
3 Pushbutton 11 Light switch
4 Spring 12 Bolt
5 Stopper 13 support
6 Rod 14 Pin
7 Paw1 15 Adiustment fork
8 Pin

CHECKS AND INSPECTIONS REASSEMBLY

1. Check components visually For reassembly of the support and
against excessive wear and other lever unit, reverse the order of
damages. assembly and, in particular comply
Check, in particular, surface con- with the following:
ditions of the lever coupling bush to 1. Lubricate brake lever bush and
support, and wear conditions of pawl ratchet gear components with speci- 1 Brake shoe 3 Control cable
teeth and scroll gear. fied grease (AGIP Fl Grease @or holder 4 Fair lead
2. Check against presence of elec- SHELL Retinax Gll). 2 Lever
tric cable discontinuity and that 2. Tighten to specified torque of
parking brake indicator switch is 9 t 15 N.m (0.9 + 1.5 kg.m), CHECKS AND INSPECTIONS
properly functioning. (6.51 f 10.84 ft.lb) bolt hinging lever
Make sure that control cables are
3. Replace worn or faulty com- to brake support.
sound; replace them if necessary.
ponents.

May 1983 22-18

 FRONT AND REAR BRAKES

Application Denomination Q.W

Brake pedal hub (inner GI) GREASE AGIP Fl Grease 15

Clutch pedal (inner 0 ) Std. 3671-69810
.Dowel pin connecting brake pedal
to master cylinder control clevis
Spring adjustment square bush for
brake pressure regulator
Spring seat fork on brake pressure regulator

Parking brake cable sliding surfaces GREASE AGIP Fl Grease 15

Knuckle of parking brake cables on rear Std. 3671-69810
brake shoes SHELL RETINAX - G - 11
Terminals of parking brake cables Std. 3671769811
Adjustment fork screw
Screw (or spacer) fixing parking brake
lever to support plate
Parking brake trip
Knuckle bush for parking brake lever

INSPECTION AND ADJUSTMENT

FRONT BRAKES
Brake pad thickness

Brake pad - rotor clearance

- when installing 0.1 mm

(3.94 . lop3 in)

- on operation (clearance
determined by pad auto- 0.05 + 0.2 mm
matic feed) ( 1 . 9 7 low3 + 7.87. 1O-.3 in) Min. S (wear limit or min.
serviceability thickness) 7 mm (0.276 in)

Dimension for brake disc burning

REAR BRAKES

Brake shoe lining min. thickness 0.5 mm (0.02 in)

Drum wear limit dimensions

- max. inner diameter 229.6 mm (9.04 in)

Dimension for brake drum burning

May 1983 22-20

 FRONT AND REAR BRAKES

BRAKE PRESSURE HANDBRAKE LEVER

REGULATOR VALVE ADJUSTMENT

Adjustment. Number of free notches

- Unloaded car on the sector gear before
- Valve piston at end of travel wheels locking 1 G-3
- Load: 60 N (6 kg) (13.22 lb) ap-
plied to hook of fixture A.4.0148

TIGHTENING TORQUES

Unit

Item
N*m I kg*m ft.lb

Unions of brake hydraulic system pipes 8 + 10 0.8 + 1 5.78 f 7.23

Unions of brake hydraulic system (on calipers and

union of shoe holder plate) IO + 15 1 + 1.5 7.23 + 10.84

Union of clutch system pipe 15 + 19 1.5 + 1.9 10.84 + 13.74

Screws retaining caliper to wheel hub 59 f 73 6 f 7.5 43.8 f 54.23

Screw securing front brake disc to wheel hub 6 A 8 0.6 + 0.8 4.34 + 5.78

Bolts securing knuckle pin to axle 3 9 f44 4 + 4.5 28.9 + 32.53

Nut securing pedal assembly unit to body 9 f15 0.9 + 1.5 6.51 + IO.84

Intermediate piston setscrew for ATE

brake master cylinder 5 f. 8 0.5 + 0.8 3.61 + 5.78

Nut jointing brake master cylinder to servobrake

BENDITALIA 12 f 15 1.2 + 1.5 8.67 + 10.84
ATE 21 f 28 2.1 + 2.8 15 + 21

Securing bolt of brake pressure regulator valve 15 f 24 1.5 f 2.4 10.84 t 17.3

Equalizer securing nut 39 f 48 4 + 4.9 28.9 - 35.4

Panhard bar securing bolt 69 f 85 7 + 8.7 50.6 + 62.9

Screws securing wheel cylinder to back plate 6 -5 .9 0.6 + 0.9 4.34 + 6.51

Bolt fixing parking brake lever to support 9 f 15 0.9 + 1.5 6.51 + 10.84

22-2 1 May 1983

 FRONT AND REAR BRAKES

TROUBLE DIAGNOSIS AND C.ORRECTIONS

The following are the indispensable presuppositions for any trouble diagnosis of braking system verification of:

- Tyre wear
- Tyre pressure
- Brake fluid or any way, verification of compliance with programmed maintenance specifications.

Condition Probable cause Corrective action

Excessive pedal travel l Leakage in brake master cylinder Overhaul brake master cylinder

l Leakage in clutch master cylinder Overhaul clutch master cylinder

l Faulty no-return valve of vacuum Replace check valve

system

l Fluid leakage from brake pressure Adjust or replace

regulator

l Fluid leakage from braking system Tighten unions

unions

l Air in system Bleed system

l Faulty brake adjustment Adjust shoe-to-drum clearance

Spongy pedal l Air in system Correct as necessary

l Faulty brake adjustment Adjust shoe-to-drum clearance

l Reservoir filler cap vent hole Clean and bleed system

clogged

l Swollen hose due to deterioration Replace hose and bleed system

or use of poor quality hose

l Distorted brake shoes, or exces- Replace faulty parts

sively worn or cracked brake
drum

0 Soft or swollen caliper seals Drain hydraulic system, flush with

alcohol and replace all seals

l Use of a brake fluid with too low Replace with specified brake fluid
boiling point and bleed system

Poor braking effect l Fluid leakage in brake lines Check master cylinder, piping and
wheel cylinder for leaks, and repair

l Air in brake lines Bleed system

l Excessive shoe-to-drum clearance Adjust

l Grease oil mud or water on lin- Clean brake mechanism and check for
ings or pads cause of problem. Replace lrnrngs or
pads

22-22
 FRONT AND REAR BRAKES

Condition Probable cause Corrective action

Poor braking effect l Deterioration of linings or pads Replace linings and/or pads. If neces-
(continued) sary grind discs a n d t u r n d r u m s

l Local fit of linings or pads Replace linings and/or pads. If neces-

sary grind discs and turn drums

l Master cylinder or wheel cylinders Repair or replace

in poor condition

l Frozen or seized caliper pistons Disassemble caliper and free up as

on disc brakes required

l Binding mechanical linkage at Free up as required

brake pedal and shoes

Unbalanced brakes l Improper tire inflation Inflate to correct pressure

l Improper adjustment of shoes-to- Readjust

drum clearance

l Grease oil mud or water on linings Clean brake mechanism and check for
or pads cause of problem. Replace linings or
pads

l Mud in brake drum Clean

l Excessive wear or deterioration of Replace

linings or pads

l Wheel cylinder in poor condition Repair or replace

l Poor sliding condition of brake Adjust

shoe

l Looseness of cylinder body or Fasten or replace

back plate securing bolts/nuts

l Scored or out-of-round drums Recondition or replace brake drum as

required. Check for improper lining
contact with drum and grind lining if
necessary

l Brake pressure regulator incor- Adjust or overhaul (if required) or

rectly adjusted or not efficient replace brake pressure regulator

l Deteriorated wheel cylinder seal Recondition or replace cylinder

rings

l Incorrect adjustment of wheel Adjust

bearings

l Incorrect adjustment of wheel Adjust

alignment

Brakes fade Use of improper linings or brake Replace linings

linings are contaminated
 FRONT AND REAR BRAKES

Condition Probable cause Corrective action

Pedal pulsates l Out-of-rround or off-center drum Fur-n drum or replace as necessary

l On disc brakes, lateral runout of Check with dial indicator, turning disc
brake rotor is excessive my hand. If runout exceeds specifica-
ions, repair or replace disc

l Excessive variation in thickness of illeasure around disc face with micro-

brake rotor surfaces neter. Replace disc as required

Rear lock (Under light brake Faulty brake pressure regulator ?eplace
pedal force)

Rear lock (Under heavy l Poor front braking effect Disassemble and adjust front brakes
brake pedal force)
l Grease oil mud or water on linings Jean or replace
or pads

l Excessrve wear of linings or pads 3eplace

l Local fit of linings or pads shave or [replace

l Master cylinder or wheel cyllndet 3epair or replace

In poor condition

Servobrake out of order l Air leakage at check valve nspect check valve

l Ait- leakaye at seal ring between Replace set-vobrake assembly

vacuum box and control body

l Air leakage at disc valve

l A i r l e a k a g e a t p i s t o n s e a l riny

l Air leakage at seal ring between Replace seal ring

master cylinder and servobrake

l D a m a g e d prplng o r c o n n e c t o r s Repair or replace

Not adjustable engine idle Engine sucks air through servobrake Replace check valve or servobrake as-
speed (no leakage at con- semblv
nectors)

Parking brake does not brake l Impt-opet- adjustment Adjust

l Front and rear cables damaged or Replace cables

broken

l Faulty connection of rear cables Check cable connection

to brakes

When parking brake control l Shoes are jammed on drums Unlock or replace faulty parts
lever is released, the car re-
l Return travel of cables is ob- Remove obstacle and replace cables
mains braked
structed

22-25 May 1983

 FRONT AND REAR BRAKES

Condition Probable cause Corrective action

-
When parking brake control l Control lever release pushbutton Disassemble lever, and release or re-
lever is released, the car re- does nor spring back place if
mains braked
(continued)

The brake ON indicator does l Wires disconnected Restore connection

not illuminate
l Faulty switch Replace

l Faulty lamp Replace

SPECIAL SERVICE TOOLS

Refer to
Tool number Tool name
I page

A.4.0148 Tool for calibrating brake p r e s s u r e

regulator

May 1983 22-26

 STEERING SYSTEM

CONTENTS

STEERING SYSTEM . . . . . . . . . . . . . . 23-2 Removal . . . . . . . . . . . . . . . . . . . . . 23-7

GENERAL DESCRIPTION . . . . . . . . . . 23-2 Disassembly _ . . _ . . . . . . . . . . . . . . . 23-8
STEERING WHEEL AND COLUMN . . 23-2 Checks and inspections. . . I . . . . . . . 23-9
Steering wheel . . . . . . . . . . . . . . . . . 23-2 Assembly _ . _ . . . . . . . . . . . . . . I . . . 23-9
Steering column . . . . . . . . . . . . . . . 23-3 SERVICE DATA AND
Steering lock-ignition switch . . . . . . 23-4 SPECIFICATIONS _.... _._.___._.. 23-l 1
STEERING LINK RODS . . . . . . . . . . . 23-5 General specifications _ . . . _ . _ . . . . 23-11
Removal . . . . . . . . . . . . . . . . . . . . . 23-5 Inspections and adjustments . . _ . _ . 23-12
Checks and inspections . . . . . . . . . . 23-6 Tightening torques . . . . . . . . . . . . . 23-l 2
Disassembly . . . . . . . . . . . . . . . . . . . 23-6 TROUBLE DIAGNOSIS AND
Assembly. . . . . . . . . . . . . . . . . . . . . 23-6 C O R R E C T I O N S . _. . _ _. _. . . _. . . _. , 23-13
Installation ................... 23-6 SPECIAL SERVICE TOOLS . . . . . . . 23-13
STEERING BOX . . . . . . . . . . . . . . . . . . 23-7

May 1983
 STEERING SYSTEM

STEERING SYSTE.M

39 4 48

28.92 + 35.43)

1 Track rods
2 Steering rack @ N.m
3 Universal joints
kg-m
4 Lower column (4 + 4.9 ft.lb)
5 Upper column 28.32 + 35.43)

GENERAL DESCRIPTION
Steering i s b y r a c k a n d p i n i o n . they reduce the variation of wheel
The track rods are connected to the movement resulting from suspension
centre of the rack by means of movements. The steering column is
flexible joints. Owing to their length, in two sections The lower part
is positioned so as to collapse under
axial loads. The upper part is pivoted
to allow adjustment of the steering
column height.

STEERING WHEEL AND COLUMN

STEERING WHEEL 4. By means of tool A.3.0451,

withdraw steering wheel from COI-
umn operating as per figure.
REMOVAL
1. Remove hub 0, to gain access
fo screws @ securing warning horn
pushbutton @ on steering wheel
and remove them.
2. Disconnect eletric connec-
tion @ of warning horn push-
button and remove it.
3. Unscrew and remove nut 0 ft-lb)
1 Hub 4 Electric con-
with washer @ securing steering 2 Screw nection
wheel to column. 3 Horn push- 5 Nut
button 6 Washer

May 1983 23-2


9. Remove the whole column.
DISASSEMBLY
1. Unscrew bolt securing universal
joint to upper column section.
Remove lower column.
2. Remove steering lock operating
as follows.
Secure column support @ together
with upper column @ on vice fitted
with protective jaws and, operating
as shown in figure, unscrew the
broken head screw securing steering
lock to column support; withdraw
steering lock.
1 Column support 2 Upper column
3. Keeping the unit on a vice,
hammer, on upper column, by means
of a plastic hammer (as shown in
figure) as long as column can be
withdrawn from support with re-
levant upper bearing.
4. Withdraw lower bearing from
column support.
CHECKS AND INSPECTIONS
1. Check against presence of dam-
ages or malfunctions in column
bearings. Lubricate them with the
prescribed grease and replace them
May 1983
STEERING SYSTEM
if necessary.
2. Check against presence of dam-
ages or absence of lubrication in
universal joints. Replace lower col-
umn if necessary.
3. Verify integrity of upper column
and, in particular, that: working
surfaces of bearings are safe from
scratches; tooth of splined parts are
not damaged or worn; hole where pin 1 Bolt 2 cutout
of steering lock works, is sound.
b. Adjust tightening of steering
4. Verify integrity of column sup- wheel inclination lever so as to
port -and replace it if necessary. obtain correct stop of steering
wheel in the required position.
ASSEMBLY C. On steering wheel and cover
For reassembly reverse order of assembled, make sure that, on all
disassembly and comply with. the lowered position of steering
following: wheel, B dimension (between
a. Apply a coat of grease (AGIP F 1 cover of steering column and
Grease 33 FD or IP Autogrease steering wheel structure) cor-
FD) to bearings where upper responds to the prescribed value.
column rotates.
b. Lower bearing must be com- Distance between cover and steering
pletely introduced on column wheel structure
support and upper bearing must B=O+6mm(O+00.236in)
be assembled so as it faces upper
plane of support.
C. Verify that upper column can
freely rotate and that no exces-
s.jve clearance is present.
d. For securing of steering lock -
ignition switch to column sup-
port, make use of proper screw
supplied as spare part, which
must be tightened into its seat
until b r e a k i n g o f Tts h e a d .
e. During junction of lower column
to upper one make sure that
securing bolt positions correctly
with respect to cutout portion. d. After tightening of components,
verify that on maximum travel
INSTALLATION condition of steering wheel,
Assemble column by proceeding in (straight ahead and straight
reverse o r d e r a n d f o l l o w t h e s e down) functioning is correct.
instructions. a. At the end of assembly, verify
proper functioning of combina-
WARNING: tion switch unit and efficiency
Make sure that undue stress is not of warning horn.
applied to steering column during
STEERING LOCK-
assemblv.
a. Loosen the wheels and couple - IGNITION SWITCH
the column lower universal joint
to pinion of steering box,
REMOVAL AND
then insert securing bolt 3
INSTALLATION
making sure that it positions 1. Remove lower cover of column
correctly with respect to pinion support (see: Column - Removal).
cutout portion 0. 2. Disconnect harness of the steer-
23-4
 STEERING SYSTEM

ing lock - ignition switch. CHECKS AND INSPECTIONS

3. Remove the broken head screw
securing steering lock to column
support.
4. R e m o v e s t e e r i n g - lock unit
withdrawing it from its seat in
column support.
5. For installation, reverse order of
removal and secure steering lock @
to column support by means of
special screw @ provided as spare
part, and tighten it as long as its head
breakes.
1. Verify good conditions of cables
and connectors.
2. Check proper operation of the
whole assembly by verifying all
positions are reached smoothly;
check also the locking device opera-
tions properly, after rotating steering
wheel and extracting key.
1 Steering lock
2 Screw

STEERING LINK RODS

@ N.m @39 f 4 8
(kg-m (4 + 4.9
fMl) 1 Spacer 7 Nut 28.92 + 35.43)
2 Plate 8 Elastic joint
3 Rod 9 Nut
4 Nut 10 Washer
5 Ball joint 11 Plate
6 Washer

5. Turn steering wheel to the right

REMOVAL to make easier the disassembly of
1. Place car on lift, block rear r o d s 0 f r o m s t e e r i n g b o x 0,
wheels, jack up front of vehicle, then remove nuts 0, 3 washers @, and
support it by stands placed in adja- plate 0, then remove rods.
cent position to jacking points (Refer
to: Group 00 - Lifting Points and
@-I
Towing).
2. Remove four screws and wheel.
3. Unscrew nut securing ball pin of
steering track rod @ to lever @ of
strut 0.
4. Using puller.A.3.0156 withdraw
ball joint pin @ of steering track
rod upwards, taking it out from strut
levers. 3 Ball joint 1 Rod 4 Washer
1 Strut
4 Steering track tocl 2 Steering box 5 Plate
2 Strut lever
3 Nut

23-5 May 1983

 STEERING SYSTEM

CHECKS AND 3. Loosen fixing nut 0, unscrew

During tightening of bolts, make sure

INSPECTIONS
that on the static load position,
ball joint @ and remove it from
upper plane of ball pin is parallel to
rod 0.
gasket face.
1. Check against damage or wear in
the steering rods ball joints, .and
verify that pivot free from crawling
or with notable sla.ck in their seats. If
necessary, replace them.
2. Check elastic joints against
damage, wear or excessive slack. If
necessary, replace them.
3. Check steering rods against
1 Rod 3 Ball joint
damage or deformations. If neces-
2 Nut
sary, replace them.
3. Lock the elastic joint fixing nuts
ASSEMBLY to the rack studs, with the front

DISASSEMBLY Proceed in reverse order to disas- suspension in nominal height, corre-

1. Extract elastic joints from rods
by means of a press and of suitable
tools (a punch and a base).
sembly and use the same tools
previously used.
On reassembly of ball joints, make
sure that the two tie rods have the
same length they had before disas-
sembly.
sponding to static load.
@ : Tightening torque
Nut fixing ball joint to lever on
steering tube and elastic joint
to rack.
39-48 N - m

INSTALLATION
(4 f 4.9 kg-m
28.92 + 35.43 ft.lb)

Assemble steering link rods on

4. Verify toe-out (Refer to:
vehicle by proceeding in reverse
Group 00 - Chassis and Body Main-
order of removal.
tenance).
1 Assemble rods on steering box
studs and fix them with plate,
washers and nuts without locking
them.
2. Connect rods to levers on
steering tubes by tightening the nuts
2. Measure articulation jut in order securing the ball joint pin to the
to maintain it on reassembly. specified torques.

May 1983 23-6

 STEERING SYSTEM

STEERING BOX

1 upper cap 9 Pinion 17 Bush

2 Adjusting screw IO Bearing 18 support
3 Spring 11 Lock ring 19 Right cap
4 Plunger 12 Lock ring 20 Pad
5 Seal ring 13 Lower cap 21 Studs
6 Bush 14 Boat 22 Rack
7 Rack box 15 Sleeve
8 Left cap 16 Clamp

steering box by estracting it from the

REMOVAL steering rod slit on the left side and
1. Place vehicle on ramp a n d remove rubber supports @.
support it by stands placed in the
jack seats (refer to: Group 0 0
Lifting Points and Towing).
2. Remove left wheel after screw-
ing up fixing screws.
3. Turn steering wheel to the right
and disconnect rods from steering
box (refer to: Steering Link Rods - 1 Universal joint 3 Pinion
Removal). 2 Bolt 4 Protection cap
4. Disassemble b o l t 0 f i x i n g fixing
6. Remove screws @
lower universal joint @ to pin- (4 4 4.9 -J (kg-m
steering box @ to body, then
ion @ 28.92 + 35.43) ft-lb)
remove brackets 0. 1 Steering box 4 Support
5. Remove plastic cap @ p r o -
7. After disengaging pinion @ 2 Pinion 5 Bracket
tecting rack.
from universal joint 0, remove 3 Universal joint 6 Screw

23-7 May 7983

 STEERING SYSTEM

DISASSEMBLY
1. Remove clamp @ fixing right
b o o t @ t o s l i d i n g s l e e v e 0.
2 . E x t r a c t e n d c a p 0, r e m o v e
plastic support @ and extract right
boot 0.
6. Remove the cover @ from rack 9. Remove pinion from rack box
b o x 0, s c r e w U P a n d e x t r a c t together with the bearings, by means
adjustment screw 0, spring @ of a plastic hammer and a supporting
and plunger @ for backlash. Then base.
lever with a screwdriver and remove
lower protection cap @ of rack
control pinion.

CAUTI0.N:
Plastic bellows be replaced whenever
disassembled from steering tube for
any reason.

1 Covei- 4 Plunger
-2 Adjustment 5 Rack box
screw 6 Lower cap
1 End cap 4 Clamp 3 Spring
2 Support 5 Sleeve
3 Right boot
7. Extract rack @ from guide 10. Remove lock ring 1 fixing
3. By means of nut and lock tube 0. bearing @ on pinion 83 , after
unscrew and extract studs 0, then placing it in a vice provided with
remove plate @ and spacer @ for protective jaws.
rod support.
4 . R e m o v e c l a m p @ fixing left
boat
84 and extract it from
sleeve 1 , then extract sleeve from
rack tube.
1 Rack 2 Guide tube

8. Remove lock ring @ fixing

pinion bearing to rack box.

1 Sleeve 5 Plate
2 Spacer 6 Nut and lock nut
3 Clamp 7 Studs
4 Left boot

5. Remove the sliding member @

from rack guide tube 0.

1 Lock ring 3 Pinion

2 Bearing

11. Disassemble bearing @ from

pinion 0 by means of a punch and
a suitable base.

1 Lock ring
1 Tube 2 Sliding member

May 1983 23-8

 STEERING SYSTEM

to point 3) and introduce it into the

guide tube after rotating pinion, in
order to realite, when assembly is
ready, reciprocate positioning be-
tween rack and pinion verified by
dimension A with pinion oriented
with cutout downwards (obtain
angle u = 90f 26).

Thickness gauge 3 Steering tube

Sliding member

(2) In case of defect, select

another sliding member from the
range of available thicknesses,
-0 for the above recommended
conditions to be met. (Thick-
-0 nesses may be distinguished by
Reference dimension for pinion-rack different-color paint spots on
positioning the pads, as follows in increasing
A = 125mm (4.921 in) order: white - yellow - r e d
green blackish blue).
1 Pinion 2 Bearing (3) If tolerance G cannot be
met with any of the available
sliding member, replace steering
3. Provide internal room of steering
tube.
box with 40 g (1.41 oz) grease (AGIP
Fl grease 33 FD or IP Autogrease
Employment of a new steering
FD), l u b r i c a t e p i n i o n b u s h a n d
tube.
assemble pinion by means of a
Replace also the sliding member
punch, a base and a plastic hammer.
and use a new one with paint
spot of the same color as the
steering tube. Maximum back-
lash in this way is 0.044 mm
6. Select rack sliding member (1.73 - 10m3 in).
depending on the available guide
tube, as follows:
Apply 15 g (0.53 oz) of grease,
a. Employment of already existing as per item 3, inside the sliding sleeve
steering tube. a n d lubricate rack tube external
(1) Check that the sliding mem- surface.
ber @ slides the whole steering 8. Assemble left boot, sliding
tube @ if pushed by hand member, sliding sleeve, then insert
with a slight stress; by means of studs, spacer and plate. Assemble
0 a thickness gauge 0 verify right boot, a new guide support,
backlash G between pad and checking that the internal tooth fits
0 slot does not exceed the recom-
mended value in any position.
the tube seat; then place end cap.
9. Lubricate plunger and backlash
adjustment screw with grease re-
Maximum allowed backlash G commended at point 3. With rack
between pad and slot rod in central position assemble
G = 0.1 mm (3.94 - 10m3 in) plunger, spring and screw and adjust
1 Bearing 2 Rackbox pinion-rack backlash, as follows.
(I) By means of spanner A.5.0204,
tighten plunger adjustment screw to
4. During assembly use plunger and
the indicative torque: 3 N.m
adjusting screw of the same material
(0.3 kg.m; 2.17 ft.lb).
(plastic or metal).
5. Lubricate rack with grease (refer

May 1983 23-10

 STEERING SYSTEM

rotated with respect to each other,

with reference to the boot body
junction line.
12. Center steering stroke by ob-
taining dimension A as per figure
indicated at step 5.

(2) Check with space in the screw is
most centered with respect to a
notch in the box; loosen screw until
the diametrically opposite space to
the one centered with the first
notch on the box is aligned.
I CJ
4 at the prescribed torque 39 + 48 N.m
1 Steering box
2 Adjusting screw
2 Aligned space and notch
4 Screw rotation
10. Verify that steering pinion ro-
tates up to the rack rod end-of-stroke
in both directions smoothly.
11. Tighten boots fixing clamps, for
both ends of each boot not to be
INSTALLATION
1. Mount steering box assembly on
vehicle by tightening securing screws
(4 t 4.9 kg.m, 28.92 + 35.43 ft.lb).
Refit end cap on the rack box.
2. With the wheels in the straight
ahead position, mount steering rods
and Tighten them at the prescribed
t o r q u e 3 9 + 48 N-m (4 + 4.9 kg.m,
28.92 + 35.43 ft.lb) with vehicle at
nominal height.
3. Check toe-out (Refer to:
Group 00 - Chassis and Body Main-
tenance).

SERVICE DATA AND SPECIFICATIONS

GENERAL SPECIFICATIONS

FLUIDS AND LUBRICANTS

Application Denomination Q.ty

Column supporf spacer for hinging to GREASE AGIP Fl grease 15 -

body (external surface) Std. No. 3671-69810

Steering column bearings GREASE AGIP Fl grease 33 FD

Steering rack rod (ext. surface) IP Autogrease FD
Pinion bush Std. No. 3671-69833
Rack-pinion backlash take-up plunger
Backlash adjustment screw (on thread)

Rack sliding sleeve (internal surface) 15 9

(0.53 02)

Rack box tint. room)

Side rod silentblock (ext. surface) FLUlD UNION CARBIDE CHEMICALS

COMPANY: Ucon lubricant 50HB - 5100
Ml LLOI L: lubricant for elastomer seal
Std. No. 4500-17502

23-11 May 1983

 STEERING SYSTEM

INSPECTIONS AND ADJUSTMENTS

1. Dimension A for rack rod centering in the steering 3. Light 5 between steering column covers and
tube steering wheel structure

A mm (in) 125 (4.921) B mm (in) O f 6 (0+0.23)

2. u cutout positioning angle on rack pinion (rack 4. Thickness of rack guide pad. The available thickness,
centered as per point 1) in increasing order are provided in the below list (they
can be distinguished by the paint mark on pads):
white yellow red green blackish blue

5. Maximum clearance G between pad and slot

a degrees 90426 G mm (in) 0.1 (0.3.10-2)

TIGHTENING TORQUES

Unit
N.m kg*m frlb
Item

Nut securing track rod ball joint to lever 39 + 4 8 4 + 4.9 28.92 + 35.43
on strut

Nut securing steering wheel to steering column 17 + 21 1.7 + 2.1 12.29 + 15.18

Nuts securing track rod to steering box 39 + 48 4 + 4.9 28.92 + 35.43

Bolts securing upper steering column to lower 27 + 31 2.7 f 3.1 19.52 + 22.41
steering column and to steering box pmron

Bolt securing steering column lower support 14 f 18 1.4 + 1.8 10.29 + 13.01
to body

Nut securing steering column upper support 16 + 20 1.6 + 2.0 11.56 + 14.46
to body (1

Nut for toe-out adjustment on track rod 55 f 69 5.6 + 7 40.49 + 50.61

Screw securing steering box to body 39 + 4 8 4 + 4.9 28.92 + 35.43

() With steering wheel release lever to the locked position

May 1983 23-12

 STEERING SYSTEM

TROUBLE DIAGNOSIS AND CORRECTIONS

Condition Probable cause Corrective action

Excessive steering wheel backlash l Loose steering box screws Tighten screws

l Damaged steering rods or universal Replace defective components

joints

Column noise in drive Worn column bearings Replace bearings

Drive noise l Loose steering box screws Tighten screws

l Worn steering levers Replace defective parts

l Excessive pinion-rack backlash Calibrate backlash

Drive hardening l Inadequate suspension angles Restore proper angles

l Worn or deflated tyres Check and restore

l Scarce pinion-rack backlash Calibrate backlash

l Scarce lubrication Lubricate

l Damaged universal joints Replace joints

l Interference of column with Calibrate backlash

switch unit

SPECIAL SERVICE> TOOLS

Refer to
Tool number Tool name
paw

A.3.0156 Track rod ball joint puller 23-5

23-13 M a v 1983
 CONTENTS

DESCRIPTION . . . . . . . . . . . . . . . . . . . 25-2 SERVICE DATA AND

REAR HUB . . . . . . . . . . . . . . . . . . . . . . 25-3 SPECIFICATIONS . . . . . . . . . . , . 25-8
Removal . . . . . . . . . . . . . . . . . . . . . 25-3 Technical data . . . . . . . . . . . . . . . . 25-8
Checks and inspections . . . . . . . . . . 25-4 General specifications . . . . . . . . . . 25-9
Installation . . . . . . . . . . . . . . . . . . . 25-4 Controls and regulations . . . . . . . . 25-9
REAR SUSPENSION . . . . . . . . . . . . . . 25-5 Tightening torques . , . . . . _ . , . . 25-9
Shocks absorbers . . . . . . . . . . . . . . . 25-5 TROUBLE DIAGNOSIS AND
Coil springs . . . . . . . . . . . . . . . . . . . 25-7 CORRECTIONS . . . . , . . . . . . . . . . . 2510
Rear rigid axle . . . . . . . . . . . . . . . . . 25-7 SPECIAL SERVICE TOOLS . . , . . 25-l 1

Refer to Group 00 - Chassis and Body Maintenance

fClr:
l Rear Axle and Rear Suspension
l Wheel Alignment
l Checking Suspension Height

May 1983
 REAR SUSPENSION

DESCRIPTION

1 Shock absorber 5 Front tension rod

2 Spring 6 Rigid axle
3 Rear tension rod 7 Panhard b a r
4 Wheel hub

The rear suspension is a rigid axle
one. The axle longitudinal anchorage
is carried out by means of two
tension rods, on each side, connected
to the body and placed according to
a Watt parallelogram, so as to limit
car raising when braking.
The transversal connection is carried
out by means of a tension rod
(Panhard b a r ) anchored on one
side to the axle and on the other to
the body, in order to prevent body
side movements with respect to the
wheels.
Between axle and body near the
wheel hubs are interposed the
suspension springs with coaxial shock
absorberry. The wheel rebounds are
limited by rubber pads assembled on
the shock absorbery.

May 1983 25-2

 REAR SUSPENSION
-.

REAR HUB

1 Grease seal ring 5 Washer

2 Inner bearing 6 Nut
3 Drum 7 Hub cover
4 Outer bearing

REMOVAL

1. Block front wheels with a

CAUTION:
suitable system, then lift rear part of
Do not drop bearing.
car and position it on support stands
(see: Group 00 - Lifting Points and
Towing).
2. Remove wheel from the opera- 6. Operating in bench and using a
tive side. screwdriver withdraw grease seal ring
3. Withdraw dust cover from its from hub.
seat. The seal ring must not be reutilited.
4. Operating as per figure, remove
wheel hub stop nut caulking and
remove it.
5. Move hub with drum, withdraw
washer and outer bearing.
9. Using tool A-3.0355 withdraw
from its seat outer ring of inner
bearing.

7. Withdraw inner bearing from its

seat.
8. Using tool A.3.0349, w i t h d r a w
from its seat outer ring of outer
bearing.

25-3 May 1983


CHECKS AND
INSPECTIONS
Clean bearings and other details
carefully, then dry them with com-
pressed air.
WHEEL BEARING
If the surfaces of tracks and conical
rollers present pittings, roughnesses
and ovalizations, replace bearing
unit.
CAUTION:
Should a bearing be no more utili-
zable, replace both the inner and the
outer one at the same time.
KNUCKLE PIN
Make sure knuckle pin is not dam-
aged and thread is sound; replace pin
if necessary (for replacement see:
Rigid Axle).
INSTALLATION
1. By using taker-in A-3.0328 as-
semble outer ring of outer bearing on
hub, inserting it wholly in its seat.
A.3.0328
/
May 1983
REAR SUSPENSION
2. By using taker-in A.3.0329, 4. Lubricate hub inner bearing
assemble outer ring of inner bearing
with 9 specified grease and insert
on hub, inserting at wholly in its into its seat. Lubricate seal ring with
seat. specified grease and insert it into its
seat on hub by using tool A-3.0459.
Lay off a coat of the same grease on
the knuckle pin, on its relevant
threaded end, on washer and on
securing nut.
3. Lubricate outer rings of bearings
with bearing specified grease (AGIP
Fl Grease 33 FD, or IP Autogrease
FD), and insert 40 + 55 g. into
the hub inner chamber.
5. Assemble hub on stem pin and
then insert outer bearing lubricated
with specific greade, washer and new
check nut.
9. Carry out wheel bearings pre-
loading adjustment (see: Group 00
Maintenance of Mechanical Com-
ponents and Body), then peen nut.
7. Apply specific bearings grease
onto the dust cover lid then assemble
it on the stem pin; re-assemble wheel.
1 Dust cover 3 Hub
2 Bearings outer 4 Grease
rings
CAUTION:
The grease must not get in touch
with drum braking surface.
25-4
 REAR SUSPENSION

REAR SUSPENSION

@ 33.35 + 36.26
(3.4 + 3.9
24.58 + 28.2)

@ N-m
(7 + 8.7 (kg-m
50.63 + 62.93) h-lb)
24.58 + 28.2)
13 Front tie rod
Upper cup 7 Coil spring
14 Brake adjuster
Rubber bumpers 6 Shook absorber anchor fork
15 Panhard bar
Lower cup 9 Rear tie rod
16 Pin
Upper gasket 10 Stud plate
17 Rear axle
Upper cap 11 Stem pin
Shock absorber 12 Gaskets

SHOCKS
ABSORBERS

REMOVAL
3. Release bolts 0 and bolt @
After duly blocking front wheels,
securing rear tie rods and Panhard
lifting car front and placing it on
bar to body respectively.
supports stands (see: Group 00 -
Lifting Points and Towing) remove
shock absorbers as follows:
1. Remove wheels.
2. Release bolts 2
0securing front
tie rods @ to body.

1 Front tie rod 2 Bolt

May 1983
25-5

1 Bolt 3 Tie rod
2 Bolt
4. Screw out rigid tube connection
o f b r a k e hydraulic system and
extract flexible hose from support
square. Apply a cap to rigid tube.
1 Rigid tube 3 Flexible tube
2 Square
5. Place column hoist provided
with A.2.0070 support under the
axle and lift it to release shock
absorbers from end-of-stroke.
May 1983
REAR SUSPENSION
6. From luggage compartment re-
lease and remove lock nut and nut of
upper shock absorber fastener, the
remove cap and anti-shock rubber
bumper.
7. Release and remove nuts and
washers of lower shock absorber
fastener, then lower hydraulic hoist,
remove springs from axle and shock
absorbers.
8. Separate from schock absorber
rubber bumper, cap, and attaching
fork, after removing the relevant
fastening screw.
CHECKS AND INSPECTIONS
1. Check shock absorber efficiency
and replace it, if oil leaks are found.
2. If necessary, verify shock ab-
sorber calibration data (see: Service
Data and Specifications - inspection
and Adjustment); replace shock
absorbers, if required.
3. Check wear status, damages and
deformations of rubber components.
Replace them, if required.
INSTALLATION
Assemble shock absorbers on car in
the inversed order with respect to
removal and remember the following
indications:
a. Assemble shock absorber com-
ponents and secure their upper
part to the b o d y .
25-6
b. Insert springs coaxially to the
shock absorbers and make sure
caps and upper spring support
gaskets are properly assembled
and positioned.
c. Set up car in nominal position,
corresponding to static load
(see: Group 00 Maintenance
of Mechanical Components and
Body) and set the bolts securing
tie rods and Panhard bar to body
to the prescribed torque.
@ : Tightening torques
Bolts securing tie rods to body
33.35 + 38.26 N-m
(3.4 + 3.9 kg-m
2 5 . 2 8 + 28.2 ft.lb)
Bolts securing Pahnard bar to
body
68.67 + 86.35 N - m
(7 + 8.7 kg-m
50.63 + 62.93 f-t-lb)
d. Restore rear brake oil delivery
tube connection and perform
brake system air bleeding (see:
Group 22 - Front and Rear
Brakes - Brake Air Bleeding).
 REAR SUSPENSION

Flexible hose connections

COIL SPRINGS 9.8 t 14.7 N - m
(I + 1 . 5 kg-m
7.23 + 10.85 ft.lb)
REMOVAL
Remove co.il springs with the same . Adjust parking brake lever
procedure followed for removal of stroke (see: Group 00 - Mainte-
shock absorbers; only remember not nance of Mechanical Compo-
to disjoin shock absorber from upper

M
nents and Body).
L A.2.0070
body coupling.
REMOVAL
If necessary, disassemble axle as

4. Slightly lift column hoist and follows:

CHECKS AND INSPECTIONS
1. V e r i f y the springs has no
stretches or deformations.
2. Verify spring efficiency by com-
paring its stiffness values with the
prescribed ones (see: Service Data
and Specifications).
3. Check wear status, verify pres-
ence of damages or deformations of
rubber components. Replace if
necessary.
remove the previously loosened tie
rod and Panhard bar bolts.
5. Slowly lower hoist driving the
axle and extracting the brake
adjustment spring from stud on the
Panhard bar.
Assemble again the whole suspension
on the car by the inversed procedure
than for removal.
1. Release and remove bolts secur-
ing tie rods to axle; remove tie rods.
2. If necessary, disassemble silent-
blocks from tie rods and Panhard bar
by using adequate bases and ex-
tractors.

IMPORTANT
. With static load car (see: Group
INSTALLATION
Assemble coil springs onto car again
in the inversed order of removal and
bear in mind all indications and notes
reported in paragraph Shock Ab-
sorbers Installation.
@) : Tightening Torque
REAR RIGID AXLE
REMOVAL AND
INSTALLATION
Place car on hoist bridge, support its
rear part by placing some stands in
the jack seats and remove the whole
rear suspension as follows.
1. Remove wheels.
2. Working from passenger com-
partment, remove rear console for
parking brake equalizer to be ac-
cessible. Then act on adjustment fork
nut and lock nut and loosen parking
brake control cables as much as to
allow their releasing from equalizer;
extract them from sheath locking
bracket.
@ : Tightening Torque
3. After providing the column hoist
with support A.2.0070, remove coil
springs with caps and gaskets (see:
Coil Springs - Removal).
00 - Maintenance of Mechanical
Components and Body) set the
bolts securing tie rods and
Panhard bar to the prescribed
torque.
3. Extract dust cover from brake
drum and caulk wheel hub nut.
Tie rod and Panhard bar Remove nut and drum complete with
hub and bearings.
securing bolts
4 . S c r e w o u t c o n n e c t i o n02 o f
3 3 . 3 5 + 3 8 . 2 6 N-m
(3.4 + 3.9 kg-m brake hydraulic system rigid tube on
24.58 f 28.2 ft-lb) jaw control cylinders and remove
rear tubes @.
5. Screw out and remove nuts @
Lubricate with prescribed grease
fastening stem pin and brake shoe
(AGIP Fl Grease 15) the hole in 7
plate @J to rear axle.
the brake adjustment spring
support stud on the Panhard bar
and the fork.
Carry out brake adjustment
spring calibration (see: Group 22
- Brake Adjustment).
Set the brake hydraulic system
connections to the prescribed
torque and perform air bleeding
(see: Group 22 - Brake System
Air Bleeding).
Rigid tube connections
7.85 + 9.8 N-m
(0.8 + 1 kg-m 1 Block shoe plate 3 Nuts
5.78 - 7.23 ft-lb) 2 Connection 4 Rear tubes

25-f May 1983

 REAR SUSPENSION

NOTE FOR CAR OVERLOADED ON REAR AXLE

Should high overloads be applied to the rear axle, like in the case of gas installation. the series rear springs can be replaced
on sedan versions with springs having part number 705.507, in case of overload of about 980 N (100 kg)(220.46 lb)
with respect to static load, they allow a rear position level increased by about 15 mm (0.59 in) with respect to the one
indicated in Group 00 - Checking Wheel Alignment.

GENERAL SPECIFICATIONS

FLUIDS AND LUBRICANTS

Type Denomination Q.ty

Wheel hub inner cavity and dust cover GREASE AGIP Fl Grease 33 FD 40+55 g
IP Autogrease FD 1.41+1.94 oz.
Std. No. 367 l-69833/34
Seal ring rim

Bearing inner rings and relevant outer races

Bearing housings on pin

Internal diameter of hole in brake adjustment GREASE AGIP Fl Grease 15

spring support stud on Parrhard bar. Std. No. 3671-69810
Brake adjustment fork

Tie rod end (front and rear) silentblock FLUID UNION CARBIDE CHEMICALS CO.
outer surface and Panhard bar (at Ucon Lubricant 50 HB-5100
assembly)
Outer surface of rubber bound bumper MILLOIL Lubricant for elastomer seal
(at shock absorber assembly) Std. No. 4500-17502

Outer surface of wheel hub seal ring OIL AGIP Fl ROTRA MP SAE S O W 9 0
IP Pontiax HD SOW90
Std. No. 3631-69408

CONTROLS AND REGULATIONS

STEERING GEOMETRY
(See: Group 00 - Rear Axle and Suspension)

WHEELS BEARINGS PRELOADING ADJUSTMENT

(See: Group 00 - Rear Axle and Suspension)

25-9 May 1983

 REAR SUSPENSION

DATA FOR SHOCK ABSORBER CALIBRATION

Alfa Romeo Part Number 542.147

Compression N (kg) (lb) 5 9 f 1 4 7 (6+ 1 5 ) (13.23G33.07)

Low speed
Extension N (kg) (ib) 78+ 1 7 7 (8e-18) (17X4+39.68)

Compression N kg) (lb) 2 7 5 f 4 1 2 (28+42) (61.73G92.59)

High speed
Extension N (kg) (lb) 638 f 834 (65 + 85) (14XW87.39)

NOTE: Values to be measured with shock absorbers at 20 L PC (68 f 3.BF) temperature

TIGHTENING TORQUES

N-m kg-m Ib+t

Item

Bolts securing Panhard bar to body 68.67 + 86.35 7 + 8.7 50.63 + 62.93

Bolts securing front and rear tie rods to body 33.35 + 38.26 3.4 + 3.9 24.58 + 28.2

Bolts securing stem pin to axle 39.24 + 48.1 4 + 4.9 29.92 + 35.43

Brake hydraulic system rigid tube connections 7.85 + 9.8 0.8 + 1 5.78 + 7.23

Brake hydraulic system flexible hose connections _. 9.8 + 14.7 1 + 1.5 7.23 + 10.85

TROUBLE DIAGNOSIS AND CORRECTIONS

When rear suspensions are suspected of being noisy, carry out a careful check to determine if the noise actually originates in
the rear suspensions or if it is due to the tires, road surface, exhaust system, engine, transaxle or wheel bearings.

Condition Probable cause Corrective action

Noise Loose wheel screws Tighten to specified torque

One or more attaching bolts loosen Tighten to specified torque

Lack of lubricating grease on Lubricate as required

bearings

Faulty shock absorber Replace

Damaged or worn wheel bearing Replace

Wheel and tire out-of-balance Balance

Damage to rubber parts such as Replace damaged parts

lower arm bushing

May 1983 25-10

 REAR SUSPENSION

Condition Probable cause Corrective action

Instability in driving. l Loose wheel screws Tighten to specified torque

This trouble is also related to
front suspensions. For trouble l Shock absorber malfunction Repair or replace
diagnoses also refer to
l Incorrect steering geometry Yielded coil springs
Group 21
l Yielded coil spring Replace

l Damaged tie rod silent-blocks Replace

l Loosen tie rod connections Tighten or replace

SPECIAL SERVICE TOOLS

Refer to
Tool number Tool name
page

A.2.0070 Rear axle support 25-6

25-7

A.3.0328 Driver of rear hub outer conical

bearing outer race

A.3.0329 Driver of rear hub inner conical

bearing outer race

A.3.0349 Hub outer bearing outer race

extractor

A.3.0355 Hub inner bearing outer race

extractor

A.3.0459 Driver of front hub seal 25-4

25-11 May 1983

 WHEELS AND TIRES

CONTENTS

CHECKING TIRE CONDITIONS . . . . . 28-2 CHECKING WHEEL CONDITIONS . . . 28-4

Checking tire ................. 28-2 Wheel balance . . . . . . . . . . . . . . . . . 28-4
Tire inflation . . . . . . . . . . . . . . . . . . 28-2 SERVICE DATA AND
Tire rotation . . . . . . . . . . . . . . . . . . 28-3 SPECIFICATIONS . . . . . . . . . . . . . . . . 28-5
TIRE REPLACEMENT . . . . . . . . . . . . . 28-3 General specifications . . . . . . . . . . . 28-5
Replacement . . . . . . . . . . . . . . . . . . 28-3 Inspections and adjustments . . . . . . 28-5
Wheel screw . . . . . . . . . . . . . . . . . . . 28-4 Technical data . . . . . . . . . . . . . . . . . 28-6

May 1983
 WHEELS AND TIRES

CHECKING TIRE CONDITIONS

CHECKING TIRE

Abnormal tire wear

1. Check tread thickness. If below Correct abnormal tire wear according to below chart.
min. allowed limit (1 mm; 0,04 in.)
replace tires.

If tires are provided with tread wear Trouble Probable cause Corrective action
indicator, when marks appear, re-
place tires.
1 Underinflation Check and adjust
2. Remove pebbles, glass or any (both sides wear) pressure
other foreign material embedded in
1 Hard cornering Reduce speed
the threads.
3. Check tread and side walls for 1 Lack of rotation Rotate tires
cracks, holes, separation or damage.
4. Check tire valves for air leakage.
Shoulder wear

TIRE INFLATION Check and adjust

Iverinflation
pressure

1. Check tire pressure. If necessary,

adjust it to specified value. Center wear

Feathered edge
Tire pressure should be measured
when tire is cold.

2. After inflating tires, check valves

for leakage. Whenever tire pressure is Incorrect toe-in or Adjust as required
checked, be sure to tighten valve caps toe-out
firmly by hand to keep dust and
water out.

Toe-in or roe-out wear

b Unbalanced wheel Balance or replace

l Malfunctioning Replace dampers

dampers

. Lack of rotation Rotate tires

Uneven wear

May 1983 28-2


TIRE ROTATION
Operation to be carried out every
5,000 km (3,107 miles).
1. Tires tend to wear unevenly and
become unbalanced after a certain
running distance. Uneven tire wear
often results i n p r o b l e m s t h a t ,
however, one tends to tink as being
caused by other car components.
Front tires also tend to wear un-
evenly because of improper align-
ment of front wheels.
2. Therefore, to equalize tire wear,
it is necessary to rotate tires periodi-
cally. Following are some different
allowed arrangements for tire ro-
tation.
CAUTION:
Different types of tires, such as bias,
bias belted and radial tires, must not
be under any circumstances. Different
types of tires can adversely affect
vehicle handling and may cause
driver to lose control.
a. When replacing a worn
damaged tire, use a replacement
tire of the same size and load
carrying capacity as that with
which the car was originally
equipped with by the Manu-
facturer. The use of tires having
different size and/or load c a -
pacity than those approved by
the manufacturer is not allowed
since it changes the cars tech-
nical characteristics.
b. For the same above mentioned
reasons, do not use tires and
wheels other than those re-
commended, and do not mix
tires of different brand or tread
pattern.
The use of tires and wheels other
than those recommended or the
mixed use of tires of different
WHEELS AND TIRES
0
--:,
-t
TIRE REPLACEMENT
adversely affect riding, braking,_ 2. After having positioned the
handling, ground clearance, wheel, fit the four screws properly
body-to-tire clearance, and into place.
speedometer calibration. 3. Tighten screws by hand as far as
C. It is recommended to fit new possible keeping the wheel in correct
tires in pairs on the same axle. position
When replacing only one tire, it 4. Tighten wheel screws with prop-
should be paired with the one er wheel wrench in crisscross and
or having the most tread in order to progressive fashion.
equalize braking action.
d. When replacing tires refer to the
procedure described in the re-
levant paragraph: Replace-
ment.
REPLACEMENT
1. To replace a tire using a jack in a
safe manner, refer to: Lifting Points
for jacking up.
WARNING:
Never get under the vehicle while it is
supported only by jack. @e sure to check wheel screws for
Always use safety stands to support tightness, after the wheel has been
side member of body construction run for the first 1,000 km (621
when you must get beneath the miles); do the same thing in case of
flat tire repair, tire rotation, etc.

WHEEL SCREW
CAUTION:
Two types of wheel screws are used:
one is designed for use with steel
wheels and the other for use with
light alloy wheels. Do not mix
different type wheel screws.
CHECKING WHEEL CONDITIONS
Inspect wheels thoroughly paying
special attention to the following
points, in order to ensure satisfactory
steering condition as well as maxi-
mum tire life. If any defect is pres-
ent, repair or replace as required.
1. Check wheel rim, especially rim
flange and bead set, for rust, dis-
tortion, cracks or other faults which
might cause air leaks. Proper func-
tioning of tubeless tires depends on
effective sealing between tire bead
and wheel rim.
2. Thoroughly remove rust, dust,
oxidixed rubber or sand from wheel
rim.
Rims bead seats should be suitably
cleaned (for ex. using neutral type
detergent, cloth, etc...) being careful
not to damage the wheel surfaces
protecting film.
3. Replace wheel when any of the
following occurs:
. Bent, dented or heavily rusted
wheel
. Bolt holes are out-of-round
. Excessive side or radial runout
. Air leaks through welds
WHEEL BALANCE
Inspect wheel and tire for proper
wheel balance; if unbalanced, correct
May 1983
WHEELS AND TIRES
@-Fc with oil or grease.
1 Screw for light alloy type wheels
2 Screw for steel type wheels
it taking the following points into
consideration:
1. Correct unbalance as soon a s
relevant symptoms appear such as
wheel tramp and shimmy.
2. Balance wheel with tire both
statically and dynamically.
WHEEL BALANCING
PROCEDURE
CAUTION:
Considering the special construction
features of the differential assembly,
it is imperative that balancing of
wheels - especially of front ones -
be performed according to the
procedure hereafter described in
order to avoid serious damage.
Front wheels
1. Lift car front with a dolly-type
hydraulic jack placing same under
relevant lifting point (Refer to:
Lifting Points for jacking up).
2. Place two stands in line with
front jacking points located under
car body.
3. Lower car till it rests on stands
but locking the jack as well (thus
achieving a three-point support).
28-4
Be careful not to smear threaded
portion of screw not relevant seat
4. Lock rear wheels by means of
two wedges, one for each wheel.
5. Set up balancing machine and
auxiliary equipment; make sure indi-
cating finger is placed under suspen-
sions cross arm and in line with the
arm-wheel support joint.
6. Start up the engine, engage 4th
speed and then rev engine up to max.
speed as per speedometer reading.
7. Perform wheel balancing accord-
ing to usual Equitron type balanc-
ing machine procedure.
Rear wheels
1. Lock front wheels by means of
two wedges, one for each wheel.
2. Lift car rear, inserting jack under
axle. Position two stands in corre-
spondance with stand rear seats and
then lower the car.
3. Set up balancing machine and
auxiliary equipment; make sure
probe is placed under the suspension
spring. Let the wheel rotate by
means of a wheel accelerator device,
then carry out balancing operations
with the modalities for balancing
machine of the .Equitron type.
 WHEELS AND TIRES

BALANCE WEIGHTS
POSITIONING a. Be sure to place correct balance
weights on inner edge of rim.
b. Do not pure more than two
weights on each side.
c. Two types of balance weights
are used: one is designed for use
with steel wheels and the other
Q Li for use with light allowy wheels.
Do not mix different type
balance weights.
d. Properly rebalance wheel and
tire whenever puncture is re-
1. Balance weights paired.

Maximum allowable at rim flange:

L, = location of balance weights 8 g (0.28 O L )
D = tramp direction
s = shimmy direction Balance weights:
10 4 40 (0.35 + 1.40 02)
Ls = location of unbalance causing
heavy area at 10 g (0.35 02) interval

SERVICE DATA AND SPECIFICATIONS

GENERAL SPECIFICATIONS

FLUIDS AND LUBRICANTS

Application TYW Denomination Q-v

Tire beads FLUID UNION CARBIDE CHEMICALS

COMPANY: Ucon lubricant 50 HE-5100
MILL01 L: lubricant for elastomer seals
Stel. No. 4500-17502

INSPECTIONS AND ADJUSTMENTS

DYNAMIC BALANCE
Max. allowed residual unbalance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 g (0.280 04
Thread thickness limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 mm (0.04 in)
Wheel screws tightening after the first . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,000 km (621 miles)
Balance weights (at 10 g (0.35 oz) interval) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 + 40 g (0.35 + 1.40 OZ)

28-S May 7983

 WHEELS AND TIRES

TECHNICAL DATA

..

May 1983 28-6

 ELECTRICAL SYSTEM

CONTENTS

HOW TO READ THE WIRING Windscreen wash/wiper . . . . . . . . . . 40-28

DIAGRAM ...................... 40-2 Windscreen wiper . . . . . . . . . . . . . . 40-29
Wiring diagram . . . . . . . . . . . . . . . . 40-2 Headlight wash/wiper . . . . . . . . . . . 40-32
Power supply routing . . . . . . . . . . . 40-3 Headlight wiper . . . . . . . . . . . . . . . . 40-33
POWER SUPPLY ROUTING . . . . . . . . 40-4 Windscreen washer and headlight
Schematic/Power supply routing . , . l 40-4 washer . . . . . . . . . . . . . . . . . . . . . . . 40-34
Fuses . . . . . . . . . . . . . . . . . . . . . . . . 40-5 ELECTRIC ACCESSORIES . . . . . . . . . 40-36
Ignition switch . . . . . . . . . . . . . . . . 40-6 Horns, heated rear window, cigar
ELECTROMECHANIC AND lighter, clock . . . . . . . . . . . . . . . . . . 40-36
ELECTRONIC DEVICES . . . . . . . . . . . 40-7 Horns . . . . . . . . . . . . . . . . . . . . . . . 40-37
Relays and timer . . . . . . . . . . . . . . . 40-7 Heated rear window . . . . . . . . . . . . 40-38
Electronic devices and intermittence; 40-7 Power window. . . . . . . . . . . . . . . . . 40-39
LIGHTING SYSTEM .............. 40-10 Power windows and door locks . e . , 40-4 1
Lamps . . . . . . . . . . . . . . . . . . . . . . . 40-10 Door lock control unit . . . . . . . . . . 40-42 1
Combination switch assembly . . . . . 40-l 1 Check Control and Trip Computer. . 40-43
Outside lighting . . . . . . . . . . . . . . . . 40-13 ELECTRIC COMPONENT LOCATION. 40-45
Front combination lamps . . . . . . . . 40-17 Engine compartment . . . . . . . . . . . . 40-45
Rear combination lamps . . . . . . . . . 40-l 9 Passenger compartment . . . . . . . . . . 40-45
Inside lighting . . . . . . . . . . . . . . . . . 40-20 HARNESS LAYOUT . . . . . . . . . . . . . . 40-46
BOARD INSTRUMENTS AND General harness . . . . . . . . . . . . . . . . 40-46
TRANSMITTERS . . . . . . . . . . . . . . . . . 40-22 Engine compartment . . . . . . . . . . . . 40-46
Cluster. . . . . . . . . . . . . . . . . . . . . . . 40-22 Passenger compartment and luggage
Engine cooling and lubrication , , . . 40-24 room (LH) . . . . , . . . . . . . _ . . . . . . 40-47
u
Fuel supply, brake and clutch oil Dashboard ( LH) . . . . . . . . . . . . . . . 40-48
minimum level transmitter, tachy- SWITZERLAND-AUSTRALIA MODEL
metric pulse generator . . . . . . . . . . . 40-26 VARIATION . . . . . . . . . . . . . . . . . . . . . 40-49
WINDSCREEN WASH/WIPER AND Tachymetric control unit - fast idle.
HEADLIGHT WASH/WIPER . . . . . . . . 40-28 electromagnet - hand brake switch. . 4049
Cl RCUIT DIAGRAM . . . . , . , . . . . . , , 40-50

May 1983
 ELECTRICAL SYSTEM

The example shows continuity be- C Orange

r-----7
i
tween terminals 2 and 3 with the CN Orange - black
control set to position 1. CB Orange -white
H Grey

pI----- @
HG Grey - yellow
iiP%?
- 1 HN Grey - black
HP? Grey - red
HV Grey - green
The chain line, on wiring diagram, G Yellow
delimits those areas containing the GB Yellow-white
specific variations for the models GN Yellow - black
indicated by U .,.I. GR Yellow - red
The detail shows a reference to knot GV Yellow - green
relevant to electronic device N ._. N Black
NZ Black - violet
M Brown
MB Brown -white

l+++(m) MG
R
RN
Brown - yellow
Red
Red - black

FT() S
SB
Pink
Pink -white
The connection identifies two wiring Pink - black
SN
variations, present in alternative and V Green
connected in the same way. The The figure shows the type of diagram Green -white
VB
wiring variations are referred to the used to identify the two connectors Green -black
VN
models indicated by U . . . , relevant to each joint: for the male z Violet
connector it is applicable diagram ZN Violet - black
(m); for the female one it is applica-
In case of mixed color, the base color
ble diagram (f).
is indicated first, followed by the
present stripe col.or.
i.e. BN = White with Black stripes
Cable colors

Cable section
A Light blue
AB Light blue - white Cable section not indicated is
AN Light blue - black 0 . 5 mm2 (0.39 . 10m3 in2).
AR Light blue _ red
In the horizontal line, table shows 6 White
position of control or of switch to be RN W h i t e - b l a c k
operated. In the vertical line it shows BR White red
the terminals between which conti- BLN Blue - black
nuity generates. BLR Blue - red

POWER SUPPLY ROUTING

This type of diagram is helpful in
identification of specific troubles
relevant to the part of electric
diagrams concerning supply i.e.: the
windscreen wiper is not functioning.
A first check shows efficiency of
instrumentation supply. From dis-
tribution diagram it can be noted
that supply of both instrumentation
and windscreen wiper are realized via
ignition switch and fusebox. T h e
result is then that ignition switch
operates correctly and no failure is
present along wiring between battery
and switch itself.
Failure must then be due either to
fusebox (see.: Fuses- Services protect-
ed by fuses) or to the following parts
of the electric system, that is in
the wiring windscreen wiper or in the
ground connection.
For fault identification, refer then to
the windscreen wiper wiring diagram.

40-3 May 1983

 ELECTRICAL SYSTEM

POWER SUPPLY ROUTING

SCHEMATIC/POWER SUPPLY ROUTING

r- - - -1
4
fO(I\
E -
I

\I
I
-,
-
I
/
\c
-

-
I

\I
-

\
-
I

m+
r!N

0: ;
LL z
Y
P
0
Y
n
II

- - - -
-
-

- - -

- - -
- - - - -

I
I -

May 1983
 ELECTRICAL SYSiEM

FUSES
LOCATION
?he fusebox is integral part of the
support board and is lo&d on left
side of the intermediate bulkhead, in
the engine compartment.
SERVICES PROTECTED BY FUSES
CHECK
CAUTION:
a. In case a fuse blows, before
replacing it, make sure that the
cause of failure has been re-
moved.
b. Use fuse having the prescribed
amperage, only. Do never use
fuses having amperage greater
than the prescribed one.
C. Correctly insert fuse into fuse-
box, aligning it carefully with
respect to its seat.
cl. Should car remain stationary
1 Fuse for a long time, remove fuse
protecting supply circuit of
clock.

In the following table, for each model, it is specified which are the services protected by each fuse.

Model

---I-
Protected Service 1350 1500 Q.* 1500
905.02 905.04 905.06
905.03 905.05 905.07
I
Power windows X X

Door lock control unit 16 1 I x

Heated rear window 76 X

Clock X
16
Horns-cigar lighter X

Passenger compartment roof lamp- Intermittence of direction and

.
hazard lights- Stop switch X

Roof lamp timer 8

Trip Computer
- .--
Windscreen wiper-Windscreen Wiper electronic intermittence genera-
%

--l---
tor. Windscreen wiper controlWindscreen washer pump control- 8 X
Cluster

Heated rear window switch- Hazard lights switch -

Heater switch

Power window switch Power window

Clock

40-S May 1983

 ELECTRICAL SYSTEM

Modal
81 1200 1360 1500 a.* 1500
: Protected Service Ampere
905.00 905.02 905.04 905.06
305.03 905.05 905.07
Cut-off solenoid valve - Reverse switch 8 X X X
8
Trip Computer - Check Control X

Side lights left front and right rear-R. H.number plate light X

Clock X
9
Check Control

Cigar lighter X

Side lights right front and left rear-i. H.number plate light X

Check Control -Trip Computer-Headlights wiper

10 Heater control lighting lamp - Cluster lighting lamp -

Side light warning lamp X

11 Risht low bean X X

12 Left low beam - Rear fog light switch X X X

13 Rioht full beam X X X

14 Left full beam - Headlights warning lamp X X X

a* = Quadrifoglio

IGNITION SWITCH

REMOVAL AND
INSTALLATION
For removal and installation of the
ignition switch - antitheft steering
lock group, refer to: Groupe 23 -
Steering Wheel and Column.

May 1983 40-6


.-
ELECTROMECHANIC AND ELECTRONIC DEVICES
RELAYS AND TIMER
LOCATION
The relays and the roof lamp timer
are inserted into the special socket
which is integral part of the fusebox
ELECTRONIC DEVICES AND INTERMITTENCES
LOCATION
The electronic device for headlights
and flashing changeover, and the
windscreen wiper electronic intermit-
tence generator, are mounted on a
support board, located in the inter-
mediate bulkhead, in proximity to
the fuse holder box.
ELECTRICAL SYSTEM
support board, located on left side of CHECK
intermediate bulkhead. For location,
The relays and the timer, must be of
refer to Electric Component Loca-
the type indicated in the specific
tion.
table on page 40-8.
The device which controls intermit- CHECK
tences of both side lights and hazard The electronic devices and intermit-
lights, is located in the dashboard tences must be of the type indicated
inside. in the specific table on page 40-g.
For identification of the various
devices, see: Electric Component
.Location.
40-7 May 1983
 ELECTRICAL SYSTEM

Relays and Timer Table

External view Symbols Position

Passenger compartment
roof lamp timer NlO
4%+L
1

Horns relay 13 2

Heated rear window

3
relay 12

Headlight wiper relay 14 4

Front power windows

5
relay 112

May 1983 40-8

 ELECTRICAL SYSTEM

Intermittences and electronic devices

Component External view Symbols

Windscreen wiper electronic

ihtermittence N14

Electronic device for

2
headlights and flashing
changeover N18

Hazard and direction L

lights intermittence N13 P - +

++

40-9 M a y 1983
 ELECTRICAL SYSTEM

LIGHTING SYSTEM
LAMPS
CAUTION:
Before starting operations on lighting
system, make sure that the ignition Lamp characteristic data, type and
switch is to the ST position and e l e c t r i c p o w e r a r e l i s t e d i n the
the battery ground cable is discon- following table.
netted.

Electric power
Lamps TYPe
IWI

Front combination lamps :

- low beam and full beam (H4 halogen lamp) 56/60

- front side light 4

- front direction indicator 21

Side direction indicator lamp 3

Rear combination lamps :

- rear direction indicator 21

- rear side light 5

- number plate light 5

- reversing light 21

- rear fog light 21

- rear side and stop light S/21

Warning lamp 1.2

Roof lamp IO

TYPES OF LAMPS
The lamps used for the car are of 2. Bayonet lamp - type B
four types. For removal the follow- To remove it from lampholder, press
ing procedure is recommended. the bulb, rotate it counterclockwise,
then withdraw it.
1. Halogen lamp - type A
4. Whole glass - type D
To remove it from lampholder,
It is pressed into lamp holder and to
disconnect connector, then rotate
remove it, it is necessary to withdraw
retaining spring being careful not to
lamp out of lampholder.
touch it with naked hands.

3. Cylindrical lamp - type C

To remove it from lampholder,
release it from contacts pulling
For installation of lamps, reverse
towards outside of lampholder. order of removal.

May 1983 40-l 0

 ELECTRICAL SYSTEM

COMBINATION SWITCH ASSEMBLY

VIEW FROM M

d
5

1 Left lever 5 Connector

2 Turning stalk 6 Connector
3 COnnector 7 Connector
4 Connector 8 Right lever

40-l 1 May 1983

 ELECTRICAL SYSTEM

T h e fOiiOWiIIQ table shows the of combination switch controls and

correspondances between positions the concerned services.

Control Position Service enabled

0 - zero position

Stalk rotation 1 - side ligho

2 - low beams

A - zero position

Left lever
Movement parallel
B - full beam flashing (paired to rotation in
the 0 and 1 positions)
to steering wheel axis

D
I .
- Headlight change over (paired to rota-
tion in position 2 )

- Right - hand direction indicator

Movement parallel OFF - Neutral position
to steering wheel plane
S - Left hand direction indicator

Control T Position Service enabled

- zero position

Movement parallel - windscreen wiper intermittence

to steering wheel plane - windscreen wiper Ist speed

- windscreen wiper 2nd speed

Right lever

- windscreen washer and/or headlight

Movement parallel to steering ON
wash-wiper with wiping stroke driven
wheel axis
from control unit

OFF - zero position

REMOVAL AND
INSTALLATION
1. Removing steering wheel.
2. Unscrew the five securing
screws and remove upper and lower
shell covers of steering column
(see Group 23 - Steering Wheel and
Column).
3. Disconnect connectors @ of
the combination switch unit.
4. Remove combination switch
unit by unscrewing the two
screws 0 1 securing it to steering 1 Screw
column. 2 Connectors
If necessary, disassemble combina-
tion switch unit separating the CWO
levers.
5. For installation reverse order of
CHECKS AND INSPECTIONS means of a tester, check electric
removal.
continuity.
Check harness integrity and, by

May 1983 40-I 2

 ELECTRICAL SYSTEM

OUTSIDE LIGHTING

OUTSIDE LIGHTING - FRONT SIDE

May 1983
 ELECTRICAL SYSTEM

OUTSIDE LIGHTING - REAR SIDE

(for the 1200 - 1350 - 1500 models)

d1

-
-
i
,
I

May 1983 40-l 4


HEADLIGHT SWITCH
Low beam/full beam light change-
o v e r is executed via left lever of
combination switch (see: Combina-
tion Switch Assembly).
DIRECTION LIGHT SWITCH
Operation of direction indicators is
executed via left lever of combina-
tion switch (see: Combination
Switch Assembly).
HAZARD LIGHTS SWITCH
Location
The switch is mounted on upper
ornament of central console (see:
Groupe 66 - Consoles).
Check
Verify switch functioning by check-
ing whether continuity between
terminals occurs in accordance with
the indications provided in table.
REVERSE LIGHT SWITCH
May 1983
ELECTRICAL SYSTEM
Location When in the O F F position = ma
When in the ON position = 0 fi
The switch is mounted on gearbox
(see: Group 13).
Check
Connect a tester to terminals of
reverse switch and verify the follow-
ing resistance values.
W h e n in the O F F position = -a
When in the ON position = 0 a
REAR FOG LIGHT SWITCH
STOP LIGHT SWITCH
Location
The switch is mounted on upper
ornament of central console (see:
Location Group 66 - Consoles).
The switch is mounted on the
relevant bracket of pedal assembly.
Check.
Verify switch functioning by check-
Check ing whether continuity between
terminal occurs in accordance with
Connect a tester to terminals of stop
the indications provided in table.
light switch and verify the following
resistance values.
40-16
 ELECTRICAL SYSTEM

FRONT COMBINATION LAMPS

1 Front combination lamp 7 Lamp

2 Halogen lamp 8 Lampholder
3 Securing spring 9 Lamp
4 Supply connector IO Plastic cover
5 Cover 11 Headlight wiper clamp
6 Lamp holder

REMOVAL AND
INSTALLATION
With reference to the exploded view
proceed as follows.
1. Operating from engine com-
partment inside, disconnect harness
from cover 0.
2. Remove grille (see: Group 75 -
Grille).
3. Unscrew the two nuts securing
combination lamps to body.

(2) Unscrew the two screws secur-

ing transparent cover @J to com-
bination lamps 0, then remove it.
5. For combination lamp installa-
tion, reverse order of removal.
6. Adjust luminous beam by fol-
lowing the procedures described in
Setting of headlights low beam.

Replacement of transparent cov-

er @ can be carried out on mounted
combination lamps 0, by operating
f r o m e n g i n e comparment inside.
4. Operating from fender inside, (1) Rotate lampholder @ counter-
unscrew nut securing combination clockwise and withdraw it from
lamps to fender itself and re- 0.
transparent cover IO
move it.

40-l 7 May 1983

 ELECTRICAL SYSTEM

(3) For installation of transparent
cover, reverse order of removal.
LAMP REPLACEMENT
Headlights and front side lights
1. Operating from engine com-
partment inside, rotate cover 0
clockwise, then remove it.
1 Cover
6. For installation, reverse order of 1. Operating from fender inside,
remova I. compress the two springs securing
transparent cover of side direction
i n d i c a t o r @ to fender @, t h e n
CAUTION: remove it.
Do not touch with the hands glass of 2. Withdraw lampholder @ from
headlight halogen lamp 2 . If this 0
direction indicator 1 _
occurs, wash the glass. 3. Replace lamp @ by pulling
the relevant bulb.
4. Install direction indicator by
Front direction indicators reversing order of removal.
1. Operating from engine com-
partment inside, rotate lamp- SETTING OF HEADLIGHTS
h o l d e r @ counterclockwise, then LOW BEAM
remove it.
Carry out the following procedure to
2. Press lamp bulb @ and rotate
adjust headlight low beam.
it in order to withdraw lamp.
1. Check that tires are inflated at
3. Replace the lamp and install
the right pressure and that car is free
lampholder 0.
from any load excepted those of
service supplies and of one passenger
equivalent.
2. Position the car and the possible
test equipment on an horizontal
plane. If no test equipment is avail-
able, place the car in front of a clear
screen.

2. Disconnect SuPPlY con-

nector 0.
3. Move car back of about IO m
3. Rotate securing spring @
(32,8 ft) and switch on low beams.
counterclockwise, and remove it.
2 Lampholder
The luminous beam must be in
4. Withdraw halogen lamp @ and 1 Lamp
compliance with geometric dimen-
replace it. On reassembly, replace the
Side direction indicators sions provided in figure.
lamp, make sure the cover is properly
positioned by correct alignment
of the notches.
5. To remove headlight lamp @,
withdraw lampholder 0, press bulb
and rotate it counterclockwise.

1 Side direction indicator

2 Lamp
3 Lampholder
4 Fender

1 Supply connector
2 Halogen lamp
3 Securing spring
4 Lamp
5 Lampholder

May 1983 40-18


A = distance of headlight centre
from ground
B = height of luminous beam
C = IO m (32,8 ft)
Orientation is correct when the
following condition occurs:
6 = 470 m m (l8,5 in)
Distance D between luminous beams
REAR COMBINATION LAMPS
REMOVAL AND
INSTALLATION
With reference to the exploded view,
operate as follows.
I. Open back door and lift rear
trim.
2. Disconnect connector.
3. Unsaew the six nuts securing
combination lamps to body, then
remove combination lamps.
ELECTRICAL SYSTEM
centre must be equal to distance E
between headlight center.
The dimensions indicated in the
diagram comply with provisions in
force in Italy. For other countries,
comply with national provisions.
For correction of possible orien-
tation errors, from engine compart-
ment inside, operate on adjusting
screws of headlights set in evidence 1 Horizontal direction adjustment screw
in the following figure. 2 Verrical direction adjustment screw
1 Combination lamps
2 Lamp
3 Lampholder
4. For installation of combination
lamps, reverse order of removal.
LAMP REPLACEMENT
The following procedure is applicable
to all lamps and lampholders.
40-19 May 1983
 ELECTRICAL SYSTEM

1. Open back door and lift rear 3. Press bulb of lamp and rotate it
trim. in order to remove.
2. Press on lampholder side 0, 4. Replace lamp and refit lamp-
pull; then remove it. holder.
5. For identification of lamp loca-
tion, refer to diagram of the follow-
ing figure.

4
0-J
Diagram refers to the left rear
combination lamp. 1 Rear fag light
The right-hand one is specular with 2 Side light
respect to the left-hand. 3 Stop and side lights
4 Direction indicator
5 Reverse light
The rear fog light is present in the 6 Number plate light
left rear c o m b i n a t i o n l a m p o n l y .
1 Lamp
2 Lampholder

INSIDE LIGHTING
1200 and 1350 model

0 H4

O-
Gl

--I
P
z h nz

0
A l -%
=-

it*
Nl

May 1983 40-20

 ELECTRICAL SYSTEM

1500 a n d 1 6 0 0 Quadrlfogllo m o d e l

Al Battery
G30 Power window and door lock connector
61 Ignition switch
G86 Passenger compartment roof lamp connector
F3 Passenger compartment roof lamp
H4 Roof lamp switch on passenger compartment pillar
F16 Ignition switch lighting lamp
NlO Passenger compartment roof lamp timer
Gl Fusebox

ROOF LAMP

Lamp replacement

1. By means of proper tool,

remove transparent cover, pressure
2. Withdraw and replace the lamp.. 3. For lamp installation, reverse
inserted into lampholder.
order of removal.

40-2 1 May 1983

 ELECTRICAL SYSTEM

CAUTION: securing c l u s t e r @ to support LIGHTING AND WARNING

Before starting operations, make sure bracket @. LAMPSREPLACEMENT
that the ignition key is to the ST 2. Remove the pressure inserted ,. Remove cluster (see: Removal
position and ground cable is discon- cover 0, disconnect harness 0,
and Installation).
nected. then remove cluster.
2. Rotate lampholder and with-
draw it; then remove lamp from
3. For installation, reverse order
REMOVAL AND lampholder itself.
of removal.
INSTALLATION 3. Replace lamp with an identical
1. Unscrew the four screws @ one then carry out installation by
reversing order of removal.

1 Cluster
2 Connector5
3 Cover
4 Bracket
5 Screw

40-23 May 1983

 ELECTRICAL SYSTEM

FUEL LEVEL TRANSMITTER 2. Connect a lamp indicator to

pins of float plug, as per figure.
Removal and installation . 3. Check device proper function-
For removal and installation see: ing by verifying the following.
Groupe 04 - Supply System.
Float lifted:
CLUTCH AND BRAKE OIL lamp indicator off
MINIMUM LEVEL Float lowered:
TRANSMITTER lamp indicator on

Check
1. Set the ignition key to the MAR
position.

40-27 May 1983

 ELECTRICAL SYSTEM

WINDSCREEN WASH/WIPER AND HEADLIGHT

WASH /WIPER
WINDSCREEN WASH/WIPER
r r
I

I m---J

r- -
PI9
0
I n I
L--
+3
r--l

Al Battery
Bl Ignition switch
82 Windscreen wiper control switch
83 Windscreen washer and/or headlight
wash/wiper pump control switch
Gl Fusebox

G85 Front service ConnectOr

L13 Windscreen washer liquid level sensor
N7 Trip Computer
N8 Check Control
N14 Windscreen wiper electronic intermittence
PI Windscreen wiper motor
PI9 Windscreen washer electric pump
CL4 R.H.D. L.H.D. Quadrifoglio model
 ELECTRICAL SYSTEM

WINDSCREEN WIPER

IO Brush
6 Bush
1 Motor 11 Bush
7 Cowl top cover
2 Motor cover 12 Spacer
8 Nut
3 Linkage 13 Nut
0 Wiser arm
4 Nut
7. Unscrew the three screws secur-
5 Spacer Remove cowl top cover 0
4. ing motor 0 to linkage @ and
REMOVAL AND (see: Group 75 - Cowl top cover). nut securing motor shaft to linkage.
INSTALLATION 5. Withdraw bush @) , unscrew
Disconnect motor 0 harness. nut 8, then remove it together
1.
0 from with spacer @ .
2. Withdraw brushes 0
0
wiper arms 9 .
6. Unscrew the three screws secur-
ing linkage @ to body, then re-
3. Lift covers of nut @ securing
move it.
wiper arms @, unscrew nuts, then
remove wiper arms.

8. Remove motor 0 and with-

draw cover @.
9. For windscreen wiper installa-
tion, reverse order of removal.

May 1983
40-29

TROUBLE DIAGNOSIS AND CORRECTIONS
Condition
Windshield wiper does not
operate
Windshield wiper operating
speed is too slow
Windshield wiper does not
stop correctly
Washer fluid does not eject
(washer motor operates)
Wiper does not operate inter-
mittently but operates at low
and high speeds
Intermittent speed is too
short for proper wiping
Intermittent speed is too long,
for proper wiping
May 1983
ELECTRICAL SYSTEM
Probable cause Corrective action
l Burnt fuse Replace fuse
l Loose connection or open circuit Restore connection
l Improper switch contact Verify combination switch; (right light);
replace, if necessary
l Foreign material interrupts link Take off foreigtimaterial
mechanism
l Disconnected rod. Connect rod.
l Seized or rusted arm shaft Replace shaft
l Short circuit of motor armature Replace motor
l Worn brushes or seized shaft Replace brushes
0 Low source voltage Verify voltage supply
. Humming of motor Replace motor
l Faulty auto-stop device Replace auto-stop device
l Faulty wiper motor Replace motor
Clogged washer nozzle or hose Free nozzle or hose
l Faulty wiper switch Replace combination switch (right lever)
l Faulty wiring Verify wiring
l Faulty intermittence Replace intermittence
l Faulty auto-stop device Replace auto-stop device
l Faulty intermittence Replace intermittence
l Line voltage below 10 volts Restore voltage
l Faulty intermittence Replace intermittence
40-30
 ELECTRICAL SYSTEM

Condition Probable cause Corrective action

Intermittent speed is erratic l Faulty wiper switch Replace switch

l Faulty wiring Verify wiring

. Faulty wiper motor Replace motor

l Faulty intermittence Replace intermittence

40-31 M a y 1983
 ELECTRICAL SYSTEM

HEADLIGHT WASH/WIPER
1500 Quadrlfogllo model

Bs

I;
1

I 1 1 1 r I!jI1

!
I
i
I
i
1w--B 1I

May 7983 40-32

 ELECTRICAL SYSTEM

HEADLIGHT WIPER

1500 Quadrlfogllo m o d a l

1 Motor
7 Nut
2 Bracket
B Wiper arm
3 Headlight wpsher hose
9 .Headlight washer hose
4 . Grille
10 Bracket
5 Wiper arm
11 Motor
6 Nut

5. Unscrew the six screws secur-

ing motors @ and @to
bracket @ and @ ! then remove
REMOVAL AND motors.
INSTALLATION
With reference to the exploded view
above proceed as follows.
1. Disconnect harness of mo-
tor (iJ .
2. Lift cover of nuts 0 8
6 and
securing wiper arms @ and 8 ,
7

unscrew nut and disconnect head-

light washer hoses @ and @.
3. By means of tool A.3.0602,
remove wiper arms @ and @.

4. Remove grille (see: Group 75 6. For windscreen wiper installa-

Grille). tion, reverse order of removal.

40-33 May 1 9 8 3
 ELECTRICAL SYSTEM

SPECIAL SERVICE TOOLS

Refer to
Tool number Tool name
Page

A.3.0602 Wiper arm puller

40-35 May 1983

 ELECTRICAL SYSTEM

HORNS HORN CONTROL

Location PUSHBUTTON Is=3
The horns are mounted inside engine
compartment on support brackets Location
located under front combination
The pushbutton is located at centre
lamps.
of steering wheel (see: Group 23 -
Removal and installation
Steering Wheel and Column).
1. Operating from engine com-
oartment inside, disconnect horn Check
h a r n e s s 0.
1. Connect ends of tester to
2. Unscrew the nut @ securing pushbutton terminal, operating as
horn 2 to support bracket 0; then per figure.
remove the bracket.
2. Check pushbutton proper func-
3. For installation, reverse order of
tioning by verifying the following:
removal.

Pushbutton lifted: -&

Pushbutton depressed: 0 a

1 Harness 3 Bracket
2 Nut

TROUBLE DIAGNOSIS AND CORRECttONS

Condition Probable cause Corrective action

I
Only one side operates l Faulty hose Replace horn

l Loose connector contact Restore connection

Poor tone quality on one side Tone adjustment not good Adjust tone by operating on the relevant
adjusting screw 0

Both horn volume reduced l Low battery charge Charge battery or replace

l Faulty charging system Verify charging system

l Faulty connector contact Rest&e connection

Both horns do not operate l Wiring cut-out Restore connection

l Faulty control push button Replace push button

l Discharged battery Charge battery

l Both horns faulty Replace both horns

40-37 &fay 7983

 ELECTRICAL SYSTEM

4. Dry end of ruling pen to remove 6

. By means of a hot air jet, heat
silver compounds. the repaired area for about 20
5. Once the repair has been carried
minutes, k e e p i n g t h e o r i f i c e o f
out, wait for about 10 minutes, then heat-gun at about 3 cm (I,2 in) from
verify electric continuity of the wire
surface. If a heat-gun is not available,
in object.
let dry for 24 hours.

During test, do not touch with the

fingers the repaired resistor,

1 Filament 3 Rule
2 Interruption 4 Ruling pen

POWER WINDOW
1 3 5 0 m o d e l ( I t a l y , o n l y ) and 1 5 0 0 m o d e l

Al Battery 821 Right front power window control switch I1 2 Front power windows relay
Bl Ignition switch 822 Left front power window control switch PI4 Right front power window motor
B9 Heated rear window control switch Gl Fusebox PI 5 Left front power window motor
812 Hazard lights control switch G36 Power window switch cable connector

40-39 May 1983

 ELECTRICAL SYSTEM

POWER WINDOWS AND DOOR LOCKS

1500 Quadrlfogllo model

I I I 1

I I I I

r e-- 1

40-4 1 May 1983

 ELECTRICAL SYSTEM

DOOR LOCK CONTROL UNIT

LOCATION
The door lock control unit is located
inside passenger compartment, in the
gear lever console, behind Check
Control and Trip Computer.

REMOVAL AND
INSTALLATION
1; @wi;ydisc;;;ey;e ,,:,I
vant harness.
2. Remove control unit @ by
unscrewing the screw securing it to
Trip Computer 0.
1 Door lock control unit
For control unit installation, reverse
2 Trip Computer
order of removal. 3 Instrument holder
4 Check Control

May 1983 40-42

 ELECTRICAL SYSTEM

3. For instrument installation, re- used to set in evidence the enabled

LOCATION verse order of removal. function in order to allow user an
Check Control and Trip Computer When reading a red led diode is easy identification.
are inserted into a special instrument
holder integrated into gear lever
console, in centre position, under
dashboard.

REMOVAL AND
INSTALLATION
1. Withdraw instrument holder 3
from console and disconnect the
relevant harness.
2. Remove Check Control 2 and
Trip Computer 1 by unscrewing,
for each one, the two securing screws
to instrument holder.

For an easier comprehension of the Indications and the Check Control

symbology used for the two instru- signallings, pairing them to relevant
ments, in the following table refer- symbols.
ence i s m a d e t o T r i p C o m p u t e r

1 T r i p C o m p u t e r 3 instrument h o l d e r
2 Check Control

Trip Computer Check Control

1 lstantaneous consumption in L/100 km 7 Windscreen washer fluid level warning lamp

2 Medium consumption for the covered distance in L/100 km 8 Engine oil level warning lamp
starting from zeroing by red Key (Start Key)
9 Engine coolant level warning lamp
3 Fuel consumption in litres since trip start, starting from
zeroing by red Key 10 Cluster warning lamp

4 Medium speed in km/h since trip start, starting from

11 Stop lights warning lamp
zeroing by red Key

5 Drive time in h/min since trip start, starting from zeroing 12 Side lights warning lamp

by red Key
13 Main red warning lamp
6 Time in hoursjmin
14 Main green warning lamp

May 1983 40-44

 ELECTRICAL SYSTEM

ELECTRIC COMPONENT LOCATION

ENGINE COMPARTMENT

1 Passenger compartment roof lamp timer 5 Front power windows relay

2 Horns relay 6 Fusebox
3 Heated rear window relay 7 Electronic device for headlights and flashing changeover
4 Headlight wiper relay 8 Windscreen wiper electronic intermittence

PASSENGER COMPARTMENT

1 Hazard and direction lights intermittence

40-45 May 1983

 ELECTRICAL SYSTEM

HARNESS LAYOUT
GENERAL HARNESS

1 Engine comparment harness

2 Front part and dashboard harness
3 Roof lamp harness
4 Luggage room harness
5 Passenger compartment harness

ENGINE COMPARTMENT

A3 Alternator with built-in electronic regulator

A8 Ignition coil L5 Thermostatic switch for engine coolant max. temperature warning lamp
Al 1 Starter L6 Thermostatic switch for engine cooling electric fan
01 Alternator charge warning lamp L7 Transmitter for coolant temperature gauge
E9 Side direction light lamp L17 Odometer pulse generator
Gl Fusebox Ml Cut-off solenoid valve
G46 Headlight connector N14 Windscreen wiper electronic intermittence
G53 Engine compartment ground N18 Electronic device for headlights and flashing changeover
G73 Rear service connector 02 Horn
G85 Front service connector P2 Engine coaling electric fan
H2 Reverse right switch P4 Headlight wiper motor
HI7 Brake fluid min. level control switch PI9 Windscreen washer electric pump
L2 Pressure switch for engine oil min. pressure 01 Air ventilation heater fan

May 1983 40-46

 ELECTRICAL SYSTEM

PASSENGER COMPARTMENT AND LUGGAGE ROOM (L.H. DRIVE)

May 1983
 ELECTRICAL SYSTEM

DASHBOARD (L.H. DRIVE)

Bl Ignition switch
F8 Air ventilation controls lighting lamp
82 Windscreen wiper control switch
84 Control switch for headlight, flashing, low beam and full beam G5 Connector
B5 Horns control switch G6 Cluster B connector
B6 Direction lights indicator switch G7 Cluster R connector
B9 Heated rear window control switch G86 Passenger compartment roof lamp connector
Bll Rear fcg light control switch H3 Stop light switch
B12 Hazard lights control switch H13 Choke switch
.
821 Right front power window control switch N13 Hazard and direction lights intermittence
822 Left front power window control switch 06 Cigar lighter
C7 Clock Q4 Air ventilation heater fan control

May 1983 40-48

 ELECTRICAL SYSTEM

SWITZERLAND-AUSTRALIA MODEL VARIATION

TACHYMEiRlC C O N T R O L U N I T - F A S T I D L E E L E C T R O M A G N E T
-HAND BRAKE SWITCH
TACHYMETRlC CONTROL UNIT - FAST IDLE/ ELECTROMAGNET
(For vehicles 1350 - 1500 and 1500 Quadrifoglio models for SWITZERLAND and AUSTRALIA)
and HAND BRAKE SWITCH
(For 1500 Quadrifoglio vehicles, A USTRA LIA models)
0
r - 1

Al Battery G7 Cluster R connector

A8 Ignition coil
Bl Ignition switch
B2 Windscreen wiper control switch
Cl Electronic rev. counter
07 Hand brake warning lamp
Gl Fusebox
G6 Cluster B connector
G30 Power window and door lock connector
G85 Front service connector
HI Hand brake switch
Ml Cut-off solenoid valve
M4 Idle speed electromagnet
N16 Tachymetric control unit

HANDBRAKE INDICATOR
handbrake indimtor as shown in
SWITCH figure.
(1500 Quadrifoglio) 3. The following resistance values.
shall be read.
Check
1. Set the ignition key to the MAR Brake engaged: 0 a
position. Brake disengaged: &
2. Connect a tester to terminal of

40-49 May 1983

 ELECTRICAL SYSTEM

CIRCUIT DIAGRAM

HZ Reverse light switch

KEY H3 Stop light switch
H4 Roof lamp switch on passenger compartment pillar
A l Batter/ HI 3 Choke switch
A 3 Alternator with built-in electronic regulator H17 Brake fluid min. level control switch
A5 Ignition distributor H27 Contact switch, on rear door, for heated rear window
A8 Ignition coil I2 Heated rear window relay
All Starter I3 Horns relay
Al2 Spark plugs I4 Headlight wiper relay
Bl Ignition switch 112 Front power windows relay
82 Windscreen wipercontrol switch L2 Pressure switch for engine oil min. pressure
B3 Windscreen washer and/or headlight wash/wiper pump L5 Thermostatic switch for engine coolant max.temperature
control switch warning lamp
84 Control switch for headlight, flashing, low beam and full beam L6 Thermostatic switch for engine cooling electric fan
B5 Horns control switch L7 Transmitter for coolant temperature gauge
B6 Direction lights indicator switch L9 Transmitter for fuel level gauge
B9 Heated rear window control switch L12 Engine oil level indicator
Bll Rear fw light control switch L13 Windscreen washer liquid level sensor
812 Hazard lights control switch L14 Engine coolant level sensor
821 Right front power window control switch L17 Odometer pulse generator
822 Left front power window control switch Ml Cut-off solenoid valve
Cl Electronic rev. counter M4 Idle speed electromagnet
C2 Electronic tachometer Nl Module for electronic ignition
C4 Fuel level gauge N7 Trip Computer
C6 Coolant temperature gauge N8 Check Control
C7 Clock NlO Passenger compartment roof lamp timer
Dl Alternator charge warning lamp Nil Door lock control unit
D2 Direction light warning lamp N13 Hazard and direction lights intermittence
D3 Side light warning lamp N14 Windscreen wiper electronic intermiuence
04 Full beam warning lamp N16 Tachymetric control unit
D5 Brake fluid level warning lamp N17 Trip control unitfor fuel flow
07 Hand brake warning lamp N18 Electronic device for headlights and flashing changeover
D8 Fuel reserve warning lamp 01 Heated rear window
D9 Choke warning lamp 02 Horn
Dll Engine oil min. pressure warning lamp 06 Cigar lighter
D13 Engine coolant max. temperature warning lamp PI Windscreen wiper motor
El Front direction indicator light lamp P2 Engine cooling electric fan
E2 Front side light lamp P4 Headlight wiper motor
E8 Low beam and full beam lamp PI0 Right front dwr lock motor
E9 Side direction light lamp PI 1 Left front door lock motor
El 1 Rear direction light lamp P12 Right rear door lock motor
El3 Tail light lamp PI3 Left rear door lock motor
El4 Raversa light lamp P14 Right front power window motor
El5 Stop light lamp PI5 Left front power window motor
El6 Rear fog light lamp P19 Windscreen washer electric pump
El7 Number plate light lamp P20 Headlight washer electric pump
F3 Passenger compartment roof lamp Ql Airventilation heater fan
F8 Air ventilation controls lighting lamp Q4 Air ventilation heater fan control
F12 Cluster lighting lamp al L.H.D. 1200 model
F16 Ignition switch lighting lamp UZ L.H.D. - R.H.D. 1350 model
F17 Switches lighting lamp U3 L.H.D. - R.H.D. 1500 model
Gl Fusebox U4 L.H.D. - R.H.D. 1500 Quadrifoglio model
Hl Handbrake switch

May 1983 40-50

p&-3-
---------
---------

I
I
 ELECTRICAL SYSTEM

H2 Reverse light switch

KEY H3 Stop light switch
H4 Roof lamp switch on passenger compartment pillar
HI 3 Choke switch
Al Battery
HI7 Brake fluid min. level control switch
A3 Alternator with built-in electronic regulator
H27 Contact switch, on rear door, for heated rear window
A5 ignition distributor
I2 Heated rear window relay
A8 Ignition coil
,I3 Horns relay
All Starter
14 Headlight wiper relay
Al 2 Spark plugs
I12 Front power windows relay
Bl Ignition switch
L2 Pressure switch for engine oil min. pressure
82 Windscreen wiper control switch
L5 Thermostatic switch for engine coolant max.temperature
83 Windscreen washer and/or headlight wash/wiper pump
warning lamp
control switch
L6 Thermostatic switch for engine cooling electric fan
84 Control switch for headlight, flashing, low beam and full beam
85 Horns control switch L7 Transmirter for coolant temperature gauge
B6 Direction lights indicator switch L9 Transmitter for fuel level gauge
B9 Heated rear window control switch L12 Engine oil level indicator
I311 Rear fog light control switch L13 Windscreen washer liquid level sensor
812 Hazard lights control switch L14 Engine coolant level sensor
B21 Right front power window control switch L17 Odometer pulse generator
822 Left front power window control switch Ml Cut-off solenoid valve
Cl Electronic rev. counter M4 Idle speed electromagnet
c 2 Electronic tachometer Nl Module for electronic ignition
c 4 Fuel lwel gauge N7 Trip Computer
C6 Coolant temperature gauge N8 Check Control
c7 Clock NlO Passenger compartment roof lamp timer
Dl Alternator charge warning lamp Nil Door lock control unit
02 Direction light warning lamp N13 Hazard and direction lights intermittence
03 Side light warning lamp N14 Windscreen wiper electronic intermittence
04 Full beam warning lamp N16 Tachymetric control unit
05 Brake fluid level warning lamp N17 Trip control unit for fuel flow
D7 Hand brake warning lamp N18 Electronic device for headlights and flashing changeover
08 Fuel reserve warning lamp 01 Heated rear window
09 Choke warning lamp 0 2 Horn
Dll Engine oil min. pressure warning lamp 0 6 Cigar lighter
013 Engine coolant mBy. temperature warning lamp PI Windscreen wiper motor
El Front direction indicator light lamp P2 Engine cooling electric fan
E2 Front side light lamp P4 Headlight wiper motor
ES Low beam and full beam lamp P I 0 Right front door lock motor
E9 Side direction light lamp PI1 Left front door lock motor
El 1 Rear direction light lamp PI2 Right rear door lock motor
El3 Tail light lamp PI3 Left rear door lock motor
El4 Reverse light lamp PI4 Right front power window motor
El5 Stop light lamp PI5 Left front power window motor
El6 Rear fog light lamp PI9 Windscreen washer electric pump
El7 Number plate light lamp P20 Headlight washer electric pump
F3 Passenger compartment roof lamp Cl1 Air ventilation heater fan
F8 Air ventilation controls lighting lamp Q4 Air ventilation heater fan control
F12 Cluster lighting lamp ai L.H.D. 1200 model
F16 Ignition switch lighting lamp a2 L.H.D. - R.H.D. 1350 model
F17 Switches lighting lamp a 3 L.H.D. - R.H.D. 1500 model
Gl Fusebox a4 L.H.D. - R.H.D. 1500 Quadrifoglio model
HI Handbrake switch

May 1983 40-53

 BODY-SHEET METAL PANELS
CONTENTS
GENERAL INFORMATION., . . . . . . . .49-2
Identification codes . . . . . . . . . . . . . .49-2
Lifting points. . . . . . . . . . . . . . . . . . .49-3
Wheel alignment. . . . . . . . . . . . . . . . .49-3
BODY COMPONENT PARTS . . . . . . . . .49-5
Body components . . . . . . . . . . . . . . . 49-5
Under body components . . . . . . . . . ,49-6
BODY CONSTRUCTION . . . . . . . . . . . .49-7
Body construction . . . . . . . . . . . . . . .49-7
BODY SEALING . . . . . . . . . . . . . . . . . . .49-9
Description. . . . . . . . . . . . . . . . . . . . .49-9
BODY ALIGNMENT . . . . . . . . . . . . . . . .49-11
Measurement operations . . . . . . . . . .49-l 1
Measurement points. . . . . . . . . . . . . .49-l 2
CAUTIONS FOR THE OPERATORS . . .49-14
Safety rules . . . . . . . . . . . . . . . . . . . .49-14
Body and outer components
protections. . . . . . . . . . . . . . . . . . . . .49-l 4
Cautions during replacement
operations . . . . . . . . . . . . . . . . . . . . .49-l 5
Cautions during welding operations . .49-l 5
REPLACEMENT OPERATIONS . . . . . . .49-20
How to read this chapter . . . . . . . . . .49-20
Symbology . . . . . . . . . . . . . . . . . . . . .49-21
Removal and installation
procedures . . . . . . . . . . . . . . . . . . . . .49-22
Radiator core support . . . . . . . . . . . .49-29
Hoodledge panel with core
support removed . . . . . . . . . . . . . . . .4g-31
Hoodledge panel with radiator core
support removed (Partial
replacement) . . . . . . . . . . . . . . . . . . .49-33
Front side member. . . . . . . . . . . . . . .49-35
Central pillar . . . . . . . . . . . . . . . . . . . .49-37
Outer side member. . . . . . . . . . . . . . .49-39
Outer side member (Partial
replacement) . . . . . . . . . . . . . . . . . . .49-41
Rear fender . . . . . . . . . . . . . . . . . . . .49-43
Drip with rear fender removed. . . . . .49-45
Lower rear panel . . . . . . . . . . . . . . . .49-46
Upper rear panel . . . . . . . . . . . . . . . . 49-47
Rear part of rear floor with rear fender
and rear panel removed . . . . . . . . . . .49-49
Rear side member with rear panel
and rear floor removed. . . . . . . . . . . .49-51
Roof panel. . . . . . . . . . . . . . . . . . . . . 49-52
May 1983
 BODY -SHEET METAL PANELS

GENERAL INFORMAi-ION

IDENTIFICATION DATA

Identification and Identification and

certification label Chanis No. certification label

Identification and-certification label Chassis no.

See Group 00 - Identification Data (according to CEE/ISO standard specifications)
See Group 00 - Identification Data

May 1983 49-2

 BODY -SHEET METAL PANELS

LIFTING POINTS

Front towing eye

and jack seat
Rear towing eye

Jack and safety stands 1. Front axle and suspension

r
WARNING:
Toe-out mm M - H =4+1
a. After lifting the car by means of hydraulic jack,
(in) M-.H =0.16*0.04
provide to support car weight by means of safety
stands. Haif toe-zlut mm L = 12 lv-- 2 f 0.5

b. Before lifting car rear (front) side place wheel chocks (in) L=1/2M -0.08f0.02
by positioning them at front (rear) wheels. Toe-out angle a=lof

Rim diameter mm 0=340

Securely position hydraulic jack and safety stands in the
(in) 0= 13.39
points identified in figure.
Camber angle fl=-295f30

Caster angle y= lf30

WHEEL ALIGNMENT Max steering angle 6 = 3350

CAUTION: 2. Rear axle and suspension

The technicians assigned to the repair and replacement
operations of sheet panels, shall always take into account,
content of the remaining part of the Workshop Manual Toe-in angle U=O+25
in order always to maintain original quality and func- Camber angle p=O+25
tioning conditions of car as a whole. As restoration of
car correct alignment is of particular importance, in the
following part are provided the data relevant to geometry
of both front and rear suspensions. For any further Wheel alignment is measured with cBr under nominal
information, refer to the specific Groups. height (see: Group 00 - Wheel alignment).

49-3 May 1983

0
z
0
m
 BODY -SHEET METAL PANELS

BODY CONSTRUCTION

BODY CONSTRIJCTION

49-7 May 1983

 BODY -SHEET METAL PANELS

BODY SEALING

DESCRIPTION

The following figures, show the body areas which are possible sealing faults.
sealed by Manufacturer.
The scalings applied to these areas, must be smooth and ICIR: Paraflex Alpha 3M
free from scratches or gaps. 8531 IE
8536/E
Take care not to apply too much sealing and not to Alternative: part. no. 3522-00014
allow other unaffected parts to come in contact with the
sealing.
Sealant for bolted joints
Body components sealing Sealant for joints between panels assembled by bolting.
Paint seal, after priming or painting, and then sleek by
means of a brush along all sheet joints in order to remove 3M - Autosealer 8573E - part. no. 3522-00045

49-9 May 1983

 BODY -SHEET METAL PANELS

View from I View from L

Detail M

BODY ALIGNMENT

MEASUREMENT OPERATIONS

Method of measurement operation . When a measuring tape is used, verify there is no

. When a tram tracking gauge is used, adjust pointers
(A) and (B) to equal lenghts as shown in the follow-
ing figure.
Check pointers and gauge itself in order to make sure
that no clearance is present.
elongation, twisting or bending.
If, during measurement qperations, tape interfere with
one or more parts of car body, accurate measurement of
distance and length will not be possible.

49-11 May 1983

 BODY - SHEET METAL PANELS

MEASUREMENT POINTS

May 1983 49-12

BODY -SHEET METAL PANELS

May 1983
 BODY-SHEET METAL PANELS

2. Outer parts protection I

. When removing external parts (hood, back door,
Arm different
moldings, finishings) it is necessary to protect body
length
surfaces with clothes, protection tape or other
materials, in order not to damage or scratch vehicle
body.
. The scratched painted surfaces must be repaired: even
a slight scratch may cause corrosion. Maladjusted
electrode
length
Align both electrod-
CAUTIONS DURING
CORRECT INCORRECT
REPLACEME-NT OPERATIONS

Use genuine spare parts.

(3) Electrode end diameter

. It is recommended always to use genuine spare parts.
It is necessary to carefully verify diameter af electrode
This allows perfect repair and restoration of vehicle
ends in order to obtain the required welding strength.
original functioning.
Before starting working, make sure that end diameter (D)
has a value proportional to sheet thickness.
Remove burnt and foreign matters from electrode ends.

CAUTIONS DURING WELDING

OPERATIONS

Spot welding 150

1. Spot welder
Before starting welding operations, carry out the follow-
D=Zt i-3 (mm)
ing checks in order to obtain welding sufficient strenght:
(1) Welder arm adjustment
a) Keep the arm as short as possible in order to obtain
welding maximum pressure. D= Electrode end diameter
,
t =Sh;thickny ; ~
b) Tighten arm and tips securely so as they do not get
loose during soldering operations.

Spot welder a/m 2. Condition and preparation of panels to be soldered

If the surface of the parts to be welded presents gap, paint
film, rust or dust, this prevents welding current flow, thus
reducing soldering area and, as consequence, strength
of welding spot.
Before starting welding, verify conditions of the parts to
be welded, carrying out proper corrections.
(1) Clearance between the parts to be welded.
Presence of any clearance between surfaces to be welded,
Arm minimum causes reduction of current flow, The welding thus
lenght obtained, results to be insufficient and poor in strength,
Before carrying out soldering, match the surfaces and,
when necessary, tighten them by means of a clamp.

(2) Electrode alignment

Align ends of upper and lower electrodes. A misalignment
of electrodes generates insufficient pressure of soldering
points and, as consequence, an insufficient strength of
points themselves.

49-15 May 1983

 BODY -SHEET METAL PANELS

(2) Electrode installment.

Operate such as sheet forms a tight angle with electrodes.
if not so, current flow will be low and the obtained
welding streng.ht insufficient.
(3) Welding of three or more overlapped sheets. In
the areas where three or more sheets are overlapped,
spot welding must be repeated.

INCORRECT INCORRECT CORRECT

(2) Welding of metal surfaces.

Prepare the surfaces to be welded, removing all impurities
and foreign matters (paint, dust, rust) in order to obtain
perfect welding.
In casa three or more overlapped
sheets ara welded, repeat welding
twice.

(4) Number of spot welding points.

Generally, efficiency of spot welders available in the
Repair Shop is lower than efficiency of spot welders used
at the Factory. As consequence, the number of spot
welding points performed at the Service Shop should be
increased by 20 30% with respect to weldings performed
at the Factory.
(5) Minimum welding pitch.
The minimum welding pitch is function of thickness
of sheet to be welded. Generally, the values provided
in the following table, should be observed.
(3) Anti-corrosion procedure applicable to all metal
surfaces.
ThicknB (t) Minimum pitch (I)
Coat the surface to be+ welded high conductivity
mm (in) mm (in)
anti-corrosion agent. It must be applyed to end of
surface to be welded, also. 0.6 IO.0241 10 (0.39) or more
0.8 (0.031) 12 (0.47) or mare
1.0 (0.039) 18 (0.71) or more
1.2 (0.047) 20 (0.79) or more
1.6 (0.063J 27 (1.06) or more
1.8 (0.071) 31 (1.22) or mom

Preliminary operation Apply anti-corrosion agent

to the whole surface, end
included.

1
3. Cautions during spot welding
I I
(I) Spot welding selection
Use the direct welding method (for the parts this method
can not be applied to, use the MIG welding method).

May 1983
 BODY - SHEET METAL PANELS

MIG welding
01 1. Conditions of panel to be welded.
1 CORRECT By means of belt sander or wire brush, remove any
f
It must form an opening of
foreign matter from surface.
about 3 mm dia., when stressing Paint films, rust or oils present on sheet surface, causes
decrease of welding strength, thus generating blow holes.

i
INCORRECT 2. Cautions during welding operations.
(II Plug welding (of pre established holes)
a) Make a hole, having 6 to 6 mm diameter (0.20
t
to 0.24 in) on one of the two sheets to be welded,
then match the two sheets and clamp them.
b) Position the torch at right angle with respect to
(2) Test to be carried out after welding, by means of
sheet, then fill metal into the hole.
chisel and hammer.
Each time welding is stopped, on the surface an
. Insert tip of a chisel between the welded sheets and
oxide film generates which causes blow holes. If this
slightly tap on chisel until, between sheets, it is
occurs, remove oxide by means of a wire brush.
obtained a 3 to 4 mm clearance (0.12 to 0.16 in); if,
c) Make sure that welding between upper and lower
on the welded part, no strain is present, test result is
sheet is perfect.
then positive.
. If sheets thickness is not equal, clearance between
sheets must be limited to 1.5 to 2 (0.059 to 0.079
in).
Take into account that the above value is only a
reference one.
. The mentioned clearance changes according ta Part around the hole

position of welding spots, flange length, welding

inclination and other factors.
D O never exceed this limits in order not to cause
detachment of welding points.
. After test, make sure that the strained part is

Panel edge
Plug welding
Reference value: 3 to 4 mm
(0.12 to 0.16 in)
I Butt weldiirg

Slightly tap by means

of a hammer
r Point to be weldad

Reference value: 1.5 to 2.0 mm

(0.059 to 0.079 in)
SEC. A-A

(2) Butt welding.

a) By means of intermittent weld, tack the two surfaces
to be welded in order to prevent strains and align the
Slightly tap by means two surfaces, then, fill in the spaces by placing small
of a hammer welding beads.

Mav 1983 49-18

-.
 BODY - SHEET METAL PANELS

REPLACEMENT OPERATIONS

HOW TO READ THIS CHAPTER

The formulation of the present part of the manual is

uniform for all the replacement operations. For its struc-
ture, refer to the following example.

:I) HOODLEDQE PANEL WITH RADIATOR CORE SUPPORT REMOVED

carry c4lyII rwl~mml rmr R.dl.LM Em. swplrt km, bm ,,nm,d, (Iv) REMINDER WHEN REM<
II) $u#lsl bl~ - BY rm.l 01 .iT SW, cut
.- .nd. b m*anl 0 .nr dir

In detail:
(1) HOODLEDGE. PANEL WITH RADIATOR CORE
SUPPORT REMOVED
In the title it is indicated the element to be removed
(hoodledge) specifying, if required, the operative
condition (in this case, radiator on core support
removed). If the element is not in the required
conditions, it is necessary, to execute preliminary
removal of the other components; in the present case,
it is necessary to remove the radiator core support,
referring to the specific replacement procedures.
(II) SERVICE JOINT
Any information concerning the welding operations
to be carried out is shown in the figure indicating the
welding method and the spot numbers, together with
accurate location of spots on the elements to be
joined.
Example: a l 3 -Welding spot number
Welding type (spot welding:
see simbology on page 2 1)
LL Parts to be welded
The parts Tepresented by chain line, set in evidence the
components which must result to be removed or for
which it is required the preliminary removal, accordingly
to step (I 1.
(III)PARTS TO BE WELDED
A list is provided relevant to the components which
are to be welded using the methods indicated in step
(II).
(IV)REM~NDER WHEN REM~V~NG/INSTALLING
Indication is provided, relevant to the main opera-
tions to be carried out, with special care in identifica-
tion of the areas concerned in the cut operations,
selection of the equipments to be used and definition
of welding methods to be adopted.

May 1983 49-20

SYMBOLOGY
BODY -. SHEET METAL PANELS

Spot welder

CUTTING AND WELDING/BRAZING

OPERATIONS
The symbology used for the cutting and welding/brazing
operations is shown in the following figures.

ed by means of air

CO2 arc welding

n n n n MIG plug weld

Cutting performed by means

myhTr air chisel

..
m MIG seam weld/point weld

Spot welding

l l l l Spot welding of two overlapped sheets

.. Brazing
@I @I@@ Spot welding of three overlapped sheets

.the value in parenthesis 1 1

indicates the number of weld spots

May 1983
 BODY -SHEET METAL PANELS

Welding - brazing

(3) Cut-off damaged parts.

Tools required:
Sealing
. Air saw
. Air chisel

REMOVAL AND INSTALLATION

PROCEDURES (4) If welding spots are not visible, remove paint by
means of rotary wire brush.
Tools required:
COMPONENT REMOVAL
. Rotary wire brush
(1) Make sure that all the damaged parts have been
detected, by measuring the installation main dimensions.
Refer to Body Alignment drawing.
Tools required:
. Centering gauge
. Tracking gauge
. Convex rule
l Rack-and-lever jack or car lift

(2) With a body-frame repair system, carry out draw

operations, depending on deformation condition. Reuse
of the reclaimable parts must be performed in accordance
with the figures contained in Body Alignment.

Caution during operation:

(5) Punch all the welding spots in order to make center-
. Carefully secure drawing chains to body and equip-
ing of a drill.
ment, so as to prevent accidental release during
operation execution. Tools required:
. Apply draw stress in the direction opposite to . Hammer
l Center punch
collision.

May 1983 4 9 - 2 2 - -.
 BODY -SHEET METAL PANELS

Caution during operation

. Punch deeply in the center of each, welding spot. A III I - Hole must have a diameter
non-centered punch does not allow complete cut of
nugget. Besides, a shallow marked hole location does Ill i -I
below 8 mr nn 0.31
I in1

flJ!lJ
not allow a reliable drive of drill.
. As a rule, punching must be executed from sides of
the components that are to be removed.
1

?
:i

E.g.: replace outer side member

leaving central pillar in its original position.

(7) By means of a chisel remove the remaining spot

welding parts.

Tools required:
. Chisel
. Hammer

PREPARATION FOR MATING PARTS

INSTALLATION
(1) By means of a sander, grind sheet in correspondence
(6) Remove welding spots by means of a spot cutter or
with welding spots.
an air drill.
Tools required:
Tools required: . Air sander
. Spot cutter . Disc sander
. Air drill
Caution during operation:
. Use a drill speed of about 1000 r.p.m. in order to
obtain the best results.

Cautions when grinding

. Take care not to cut much on base metal: this may
generate decrease of sheet thickness and, then,
welding strength.

Cautions during operation:

. Take care not to drill mating parts. In case holes have
been made, plug them making use of gas or MIG plug
welding.
Presence of holes, decreases strength of the concerned
component, besides, it may generate water leakage.
. When, for new components, are used holes already
drilled in welded parts (just as per those of the spot
welding) make use of a drilling machine having small
diameter drill (below 8 mm (0.31.in)) and complete
welding as soon as possible.
I CORRECT INCORRECT

49-23 May 1983

 BODY -SHEET METAL PANELS

l Carefully remove iron powder from the surfaces

which have been grinded and from surrounding areas.
Presence of iron powder, causes decrease of welding
efficacy and can also generate corrosion,

(4) Apply primer to edges of new components and

of body panels which are to be welded.

(2) By means of a hammer and dolly correct deformed

areas.
Tools required:
. Hammer
l DOllY

Cautions during operation:

. Check against presence of even the smallest defor-
mations, in particular, in the inner panels where
they are hard to be found. Infact, if they are not
removed, they can cause a strength decrease due to
stress concentration.

Before welding apply conductive antirust paint on edges

of all sheet parts which are to be assembled.

Recommended paint:
Part. No. 3540-44401
SAVIU: Zincovid No. 7949
SCHRAM LACK: Extrinom Punktschweifarbe
GLASURIT: Glassomax 7 F 4625 (red color) *

* To be used with catalyst

Carefully check meting parts of each pillar Glassomax Harter 965-7/l in the proportion 1 :I0
(part. No. 3541-20003).

Panels must be welded within 15 minutes of the paint

(3) Remove paint from welding edges. application (air drying time of paint film).
Tools required:
. Belt sander The film thickness after drying must be 0.005 to
. Disc sander 0.025 mm. (2 to 9.8) 10s4 in.

May 1983 49-24

 BODY - SHEET METAL PANELS

PREPARATION FOR NEW COMPONENT Cautions during operation:

INSTALLATION . Remove paint from both sides of components that
are to be welded, such as the surfaces to be spot
(1) If a partial replacement is to be carried out, it is
welded, spot welding rims and edges of surfaces to be
necessary to maintain an overlapping tolerance of about
butt welded.
50 mm (1.97 in) during cut of non-usable sheets, in order
The remaining paint, prevents current flow into spot
to have a sufficient mating surface.
weldings, with consequent poor strength of spot. It
Tools required: can also generate depressions in the plug MIG weld-
. Air saw ing.
. Hack saw
. Tracking gauge
. Convex rule (or equivalent)

It is recommanded always to use genuine spare parts. This

ensures a perfect repair and restoration of vehicle func-
tioning.

(4) Apply primer to component and body surfaces

which are to be spot welded.
Tools required:
. Wire brush
. Conductive anti-rust paint
(2) MIG plug weld.
This method must be used for those areas which can
not be reached by spot welder. To carry out this opera-
tion, drill, in the welding spots, making holes having 5 to
6 mm. (0.20 to 0.24 in) dia.
Tools required:
. Puncher
. Air drill

INSTALLATION
(1) New service parts temporary installation.
Tools required:
Holes must have 5 to 6 mm . Vise pliers
(0.20 to 0.24 in) dia . Convex rule
. Tracking gauge (sight)
. Centering gauge
(3) Remove paint from components to be welded. . Port power
Tools required: . Jack
. Belt sander . Spot welder
. Disc sander . Mig welder

49-25 May 1983

 BODY - SHEET METAL PANELS

Cautions during operation: (3) Grind MIG welding by means of a sander machine.
. Position components as per figures provided in Body Tools required:
Alignment. Into body compartments, install the . Air sander .
movable parts (i.e. windscreen, doors, hood, back- . Cl isc sander
door) in order to carry out check of clearances,
grades and parallelism. If necessary, adjust sheets
until correct alignment is obtained.
. Clamp parts to be welded by means of pliers and
some welding spot.

CORRECT INCORRECT

Cautions during operation:

. Take care .not to grind excessively on spot weldings:
it may generate decrease of sheet thickness and,
consequently, welding strength.
. Remove iron powder from grinded surfaces and
(2) ExecuTion of the required weldings.
surrounding areas.
Carry out welding complying with specifications provided
Presence of iron powder, causes decrease of welding
in Cautions during Welding.
efficacy and can also generate corrosion.
Tools required:
l Spot welder
. M IG welder
. Autogenous welder

(4) After welding execution, remove clamps used for

securing edges and remove possible dinging.

May 1983 49-26

 BODY -SHEET METAL PANELS

(7) For under body protection, apply a coat having 4 mm

(0.16 in) thickness:

Antidrum: part. No. 3523 + 00001

Alternatives: 3M
Body Plast 8874 E
Body Schutz 8864 E
WI Grey protective acrylic 854751

(5) Apply anti-corrosion agent to the welded compo-

nents.
(6) Apply sealer to joints.
This operation must be carried out carefully in order to
prevent corrosion in the welded joints.
Refer to figures provided in Body Sealing.

m Area to he protected

49-27 May 1983

 BODY -SHEET METAL PANELS

May 1983 49-28

 BODY - SHEET METAL PANELS

RADIATOR CORE SUPPORT

Parts to be welded c. Radiator core support and hoodledge panel upper

a. Radiator core support and engine support lower cross Par-t
member d. Radiator core support and engine support lower cross
b. Radiator core support and hoodledge panel upper member
pati e. Radiator core support and hoodledge panel

REMINDER WHEN REMOVING REMINDER WHEN INSTALLING

. By means of air saw, cut along line A. . By means of clamps, temporarily secure new radiator
core support, then adjust it.

49-29 May 1983

 BODY - SHEET METAL PANELS

. Install parts temporarily

l Check and adjust clearances, grades and parallelisms.

May 1983 49-30

 BODY - SHEET METAL PANELS

HOODLEDGE PANEL WITH RADIATOR CORE SUPPORT REMOVED

Carry out replacement after Radiator Core Support has been removed.

) Front

Parts to be welded h. Upper hoodledge assembly and engine upper cross

a. Upper hoodledge assembly and lower hoodledge member
b. Lower hoodledge assembly and dashboard lower i. Hoodledge assembly and engine upper cross member
sheet (spring seat cap reinforcement)
c. Upper hoodledge assembly and dashboard lower 1. Hoodledge assembly and hoodledge side reinforce-
sheet ment
d. Lower hoodledge assembly and side member m. Hoodledge assembly, hoodledge side reinforcement
e. Lower hoodledge assembly and side member and engine upper cross member
f. Lower hoodledge assembly and front side member n. Hoodledge assembly, hoodledge side reinforcement
g. Upper hoodledge assembly and engine upper cross and engine upper cross member
member

REMINDER WHEN REMOVING

. By means of air saw, cut according to lines A, B, D
and, by means of air chisel, cut according to line C.

49- 31 May 1983

 BODY -SHEET METAL PANELS

R EM I N D E R W HE N I N S TA L L I N G

. When are removed welding spots of the three over-
lapped sheets drill the whole (welding spots are
identified by dimension line shown in the figure).
g Install together radiator core support and hoodledge
panel; then verify alignment dimensions concerning
hoodledge panel. Refer to drawings provided in
Body Alignment.
. Carry out, from both sides, MIG plug welding of
drilled sheets.

MIG welding

May 1983 49-32

 BODY -SHEET METAL PANELS

HOODLEDGE PANEL WITH RADIATOR CORE SUPPORT REMOVED

(Partial Replacement)
Carry out partial replacement after Radiator Core Support has been removed.

Service joints

Parts to be welded
a. Upper part hoodledge and lower part hoodlege

REMINDER WHEN REMOVING REMINDER WHEN INSTALLING

. By means of air saw, cut according to lines A and B. Precaution when cutting the spare half hoodledge panel
l Cut spare half hoodledge panel aligned with
non-replaced panel part.

Overlapping
tolerance

49-33 May 1983

 BODY -SHEET METAL PANELS

Dimension check and fender temporaneuous installation

L Install together radiator core support, half hoodledge
panel and body.
0 Check alignment dimensions referring to drawings
provided in Body Alignment.

May 1983 49-34

 BODY -SHEET METAL PANELS

FRONT SIDE MEMBER WITH HOODLEDGE PANEL REMOVED

Carry out replacement after Hoodledge Panel has been removed.

Service ioints

Parts to be welded
a. Plate and replaced side member
b. Plate and present side member

REMINDER WHEN REMOVING REMINDER WHEN INSTALLING

. By means of air saw, cut according to line A in figure, Precaution when cutting spare side member.
in correspondence with the hole located on side l Cut spare side member aligned with n&-replaced side
member. member part.

49-35 May 1983

 BODY -SHEET METAL PANELS

CENTRAL PILLAR
Service joints

SECTION A-A

Parts to be welded
a. Pillar and pillar inner reinforcement C. Outer pillar and inner pillar
b. Outer pillar and inner pillar d. Inner pillar and roof panel side member

REMLNDER WHEN REMOVING l -Remove paint in correspondence with the four

welding spots of pillar reinforcement lower part at
. Unscrew the two screws securing rib to roof panel
about 115 mm (4.52 in) from lower edge of outer
inner side member.
side member (see sect. A-A).
. BY means of air saw, cut according to lines A and B, Punch the four welding spots and remove the rein-
shown in figure. forcement pat-t.
. By means of disc sander carry out grinding of contin-.
uous welding joining central floor side member @
to inner central pillar @ _

1 Reinforcement
2 Body side ring

3 Central floor side member

4 Inner central pillar

49-37 May 1983

 BODY - SHEET METAL PANELS

. By means of clamps, temporarily secure central pillar.

REMINDER WHEN INSTALLING
Precaution when cutting spare pillar
. Cut spare pillar aligned with the upper and lower part
of non-replaced pillar part.
Check component alignment.
. After continuous welding of central pillar, carry out
tinning.
. Temporarily secure both front and rear doors.
. Check and adjust clearance, grades and parallelism.

===T===
Overlapping 7
I
tolerance

I
=F

Overlapping
tolerance

May 1983 49-38

 BODY -SHEET METAL PANELS

OUTER SIDE MEMBER

Service joints

Parts to be welded
a. Outer side member, front side member and inner c. Outer side member and closing inner central pillar
front pillar d. Outer side member and inner wheelarch
b. Outer side member, diaphragm and central floor side e. Outer side member and outer wheelarch
member f. Outer side member and central pillar reinforcement

. Remove paint in correspondence with the four

REMINDER WHEN REMOVING
welding spots of pillar reinforcement lower part at
. By means of air chisel, cut according to line A shown
about 115 mm (4.52 in) from lower edge of outer
in figure. side member (see section A-A).
Punch the four welding spots.
l By means of a drilling machine, remove welding spots
of the 3-layered sheet joints.

49-39 May 1983

 BODY-SHEET METAL PANELS

REMINDER WHEN INSTALLING

Precaution during cutting of outer side member l The continuous welding areas of outer side member
. Cut outer side member aligned with non-replaced to central, front and rear pillar, must be tinned.
panel part

Overlappine
tolerance

Welding indications . Apply anti-corrosion agent to boxed part inside.

. Use the MIG welding method to weld the three
overlapped sheets along the whole perimeter from
both sides.

May 1983 49-40

 BODY -SHEET METAL PANELS

REMINDER WHEN INSTALLING

Precaution when cutting outer side member n MIG welding

l Cut outer side member aligned with non-replaced
panels

. The continuous welding areas of outer side member

to central, front and rear pillar, must be tinned.
. Apply anti-corrosion agent to boxed part inside.

Welding indication
l Use MIG welding method to weld the three over-
lapped sheets along the whole perimeter from both
sides.

May 1983 49-42

 BODY --SHEET METAL PANELS

.d
REAR FENDER
Service joints

Parts to be welded
a. Fender and outer wheelarch e. Fender and floor
b. Fender and inner wheelarch f. Fender and drip
C. Fender and inner fender reinforcement g. Fender and upper rear panel
d. Fender and outer wheelarch h. Fender and upper rear panel

REMINDER WHEN REMOVING Take care not to cut frame of rear fender.
. By means of air chisel, cut the area shown in figure.

REMINDER WHEN INSTALLING

Precaution when cutting spare fender

l Cut spare fender aligned with non-replaced panel
part.

49-43 May 1983

 BODY -- SHEET METAL PANELS

Fender temporaneous installation . The fender area of continuous welding to roof

. By means of clamps, temporarily secure rear fender. panel side member, must be tinned.

Sealer application
. Apply sealer to wheelarch outer side.

. Temporarily secure the adjacent components: door

and backdoor. Check clearances, grades and parallel-
ism.

May 1983 49-44

 BODY -SHEET METAL PANELS

DRIP WITH REAR FENDER REMOVED

Carry out replacement after Rear Fender has been removed.
Service joints

Parts to be welded
a. Drip and rear fender inner frame
b. Drip and rear panel,

REMINDER WHEN REMOVING REMINDER WHEN INSTALLING

. By means of air saw cut according
shown in figure.
Take care not to cut fender frame.
to lines A and B
Caution when cutting spare drip
l Cut spare drip aligned with the non-replaced drip
part.

49-45 May 1983

 BODY-SHEET METAL PANELS

LOWER REAR PANEL

Service joints

Parts to be welded
a. Cross member and rear panel
b. Cross member and floor
c. Cross member and side member

REMINDER WHEN REMOVING

l By means of a saw, cut areas A and B taking care not
to cut central area, mentioned in the figure, in order
not to cut floor in correspondence with spare wheel
compartment.
l Punch junction points of lower rear panel to rear
floor of spare wheel area.
Precaution during welding
. For the spot welding, make use of a brass wire.

I+1
Centml area

May 1983 49-46

 BODY - SHEET METAL PANELS

UPPER REAR PANEL

Service joints

Parts to be welded
a. Rear panel and drip
b. Rear panel and outer fender
C. Rear panel and outer fender
d. Rear panel and floor

REMINDER WHEN REMOVING REMINDER WHEN INSTALLING

. BY means of air saw, cut according to line A. l By means of clamps, temporarily secure the upper
rear panel.

49-47 May 1983

 BODY - SHEET METAL PANELS

. Temporarily secure backdoor and check clearances, Precaution during welding

grades and parallellisms. . For the spot welding, make use of a brass wire.
Check correct positioning and alignment of bumper
to rear panel.

May 1983 49-48

 BODY -SHEET METAL PANELS

REAR PART OF REAR FLOOR WITH REAR FENDER AND REAR PANEL
REMOVED

Carry out replacement after .Rear Fender and both Lower and Upper Rear Panel have been removed.

Service joints
: -4~ e -6mb
1
-
s
F

Parts to be welded
a. Rear floor and rear side member d. Rear floor, rear side member and inner rear wheelarch
b. Rear floor and rear side member e. Rear floor and rear seat cross member
C. Rear floor and central cross member f. -Rear floor and outer fender

REMINDER WHEN REMOVING . By means of a drilling machine, remove welding spots

. By means of air saw, cut according to line A. from the S-layered sheets joints.

49-49 May 1983

 BODY - SHEET METAL PANELS

REMINDER WHEN INSTALLING

Secure rear floor temporarily and carry out marking
along side member and cross member from floor
underside.
This easy drilling operation of the MIG welded spots.
In order to obtain the best welding result, make use
of spot welder as far as possible.
Carry out holes for the MIG welding in the rear floor
where spot welder can not be used.
In rear floor installation, temporarily secure fender
and rear panel.
Check installation dimensions in accordance with
drawings provided in Body Alignment.
With the components temporarily secured, carry out
temporaneous MIG weldings in some points of rear
floor. . Apply sealant to non-replaced surfaces of rear wheel-
arch and of floor, in accordance with Body Sealing.
. Apply anti-corrosion agent to weldings under floor,
then apply primer.

May 1983 49-50

 BODY - SHEET METAL PANELS

REMINDER WHEN 4NSTALLING

l After temporaneous securing of side member to
rear floor, carefully check dimensions provided in
Body Alignment.

May 1983 49-52

 BODY -SHEET METAL PANELS

REMINDER WHEN INSTALLING

. Before carrying out welding, apply the adhesive to l Apply sealant to the areas indicated in Body
joints between roof and central rib. Sealing.
. Carry out tinning in the areas between roof and rear
fender, which are continuous welded.

May 1983 49-54

 DOORS

CONTENTS

FRONT DOOR . . . . , . . . . . , _ . . . . . , M 55-2 Internal finishing panels . . . . . . . . . 55-7

Door assembly . . . . . , _ . . . . . , . . . .
55-3 Fixed glasses . . . e . . . . . . . . . . . . 1 _ 55-7
Internal finishing panels . . . . . . , . . 55-3 Window regulator devices and
Window regulator devices and glasses . . . . . . . . . . . . _ . . . . . . _ _ . . 55-7
glasses . _ . . . . n . . . , . . . . . , , . . . . 55-3 Door locks and handles . . . . . . . . . . 55-8
Door locks and handles . . , . . . . . . . 55-4 Moldings and seals . . . . . . . . . . . . . . 55-8
Door mirror 1 . . . . . . . . . . : . . . . . . . 55-4 SERVICE DATA AND
Moldings and seals . . ..,.....,,.. 55-4 SPECIFICATIONS. m . . ~ ~. . . m ~. . _ _ . . 55-9
REAR DOOR . . . . . . . . . , . . . . . . . . . . 55-6 Tightening torques . . . . . . . . _ . . . . 55-9
Door assembly. . . _ d . . . . , . . . . . . , 55-7

May 1983
 DOORS

FRONT DOOR

@II* 1 3 5 21
(1.36+2.2
9.83 + 15.9)

1 Door
15 Tie rod
2 Door lock device
16 Hinge
3 Lock block clamp plate
17 Window regulator device
4 Lock block 18 Panel lower clamps
5 Handle 19 Seal
6 Molding and weatherstrip 2 0 Sealing screen
7 Molding 21 Upper trim and weatherstrip
8 Molding 22 Door lock control
9 Glass velvet seal with trim 2 3 Panel
10 Glass 24 Window regulator handle
11 Door mirror 2 5 Arm rest
12 Ring nut 26 Power window switch (1500 and 1500 Quadrifoglio models)
13 Rubber 27 Power door locks device (1500 Cluadrifoglio model)
14 Hinge

May 1983 55-2


DOOR ASSEMBLY
REMOVAL AND
INSTALLATION
With reference to exploded view
proceed as follows:
1. Disconnect door from tie rod
a n d f r o m h i n g e s @ and @ b y
unscrewing the six screws, then
remove it.
la. Only for the 1500 and 1500
Quadrifoglio models.
Disconnect harness and then proceed
as per step 1.
2. For door installation reverse
order of removal and tighten screws
securing .hinges t o d o o r t o r h e
prescribed torque.
@ : Tightening torque
Screws securing hinges to door
1 3 G-21 Ndm
(I .36 + 2.2 kg-m
9.83 + 15.9 ft4b)
INTERNAL FINISHING
PANELS
Cover end of the tool used for
removing plastic rivets in order not
to damage or scratch the body.
REMOVAL AND
INSTALLATION
Lift ornament of arm rest @
1.
and unscrew the three securing
DOORS
screws, then remove it. 3. Unscrew the five nuts securing
2. Remove ornament covering the window regulator @ to door, then
door securing screws, then remove remove it.
window regulator handle @ .
3. Remove plastic rivets securing
panel @ to door. Remove panel
by bending it.
4. Remove plastic rivets securing
upper trim @ to door.
5. Remove hook of door lock
control rod. then remove upper
t r i m @) ,
6. For upper trim and panel 3a. Only for 1500 and 1500 Quadri-
installation, reverse order of removal. foglio models
Disconnect harness of window
regulator motor, unscrew the five
WINDOW REGULATOR nuts securing power window @
to door, then remove it.
DEVICES AND
GLASSES
REMOVAL AND
INSTALLATION
1. R e m o v e p a n e l @I upper
trim @I and sealing screen @ .
2 . L o w e r g l a s s @j) c o m p l e t e l y ,
unscrew the two nuts securing
w i n d o w r e g u l a t o r d e v i c e @ to
glass, then remove by rotating it.
4. Install window regulator and
glass by reversing order of removal.
55-3 May 1983
 DOORS

DOOR LOCKS
AND HANDLES

REMOVAL AND
INSTALLATION
1. Remove panel @I upper
trim @I and move sealing
screen @ .
2. Lift glass @J completely in
order to avoid damage.
3. Remove plastic fasteners secur-
ing levers to door.

4. 1500 Quadrifoglio model
-Release connecting rod between
lock @ and door lock electric
device 0 . To remove it, if neces-
sary, disconnect harness, and un-
screw the two nuts securing it to
door.
DOOR MIRROR
6. Withdraw clamp plate of lock
block @ by means of proper tool REMOVAL AND
and remove lock block @. INSTALLATION
1. Remove panel @ and upper
trim @J _
2. Withdraw rubber @I and un-
screw the two screws securing mir-
ror @I to door.
3. Unscrew ring nut 1 and
O@
remove door mirror 11 .
4. Install door mirror by reversing
order of removal.
UOLDINGS AND
7. Unscrew the three screws secur-
SEALS
ing lock @ to door then remove
Cover end of the tool used tor
lock.
removing moldings in order not to
8. Unscrew the two nuts securing
damage or scratch the body.
handle @to door, then remove
hand le.

REMOVAL AND
INSTALLATION
1. Operating as per figure, remove
molding with weatherstrip @.

9. Install handle and lock by

5. Release connecting rod between
lock block @ and lock 0.
reversing order of removal.
10. Verify proper functioning of
door opening control and, if neces-
sary, loosen the three screws securing
door lock clamp and move it until
perfect closing is obtained.

May 1983 55-4

 DOORS

2. Remove molding 8 .
3. Remove panel 8 and upper CAUTION:
trim with weatherstrip @ . Apply proper grease to hinges, tie
4. Remove door mirror 0 . rod and door lock device.
5. Remove molding 7 .
6. Remove glass 8 0 and glass
velvet with trim 8.
7. Reposition moldings and seals
by reversing order 05 removal.
8. With reference to the following
figure take care to secure glass velvet
seal on clamp @ of glass guide 0
located inside the door.

1 Glass guide
2 Glass velvet seal clamp

55-5 May 1983

 DOORS

REAR DOOR

3 N-m
(kg+n
ftw

1 Door 14 Hinge
2 Spacer 16 Window regulator device
3 Ooor lock device 16 Hinge
4 Rubbers 17 Panel lower clamp
5 Handle 18 Seal
6 Fixed glass 19 Sealing screen
7 Melding 20 Upper trim and weatherstrip
8 Fixed glass guide 21 Door lock control
9 Molding 22 Window regulator handle
IO Glass velvet seal with trim 23 Arm rest
11 Glass 24 Panel
12 Molding and weatherstrip 25 Door lock electric device (1500 Duadrifoglio model)
13 Door lock control

May 1983 55-6

 DOORS

DOOR ASSEMBLY 2. Remove ornament covering the WINDOW REGULATOR

door securing screw, then remove
REMOVAL AND window regulator handle @I _
DEVICES AND
INSTALLATION 3. Remove plastic rivets securing GLASSES
With reference to exploded view panel @ to door. Remove panel
proceed as follows: by bending it.
REMOVAL AND
1. Unscrew the four screws secur- 4. Remove plastic rivets securing
INSTALLATION
i n g h i n g e s @ a n d I@ t o d o o r upper trim @ todoor.
5. Remove hook of door lock 1. Remove panel I@ , upper
and remove it.
control rod, then remove upper trim @ and sealing screen 19 .
la. Only for the 1500 and 1500
trim @ . 2 . L o w e r c o m p l e t e l y g l a s s 81 1
Quadrifoglio models.
and windscreen the two nuts securing
Disconnect harness and then proceed
window regulator device to glass.
as per step 1.

3. Unscrew the three nuts securing

2. For door installation reverse
order of removal, tighten screws
securing hinges to door to the
prescribed torque:
window regulator @ to door and
remove it from lower side by lifting
glass 0 .
6. For upper trim and panel
installation, reverse order of removal.

0: Tightening torque FIXED GLASSES

Screws securing hinges to door
13+21 N - m
(1.36 + 2.2 kgam
REMOVAL AND
9.83 f 15.9 ft.lb)
INSTALLATION
1. Remove panel @ , upper
trim and lower completely
glass 8
11 .
INTERNAL FINISHING 2. Unscrew the screw securing

PANELS sealing screen 19

spacer 0.
8
fixed glass guide 8 to door, move
and recover

Cover end of the tool used for
removing plastic rivets in order not
to damage or scratch the body.
REMOVAL AND
INSTALLATION
1. Lift ornament of armrest @
and unscrew the three securing
screws, then remove it.
3. Unscrew the screw securing
fixed glass guide @ to door frame.
4. Slightly detach the glass velvet
seal @I in correspondence with
fixed glass guide @ and remove 4. Remove fixed glass guide @
and fixed glass @.
guide.
5. Remove glass 0 .
5. Remove fixed glass.
6. Install fixed glass by reversing 6. Install glass and window re-
order of removal. gulator by reversing order of re-
moval.

55-7 May 1983

 DOORS

DOOR LOCKS 6. Only for 1500 Quadrifoglio

model
AND HANDLES Release connecting rod between
lock @ and door lock electric
REMOVAL AND device @ _ To remove it, if neces-
INSTALLATION sary, disconnect harness and unscrew
1. Remove panel @f upper the two nuts securing it to door.
trim @ and move sealing
screen @ .
2. Lift glass @) completely in
order not to damage it.
3. Release door lock control
rod @) from door lock 0.

MOLDINGS A N D
SEALS

Cover end of the tool used for

removing moldings in order not to
damage or scratch body.

4. Unscrew from door the door
lock control rod @ securing screw
and remove it.
7. Unscrew the three screws secur- REMOVAL AND
ing lock @ to door, then remove INSTALLATION
lock. 1. Operating as per figure, remove
8. Unscrew the two nuts securing molding with weatherstrip @ .
handle @ to door, then remove
handle.

5. Release from door the door

opening control rod.

9. I n s t a l l h a n d l e a n d l o c k b y 2. Remove molding @ and @.

reversing order of removal.
IO. Verify proper functioning of
door opening control and, if neces-
sary, loosen the three securing screws
of lock clamp and move it .until
perfect closing is obtained.
3. Remove panel @ and upper
trim with weatherstrip @ .
4. Remove fixed glass-guide 8 ,
fixed glass @ and glass 11 8 .
6. Remove glass velvet seal with
trim @ .

May 1983 55-8

 DOORS

6. Reposition molclings and seal by

reversing order of removal. CAUTION:
7. With reference to the following Apply proper grease to hinges and
figure, take care to secure glass velvet door lock device.
seal on clamp @ of glass guide @
located inside the door.

1 Glass guide
2 Glass velvet seal clamp

SERVICE DATA AND SPECIFICATIONS

TIGHTENING TORQUES

N-m kg.m ft-lb

Item

Screws securing hinges to front door 13421 1.36 + 2.2 9.83 f 15.9

Screws securing hinges to rear door 13+21 1.36 + 2.2 9.83 f 15.9
I I I

55-9 May 1983

 HOODS

HOOD POSITION rod is positioned in the center of

hood lock slit by operating on
ADJUSTMENT the two screws 0. Then,
Loosen the four screws securing temporarily tighten the lock.
hinges to hood and move hood
forward, backward and side to side
until correct position is obtained.

1 Screws 2 Hood lock device

1 Hood 3 Body
2 Hood bumper
. With the hood lock temporarily l Fix hood lock by tightening
tightened to body, verify that
securing screws.
hood bumper 0, located on . Verify proper functioning of

CAUTION:
. During installation of hood
lock @ make sure that striker
8
hood 1 come in contact with
body 3 ; if not so, properly
change hood bumper height
.
hood lock opening control.
Lubricate hood lock mechanism
with proper grease.
by screwing or-unscrewing them.

REPLACEMENT OF HOOD OPENING CONTROL CABLE

CAUTION:
In case of breakage of hood opening
control cable, it is possible to open
the hood by pulling the nylon-made
emergency cable @, lowted in the
,passenger compartment inside.

1. Cut the cable in proximity to

hood lock device @ and loosen
screw of sheath supporting brack-
e t @.
2. Operating from vehicle inside,
withdraw cable and sheath of hood
opening control lever 0.
3. Insert the new cable with sheath
and secure it to hood opening
control lever.

1 Cable 4 Bracket
2 Hood lock device 5 Hood opening control
3 Cable retaining ring 6 Nylon-made emergency cable

56-3 May 1983

 HOODS

4. O p e r a t i n g f r o m e n g i n e com- 6. If necessary, adjust sheath oil letting it slide into sheath.

partment inside, insert cable 0 into
eyelet of hood lock @ and secure
cable end to cable retaining ring 0.
5. Verify functioning of hood
opening control.
position by operating on special
bracket @.
CAUTION:
. Lubricate the cable with suitable
. Do not bend excessively cable
sheath in engine compartment in
order to prevent opening stress
increase.

BACKDOOR

1 Backdoor Vibration-damper striker

13 Vibration damper striker
2 Backdoor trim Seal
1 4 Badge
3 Hinge Backdoor lock device
16 Label
4 Shook absorber Shock absorber
16 Electric contactS
6 Seal Hinge
17 Backdoor striker
6 Movable shelf Support

REMOVAL AND . Provide a support for backdoor

W ith reference to exploded view
to be used on removal from
INSTALLATION above proceed as follows:
shock absorbers.
1. By means of a screwdriver drill,
Before removal or installation, l Release the two cables sup-
remove the two rings securing rods of
proceed as fol lows: porting shelf under rear window.
. shock absorbers @ and @I and
Place a cloth or other padding
withdraw rods from their seat.
on backdoor corners in order to For removal and installation of
avoid damaging or scratching backdoor, two operators are re
vehicle body. quired.

May 1983 56-4


REPLACEMENT OF BACKDOOR OPENING
CONTROL CABLE
1. Cut cable @) in proximity to
backdoor lock device @ and loosen
1 Cable
2 Backdoor lock device
3 Cable retaining ring
May 1983
HOODS
2. Operating from vehicle inside,
withdraw cable and sheath from
backdoor opening control lever 0.
screw of bracket @ sheath securing. 3. Insert new cable with sheath and
secure i t t o backdoor o p e n i n g
control lever.
4. Operating from luggage room,
0
insert cable 1 into eyelet of back
door lock device @ and secure
cable end on cable retaining ring @ _
5. Verify proper functioning of
backdoor opening control.
6. If necessary, adjust sheath
position operating on special brack-
et @.
CAUTION:
. Lubricate the cable with proper
oil letting it slide into sheath.
. Do not bend excessively cable
sheath in the luggage room, in
order to prevent opening stress
4 Bracket
increase.
5 Backdoor opening control
56-6
 INTERNAL TRIMMING

TRIM

ROOF TRIM

1 Roof
2 Taps
3 Sun screen
4 Sun screen
5 Passenger handle
6 Passender handle
7 Roof lamp
8 Passenger handle
9 Inside mirror support
10 Roof lamp
11 Inside mirror

REMOVAL AND screws securing mirror support @

INSTALLATION to roof nanel and remove it. .
5. Remove sun screens
0
Be careful not to stain roof. and @.
6. Remove weatherstrip of doors
With reference to exploded view a n d o f backdoor in contact with
above proceed as follows: roof; move upper part of front
1. Open protection of screws secur- pillar trim.
ing passenger h a n d l e s 0, @ 7. Remove roof trim @ and
and @ to roof panel, unscrew them w i t h d r a w i t f r o m backdoor c o m -
and remove handles, partment.
8. For installation, reverse order of
removal.

C A U T I O N :
For installation, it is recommended
to position roof trim starting from
2. By means of proper tool, remove rear side and then use a cord to
taps 0. reposition windshield seal in its place
3. Disconnect harness and remove (see: Group 75 - Windshield - 1 Roof trim 4 Cord
roof lamps @ and @I . Installation). 2 Front righr 5 Windshield
4. R e m o v e i n s i d e m i r r o r @) in pillar 6 Body
order to gain access to the t h r e e 3 Windshield seal

May 1983 66-2

 INTERNAL TRIMMING

FLOOR TRIM
 INTERNAL TRIMMING

REMOVAL AND 4. Remove seals of front door material trim @ .

INSTALLATION compartments in the part where they 7. install floor trim by reversing
cover floor trim and remove the order of removal. After installing
With reference to exploded view
adhesive tape strips securing trim to handbrake cables, adjust it by
above proceed as follows:
body. following procedures described in
1. R e m o v e r e a r s e a t @, f r o n t
5. Unscrew nut and lock nut of Group 00 - Maintenance of Mechanic
seats 0, rear console @, speed
parking brake @ adjustment fork Components and Body.
level console @ and safety belt
and withdraw the two cables from
anchors @I and 0 (see the
bracket 0.
relevant paragraphs).
2. Unscrew the fourteen screws
securing kick plate @ to body and
remove them.
3. By means of proper tool, with-
draw plastic rivet securing to body 6 . R e m o v e f l o o r t r i m b y with-
the accelerator pedal end of trav- drawing it from parking brake and, if
el 0; then remove it, necessary, remove soundproofing

CENTRAL PILLAR TRIM AND FRONT SAFETY BELTS

a*27 f f 4 3
(2.8 +f
(2.8 + 4 4.4
.4
20.25 f 31.8)
1 Door opening seal p::
2 Door opening seal
3 Central pillar trim
4 Safety belt
5 Safety belr anchor on tunnel
6 Central pillar trim cover

REMOVAL AND
INSTALLATION
With reference to exploded view
above, proceed as follows:
1. Move front seat completely
forward.
2. Remove door opening seals @
and @ in the part where they cover
central pillar trim 0.
3. Lift protection of screw securing
safety belt @ suppot~, unscrew it
and remove the support.
4. After removing protection, un-
screw the screw securing safety
belt @ anchor bracket to body.

May 1983 66-4

 INTERNAL TRIMMING

9. -Install safety belt and pillar trim

by reversing order of removal. All the
anchor safety belt screws, must be
tightened to the prescribed torque.

@ : Tightening torque
Safety belt anchor screws
27 + 43 N.m
(2,s + 4,4 kg-m
20.25 + 31.8 ft-lb)

CAUTION:
If the vehicle is collided or over-
turned, replace t h e e n t i r e b e l t
assembly regardless of nature of
accident.

5. By means of proper tool, remove

plastic rivet securing cover @ to
trim @ and remove it.
6. Remove pillar trim @ by
lifting it.
7. Unscrew the screw securing FIXED PART TRIM
safety belt @ retractor and remove OF SHELF UNDER
it. REAR WINDOW

3. Unscrew the screw securing to

body hinge @ of movable shelf,
and remove hinge.
4. Unscrew the two screws securing
to body the seat back clampings
device @ and remove it.
5. By means of proper tool, wirh-
draw the two plastic rivets and
unscrew the two screws securing
to body, trim @ of fixed part of
shelf under r e a r w i n d o w , t h e n
8. After removing protection, un- remove trim.
screw the screw securing safety belt
0
anchor 5 on tunnel and remove it.
1 Fixed part trim of shelf under fear
window
2 Movable shelf hinge
3 Seat back clamping device
4 Seat back fixed part

REMOVAL AND
INSTALLATION
With reference to the exploded view
above proceed as follows:
1. Remove movable shelf under
rear window.
2. Unscrew screw securing seat
back fixed part @ to body, lift seat 6. Install trim by reversing order of
back and remove it. removal.

66-5 May 1983

 INTERNAL TRIMMING

REAR PILLAR TRIM

1 Back door seal 3 Plastic cap

2 Rear pillar trim 4 Door opening seal

REMOVAL AND
INSTALLATION
1. Remove door o p e n i n g s e a l @ 2. Detach plastic cap @ and 3. Install trim by reversing order of
in the part where it covers trim 0. remove pillar trim 0. removal.

LUGGAGE ROOM SIDE TRIM

1 Luggage room side trim

2 Fixed part trim of shelf under rear
window
3 Movable shelf hinge
4 Seatback clamping device
5 Seat back fixed part

REMOVAL AND
INSTALLATION
1. Remove seat back clamping 2 . By means of proper tool, remove 3. Install side trim by reversing
device @, seat back fixed part @ plastic rivets securing side trim to order of removal.
and trim of fixed part shelf under body, then remove it.
rear window @ (see: Trim of fixed
part shelf under rear window).

May 1983 66-6


REMOVAL AND
INSTALLATION
Take care not to stain seat and seat
badk upholstery.
With reference to the above exploded
view proceed as follows:
1. Move seat completely forward
and unscrew the two rear screws
securing guides @ and 0 to
floor.
2. Move seat completely backward
and unscrew the two front screws
s e c u r i n g g u i d e s @ a n d I@ t o
floor.
3. Remove seat together with
guides, from car.
4. If necessary, remove guides @
and 0 from seat.
(1) By means of proper tool, release
the seat turnover control lever @
from guides.
May 1983
INTERNAL TRIMMING
(3) Remove plastic trims @
and @ .
(4) Unscrew the four screws secur-
ing to seat @ the seat back adjust-
m e n t d e v i c e @J a n d h i n g e 0;
then remove seatback 0. 1
e
(2) Remove guides by unscrewing
the four securing screws to seat @.
(5) Remove the four screws securing
trim @ to seat back @ up-
holstery.
(3) Install guides and control lever
(6) Lift clamps securing seat back
by reversing order of removal and
upholstery, turn it inside out and lift
tightening screws to the prescribed
it until protections @ and @ of
torque.
seat back adjustment device @I
securing screws and of hinge @ are
@ : Tightening torque
uncovered.
Screws securing guides to seat
1 7 f 2 0 N.m
(1.8 + 2.1 kg-m
13.0 + 15.2 ft-lb)
5. If necessary, remove seat back
adjustment device @ , hinge ~ 0,
and seat back 0.
(1) Lift cover @ of seat back
adjustment device @ .
( 2 ) K e e p i n g k n o b @ still, by
means of proper plier, rotate counter-
clockwise the plate securing knob;
then remove it.
(7) Remove plastic protections @
and @I a n d u n s c r e w t h e f o u r
s c r e w s s e c u r i n g t o seatback t h e
seatback adjstment device and hinge;
then remove them.
66-8
 INTERNAL TRIMMING

@ : Tightening torque 7. Install seat on car by reversing

Securing screws of seat back
adjustment device and of hinge
17 + 29 N-m
(1.8 + 3 kg-m
13 + 21.7 ft.lb)
6. If necessary, remove headrest by
operating on knurled part as shown
in figure.
order of removal and tightening
screws securing seat guides to floor,
to the prescribed torque.
@ : Tightening torque
Screws securing seat guides to
floor
IO+11 N-m
(1.1 + 1.2 kg-m
8 + 8.7 ftdlb)

(8) For installment reverse order of

removal. Tighten the screws of
seatback adjustment device and of
hinge to the prescribed torque.

REAR SEATS

1 Seat
2 Seat back fixed part
3 Seat back
4 Shelf under rear window fixed part
5 Seat back clamping device
6 Luggage room and seat back trim
7 Seat back
8 Seat back hinge

66-9 May 7983

 INTERNAL TRIMMING

REMOVAL AND 4. Unscrew nut securing seat

INSTALLATION back @ to body @ and remove it.

Take care not to stain seat and seat

back upholstery.
1. Lift and remove seat.
2. Unscrew the screw securing to
body @ the seat back fixed
p a r t @ then lift seat back and
remove it.

1 Seat back
2 Kick plate
3 Door compartment seal
1 Seat back fixed part 4 Body
2 Seat back
3 Body
4 Door compartment seal
5. Carry out same procedure for
3. By means of proper tool, with- removal of the other seat back.
draw plastic rivets securing luggage 6. Install seat backs and seat, by
room upholstery to seat back. reversing order of removal.

CONSOLES
REAR CONSOLE
REMOVAL AND
INSTALLATION
1. Remove rubber bellows located
on parking brake.
2. Remove ashtray, which is pres-
sure secured.
3. Unscrew the screw securing
console and remove it by moving it
first forward in order to withdraw
it from clamp located on floor
tunnel.

1 Rubber bellows 3 Ashtray

2 Console

4. Install console by reversing order

of removal.

May 1983 66-10

 INTERNAL TRIMMING

CE:NTRAL CONSOLE

May 1983 66-12

 INTERNAL TRIMMING

REMOVAL AND i. Unscrew the four screws secur-

INSTALLATION ing heater control assembly @ to
console 0.

8. Remove the four screws securing

CAUTION: console @ to dahsboard.
. Disconnect battery ground
cable.
. Before removing the com-
ponents fitted with harness,
make sure that relevant con-
nections have been discon-
nected.
5. By means of proper tool, remove
finisher 0.

With reference to exploded view

above proceed as follows:

1. Remove by pulling, knobs @

and @ of heater control assembly.
2. Detach finisher @I and discon-
nect harness of clock @ , lighter
s e a t @ and lamp 0 . ,- 9. Remove console 0 being
3. Remove finisher @I .
4. If necessary, remove lighter
l/rE==ilh- careful during lamp @ and harness
removal.
10. Install console and its com-
seat @ by unscrewing ring 6. Disconnect harness of
nut @ and withdrawing bush @ s w i t c h e s 0, @, @ a n d @: ponents, by reversing order of
and ornament @ . then remove finisher 0. removal.

66-13 May 1983

 INTERNAL TRIMMING

DASHBOARD

May 1983 66-14

 INTERNAL TRIMMING

5. By means of proper tool, remove

REMOVAL AND ornaments @ and @ .
INSTALLATION 6. By means of proper tool, remove
finisher @ of duct @ and unscrew
the two screws securing dash-
board @ to body.
CAUTION:
. Remove battery ground cable.
. Before removing the compo-
nents fitted with harness, make
sure that relevant connections
have been disconnected.

7. Unscrew the seven screws secur-

ing dahsboard @ and @ to body.
With reference to explbded view
above proceed as follows:
1. Remove central console (see:
Central Console).
2. Remove steering wheel and
column shell covers (see: Group 23 -
Steering Wheel and Column).
3. Remove cluster 0 .
(1) Unscrew the four screws secur-
ing cluster 0 to support brack-
et@. -

/I \
Low view
CAUTION:
To remove the whole dashboard, two
(2) Open cover @ pressure in- operators are required.
set-ted, disconnect harness; then
remove cluster 0 . 8. R e m o v e the whole dash-
4. Operating as per figure, remove board @ and @.
spring securing center ventilation 9. If necessary, disassemble dash-
d u c t @ control cable to heater b o a r d c o m p o n e n t s @ and @.
control assembly. (1) By means of a drilling machine
fitted with suitable drill, countersink
the four rivets securing upper dash-
board @ to lower dashboard @.

66-15 May 1983

 INTERNAL TRIMMING

SERVICE DATA AND SPECIFICATIONS

TIGHTENING TORQUE

Unit
N-m kg-m ft.lb
Item

CENTRAL PILLAR TRIM AND

SAFETY BELTS

Safety belt anchor screws 27 + 43 2.8 + 4.4 20.25 + 31.8

I I

FRONT SEATS

Screws securing guides to seat 17 + 20 1.8 + 2.1 13 f 15.2

Securing sraws of seat back adjustment

device and of hinge 17 + 29 1.8 +. 3 13 + 21.7

Screws securing seat guides to floor 10 + 11 1.1 + 1.2 8 + 8.7

66-l 7 May 1983

 EXTERNAL TRIMMING

CONTENTS

FRONT BUMPER . . . . . . . . . . . . . . . . . 75-2 G LASSES . . . . . . . . . . . . . . . . . . . . . . . 75-7

REAR BUMPER . . . . . . . . . . . . . . . . . . 75-3 Windscreen . . . . . . . . . . . . . . . . . . . 75-7
DRIP COVER MOLDING . . . . . . . . . . . 75-4 Rear window . . . . . . . . . . . . . . . . . . 75-9
GRiLLE . . . . . . . . . . . . . . . . . . . . . . . . 75-5 SPECIAL SERVICE TOOLS . . . . . . . . . 75-l 1
COWL TOP COVER . . . . . . . . . . . . . . . 75-6

May 1983
 EXTERNAL TRIMMING

FRONT BUMPER.

1 Bumper 4 Fog light

2 Bracket 5 fog light
3 Bracket

REMOVAL AND
INSTALLATION
With reference to exploded view
above proceed as follows:
disconnect fog 3. Unscrew the four screws secur-
1. If present,
ing brackets @ and @ to sills.
light @ and @ harness.
2. Operating from engine com-
partment inside, disconnect harness
of the two electromagnetic horns,
unscrew the nut securing each horn
t o b r a c k e t , a n d remove horns.

5. Remove bumper and, if neces-

sary, disassemble fog lights.
4. Unscrew the two screws securing 6 . C o n n e c t b u m p e r t o b o d y by
bumper to fenders. reversing order of removal.

May 1983
75-2
 EXTERNAL TRIMMING

REAR BUMPER

1 Bumper 4 Bracket
2 Bracket 6 Nuts
3 Bracket 6 Bracket

REMOVAL AND
INSTALLATION
W ith reference to exploded view
above proceed as follows:
1. Lift luggage room upholstery
and rear trim.
2. Unscrew the four screws secur-
ing bumper brackets @ and @ to
brackets @ and @.

\ 6. Install bumper, by reversing

order of removal.

4. Remove bumper.
5. If necessary, unscrew the eight
3. Unscrew the two screws securing screws securing brackets @ and @)
bumper @ to body. to rear floor.

75-3 May 1983

 EXTERNAL TRIMMING

GRILLE

1 Badge 3 Hood
2 Grille 4 Screw

REMOVAL AND 4. Install grille by reversing order

INSTALLATION of removal.

With reference to exploded view

above proceed as follows:
CAUTION:
1. Open hood completely removing
. Be careful not to exert excessive
it from stay.
force during operations, as grille
2. By means of a magnetic screw-
is made of plastic.
driver, unscrew screw @ securing
. Take care to keep oil away from
grille @ to body.
grille.
3. Remove grille, by means of
suitable wooden tool.

75-5 May 1983

 EXTERNAL TRIMMING

COWL TOP COVER

1 cowl top cover 5 Windscreen washer pipings

2 Windscreen seal 6 Windscreen wiper arms
3 Plastic nut screw 7 Sprayers
4 Seal rubber

With reference to exploded view I 4. Unscrew the two screws, pro-

above proceed as follows: i tected by a cover, securing cowl top
1. Open hood and remove seal @. cover @ to body; then lift cowl.
1 5. Disconnect windscreen washer
2. Lift protections of nuts securing
wiper arms @, unscrew the relevant
I p i p i n g s ($ s e p a r a t i n g t h e m f r o m
screws; then remove wiper arms. sprayers @ w h i c h a r e p r e s s u r e
3. By means of proper tool, remove \ inserted into cowl top cover, then
the five springs securing cowl top
\ remove cowl top cover.
cover 0 to body. 6. Install cowl top cover by revers-
\ ing order of removal.

May 1983 7566


REMOVAL
With reference to exploded view
above proceed as follows:
1. Remove wiper arms @ and
move cowl top cover @ forward
(see: Cowl-Top Cover).
2. Operating from vehicle inside,
6. Carefully pull upper part of
windscreen, remove it from body,
then remove it completely.
INSTALLATION
For installation, two operators are
required.
May 1983
EXTERNAL TRIMMING
remove, by means of proper tool
ornament 0.
3. Remove door opening seal @
in the part where it covers pillar
trim 0.
4. By means of proper tool, remove
CAUTION:
By means of silicone, lubricate rim of
windscreen weatherstrip in order to
allow an easy insertion of weather-
strip on body.
p i l l a r t r i m 0, then remove it.
5. Operating as per the following
figure, set end of tool A.9.0051 out
of every 10 cm (4 in), starting from
centre of windscreen upper rim;
between body and windscreen seat.
1. Into weatherstrip rim 0, insert
two cords (A and B) arranged as per
figure in order to allow repositioning
of weatherstrip @ on body.
 EXTERNAL TRIMMING

2. Rest windscreen on lower side of

ito seat into body and verify it is
properly centered with weather-
strip @ mounted on lower side,
only.
3. Slowly pull first cord starting
from upper rim and follow position-
ing of weatherstrip rim by slightly
tapping, with the hand, on wind-
screen from outside.
4. Repear same operation with
second cord until complete installa-
tion of windscreen.
5. Carry out installation of pillar
trim, of door compartment seal and
1 Roof trim
of ornament, by reversing order of
2 Windscreen seal weatherstrip
removal. 4
3 Right Cord front pillar
6. Install cowl top cover and wiper
arms.
56 Windscreen Body

REAR WINDOW

1 Rear window 3 Backdoor

2 Rear window 4 Movable shelf
weatherstrip

75-9 May 1983


REMOVAL
With reference to exploded view
above proceed as follows:
1. Open back door and release the
two cables supporting shelf @
CAUTION:
Do not damages filaments of heated
rear window with tool A.9.0051.
4. Carefully pull upper part of rear
window, release it from back door
and remove.
May 1983
EXTERNAL TRIMMING
under rear window.
2. Disconnect electric cables of
heated rear window.
3. Operating as per the following
figure, set end of tool A-9.0051 out
INSTALLATION
For installation; two operators are
required.
CAUTION:
By means of silicone, lubricate rim of
rear window weatherstrip in order to
of every 10 cm (4 in), starting from
center of rear window upper rim,
between back door @ sheet and
rear window weatherstrip seal 0.
allow an easy insertion of weather-
strip on body.
1. Into seal rim @ inset-t two
cords (A and B) arranged as per
figure in order to allow repositioning
of weatherstrip on back door.
 AIR VENTILATION

CONTENTS

WIRING DIAGRAM . . . . . . . . . . . . . . . 80-2 Heater fan switch . . . . . . . . . . . _ _ . 80-5

AIR VENTILATION UNIT a. .,. . . , . . . 80-3 TROUBLE DIAGNOSIS AND
Removal and installation . . . . . . . . . 80-4 CORRECTIONS . . . . . . . . . . . . . . . _. . 80-5

c:
May 1983
 HEATER
.-

WIRING DIAGRAM-~

G1.5

111213141 r i
I I@
I I,i,i 1 I I
I1 G1,5 B
I---d
M I

A l Battery
El Ignition switch
84 Control for headlight, flashing, low beam and full beam
F8 Air ventilation control lamp
G I Fusebox
Ql Air ventilation heater fan
Q4 Air ventilation heater fan control
(IV - Low speed)
(2V - High speed)

May 1983 80-2

 HEATER

AIR VENTILATION UNIT

Air ventilation unit shell covers

2 Heater fan
3 Door
4 Air ventilation unit controls
5 Door
6 Air ventilation unit shell covers
7 Heater core
8 Door
9 Outer air duct frame
10 Outer air duct
11 Incoming air intake nozzle
12 Center ventilation duct
13 Air ventilation unit
14 Engine compartment cross member
15 Liquid delivery pipings

80-3 May 1983


REMOVAL AND
INSTALLATION
CAUTION:
. Remove battery ground cable.
. Before removing components
fitted with harness, make sure
the relevant connections have
been disconnected.
. Be careful when removing air
ventilation unit pipings, other-
wise liquid leakages from heater
core may occur.
With reference to exploded view
above proceed as follows:
1. Remove lower finisher of central
console and unscrew the four screws
securing air ventilation unit con-
trols @ to console (see Group 66 -
Central Console).
2. Unscrew the four nuts securing
air v e n t i l a t i o n u n i t @) t o b o d y .
3. Operating from engine com-
partment inside, disconnect harness
of heater fan 0.
4. By means of two terminals,
clamp liquide delivery pipings @
to air ventilation unit 0, in order
to prevent leakages.
May 1983
HEATER
5. Loosen metal clamps securing (2) Remove or cut seals.
pipings @ to air ventilation unit; (3) Separate the two shell cov-
then remove pipings. ers 0 and @.
(4) If necessary, with reference to
exploded view above, release control
cables of doors @ and @ b y
operating with suitable wrench on
the screw securing levers to door
hinges as shown in figure.
6. Unscrew the two screws securing
f r a m e @ of ourer air duct @ to
air ventilation unit; then remove
both.
Door hinge
Lever
Door control cable
Screw
(5) If required, disassemble com-
ponents o f a i r v e n t i l a t i o n unit
controls operating as per figure.
7. Carefully withdraw air ventila-
tion unit and air ventilation unit
controls a.
8. If necessary, disassemble air
ventilation unit in order to gain
access to its inner components.
(I) Operating as per figure, remove
the eight springs keeping together
shell covers 0 and @ of air
9. If necessary, o p e r a t e o n a i r
ventilation unit.
ventilation unit components present
in the dashboard by following
the indications provided in Group 66
- Dashboard.
10. Install air ventilation unit by
reversing order of removal.
80-4

CAUTION:
. .After restoring hydraulic con-
nection, it is necessary to top up
header tank of engine cooling
system.
. Lubricate air ventilation unit
control cables by means of
proper oil.
TROUBLE DIAGNOSIS AND CORRECTIONS
Condition
Insufficient heating performance
(No heated air flow to ducts)
Insufficient air flow to floor
Insufficient defrosting perfor-
mance (Cold air to ducts)
Insufficient air flow to defroster
(Refer to: Group 66 - Dashboard)
Control lever drags
Noise from blower motor
HEATER
HEATER FAN SWITCH
I I I
E l
Probable cause
b Cooling water temperature too low
D Heater care plugged
l Insufficient cooling water level
I Malfunctioning air mix door
l Blower motor speed too lo w
l Malfunctioning air floor door
l Malfunctioning door control
Refer to No heated air flow to ducts
l Blower motor speed too low
l Malfunctioning air main duct door
l Malfunctioning door central
l Bad cable sliding
l Control cable bent excessively
l . Air intake door not operate
properly
l Loose bolt in blower motor
? Broken blower blade(s)
80-S
LOCATION
The switch is located in the lower
ornament of central console (see:
Group 66 - Consoles).
CHECK
Check switch proper functioning by
verifying that continuity between
terminals occurs in compliance with
the indications provided in table.
Corrective action
Check thermostat: replace if necessary
Clean heater
Refill
Check door and adjust
Check blower motor and:
-- restore poor connections
- replace blower motor if necessary
Check door and adjust
Check control and adjust
Check blower motor and:
- restore poor connections
- replace blower motor if necessary
Check door and adjust
Check door control and adjust
Adjust
Correct
Check and adjust
Check and tighten
Replace blower
May 1983
 models

@iSl MANUAL SUPPLEMENT

ASSISTENZA TECNICA Lj%-@j.

PA333500883300
May 1 9 8 8
Instructions for the insertion of the technical data in the binders

When inserting the updating pages in the I_Alfa33)

V O L U M E Ii binder, it is advisable to proceed as shown
in the diagram below and to follow the order indicated.

I R43279000004X4 (with updating list)

r
CONTENTS PA3279000BR4X4 (with updating list)
INTRODUCTION LIST
PA327900000BRK)
(Elue tard)
PA3279000000AC (with updating list)
\
.:.
PA3279OOOOS WOO

PA327900883300

VOLUME I
L PA 3279OOOOOOOO VOLUME II -

i,

D e tailed contents:

PA32790000004X4 iorkshop M a n u a l (Alfa] -x4] m

PA3279000BR4X4 W o r k s h o p M a n u a l r-33) lm] giardinettaH
PA3279OOOOOBRK W o r k s h o p Mamal c-33) giardinetia
PA3279OOOOOOAC *installation Instructions [Alfa)
a i r conditioner
PA3279OOOOTDOO Workshop Manual f=E& cj{ 1.6 -ml
PA327900003300 Workshop Manual- m o d e l s
3ImEl

PA3279OOOOSWOO Workshop Manual m o d e l s s,pma wagam

PA327900883300 Workshop Manual m o d e l s

NOTE: For correct interpretation of the issue number, refer to the following code figures:

PA Ixlx]vlvl

Models group according

I Updating progressive number (N ~0, 1, 2 . ..)

code distinouishing
variow anuals in the
sa: , binder

PA333500883300 May 1 9 8 8
 FOREWORD

This manuals is intended f o r models 33 1.3 33 1.3 s 33 1.5 TI 33 1.7 IE 33 1.7 +

331.e-m 33 1.5 4x4 lt complements the manuals referring to ihe corresponding ( A l f a

models indicated here below:

PA32 7900000000 WORKSHOP MANUAL

PA3279000004x4 WORKSHOP MANUAL
PA3279OOOB R4x4 WORKSHOP MANUAL
PA327900000B RK WORKSHOP MANUAL
PA3279OOOOTDOO WORKSHOP MANUAL m
PA32 7900003300 WORKSHOP MANUAL - models m

Key to symbols:

means that the corresponding Group in thti. basic manual

(Alfa]
b should e referred ta, for ll details not dealt with
specifically in this manual.

May 1988 II PA333500883300

 QUICK REFERENCE INDEX

COMPLETE CAR l=Gi-l

ENGIN MAIN MECHANICAL UNIT pLiil

FUEL SYSTEM G7i-j

IGNITION, STARTING, CHARGING
SYSTEM pq

ENGINE C O O L I N G S Y S T E M -IGRriLq

[Alfa]
4 CLUTCH ,, p-j
..

GEARBOX .::iI: [GR.l

MOTION TRANSMISSION -pq

(Alfa33)
4
DIFFERENTIAL AND DRIVE SHAFT [GR.l
ASSEMB LY

FRONT SUSPENSION .+5-l

FRONT AND REAR BRAKES :pLJi-j

STEERING SYSTEM p3i-j

REAR SUS.PENSION GR. 25

WHEELS AND TIRES GR. 28

El
ELECTRICAL SYSTEM pGq

BODY-SHEET METAL PANELS :[GR.J

.DOORS pq
I .
HOODS pq

[Alfa] + ( INTERNAL TRIMMING [GR.1

EXTERNAL TRIMMING [GR:l

AIR VENTILATION
\

III May 1 9 8 8
 COMPLETE CAR

CONTENTS

GENERAL VIEWS . . . . . . . . . . , . . . . . . . . . . . 00-2 TROUBLE DIAGNOSIS SAND CORRECTION

Dimensions and weights . . . . . . . . . . . . 00-3 ON IGNITION SYSTEM LE3.2 JETRONIC
M:ODEL VARIATIONS . . . . . . . . . . . . . . . . . . 00-4 (1.7 IE with catalytic converter) . . . . . . . 00-21
IDENTIFICATION DATA . . . . . . . . . . . . . . . . (*) ELECTRIC TROUBLESHOOTING
Identification label . . . . . . . . . . . . . . . . (*) PROCEDURE
Car identification codes . . . . . . . . . . . . (*) (1.7 IE with catalytic converter) . . . . , . . 00-27
LIFTING AND TOWING POINT . . . . . . . . . . . (*) INJECTION-IGNITION WIRING DIAGRAM
SPECIAL SERVICE TOOLS . . . . . . . . . .. . . . (*) (1.7 IE with catalytic converter) . . . . . . . 00-35
INSTRUCTIONS FOR PRE-DELIVERY TROUBLE DIAGNOSIS AND CORRECTION
EXECUTION AND PERIODICAL ON INJECTION-IGNITION SYSTEM
MAINTENANCE COUPONS.. . . . . . . . . . . . . (*) (1.7 IE without catalytic converter) . . . . OO-391
MAINTENANCE SCHEDULE . . . . . . . . . . . . 00-6 TROUBLESHOOTING PROCEDURE
NEW IDENTIFICATION LABEL.. . . . . . . . . . 00-1013 ON INJECTION SYSTEM
MODEL VARIATION (1.7 IE without catalytic converter) . . . . 00-3516
(according to new identification label) 00-1014 TROUBLESHOOPING PROCEDURE
FLUIDS AND LUBRICANTS CHARTS . . . . . (*) ON IGNITION-SYSTEM
RECOMMENDED FUEL AND LUBRICANT . 00-11 (1.7 IE without catalytic converter) . . . . 0035113
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-11 INJECTION-IGNITION WIRING DIAGRAM
Fluids and lubricants . . . . . . . . . . . . . . . 00-11 (1.7 IE with catalytic converter) . . . . . . . OO-35/18
APPROXIMATE REFILL CAPACITIES . . . . , 00-12 COMPONENTS AND BODY MAINTENANCE (*)
/ ENGINE MAINTENANCE . . . . . . . . . . . . . . . 00-13 SERVICES DATA AND~SPECIFICATICNS . . 00-36
L Engine m,ai,nfenan,ce . . . . . . . . . . . . . (*)
Basic mechanical system.. . . . . . . . . . 00-13
Fuel system . . . . . . . . . . . . . . . . . . . . . . 00-13 Componnts~ancjbody maintenance . . 00-36
-.:.
Exhaust checking . . . . . . . . . . . . . . . . . 00-15 SPECIAL SERVlCETOOLS. . . . . . . . . . . . . :. . 00-37

>I
(*) See: REPAIR MANUAL [Alfa] VOLUMES I and II - Group 00

PA327900883301 October 1988

 GENERAL VIEW

l
-I

October 1988 00-2

DIMENSIONS AND WEIGHTS ENGINES
ENGINES ENGINES
ENGINES WITH ELECTRONIC WITH TURBO
WITH ONE CARBURETOR WITH TWO CARBURETORS
FUEL INJECTION COMPRESSOR
8
*T
Mode1 33, 33 1.3 33 1.3 s 3 3 1 . 5 TI 3 3 1.5 a x a 33 1.7 * 33 1.7 IE 33 1.7 * 33 1.5 TO

908.260 908.060 908.080 908.100 908.220 908.160 908.140 908.180~ 908.120

Identification number 908.061 A 908.110 908.170 908.200A
908.1OlA 908.161A 908.150A

Wheelbase P (mm) 2470 2465 2455

Front Ca 1367 1362 1367 1397
1366
Track (mm)
1362 1364 1375 1364 1364
Rear cp
I
Overall length LU (mm) I 4015 4040

Front Sa h-4 800 790 825

Overhang
Rear SP 760 760 760

Overall width La fmm) 1612

Height funladen) H (mm) 1340 1345 1370 1345

Min. steering radius (mm) 5500 5350

Kerb weiaht (kg) I-~ 910 I 970 I 930 I 1010

Max. allowed gross weight (kg) 1335 1395 1355 1435

Payload (kg) 3 5 5

Max. allowed axle Front 800 800

(kg)
gross weight lac.!,. 800 900

Max. towing gross weight (kg) 1 1000 I 1100 I 1000 I 1100

Front
2
Seating cepacity
Rear 3

(A) With ecological meterials for countries where antipollution regulations are
in force
(*) With 1.2 engine not marketed in all countries
[A) With ecological materials.
 MODEL VARIATION

ENGINES ENGINES
WITH ONE CARBURETOR WITH TWO CARBURETORS

33+ * 33 1.3 33 1.3 s 3 3 1 . 5 TI 33 1.5 axa

Modal

Body
5 door saloon

I I
L R L R L R L R L R
Drive

- on certification
Identtflcatwn label and
908.260 - go8,061.
908.060 / _ ( 908.080 1 _ 1 ;;;:, 1 908.10 / 908.220 j -
NO.
- on identification
label

on identification
905AB 905Al G 905Al H 905A2V 905A2T
label

Type approval
NO. - on intermediate
905AOO 905AlO 905A20
bulkhead label

-L-
Chasris No.

- on intermediate
Serial No bulkhead label

30586 30587 30588

- on cylinder
Engme No. Type and serial frofl from from
block label
NO. 0000001 0000001 0000001

Tire dimensions 165/70 SR 13 175/70 RI 3 82T

Rim dimensions 5% J x 13
\

(A) With ecological materials

(*) With 1.2 engine not marked in all countries
 MODEL VARIATION

5 DOOR STATION WAGON

Drive L R T
- on certification
Identification No. label 906.600 - 908.600 -
- on identification
label
- on identification
905Al D 905Al F 905A2S 905A2U
label

! - on intermediate
Type approval No. .-8 bulkhead label
905AlO 905A10 905A20 905A20
Chassis
No.
l
- on intermediate
bulkhead label
Serial No / 05379411 -

I
- on cylinder
block label
30587 30508
Engine No. Type and serial No.
30168
from
0000001
from
0000001
from
0000001
3oda88
0000001

Tyres dimensions r 165170XRl3 175170R1382T

Rim dimensions 5%Jx13 5%Jxl3

C (A) with ecological material

 MODEL VARIATION

Mode1

Body

Drive

Identification No.
- on certification
label
- on identification
z! 908.650 908.660 -
label
- on identification 905A4A
label 905A30 905A3F 905A3G

-/on intermediate
Type approval No. Ibulkhead label
905A30 905A30 905A30 905A40
Chassis
No.
--
-Ion intermediate
jbulkhead label
Serial No. 65407756 -
l

- on cylinder
block label
VM82A
Engine No. Type andsrial No. 3E18
0000001
30558
from
0000001
from
0000001

Tyre dimensions 185160R1482H 175/70iY382T

Rim dimensions 5XJx14 5%Jx13

(A) With ecological material and electronic injection engine for countries where antipollution regulations are in force
(A) With ecological material
-
 APPROXIMATE~ REFILL CAPACITIES

Mode1

L _
Component

FUEL TANK

FUEL RESERVE 6.5 (1.43) - 6.5 (1.43) - 6.5 (1.43) - 6.5 (1.43)

With filter (*) 3.6 (7.94) 4 (0.88) 3.6 (7.94) 4 (0.88) 3.6 (7.94) 4 (0.88) 4.57 (10.07) 5.25 (1.15)
ENGINE OIL SUMP
% Without filter (*) 3.15 (6.94) 3.5 (0.77) 3.15 (6.94) 3.5 (0.77) 3.15 (6.94) 3.5 (0.77) 4.35 (9.59) 5 (1.10)
-
P
GEARBOX - DIFFERENTIAL OIL 2.4 (5.29) 2.6 (0.57) 2.4 (5.29) 2.6 (0.57) 2.4 (5.29) 2.6 (0.57) 2.4 (5.29) 2.6 (0.57)

REAR D!FFERENTIAL OIL - - - 0.9 (1.98) 1 (0.22) -

ENGINE COOLING SYSTEM - 7.3 (1.61) - 7.3 (1.61) - 7.3 (1.61) - 8

CONCENTRATE ANTIFREEZE + -15C (+5F) - 2.2 (0.48) - 2.2 (0.48) - 2.2 (0.48) - 2 (0.44)
QUANTITY DEPENDING ON + -2OC (-4F) - 2,6 (0.57) - 2,6 (0.57) - 2,6 (0.57) - 2464 $:-]
TEMPEFiATUR 3 -35C (-31F) - 3.65 (0.80) - 3.65 (0.80) - 3.65 (0.80) -

ANTIFREEZE QUANTITY READY + -2OC (-4F) - 7.3 (1.61) - 7.3 (1.61) - 7.3 (1.61) - 8 (1.76)
FOR USE

() The indicated quantity refers to periodical changes.

 COMPLETE CAR

CHASSIS AND BODY MAINTENANCE

TECHNICAL DATA - INSPECTION AND ADJUSTMENT
Axles and suspensions

;n :
CU -1 ?
tl tl
0 :
0
II ; II
d I +
2
- -

67
k

l tl
0
II
m
0 Il
-. 0
k
+I 2 z

a
9 0 fl tl
+ CU II Eu
a tl e
i
II II
d II
CL >
II 0
1
I
z

PA3335OOpOS WO 1 0 0 - 5 MAY 1 9 8 8
 I
: -.

1 MODEL VARIATION

ENGINES
ENGINES ENGINE WITH
WITH lW0
WITH ELECTRONIC FUEL INJECTION TURBO COMPRESSOR
CARBURETORS
I
Mode1 33 1.7 * I 33 1.7 IE I 33 1.7 * I
33 7.8 TO
I I I

Body 5 door saloon

l I I I I
L I
l R I
I L II R Il L II R L I R
Identification
- on certihcatlon
label and go8,161A ( 908.170 ( ;;;;NX;;, (
_
908.160 908.150. / 905.180. /
- on identificat!on
NO. label

- on identification
905A3 905A3D 905A4
label
l

Type approval
NO.
- on intermediate
905A30 905A40
bulkhead label
Charsis No.

- on intermediate 05411704 05410692 - -

- ~ - 05411250 -
Serial No bulkhead label
A A

- o n cylinder
30550 305.58 305.58 VM82A
Engine No. Type and serial block label from from from from
NO. 0000001 0000001* A000001 00001

Tire dimensions 185/60 R1482H 185/60 R1482H 175170 RI 382T

Ftim dimensions 5% J x 14 5% J x 13
-
(A) With ecological materials
908.200
(*) Not including numbers go8,,50 that take the serial number AOOOOOl, as with number 908.180
 COMPLETE CAR

MAINTENANCE SCHEDULE

The following schedule is valid for the Italian market only

s
I s 3 3
- - -
X X X X
- - -
X X X
- - -
X X X X X
- - -
X X X
- -
X X X X
- - -
X X X
- -
X X X X X X
- - -
X X X X
- - -
X X X X
- - -
X X X X
- - - -
X X X X X X
- - - -
X X X X
- - -
X X X X X
- - - -
X X x X
- - - -
X X X X X X
- - -
X X X X
- - - -
X X X X X
- - - -
X X X X
- - - - -
X X X X X X
- - - -
X X X X
- - - -

X X X X ic
- L-

Y
z
8
.z
8
.k0
.-P "0
B" E
m
E P,"
2. . P
B ?
L 2
3 E 3
;
.- <u >
z
E m
0 E 2
2 2 8
z L9 E
c 9 Y2
0
Fi s
& u:
E m
Ty 0
2 .E m
Y
I P
yo0
6 6
- 5
-
r. CO
2

May 1 9 8 8 00-6 PA333500883300 /

 2 Km/1000
2 A - - - - -
~g

8
si
~~
N. OPERATION
(1)
~10 20 30
- -
4 0 -5c 60 7c l
- -
80 90 13(
-
-rl
170 18( 1 . 190 200
Notes

19 Check terwon of and if necessary replace drive belts of: alternator. coolar X X X X
2 pump and air~conditioner compresser (If fltted)
8
- - - - -
Replace drwe belt of alternator and air condltioner compresser (if fmed) X X

- - - - -
; X X
- - - - -
X X x X X X
- - - -
23 Clean and check air filter element X X X X X X X
- - - - -
24 C h e c k trghtness of au mtake syslem downstream from the air flow gaugl X X X X X X
(petrol Injection only)
- - - - - - -
25 Replace fuel filter (where necessary) X X X
+t-
- - - - - I I
Replace air folter cartrldge X
- -
X X
- -
X
-
X
-PL--
Clean carburetor jets and crankcase ventilation systembackfwe shleld X X X X X
l I
I
X
I

IXI
- - - - -
28 Check exhaust emissions X X X X X X
1 - - - l I
-
l
29

30
Check and if necessary adjust ignition timing

lnspect and clean spark plugs X

X
- -
X
X

X
X
- -
X
X

X
-
X X
X
-k-l---
- - - -
31 Replace spark plugs X X X X X
- - - - %-t---
I I

42
32 Check battery electolyte level. top up. tlghten and grease termmals X X X X X X (4)
.
- - - -
33 Lubricate door and hootybackdoor hinges. Adjust strikers. as necessarb X X X X X X
Greasing of hood and backdoor catches
- - - - -
34 Check underbody and body work X X X X X X
- - -

%
35
I
I Test vehicle X X
- -
X X
- -
X
-
X X

e (1) A = 1500+2500 Km (621t932 mi) (4) Check frequently when refuelling

s (2)
(3)
To be performed in any case every 6 months. Check oil level frequentlywhen refuelling
Check more frenquently if driving in very dust areas
(5)
(6)
TO be performed more frequently when driving under particular stress conditions (sport driving) or on hillv roads
TO be performed in any case every 12 months
g
 COMPLETE CAR

MAINTENNCE S C H E D U L E
Th,e following schedule is not valid for the Italian market and for countries where antipollution
r&julatjons are in force

- - - - -
X X X X X
- - - -
X X
- - -
X X X X
- -
X .x
- - -
X X X X X X
- - -
X X X
- - -
X X X X X X
- -
X X X
- - -
X X X X X X
- - -
X X X
- - - -
X X X X X X
- - -
X X X
- - -
X X X X X X
- -
X X X
- - - -
X X X X X X
- - - -
X X X
- - - -
X X X X X X
-
X X
- - -
X X X X
- - -
X X
- - -

a= X X X
- -

u
m
m
20
3
s"
t
v1
I
Li
r
5
'm
-0
k
Y
E
6
-

May 1988
oo-7/1 PA333500883300
 Km/1000
Notes
30 40 50 60 70- 80 90 100~ 110 120 130 140 150 160 170 180 190 200 ~~

Check tension of and If necessary replace drwe belts of; alternator. coolant X X X X
pump and air conditioner compresser (If fltted)

20 Replace drive bett of alternator and air conditroner compresser (If fltted)
I / Il

21 Replace camshaft drive belts

I Il

22 Check fuel system for leaks X X

23 Clean and check air filter element X

24 Check tvghtness of air mtake system downstream from the air flow gauge X
(petrol Inlectlo only)

25 Replace fuel fllter (where necessary)

I I I l
26 Replace air ftlter cartndge X
8 I I I I
4 27 Clean carburetor lets and crankcase ventllatlon systembackflre shleld X

28 Check exhaust emlssions X X X X X X X X X X X

29 Check and if necessary adjust Ignition timtng X X X X X X X X X X X

30 Inspect and clean spark plugs X X X X X X X X X X

1Il$lVIil F Il
31 Replace spark plugs X X X X X X X X X

32 X X X X X X X X X X (4)
Check battery electrolyte level, top up, tighten and grease terminala

33 Lubricate door and hoodbackdoor hinges. Adjust strikers, as necessary. X X X X X X X X X X

Greasing of hood and backdoor catches 8
1 I I I I I I I I 1 I I I I I I I I
34 Check underbody and body work X 1x1
I i
lx1
l I
1x1
I I
14
l I
1x1
I I
1x1
I I
1x1
I I
1x1
I I
1x1
I I

35 Test vehicle x x X X X X X X X X X

(1) A =1000~1500 k m (621 t932 m i ) (4) Check frequently when refuelling

?
-L (2) T O be performed in any case every 6 months. Check oil level frequently (5) TO beperformed morefrequentlywhendriving underparticularstressconditions
when refuelling (sphrt driving) or on hilly roads
(3) Check more frequently if driving in very dusty areas (6) TO be performed in any case every 12 months
 COMPLETE CAR

MAINTENA.NCE SCHEDULE
The following schedule is valid only for those countries where antipollution regul,ations are in force

E 32 9 Lu

- 7
X X
-
X X
-
X X X X X
- - -
X X
- -
X X X X x
- -
X X X
-
X X X X X X
-
X X X
-
X X X X X
- -
X X X
- - -
X X X X X X
- -
X X X
- - -
X X X X X
- -
X X X
-
X X X X X X
- -
X X
- -
X X X X
- - -
X X
- -
X X X X X,
- -
X X
- - -

X X X X X

- -

B
u
%
.3
E
5
E
n
n
5

i
il
Y
p:
6
-
m
i

PA333500883300 May 1 9 8 8
, 00-8
 COMPLETE CAR

u w .u .u

x Ix X
-

$
X
- -
X X
- - - -
X X
- - - - -
x X X X
- - - L -
i- X X
.
F- f - - - -
X
- _ - - - - -
X X
--_ - - - - -
X X X X X
- - - - -
X X
- -
X X
- -
X X
- - -
X X

X X
- - - - -
X X X X X X X
- - - - - -
X X
- - - - - - -
X X X X X X X X
- - - - -
X X
- - - -
X X X X
-
X X 1
X x ~ X
-
X X X X X X
-

X X

May 1988 PA333500883300

 Km11000 I
A - -
No. OPERATION
(1)
10 20 30 40
- -

34 Check sensor OI oxygen contents in exhasl gas

- -

35 Replace catalyst of exhaust gas

- -

(6) T O be performsd more frequently when driving under particular stress codltions
(1) A= 1000+1500 K m
(sport driving) or on hilly roads
(2) Check oil level every 500 km and when refuelling (7) T O be performed in any case every 12 months
(3) Check more frequently il driving in very dusty areas (8) T O be performed in any case every 5 years
(4) Check frequently when refuelling
6) Operation relevant to emission control
(5) T O be performed in any case every Iwo years
 COMPLETE CAR

-
MAINTENANCE SCHEDULE
,/ ,
The present periodical maintenance schedule, for all markets, is applicable to vehicles equipped with SERVICE BOOKLET having the new
programmed maintenance.

OPERATION

ine oil and oil filter check ti

Replace oil in gearbox - differential (and rear differential in

Check brake and clutch fluid levels X ( X 1 X 1 X 1 (6)

14 1x1
19 Check axial and radial play of supercharger rotor shaft and
by-pass valve (only in diesel engine vehicles)
X~
I i lx1
20 Check idle r.p.m. (petrol versions) x x x x x x x
xIxI x Ix1
?l

22
Check idle r.p.m. (diesel engine versions)

Replace exhaust gas oxygen sensor ( Lambda sensor) (only in

X
--lTrl-
x x
vehicies with catalytic converters)

23 Check integrity and tension of cooling liquid pump, alternator

/ and conditioner compresser (if installated) drive belt x x x x x x X x x
i..
ti

PA3279Otj883301 oo-lO/l October 1986

 COMPLETE CAR

N. OPERATION Note
140 160 180 200

24 1 Replace timing belts X

I I I /XI

25 Check tightness of fuel supply circuit

Check fuel vapour emission contrai circuit (if installed) X
,,

26 Check air,filter cartridge X X

27 Check tightness of air supply system downstream the air flow x

meter (only in fuel injection engines)

26 Replace fuel filter (where foreseen) x x x X

X X X
2g Replace air filter cartridge

30 Clear flamedamper in exhaust gas recycling circuit (except in

diesel or fuel injection cars) I I lx1
x X

31 Check exhaust emission (only in vehicles with catalytic converter) X X X X 1 x x x

33 Check spark advance (except diesel models) x x x x x x x

33 Replace spark plugs (except diesel engines) X ~X

34 Check electric connections in engine compartment (condition X X X

and positipn of connectors and hoods)

x/ x(xI xl
-
36 Grease dqor and hood hinges, grease hood locking catches.
X J
I IxIxIxlx

36 1 Test vehicle Ix 1x1 xl xl x x x

(1) A = 1500 - 2500 Km (5) TO be performed more frequently ihen drivlng particular in stress
(2) Check oil level every year and when refuelling conditions (sport drlving) or on mountain roads
(3) Check more frequently if driving in very dusty areas (6) TO be replaced in any case every 1,2 months
(4) Check frequently when refuelling (7) TO be performed in any case every 2 years

October 1988 oo=s 0/2 PA327900883301

 P

NEW IDENTIFICATION LABEL

/@@&
I
- - A L F A L A N C I A INDUSTRIALE S . P . A .

- QI 1 I
1
2

I Ul2-
- HOTORE-ENGiNE
* 3
- -,fl
'6 . VERSIONE-VERSION

, N PER RICAfl8I - -,5

ti F O R SPARES /
L

1 - Homologation code 5 - Serial number with relation to finished units: necessary

when ordering spare parts, for identification of produc-
2 - Body marking tion or assemply plant and as reference for introduction
of modifications.
3 - Engine type mumber
6 Marking of correct value of smoke absorption coeffi-
tient (for diesel enginesonly).
4 - Base type and vehicle version

<.._E BODY MARKING (1) - Constructor identification code

8
(2) - Vehicle mode1

ZAR/ ,905AOO + 0 5 4 5 5 . 7 3 7 (3) - Chassis serial number

, l I
(1) (2).

PA3q7900883301 0040/3 October 1988

 MODEL VARIATIONS
(According to E.E.C. markings adopted on new identification labels)

I
ENGINES WITH ONE CARBUTEROR ENGINES WITH TWO CARBURETORS

Mode1 33+ * 3 3 1.3 3 3 1.3 s 3 3 1.9 l-l 3 3 1.5 PXI

Body 5 DOOR SALOON

Drive LEFT LEFT LEFT

I

- on identification
905AP I 905Al G I 905Al H 905AZV 905AZT
label
/

vehicle type No. - on Srvice compartment

front cross member,
905AOO 905AlO 905A20
right side,
horizantal plane.

- on service compartment
Chassis serial No: front cross member, 05.455.737
right side,
horizontal plane

- on special
rised block 30565 30566 30567 30588
Engine type and serial No. on engine block, :
Upper right part
0000001 0000001 0000001 0000001
flywheel side

Tyre dimensions 165/70 SR 13 175/70 R13 62T

I

8 Rim dimensions 5% J x 13
2 ;
g .
3) With 1.2 engine commercialised only in certain countries.
St
2
0
4
 MO~DEL VARIATIONS
(Accordinb to E.E.C. marking adopted on new identification label+

ENGINES WITH TWO ENGINES ENGINES WITH

CARBURETORS WITH ELECTRONIC FUEL INJECTION TURBO COMPRESSOR

Mode1 33 9.7 fi 33 1.7 I!i 33 1.7 + 331.8TO

..
Body 5 DOOR SALOON
I I l
Drive lefilright leftlright leftlright left

T
-r ..

- on identification
label
I
905A3
I
905A3D I 905A4

I I I
8
0 vehicle type No. - on service compartment

z front cross member,

right side, 905A30 905A40
horizontal plane.

- on service compartment
front cross member, 1
Chassis serial No. 05.455.737
right side,
horizontal plane

--on special
raised block 30550 305.58 305.58 VM82A
Engine type and serial No. on qgine block, from from from
from
Upper right part 0000001* A000001 00001
0000001
flywheel side

I I

Tyre dimensions 185/60 RI 482H 185/60 R1482H 175170 R1382T

I
0 Rim dimensions 5lz J x 14 5% J x 13
0
OF
() Excluding Nos. 908.2201908.150 which take serial No. A000001 as with No. 908.180.
2
QJ
 COMPLETE CAR

RECOMMENDED FUEL AND LUBRIC&NTS

,:,--

00-l 1
FUEL

For coke@ engine functioning the specification is for premium grade or unleaded petrol: RON 2 95.

For models 33 1~7 + and ,33 1.7 IE with electronic injection and catalytic convertor only unleaded petrol to the following
specifikations must be used:
~
- Octane Number (Research method) R.O.N. 2 95 (for Switzerland, Sweden versions)
- Octane Number (Research method) R.O.N. 2 91 (for Australia version)

WARNING:
._
Never mneither in an emergency nor in small quantities use conventional lead petrol. TO d6 SO Will result in permanent
damage tothe exhaust gas catalyzer.
TO preuent the tank from being accidentally filled with lead petrol, the inlet filler has been designed in such a way as to
permit, the entry of only special filler spouts fitted exclusively on unleeded petrol pumps. Should the tank be filled with
even a small quantity of lead petrol, do not start the engine, but proceed to the complete emptying of the tank and the
fuel delivery system.

FLUloS AND LUBRICANTS

except:

Name
Type Application Classification Notes
, AGIP IP SHELL

API SF/CC Sint 2000 Sintiax Super Plus~ Envikmental

Engine - 01 MIL L461528 SAE lOW/40 SAE lOW/40 Motor Oil temperature
CCMC G2Dl SAE 15W15b -lS+t40%

Oil
Environmental
Gearbox - 13 SAE J 306a Rotra MP Pontiax HD Spirax HDI
temperature
Differential APIGL-5 SAE 8OW190 SAE 8OW/90 SAE SOWl90
- 30 f t 40%

May 1988 00-11 PA3335008833pO

 APPROXIMATE REFILL CAPACITiES
83 ~~~

Mo&is 33, x 3 3 1.3 3 3 1.3 5 3 3 1 . 5 TI

33 1.5 a x a 3 3 1.7 + 3 3 1.7 IE 331.BTO

Measurement unit
, Kg Liters Kg Liters
Components

FUEL TANK - 50 - 50

FUEL RESERVE - 63 6,5

With filter- PI 386 4 4.57 5,25

ENGINE OIL SUMP
Without filter (0) 3,15 3.5 4,35 5

GEARBOX - DIFFERENTIAL OIL 24 2,6 2,4 2,6

REAR DIFFERENTIAL OIL ( LIXU models) 03 1,o - -

ENGINE COOLING SYSTEM - 7,3 - 7,5

CONCENTRATE ANTIFPEEZE - 15oc 22 2

QUANTITY DEPENDING ON - 20 oc - Z6 - 2,64
- 35C 3,65 4
TEMPERATURE

ANTIFREZE QUANTITY READY

- 2 0 % - 7,3 - 7,5
FOR USE

(0) The indicated quantity refers to periodical changes

(*) Not marketed in all countries with 1.2 engine. i,. ,^ - -
2
 COMPLETE CAR

ENGINE MAINTE#NANCE ~

BASIC MECHANICAL B e f o r e extracting the dipstick, dis- 1. RelFase clips which secure caver
SYSTEM
connect the minimum oil level sensor
0 1 to container.
wiring from the stick. 2. Lift caver enough to remove car-
tridge without damaging sleeve 0.
3. Clean the cartridge thoroughly. by
CHECK AND POSSIBLE blowinglow pressure compressed air
COOLING SYSTEM in the o&posite direction with respect
ADJUSTMENT OF VALVE
CLEARANCE to the normal air flow.
Proceed as per [Alfa] except for
!n
As for Alfa 33 except for the 1 . 7
engine with hydrauli tappets which
the table referring to antifreeze fluid
composition provided in System
does n o t r e q u i r e any check o r Refill, which has to be changed as
adjustement of valve clearance fOllOWS. for 1.7 engines

CHEtiKING, REPLACING
AND ADJUS-kING DRIVE
BELTk
M i n i m u m out- OC -15 -iO -35
side temperature (OF) (+ 5) (- 4) (-31)
Alternatix and water pump con- Concentrated anti-
trol bkt, freeze Std. No.
As for &Alfa] except for 1.3 - 1.5 - 3681-69956 I 2.2 2.6 3.65
(Imp Gal) (0.48) (0.57) (0.80)
1.7 engines with one carburetor where
the tension value to be measured with Diluting drinkable
the appropriate tool is: water I 5.1 4.7 3.65
(Imp Gal) (1.12) (1.03) (0.80)
78+8? N(8 +9 kg)
R e a d y - t o - u s e anti-
Replzki~g timing belts with en- freeze Std. No.
gine bn car 3681-69958 I - 7.3 -
(Imp Gal) - (1.61) -
As for [Alfa), only for 1.7 engines 1 A i r fiker caver
the pr&&dure for the, a-1 2 Corrugated sleeve
modeLis tp be applied

CHANGiNG ENGINE OIL

CYLINDER COMPRESSION
AND ~REPLACING OIL 4. Clean the cartridge container.
TEST
FILTER 5. Insert the cartridge into container
positioning t h e p r o t r u d i n g p a r t
As p,e( IAlfa except for the table As per (Alfa331 . downwards and hook the caver clips
referripg to the refill capacities.which again. -.
has to be modified as follows:
for 1.7 engines

Replace the element at the re-

ENGItiE OIL QUANTITY commended intervals (see: Vehicle
FUEL SYSTEM Maintenance Schedule).
I
~ Capaclty
(Imp. Gal.)
CHECK, CLEANING AND
Engine ;oil sump at max .

li?Wl
Cil filte; and inner
ducts
Periodical change (engine oil
for sum,p and filter)
REPLACEMENT OF AIR
(ci?) FUEL~ FILTER REPLACEMENT
FILTER CARTRIDGE
0.6
(0.13)
A s p e r (Alfa] e x c e p t f o r 1.7 A s p& IAlfa33] exce,pt f o r 1 . 7
4.0
e l e c t r o n i c i n j e c t i o n engines w h i c h electronic i n j e c t i o n engines w h i c h
(0.88)
require the following procedure. require the following procedure.
I

PA~335Q0883300 do-13 May 1988

I

1. U n s c r e w t u b e s @ and 0 fit-
tings and recover the gaskets.
ProPerlyp!ugfittings to prevent
fuel outletl
2. Loosen clamp @ and remove
filter @. ~
3. Remou;nt the new filter in order
that the arrow printed on filter body be
positioned towards fuel delivery direc-
t i o n . v a l u e )
4. Complete the filter assembly oper-
ating in opposite order in respect to
removal.
1 Filter sup,port clamp
2 F u e l outlet t u b e
3 Fuel inlet tube
4 F u e l filter
CHECKING &EL SUPPLY
PRESSlJliE ANDCIRCUIT
TIGHTNEh
As for [-33) except for 1.7
electronc ~ injection engines w h i c h
require the following procedure
May 1 9 8 8
COMPLETE CAR
E,ffect checking as follows:
1. Circuit pressure checking
a. Disconnect fuel delivery tube @
downstream from the damper @
b. Connect a gauge by means of a
T adaptor between damper @ and
tube @ previously disconnected.
c. Detach tube @ from pressure
gauge 0.
This is in order to avoid that any pos-
sible anomalies on idle rotation speed
could cause unusual readings.
d. Start the engine; at idle speed check
that fuel pressure value is:
280 i 320 KPa
(2.8 c 3.2 bars; 2.9 + 3.3 Kg/cm)
e. Reconnect tube @ to pressure
gauge; at idle, fuel pressure should
drop of 0.5 bars approximatively and
then rise again when throttle valve Will
open. Should thisoccur, please check
any possible tube @ depression
leaks.
1 Depression tube
2 Fuel pressure gauge
3 Throb damper
4 Tube delivery to fuel distribution manifold
00-14
2. Checking on circuit tightness
a. With pressure gauge plugged, and
with engine on idle,throttlethedelivery
tube immediately downstream from
pressure gauge, de?ecting a pressure
increase up to
400 KPa
(4 bars; 4.1 Kg/cm*)
(do not let the pressure exceed this
b. With pressure on 2.5 bars check
that fuel delivery tubes and fittings do
not show leaks.
c . I f f u e l p r e s s u r e does not reach
this value and if no leaks are detected
check t h e filter and/or t h e p u m p
ooeration.
CHECKING AND POSSIBLE
ACCELERATOR CONTROL
ADJUSTMENT
As for (Alfa] except for 1.7 ele-
ctronic injection engines which require
the following procedure
1. Check table s l i d i n g
Checkthattheacceleratorcontrolcable
slides freelv in its sheath
2. Check table c l e a r a n c e
a . W i t h t h e a c c e l e r a t o r p e d a l re-
l e a s e d , check that the accelerator
pedal on control lever has an axial
clearance of G I = 1 f 2 m m .
b If necessary, proceed to adjust the
table c l e a r a n c e e x t r a c t i n g t h e
adjustement clip 0 in order to give
tbe prescribed clearance to the table,
and,reinserttheclipinthenewposition.
PA333500883300
 COMPLETE CAR

CHECKING OF
EMMISSIONS

CHECK A!D ADJUSTMENT

OF IDLE, R.P.M. AND
EXHAUST EMISSIONS

Effect the following preliminary

checks:

a. Cleaning and replacement of air

filter cartridge.
b.lgnition system efficiency: spark
plugs, tables, cap, frotary rotor (see
G r o u p 0 5 - transistorised ignition
1 Acklerator table without contacts).
/ c. Ignition timing.
2 Adjustment clip
3 Accelerator table sheath d. Checking of accelerator control
adjustment (sec Group 04 - Checking
and accelerator control adjustment).

CAUTION
3. Cfhe,&king on maximum If during engine tune up there is no
throttle valve opening extra cooling fan available, keep
checking the therinometer and the
a. With accelerator pedal pressed water temperature warning light on
a s fa~r as it Will go, check that the dashboard and immediately suspend
1 Tail p i p e
accelerator control cam cari still rotate testing if temperature goes u p , 2 CO-tester probe
by meaning that engine is overheating.
. Gp=l i2,mm
6 . If! n o t w i t h i n s p e c i f i e d v a l u e ,
If necessarv, proceed to adjustement adjust ~ idle-rpm just by turning
by acting on stop screw @ below the Single carburetor models relevant idle-adjusting screw @
accelerator pedal. Check idle-rpm and overall CO% as which~ makes it possible to change
follows: rpm without changing CO percentage
, --

1. Insert CO-tester probe @ into (Carbcin monoxide).

l
.. ,_,
the tail pipe 0. 7. Verify that CO percentage
2 . Connect a n electronic tachome- picked up by tester corresponds to
terto the engine. specifi,ed value and that engine
runs smoothly.
3. Start the workshop g a s ex-
hauster.
4. Start the engine and warm it UP Allowed CO%
t o n o r m a l running temperature. 1.5 + 1.8
5. Now check that engine rpm is
within specified value.

Idle-rpm
900 + 1000 r.p.m.

1 Accelerator pedal
2 Stop screw

.. :,, ,, ,
L. ., 1

<. 8

PA333500883300 00-X l May 1988

 COMPLETE CAR

If notwithinspecifiedvalueorincaseof Double carburetor models misalignment (40 mm Hg) between

e n g i n e tune u p a f t e r e n g i n e ; cylinders of the same carburetor then it
Check i d l i n g - r p m , CO% o n each
overhauling or after having cleaned or Will b e n e c e s s a r y t o r e p l a c e t h e
cylinder a n d l i n e - u p o f c a r b u r e t o r
replaced the carburetor, an adjustment carburetor.
throttle valves as follows:
involving mixture meteringscrew 1
B e f o r e b e g i n n i n g t h i s t e s t check 4. Make sure that all cylinders are
a n d throjtle v a l v e s c r e w 3 i s
C!il accelerator table adjustment 1 Refer functioning correctly by grounding one
requised. In this instance, proceed as
t o : G r o u p 0 4 - A c c e l e r a t o r Gable spark plug at a time and checking that
follows: theincreaseinr.p.m. isidenticalforeach
Adjustment)
,( 1) RemoJe seals from mixture cylinder. ~
metering, screw a and from throt-
tle valve sctew 0.
( 2 ) Tighte~n i d l i n g s c r e w @ all t h e
,way.
(3) ,Now act on throttle valve
s c r e w @ and on mixture metering
screw@ till following conditions are
present: ~

Mm
750 + boa
C O %
0.5,+ 1 % t o t a l

( 4 ) Loosen idling adjusting

s c r e w OI ti,ll a 900 + 1 0 0 0 rpni
idling speed i$ reached.
(5) Act don mixture metering
screw @ till the smoothest possible
engine running is obtained, while
keeping C$I% within the prescribed
,
values. ~

~% CO 0,5 + 1

(6) F i t back i n t o p l a c e m i x t u r e
m e t e r i n g nd t h r o t t l e v a l v e s c r e w
seals.
(7) If further optimizing of idle-rpm
is desired, jus? act on relevant idling
adjusting,screw @ .

1 Electronic rev counter

1 Idling mixture metering screw
2 Idling adjusting screw
3 Throttle valve adjusting screw
1. Insert t h e t u b e o f t h e mercury
vacuometer in the appropriate fittings.
2. Starttheengineandrunittonormal
running temperature S O that the
temperature is equal to or greater than
45oc.
3 With the gear shift in neutral, open
t h e mercury vacuometer valve and
check t h a t t h e A p v a l u e s o f t h e
m a n o m e t e r s fall w i t h i n 4 0 m m H g .
Correctanydifferencesbetweenleftand
right carburetors by acting on the
throttle valve screws. Should there be
2 CO tester
If necessary act on the mixture meter-
ing screw of the out-of-tune cylinder
until correct functioning is obtained.
5. Adjust the engine speed to 850 -
1 0 0 0 r.p.m. by acting on the throttle
valve screws, c h e c k i n g t h a t t h e
m a n o m e t e r r e a d i n g s fall within the
specified values.
6. Using the CO% tester, check that
the exhaust CO emissions are 1.5 - 2.5%.

May 1988#
00-l WI PA333500883300

T O obtain better CO exhaust emission
adjustment it is necessary to operate
measuring the values cylinder by
cylinder using special service tool
C, 3.0054 connected as follows:
1 A. Raise car on lift and disconnect
exhaust manifold from cylinder
h e a d s .
2 A. Now~fit small flanges C.2.0054
with relevant gaskets and pipes for
collection, of exhaust fumes - bet-
ween Bach exhaust manifold flange
and relevant fitting on cylinder
heads. ~
3 A. C o n n e c t e x h a u s t m a n i f o l d
back tb cylinder heads.
The other ends of the four collection
pipes emerge in the engine compart-
ment andi being equipped with suit-
able pfugs, are set up to test each
cylinddr CO%.
c.2.oo!x
7. Ch,eck the idle r.p.m. and if
necessary adjust it again repeating
the operations described at step 5.
8. @-set the play in the idle levers
to 1 mm by tightening the stop screws
and then check that the carburetors
open simultaneously by acting on the
:Point where the accelerator table is
attached, effecting short Sharp spurts
of acceleration (1200 - 1300 r.p.m.).
Adjustthe stop screwsfurther toobtain
Perfect synchronisation of the carbu-
retors.~
9. Close the vacuometer valves and
remove the tubing from the fittings.
PA333500883300
COMPLETE CAR
Check idle r.p.m. Check exhaust emission
The procedure is valid for 1.7 elec- Procedure is applicable to 1.7 elec-
tronic injection engines with or with- tronic i n j e c t i o n engines w i t h o u t
out catalytic convertor. catalytic~convertor only.
After adjustment of the idle r.p.m.
1. C o n n e c t t h e e n g i n e t o a r e v
following the above described pro-
counter.
cedure, ~proceed t o t h e c h e c k a n d
2. Connect an exhauster to the
adjustment (if necessary) of the ex-
exhaust tail-pipe.
haust emissions by operating as fol-
3. Start the engine and run it to
lows. ~
normal running temperature (Engine
oil temperature 75-8OoC). 1. Switch on the gas exhauster, start
the engine and run it to normal runn-
4. With the gears in neutral and the
ing temperature.
ancillary devices tut out check that 2. With engine on idle and using a
t h e e n g i n e r.p.m. falls w i t h i n t h e suitable,exhaust gas tester, check that
specified values. the percentage of CO and the quantity
of hydrocarbons are less than the
specified values.
For 1.7 electronic injection engines
Admissible CO% 0.8 - 1.7
with catalytic convertor.
\
f100
idle r.p.m. 950 _ 5.
For 1.7 electranic injection engines
idle r.p.m. 800 - 900
5. I f t h e i d l e r.p.m. does n o t ifaIl
within these values, adjust by operat-
ing as follows:
(a) Loosen the locknut @ and turn
the screw @ until the correct r.p.m.
is obtained.
(b) Lock the locknut 0
1 Exhaust tail-pipe
2 Probe of exhaust tester
3. Should the CO% be above the
admissile limit it Will be necessary to
act on ~ the appropriate screw p9s-
itioned iIn the debimeter.
4. It Will then be necessary to check
thatidler.p.m.fallswithinthespecified
values850f50r.p.m.andif itdoesnot
1 Locknut the ldle r.p.m. Check Will have to be
2 Idle r.p.m. adjustins screw repeated.
00-l SI2 May 1 9 8 8
 C O M P L E T E C A R

Check of ,e#hahst emissions
T h e Nprocedure is valid for 1 . 7 elec-
,tronic injeckion engines with catalytic
convertor.
1. D i s c o n n e c t t h e w i r i n g ,of t h e
Lambda sensor.
2. Using the spanner A-5.021 2, un-
screw the plug! 0 located at the inlet
of the catalytic silencer box @
4 Start the engine and check that
with the engine running on idle the
CO% and the quantity of unburned
hydrocarbons are less than the speci-
fied values.

After adjustment of the idle r.p.m.

following the above described pro-
cedure, pr@ed t o t h e c h e c k a n d
adjustmentI (if necessary) of the ex-
haust emi.ssions by operating as fol-
lows.
T h i s sempl~ified procedure is for use
w i t h engines e q u i p p e d w i t h F I A T
TESTER typle wiring.
Use wiring~ ir&rument No. C. 90034
illustrated ih thecircuitdiagram below:
3 WAY CONN,ECiOR FOR 470 OHVS 112 W
MIN AND MAX {WITCH 3 WAY CONNECTOR FIAT TESTER
PIN C
When the engine is in its normal runn-
ing state a?d the lambda probe is
disconnecte~d, the value correspond-
A-5.02127 / ing
to the total emiskons before the cata-
lytic exhaust head shall be included
in the rangementioned below.
volume % CO: 0.8 (min) to 1.5 (max)
5 . S h o u l d lthe C O % n o t fall within
the specified values, it Will be necess-
ary to act on t h e a d j u s m e n t s c r e w
located iin the debimeter in the plugged
seating.,lt ,will t h e n b e n e c e s s a r y
to check that the idle r.p.m. falls within
the specified valupsof 900-1050 r1p.m.
and if it does ndt to follow the pro-
cedure described at the previous step.
Once the setting has been effected,
re-plugg theseating with the apropria-
te seal and reconnect the lambda
sensor.

1, Plug for sampling exhatist gas

2. Catalytic silencer box
1, W arm ~up engine
2 . Remotie min.,,and m a x s w i t c h e s
w i r i n g side,connectorandthe 3 w a y
3. Fit the tool C.2.0051 on thefitting
connecter Of the instrument.
for sampling exhaust gases and con-
4 . Insert ~ the cormector of the in-
nect it with tube @ to the exhaust
strument it$ the 3 tiaytroublediagnosis
I ,. gas tester
connecter.
5. Check the state of the LEDdiode
and proceed to adjust the screw of the
potentiometer located in the plugged
seating. ?he correct setting is obtained
when the ~ON time of the flashing
LED is eqtial to the OFF time. When
this setting has be&n obtained replug
the seating of,the CO screw.

As an alternative to the above pro-

cedure, orjerate as follows.

2 Catalytic s i l e n c e r b o x
2 Tube connected to exhaust gas tester

May 1;988 00-16 PA333500883300

 COMPLETE CAR

CHECK ANiD ADJUSTMENT 1. Put the vehicle on auto lift.

2. Working from en ine room, dis-
OF T H E IDLE R.P.M.
connect connectors Q1 and @ of
For @m-l only lambda probe and disengage wiring
from clips.
Carry out the adjustment of the idle
r.p.mi w i t h t h e e n g i n e w a r m e d up,
the g~ears in neutral and all ancillary
devices tut out, operating as follows.
Unlock the locknut and turn the
a d j u s t i n g s c r e w 0 until the speci-
fied value
9 2 0 + 960 r.p.m.
is encountered.

w 1

1 Lambda probe resistance connecter

1 Catalytic muffler
2 Lanibda probe signal connecter
2 Supporting split ring

3. Clamp
4. Flange connecting catalytic 3 Working from below the vehicle,
muffler - exhaust manifold u n s c r e w Lam,bda p r o b e 0 a n d
5 . Install a n e w c a t a l y t i c m u f f l e r remove it.
working with opposite order in respect
to removal, fitting a new gasket on
1 Adjusting screw flange connecting exhaust manifold.
6. Check that, with the engine runn-
ing, there are no leaks from p i p e
CAkYTlC MUFFLER connections and that the exhaust
REPLACEMENT system is not unusually noisy

T h i s :procedure is for electronic in-

j e c t i o n 1 . 7 engines w i t h c a t a l y t i c
LAtiBDA ;PROBE
muffler only.
REPLACEMENT
When Km stated on Chart of Vehicle
Mainten:ance Operations are co- This procedure is valid for electronic
verecl, please proceed to replace cata- injection 1.7 engines with catalytic
lytic muffler as follows: convertor only.

At km stated on Chart of vehicle

1 Laibda p r o b e
1. &t the vehicle on auto lift. Maintenance Operations replace
lambda probe as follows:

2 . Loosen clamp @ b o l t .
~ 4. On installation, spread the probe
3. Unscrew the three bolts on flange body thread with grease R. Gori Never
@ contiecting catalytic muffler and Seez or Bosch 5.964.080.1005 and
exhaust manifolds. tighten iifully
5. Reconnectthewiringofthelambda
4. Unscrew catalytic muffler @ probe.
from split rings @ and remove it dis-
engaging it from rear track of exhaust
pipe.~

PA3335kJ883300 00-l 7 May 1 9 8 8


CHECK ON AIR SUPPLY
SISTEM TIGHTNESS
DOWNSTREAM FROM THE
AIR FLOW SENSOR
This procedure is for electronic injec-
tion 1.7 engines with catalytic con-
vertor 0nly.i
Makesurethatallpipefixingclampsare
fully,tightened
Start engine at idle r.p.m., then manu-
ally deform; pipings#and sleeve down-
stream from the air flow sensor
Should ,there be any faulty pipes with
air inlets to engine undetected by
sensor, some variations of idle r.p.m.
Will take place
T O easethe location of any possible
leaks in the air supply system, spread
some suds on involved pipes.
TROUBLiZ?HOOTING
PROCED~URE TO CHECK FUEL
$UPPLi/ FYSTEM TIGHTNESS
This procedure is valid for electronic
injection i -78 engines with catalytic
convertor pnly.
This procedure is to be effected when
reaching the km stated on Chart of
Vehicle Ma,intenance Operations,and
if the foll,owing symptoms occur:
- P e t r o l i smell.
- Visual signs of leaks from system
fittings and connections.
- Effectithe procedure stated in para-
.graphFuelEngine-CheckonFuel
S u p p l y ,Pressure a n d C i r c u i t
T i g h t n e s s - steps 1. and 2..
completing it with what follows:
a . Make s u r e that f i r e - f i g h t i n g
applicances are available in order tobe
able to operate safely.
May. 1 9 8 8 ~
i
COMPLETE CAR
b. W arm engine up to normal run-
ning speed.
c. Disconnect ignition.
d . Effect a v i s u a l c h e c k . o f f u e l
system components and fittings in
order to locate leak origin.
e. Check the whole system (connect-
ing pipes, fittings, components) using
a gas detector.
f. Close to leak area, one Will note
a tester pointer reaction.
This test with tester must be effected
slowly in order to compensate for
the time delay of tester response.
_,_<-
9. Following leak location, follow
procedure steps d. and/or e. then
eliminatethe leakreplacingfaultycom-
ponents or properly tightening loosen-
ed clamps. .h
h. On completion of operation, start
the engine letting it idle run for few (
minutes and then switch ignition off.
i. Repeat test as per steps c. and d.
to check that diagnosis is correct and
repair is efficient.
1. At end of whole procedure, road
test for about 30 minutes and then
make a final test to be sure of system
integrity.
TROUBLESHQOTING
PROC.EDURE TO CHECK FUEL
VAPOUR EMISSIONS
CHECKING SYSTEM
TIGHTNESS
Possible causes could be:
- Leaks of vapour from system
components, accessories and
connections.
00-18
v a l n v e 9
0
a. D i s c o n n e c t p i p e 8 from dump
air source to the
with a gauge con-
nected.
b . Pressurize the system with
compressed air to reach a pressure of.
2.49 KPa (0.025 bars;
0.0255 Kg/cm2; 254 mm HzO)
and then close the connection. If one
cari (reach the specified value, open
the compressed air supply system
and check the system tightness (with
...
gas deteetor).
c. Measure pressure drop in system
(it must not iexceed
0.125 KPa (0.00125 bars;
0.0127 K&cm2; 12.7 mm Hz0
in 10 minutes).
d. If within 10 minutes the pressure
drop exceds this value, locate leak
spreading pipes with suds or using
gas detectorl
e. When there are leaks, some soap
bubbles Will, appear.
f. Should the leak corne from fuelcap
filling union area, first replace the cap.
If after replacing cap, tightness is re-
stored, this means that cap was faulty,
otherwise replace the union.
g. Replace faulty components or
tighten loosened clamps.
h. Repeat procedure b. and c. to
check diagnosis efficiency.
1. If after effecting the above men-
tioned process, leaks still exist, effect
diagnostic procedure to check the
supply system tightness of fuel in-
jection system.
PA333500883300
 COMPLETE CAR

1 Fuel vapour s&on pipe 5 Fuel vapour exhaust pipe a Fiel vapour recovery pipe
2 D&ompression pipe for dump valve control 6 Compensation valve 9 Dump valve
3 Air delivery pipe 7 Fuel vapour separator 10 Fuel vapour filter.
4 Fu!el tank

PA333500883300 00-19 May 1 9 8 8

 DIAGNOSTIC AND CORRECTIVE INTERVENTIONS
ON LE3.2 JETRONIC ~
INJECTION SYSTEM
Procedures and diagrams
for electronic injection 1.7 engines with catalytic converter only,

PA 32 790084330 1 00-21 October 1988

 ,

COMPLETE CAR

:ii
II 1

October 1988 00-22 PA327900883301

 r ~

COMPLETE CAR

THE ENGINE DOES NOT START

During a start attempt, check the correct

Effect an electronic and functional test

Check ignition system: integrity of igni-

Ch& the:presmwxofxoltgge to tion distributor, spark plugs and as-
.plugs sociated tables.

Check the efficieny 6f inrake, tiucts,

filter ai/ fjow sensor. rhrottle body.

PA33350b883300 00-23 May 1 9 8 8

 COMPLETE CAR

THE ENGINE STARTS WITH DIFFICULTY

May 1 9 8 8 00-24 PA333500883300

 COMPLETE CAR

IRREGULAR IDLE RPM

Check for correct air flow. throngh

Check that on a suckins ducts dont

Effect electrical troubleshooting from

ANObjlALIES IN ACCELERATION AND BURSTS IN RELEASING

Checkicorrect fuel system pressure and

ignition system efficiency (spark plugs,
timing; etc.).

Checklthat no leaks do exist in air iri-

P
take ducts

YES

Check G60 ground efficiency.

YES

Check minimum & maximum opening

No. 4 of electrical troubleshooting.

PA333500883300 00-25 May 1 9 8 8

 COMPLETE CAR

EXCESSIYEFUEL CONSUMPTION

Check correqt functionality of the engine

water tempqature sensor and relevant
wiring by effpcting test No. 5 of electri-
cal troublpshooting.

YES

Check valve clearance of engine timing.

UNCORRECT DISCHARGE EMISSIONS

Check functionality of Lambda probe by

e f f e c t i n g electrical troubleshooting
procedure. ~

Zonnect a CO-tester upstream, from

:he catalyst disconnect Lambda probe
md verify a CO value increase.

Reconnect Lambda probe and check a

CO value lqwering.

Check valve clearance, air supply

system for leaks in air intake ducts.

Check catalhst muffler.

May 1988 00-26

 COMPLETE CAR

~ELECTRICAL TROUBLESH00TlNG PROCEDURE

for electronic injection 1.7 engines with catalytic convektor

NOTE:
TflI6 TROUBLESHOOTING MAINLY DEALS WITH THE ELECTRICAL/ELECiRONIC DIAGNOSIS
OF SYSTEM AND SENSORS AND ACTUATORS ASSOCIATED TO IT.
&ATTHE END OFTESTTHEANOMALY SHOULDREMAIN,lTWILLBENECESSARYTOCHECK
biAI;N MECHANICAL DEVICES SUCH AS. VALVES, CYLINliERS, COUPLINGS TIGHTNESS OF
AIR IINTAKE DUCTSi, ETC.

.May~ 1 9 8 8 00-27 PA333500883300

 Lheck fuel system pressure
- Connect a pressure gauge to fuel
F NO

-i
During a starting, check +12-V on fuel
pump t e r m i n a l s .
NO

t--
Check G4 Fuse (15 Ohm)

circuit

?.
- Try a prolonged starting and check
p r e s s u r e presence between 2.8
bars and 3.2 bars.
c YES
Check that negative terminal of pump is
Check fuel filter and any possible duct at ground.
NOTE:
The pump must turn for a few seFonds /, throttlings.
even with the only key in the MAR- YES
CIA running position. i

Check efficiency of pressure gauge.

YES c YES

r(:heck electrical circuits consisting of:

Check that relay S1.2.a is energized.
terminal 30 of relay S12.b and
1
ground = 12 V
YES terminal 85 of relay S12.b and
c
ground = 12 V
Check that fuel pump rotates. terminal 86 of relay S12.b and
Check circuit downstream from relay ground = 12 V
S12a up to fuel pump, beginning from I I
terminal 87 of relay S12.b and
terminal 87 of the same r,elay. YES ground=12V
.
l
Probable failure on electronic CU. NO
I c

S e a r c h f o r fauhin vehicle wiiing.

Go on with diagnosis.

r
TEST No. 1
Eliminate ground connections on pin 12
s-1 of CU connecter.
 P

COMPLETE CAR

TESTNo. 2 - CHECKINGS ON GROUNDS (PIN 4 AND 5 OF CU)

mi l Set hwltimeter to 200 Ohm FS.

Check cohtinuitir between:

- pin, 4 of CUconnector and G60
gr?und;
- pin 5 of CU connecter and G60
grqund.
Check also G60 grounds functionality.

YES

TEST: No. 3 - CHECK CONNECTION TO RPM SIGNAL (CU PIN 1)

Set ~multimeter to 200 Ohm FS.

,a E l e c t r o n i c C U connecter discon-

I I
Checb wiring continuity between pin NO
1 of CU connecter and
and terminal
terminal 11 of
of u Restore
Restore wiring.
wiring.
ignitibn coil.
t-d

(ES

TEST No. 4

PA333500883300 May 1 9 8 8
 COMPLETE CAR

, TEST Ntj. 4 - CHECK ON MIN. & MAX. OPENING THROTTLE SWITCH (CU PIN 15,AND 14)

l Set molfimeter fo 200 Ohm F.S.

Insert multimeter probes between CU

connecter pin 15 and ground. NO Check setting and efficiency of mini-
mum opening switch.
Check the ~existanceof a resistance
value lower than 10 Ohm.
Press accelerator and check an in-
finite resietance value.
YES

T
L i
l

t
Check wiring continuity between: NO
- black wire on S6 switch connection Restore wiring.
and ground;
- white wire on S6 switch connection l
-i
and CU connecter pin 15.

Insert rn~ Ihi meter probes between

connector oir 1 14 and ground.
NO Check setting and efficiency of maxi-
mum opening switch.
Check thr presence o f a n infinite
resistance ilue.
Fully dep 1s the accelerator and

I
check a rc stance value lover than
10 Ohm
YES

F-4
L

Check wiring continuity between yellow

NO
wire on S6 switch connection and CU Restore wiring.
connecter pin 14.

ES

TEST No. 5

00-30 PA333500883300
 ,s

COMPLETE CAR

,-
TEST No. 5 I CHECK ON ENGINE WATER TEMPERATURE SENSOR (CU PIN 8)

l Set~multimeter to 20 KOhm F.S.

. Disconnect electronic CU connecter.

Check between pin 6 of CU connec-
pendipg on engine water temperature
as pe,r curve.
1
NO Check wiring continuity between:
- electronic C,U connecter pin 6 and
brown wire on S7 temperature
sensor;
- G60 ground and black wire on S7
sensor connection.

,,

I YES

Replace S7 sensor

TEST No. 6

PA333500883300 00-31 May 1 9 8 8

,'
 COMPLETE CAR
1
8,

; TEST No! 6 - INJECTOR SYSTEM CHECKING

Check resistance between CU con- NO Disconnect qecfors removmg relevant NO

vector pin 3and terminal 87 of S12.a - Replace faulty injectors.
- connectors.
relay. Measure reslstance on termmal of every
Read from~8 to 5 Ohm. , single injecter. that Will result between I
14 and 18 Ohm.

Checkon singleconnectorsof injectors NO

WIRING SIDE, that one of JWO pins be - Repairwiring fautt
connected to terminal 87 of S12.a relay:
and the other to pin 3 of CU connecter.

I YES
.

Y ES

~
I TEST No. 7

May 198b 00-32 PA333500883300

 I m
l - Set multimeter to 20 V F.S.
l ~Electronic -CU onmector discon;
nected.
c Check presence of + 12 V between ter- Check wiring continuity between
With ignition key on RUN position,
check presence of + 12 V between
NO
connecter pin 2 and ground.
L J
c 512.6 relay shoe terminaIL 67~ -and
With ignition key in RUN position
check presence of + 12 V between
CU connecter pin 7 and ground.
1
YES
TEST No. 6
Check integrity of fuse No. 2.
With ignition key in RUN position check
presence of + 12 V between S12.b main
relay shoe terminal 30 and ground.
Restore wiring between S12.b relay
shoe terminal 30 and CU connecter
pin 2.
I
Restore wiring btween pins 2 and.7
of ECU connecter.
I I
mina1 86 and S12.b relay shoe terminal
S12.b relay shoe terminal 85. and
groud G60. if necessary restore
7
87.
1wiring.
1
1 OYES
With ignition keyin RUNposition,check
presance of + 12Von G67 connection
pin 2. If necessary, restons wiring.
l NO
Check vehicle wiring (e.g. wiring be-
tween G67 connection and G99a con-
nection, between G99a connection and
Gl fuse holder box, integrity of fuse
No. 7 and relevant supply from starting
l block.
I I
Check presence of +12 V between Check presence of + 12 V between:
-m G67 connection pin 3 and ground.
ground.~ G67 connection pin 4 and ground.
7 Ifnecessary rester; w i r i n g .
IYES
7 NO
Replace 512 relay.
I Check vehicle wirina between positive
battej and pin 3 and4 on G67 connec-
tion
 ,i

,,

~ COMPLETE CAR ~

1, TEST N{. 8 - CilECK ON LAMBDA PROBE (CU PIN 13)

,,

Conmct wiring side connecter to CU.

l Set multimeter to 20 V F.S.

With startect e n g i n e c h e c k t h e NC NO - Restore wiring retative to heating

presence :of ,12 V o n p r e h e a t l n g - Check G4 (7.5 A) fuse integrity.
resistance
r e s i s t a n c e termlnals of Lambda
p r o b e .

- Disconriect resistance preheating B NO

Replace Lambda probe group. l
connecter of Lambda probe.
- Set multimeter to 200 Ohm FS.
- C h e c k h e a t i n g r e s i s t a n c e func-
tionality maa,suring a value be-
tween 3 Ohmland 20 Ohm.

YES

I l I 1

- Set multimeter to 2 V FS. 9/ Replace Lambda probe.

- Takemout cap from Lambda probe
connactor (wiring side).
- With ivehicle warmed up and
running check between connec-
tion point of Lambda probe and
groubd~ for a voltage value be-
twee,n 30 mV and 1 mV.
,

- key removed. NO
ti Restore wiring.
- Disconnect CU connecter.
- Checkcontinuity between wiring
sidesconnector pin 13 and lambda
probe oonnection point.

END OF
ELECTRIWELECTRONIC
TROUliLESHOOTING
~
If test tesults were positive, but fault
still remains, t r y r e p l a c i n g i n t h e
order: ~

- CU!
- A i r fl+w sensor.:

0 0 - 3 4 PA333500883300
 COMPLETE CAR
,~. / l

I INJECTION - IGNITION WIRING DIAGRAM --

for electronic injection 1.7 bngines with catalytic c,onverter only

- , 3@-
-~ ,----1--
-----
r2-7

PA32 790088330 1 October 1988

 COMPLETE CAR

~DIAGNOSTIC AND CORRECTIVE INTERVENTIONS

ON LE3.2 JETRONIC ~
INJECTION/IGNITION SYSTEM
Procedures and diagrams
for electronic injection 1.7 engines without catalytic converter only

PA 42 790088330 1 00-3511 October 1988

 COMPLETE CAR

October 1988 00-3512 PA327900883301

THE ,ENGINEDOES NOT START
*

Check the presence of voltage to spark plugs

YES

.]I
Effect troubleshooting procedure on injection

PAd27900883301 00.3513 October 1988

T,HE EN~INE ~TART wtTti BIFFICULT?

Effect troubleshooting procedures on

Check air su$plyI system for leaks In

tntake ducts or.c(ogged filter and fuel

~
WITH COLD ENGINE
~8 Check functionality of extra air valve. , With cold engine, 2 mins. after ignition
throttle extra air valve pipe and verify
that RPMs at minimum diminish noti-

Replace extraair valve.

NO
With hot engine, 3 mins. after ignition
With enginerunning verify presence of
throttle extra air valve pipe and verify
+ 12 V on connecter on wiring slde of
that RPMs at minimum diminish noti-
extra air valve.
Ceably. IY t
l I
l
YES

Check wiring continuity between:

- extra air valve and G60 ground;
- extra air valve and fuel pump relay
S12a terminal 87b ,

O c t o b e r 1988 00-3514 PA 32 790088330 1~

IRRkGULAR IDLE RPM EXCESSIVE FUEL CONSUMPTION

lant temperature sensor and relative wirlng

Check for correct air flow through throttle
b o d y . procedures for injection system.
Check that there are no leaks in the air intake
duc+ and that the air filter is not clogged.

YES

YES

tien system and injection system.

1 Ckeck electromtector trghtness.

YES

ANOMALIES IN ACCELERATION AND BURSTS JN RELEASING

Check correct fuel system pressure and Effect troubleshooting procedures for igni-

shooting procedures for inlection system.

_III
Check that there are no leaks in the air inta-

PA 32 790088330 1 October 1988

 COMPLETE CAR

TROUBLESHOOTING PROCEDURE ~
/
FOR INJECTION SYSTEM ~
~
for electronic injection 1.7 engines without catalytic converte;

NOTE:
THIS TROUBLESHOOTING MAINLY DEALS WITH THE ELECTRICALIELECTROikIC DIAGNOSIS
OF TH~E SYSTEM AND SENSORS AND ACTUATORS ASSOCIATEb TO IT. ~
IF AT.~THE END OF. TESTS THE ANOMALY SHOULD REMAIN, IT WILL BE NECESSARY TO
CHEF! MAIN MECHANICAL DEVICES SUCH AS VALVES, CYLINDERS, COUbLINGS, TIGHT-
NESS OF AIR INTAKE DUCTS, ETC.

PA327900883301 00.3516 October 1988

 >

COMPLETE CAR

i-
TEST1 No.1 - CHECK OF FUEL PUMP CONTROL

NO During a starting, check + 12 V on fuel NO

l pump terminals. Check G4 Fuse (15 A)
/Check fuel system pressure.
. Connect a pressure gauge to fuel
I
cir&t.
- Try~a prolonged starting and check YES YES
pressure presence between 2.8 bars . v
and 32 bars.
Check fuel filter and any possible dUCt Check that negative terminal of pump is
NOTE: ~
throttlings. at ground.
The pump,must turn for a few seconds
even, wjth the key in the MARCIA run-
ning, position.
YES , YES
. v
_:,
l- Check efficiency of pressure gauge.
i., - Remove key.
- Disconnect connecter of injection ECU
- Put at ground pin 12 of the same con-
nectar.
YES - Rotate key to RUN position.
v
E S
Replace fuel-pump.

Check that relay S12a is energized. -

YES
w
I 1
Check circuit downstream ,from. relay NO
t--/ C h e c k t h a t f u e l pump rotates.
S12a up to fuel pump, beginning from
terminal 87b of the same relay, and the
circuit of terminal 30 of the relay itself.
I I YES
4
NO
v
Probable failure on ECU

Restore wiring. Go on with diagnosis.

/

Eliminate ground connections on

12 ECU connecter.

Check electrical circuits consisting of:

_ terminal 85 of relay S12b and ground
i o v
_ terminal 86 of relay S12b and ground
Replace relay S12a. = 12v
i

NO

Restore wiring of terminals 85 and 86

1 of relay S12a.

TEST Na. 2

Ohober 1 9 8 8 00.3517 PA327900883301

 COMPLETE CAR

YEST No. 2, - CHECKING OF GROUNDS (PIN 4 AND 5, OF CU)

Disconnect !Injection CU connecter.

Restore wiring between:

Check conti@ity petween: - pin 4 of CU connecter and G60 ground;
- pin 4 of CU c,onnector and ground; -D - pin 5 of CU connecter and G60 ground:
- pin 5 of CU connecter and ground.
Check also G60 grounds functionally.

TEST No. 3 - CHECK CONNECTION TO RPM SIGNAL(CU PIN 1)

~,

Disconnect Iljection CU connecter.

I Check wiring contlnuity between pin 1 of

CU connecter and terminai 1 of ignition
NO
w
Restore wiring.

/EOll I

ES

TEST No. 4

PA327900883301 00=35/8 October 1988

 COMPLETE -CAR

TEST No. 4 - CHECK ON MIN. 81 MAX. THROTTLE OPENINGSWITCH (CU PIN 15 AND 14)

-Fi Set multumeter to 200 Ohm FS.

Key removed.

j: :
CU
~Dlsconnect injection electronic CU

1)
1
Insert multimeter probes between CU
connecter pin 15 and ground.
Check the existante of a reslstance
q?
Check setting and efficiency of mini-

1 .l
vajlue~lower than 10 Ohm.
Piess accelerator and check an infinl-
Itel resistance value. I
1 YES

Chech wiring continuity between:

I
NO
I
- black wire bn S6 swifch connection b Restore wlring.
and ground.

Check wiring continuity between: NO :

white wire on S6 switch connection b Restore wiring.
and CU connecter pin 15 for inter-
ruption, short-circuit on Interference
with other tables.

Insert multimeter probes between Check setting and efflciency of maxi-

connecter pin 14 and ground.
Check the presence of an infinlte
resistance value.
1 Fully depress the accelerator and 1

I
check a resistance value lower than 10
Ohm.

Check wiring cxontinuity between yel-

low wire on S6 switch connection and
CU connecter pin 14, for interruption,
short-circuit or interference with other
1 Gables.

;ES

TEST No. 5

,00=35/9 PA327900883301
 COMPLETE CAR

TEST No. 5 - CHECK OF ENGINE COOLANT TEMPERATURE SENSOR (CU PIN 8)

Set multimeter to 20 KOhm FS.

Key rerhoved! -
Ciisconnect injection electronic CU
connecter.

1
t
:heck between pin 8 of CU connecter :heck wiring continuity between:
ind ground, a reststancevalue depen-
.electronic CU connecter pin 8 and NO Westore w i r i n g .
ling on engindcoolant temperature as

i
brown wire on S7 temperature sen-
Ier curve
sor; --
G60 ground and black wire on 57
sensor connection 25.

I YES

Replace S7 sensor

TEST No. 6

PA32 790088330 1 oo-35/10 October 1988

 r

COMPLETE CAR

TEST No. 6 - CHECK OF ELECTROINJECTORS CIRCUIT

Set multimeter to 200 Ohm F.S.

Di,sconnect injection CU connecter.

Disconnect electroinjectors removing NO

Check resistance between CU connec- Replace faulty injectors.
relevant connectors.
Measure resistance on terminal of
every single injecter, that Will result
between 14 and 18 Ohm.

Check on single connectors of injec. NO I --

1
nestore wiring.
t o r s WIRING SIDE, that one of two
pins is connected to terminal 87a of
S12a relay and the other to pin 3 of CU
connecter.

TEST No. 7

Octdber 1988 00~35111 PA327900883301


TEST No. 7 r CHECK OF +12 V PIN 2 AiUD PIN 7 OF CU
,fLlfq
Disconnect infeqtron CU conpector.
With igniiion key on RUN position,
check presence of + 12 V between CU
connectdr pin 2 and ground.
Whith ignitjon key- in RUN position
check presence of + 12 V between CU
conneotor pin ,7 and ground.
PA 32 790488330 1
COMPLETE CAR
NO
+ Check Integrity of fuse NO. 2.
With ignition key in RUN position,
check presence of +12 V between
NO
S12b main relay shoe terminal 30 and
ground.
Restore wiring between S12b relay
shoe terminal 30 and CU connecter
pin 2.
Restore vehicle wiring betwen positl- NO,
ve battery and S12b relay shoe termi-. 4
nal 87.
Restore wiring between pins 2 and 7 of
oo-35/12
With ignition key in RUN position,
, Check presence of + 12 V between ter-
mina1 88 and S12b relay shoe terminal
87.
, Y E S
Cheik presence of + 12 V between
S12b r e l a y s h o e terminal 8 7 a n d
g r o u n d . JO
I
I I
Check wirlng continuity between S12b
relay shoe terminal 85, and ground l- J
GSO, if necessary restore wiring and
,: check ground G60 integrity.
:
I
YES
. ,
Check continuity of wiring between
pin 86 relay shoe S12b and fuse box.
October 1988
 v

COMPLETE CAR

TROUBLESHOOTING PROCEDURi
FOR IGNITION SYSTEM
for electronic injection 1.7engines without catalytic cbnverter

NOTE:
~ THIS TROUBLESHOOilNG PROCEDURE MAINLY DEALSWITH THE ELECTRICALIELECTRONIC
DI:AGNOSIS OF THE SYSTEM AND SENSORS AND ACTUATORS ASSOCIATED TO IT.
~IF AT THE END OF TESTS THE ANOMALY SHOULD REMAIN, IT WI~LL BE NECESSARY TO
~CHECK MAIN MECHANICAL DEVICES SUCH AS VALVES, CYLINDERS, COUPLINGS, TIGHT-
NESS OF AIR INTAKE DUCTS, ETC. -.

PA327900883301 October 1988

THE ENGhE DOES NOT START

l
Check the presence of voltage to spark
iplugs (by attempting ignition). ..
.
NO
* Set multimeter to 20 V F.S.
Key in RUN position.
Check presence of + 12 V between igni-
tion coi1 terminal 15 and ground.
Check vehicle, system functionaiity (eg:
NO c continuity between ignition coil termi-
nal 15 and starting block; starting block
supply and functionality).

Check presence of + 12 V between igni- NO Restore wiring between CU (N20) con-

tion CU connecter pin 3 and ground. c nectar pin 3 and coi1 (AS) terminal 15.

YES
. i
Check presence of + 12 v between igni- Restore wiring between ignition module
tion module (Nl) connecter pin 4 and
NO ,
(Nl) connectai pin 4 and coil (Aa) termi-
ground. nal 15.

YES

/ES
Set multimeter to 200 Ohm FS.
Key removed.
Check wiring continuity between igni-
tion module (Nl) connecter pin 2 and
ground.

Check ignition distributor functionality NQ Replace anomalous components (cap,

and integrity: * tables, brushes, sensor, etc.).
cap:
- tables;
- distribution brushes;
- Hall effect sensor.

YES

1
.

spark and
Restore wiring.

Set multimeter to 200 Ohm F.S. -I

Disconnect Hall sensor connecter and

ignition CU connecter.
Check wiring continuity between:
. ignition CU connecter pin 2 and cree.
ned table braid on Hall sensor con.
nectar (wiring side).
. ignition CU pin 4 and yellow wire on
Hall sensor connecter (wiring side).
. ignition CU pin 12 and black wire on
Hall sensor connecter (wiring side).

O c t o b e r 1988 PA 32 790088330 1
 YES

NO Restore wiring.-

Check wiring continuity (after having cli-

sconnected ignition CU (N20) connecter
and ignition CU (Nl) connecter between:
. ignition module connetor pin 3 and
ignition CU pin 1
- ignition CU connecter pin 13 and igni-
tion module connecter pins 5 and 6
_ ignition module connecter pin 1 and
white wire on ignition coi1 terminal 1.

IYES

l
Check ignition coi1 (A6) functionality ve- Replace ignition coil.
rifying values listed hereunder:
primary winding resistance: from 0.5
to 1.5 Ohm;
- secondary winding resistance: from 6
1,,YES
t o 1 2 kOhm.

Disconnect white wire on coi1 terminal 1

(signal for speed indicator) and check
that there is no short-circuit towards
ground.

YES

,Eventually replace ignition module (Ni)

andlor ignition CU (N20).

l I

October 1988 I
 ADVANCE VARIATION CHECK
TEST No. i

If any variation exists, but outslde the

Connect stroboscopic gun and check:
- with cold englne advance higher than
the piescribed value;
- with bot engine, prescribed advance

1 value.

l
Wlth engine running steady disconnect NO ,q-iiiqq
Disconnect ignition CU connecter (N20).
engine coolant temperature sensor con- l Check wiring continuity between igni-
hemor (L24) and ,read advance value. tion CU co.nnector pin 7 and sensor
Connect to ground the brown-white wjre brown-white wire.
of the sensor and check an advance va-
riation with respect to that previously
~read. YES
.
8
Replace ignition CU (N20).

Check sensor (L24) functionality.

NO b Replace sensor (L24).
- with, hot engin? read aporox.O Ohm
between sensor pin and ground;
,J- with,cold engine read infinite resistan-
~ce between sensor pin and ground.

YES

TEST No. 2

:O.ctober 191 OO= PA32 790088330 1

J
 Discinnect minimum and m a x i m u m
thrdttle opening switch connecter ahci
read advance value.
Short-ctrcuit pin 15 (white wire) with pin NO
16 (black wire) and check an advance va-
riation with respect to thevalue previou-
sly read.
Check wiring continuity between:
. connecter pin 16 of minimum and ma-
ximum throttle opening switch S6 and
ground G60.
. connecter pin 15 of minimum and ma-
ximum throttle opening switch S6 and
ignition CU N20 connecter pin 6.

YES YES
T !.
1 I
Semove short-circuit between pin 15
Replace ignition CU (N20).
and pin 16.
I I

Read advance value. Check wliing continuity between:

Short-circuit pin 14(y@low wire) with pin . connecter pin 14 of minimum and ma- 711 tlace ignition CU ( N20).
16 (black wire) and cheok an advance va- ximum throttle opening switch S6 and
riatton wlth respect to value previously ignition CU connecter pin 14.
read.

YES

Chsck adjustment and efficiency of mi-

nimum mand maximum throttle opening
i1 +vibhi6.

PA327900883301 00=35/1:7 October 1988 I

 COMPLETE CAR

~INJk.CTl~hl - IGNITION WIRl,NGi DIAGRAM

1, i
for electronic injection 1.7 engines without catalytic converter only

PA 32 79008#3~01
 33+ *

331.3 ~~

33cl s 33 1.5 axa

33 1.5 7-I

33 1.7 IE
Features

Vehicle static loading arrangement (1 j A + B = 490 + 245 = 735 N

(50 + 25= 75 kg)

C=490 N (50 kg)

c

Front wheel alignment mm A=-12Ys0 A=-12Z;s A - - 2:';

Rear wheel alignment mm B = 27?$ B = 41:s B = +33 t;s

Front wheel toeout (2) (3) mm M-H=4+2 M-H = 2 f 2

Front toe-out angle a= 10 a= 10

Whael rim diameter mm 340 I 365 (4)

I 340

Flair wheel toc-in a=-20?10 a = Oo f 25

8
I
Front wheel camber (3) p=-1030 P --1055+30

Rear wheel camber (3) p - oo f 2 5

Front wheel caster (3) y = 2 t 30 y - lOi30

I

Outer angle 6,= 27'50 6, = 29038'

Steering lock (3)

Inner an& 6, = 330 45' a2 = 35010

* Not marketed with 1.2 engine in all countries

(1) Load vehicle, move it upand down on suspensions a few rimes. Checking operations must be performed with vehicle fully set up
for driving.

(2) When turning a steering side rod joint by 360. M - H dimension changes by 2 mm (0.079 in)

(3) These values are referred to a vehicle in nominal driving condition, i.e. with static load

(4) With rim 5 /2 J x 14

 ,

,
7,

COMPLETE CAR

SPECIAL SE#RVICE TOOLS

Tool number Refer to

Tool name
page

,A.3.0156 Puller of pin from stub axle -

18

A.4.0146 Tool for suspension height check

A.4.0149 Tool for suspension height check

~

;
Probe for suspension height check
A.4.0150 -
88, (to be used with A.4.0146 - A.4.0149

Magnetic adapter for suspension height check

-
(to be used with A.4.0146 - A.4.0149)

A.4.0206 Magnetic adapter for suspension height check

, (to be used with A.4.0146 - A.4.0149)
., ,

Toothed wrench for locking

A.50195
camshaft pulley

A.5.0212 Wrench for exhaust gas sampling plug

c.2.0051 Fitting for exhaust gas sampling 00-14

i
I
x.

PA33;3500883300 May 1988

 ~._....~
ENINE MAIN MECHANICAL UNIT
~DRIVE UNIT REMOVAL AND
~INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . OI-2
Removal (1.7 I.E. with catalytic conver-
ter); . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-2
~ Installation (1.7 with catalytic converter) OI:7
Removal (1.7 I.E. without catalytic con-
verter) . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-8
jnstallation (1.7 without catalytic con-
verter) . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-811
. Supply and adjustment . . . . . . . . . . . . . 01-811
SEPARATION AND ASSEMBLY
0F THE UNITS.. . .;. . . . . . . . . . . . . . . . . . . (*)
ENGINEDISASSEMBLY . . . . . . . . . . . . . . . . 01:9
. . Preliminaries . . . . . . . . . . . . . . . . . . . . . 01-12
~ ,:Engine unit . . . . . . . . . . . . . . . . . . . . . . . OI:12
Pistons and connecting rods . . . . . . . . (*),
cylinder heads . . . . . . . . . . . . . . . . . . . . (*)
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . (*)
CHECKS A N D INSPECT~ONS . . . . . . . . . . . . 01-14
Cylinder heads and valves . . . . . . . . . . . 01-14
. Camshaft support . . . . . . . . . . . . . . . . . (*)
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . (*)
i Crankshaft . . . . . . . . . . . . . . . . . . . . . . . (*)
Main and connecting rod bearings . . . (*)
Pistons and connecting rods . . . . . . . . (*)
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . (*)
Cylinder block . . . . . .,. . . . . . . . . . . . . . (*)
Piston - cylinder wall-fit . . . . . . . . . . . . . (*)
ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . (*)
(*) Refer to VORKSHOP MANUAL
, ,,
Precautions . . . . . . . . . . . . . . . . . . . . . . 01-14
Cylinder heads . .. . . . . . . . . . . . . . . . . . 01-14
Pistons and connecting rods . . . . . . . . (*)
Crankshaft . . . . .#. . . . . . . . . . . . . . . . . . (*)
Engine unit . . . . . . . . . . . . . . . . . . . . . . . 01-14
ENGINE LUBRICATION SYSTEM . . . . . . . . . (*)
Description . . . . . . . . . . . . . . . . . . . . . . . (*)
Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . (*)
Otl filter . . . . . . . .. . . . . . . . . . . . . . . . . . (1
HYDRAULIC TAPPETS . . . . . . . . . . . . . . . . . (*)
Operation description . . . . . . . . . . . . . . (*)
Differences from mechanical
tappets. . . . . . . . .. . . . . . . . . . . . . . . . . . (*)
General1 specifications . . . . . . . . . . . . . (*)
SERVICE DATA AND SPECIFICATIONS
(for petrolengines only) . . . . . . . . . . . . . 01-18
Technical data . . . . . . . . . . . . . . . . . . . . 01-18
.Inspection and adjustment . . . . . . . . . . 01-19
General, specifications . . . . . . . . . . . . . 01-35
Tightening torques . . . . . . . . . . . . . . . . 01-35
SERVICE DATA AND SPECIFICATIONS
(for diesel engines only) . . . . . . . . . . . . 01-36
Technical data . . . . . . . . . . . . . . . . . . . . 01-36
Inspection and adjustment . . . . . . . . . . 01-37
General1 specifications . . . . . . . . . . . . . (*)
Ttghtening torques . . . . . . . . . . . . . . . . (*)
TROUBLE DIAGNOSIS AND
CORRECTIONS . . . . . . . . . . . . . . . . . . . . . . . . (*)
SPECIAL SERVICE TO,OLS . . . . . . . . . . . . . . (*)
VOLUME I and VOLUME II - Group 01
October 1988

11,
,DRIVE U N I T REMOVAL A N D IINSTALLATION
, These procedures are for electronic injection ,A.7 engines
REMO:$AL
1.7 LE. with catalytic converter
During enghte,removal from car, it is
necessary to remove engine and gear-
box - differentialas single unit. Put the
vehicle on ~the auto lift and engage
, first ,geas ~
WARNING: ~
Great tare dis required when dealing
with a hot engine. ,,
~~1. Preliminary operations
a. Operatimg from passenger compart-
ment, withdraw knob from gear lever,
then remove the two protective rubber
gaiters from gear lever.
b. Remove fhe hood.
c. Workingi from inside the engine
compartment, disconnect the battery
ground table.
For followhg procedure steps, refer to
, hgure at pa/7e 101-3.
, 9. Air filter, ~airflow sensor and sleeve
8 removal. ~
a. Unhook air filter caver 0 and re-
move filter elenent.
b. Disconhect multiple connecter 0
from air flow sensor 0.
c. Disconnect pi e @ from oil va-
pour separator6 1 .
d. Disconnect #metaI, fitting @ from
sleeve a.
e. Unscrew the three fixing screws of
air flow sensor 0 to support @I
f. Loosen s)eeve @ fixing clamp to
throttle body @ .
g. Remove air filter caver 0 comple-
te with air fl~ow sensor 0 and sleeve
@. ,.,
h. Unsc&the three support @ fixing
nuts and bolts and remove the support
from body. ~
, 3., Removal of spark plugs supply ca-
, b l e s .
a. Disconnect high voltage tables
from spark plugs and coil.
bctober 1 9 8 8
ENGINE MAIN MECHANICAL UNIT
,
b. Disgonnect the ignition distributor
cap @ and remove it complete with
leads from engine.
4. Removal of air a.nd fuel vapour pipes
Disengage the following pipes, di-
sconnecting them from stated compo-
nents:
. Pipes @ and @ from supply
manifold @ .
. Pipe @ from throttle body and pi-
pe 0 from pneumatic gauge on
ignition distributor @
. Pipe 0 from metal fitting 63
. Pipe 8 from idle rpm setting fit-
ting.
. Pi e 8 from supply manifold
630.
. Pipe 0 unscrewing fitting on
supply manifold @
5. Removal of cooling system piping
a. Unscrew and remove the coolant ex-
pansion tank plug.
b. Raise the car from beneath, refer-
ring to Figure at page,Ol-6, iemove the
right hand drain plug and then the left
hand drain plug 0 under the cycin-
der block and drain off the coolant; ~
screw on the plugs again after drai-
ning and relower the car.
Put a suitable conteiner under the car
to collect the coolant.
c. From the part stated, disconnect
the followin hoses and sleeves:
l Sleeve &a from thermostat and
radiator and remove it.
l Sleeve @ from the union on the
engine.
l Hose @ from throttle body @ .
. Hose @ from T fitting on engine
rear side.
6. Removal of fuel hoses
a. Discinnect hose @ from damper
a.
01-2
b. Disconnect hose 0 from pressure
w-w 8.
7. Removal of eccelerator control ca-
ble
a. Rotate the accelerator lever 8
and withdraw the pawl on control ca.
ble end. ~
b. Remove split ring and draw the ac-
celerator table sheath from the brac-
k e r .
6. Removal of ignitionlinjection wiring
a: Disconnect the two Lambda proble
cpnnections8 @a and disengage table
from clamps.
b. Unscrew the two fixing screws and
remove the solenoid starters @ from
body.
c. Disconnect connection @ bet-
ween injectionlignition wiring and ve-
hicle wiring.
d: Disconnect connecter @ from the
switch on throttle body @ .
9. Removal of supply manifold
Unscrew the three.fixing nuts to the
two supply manifold @ ends and re-
move it with jts relevant gaskets, com-
plete with throttle body.
The two central nuts also fix the
engine Iqfting brackets I; on
right side the bracket supporting
the oil dipstick is also fixed.
Suitably plug the intake manifold
on engine.
10. Removal of the clutch control hose
a. Extract the fuseholder box @.
b. Unscrew the pipe fitting @ of
clutch pump and withdraw the hose
from service tank sheet.
PA 32 790088330 1
 ENGINE MAIN MEC~HANlCAL, UNIT
LO,dTION OF DSIVE UNIT ENGINE MOUNTINGS
As for
ENGINE CO,MPARTMENT. LOCATION COMPONENTS
Engine 1.7 Electronlc Injection
i
1 Coolant delivery hose . to radiant
2, Englne Ilftlng brackets
3 Alr~flowllnjectlon CU sensor
4, Coollng system breather pipes
5, Akflow sensor fixlng screws
6 Alr!flow sensor support
7 Injection wlrlng multiple connecter
0 Throttle body swltch conneotor
9 Corrugated sleeve
10 ~Throttle body
11 ~Vacuum plpe to set pneumatlc
advancs
12 Ignltlon dlstrlbutor
* 13, Akdelivery tube to fuel vapour
flltsr
14 Metal flttlng
* 45 ~Vaouun dellvery tube for pneumatfc
~ ~advanoe control Ignltlon dlstrlbutor
PA3F7900883301
.
16 011 vapour recovery tube
17 011 vapour
s e p a r a t o r (oil~fllllng
unlon)
15 Fuseholder box
19 Ploe of clutch control hvdraullc
sistern
* 20 Lambda probe connectlon
21 Retum oloe of coolant from
radiant
22 Sleevs of return coolant from
radlator
23 Pressure gauge
24 Fuel dellvery tube
25 Exoess fuel return tube
26 Damoer
27 Servobrake vacuum pipe
25 Vacuum pipe for fuel vapour fllter
* 29 Vacuum plpe for fuel pressure
_ wwe
OI-3
, ..
30 Alr supply malnfold (air Intake
box)
31 Accslerator throttle control lever
32 Supplementary air feed tubs
33 Idle regulatlon by;pass tube
34 Collant dellvery slseve to radlator
35 Connectlon between IhJeotlon
wlrlng and vshiole wlrlng
36 lnjectlon wlrlng solenold starters
37 Alr fllter oovsr
3; F$vapour fllter
,r) r=~;~1.7 fE wlth catalytlc converter
October 1988
 E N G I N E M A I N MECHANICAL UN1-i

1.7 IE with catalytic converter

Il Starter energizing table
?Starter supply bablbs
3 Odometrlc sensor table
4 Engine compartmeht wirlng 1.7 IE without catalytic converter
5Ground Gable wlring
I~6Power module on ianition
distributor -
7 Engine coolant temperature
indicator table:
0 Englne coolant minimum level
sensor table ~
9 Col1 low.voltag& table
10 Electrlc fan tables for thermal
c o n t a c t c o n s e n t
11 Foglamps cablbs
12 Horn tables
13 Frontoptlcql gioups supply tables
14 Alternatorz arid alternator
w a r n i n g Ilgot s u p p l y table
15 Eleotrical fan supply tables
16 Mln. level oil s8nsor table
17 E;g;;e max. oi/ pressure warning

19 Englne min. oil, pressure warning

table

VIEW OF Et+GiNE COMPARTMENT LOCATION OF WIRING

Octoberd988 01-4 PA327900883301


ENGINE MAiN MECHANlCAL: UN!IT
41; aemoval of electrical tables
For folhwingremovals, refer to figure
at pageO#l-4.
a. Disconnect the following electrical
tables, removing them from stated
component:
9 tables 8 , from optical groups.
. tables 0 , from foglamps con
nectors.
l tables 0 , from horns.
l table 6 0, from the movable con-
nection of engine coolant mini-
mum level sensqr.
. low voltage tables @ from coil.
l tables @ , from thermal contact
of electric fan consent on racliator.
~
tables 0
l 16 , from electric fan con-
r+ct,ions
l dable @ , removing the pressure
mountetl connecter on alternator.
l table 0, from engine collant
temperature sensor.
l Gable 0, energizing the starter
from movable connection.
. table 0, supplying the starter
~terminal.
l ~table @ , from engine minimum
oil pressure handcontact.
. Gable 0, from engine maximum
temperature thermal contact.
iable @ , from oil level dipstick.
l
l bround table @ unscrewing the
engine cylinder block nuts, rear si-
cje.
b. Release all wiring from wireblock
a@ disengage them from the engine
in order not to obstruct their removal.
b.1 Disconnect odometer table @
connection, located in service tank.
PA j2 790088330 1
,,
12. Loosening nut of engine central
support
With reference to the following figure
loosen bolt 0 fixlng central support
0 to the body without removing it.
1 Boit
2 Central support
For following procedure steps, refer to
Figure at page 01-6.
13. Oil draining
(if required, as a function ofI ~
intervention to be carried out)
,
i
a. Raise the car on auto lift.
b. Unscrew cap @ and drain engine
oil. Rescrew the cap, when this opera-
tion has been com leted.
c. Unscrew cap 616 and drain gear
box-differential oil. Rescrew the cap
when this operation has been comple-
ted.
14. Removal of exhaust pipe
a. Disconnect mainfolds @ from en-
gine right and left heads, unscrewing
the relevant fixing nuts.
b. Unscrew the three bolts @ con-
necting discharge mainfolds @ to
catalytic muffler @ and disconnectm
them recovering the gasket.
01-5
r
~
c. Remove the discharge mainfolds
@ lrecovering the gaskets and with-
drawing from bottom the wirlng of
lambda probe, previously disconnec-
ted.
15. Removal of reversing light table
Disconnect reversing light table 0
from gearbox switch.
16. Mechanical disconnection and re-
moval of drive unit
a. Unscrew screws @ fixing right
and mleft semishafts to rlght and left
shafts of the dlfferential, and disenga-
ge the semishaft.
b. Unscrew to bracket attachment
screw 0 on the engine antishock
support bracket and position a co-
lumn lifter under the drive unit. This
column lifter Will be fitted with a suita-
ble supporting bracket R.4.0156 to ta-
ke part of the drive unit weight.
c. Lqosen and remove the two screws
@ ~fixing the engine front support to
cross member.
T-
~ TL ,RA.0156
d. Loosen and remove the remaining
screws 0 and 0 fixing the front
cross member to body.
e. Loosen bolt @ connecting front
traverse to right strut.
f. Unscrew and remove the bol; @
connecting the front cross member to
the Ileft strut @ ; then disengage the
stru~t from the cross member.
October 1988
 ,;

E N G I N E M A I N MECHANICAL UFflT
8
,

VIEW OF UNDERPART OF VEHICLE - LOCATION OF ,COMPONENTS

1 Screws fixing cross member to body 10 Engine oil drain plug

2 Cross member to right strut connecting bolt 11 Reverse light table
,3 Stabillzlng b a r 12 Muffler central silencer
,4 Screws flxing engine front support to crossmember * 13 Exhaust manifold-catalytic muffler fixing bolts
5 Coolant drain plugs l 14 Catalytic muffler
6 Cross member to left strut connecting bolt 15 Gear box differential oil drain plug
7 Cross member to body flxlng screws 16 Constant velocity joint screws
8 Suspension left strut 17 Bracket screws supporting engine anti-shock supportlng bar
,9 Exhaust manlfolds 18 Exhaust manifold flange nuts

(*) For models with catalytic converter, only

O c t o b e r 1988 OI-6 PA327900883301


ENGINE MAIN MECHANICAL,,UNIT
g. Unsciew and remove the two bolts
0:connectimng the front cross mem-
ber to the left $rut @ .
h. Swing the front cross member
round as shown in the illustration to
allok the drive unit to be taken out
downwards.
i. Unscrew and remove the two screws
fixiqg the drivce unit rear support 0
to tbe body.
1. Remove boit fixing engine central
supbort to body, unloosened at step
1 2 .
m. l!ower column lift and take the drive
uhit out from the engine comp,artment.
1 I,,
:l
~ Tightening torques
Ih$T;ALLATION
11.7 IIE w;ith catalytic con-
v,erter
1. ereliminary Operations
CAbTiON:
Dribe unit assembly must be perfor-
me:d in such a way that the gfearboz
rear support and the engine front sup-
port are not respectively upwards and
longitudinally preloaded.
a. Raise the drive unit wi!h the column
lif{er used for disassembly until the
centre ,support axis 0 is ai about
the halfway point of the body slot and
tighten the relevant boit 0.
PA327900883301
,
~
1 Rear support of gearbox
1 Boit
2 Pin
2 Central support 3 Rear support securing screw
4 Bolt securing gearbox rear support
b. With referdnce to figure at page
01.6, rotate the front crossme,mber
complet@ with stabilizing bar in moun-
h. Insert the side rod @ into support
ting position and fix it with bolt @ to
on right side longitudinal member
strut @ then fully tighten bolts @ @ first and
and 0.
0
c. Tighten screws 4 fixing the engi-
ne front support.
d. Tighten !he foilowing components
to !he specified torque.
0 * cro&nember an6 stabilizing
bar backet to body
66,5 + 83,3 N.m
(6,s + 8,5 kg.m)
l Screws fixing stabiliting bar
to strut
14,7 i 23,5 N.m
(1,5 + 2,4 kg.m) 1 Ri,ghl cylinder head
2 Right side longitudinal member
l Screws connecting semishaft 3 Support
. differential shafts (in engine 4 Side rod (engine antishock bar)
5 Front screw
oil) 6 Rear screw
33 + 36 N.m
(3,4 + 3,7 kg.m)
2. Reinstallation of reverse light table
and of exhaust pipe
e. With reference to following figure
remove lift and loosen lower b&t @ a. Reconnect the reverse light table to
gearbox switch.
b. Remount exhaust mainfolds in re-
verse order with respect to removal,
vant poitit fixing it to body andtighten new gaskets between mainfolds and
screwS 0. engine cylinder heads and between
g. Retighten lower nut @ mainfolds and catalytic muffler.
01-7 October 1988

3. Reassembty of electrical tables
Lower the auto lift and, with reference
Nto figure on oage 01-4, reconnect elec-
~trical cablesworking in reverse order
,to that described under Removal
,step 11. ~~
~ l
For fol!owing procedhes steps, refer
Gto Figure 01-3.
,4. Reassembly of, clutch control hose
Refit hose ~@ to;clutch pump and ful-
ly tighten it. ~
,5. Reassembly of air intake manifold
;Refit inlet manifold @ on intake ma-
nifolds, fitting n~w gaskets, then tigh-
:ten securingi nuts.
Mind that centr&nuts ontwo sides of
the manifold~ serve also to fix brackets
6. Completion of reassembly
a. Reconnect injectionlignition wiring
in reverse order to that described un-
:der Removal 1 Step 8.
,ib. Reponnect ti-ie~ accelerator table to
lever 0 on thr,ottlebody.
c. Reconnect hoses @ a n d 8 re-
spectively to damper Q and pressu-
re gauge 0.
d. Reconnect pipelines of engine coo-
ling system pin reverse ordxer to that
described under Removal - Step 5.
e. Reconnect fuel vapour and air in pi-
pelines in reverse order to that descri-
bed under Removal - Step 4.
:f. Reconnect tables supplying spark
#,plugs and reinstall the ignition distri-
butor cap ~0 .
g . Reinstall air filter caver 0 , air
flow sensor i0 and corrugated slee-
ve@ in reverse order to that descri-
bed under Removal: - Step 2.
ENGINE MAIN MECHANICAL IdIT
h. Remount hood.
i. Remount the battery negative termi-
nal.
1. Operating inside the passenger com-
partment refit the gear lever knob and
rubber gaiters on the gear lever.
REMOVAL
1.7 IE without catalytic,converter
l Pipe 0 unscrewing fitting,on syp-
During engine removal from the car, it
is necessary to remove engine and
gearbox-differential unit as a single
unit. Put the vehicle on the auto lift
and engage first gear.
WARNING:
Great tare is required when operating
on a hot engine.
1. Preliminary operations
Operate as described at Step 1 page
o-2
For the following procedure steps re,
fer to Figure at page 01-9.
2. Air filter, air flow sensor and sleeve
removal
Operate as described at Step 2 page
01-2.
3. Removal of spark plugs supply ca-
bles
Operate as described at Step 3 page
01-2.
4. Removal of air pipes
Disengage the following pipes, di-
sconnecting them from stated compo-
nents:
OI=8
l Pipe @ from supply manifold @ .
l Pipe @ , from throttle body and pi-
pe 0 fro,m pneumatic gauge on
ignition distributor 0.
Pipe @ , from idle RPM setting fit-
t i n g .
l Pipe 8 , from supply manifold @
ply manifold @
5. Removal of cooling circuit pipes
Operate as described at Step 5 page
01-2.
6. Removal of fuel supply hose
Operate as described at Step 6 page
01-2.
7. Removal, of accelerator control ca-
ble
I
Operate as described at Step 7 page
01:2.
8. Removal of: ignitionlinjection tables
a. Unscrew two screws and remove so-
lenoid starters @ from body.
b . D i s c o n n e c t connection @ bet-
ween ignitionlinjection wiring and ve-
hicle wiring.
c. Disconnect connecter @ from
throttle bodyswitch @ .
9. IRemoval of supply manifold
Operate as described at Step 9 page
01-2.
10. Removal of clutch control hose
Operate as described at Step 10 page
01-2.
PA32 790088330 1
 ENGINE MAIN :MECHANICAL UNIT
11. Removal of electrical tables
Operat as described at step 11 page
01-5 with reference to Fig. page 01-4.
12. ~Loosening nut of engine central
support
Operate as described at step 12 page
03-5.
Forfollowing procedure steps refer to
Figure at page 01-6.
13. :Oil draining
(if required, as a function of interven-
tion to be carried out, operate as de-
scr/bed at step 13 page 015).
14.Removal of exhaust pipe.
a. Disconnect exhaust gas manifolds
from right and left engine heads, un-
screwk-rg the relevant fixing nuts 18.
b. Discqnnect exhaust pipe on vehicle
rear side unscrewing screw of connec-
ting clip to final trunk of exhaust pipe
and remove it from elastic support.
Removal of ,reversing light table
Disconnect reversing light table 11
from gearbox switch.
16.~ Mechanical disconnection and re-
moval of drive unit.
8 that the engine pump drain plug and
Operate as described at step 16 page
dl-~5.
INSTALLATION
1.7 IE without catalytic converter
1. Preliminary operations
Operate as described at step 1 page
01-7.
2. Reinstallation of reverse light table
and of exhaust pipe.
a. Reconnect reverse light table to
gearbox switch.
b. Remount exhaust manifold opera-
ting in reverse order to removal, with
new gaskets between manifolds and
engine heads.
3. Reassembly of electrical tables.
Lower the auto lift and, with reference
to figure on page 01-4, reconnect elec-
trical tables working in reverse order
to that described T Removal step 11.
For following,procedure steps, refer to
Figure 07-3.
4. Reassembly of clutch control hose
Refit hose @ to clutch pump and ful-
ly tighten it.
5. Reassembly of air intake manifold
Refit inlet manifold @ on intake ma-
nifolds, fitting new gaskets, then tigii-
ten securing nuts.
Mind that the central nuts on two si-
des of manifold serve also fix brackets
0
OI-811
6. Completion of reassembly
a. R,econnect injectionlignition wiring
in reverse order to that described un-
der !Removal step 8.
b. Reconnect accelerator table to le-
ver @ ON THROTTLE BODY.
c. Reconnect hoses @ a n d @ re-
spectively to damper @ and pressu-
re gauge 8.
d. Reconnect pipelines of engine coo-
ling system in reverse order to that de-
scribed under Removal step 5.
e. Reconnect tables supplying spark
plugs and reinstall ignition distributor
Cape 0 .
f. Reinstall air filter caver 0 , air
flow sensor 0 and corrugated slee-
ve G9 in reverse order to that descri-
bed under Removal step 2.
g. Remount hood.
h. Remount battery negative terminal.
i. Operating inside the passenger com-
partment refit the gear lever knob and
rubber gaiters in the gear lever.
REFILLING AND
ADJUSTEMENTS
a. Refill e n g i n e a n d g e a r b o x -
differential with type and quality of oil
recommended.
WARNING:
Before refilling with oil, make sure
gearbox drain plughave been screwed
back on.
October 1988
 ,,s ,

l ENGINE MAIN MECHANICAL UNIT: ,~

GEARBOX-DIFFERENTIAL OIL d. Bleed the clutch hydraulic system ..

ENGINE OIL
and top up said circuit (as per Alfa 33 -
Type: Type: Group 12).
e. Start the engine and, when at nor-
AGIP Sint 2000 SAE loWl40 AGIP Rotra MP SAE 8OW/90 mal running temperature, check cor-
lb; Sintiax +A! lOWI40 IP Pontiax HD SAE 8OW190 rect engine idle rpm running, the cor-
SHELL Super Plus Motor Oil SAE SHELL Spirax HD SAE 8OW/90 rect ignition timig and CO percentage
15w150 ~ at exhaust.
Quantity: For engine tuning see Group 00 - Engi-
Oil quanrity for full refilling 2,4 kg ne Maintenance.
(lump, filter and duc&):

b. Effect cooling system refilling with

speciasl fluid (See: Group 00 - Engine
Maintenance - Basic Mechanical Sy-
Stern).
c. Effect the setting of the accelerator
control table (see: Group 00 - Engine
Maintenance - Engine Supply).

pctober 1988 OI-812 PA32 790088330 1

2 Outer parts
-2
2 1 Electroinjectors~
8 2 Fuel supply manifold
0 3 Lifting brackets
4 Supply manifold
!i 5 Fuel puise damper
6 Fuel pressure gauge
7 Intake manifolds
6 Supplementary air solenoid valve
9 Gasket
10 Coolant temperature sender (for indicator)
11 Gasket
12 Coolant temperature sender (for CU)
13 Dipstik
14 Single contact min. oil pressure
15 Ignition distributor with power module
16 Union
17 Coolant pump
16 Front protection of drive belts
19 Water pump pulley m
2 0 W a t epump
r - a l t e r n a t o r belt
21 Alternator
22 Thermostat
23 OIl filter
24 Max. engine temperature thermal contact

d -
v
8+10
(0,8+1) '
 E N G I N E MAIN M E C H A N I C A L U N I T

Interna1 p a r t s

J5+8
+
( 0 . 5 0,8) (8,3 + 8,8)

l
I

1 Jockey puylley 15 Valve guide

2Timing belt ,16 Lower spring seat ~
3 Right tlmin pulley 17 Washer
4 Timing belt rear caver 19 Seal cap
5 Englne front caver 19 Springs
6 Crankshaft seal ring ,20 Spring seat
7 Engine block 821 Cotters
6, Spacer 22 cup
9 Timlng Pulley 23 Camshaft Support
10 Water-pump-alternator pulley 24 Camshaft ~
11 Spacer 25 Covei
12 Washer 26 Gasket
13 Valve 27 Seal ring
14 Cylinder head 26 Timing belt front caver

O c t o b e r 1988 OI-10 PA327900883301

.
 ENGINE MAIN MECHANICAL ,$JNIT

Interna1 parts

0T N.m
(k9.m)

1 Main bearings 13 Compression rings

2 Woodroff key 14 Oil scraper ring
3 Thrust half-ring 15 Oil p u m p
4 Oil pump gear 16 Oil sump
5 Bush 17 Engine oil drain plug
6 Seal ring 16 Main bearing caps
7 R,ear caver 19 P i s t o n
8 Oil vapour separatar filler inlet 20 Connecting rod
9 Flywheel 21: Connecting rod bearings
10 Washer 22 Connectini rod cap
11 Lock ring 23 Crankshaft
12 Pin

$j33%00883300 ,Ol-11 May 1 9 8 8

 4. Remoie spark plugs and ignition
PRELIMINARY qlistributor.
OPERi+TION,S (1) Unscrew and remove spark plugs
from cylinder heads.
1. Remove #drive unit from car ac- (2) Loosen distributor @ securing
cording t8 procedures: D r i v e U n i t nut @ and withdraw distributor from
Removql An4 Installation. rear caver.

2. Remove Qearbox - differential unit

and clutcq uni? from engine according
t o proc&d,ures: S e p a r a t i o n a n d As-
semblv, of the Units (sec: WORKSHOP
MANUiL c-1 - Group O-l ).
,

1 Bracket
2 DalrIper
ENG$E UNIT 3 Fuel pressure gauge
1 Ignition distributor
4 Intake manifold 2 Distributbr securing nut
5 Bracker
6 Injecter
The engin? is on the stand without inlet 7 F u e l supply hose
m a n i f o l d #and with no spark plugs,
tables, a,nd d i s t r i b u t o r c a p a l r e a d y
rehoved on engine removal. ~ i
,l
,3. Sequentially removethe followinb 5. Remoue alternator.
parts: (1) Loosen securing bolts @ fixing
- Oil filter @ &ing suitable span- alternator @ and remove drive belt.
1 . Rempval ,of fnjection w i r i n g ner. (2) Remove bolts and take out alterna-
(1) Di&onnect injection wiring con- - D i p s t i c k @ f o r m i n i m u m Oil tor (2).
nectors $om following components: pressure check (3) Unscrew screws @ and remove
- T h e r m a l s w i t c h @ from right b r a c k e t @ and @ .
- supplementary air valve
cylinder head.
-: pow&r m o d u l e o n i g n i t i o n tem-
peiature
- engine tiater temperature sensor
- Imje&ors
Disenglge viring from wire clips and
remove $iring from engine

2; Reniove fuel distribution manifold.

(1;) Unsciew fixi,ng screws from bracket
@ supporting damper @ a n d
pressure gauge @

(2) Uns,crew screws (two per side) fix-

ing bradkefs @ which support the
fuel hose 0. ,B :

(3) Remove fuel hose disconnecting Bolt ~

1
it from fouy injectors @. 1 Oilfilter 2 Alternator
(4) Rehove four injectors @, ex- 2 Pressure switch 3 Screws
tracting, them from thermal switches 3 Dipstick 4 Bracket
4 Thermal switch 5 Bracket

May19i8, OI-12 PA333500883300

,
,
,

8,
T!

~ ~ ENGINE MAIhI MECHANICAL UNIf

6. Flem&e sleeve and cooling sys- 9. Propeed as per (Alfa331 from

tem union. step 11 to end, but for step 21 Re-
move Cylinder Heads, which should
(1)L~o~enclampsfixingfollowingcool- be modified as follows:
,ing system hoses: (1) Unscrew the six screws @ which
- Hqse, @ connecting between secure cylinder headsto, engine block.
thermostat and union 0 (2) Remove heads along with cam-
- Hose 0, c o n n e c t i n g b e t w e e n shaft Supports and the gaskets on en-
ihkrmostatand u n i o n @ gine bldck.
- Hdse' ,@' connecting thermo-
s$f a,nd right manifold.

( 2 ) Rehove hose @ a n d @ .

1 Union
2 Screws

7. Remove thermostat.
Remove screw @ fixing thermostat
@ on cylinder block and remove it.

1 Screws securing heads and camshafi sup-

ports:to engine block

~CYLINDER H E A D S

Procedure is as per [=33)

t a k i n g
into account that camshaft supports
have no caver. Therefore, on head
supports disassembly, recover the oil
still present in the supports.

1 Screw
8, 2 Thermostat

1 Hose &necting thermostat-union

2 Un~ion
3 H+e connecting thermostat-union 8. Remove intake manifolds
4 Thermostat
(1) Unscrew all, three nuts securing
5 Hose connecting thermostat - right mani-
!Old
each intake manifold and remove
them from heads with relevant
gaskets.
(2) If necessary, remove water tem-
perature transmitters from iniake
hanifolds.
(3) If necessary, working on bench, p.2.0226
(3) $nscrew and take out screws @ unscrew the two fixing screws and
fixing union m@ on cylinder block, r e m o v e supplementary, air solenoid 1 Camehafl support
..
the,n ;reniove union. valve from right manifold. 2 Cylinder head

May 1 9 8 8 I
PA3!3500883300 cil-13
 ~

,
ENG!NE M A I N MECiiANICAL UNIT ;
l
, 8

CHECKS AND INSPECTIONS

,l
These procedures are for electronic injection 1.7 engines with CatalYtiC CO~ve~or CnlY
cup is free, of any trace of sizing,
CYLINDER HEADS etching, or unusual wear.
WARNING~ AND VALVES
,Procedures-described for (Alfa] 2. Check fhat the cups Upper plane
are stik ,valid( except for what fol- As per (A-33) except on which cams work is free of unusual
lows. ~ wear.
,For technfcal data of 1.7 injection
engtne, please refer to Service CUPS
Data and Specificattons.
1. Check that outside surface of

18 ENGINE ASSEMBLi(
These procedures are for electronic injection 1.7 engines vvith catalytic convertor only
1
- Lubricate thoroughly cups @ ENGINE, UNIT
WARNING before inserting them into cam-
!, ~Procedures described for IAlfa33) shaft support @ seats.
~are still~ valid but for what stated - On reassembly of camshaft sup- As per (Alfa] but modifying the
L here beloW,. ~ port on head, make sure the cam- mentioned iteps.
For technical data of 1.7 injection shaft is in rest position (no cam
engine, please refer to Service engaged; valves closed). l Step 15.
Data and ~Specifications. - Secure camshaft support to head Install cylinder heads
with gasket between tightening
the four nuts in crosswise order (1) Turn crankshaft till the piston in
to the temporay torque specified. N o . 1 cyltnder, is set! at Top Dead
WARNIhGS :. Center in the explosion. stroke; this
correct positioning is further ensured
1. L u b r i c a t e , with ensine oil bear- $ : Temporarytightening, torque by the T~ notch @ on the flywheel
ings and slipbing surfaces before as- Nuts securing camshaft sup- matching with the reference @ on the
sembly. ~ ~ ports to cylinder head rear caver 0.
+ 115 N:. m
2. Use new gaskets, seal rings and
+ 1.5 Kg.m)
lock r i n g s ! .
3. Scred sprews and nuts to speci-
fied tightening torque.
4. Apply: specified sealant to com- - Before fitting rear caver onto sup-
ponents, likted here below. port, insert 0.10 + 0.15 I engine
oil into support itself.
. Oil sump, block side
Mastics rclass: 3522-00040
DOvV C,GRNING Silastick 732
R T V ~
. Watar tubes,.plugs, caps, cylinder
heads and block.
Mast,ic class 3524-00011
Loctite 601 (green)
Before applying sealants eliminate
any possible trace of old sealants by
degreasing the surfaces.

CYLIN~I~R H E A D
Operate as stated 1 7 notch
per c-33) taking into account 1 Camshaft 2 Reference
the following: 2 Hydraulic tappets cup 3 Cylinder block rear caver

Ol-,14 PA333500883300
 8 ~
,

ENGINE MAIN MECHANICAL U~NIT

(2) Set the camshaft in rest position

(no ca engaged; valves closed).

(3) F,it the~cylinder heads with crank-

shaft sipport on the cylinder ,block,
and ~ifis&the appropriate gasket.

Proceed as per (Alfa] f r o m

Step;(t).

l Step 18.
Install timing belts.
b 2

(1) Fit~ camshaft drive pulleys and

tighttin he retaining screw to specified
torque being caeeful, at the same time,
to stbp~ ptlley rotation by tieans of
toothecj spanner A.5.0195.
$ : Tightening torque
Camshaft pulley retaining
scr3v.
~83 + 70 N.m
~(6.4 + 7.1 Kg.m)
1 Timing belt rear qover
2 Left timing pulley
(5) Realign notch T on flywheel ~
with the fixed reference mark (piston
of cylinder No. 1 at T.D.C. in the ,ex-
plosion stroke) and, keeping shafts in
this position, fit the left timihg belt cinto
pulleys.
1 Timing belt rear guard
2 Right-hand timing pulley
(9) Verify that distance S between
timing belt and contour of engine front
support is not less than the minimum
value prescribed.

Minimum distance S between

The belt shall be fitted with its drag- timing belt and engine front
ging side, opposed to straighteners, support:
under tension. 9 mm

(6) Loosen the nut securing the belt

8
(2) Vdrify that the crankshafts anqu-
lar $ositiM corresponds to the Top
Dead @enter of cylinder No. 1, in the
explb<ion stroke (alignment between
notch ;T on flywheel and rear caver
refererce mark).
(3) R;!ate crankshati counterclock-
w i s e (,seen from rear side) by 45O in
order io tiove piston of cylinder No. 2
backwarc(sso a,s to prevent valves strik-
i n g again? piston during c a m s h a f t
rotati&. ~ to correct position sincb camshaft
(4) ,Pysifion the left camshaft SO that
the topth and the two adjacent milled
groovys of the left timing pulley are
visibleithrough the appropriate hole on
rear gIuard 0,
straightener SO that it cari exert~the
spring load on the belt.
(7) Rotate the crankshati 45O to move
piston of cylinder No. 1 backwards#so
as to prevent valves striking against
piston itself when positioning the cam-
shaft.
(6) Position the right-hand camshaft
SO that the toot,h and the two adjacent
milled grooves of right-hand tiniing
pulley are visiblesthrough the appropri-
ate hole on rear guard 0; then bring
the crankshaft back in the position, in-
dicated in Step (2) and fit the timing
belt onto pulleys.
(11) Rotate crankshaft in jhe function-
ing-direction SO as to permit belts to
assume their final position.
CAUTION: (12) Rqtate crankshaft until piston of
Pulley tends to rotate with respect cylinder No. 1 is at its T.D.C. in the ex-
plosion stroke. (Notch T on flywheel
interacts With the intake &lve of alignerj with reference mark). Then,
cylinder No. 3. For thisreason, use furtherrotate the crankshaft counter-
appropriate wrench A.5.0195 in ord- clockwise (seen from rear side) until
er to keep the pulley in the--correct notch v on flywheel is aligned with the
reference mark (right-hand camshaft l
position for belt installatic@.
in rest position, no cam engaged).

PA3d3500883300 May 1 9 8 8
 ENGINE MAIN MECHANICAL UNIT, ~
;

: Tightening torque
: . Water temperature sender

(for temperature gauge)

+ 41 N.m
y:4 + 4.2 Kg.m)
. Water temperature sender

(for injection CU). Max

torque
1 5 N . m
(1.5 Kg.m)

! (13) Loosen the nut of right-hand belt 1 Cooling fluid pump pulley
straighten~er,, then tighten it to the 2 Screws

prescribed torque, (3) Fix thermal contact on right head,

tightening screwto specified torque.

2 3 . S c r e w onto block, p r e s s u r e
CAUTIOk ~ switch to signal minimum oil press- 8 .: Tightening torque
, Dr$ing ~this operation, do not press ure, tightening it to specified torque. ~ Thermal contact screw on ~
the beltstraightener to prevent alter- right head
i ing the ~load, envisaged for belt : Tightening torque 33 + 41 N-m
@J
straightener ~itself. Pressure switch (3:4 + 4.2 Kg.m)

$ : Tightening, torque
Nut securing belt straightener
(on cold engine)
37 +B 46N.m
(3.d f 4.7 Kg.m)
1 (14) Starting~ from the position cor-
~ responding to notch V on flywheel, ro-
1 tate the, crankshaft one complete revo-
~lutton in the counterclockwise direc-
tion (seen from rear side) until notch
33 + 41 N.m
(3.4 i 4.2 Kg.m)
24 Fit intake manifold.
(1) If you previously removed it, fit
supplementary air solenoid valve on
right intake manifold.
(2) Insert intake manifolds com$ete
with new gaskets on stud of two heads,
then fix them with associated nuts.
(4) Connect thermostat to right intake
manifold through sleeve, then fix ther-
mostat on engine block.
,26. Refit hoses of cooling system.
Mount sleeve @ c o n n e c t i n g ther-
, ;mostat @ to union @ and sleeve
~0 which connects thermbstat @ to
left intake, manifold 0; tighten all
screws of isleeve screwing clamps.

/-o
V is realigned with the reference mark
~ (left-hand camshaft in rest position; no 2
@ : Tightening torque
~ cam engaged).
Nuts securing intake
(15) Repeat Step (13) for the left-hand
manifolds
belt stnaightener.
24 N-m
(16) At the end of operations, recheck
+ 2.4 Kg.m)
, the correspondence of timing refer-
ence marks on pulleys with the ap-
propriate holes on timing belts rear
g u a r d s :and with notch T o n 25. Fit the union, temperature sen-
flywheel,i aligned with the reference ders, thermal switch and thermostat!
mark. ~ ( 1 ) F i t u n i o n o n block, t i g h t e n i n g
scyews on intake manifolds.

fr0ceed~a.s per [Alfa] up to Step

20 inciuded, then complete reassem-
bly oper&ng as stated below. @J : Tightening torque
Union kecuiing screws
~ 24 N.m
21. Fit: front plastic covers of timing + 2.4 Kg.m) 1 Hose
2 Left intake manifold
belts. ~
3 Union
22. Mo&t pulley @ on pump hub (2) Fit water temperature senders 4 Hose
and it with screws 0.
tighkn on intalte manifolds. 5 Thermostat

May 1988 0 1 - 1 6 PA333500883300

 ~ ENGINE MAIN MECHANICAL UNiT
27. Fitloil filter by manually tightening
it and insert dipstick.
,
28. Bi means of a suitable box span-
ner fit Fpark plugs tightening them ac-
cording t9 specified torque.
$ : Tightening torque
Spark plugs:
i5 + 34 N.m
~ (2.5 + 3.5 Kg.m)
829. Fii alternator and control belt.
(1) Fecure bracket @ and @ to en-
gin? fiont caver and tighten the two
relevant screvis 0.
(2) POsition alternator on engine sup-
ports &d tighten bolts @ without fully
locking them.
(3) K&y alternator and water pump
drive belt on relevant pulleys.
(4) Adjust belt tension according to 30. ,Retiount injectors on intake
specified value and then lock bolts manifolds, replacing relevant O-rings,
and fix lfuel manifold.
Load: 8 Kg
Arrow: 15 mm 31. Position injection wiring on engine
and reconnect it to stated compo-
nents:
- supplementary air solenoid valve
- power module on distributbr
- engine water temperature sensor
- injectors.
32. Fil1 the engine with specified en-
gine oil and with specified quantity.
AGIP Sint 2000 SAE lOW/40
IP Sintiax SAE iOW/40
SHEEL Super Plus Motor Oil SAE
15Wl50
Oil quantity required for complete
1 Bolts lrefill (sump, filter a n d
2 Alternator oil channels):
3 Screws
4.1 litre
4 Bracket
5 Bracket
QI-17 May 1988
 1200f 1350 1500 1700
305.58 305.58 A
Features

Otto 4 stroke
Cycle

Numbers of cylinders and arrangement 4 horizontally opposad

L

Laft head Right head

Cylinder identification

Bore - Stroke mm 80x 59 80 x 672 80 x 67.2 84 x 67,2 87x72 87x72

Displacement cm3 1186 1351 1351 1490 1712 1712

Combustion chamber volume cm3 37 42,2 39.7 44 49.5 49,5

Compression ratio 9 93 ~9

Max 50 (68) 58 (79) 63 (86) 77 (105) 86,7 (118) 79 (110) 77 (105)

Power DIN kW (HP) 42 (57.3) 43 (58,4) 47 (64) 51 (70) 50,6 (69,8) 46 (64) 44,9 (61.3)
Specific
at 6000 r.p:m. at 6000 r.p.m. at 6800 r.p.ni. at 66Oq r.p.ti. at 6800 r.p.m. at 6 8 0 0 r.p.ti. a t 6 6 0 0 r.p.m.

N.m (Kg.m) 80 111 (1?,3) 119 (12.1)~ 133 (13.6) 148 (15) 148 (15,4) 145 (15,2)
Max Torque DIN at 3200 r.p.rir. at 3600 r.p.m. at 4000 r.p:m.~ at 4000 r.p,m. at 3600 r:p.m: at 4 6 0 0 r.p.ni. a t 4 6 0 0 r.p.m.

Piston ~mean speed (1) mis 1 1.8 13,4 13 14,4

Cylinder compression (2) kPa (bar; Kglcm)

1029.6 (10,3; 10,5)
Min. pressure
98 (0,98; 1)
Max difference in pression between cylinders
l
Dil pressura (3) kPa (bar); kg/cm*)
196 (1,96; 2)
- min on idle r.p.m. 117.68 + 274.60 (1,18 + 2,75; 1,2 + 2,8)
441 (4,41; 4,5)
- min on max r.p.m. 411.89 + 568,81 (4.12 + 5.69; 4,2 + 5,8) 490 (4,90; 5.0)
- max on idle r.p.m.
_
(1) At max power output rpm. (3) Values to be read at engine operating temperature (oil at 90% = 194oF)
(2) Values to be read in these conditions: () Not marketed in all countries
- engine at operating temperature (4 For countries where antipollution regulations are in force.

- fully opened throttles /

- engine cranked by starter motor, sparking plugs removed
 ENGINE M A I N MECHANICAL UNIT ~

<--,;,
INSPEOTIdN AND ADJUSTMENT
CAMSHAFT SYSTEM

Unit: mm (in)
.-.
Single carburetor engines Double carburetor engines

1200 * 1350 1350 1500

3g5.85 305.86 305.87 305.88
LEFT SUPPORT

Camshaft 545.766 546.232

Inta ke 035 + 0,40

Tap~e! clearance
Exhaust 0.45 + 0.50 ~

Value~of timing marks Right support

23O

on camshaft supports Left support

23O

* vot marketed in all countries

AllIvaIlues are with engine cold

~
I

1 Rear guard for right - hand timing belt 2 T-shaped notch ,on flywheel 3 Rear guard for left - hand timing belt

Unit: mm (in)
r I
Double ~
Electronic injection angines
carburetors engines
8
1
1 7 0 0 ) 1700 1700
i ~305.50 ~ ~ 305.58 305.58 a

Camshaft 580.429 581.191 549.315

Intake 0 (Y
Tappet clearance
Exhaust
0 r?

Camshafi pulley alignment reference position (with T-shaped (**)

right-hand pulley
notoh on #flywheel alignad with the reference mark on engine
rear~cover, with the piston of cylinder No. 1 at T.D.C., in the
left-hand pulley (***)
explpsion ,stroke).
8,
A For countries where antipollution regulations are in force , ;
8,
(:) ~Engine with hydraulic tappets (with take-up of slack)
(T) Tooth with two - ..,red grooves on right-hand camshafi pulley, in correspondence with the related hole on rear guard @ of timing pulley.
(* l ) ~Tooth with two milled grooves on the left-hand camshaft pulley in correspondence with ;the related hole on rear guard @ of timing pulley.

May 1 9 8 8
 m

n For countries where antipollution regulations are in force

(0) Crankshafl rotation ACW seen from flywheel side.
(*) Not marketed in all countries.
 ENGINE MAIN MECHANICAL QNI,T ~

CYliItjDkR BLOCK

(0) Area for dimension check Unit: mm

Engines
Inspection data
1200*-1350 1500 1700
305.85186187 305.8% 305.50-305.58

Glass A 80,00+80,01 84,00 f 84.01 87,000 + 87,010

84.01 + 84.02 87,010 87,020
i ,,
Class B 80.01 +60.02 f
Class C 60.02 t80,03 84,02 + 84,03 87,020 i 87,030
,S
80.03 C80.04 84.03 G84.04 87,030 + 87,040
Glass D
C$n,der ;bore a 80,04+80,05 84,04 t 84,05 87,040 f 87,050
Glass E
1 s t 80,20 + 80.21 84,20 + 84,21 87,200 f 87,210
Oversize 2nd 80,40 + 80,41 84,40 f 84,41 ,87,400 f 87,410
3rd 80,60 + 80,61 84,60 i 84,61 87,600 + 87,610
1

Out-etsquare between cylinder bore centreline 0,05

and benfreline of main bearings
i;
Standard 0.01
Taper and out-of-round limit
Max 0,02

Cylindei bore surface roughness (0,541) 10-Z

Cylinder bore grinding angle goo+ 1200

63,663 +63,673

63,673 f 63,683

width of rear main bearing support Y 23.68 i i3,73

-
(*) ,Nbt marketed in all countries.

~P A 3 3 3 5 0 0 8 8 3 3 0 0 May 1 9 8 8
 Unit: mm (in)

ENGINES
L

1200-1350 1700
305.85 (1) 1500 305.50 (5-6) 1700 A
305.86 (2-3) 305.88 (3-4) 305.58 (5-6) 305.58 (6)
Inspection data
305.87 (2-3)
L

1
Pistone Borgo Pistone Mondial
C!as$ A (Blue)
79,960 + 79,970 83,960 + 83,970 86,960 + 86,970 86,950 t 86,960 86,950 + 86,960
Class B (Pink)
79,970 + 79,980 83.970 i 83,980 86,970 + 86,980 86,960 + 86,970 86,960 + 86,970
Standard Glass C (Green) 79,980 + 79,990 83,980 f 83,990 86,980 + 86,990 86,970 + 86;980 86,970 + 96,980
Class D (Yellow) 79,990 + 80,000 83.990 + 84,000 86,990 + 87,000 86,980 + 86,990 86,980 + 86,990
Class E (White) 80,QOO + 80,010 84,000 f 84,010 87,909 + 87,010 86,990 + 87,000 86,990 f 87,000
I !

1 s t 80i154 + 80,170 8 4 , 1 5 4 + 84,170 8 7 , 1 5 0 + 87,170 87,144~+ 87,160 87.144t87.160

2nd 80,354 + 80,370 8 4 , 3 5 4 f 84,370 87,350 + 87,370 87,344 + 87,360 87,344 t 87,360
Oversize
80,554 t-80.570 8 4 , 5 5 4 + 84,570 87,550 + 87,570 87,544 + 87,560 87,544 f 87,560
3rd

First compression ring groove height c 1,525 ~+ 1,545 1,515 +~1,535 1,535 f 1,555 1,535 t 1,555

Second compression ring groove height d 1,775 ; 1,795 1,775 + 1,795

Oil scraper~ring groove h e i g h t le fILO? + 4,035 3,015 + 3,035

Pin-Seat bore b 21,004 + 21,008

A For countries vvhere antipollution regulations are in force

( 1 ) H = 7 . 6 m m ~MONDIAL P i s t o n
..
( 2 ) H=11,7mm
(3) H = 16.5 mm BORGO
.,
(4) H = 15.5 mm
,,
(5) H q 6,0 mm
2
c.2 (6) H = 13.9 mm MONDIAL
0
 Unit: mm (in)

I Engines

Inspection data
1200 * 1350 1500 1700
305.85 305.86 - 305.87 305.88 305.50-305-305.58

First compression ring 1,478 ~1,490 1,478 + 1,490

Ring thickness b Second compression ring 1,728 + 1,740 1,728 + 1,740

Oil scraper ring 3,978 f 3,990 2,978 + 2,990

I I

+
First compression ring 0,30 + 0.45 0.30 045 (2) 0,30 + 0.50
0,30 + 0,50 (3)

Second compression ring, 0,30 + 0,45 0,30 + 0,45 (2) 0,30 f 0,50
0.30 + 0,50 (3)
Ring gap a (1)

Oil scraper ring 0,25t 0,40

0,25
0.25
++ 0,40
0,50
(2)
(3) 0,25 + 0,50

Limit gap for each ring 1

(1) TO be measured inside the cylinder b6im6r inside a ring gauge

(?) Borgo ring
(3.l Gostze ring
() Not marketed in all countries
 8,
m,, ,l l

~ ~
( ENGINE MAIN MECHANICAL UNIT ~
i, , i
~ ~
fi ,.,

Unit: mm (in)
1
8 I
1,
Engines
~
hpac?ion d a t a
, 1200 * 1350 1500 1700
305.85 305.86 - 305.87 305.88 305.50 - 305.58

P i n diarndter a 20,996+ 21,000

P i n - p i s t o n slack o,oo$ + 0,12

1

Mai 1988 OI-24 PA333500883ilOO

 ENGINE M A I N MECHANICAL~, UNI-r

COh$ECTlNG ROD AND CONNECTING ROD BEARINGS

i,
Connecting rod (1)

Unit: mm (in)

Engines
Inspection data
1200* 1350 1500 1700
305.85 305.86/87 305.88 305.50/58

Small end bush bore diameter a 21,007+21;015

~
F$end bore diametar b 52,696 + ,53.708
.,

Connpc$ng rod bearings

l Unit: mm (in)

Inspection data
T

Standard

1st 1,956 + 1,962

Conneqting, rod bearing 2nd 2,083 +:2,089 l
O\iersize
thickness a 3rd 2,210 +2,216
i 4th 2,337 + 2,343

(1) If thd connecting rods are completely removed. usa post-modificatin ones (Std No. 542 128)
If the connecting rods are partially replaced it is still possible to mount pre-mobificationones (Std. No. 535.022)

(*) ~Net marketed in all countries

l
l

.-

PA33@5!0883300 OI-25 May 1 9 8 8

 18

UNIT
~
,,
ENGINE MAIN MECHANICAL
8
l

FLYWHEEL

Unit: m (in)

1 Engine
Inspectiondete
1200 * 1350 a 500 1700
305.85 305.86/87 305.88 305.50/58
,

~ 24,0 + 2 4 . 2
8,
G 0.2
~ , > 2 0 . 9 5

Parall,elism bof thedriven plete.contact face compared

with flywheel-to-cranksheft support face (as read et OS@
a 108 mm (3.94 in) radius)

Maximum outof-flat of driven plate contact face 0.02 ~

3urfece~roughness of driven plate contact face 2.10-3

~
(1) The quamtity of material removed bv grinding dimension b, must be the seme both on clutch driven plate contact fece and on the l
im ~ fece of the register for the clutch caver, SO that dimension a is kept constant., Dimension c must not be lowerthan the specified l
lit-oit.
(1 No! marketed in all countries

_
,Myy 1 9 8 8 OI-26 PA333500883300

,
 ~ ~
?

ENGINE MAIN MECvANICALs UNI$

CRA$lKSHAFT, THRUST RINGS AND MAIN BEARINGS

~

Cranlishaft

Out of. round X - Y

1 Flywheel locating dowel Taper A - B

2 Gear tooth beginning line

Unit: mm (in)
Eng/ne
Inspection date
1200 * 1350 1500 1700
305.85 305.86187 305.88 305.50/58
Standard 59,944 + 59,957

lst* 59,690 + 59,703

2nd 59,436 f 59,449
ye,in jpurnal diameter d Undersize
3rd 59,182 + 59,195
8
4th 58,928 + 58,941

,i
Blue 49,984 : 49,992
Standard 49,992 4 50,000
Red
Crank;pin diameter e ~ ~ 49,733d 49,746
1 1st
2 n d 49,479 $49.492
Undersize 49,225 + 49,238
3rd
4th 48.971 + 48,984

Rd& main jciurnel length c Standard 28.51 + 28.55

Oversize 28,764 + 28,804 (1)
Front and centre1 main
journals 1,8?2

Fillet tadii r Rear main journal 1,5+1,7
Crank pins 2.8 ~+ 3

;Front main joucnals .i

Length of fillet radli portions If 2,ll 7 2.81

Central main journal 24.05 % 24.15

Lyth of parallel portion a
Rear main journal 24.22 + 24,32

&rface roughness of main journals and crankpin 0.16. 103

I
X-;V &ality and limit for taper O,qOS
A-p of main journals and crankpins o.o;

MAX. error of parallelism between crankpins and,main journal6 0,015

m,,
Max. misalignment among main journsls 0.02

0.25

(J No/ marketed in all countries

PI-27 May 1988

 ,
:

ENGINE MAIN MECHAhlICAL UNiT

8.

Unit: mm (in)
~
l E n g i n e
Inspection data 1200 * 1 3 5 0 1500 1700
3 0 5 . 8 5 305.86187 305.88 305.50/58
Max. miialignment betwaen tha centrelines of the MO
0.03
pairs of crankpins and the journals centreline
,l,

Rear crankshaft bush diameter b 16,065 + 16,080

Fitmant~ of raar crankshaft gear CL

22O f 260
(distri,butor/oil pump drive)

il j. Requtting eoually spaced on both shoulders

,,N
Thrust rings

Unit: mm (in)

Engine
Inrpection data
1200 * 1500 1700
305.85 ho%87 305.88 305.50/58

Standard 2,310 f 2,362

Thickness a:
1, Oversize 2,437 + 2,489

Main tieqrihgs
,

,,,
xa

Unit: mm (in)

1 Engine
,s Inspection data 1200 * 1350 1500 1700
,i 305.85 305.86/87 305.88 305:5&58

Standard 1,832+1,84i

ihickness a lit 1,959 + 1,968

2nd 2,086 + 2,095
Oversize
3rd 2.27 3 + 2 , 2 2 2
~
4th 2,340 + 2 , 3 4 9

(*) Not marketed in all countries

May 1988 01-28 PA333500883300



ENGINE MAIN MECHA~WCA~ LJNIT

CAMSHAFT SUPPORT, CAMSHAFT AND TAPPET BUCKET

,
Camshaft support and tappet bucket

, -b--l- ~

l Unit: mm (in)
i
E n g i n e

1200 * 1350 1500 1700

305.85 305.86187 305.88 305.50/58

Front 35,015 +35,040 35,015 + 35,040

Bore of cbmshaft journal bearing
di&-&f a* Central 46,500 f 46,525 48,000 + 48,025

Rear 47,000f47,025 49,200+ 49,225

Seat tappet bucket d i a m e t e r b 35,006 f 35,027 35,000 + 35,025

Tappit bucket diameter c 34,975 + 34,995 34,975 + 34,995

(1 Not marketed in all countrias

~

PA333500883300 May 1 9 8 8
 Front Central Rear

I I

(0 .n
U n i t : m m

L Single carburetor engines Double carburetor engines Engine with electronic ignition

Inspection data 1200 * 1350 1350 1500 1700 1700 1700

305.85 305.86 305.87 305;88 305.50 305.58 305.58 A

Intake 8,50 10,2 9,80 9,50

Cam height
Exhaust 8.50 95 w 8,45

Front a 34,940 f 34,962

Camshaft journal diameter Central b 46,440 + 46,456 47.940 + 47,956

I ~$9,140 + 49,156-
Rear c 46,940 + 46,956

() Not marketed in all countries

(A) For countries where antipollution regulations are in force.

(T) Not marketed in all countries
 Cylinder head Unit: mm (in1
-
Engine

Inspehon data 1200* 1350 1350 1500 1700 ~-1700

305.85 365.86 305.87 305.88 305.50 305.58

Valve guide seat diameter d 13,000 + 13,018

Standard 13,050 + 13,068

l
Valve guide O.D. a
Spare 13,064 + 13,082
l
Diameter of valve guide bore b 8,013 + 8,031

Diameter of saating for valve Stern sealing cap. f~ 10,85 + 10.95

Valve guide protrusion 8 9,3 + 9,5

Min. cylinder head thickness after resurfacing c (1) 77,676 + 77,750

Max. error of parallelism betweenhe,ao surfaces ~~ 0,05

Max. out of flat on head lower surface 0,03

Head lower surface roughness 1.6 . 10-S

(1) Resurfacino of cvlinder head with hemispherical combustion chamber must be done on both heads of the same engine
(*)~ Net marketed inaIl couWieS ~~~~
 l-b-4 Unit: mm (in)

Engine

Inspection data 1200 * 1350 1350 1500 1700

305.85 305.86 305.87 305.88 305.50 - 305.58

Intake 7,985 + 8,000

Valve stem diameter a
Exhaust 7,968 + 7,983

Intake 38,00 + 38.20 39,70 + 39,90

Valve head diameter b
Exhaust 33,00 + 33,20

(1 Net marketed in ail countries

 ENGINE MAIN MEi2HANICAL U~lilIT

VALVE SEAT RECUTTING DIMENSIONS

file~aft~r, max recutting

Unit: mm (in)

Engine

Inspection data 1200 * 1350 1350 1500 1700

305.85 305.86 305.87 305.88 305.50/85

Intak 37,3 39.0

Referr&e diameter OR
, ~ Exhaust 31;9 31,9

Fut liinit of ;Valve seat top surface a 2.9 23

, Intaka 1,07 +1,37 ~ 1.07 + 1.37

Fut limii ofvalve seat mating surface b
Exhaust 1,26+1,56 1,26+ 1,56

Valve seat top surface limit angle a 1200 120"

Valve setit rnating surface limit angle fi 9Oi 90030' ~ 90~+90~30

Intake 500 700

Valve se+ inner face limit angle y
Exhaust 300 300
l
1) Net marketed in all countries

PA33i500883300 OI -33 May 1988

 ,,,
,! ;,

ENGINE MAIN MECHANICAL UNil? I

FiTMEbTP&AYS OR INTERFERENCE FITS

Unit: mm (in)
~
Engine
inspection data
1 ; 1 7 0 0 1700
;, 1200-1350-1500
305.85 - 305.86 - 306.88 305.50 305.58
'1
305.87
0,03 f 0,05 (1)
Standard 0,03 + 0,05 0,040 + 0,060
0,04 + 0,06 (2)
Cylin@ borelpikn play
0.03 +0,06-(l) 0,040 + 0,066
Oversize 0,03 + 0,06 0.04 + 0,066 (2)

0,035 + 0,057 (1)

First compression ring ~ 0 , 0 3 5 +0,067 0,045 f 0,077
0,045 + 0,077 (2)

Ringlgroove end float Second compression ring 0,035 + 0,067

Oil sciaper ring 0,025 + 0,057

'i Maximum foieach ring Cl

Pinlsm~ll en! bush bore play l 0;007+0,019

Pinlpistpn bore play 0,004 + 0,012

Front and rear 0,024+0.06<

Main~ bearing to- Central 0,034+0,075
journ,al Iplay Maximum (with 61
bearing in Seat)

(1) Borgo Piston

(2) Mondisl~ Piston

May 1988 PA333500883300

 i>
,!,

ENGINE MAIN MECHAN~CAL ?N~T

HEAjING TliMPERATURES

As per (Alfa2 .

~
;,

GENERAL SPECIFICATIONS

FL,~IbS;~AND LUBRICANTS

Unit: I (Imp. Gal)

aty
Application Type Denomination
(litres)

Engir!e oil sump at max level AGIP SINT 2000 lOW40 3.5
Std. No. 3631 - 69352
Filter~ an? interyal piping 0.6
IP SINTIAX iOW40
OIL
Peri$lical change with filter replacement () Std. No. 3631 -69353 4 . 0

SHELL Super Plus

Motor Oil 15W50

(*) Fllter removal involves only the partial emptying of interna1 piping.
I

SEAkItiG C,OMPOUNDS 1,;

81 8, *
As:,f$r [Alfa331 together with .the following torques for; 1.7 engines

GRINDINGS

TI~HT~ENING TORQUES

A s f o r C-33) except as follows for 1.7 engines

c

Measurement unit
N.m Kg.m
Ne+

.&rews securing engine front cross member and anti-roll bar bracket
to bod; 66.5 i 63.3 6.6 i 6.5

Sctews! Isecuring anti-roll bar to strut 14.7 + 23.5 1.5 + 2.4

Scie~s connecting copiant velocity joints to differential shafts 33 + 36 3.4 f 3.7

C<alant temperature sender for fuel injection electronic control unit 15 1.5

PA333500883300 41-35 May 1 9 8 8

 ~ ~

E N G I N E M A I N MECHANICAL UNIT ~

8,
1 ~~ssE~~~c~ DATA AND SP EC IFIC A T I O N S
F o r d i e s e l engines only
~T+iNICA;L DATA
As for 33l.ETO exc&t for those features listed below:
ENGIN$

Features Dka

Engine t~ype VM82A

4 - Stroka Diesel
(Precombustion chamber OMET)

Number,of cylinders and arrangement 3 in line

Cylinded identification
Runningidirection

Bore - Stroke mm lin) ~ 892 x 89.2 (3.62 x 3.51)

Displace~ment cm3 (cu. i n ) 1779 (108.58)

Combustion chamber volume cm3 (CU. in) 23.2 to 24.3 (1.41 to 1.48)

Compression ratio 22,: 1

Maximum 5 5 (75) (73.97) (1)

Power C~EE ;(at 4000 r.p.m.) kW (CV) IkP)
Specific 30.55 (41.66)~ (41.08) (1)
1 ,,
Max. torque DIN (at 2400 r.p.m.) N.m (kg.m; ftlb) 1, 150 (15.3; ti10.63) (1)

Piston, mean speed (2) m/s (ft/s) ,; 11.893 (39.02)

1,
Cylinder compression (3)

Specified value 2156- ( 2 1 . 5 6 ) ( 3 0 6 . 6 5 )

kPa (kglcm; p.s.i.)
Max. difference in pressure between cylinders 9 8 (0.98) (13.94)

Engine oil pressure (4)

At idle r.p.m.
kPa (kglcm; p.s.i.)
At peak r.p.m. 400 (4; 56.89) (1 550 (5.5; 78.23) (* 1
1

il ) Tolerance up to: - 4%
(2) At ~maximum power output r.p.m.
13) Beadings to be taken with engine at operating temperature driven by starter motor (140 to 160 r.p.m.)
(4) Readings to be taken with engine at operating temperature (oil at 90C; 194F) l
(6) Min. allowable value
i(6) Ma;. allowable value

May 19i8 01-36 PA333500883300

 r
~ 1

ENGINE MAIN MECHANICAL UNIT

CRiXKS AND ADJUSTMENTS ~

,

TIMING DATA (1)

Camshadt Alfa Romeo Part No. 129.958

Intake 0.30 (0.012)

Normal;valve clearance a
8, ~ Exhaust 0.30 (0.012)
1 ~
Intake ~ 7.20 (0.283)
Normal cam lift
Exhaust 7.64 (0.301)
I I
(1) AIl values refer to cold engine

TI~II~~~: DIAGRAM (ANGULAR VALUES) (11

(crarjkshpjt clockwise rotation, viewed from front side)
T.D.C.

Opens (B.T.D.C.) a 220 k 5O

1
<le>< 1 ~ 460,? 50
I n t a k e Closes (A. 8. D. C.)
1:
<c#l 250
Intake phase angle

Opens (8.B.D.C.) d 60 f 5O
diagrani
Exhaust Closes (A.T.D.C.) b ~ 24+5

Exhaust phase angle f 264=

Clearance for checking mm (in) 1.2 (0.047)

88
Intake O p e n s (A.T.D.C.) 3O+2O

Closes (A.B.D.C.) 200 f 30

iDia,gram f o r
timlng check Clearance for checking m m (in) 1 . 6 5 (0.065)

Exhaust Opens (8.8.D.C.) 260 f 30

Closes (B.T.D.C.) 1oo+2

(1) ~AI1 values refer to cold engine

PA13335?0883300 m-37 ,,,, May 1948

 E N G I N E M A I N MECHAiUICAL UNIT~ ~ ~

r CYLINDER LINERS, COMPRESSION RINGS, GUDGEON PINS AN,D F!ISTONS

Cylinder liners

Unit: mm (in)
8 Engine
,m
Inspectiqn data 1800

VM 82A
,,
1, 1
92.000 to 92.010
Liner bore
i a Grade A
I (3.6220 to 3.6224)

Recess of cylinder liner outer rim from engins block (1) c 0.11 to 0.23 (0.0043 to-0.0091)

L i n e r stand;out b from engins b l o c k (1) 6.00 to 0.0,~ (0 t o 0 . 0 0 2 4 )

M a x lbv& oya)ity and taper fat wear limit) 0 . 0 1 0 (6.0004)

Liner inner surface roughness (new) /Jrn (in) ~ ,0.8 to 1,.2[~0.0315 to 0.0472)~10]~

;,
(1) For this measurement, fit liner retaining tool A.7.0411 and tighten screws to 59Nmf6 kg.m) (43.38 ft:lb)
,

Mezxuret)ent of gasket thickness +t+eeqliner and engine block ~ I

4 Unit: mm (in)

Engine
1

I'
!1800
~ Recess of cylinder liner outer rim from engine block c
I VM 82A

Gasket d thickness
i
0.11 to 0 . 1 4 1 0 . 0 0 4 3 to 0 . 0 0 5 5 ) ; 0.15; b.0059)

0 . 1 5 t o 0 . 2 0 ( 0 . 0 0 5 9 to 0 . 0 0 7 9 ) ~ 0 . 2 0 (0.0079)

0 . 2 1 t o 0 . 2 3 ( 0 . 0 0 8 3 t o 0.0091) 0 . 2 3 (0.0091)
.
1

01-38 PA333500883300
 !, r

ENGINE MAIN M&HANICAL IJNIT ~

,,
Compression rings

0 -. 7 --.
WL a
Unit: mm (in)

Engine

Inspection data 1 8 0 0

VM 82A

1 st compression ring 2.075 to 2.095 (0.0817 to 0.0825)

Ring thickness a 2nd compression ring 1.978 to 1 .s90 (0.0779 to 0.0783)

l ~ Oil scraper ring 3.978 to 3.990 (0.1566 to 0.1571)
81,
1 st compression ring 0.40 to O.b5 (0.0157 to 0.0256)

Ring gap (1 ) b 2nd compression ring 0.25 to 0.45 (0.0098 to 0.0177)

; Oil scraper ring 0.25 to 0.58 (0.0098 to 0.0226)

(1:) ~TO! be measured by ring gauge or in cylinder liner

,,

IGudgeon pins

Unit: mm (in)

Engine

Inspection data 1800

VM82A
.

igec ,,n pin biameter a 29.990 to 29.996 (1.1807 to 1 ,1809)

May ~1 9 8 8 PA3335008833Ob
 88,

i ENGINE MAIN MECHANICAL UNIj- ;

Pistons~ (with insert)

b
c
d

Unit: mm (in)

,Engine

Inspection data 1800

~
VM 82A
~
Pistbnidiameter:(l) (a Grade A m,91.965 to 91.9P5 (3.6206 to 3:623 1)

1st coypqession ring groove height b 21175 to 2.205 (0.0856 to 0.0868)

~
2nd cdmpression ring groove height c 2.060 to 2.080 (0.0811 to 0.0819)

Oil scr:aper ring groove height d 4.020 to 4.040 (0.1583 to 0.1591)

:, ,
Gudgeon pin bore dia. in piston 8 30,002 + 30,007
~ ~

,,
,,
Max pistqn skirt wear limit ~ 8, ~ 0.050 (0.002)

Mai gudgeon pin bore ovality (at wear limit) 0.050 (0.002)
,

(1) TO tic measured perpendicularly to gudgeon pin, at 19.75 mm (0.7775 in) from lower edge of piston skirt
(2) Cor t,his measurement use special cylinder liner retaining tool A.7.0411 and tighten the screws to 59 N.m (6kg.m)

,
Measur;ement of cylinder head, gasket thickness Unit: mm (in)

E n g i n e

~ I t ~
,i, 1800
Cylinder head gasket thickness Identification notches
VM 82A

Piston projection at, T.D.C. with respect to liner

outer rim f (1)

~ 1.420 10.0559) 0 0.480 to 0.570 (0.0189 to 0.0224)

1.520 (0.0598) 2 0.580 to 0.610 (0.0228 to 0.0264)

1.620 (0.0638) 1 0.880 to 0.770 (0.0268 to 0.0303)

May 19i8 PA333500883300

L
 8
,

:, Y

ENGINE MAIN M~ECHANICAL $lT~

CRAfiKkHAFT, CYLINDER BLOCK AND MAIN BEARINGS; CQl)lNECTING PODS, BIG END
BEAFING AND FLYWHEEL

ICrat)@shaft
I.,
d3 dl 62

Ovality X-Y

Taper D-E
Unit: mm (in)

Engine
Inspection data
1800

I
62,995 f 63,010

63,005 + 63,020

69,985 + 70,000

Standard 53,940 953,955

Crankpin diameter 6
1st 53.670 + 53,690
;. ~ Undersize
2nd 53,420 + 53.440

Fear main journal length C ~ 27,975 G-28.025

Front and intermediate
2.7 +3
main journals dl
Fi!lets 2.7 +3
Rear main journals dz
i 2.7 f 3
Cran kpins ch.
Main, journal and crankpin surface roughness /.0-n (in) 0,12

Max. main journal and crankpin ovality at wear Emit 0 , 0 1 0

~
Max. main journal and crankpin taper at wear limit 0.10

Jvlax. main journal eccentricity 0.03

F;inal dimension L 430.5

,
Note: Finitride crankshaft after grinding.

PCj33500883300 May 1988 i

I
i, ,, ,

l
ENGIR;E M A I N MECHANICAL UNIT ~

Cylinder: block hd main bearings

,

Unit: mm (in)

~
Inspection data

Front bearing housing bore dia. A in engine block ~ :67.025 to 67.050 (2.6388 to 2.6398)
8

S t a n d a r d 63.060 to 63,110 (2.4826 to 2.4846)

Front bearing inner dia. 8 in engine block
1st 62.810 to 62.860 (2.4728 to 2.4748)
Undersize
2 n d 62.560 to 62.610 (2.4630 to 2.4650)

Intermediate bearing housing bore dia. C in bearing split rings (1) 66.670 to 66.687 (2.6248 to 2.6255)

I Standard I 63.050 to 63.093 (2.4823 to 2.4840)

Intermediate bearing inner dia. D in baaring
62.BOO to 62.843 (2.4724 to 2.4741)
split rings (2)
, 62.:550 to 62.593 (2.4626 to 2.4643)

Rear bearing inner dia. E in bearing split ring 69.800 to 69.825 (2.7480 to 2.7490)
69.550 to 69.575 (2.7382 to 2.7392)

Rear bearin,g housing shoulder distance F I 33.060 to 33.130 (1.3016 to 1.3043)

Crankshaft ;abutment flange thickness G 1, 7.90 to 8.10(0.3110 to 0.3189)

Standard 2.311 to 2.362 (0.0909 to 0.0930)

Shimrings thickness l-l 1 St 21411 to 2.462 (0.0949 to 0.0969)
Oversize
2nd ~ 2.511 to 2.562 (0.0988 to 0.1008)

1
(1) For thie measurement, fit.linear retaining tool A.7.0411 and tighten screws to 59 Nn (6 kg.m; 43.38 ftlb)

(2) TO be measured with bearing split ring screws thightened to 39 to 44 N.m (4 to 4.5 kg.m;), ,, ~

: May 1988 OI-42 PA333500883300

88 ~
 1

E N G I N E MAlN~MECHANICAL~UhjIT

Connecting rods and big end bearings

Unit: mm (in)

Engine
8 Inspection data 1800

V M 8 2 A

Connecting rod small end bearing bore a 30.030 to 30.045 (1.1823 to 1.1829)

Connec$ing rod small end bearing outside diameter b 34.089 to 34.129 (1.3421 to 1.3437)

Bush housing inner dia. c in small end 34.000 to 34.025 (1.3386 to 1.3397)

Big end inner dia. d (1) 57.563 to 57.582 (2.2663 to 2.2670)

Connecting rod big end bearing bore (1) le

I Standard

1st
I
53.975 to 64.014 (2.1250 to 2.1265)

53.725 to 53.764 (2.1152 to 2.1167)

Undersize
2nd, 53.475 to 53.514 (2.1053 to 2.1068)

(18) ~TO be measured with connecting rod screws tightened to 79.4 to 84.3 N.m (8 to 8.6 kg.m; 57.84 to 62.18 ft.lb)

PA333500883300 01-43 May 1 9 8 8

 1,
1
,:
~
ENGINE MAIN~ b/iiCHANICAL U~NIT ~
1

FITl$NT PLAYS AND INTERFERENCE FITS

~ Unit: mm (in)
,,
l
Engine

Inspection data 1800

VM 82A

New 0.625 to 0.045 [(0.984 to 1.772).10]

Cylinder liner/piston clearance
l Wear limit 0.5 (19.68.1 03)

i 1 st compression ring 0.080 to 0.130 [(3.149 to 5.118):10-3]

1~
~
Ringlgroove. end float 2nd compression ring 0.070 to 0.102 [(2.756 to 4.016,.10-3]

Oil scraper ring 0.030 to 0.062 [(1.181 to 2A41j.10-3]

Pinlpiston bore clearance 6,006 + 0,017

New 0.034 to 0.055 [(1.338 to 2.16E~>:lO-~]

~
Pin/small-end bush bore clearance
, Wear limit 0.100 (3.937.10-3)
,~ 8:
Rear main journal 0,050 + 0,080
Main journal/bearing running
c l e a r a n c e (,new) Front main journal 0,050 + 0,115
~
Intermediate main journal 0,030 + 0,088
l

Big-yd baaringlcrankpin running clearance (newj g,O22 +,0,076

Main journal andcrankpin/bearing running clearance (at wear limi,t) 0.200 (7.874.10)

Crankjhaft end float 0.1,21 to 0.323i[(4.764 to 12.716j~lO]

81,
Big-end end float 0120 to 0.40 p(7.874 to lE~748,~10-~]
~

,New 0.640 toO.l10 [il.575 to 4.331,.10-31

Camshaft j,ournal/bearing
running clearance
Wear limit 0.200 f7.874.103)

New 0.020 to 0.062 [(0.787 to 2.441,.10-3]

Rocker bush/shaft
runnin~g clearance
,, ~ Wear limit 0.200 (7.874.10-3j

,
New 0.025 to 0.070 [CO.984 to 2.756j.10-3]
Tappet/housing
running clearance
,m, Wear limit O.ldO (3.937.10-3)
I
I ntake 0.640 to 0.075 [(1.575 to 2.953 .10-31
Valve stem/guide running clearance
E x h a u s t 0.060 to 0.095 [(2.362 to 3.740).10-3]

Intake 0.085 to 0.124 [(3.346 to 4.882L103]

Valve seat/housing interference fit
Exhaust 0.062 to 0.102 [(2.441 to 4.016).10-3]

Valve guidelhousing interference fit 0.020 to 0.047 [(0.787 to 1 .850~>.10-3]

Rotoristand-outs in oil pump 0.930 to 0.073 [(1.181 to 2.874).10-3]

Oil pump innerlouter rotor max, clearance 0:OiO to 0.20 [(2.756 to 7.874)*10-3]
I

New 0.130t00.185[(5.118t07.283)~10-3]
Outer rotorlhousing
clearance in oil pump
Wear limit O.S? (19.68.10-3)

Gear end!float in pump body 6.05 to 0.07i[(1.968 to 2.756).10-3]

May 19!8 61144 ~; ~ PA333500883300

,
A 8
~ ~
,
 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 04-2
( General description . . . . . . . . . . . . . . . . . 04-2
. Injection system Jetronic LE 3.2 . . . . . . 04-2
Ignition system . . . . . . . . . . . . . . . . . . . . 04-2
. Air, fuel, fuel vapour system chart . . . . . 04-3
i Wiring diagram for injection system . . . . 04-4
. Main components . . . . . . . . . . . . . . . . . . 04-5
important general data . . . . . . . . . . . . . . 04-B
AIR SUPPLY SYSTEM . . . . . . . . . . . . . . . . . . . 04-9
. Airfilter . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-10
Air flow sensor . . . . . . . . . . . . . . . . . . . . . 04-10
Extra air solenoid,valve . . . . . . . . . . . . . . 04-g 1
. Throttle body . . . . . . . . . . . . . . . . . . . . . . 04-11
. Su,pply manifold . . . . . . . . . . . . . . . . . . . . 04-12
FU~EL SUPPLY SYSTEM . . . . . . . . . . . . . . . . . 04-14
F u e l t a n k . . . . . . . . . . . . . . . . . . . . . . . . . . (*)
~ Fu:el p,ipes . . . . . . . . . . . . . . . . . . . . . . . . . (*)
. Fuel pump . . . . . . . . . . . . i . . . . . . . . . . . 04-15
. Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . (0)
. Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . 04-15
. Electroinjectors . . . . . . . . . . . . . . . . . . . . 04-15
Fuel pressure gauge . . . . . . . . . . . . . . . . .04-16
FU~EL VAPOUR EMISSION
C~NTROL,SYSTEM . . . . . . . . . . . . . . . . . . . . . 04.i7
. Fuel vapour separator . . . . . . ., . . . . . . . . 04-18
Compensation valve . . . . :. . . . . . . . . . . 04-18
. Dump,valve . . . . . . . . . . . . . . . . . . . . . . . . 04-18
) Fuel vapour filter . . . . . . . . . . . . . . . . . . . 04-18
CALlB,RATiON AND ADJUSTMENTS . . . . . . 0 4 - 1 9
Throttle body calibration (flow) . . . . . . . 04-19
~
(y) ~R~efer to WORKSHOP MANUAL VOLUMES I and II - Group 04
(A) ~Refer to Group 00
(ta) Refer to Group 07
(A) For electronic injection 1.7 engines with catalytic converter only
P(i 31! 7+0088330 1
lAccelerator throttle switch calibration . 04-20
Fuel pressure checking and fuel
tightness . . . . . . . . . . . . . . . . . . . . . . . . , . . . .(a)
Adjustment for accelerator control table (a) ,
Idle rpm adjustment . . . . . . . . . . . . . . . . (0) c
CO percentage adjustment at exhaust . 04-20
ELECTRICAUELECTRONIC
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . 04-21
:Fuel level gauge . . , . . . . . . . . . . . . . . . . . (*)
Electronic CU . . . . . . . . . . . . . . . . . . . . . . 04-21
Accelerator thro,ttle switch . . . . . . . . . . . 04-21
Collant temperature sensor . . . . . . . . . . (i*)
EXHAUST SYSTEM . . . , . . . . . . . . . . . . . . . . . 04-23
,Precautions for Catalytic mufflervehicles 04-23
Checks mand inspections . . . . . . . . . . . . . 04-23
Removal #. . . . . I .,. , . . . . . . . . . . . . . . . . . 04-23
~lnstall,ation . . . . . . . . . . . . . . . . . . . . . . . . 04-24
IReplacement of catalytic muffler . . . . , (0)
Lambda probe replacement . . . . . . . . . . (0)
Troubleshooting for catalytic muffler . . 04-25
SERVICE DATA AND SPECIFICATIONS . . , . 04-26
Technical data .. . . . . . . . . . . . . . . . , . . . 04-26
Check,s and adjustment . :. . . . . . . . . . . 04-26
General specifidations . . . . . . . . . . . . . . 04-27
SERVICE DATA ANDI SPECIFICATIONS . . . . 04-28
Technical data 1.. . . . . . . . . . . . . . . . . . . 04-28
General specifidations . . . . . . . . . . . . . . 04-28
Checks and adjustments . . . . . . . . . . . . (*)
Tightentng torqwes . . . . . . . . . . . . . . . . . . (*)
SPECIAL SERVICE TOOLS . . . . . . . . . . . . . . . 04-30
October 1988

GENERAL DESCRIPTION
The JETRCNIC LE 3.2 electronic sy-
stem consists an inductive discharge
transistorized injection system equip-
bed with a control unit (CU).
The ignition, how,ever is ensured by an
electronic ignition system equipped
with an electronic power module.
The data necessary for controlling the
system is colfecfed by means of sen-
sors that transform the data into elec-
trical signais.This data concerns:
l battery voltage
. position of the accelerator throt-
tle (comoletely closed or open)
JETRONI~C ~LE 3.2 INJECTION SYSTEM
, ,
The system, vvhich consists of an air
system ancl of a~fuel system includes
t h e followirig:!
. A~filter-equiboed fuel pump
. a pulsation damper whose task is
to eliminate pulsations due to
pressure peaks
. a8 pressure, gaug,e which keeps
constant pressure difference bet-
ween f,uel system and intake ma-
nifold
~
!hNITIqN SYSTEM
This system consists of:
i an el,ectronic power module
t a high V~oltage shock generating
coil 1~
8,
H
D E S C R I P T I O N ~ .~
For electronic injection 1.7 engines
. air intake temperature
. engine coolant temperature
. quantity of air taken in by the en-
gine
. quantity of oxygen present in the
exhaust gases
. engine r.p.m. (fromsthe distribu-
t o r )
The electronic CU calculates the ope-
ning time of the electroinjectors with
relation to the instantaneous r.p.m.
and load condition of the engine.
Having carried out the calculation, the
CU sees to the opening of the elec-
l f o u r e l e c t r o i n j e c t o r s mwhi,ch, l
owing to pressure gauge, supply ~
a f u e l q u a n t i t y dependent o n ~
their opening time
! an air flow sensor, which measu-
res ait taken in by engine (adju-
sted in relation to air temperatu-
re)
. supplementary air solenoid valve
suppliyng extra air ,when the en-
gine is cold
. a h i g h v o l t a g e d i s t r i b u t o r s u p - , . electrical iwiring at low and h/gh
plying power to spark plugs
. four ignition spark plugs
04=2
~
troinjectors for this time. Since the dif-
ference between fuel pressure and air
pressure in the manifold is mantained
constant by a regolator, the quantity
of fuel injected, is proportional to the
delivery time.
Furthemore the injection CU is able to
carry out from~ time to time certain
operations considered necessary un-
der certain engine conditions (e.g.
electroinjector for cold stafl, interrup-
tion of fuel delivery when engine is de-
celerating).
The injection CU also controls the deli- -_
very of the fuel1 pump. ,;
,
a switch on accelerator, throttle re-
i cognizing the two cases of open or
~closed throttle
. an engine Coolant temperature sen-
sor for injection CU
. an rpm sensor
. pipes andl electrical wiring, inclu-
ding remote control switches and
CU (inserted in air flow sensor) . .
. a lambda, probe determining oxy-
gen differences, in exhaust gas,
with respe,ct to thesair (only for mo-
dels with catalytic converter):
voltage ~
PA 32 790088330 1
,, ,
l
 FUEL SYSTEM

,, 1
AIR, FUEL, FUEL VAPOUR SYSTENl CHART

1
--

PA32~9qO883301
October 1988
 ,:t

8~! INJECTION SYSTEM WIRING DIAGRAM

~

I
------.-
-..C ~-__--
-s&?y$
Q

qctober 1988: PA327900883301

i
i
~,; ,,
l ,
 ~
MA/N, COiMPQNENTS
FUEL PUMP
The pump is of the rotating type with
cells Sand rollers, driven by an electric
moto; which remains immersed in the
fuel under pressure downstream the
pumping ,unit. This arrangement re-
sults~in ~a reduction in noise and fur-
thermore the fuel under pressure acts
as ~a~ hydraulic support between the
spindle Iand relative supporting bu-
shesl The pump delivers more fuel
than the engine effectively requires, in
orde? to maintain effective pressure in
the supply system under all possible
operating conditions, If the key is in-
serted in the ignition and turner to the
MAPCIA (running) position, the
pump is not supplied with power;
when the key is turned on the AVVIA-
MENTO (starting) position, the cqn-
trol unitmeasures the r.p.m. from igni-
tio,n ,distributor and, when this ex-
ceed~s a ,determined value sail control
unit seessto supplying the fuel pump.
Whit this electrical safety circuit, in
the case of a faulty electroinjector
,wifh~ ingition inserted, one prevents
the corrisponding circuit from being
filied with fuel.
!,
1 Fu:el p,ump
DAM~ER
Thei damper is connected upstream
the fuei distribution tube. The function
of the damper is to eupress hamme-
rings that cari occur especially when
the :engine is running on low r.p.m..
The~ hammering is generated by jumps
in fuel! pressure that arise from the
opening and closing of the electroin-
jectors or the pressure regulator.
P A d2 790088330 1
FUEL PRESSURE REGULATOF)
The fuel under pressure enters the lo-
wer chamber of the regulator and acts
on a membraneiwhich, overcomin~g the
action of a spring, rises togheter with
a small plate and openslthe passage
to tank return t,ube. In addition to the
regulating function of the spring,
which has a fixed setting, there is also
that of the vacuum pressure of the
supply manifold transmitted to there-
gulator Upper chamber via a hose con-
nected to the manifold.
When this pressure from the supply
manifold increases the membrane ri-
ses, opening the fuel return passage
and determining an equal decrease in
the fuel pressure itself. Thepurpose of
this additional adjustment isto main-
tain the jumps in pressurebetween
the fuel upstream the electroinjectors
and the air in,the manifold constant. In
this way the fuel delivered dependsex-
clusively on the opening time of the
electroinjector itself. .
1 Hammering
2 Pressure regulator
3 Vacuum, tube
ELECTROINJECTORS
There is one electromagnetically ac-
tuated injecter for each cylinder; the
electroinjectors are connectedelectri-
cally in parallel a n d /nject simulta-
neous!y once for each rotation bof the
crankshaft half of the necessary quan-
tity of fuel.
04-5
i
i ,,
An ete,ctroinjector consists essentiaffy
of a
coil, a moving tore, a guide for the
needle and the needle. The tore of the
moving magnet is in one piece with
the needle which is pressed against
the sealed seating of the body of the
electroinjector by a spring. the needle
of the electroinjector is opened as a
resultiof magnetic field created by the
magnet and this is effected when the
electronic CU sends an appropriate
electric signal.
The stroke of the moving tore, and
theretore of the needle, is very limited
(0.15 mm approx.) as a consequence
of a stop disc which has the purpose
of preventing the moving tore from
banging against the fixed interna1
part.
The opening tirne of the needle is 2-10
ms according to the signal arriving
from the CU. The tip of the electroin-
jector is fitted with a thermal insula-
ting bushing in teflon, the purpose of
which is to prevent the evaporation of
the fuel and the consequent crystali-
sation of the dry deposit on the nee-
dle. This bushing #,must not therefore
beremoved when fitting the electroin-
jector.
SUePLEMENTAtiY ,AIR
SOLENO,ID VALVE
The iupplementary air solenoid valve
determines, with the engine cold, the
passage of supplementary air to the
engine by means of the accelerator
throtfle by-pass.
A bi-metallic lamina inside thevalve is
affected by the temperature of the cy
lindei head in such away as to obtain
maximum closing of theby-pass when
the engine is hot. In addition to this, a
heater winding heats the lamina and
closes the by-pass more quickly than
would occur with the heating of the
whole engine mass.
October 1988

,The purpose! of the device is to give
smootherengine running when the en-
,gine is qold,, compensating for the
greater resistances, due to friction,
4th an increased fuel supply.
J Supplementary air solenoid valve
A I R FLOW~
$ENSORJ~~NTR~L UNIT
1 temperature.
The air flow sensor has the task of fur-
nishing the e(ectronicCU with an elec-
trie signa!, ;by means of a potentiome-
ter, with relation: to the air flow taken
jn by the engme!This signal is used by
tbe CU to ;determine, the duration of
the injection itime.
The sensitive element is a floating
throttle which opens according to the
amount of air taken in (a function of
the engin+ r.~p.m. and the opening of
,the accelerator throttle). The angular
~Position of~the floating throttle is mea-
sured by a ~poientiometer which is
~~firmly fixed to the spindle of the floa-
,ting throttle Itself.
A compensating throttle coupled to
the floating throttle compensates for
any oscillations in the pressure of the
,flow due to badkflow that may occur,
~eothat thesd do not affect the measu-
,rtng of the air fl;ow.
#A sensor for measuring the temperatu-
ire of the a,ir tak~en in is located at the
,~entrance of lthe, air flow sensor. The
$lectr,onic CU for the control and mo-
initoring off the whole injection system
~$s located in~ the Upper part (caver) of
/the air flow sensor.
_
,
October 1 ,,
9 8 8
i
FUEL SYStEM 8
1 Air flow sensor
C O O L A N T
T E M P E R A T U R E SENSOR ~~ ~~
~, IQLE ADJl/STMENT B Y - P A S S
When starting the engine from cold,
during the warming up of the engine, ~ A tube connecting the corrugated air
the engine requires a considerably en-
riched mixture. This enrichement must
be reduced as themtemperature of the
engine increases and eliminated when
the engine reaches normal running i ,, by means ofI an adjusting screw. By
These variations in temperature :are
transmitted to electronic CU by the, ~
coolant temperature sensor and the: ~ , In;fact, the variation in the amount of
CU then control the quantity of fuel in-
jected.
1 Engine coolant temperature sensor
SWITCH ON BODY
OF ACCELERATOR THROT-
TLE
The switch on the throttle body is firm- ,.
ly fixed to the spindle of the accelera- ~
tor throttle valve. The switch contains
04-6
a full load contact. In this way a signal
is sent to the electronic CU when the
engine is running under conditions of
full load and the CU is able to alter the
air-petrol ratio according to the requi-
rements of th,ese engine conditions.
When the aceelerator is released the
fuel supply is tut off by means of the
minimum throttle opening switch.
When the accelerator throttle valve
closes and the engine r.p.m. (s higher
than 1600 r.p.m., the fuelsupply is tut
off until the engine r.p.m. cornes down
to: 1100 rpm approx., where the fuel
supply is restored. The main purpose
of fuel tut-off when the accelerator is
released is to reduce both fuel con-
sumption and the emission of unburnt
hydrocarbons which usually form du-
ring this phase.
intake sleeve#with the supply manifold
acts as a by;pass to the accelerator
throttle; the amount of air that cari
pass through, this tube cari be varied
acting on this adjusting screw thejdle
r.4.m. of the. engine cari be altered wi-
thout affectrng.the exhaust CC%.
air taken in by the engine whsn this
screw is adjusted is measured by the
air flow sensor which in turn provides
for the proportional correction of the
quantity of fuel that is injecfed.
1 lLo6k n u t
2 r~ldle r.p.m: adjusting screw
PA32 790088330 1
 The iollowing components are fore
seen ~on~ly on models with catalytic
converter.
FiLtiEl+INLET F O R reducing exhaust emissions. The con-
U,F$EADED PETROL
Th filIer inlet of the fuel tank is fitted
with ~a special device which prevents
filling with petrols other than those
whlich are unleaded.
Only lthe~ delivery nozzles of unleaded
petrol pumps are able to pass through
the ne& of the filler inlet, thus ope-
ning ~the valve and filling the tank.
LA~B~A P;ROBE
The sensitive element of the lambda
probe consists of a ceramic capsule
coated wlth porous platinum on both
sides; the external side cornes into
contact,with the exhaust gases, whilst
the /nternal side cornes into contact
withatmospheric air.
The ~difference in the oxygen content
between the air of the atmosphere and
the r$xhaust gases is transformed into
a n 8ele,ctrical potential difference
aqross ~the two sides of the capsule.
Thisi electrical signal is sent to the,
electronic CUwhich carries out those
correct)ons necessar = y for obtaining
the stechiometric air-petrol ratio re-
quired for the maximum operating effi-
cenqy of the catalyst, thus keeping
harrhful emissions contained in the
exhaust gases to a minimum.
The probe is electrically preheated to
obtain a,faster response time.
1 Lambda Probe
PA~2~9E0883301
CATALYTIC MUFFLER
A catalytic converter is mounted in the
exhaust system with the purpose of
verter consists of an alumina,monol/th
coated with anactive material compo-
sed of noble metals and housed in a
special steel container which is resi-
stant to high temperatures. The sy-
stem convertsthe HC and CO semis-
sions contained in the exhaust gases
into waterand CO, (non-toxic substan-
ces).
The catalyst is efficient within a cer-
tain temperature range. At low tempe-
ratures no catalytic conversion oc-
curs. High temperatures cari cause de-
formation of the metallic container
and deterioration of the aluminaand a
consequent loss in the efficency ,of
the operation ~of the catalyst ~itself.
High temperatures cari be caused by
an excessive quantity of unburnt fuel
passing through the alumina, follo-
wing overloading of the engine or by
the engine being badly tuned and out
of adjustment.
* The vacuum pressure is taken up-
1 Catalytic muffler
, :
FUEL ~APOUR~EMISSION
CONTROL SYSTEM
Fuel va ours emanating from the fuels
tank d 4 are collected, by means of a
special tube 0 in a liquid vapour se-
1
parator@ which-is arranged in such
a way as to permit the return of con-
densed fuel to the tank.
The tank has a sealed filler cap to pre-
vent fuel vapours from escaping into
the atmosphere.
The fuel vapours coming from the se-
parator 0 through the Upper outlet,
are conveyed to a fuel vapour filter 6B.
The vapour flow is controlled by a val-
ve q which opens or closes the pas-
sageto the fuel filter in relation to the
vacuum pressure existng upstream
the throttle body. When the vacuum
pressure is lower than the specified
value (e.g. with the engine switched
off or on idle) the dump valve is closed
and prevents vapours from flowing to
the vapour filter. If this is not the case
(engine running under normal condi-
tions) the valve is open and the fuel va-
pours are able to flow to the filter whe-
re they are absorbed by activated car-
bon.
As a result of the difference in pressu-
re existing inside the vapour filter, the
activated carbon is washed by a
current of air.
stream ;the throttle. In the washing
action, the fuel vapours mlxed with at-
mospheric air are conveyedto the sup-
ply manifold where they are added to
the air taken in by the engine.
Should the pressure in the fuel vapour
separator tend to a drop when the en-
gine is stopped, due to a fall in tempe-
rature, a compensation valve @ si-
tuated in the fuel vapour recovery tu-
bing @ between the separator 0
and~the vapour filter @ , lets in at-
mospheric air thus maintaining the sy-
stem at atmospheric pressure.
Thel dump valve @ as an interna1
spring which is set in such a way as to
open the passage should the vapour
pressure in the tank be excessive. In
this, case the fuel vapours cari be di-
scharged into the vapour filter @
and: held in the activated carbonof the
fiiter i t s e l f .
October 1988
 l
l

1 Fuel vapour intake tube ~6 Compensation valve

2 Vacuum pressure tube for dump valve 7 Fuel :iapour separator
,; control 8 Fuel vapour recovery tube
1 3 External air delivery tube 9, Dum&+e ,
il 4 Fuel tank 10 Fuel !vapour filter ~
5 Fuel vapour breather; hose
~

IMPORTjihjT GENERAL DATA

Never istart the engine when the
battery latiles are not properly
connected.
TO star-t the engine, never use a
rapid baftery charger.
Never discdn,nect battery from ve-
hicle electrbnic system when the
engine is started.
In no case use a rapid battery
3 charger.:
When painting in furnace at tem-
perature over 80 OC, remove the
electronic control unit.
Make sure that screened wire
connections are properly connec-
ted.
Never connect or disconnect elec-
tronic CU conductor plug when
ignition is switched on.
Never connect to ground high or
low voltage tables, for testing.
. Should any accessories be moun-
ted on vehicle, it is always advisa-
ble to disconnect electonic CU
and to check the functioning ac-
cessories with the CU disconnec-
~ ted. It isi very strongly advised ne-
ver to connect any leads (other
than those of the CU itself),to the
wiring of the CU.

~
Octoper 91 04-8 PA3279E0883301
1,
,, ,
 71

FUEL SYSTEM

1 Air filter
2 Air flow sensor
3 Corrugated sleeve
4 Throttle body
5 Air inletloutlet hose from supplementary
solenoid valve
6 Metal fitting
7 Oil vapour exhaust hose
8 Vacuum pressure intake tube
9 Fuel vapour circulation pipe
10 Fuel vapour fllter
11 Air manifold
12 Extra air solenoid valve
13 By-pass tube to set idle rpm
14 Air intake sleeve

() only for vehicles with catalytic converter

 ,

FUEL SYSTEM
,,

AIR FILTER AIR FLOW SENSOR

The body of fhe air flow sensor incor-

porates the blectronic control unit for
the pilotiqg of the fue! injection sy-
Stern.

REM,OVAL

1. Disconnect the multipolar connec-

tor @ from the body of the sensor
0.
2. Loosen the clips securing the ducts
@- 0 and 0 and detach them from
the air flow sensor.
3. Unscrew the three screws shown in
the fi ure and remove the air flow sen-
s o8 r 2 .
4. Only if necessary, unscrew tbe four
screws (one of which lies beneath a
sealed plug) and remove the caver of
the air flow sensor. The electronic
control unit is coniained in the caver.

1 Air filter caver 6 Air filter container

2 C l a m p 7 Spring element
3 CU flow meter 6 Spacer
4 Corrugated sleeve 9 Air intake sleeve
5 Adjustment kcrew to fix air filter container 10 Filtering element
to body ~

1 Air inlet duct

REMOVAL:
,Disassemble air cleaner body as fol-
lows (see figure):
1. Unfast the clamp @ and discon-
nect air cleaner caver sleeve from air
flow sensor 0.
21 Unfasten the four spring clips secu-
ring caver 0 and remove it; remove
the filtering element @ .
3. Unscrew three screws 0 securing
CHECK AND INSPECTIONS
Thoroughly clean filtering element by
blowing low pressure compressed air
through the filter in the opposite direc-
tion to that of the normal air flow. If
necessary, replace filtering element.
ASSEMBLY
Assemble air flow sensor/CU follo-
wing disassembly procedure in rever-
2 Air flow sensor
3 Corrugated air intake duct
4 Multipolar connecter
CHECKS AND ADJUSTMENTS
Press gently on the floating throttle of
the air flow sensor and check that it
rotates freely and smoothly as far as
the travel stop. If necessary, clean the
interna1 surfaces of the air flow sensor
with a cloth. ~
REFITTING
l

cartridge @ to body; remove filter Refit the air flow sensorlelectronic

container @ with spring element
0
0 and spabers 3 disconnecting
sieeve @ from air intake.
4. In necessary, loosen clamp and di-
sconnect sleeveGI from container
63. :,
se sequence.
. Position the filtering element in
the container SO that the folded
protrudding part is facing down-
wards.,
control unit by reversing the order of
its removal. i
If it is being replaced, proceed to the
checking and adjustment (if necessa-
ry) of the exhaust CO% (see Setting
and Adjustments).

October 1988 ~ 04-l 0 PA3279E0883301


SUPPLEMENTARY AIR
SOLENOID VALVE
CH~ECK AND ISPECTIONS
1; Check solenoid valve opening
a. Make sure that the engine is cold,
then start and throttle several times
outlet tube 0 of solenoid valve @
b: Check that engine rpm falls and con-
tinues ito fait with the passage of time
(at rooin temperature of 20C no fall in
r.,p.m. Will be noticed after 3 minutes).
2. Check solenoid valve closing
V$fh the engine at normal running tem-
perature, throttle outlet tube 0 of so-
lenoid,valve and make sure that engine
rpm does not decrease.
i@
1 Air outlet tube
2 Supplementary air solenoid valve
3 Air inlet tube
REPLACEMENT
1. ~Disconnect battery negative termi-
n a l .
2,~Remove air filter caver, air flow sen-
~r~~~o~~~~$~l~~@ and @
from starter 3 .
PA3279E0883301
r
FUEL SYSTEM
4. Remove plastic caver @ .
6Unscrew the two ftgure-shown;bolts
fixing starter 0 and remove it.
One of the bolts fixes ground supports
and battery negative terminal
81 .
1 Air outlet tube
2 Solenoid valve control table
3 Supplementary air solenoid valve
4 Air inlet tube
THROTTLE BODY
REMOVAL
1. Rotate accelerator control lever @
and withdraw pawl on end of accelera-
tor table.
2. Remove lock ring and withdraw
sheath end from bracket @
3. Loosen clamp and disconnect tubes
@ from throttle body @ .
4. IDisconnect c o n n e c t a r 0 f r o m
switch.
5. Loosen fixing clamp and disconnect
sleeve @ from throttle body.
I-Baftei~ negativ cible
2 Ground support
3 Starter
4 Starter energization table
6 Starter supply table
6 Cover
6. Disconnect connecter 0.
7. Loosen clam s and disconnect tu-
bes @ and 4dfrom solenoid valve. 1 Sreather tubes of engine COOting system
2 Acceterator throttle switch connecter
6. Unscrew fixin screws and remove
3 Corrugated sleeve
solenoid valveQ 3. 4 Accelerator control lever
9. Proceed to assembly operating in 5 Bracket
reverse order in respect to removal. 6 Throttle body
04-I 1 October 1988

6. Disconnect depression tube 0.
7. Unscrew four fixing screws and re-
move throttte body @ and gasket
f r o m supply~,manifold @ .
The two upper screws fix braket @
aswell.
~ImNTAK~ ~MANFOLD,
(AIR INTAKE BOX).
1 Intake manifold
2 By-pass tube to set idle rpm
3 Supplementary air feed tube
4 Servobrake depression tube fitting
5 Gaskets
6 Throttle body switch wiring
7 Cooling,system breather pipes
6 Sheath fixjng bracket of acceleratorcable
REMOVAL
1 /
With reference to figure, operate as
follows: ~ sensor.
Qctober 1 9 8 8
FUEL SYSTEM
REMOVAL
Proceed to assembly operating in re-
verse order in respect to removal, fol-
lowing these instructions:
. Fit a new gasket between throttle
body and intake manifold.
. Effect calibration and setting
(see: Calibrations and Settings).
1 Cracket fixing accelerator table sheath
2 Throttle body
3 Depression tube
4 Supply manifold
9 Throttle body fixing screw to 15 Throttle body
manifold 1 6 G a s k e t
10 Corrugated sleeve 17 Depression tube for fuel vapour cleaner
11 Accelerator control table (for models with catalytic converter only)
12 Lock ring 18 Depression tube for fuel pressure
13 Accelerator table sheath 19 Engine lifting bracket
14 Depression tube for ignition advance 20 Nut fixing supply manifold
pneumatic regulator
1. Remove air filter caver and air flow 2. Rotate accelerator control lever and
unhook pawl at accelerator table end
0.
04-l 2 PA3279E0883301

3. Remove lock ring 0 and discon-
nectsheath @ from bracket a
4. Disconnect wiring @.
5. Dfsconnect tube @ from throttle
body.
6. Ldosen clam s and disconnect tu-
bes @ and 63 from manifold 0.
7. Disconnect tubes 63 C$d @
from manifold and tube @ from
throttleibody; (only for models with ca-
talytic converter).
6. Unscrew fixing c9 and separate
servobracket depression tube from
manifold.
9. Loosen clamp and disconnect slee-
ve @ from throttle body 0.
PAd279E0883301
FUEL SYSTEM
10. Unscrew three nuts @ on each
manifold end and remove manifold
with gasket 0.
Central nuts also secure the engine lif-
ting brackets @ .
11. If necessary, remove four screws
@ and separate throttle body @
with gasket @ from manifold.
Two u per screws also secure brac-
kets 6 8 .
04-13
II
ASSEMBLY
Proceed to assembly operating in re-
verse order in respect to removal, fol-
lowing these,instructions:
. Fit new gasket between:
,- Throttle body and manifold
- M a n i f o l d a n d ducts o n
heads.
. ~Effect check and, if necessary,
adjust accelerator control table
(see: Group 00)
. Effect check and, if necessary,
adjust idle rpm (see: Group 00).
October 1988
 A () only for models with catalytic converter

6 Ground table 11 Filler pipe

s!0 12 E
Pressure
l e c t r o i ngauge
jectors 7 Fuel tank fixing st!ap 12
13
Fuel pump
Excess fuel recovery pipe
3 Fuel filter 8 Fuel level gauge assy
4 Fuel supply tube 9 Level gauge fixing screw 14 Pulsation damper
5 Tube support spring 10 Tank 15 Fuel supply hose

. . ,
 - FUEL SYSTEM

FUEL PilMP DAMPER 2. Disconnect electroinjectors connec-

tors one,by one; each time detect CO
percentage at exhaust and check that
REPLACEMENT value remains constant at all checks.

REPLACEMENT 1. Loosen clamps and disconnect fuel 3. If this is not the case, locate the
inlet and outlet tube 0 and @ faulty electroinjectr and replace it.
from damper. (seei Replacement).
1; put the vehicle on auto lift and di-
sconnect battery negative terminai. 4. In all cases, a visual index of elec-
troinjectors functionality is provided
2: Operating from below the vehicle, WARNING: by comparing spark plug electrodes.
left rear side, disconnect tables 0 Be careful: fuel system could be
supplying the ,a. pressurized - A too-rich mixture shows black
puma
colour.
3. linch tubes @ and @ , then loo- - ~A too-poor mixture shows light
sen champs and disconnect tubes 2. Unscrew figure-shown fixing nut colour.
from the pump. a8 remove damper @ from bracket
3
CD and extract the

REPLACEMENT

1. Disconnect battery negative termi-

nal.

2. Disconnect supply wiring connec-

tors 0 from electroinjectors.

3:Unscrew figure-shown fixing screw

and lift the fuel suppl,y hose 0
freeing it from electroinjectors.

1 Damper
2 Fuel inlet tube into damper3 Support
WARNING:
bracket ~
4 Fuel outlettube from damper Pay attention SO that residual pres-
1, Fuei outlet tube from pump ,
2~ Fuel pump
sure in the .tubing does not cause :
3 Fuel inlet tube into pump sprays of fuel.
4 Pump supporting clamp
5 Pump supply table 3. Refit a new damper working in rever-
se order respect to removal.

ELECTROINJECTORS
5. Mount new fuel pump fixing it with rele-
vant clamp, then reconnect b%es.
CHECKS AND INSPECTIONS
6. Reconnect pump supply tables, being ca-
reful to connect the correct lead to the cor:
rect terminal.
Check on correct electroinjectors ope-
ning
7. On completion of refitting, remove pliers
on imlet and outlet tubes and reconnect bat- 1. Detect CO percentage at exhaust
tery. (see: Group 00 - Engine Maintenance).

P32:79EO883301 04-l 5 October 1988 ~


1 Fuel supply ihose
2 Electroinjectors supply wiring
4. Remove e,lectroinjectors 0 com-
:plete with b-ring @ ancl gasket @
-. .-
1 Fuel supply, hose
2 Electroinjectors
3 G a s k e t
4 0-rings ~
5. Proceed to asseq7ply operating in
reverse ordb in respect to removal,
following ;these instructions:
,- Replace all O-rings and gaskets.
- Positioh electroinjector and rele-
vant cdnnector outward.
- Reco,nRect all components remo-
vedat iemoval time.
October 7988
4. Effect assembly operating in rever-
FUEL PRESSURE se order in respect to removal.
G A U G E
REPLACEMENT
WARNING:
Operate carefully: fuel system
coud be pressurized.
1. Unscrew the two connecting fittings
oEue supply hose @ to regulator
2. Disconnect tube 0 from regula-
tor.
3. Connect tube @, unscrew f lg$:
shown nut, and remove regulator
1 Pressure regulator
2 Depression tube for pressure regulator
3 Fuel supply hose
4 Excess fuel recovery tube
04.16 PA3279EO883301
 r,
FUEL SYSTEM

FUEL VAPOUR EMISSION CHECK SVSTEM

For electronic injection 1.7 ,engineq, with cataly;tic convertor

PA333500883300 May 1 9 8 8
 FUEL SYSTEM

FUEL, VAPOUR 2. Disconnect valve @ from fuel

recovery tube circuit.
SEPARATOR

REMOVAL AND ASSEMBLY

1. Move, away left side covering of

trunk. :

2. Loosn Aamps and disconnect

tubes 0~ and @ from separator.
~
i
3. Unscrew t h e t w o s e c u r i n g n u t s
indicated in the fig,ure and remove the
s e p a r a t o r ~@

1 Retainer valve

3. Ceck that valve works properly that

is, that otherwise, replace valve it allows
the passage of air only in the direction
shown by the arrow. Fuel vapour recovery tube
Dump valve
Depression tube
Supply tube to fuel vapour filter

1
1 Fuel vapour recoverv tube Proceed to assembly operating in
2 Fuel vapour separator
reverse order in respect to removal,
3 Fuel vapour exhaust pipe
properly repositioning the valve as
shown in previous figure.

4. If nec!essary, blow compressed air

inside the separator to clean it.
4 . P r o c e e d to assembly in revers&
order in respect to removal, properly
5. For essembly, operate in reverse
repositioning the valve as stated in the
order in respect to removal.
figure in step @

FUEL VAPOUR FILTER

DUMP VALVE
COMBPENSATION VALVE
REMOVAL AND ASSEMBLY

REMOVAL AND ASSEMBLY

1. Discohnect tubes 0, 0, a n d
REMOV:AL, CHECK AND
@ from filter.
INSPECTIONS, ASSEMBLY
i 1. Operating in the engine compart-
ment, front left areabelow fuel vapour 2. Unscrew fixing screw positioned
1. Partially remove the trunk left side filter, remove valve @ from tubes under filter @ , lift it and remove it.
coverin& @,@,and@.

May 1988 04-l 8 PA333500883300

 i,
FU:EL S Y S T E M

1 External air tube 3. For assembly, operate in reverse or-

2 Fuel vapour intake tube der in respect to removal.
3 Fuel vapour Inlqt tube
4 Fuel vapour fllter

CALIBRATIONS AND ADJUSTM~ENTS

For electronic injection 1.7 engines only
CA;LIBRATIOW T,HROTTLE BODY
(Fviow)

1,. Loosem clamp and disconnect slee-
v,e ~0 fiom throttle body -0 .
2. Disconnect depression tube under
,tprbttlebody @ and suitably plug
thq relevant fitting.
3. Loosen switch @ fixing screws on
throttle body.
4. Disconnect accelerator control ca-
ble.
5. Verify throttle body calibratioh with,
a flowmeter, working as follows:
a. Dismantle C.2.0056 buffer, separa-
ting it from the relevant threaded
Stern.
b. Screw C.2.0057 fitting on buffer, and
screw the threaded stem on fitting (as
per figure).
c. Connect flowmeter to C.220056 buf-
fer and rest buffer on throttle bpdy.

cl. Measure air flow through the throt-

tle and check that this is within the
specified values (plug the air intake fit-
ting on the throttle body).

Blowby of air: accelerator throttle in

the closed position (Solex flowmeter):

400 ~10 on N scale

1 Throttle body
2 Cbrrugated sleeve
., 3 Akcelerator control table
4 Accelerator throttle switch

P A 32 790088330 1 04-I 9 October 1988

 _
,
~,6. If you do& detect specified values,
~proceed to setting.
~a. Break seal 0 and act on adjusting
screw 0~ u?til speciofied flow value
is obtained.
b. On completion of the setting reseal
the seating ~of, the adjusting screw
#with the relative cap.8
,17. Remount disconnected compo-
~nents operating in reverse order, then
!:effect further setting.
ACCELERATOR
TH-ROT;TLE
SWITCHs
CALIBRjITION
1. Disconnect female connecter from
throttle swhch.; Check on male con-
nectar the: following resistances with
a tester. ~
a. With throttle entirely closed bet-
weenterminals2and 18 one must de-
tect a resistance of ablout 0 .
b. Slowly rotate throttle: with tester
,between terminals 2 and 18 one must
#detect an infinite resistance before
throttle bas rotated by 1 with respect
to fully closed position.
2. If this Con~dition doesnt take place,
lbosen screw @ and rotate switch
until the contact is obtained (resistan-
lce ~0 ) between terminals 2 and 18
with completely closed throttle; then
tighten screws again.
,October 1948
I
FUEL SYSTEM
3. Rotate throttle 60 f 4 and check Whenever detected values are higher
full load contact closed, detecting fol- than maximum specified values,
lowing resistances on male connec- check power supply components and
tors, with tester. if they are faulty, replace them.
- With accelerator throttle open by
an angle of a3 60 f 4O between
terminals 3 and 13 one must de-
tect a resistanceof 0 approxi-
WARNING: ~
mately.
CO percentage setting and exhaust
4. If these value are not detected,
-.shoul be carnied out, if necessary, only
check accelerator control of replace
if an air flow sensor and electronic CU
switch.
have been replaced.
1
/-o
Operate as stated below::
1.~ Remove seal cap
1 A i r f l o w ~sensorlelectronic C U
2 CO Setting screw seat sealing cap
1 Screw fixing switch to throttle body
2 Idle rpm terminal (it corresponds to posi-
tion A: closed throttle)
3 Max. rpm (it corresponds to position B:
open throttle)
2. Start engine and run it to normal
running temperature.
3. Connect a suitable exhaust gas
analyzer on exhaust pipe outlet.
CO PERCENTAGE
TIMING AT 4. Cautiously act on CO percentage
EXHAUST adjustment screw until specified value
isobtained.
Detect CO percentage on exhaust gas
following the procedure stated in 5. When this operation is complete,
Group 00 - Engine M.aintenance - Ex- put a new seal cap on CO adjustment
haust Emission Control. screw Seat.
04.20 PA 32 790088330 1
 r

FUEL SYSTEM

~
ELECTRICALIELECTRONKI COMPCUVENTS
For electronic injection 1.7 engines only

ELECTRONIC
CONTROL UNIT
CHECK OF FUNCTIONING
1. Make sure that lambda probe is effi-
tient (see: Group 00 - Electrical Trou-
bleshooting Procedure - Test No. 8).
2. Unscrew four fixing screws shown
in figure (one of which is under seal
cap).
4. Remount CU operating in reverse or-
der in respect to removal, then apply a
new seal cap (in screw Seat). If CU has
bee~n replaced, proceed to check and if
necessary, to effect setting of CU per-
centage at exhaust (see: Calibration
and Setting).

2. Start the engine, run it to normal ACCELERATOR

running temperature and keep it at THROTTLE SWITCH
idk? r.p.m.
,;,
REMOVAL AND ASSEMBLY
31 Connect a suitable exhaust gas
analyzer at exhaust pipe outlet and de- 1. Disconnect connecter 0.
tect CO percentage of gas (with lamb-
da probe connected). 2. Unscrew two fixing screws and re-
move switch @ from throttle body
4. Disconnect depression pipe from 0.
pressure regulator .and meanwhile
Iook at exhaust gas analyzer Sauge.

- If CO percentage rises momentari-

1 Electronic control unit
\y and then goes down to normal 2 Multipolar connecter
values, this means that CU works
properly (When it is informed that
mixture is too rich it Will reduce in-
jection time).

- If CO percentage rises and stabili- 3. Remove CU 0 with seal gasket

ses at high values, this means that 0.
~CIJ is not able to correct CO per-
6entage. One cari deduct that CU
dis faulty (since lambda probe is to
ibe considered as efficient follo-
wing check effected and Step 1).

SEMQVAL AND ASSEMBLY

ThA electronic CU is built into the air 1 Connecter

2 Throttle body
f!ow sqkor caver.
3 Accelerator Throttle switch

If necessary, remove CU from air flow

sensor and operate as follow. 3. Fedmount switch operating in rever-
~ ~ se order in respect to removal; then ef-
1. !Disconnect multipolar connecter 2 Gasket
fect switch .setting (see: Calibration
Q. 3 Air flow sensor and Setting).

i(3279EO883301 04.21 October 1988

1 Gaskets
6 Catalytic muffler 10 Rear muffler
2 Front manifolds
7 Gasket 11 Clamp fixing bolt
3 Nut
8 Lambda probe 12 Clamp
4 Plug for CO% sampling upstream catalytic muffler
9 Buffer 13 Nuts fixing manifold to heads
5 Support ring
 FUEL SYSTEM

lp;RkCAUTIONS TO ADOPT FOR CATALYTIC MUFFLER EQUllPPED VEHICLES

. Use only lead free petrol.

. Avoid petrbl level in tank from becoming very low.
. Dhnt start engine with a disconnected spark plug.
. Dlont overload excessively the engine for long periods of time. Be careful whep towing uphill for long periods.
. DP not switch ignition off while vehicle is moving. Ignition is to be switched off with vehicle stopped.
. D:o net stop or park car on or near inflammable materials (dry grass, fuel residuals, dry leaves, wastes, etc.).

Cl$CKS AND
INSPSCTIONS

1. : Check mufflers and exhaust pipes MANIFOLDS AND

makit/tg sure they are not in any way MUFFLERS
damaged or cracked and show no evi-
denc$ of corrosion; contrarywise,
Referring to the figure proceed, with
replace jhem.
removal as follows:

Cata(ytiC m u f f l e r m u s t b e always
repla%ed at ,I<m interval stated i n
Group 00 - Vehicle Maintenance
Chat?.
~ release this one from support @tain-
2. Thoroughly check support ring
and do ?ot hesitate to replace them if
they mare cracked, porous or worn.
3. check buffer on exhaust pipe
end.
1. Fiaise car on lift.
2. Remove rear muffler as,foli,qws:
( 1 ) L o o s e n clamp @ connecting
3. Fiemove central muffler @ as
central element with rear pne and
follows:
(1) Operating from below the engine
ing rings@.
(2) With a suitable hammer, lightly room. d i s c o n n e c t connectors @
and repeatedly strike all around the shown; o n f o l l o w i n g p i c t u r e a n d
disengage plastic clamps wirings
muffler pipes connection are? and
then alternately turn muffler @? clock-
wise and counterclockwise SO as to
make separation easier.

1
REMOVAL

WARNINGS,:
- ~Instructiotis hereafter described
~have been drawn up S O a s to
~allow separate removal of the
~exhaust systems single com-
ponents.
- C o n s e q u e n t l y , removal p r o -
(cedure may be changed depend- 1 Lambda probe connecter
inri on the operations purpose.
- ~When rem- .ng t h e entire ex- (3) If necessary, use a plastic ham-
haust system, it is advisable to mer and lightly strike the muffler in the
~get someone to help you with it. direction of removal till rear muffler (2) Remove muffler (refer to item 2.
cornes off the central muffler. above).

P(li33500883300 04-23 May 1988

 (3) Unscrew nuts @ securing cata-
lytic muffler @ and exhaust manifold
I@. ~ Verify integrity of support rings and
(4) Free! cetalytic muffler @ support
brackets! f r o m lock r i n g s @ a n d
r e m o v e it.~
4. Remove manifolds @ as follows:
(1) Disconnect manifold @ from
catalytic muffler unscrewing nuts 0.
(2) Loqsen n u t s @ s e c u r i n g
manifold fl8nges to cylinder heads and
then remove rear element @ and
gasket 0.
SUPPORT RINGS
replace them if necessary.
INSTALLATION
Fit single parts back together follow-
ing removal operations in reverse se-
quence and paying close attention to
below instructions:
a. Always fit new gaskets between \
manifold flanges and cylinder heads, .
and on flange between muffler and ex-
haust manifold.
b. Having completed installation,
check and make sure that support
rings move freely and are free of un-
due stress; check brackets making
sure they have been properly secured.
c. While engine is running check all
pipe connections for gas leaks and the
whole exhaust system for unusual
noises.

04-24 PA333500883300
 r

FUEL SYSTEM ~

~TROUBLESHOOTING FOR CATALYTIC MUFFLER

~
~MARNING:
:Hightemperature of atalytic muffler could damage,alumina monolith an! consequently weaken the conversion efficiency.
~It~co$d also damage the container and cause fire.
1,

Integrate troubleshooting of basic manual as follows:

8
Troubles Probables causes Corrections
,

Ov,erheating of catalytic muffler l Scaling of one or more spark plugs Clean or replace spark plugs

9 Clogged fuel filter Clean or replace

l Very dirty air fi!ter cartridge Replace

l Accelerator not set properly Effect accelerator setting

. Engine and relevant accessoires Effect accelerator timing

.not set according to specifications

9 Imperfect exhaust manifold tightness Eliminate -leaks

l Battery voltage too-low (or faulty Recharge battery (or review the system)
recharge system).

Catalytic muffler overheating could

.also be due to:

l Fuel level extremely low in tank. Keeb fuel at proper IeVel

l Engine overloads for long periods Avoid engine overload

of time, i.e.8 maximum speed rum,
drawing of trailers, or run on long
hilly roads.

PA3279EO883301 04.25 ~ October 1988

i- -----

~ ,
FUEL SYSTEM
l

~ SERVICE -DATA AND ~SPECIFICATIONS

For electronic injection 1.7 engines o$ym

TEC,HNICAL DATA

Litres

50
Overall,capa&

Rserve 65

CHECKQ AND TIMINGS

Acceleratdr throttle switch calibration

2. Idle rpm terminal

(corresponding to position A: closed,throttle)
3. Maximum rpm terminal
(corresponding to position 6,: open throttle)

,
Unit:

Rpistances

TerminaIs 2-la8 T e i m i n a l s 3-18

0 ce
Accelerator~throttle completely closed
m 0
Accelratci~ t h r o t t l e oDen a t a n a n g l e 13 = 6 0 + 4

$alibrat/o~n accelerator throttle body (flow)

Fldw 1 Seal
di!ection _ 2 Adjustment screw
3 Depression intake fitting

Reading

Air blowby with throttle disk in closed position (flowmeter Solex) (1) : 400 + 10 N scale

(1) TO detect plug depression intake fitting. Use C.2.0056 buffer with C.2.0057.

O c t o b e r la88 04-26 PA3279E0883301

 FUEL S Y S T E M

Abcelerator c o n t r o l

Clearance between throttle control and accelerator table pawl

(w;th accelerator pedal at rest) tq

01 = 1 + 2mm
-1
.
!
I
i
Cllearance between throttle control and stroke end
(with accelerator pedal fully pressed)
~~
-
G2=1+2mm

Idle rpm; emissi.on at exhaust

Engine idle rpm (at hot engine, in neutral, clutch engaged rpm -50
950 +O 850+50

- total, upstream catalytic

muffler with lambda probe 56 i n v o l . 4 0,8 f 0,2
/ disconnected
CC percentage at \dle rpm
- total, at exhaust pipe % in vol. < a2 0,8 f 1,7
outlet

- total, upstream catalytic < 500

p.p.m.
.:muffler
HC values at idle rom
- total, at exhaust pipe
p.p.m.
,l outlet

~(*r) For models without catalytic converter 1

Fuel !supply system

kPa (bar; kQ/cm2 )

Working pressure (1) 2 8 0 + 320 (2.8 + 3,2; 2.9 + 3,31

I
&ax. allowed pressure for system test 400 (4; 4.1)

0) T O be detected upstream the damper, with depression intake hose disconnected from pressure regulator.

: GENERAL PRESCRIP~TIONS

FLUIDS AND LUBRIFICANTS

Application Type Denomination

Accelerator pedal spindle GREASE ISECO Molykote Longterm n. 2

(on support rubber Categ. -3671-69831

~Pd3279EO883301 Oh-27 , ~ October 1988

 l I I
central
Position 1st Carb. 2nd Carb. RH LH -RH LH
I
Diffuser 0 mm 23 II 24 I .28 1 28

Centering device 0 MM 3.5 4.5 12189.01 3,5

Main jet 0 . 122 130 118 125

Main air jet corrector 0 . 180 170 180 190

Diffuser F 6 8 F67 9164.01 F67

&
!i Idling jet 0 . ~~ 50 ~46 48m

Idling air corrector 0 175 115 195

l I l

Progression holes 0 . 120- 100 120-120 100 - 140- 140 100- 120 - 130
100 - 100 120 140 - 140 140- 150

Needle valve 0 . 175 150 175

Float weight 9 li 10 Il,8

Starting jet 0 mm - 0,80 0.90

Starting diffuser - 7482.03 F7

2 Acceleration pump capacity for 20 pumps - 7+9 6+9

2 Level of floas chamber mm 7 5+6 9 + 9.5

2
0
(0) Dimensions in 102 mm
fs
() Net marketed in all countries.
2;
% Displacement 1500 1~ -1700
.ENGINE
Type 305.88 305.50

ALFA ROMEO 580.778 - 580.777 580.776 - 580.775 546.860 - 546.861 546.858 - 546.859
Part No.
CARBURETOR Twin Dellorto- Twin Weber Twin Dellorto Twin Weber
M.odel
DRLA40FD - DRLA40FS 40lDF81 _ 40lDF80 ~DRLA40FD _ DRLA40FS 40lDF69 - 40lDF68

Position RH LH RH LH RH LH RH LH

Venturi . 0 mm 30 30 32 32

Centering device 0 mm 12189.01 3.5 - -

Main jet 0 . 135 140 142 140

Main air jet corrector 0 . 205 200' 180 190

0
e
8 Diffuser 9164.01 F70 9164.4

Idlino iet 0 . 46 50 52 50

Idlino air corrector 220 220 195

Progression holes 0 . 100-140-140 100-120-130 100: 140 - 140 106-120-130

140-140-140 140-150 140-140 140-150

Acceleration pump jet 0 . 35 33 (incl. 3) 35 35

Needle valve 0 . 150 175 150 175

Float weight . 9 10 11.8 10 11,8

Starting jet 0 mm 0,80 0,90 80 90

Starting diffuser 7482.03 F7 ( - 7482 F7

l I l

Acceleration pump capacity for 20 pumps 5+7 6+9 5;5 S6.5 528

Levelof float chamber mm 5+6 8.5 + 9.5 2oz22

'(0) Dimensions in 10'

 ,l
,

FUEL SYSTEM

SPECIAL SERVICE TObLS

[ For electronic injection 1.7 engines only

Identif(cation Number Denomination Page peterence

~ Key for plug of exhaust gas

4.5.0212, sampling fitting of Lambda probe

&2:0051
Fitting for exhaust gas sampling
of Lambda probe

Buffer for air flow checking 04-19

C.2:.0056# 04-26
to be used with C.2.00%

04-l 9
Fitting to be used-with C.2.0056 04-26

October lg88 04.30 PA3279E0883301

, 8
8
,i

~ Y
~

IGNITION, STARTING, CHARGINGN SYSTEM

C O N T E N T S

IGNITION ......................... 05-2 Checks and inspections . . . .,. . . . . . (*)

~Fuel: injection-ignition
~diring ,diagram .................
~Technica,l data and specifications . . 05-2
D~istributor and ignition
advance diagrams . . . . . . . . . . . . . . . 05-3
C,heck and adjustment of
ignition timing . . . . . . . . . . . . . . . . . .
Coil, . . . . . . . . . . . . . . . . . .. . . . . . . . . 05-9
,Spark plugs . . . . . . . . . . . . . . . . . . . .
BAT?ERY . . . . . . . , . . . . . . . ._. ,. . . . ,, . 05-9
Service data and specifications . . , . 05-9
~STARTER . . . . , ,. . . ,. . . . . . . . . . . . ,. . ,.
IWiring di,agram . . . . . . , . . . . , . . , . (-1
Disassembly . . . . . . . . ., . . . . . , . . . .
Reassembly . . . . . . . . . . . . . . . . . . . (*)
(*) Test stand, inspection . . . . . . . . . . . . (*)
Serviae ,data and specifications . . . . 05-I 0
Trouble diagnosis and corrections . ,. (*)
CHARGING . . . . . . .~a . . . . . . . . . . . . 05-I 1
Wiring diagram . . .. . . . . . . . . . . . . (00)
05-8
Disassembly . . . . . . . . . . . . . . . . . . . (*)
Checks and inspections . . . . . . , . . . (*)
05-9
Reassembly . . . . . . . . . . . . . . . . . . . (*)
Test standinspectiqn . . . . . . . . . . . . (*) j
Service data and specifications . . . . 05-I 1
05-I 0
Trouble diagnosis and corrections . . (*)
(*)

(*) ~Fefer t o W O R K S H O P M A N U A L (Alfa] VOLUMk I AND VOLUMl+II - ;Gryp 05

(4 Refer to WORKSHOP M A N U A L @j@) modek - Group 0 5 ~ ~

(4 IRefer to: Group 00

PA333500883300 ,05-l May 1 9 8 8

i
Technical data and inspections

1700 1700
1200* - 1350 1350 1500 1700 Electr. injection Electr. injection
Engine 305.85 - 305.86 305.87 305.88 305.50
305.58 305.58 A

Alfa Romeo 581.293 581.292 581.363 581.291 548.604

Bosch Bosch Bosch Bosch Bosch

Type 0.237.601 0.237.601.021 0.273.601 ,017 8.237.540.173 0.237.601.014

Firing order l-3-2-4

Puise Generator Coi1 Resistance R 1100+10%

Interna1 resistance of distributor rotor arm n 1000

mm -
Air~pP (in)

(A) For countries where antipollution regulations are in force.~

Not marketed in all countries.
 ;i IGNITION, STARTING, CHARGING ~SYSTEM

DISTRIBUTOR ADVANCE CURVES

ENGINES
1200 - 305.85
1350 - 305.86

Automatic ,advance curve

tis id 250 500 1000 1500: 2&00

, ~ 2500 3000

,;, Distibqtor r . p . m . ~

Vacuum pressure corrector curve

100

I II
8, I l I I Il
I I I I I I I I I I I I I MI-l I L ! ! ! I III l I I I

OP

I I I I I I I I 1
I I I I I I I I I I I I I I I
I I I I I I l I I I I IPI l l
cn
;-cv-
~ 0 100 200 300 400 500 600
Vacuum pressure m. bar

b5-3 PA333500883300
 ~
IGNITION, STARTING, CHARGING SYSTEM

DISTRIBUTDR ADVANCE CURVES

~;
ENGINES
1 1350 - 395.87
1350 - 305.88

A u t o m a t i c adtiance c u r v e

1000 1500 2qop 2509, 3000

Distibutor r.p.m.

Vacuum pressure corrector curve

Y~0 .~ 100 20,o 300 4 0 0 509 600

Vacuum pressure m. bar

May 1988
 8

IGNITION, STARTING, CHARGING SYSiEM

DISTRIBUTOR ADVANCE CURVES

ENGINE :
1700 - 305.50

Automatic advance curve

Distibutor r.p.m.

Vacuum :Pressure corrector curve

$00

t i i i i i i i i ,i i in-i i
I i l i i i i i i ,i 34 4 i i/i i i i

k 5;c , I I I I I I I 1 I I
0 100 200 30,o 400 500 600
Vacuum pressure m. bar

P333?00883300 05-5 ~ j May 1 9 8 8

 IGNITION, STARTING, CHARGING SiSTEq

DiSTRIBUTOR ADVANCE CURVES

ENGIilE
1700 - 305.58

P n e u m a t i c advance curve

a3ueApe .4o~nq!.w!p 40 saaJ6aa

May 1988 PA333500883300

05-6
 r

IGNITI~N, S T A R T I N G. CMARGING ~SYSTEM

!N
D I S T R I B U T O R ADVANCE +M~ES
/: ,
ENGINE ,
1700.305.58 :,
Ii
FOR COUNTRIES WHERE ANTIPOLLUTION REGUiATION ARE IN FORCE
,
Automatic adyance cude
Qistributor
_.
;. r;p.m.:.

1 ;,

_ Vacym
I pressure corrqctor c,urve. ~

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
,;
-100 Jk
0 100 200 300 400 ~ 5OOl 600
V a c u u m pIessure m b ~ ~

October 1988
 IGNITION, STARTING, CHARGING SYdTEh

CHECKING 5. Disconnect the v,acuum advance ho- ~ ,m 7. Reconnect the vacuum advahce ho-
hND ADbUSTING se from distributor; with the strobo- se to the distributor.
BHElGN,lqlO~N TIMING scopie gun cgeck that at idling rpm:

8. Using the $roboscopic gub, check

FARNING: ~
A very accurate check of the timing at
idle speed, has !to be performed very
carefully, Sin&e incorrect timing at idle
greatly affects exhaust emission level
which would not remain within the
s p e c i f i e d ,values.
For engines with carburetors, the pro-
cedure described in the paragraph
Cheqk of FiXed and Maximum Advan-
ce in the ~ manual are to be fol-
slowed tak/ng i$o account t h e n e w
~technical yata given in the table.
For the electrroqic injection 1.7 engine
with catalytic convertor, the following
,procedure isto be fo!lowed:
! T T.D.C. of cylindr No. 1.
1. Connect tbe supply terminal of stro-
Iboscopic guh th battery and the pick-
m,up t o h i g h Qoltage table of cylinder
iNo. 1:
2. Connect an electronic rev-counter
,,to the enqin~e insertipg the terminals
On the coi1 pow&r supply and the pick-
UP
,; on the high tension lead of the coil.
~3. Removd the plastic plug on engine
~ r,ear caver.
~4. Start the engine, warm it up to, ope-
rating temperature.
Oil Temperature:
175,thru 80%
950 + 100
_ 5. r4.m.
the marker on rear cqver is aligned
with notch I on flywheel of the engine.
..
I Ignition advance at idle engine speed.
II Advance at 5250 rpm.
Advance (With vacuum correcting ho-
se disconnected)
8O f before T.D.C.
8. If specified alignment does npt,oc-
cur, proceed to adjust timing opera-
ting as followS:
(1) Unscrew the securing nut on th6 di-
stributor.
(2) Rotate the distributor body coun-
tercklockwise to advance, or clockwi-
se to retard the ignition setting.
(3) Retighten the distr/butor securing
nut.
(4) Check that timing is within speci-
fied values.
also that at engine rpm of
5250 r.p.m.
the marker of engine rear caver is ali-
ghed with notch II on engine flywheel.
9. Remount the plastic plug.on engine
rear caver.
For the electronic injection 1.7 engine
~without cataiytic convertor, the follo-
wing procedyre is to be followed:
1. Disconnect the minimum and maxj-
mum accelerator throttle opening
switch connecter and short-circuit the
three wiring side plus.
2. Disconnect vacuum pressure hose
fr@m ignition; d i s t r i b u t o r .
, 3.~ Check with stroboscopic gun that
the advance,value is 8. If this is not
the case, rotate the distributor.
N O T E :
Connecting to,ground those plus relative to
the minimum and maximum accelerator
throttle opening switch, the ou controls the
coi1 power unit SO as to dotaln a fixed igni-
tion advance value at 8 independently at
engine r.p.m.

Engines 1200 - 305.85 1350-305.87

1350-305.86 1500 - 305.88 1700-305.58 A 1700-305.58

8"+1" 8"kl's 80+13 8 (2)

Fixed advsnce at 900rpm at 900 rpm at 900 thru 1050 rpm
i, -
340 (3) 340 3z.
~, Maximum adiance at 4500 rpm at 5250 rpm -
at 5500 rpm

(1) The timlng values are to be measured wlth the vacuum advance hose disconnected
(2) The value is measured indipendently of the engine speed
,(A) For couniries where antipollution regulations are in force ,
(3) For an:addltional check, check for 30 at 4500 r.p.m.

O c t o b e r ,1988 ~ 05-8 PA333500883301

 ,
,

,' f

4GNITION, STARTING, CHARGING: SYSTEM

IGNITION COIL (BREAKERLESS IGNITION)

Electriqal data and checks

1200-305.85 1700-305.50
ENGINE 1350-305.86/87 1700-305.58~ 1700-305.58
~ 1500-305.88

AlfaRomao Class 547.811 542.162

8
B O S C H BOSCH
Tvw
0.221 .122.323 0.221.600.002
,

Primary winding voltage V 12

Primlry winding resistance Rl (20%) B 0.7 thru 1

PrimBry winding resistance R2 (ZOOC) B 6700 thru 9600

(a) Fbr !countries where antipollution regulations are in force.

SPARK PLUGS

l BATTERY
SERiUCE DATA AND SPECIFICATIONS
As p&(Alfa]except for the data given below
I

1200-305.85 1350-305.86187 j 500-306.88

1800-VM82A
1700-305.50 1700-305.58 1700i305.58a

Capaci!y Ah 50 - 55 (1)

Discbaige current A ,225-255(l)

(4) For ,countries where antipollution regulations are in force.

(1) Only for ,engines mounted on 4x4 models and for models marketed in Sweden.
:,
1

PA3335QO883300 May 1 9 8 8
0519
 1200-305.85 -~_ 1~~5OZjO~@Y87 l7!0-305.58i~
1800-VM$2A
1500-305.88 1700-305.50 1700-305.58

533.051 533.052 536.611 547.199 195.27.05.030.00

BOSCH DUCELLIER MARELLI BOSCH BOSCH

EF 12 V - 0.8 kW .6246/C E95 - 0.9 kW EF(R) 12 V - 0.85 kW EV-12V-2.2kW
00012 11215 12v 0001208 266

Voltege V 12 -12 12 12 1 2

On load test (pinion meshed with crown

tiheel with torque dynamometer) V
10 10 9.8 8
- Voltage A s 680
s 230 s 200 215
- Absorbed current 5 1450 z 1450 1800 a 1200
rm
- Speed N - m 5 19
- Torque (0.5) (i.5, (Z.5, (1.9)
(kg-m)
z
A~ Across-line test (pinion mashed with
0 locked crown wheel)
- Voltage V 8 ~~~ 8 4
A S 380 400 - s 1300
- Absorbed current
N.m 211~- ~~ -12 a37
- Mrque (a 3.8)
(2 1.1) (1.2)
(ft.lb) (kg.mJ

Ovrrunning~torque N-c,- ~~ 13 thru 22 l-l-thrul7~- ~~ 15i3 - 14f22

~- ( d l - n i ) (kg.cm) 1.3 thr; 2.2 1.1 thru 1.7 ~~ (1.5 f 0.3) 1.4 thru 2.2

EM switch on starter motor

- Max absorption current at rated

voltage A a 40 - -
- Min pickup voltage V -~~8 a 7.8

Pinion module 2.1167 - 2.1167

 8

~ IGNITIObJ, STARTING, CHARGING:S;YSTEM

CHARG,ING
SE~RVICE DATA AND SPECIFICATIONS

1200-305.85
ENGINE 1350-305.86/7 1700-305.58~1,
1800-VM82A
1500-305.88 1700-305.58
1700-305.50
, I I 1
I
Alfa Rom00 547.949 ~ 549.399 547.565
Pan No.
Albrnator
BOSCH BOSCH
TYPE ~ Kl (R)14V-23/65A K1-14V-23/65A
0.120.489.480
0.120.488.118/119
- I I I I
Nominal Voltage V - 14 -

Volt& range V - - -
,
~Max current output A 55 65 65
~ 8,
Output st.9rts rm 1000 (1) - -
Current
outplp ~ 1500 (1) - -
213 max output rpm

Max wtput 6000 (1) - -

rpm

Bru$ woar limit mm (in) - - 5

si? - - 4kO.l
Roto; winding resistance

B - - -
Voltage ygulator resistance
~ , ,
L-2 - - 0 thru 10
D i o d e r r+stanEe

(1) ValueS fead with engine at normal running temperature, at 25oC (77oF), at nominal voltage force.
Fo{ cobntries where antipollution regulations are in force.

FLUlD!S AND,LUBRICANTS
As per (Alfa]
TIGHiENING TORQUES

PA333500883300 May 1 9 8 8
~ ~
 CONTENTS
~

CCOLING SYSTEM . . . . . . . . . . . ...... (*) HEADERTANK PRl%SURIZED PLUG . . . . .. 0(*)

W&TER PUMP . . . . . . . . . . ,1, . . ...... (*) SERVICE DATA AND
THERMOSTAT . . . . . . . . , . . . . . . ...... 0 7 - 2 SPECIFICATIONS . . . . . . . . . . . . . ........ 0 7 - 3
~Removal and reassembly . . . . . . . . 07-2 Technical data . . . . . . . . . . . . . . . . . . . . (*)

a
~ ~ Checks and inspections . . . . . . . . . 07-2 Inspections and adjustments . . ..*a..
(*)

RADf ATOR . . . . . . . . . . . . . . . . . . . . . . . . (*) i General specification . . . . . , . . . . . . . . 07-3 ,

COOmLANT TEMPERATURE Tightening torques . . . . . . . . . . . . . . . . 0 7 - 3
SeNSOR (FOR IGNITION CU) . ...... 0 7 - 2 TROUBLE DIAGNOSIS AND
Removal and installation . . . . . . 07-2 CORRECTIONS . . . . . . . . . . . . . . . . . . . . . . . (*)
ELECTRIC FAN CONTROL THERMAL
CCNTACT . . . . . . . . . . . . , . . . . , . . . . . . . . . . . (*)

(*) See: WORKSHOP MANUAL [Alfa] VOLUME SI- Group 07

P,4i279EO883301 October 1988

 8,
1 ,,

~
ENGINE,COOLINh S Y S T E M ~

1:
~ TI~ERMOSTAT I
REMOVAL &ND CHECKS A?D
It$JSTALLAT:lON INSPECTIONS

1: Drain coolant of cooling system into

alsuitable container.
0
21 Disconnect hose 1 from thermo-
stat,0x
31, Unscrew screwIfixing thermostat to
engine block. ~
4 DisGnnect tubes @ , 0 , @ ,
and 5 from ithermostat, then reme
ve it.
5. Proceed to installation by operating
@reverse order of removal, then fil1 sy-
Stern wtth specified coolant.
6: &art engines for few minutes and
check that no coolant leaks occur.
Using suitable tools, check that initial
thermostat opening occurs at a fluld
temperature of:
64 thru 66%
Otherwise replace thermostat.
1 C o o l a n t d e l i v e r y hose t o r a d i a t o r
2 Tube connecting thermostat-RH.
manifold
3 Tube supplying coolant to radiant
4 Tube connecting thermostat-L.H.
manifold
5 Tube connecting thermostat to filler tube
6 Thermostat

)
COOLANT TEMPERATURE SENSOR;
, , (FOR INJECTION CU)
For electronic injection 1.7 engines only

REMOVAL khiD 1 2 1 Coolant delivery hose to radiator

Q r-0
2 Thermostat
INSTALLAPIO,N
3 Connecter
~ 4 Coolant sensor (for injection CU)
l,! Drain coolant of cooling system lnto
a suitable container.
0
2. Disconnecti sleeve 1 from ther-
5. Proceed to installationby operating
mostat~ 0 : in reserve order to removal, tightening
3. Disconnect connector @ . sensor to a torque of not more than:
15 N.m (1.5 kg.m)
4. unscrew sensor
CD and remove it
from the R.H. feedmanifold. 6. Refill system with specified coolant.

$Ictober 1988 07.2 PA3279E0883301

 ,,
~
,
r

ENGINE COOLING SYSTEM ~

SERVICE DATA AND SPECiFICATIQNS

GENBRALDATA Min. external

As per ;(Alfa] except for:

Avoid contact with painted parts.

F r e s h water I 5.1 4.7 3.65

(Imp. gall.) (1.12) (1.03) (0.80)

TIGfifENING TORQUES

Unit of measurement

Il,
Elec$ic {ah control thermal contact on radiator 29 thru 34 3 thru 3.5
i ;,
Cqoling iemperpture transmitter on feed mar(ifold 33 thru 41 3.4 thru 4.2
~
Wat+ pump securing screws 19 thru 24 1.9thru 2.4

CoolBnt level sensor for injection CU (max. torque) 1 ,15 I 1.5

May 1988
 GEARBOX

C O N T E N T S

5 - ~PEED ~AN~AL GEARBOX . . . . . . . . . . . . . . (*) General specifications . . . . . . . . . . . . . . . . . . . . . . . . . . (*)

GEARBOX &TER LiNKAGE . . . . . . . . . . . . . . . . . .i 3-2
SERVICE DATA AND
SPEI<ICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-3
Inspection and adjustment . . . . . . . . . . . . . . . . . . . (*)
Tightening torques ~.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (*)
TROUBLE DIAGNOSIS AND
CORRECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (*)
SPECIAL SERVICE TOOLS . . ..a................ (*)

,,
(*,) -,r to WORKSHOP MANUAL [A-) VOLUME I and VOLUME II - Grpup 13.
8

~
~ ,
;
,

May 7 9 8 8
PA$33500883300
,
 8
,

GEARBOX ,

~
, s 1, GEARBOX OUTER LImNKAGE
~ As per (Alfa) Volumes I and II except for the following procedures.

REAR; WHEEL; DRIVE Reqove lever and if necessary the If necessary remove the silent-
SC LEGTOR silentblock @ from lever support. block @ from the bar.

4 x 4 v+sion
8
Disasset$bly
Place th gearbox - differential -
propeller ~ shaft group on a stand
fitted with suitable support brackets,
and proceed to dismantle the rear
wheel drive selector in the following
wav. ~
1 Flepqve~ . t h e retainer split
pin 01 of the stud @ connecting
the rear hheel drive selector bar @
and the corresponding rod. Remove
the stud. ~

The split~ pin must not be reused.

1 Lever support Inspectio& and checks

2 Bolt Check that the silentblocks situated
3 Screw on linkage articulated joints are in
4 Rear wheel dritie selector bar
good condition; replace them if
5 Rear wheel drive selctor lever
6 Silentblock
necessary.,
7 Silentblock
Assembly
1 Rear wheel drive selector bar Go on assembling rear drive selector
2 S p l i t piR following disassembly procedure in
3 Stud ~
reverse sepuence.
4 R e a r paver

2 . _ Urrscrew b o l t @ c o n n e c t i n g 3. Loosen screw @ connecting

r e a r w h e e l -1 drive selector lever @ rear wheel drive selector le-
I and lever ~Support 0, ver @and corresponding bar @.

May 19818
13-2 PA333500883300

~
 Models

Characteristics

9135 9137 9135 11135

Speed selector Gear Gearbox
lever positions ratio
Overall Speed OW?dl Speed OVl?dl Speed Overall Speed
ratio at ratio at ratio at ratio at
1000 r.p.m 000 r.p.m 1000 r.p.rr 1000 r.p.m

1st .1:3,143 1:12,921 8,010 1:11,629 9,081 1: 12,220 8,641

2nd 1:1,864 1: 7,663 13,506 1:6,897 15,311 1: 7,247 14,571

1st 3rd 5th
3rd I:l,323 1: 5,439 19,029 1:4,895 21,573 1:5,144 20,529
-
4th 1:1,027 1:4,222 24,514 1:3,800 27,790 1:3,993 26,446

5th 1:0,854 1:3,511 29,479 1:3,160 33,418 1:3,320 31,807

R.G.

1st
1: 2,091

1:3,750
1l
1:14.58 7.099
1: 12,707 8,145 1:11,437 9,233 1:12,018 8,787

2hd 1:2,050 1 z7.97 12.986

3rd 1:1,387 1: 5.393 19.191

-
2nd 4th .R.G. 4th I:l,027 1:3.993 25.920
5th 1:0,825 1:3.208 32.263

R.G. 1:3,091 1:12.018 8.612

(A) Electronic injection engine

() Noi narketd in all couniries with 1.2 engine
 TECHNiC% DATA

Features

Crown gekr ancI pinion ratio

Speed seiector Gearbox 9. 17 (1)

lever position ratio Gearbox kpeed at Gearbox Speed at Gearbox Speed at
differefitial 1,000 r.p.m. differential r.p.m. fifferential r.p.m.
>verall ratio Kmlh jverall ratic Km/h verall ratio Kmlh

lS' 1 : 3,143 1 : 12,921 6.010 1 : 11,629

2nd 1 : 1,864 1 : 7,663 13,506 1 : 6,897

3rd 1 11,323 1 : 5,439 19,029 1 : 4,895

-
41h 1 : 1,027 1 : 4,222 24,514 1 : 3,800

5th 1 : 0,854 1 : 3,551 29,479 1 : 3,160

R.G. 1 : 3,091 1 : 12,707 6,145 1 : 11,437 9,233

~;

1s' 1 : 3,750 1 : 15,416 6,850 1 : 11,932 8,850

2"d 1 : 2,050 ~~1 : 8,427 12,531 1 : 6,523 16,189

3* 1 : 1,387 1 ; 5,702 18,520 1 : 4,413 23.930

4th 1 : 1,027 1 : 4,222 25,012 1 : 3,268 32,313

1 : 0,825 :3;391 3 1 , 1 4 1 1 : 2,625 -40,228

R.G. 1 : 3,091 1 ~~12.707 8,310 1 : 9,835 10.737

c (A)
(1)
With electronic injection engfne for countries where antipollution regulations are in force.
Post modification, from chassis.
 After modification

,APP- Application Type Name Q.W

no.

Inner surface of:

- Seal ring of main selector rod GREASE ISECO Molykote, BR2
- $eal iring of primary shaft Std. No. 3671-69841
- SeaI, ring of differential shaft
- ~Seal !lip and work seat on shaft

Outer surface of:

- Seal ~rings OIL See item 5

Outer races of differential casing and pinion AGIP: Fl Grease 33 FD

GREASE
taper roller bearings Std. No. 3671-69833

MatingI surfaces of:

OIL See item 5
-, Ring nut securing bearing to differential sha

13-6 PA3335000OS W00

 F R O N T SUSPENSlbJ

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . (*) General specificatipns . . . . . . . . . . . (*)

. . . . . . . . . . . . . . . . (*) I n s p e c t i o n a n d adjustment . . . . . . . 21-2
FRONT WHEEL HUE
FRONT SUSPENSION . . . . . . . . . . . . . . . . (7 Tightenin,g torques ........ . . . . . . 0
SERVICE DATA AND TROUBLE DIAGNOSIS AND
Sf%CIFICATIONS . . . . ,.,......,........ 21-2 CORRECTIONS . . . .. . . . . . . . .,. . . . . . . .

(1
~Technical data . . . . . . . . . . . . . . . . . . . . 21-2 SPECIAL SERVICE TOOLS . . . . . . . ., . . . (*)

Refer to Group 00 - Chassis and Body Maintenance

for:
l Checking Suspension Height
, ,
l Wheel Alignment ~

I*) Refer to: WORlbHOP MANUAL (Alfa] II

Q
VOLUME I and VOLUME II - Group 21 :

PA~335oooos woo MARCH 1988

 ~

!
8
,m I
,; ,,, 8

F R O N T SUSPENSlON 8 ~
,,
,,

i
1,
SERVICE DATA AND SPECIFfcATIOMS
TEC~NI& DATA
+IL ~SPRI$lG, SHOCK ABS&BER AND ANTI-ROLL BAR

I
Alfa Romeo Part No. 131883 $ 133018

Wire diameter mm (in) 13.2 (0.520) 13.6 (0.53)

Coi1 spring ~ Coi1 diameter mm (in) 160 (6.299)

~ T Free length mm (in) 310 (12.205) 333 (13.11)

t Stiffness N/mm (kg/mm) (Ib/in) 21.6 (2.2) (123.2) 24.5 (2.5)

SPICA
3
Type ~ BOGE- -8

HYDRAUIX
Shock abqoiber
Piston rod diameter mm (inl 20 (0.787)

196 (7.718; (1)

Stroke mm (in) 185 (7.283)
187 (7.36:) (2)

Alfa Romeo Part No. - 131835

Anti-roll bar
Diameter mm (in) 18

il,) For shock a@so<ber SPICA only ~

J2) For shoc$ aljso[b&r BOGE only
8, ~

INSbECtlON AND ADJUSTMENT

QAT/i OF ,SHOCK ABSORBER SElTING
,

260+40 (26,5&4) 156,9*40 (1614) ~ 26OzMO (25.5+5)

529,5+40 (54M) 490f50 (49,9&5)

,l Expansion 1280&40 (130,5+4) 1421,9+40 (145f4) 12751r40 (130+4) 165OCl50 (168,2+15,3)

N (kg)

(A) With ele$&nic injection engine for countries where antipollution regulations are in force.,
NOTE: The shock absorbers are integrated in their strut tubes.
-,

, MAY 1989 21-2 PA33350000SW01

, i L ,,
,
~
 ) SI I,
,
~
*
,s i

R E A R SUSPENSlON
~

INSPECTION A N D A D J U S T M E N T
DAT+ OF SMOCK ABSORBER SETTING

33 1 . 5 Tl
33 1 . 3 331.5 a x a
33 1.3 5 33 1 . 7 *

33 1.7 IE 33,1.7 B A
33 1.7 IE a

,
~HOK A B S O R B E R LH RH LH RH LH RH

Type BOGE 8OGE BOGE

~
) Alfa Romeo part number 581045 581044 549123 549122 581046 581047

Compression N (kg) 150?

30 (15 * 3;) 157+40(16+4) 250 + 50 (25,5 + 5)
L o w qpeed
Expansion N (kg) 3306; (33 622;) 392 + 40 (40 k 4) 4902~~ (49 t 9+~{)
,
8,
Compression N (kg) 460 + 60 (46.9 i. 6.1) 530 k 4 0 (54 + 4) 490 f 50 (?9,9 f 5)
Hidh speed
, Expansion 1422 + 4 0 (145 2 4) 1650+150 (168,2?15,3)
N (kg) 1 4 8 0 + 130 (150,9 f 13,2)
*

Versions 33+* 3 3 1 . 5 Ti
33 1 . 3 33 1.5 axa
3 3 1 . 3 5 331.ero

Tvpe SP!CA SPICA SPICA

Alfa Romeo part number 548615 548614 548190 549191 549300 549301

Compression N kg) 18640(19?4) 260 + 40 (26,5 f 4) 255 f 40 (26 i 4)

Low Ispeed
Expansion N kg) 265 f 40 (27 + 4) 510 5 40 (52 f 4) 510 k 40 (52 f 4)

Compression N (kg) 461 f 4 0 (47 f 4) 490 + 4 0 ( 4 9 . 9 k 4 ) ; 491 f 40

(50 f 4)

Expansion N (kg) 1216 i- 4 0 (124+ 4) 1280 f CO (130.5 f 4) 1275~40(130~4)

I
NOTE: The shock absorbers are integrated in their strut tubes
(1 ~ Not marketed in all countries with 1.2 engine.
(A) With electronic injection engine for countries where antipollution regulations are in force.

PA:33500883300
21-3 May 1988
 CONTENTS
DESC~RIPTION . . . . . . . . . . . . . . . . . . . (*) Control lever . . . . . . . . . . . . . . . . . . (*)
SER~V~ICE BRAKES . . . . . . . . . . . . . . . . (*) Control tables . . . . . ., . . . . . . . . . , . (*)
Brake system bleeding . . . . . . . . . . . (*) SERVICE DATA AND
Pedal assembly. . . . . . . . . . . . . . . . . (*) SPECIFICATIONS.. . . . .. . . . . . :. . . . 22-2
Brake:master cylinder . . . . . . . . . . . (*) Technical data . . . . . . . . . . . . . . . . . 22-2
Hydraulic system piping. . .. . . . . . . (*) General specifications , . . . . . . .. . , (*)
Brakle:pressure proportioning valve . (*) Inspectjpnand adjustment. . . .,. . . . (*)
Servobrake . . . . . . . . . . . . . . . . . . . . (*) Tighteningtorques . . I . . . . . . . , , . . (*)
Vacuum system . . . . . . . . . . . . . . . . (*) TROUBLE DIAGNOSIS AND
Front disc brake . . . . . . . . . . . . . . . . (*) CORRECT;IONS . . . . . . . . , . . . . . . . . . (*)
Rear drum brake . . . . . . . . . . . . . . . (*) SPECIAL SERVICE TOOiLS , . . . . . . . . (*)
PARKING BRAKE . . . . . . . . . . . . . . . . (*)

(*) Refer to WORKSHOP MANUAL and VOLUME II -

Group 22

PA333500883300 May 1988

,
 1,
1, S E R V I C E DATA AND SPECI~FCATIONS
TECHNICAL D A T A

FRON% BRAKES

Caliperi, brake pads and discs

3 3 1.1 a x a
33%7IE, A 3 3 1.7 +
3 3 1.3 s 331.ETP
3 3 1.55 7-I 3 3 1.7 + A
Features

.. A.TE Part No. 547168/9 547808/9

I
Calipers Tvpe -
Part No> 54717819
.DBA

7 9 5 3 5 7 720402
ATE Part No.
I ,
~ Tvpe 795356 -
DBA P a r t N o .
8,
Brake ppds ~LIGiiT: BLUE (FRENDO)
Colours
~ BLACK (FE RODO)

Pad nominal thickness S mm (in) 15 16,5

l
Exteimal d i a m e t a r mm (in) .: 2 3 9
Discs
Nominal thickness C m m (in)-- 12,+-y ~ 22y

(*) Not mqrkeied in all countries with 1.2 engine.

(A), With electromc injection angine for countnes whbre antipollution regulations are iti force

PA333500883300
2272
 ,
,!
r ~

l FRONT AND REAR BRAKES ~

REAR BRAKES SERVOBRAKE

Unit: mm (in)
Type: BENDITALIA or ATE
Diameterof working cylinder 7 in
~ Drum nominal diameter : 9 8

Part N O. 130.695 131245

-0,l
Dri~i nominal interna! diameter 228,6 + 0.2 203.2 +o,2

Eraka lining thicknass 5 5

BRAAKE :MASTER CYLINDER BRAKE PRESSU#RE PROPORTIONING

VALVE,
Typz$: BENDITALIA Part N-o. 546.657
RE;1 BENDITALIA
~ Part ;5*98
Diameter 20:64 mm (0.812 in)
32 mm (16 +16)
1.26 in (0.63 + 0.63j

fype: ATE Part No. 548.682

Diapeter 20.64 mm (0.812 in) Braka pad thickness
32 mm (17 +15)
Strbka
1.26 in (0.67 +0.59)

l Unit: mm (in)
INSiiECilON A N D A D J U S T M E N T
Brake pat Sin@e Vantilatad
FRONT BFiAKES
Dimensions forbraka disc grinding (singla or vantilatad) Thickness:

Sing!e

(*) Serviceability limit is determined, anyway, by the

lighting up of brake pad waar warning lamp

l vantilated

( 1 ) Clrcumferential
(2) ~ Radial

Braka disc thicknass

Unit: mm (in)
,,
Braka disc Single Ventilated
,
l;hick+s:

rZm~in tifter machining 10 (0.394) 21 (0.827)

$iin ierviceability thicknass 9 (0.354) 20.2 (0.795)

;aL disc banking 0.03(0.00118) 0.03.(0.00118)

May 1,988
 1:,

F R O N T A N D R6AR:BR,AKES
~
Unit: mm (in)
8; REAR ~BRAKES Drum nominal
diameter
As per r-33) except:

Dimensiojsiforbrake drum turning Emax after turning 229.1 (9,021 204 (8.03)

E max serviceability
229.6 (9.04) 204.5 (8.05)
limit dimension,

Roundness error < 0.03 (0.00118) <O.O (0.00118)

Concentricity eryor < 0.08 (0.00315) <O.OS (0.00315)

Brake shoe lining

min. thickness
0.5 (0.0197)
(wear or serviceabi-
lity limit)

BR,AKi ~PRESSURE PROPORTIONING VALVE HANDBRAKE LEVER

ADJUSTM ENT
Adjustm$mt
Number of free notches
on; the sector gear before
Drum nominal diameter wheels locking 1+3 ,'

- V&hi$e at nominal height :one passenger and tank filled up

- Valve piston ai end of travel

- Appl~y a load of 49 N (5 kg ;Il.02 lb) - Apply a load of 78.4 N (8 kg; 17.64 lb);
8 ~
to th~e rqcker hook to the rocker hook ~

~GENERA~L $PEC;IFICATIONS

FLUIDSANC) LUBRICANTS

Application Tvpe Denomination

I

Std No. 3681.69906

Refilling of brake Flutd system Fluid
AGIP brake fluid DOT,? :
Std No. 3681-69996
IP Auto FluidFR DOT 4
Std No. 3681.69906

22114 PA333500883300
d
 CONTENTS
~ DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . (*)
SERVICE BRAKES . . . . . . . . . . . . . . . . . . . . (*)
-Brake system bleding . . . . . . . . . . . . . (*)
Pedal assembly . . . . . . . . . . . . . . . . . . . . (*)
Brake master cyiinder . . . . . . . . . . . . . . (*)
Rydraulic system piping .. . . . . . . . . . . (*)
~Brke pressure proportioning valve . . (*)
Servobrake . . . . . . . . . . . . . . . . . . . . . . . . (*)
Vacuum system . . . . . . . . . . . . . . . . . . . . (*)
Front disc brake . . . . . . . . . . . . . . . . . . . (*)
Rear drum brake . . . . . . . . . . . . . . . . . . . (*)
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . (*)
Control lever . . . . . . . . . . . . . . . . . . . . . . . (*)
Control tables . . . . . . . . . . . . . . . . . . . . . (*)
SERVICE DATA AND
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . 22-2
Technical data . . . . . . . . . . . . . . . . . . . . . 22-2
. . . . . . . . . . . . . . (*)
General specifications
81nspection and adjustment . . . . . . . . . . 22-3
Tightening torques . . . . . . . . . . . . . . . . . (*)
TROUBLE DIAGl\iOSIS AND
CORRECTIONS . . . . . . . . . . . . . . . . . . . . . . . (*)
SPECIAL SERVI& TOCLS . . . . . . . . . . . . (*)

(*) Refer to: WORKSHOP MANUAi [-33)

VOLUME I and VOLUME II - GroUp 22

l
MARCH 1988 ~
 F R ON T BRAKES

Calipers, brake pads and discs

Mode1

Features
ATE part. No. 5471 SS/9 54780819 54716819
Callpers Type
DBA part. No. 54717819 54717819

ATE part. No. 795357 720402 795357

~~Type
DBA part. No. 795356 795356 -

Brake LIGHT BLUE (FRENDO)

Colours
BLACK (FERODO)

Paci nominal thickness Y mm (in) 15 16,5 135

External diameter mm (in) 239

~Discs
Nominal thickness c mm (in) 12.7-O. (O.5-o.oo*) 22-0, (0.5-0.008) 12.7-O. (0.5-.oo*)

(A) With electronic injection engine for countries where antipOhtiOn ragUlatiOnS are in force.
C
 R+ BRAKES SERVOBRAKE
Unit: mm (lb)

9 t
TYPE: ATE ;Or BENDITALIA
i ;Drum nominal diameter:
Diameter o[ working cylinder 7 in
Pifi No., 130.895 131.245
Dr$ml nqminal :internal diameter 228.8+0,2 203.2;;;
-3
,, (9+7.9 10=3) !3$ : $3)
BRAKE PRESSURE PROPORTIONING
~Brake litjing thickness 5 (0.197) 5 (0.197)
VALVE
(7) ~+y for 4x4 versions
C
Bi+KE MASTER CYLINDER Type: BENIJITALIA Part No. 544.498
R A T I O 0.38

Type~ , BENDITALIA Par-t. No. 548.857

Diameter 20:84 mm (0.812 in)
Strole 32 mm (18+18)
,, ,, 1.28 in (0.83+0.83)
i
i Part. No. 548.882
Ty$: ATE
Dikmeter zO.84 mm (0.812 in)
Stioke 32 mm (17+15)
1.28 in (0.87+0.59)

IdPECTION AND .ADJUSTMENT

FRONT BRAKES
Dih$nsions for sbrake disc grinding (single or ventilated) Brake pad thickness
L

4
I . Unit: mm (in)

Brake d i s c Single Ventilated

Thickness:

,s ~ 15.15 (0.598)118.5 (0.850)

,
S min. #(&ear limit or min. ~
service{bilii thjcknqss) (3 7 (0.278) 7 (0.278)

(*) Serviciabi!ity Amit is in an; case determined ,by the lighting up

~ of brake pad Wear warningi lamp.
l
(1) Circumferential
(2) Radial

Blake disc thickness Unit: mm (in)

i
Brake disc Single

Thickness:

Cmin after machining 10 (0.394) 21 (0.827)

;eimii serviceability thickness 9 (0.354) 20.2 (.795)

Max ldisc banking 0.03 (0.00118) 0.03 (0.00118)

i$A3335ooposwo1 2231 ~ MAY 1 9 8 8

, 1
1
8 l
DESCftIPTION . . . . , . . . . . . . . . . , . . . (1 General1 specifications . . . . . . . . . . . (*)
FIE&R) H~UB . . . . . . . . . . . . . . . . . . . . . . (*) Inspection and adjustment , . . . . . . . 25-2
REAR SUSPENSION . . . . . . . . . . . . . . . (*) Tighten~ing tbrques . . ., . . . . . . . . . . . (1
$EF$ICE DATA AND T R O U BL E DIAGNOS~S ANO

SPEkiF ICATIONS. . . . . . . . . . . . . . . . . 25-2 CORRECTIONS,. . . . . . :,.. . . . . . .,. . . (*)

Tfzhnical data . . . . . . . . . . . . . . . . . 25-2 SPECIAL SERVICE TOOLS . . . . . . . . . 1)
,i

(1 Refer to WORKSHOP MANUAL m

\ I
VOLUME l,and VOLUME II -
Group 25

PA332j500883300 ~ hiay 1 9 8 8
,,
 REAR SUSPENSION

~
~
~SE#RVICE DATA AND SPECIFICATION -..
TECHf4ICAL D A T A
COIL SifRING AND SHOCK ABSORBER

Versions 33+ * 3 3 1.7 *

33 1 . 3 3 3 1.7 + A
3 3 q.3 s
33 1.5 TI 331.s-rcl 3 3 1.5 a x a
33 1.7 IE
33 1.7 IE, A
Festures
,:

Alfa Romeo Part No. 130938 131805 131990

,
Wire diameter mm 11,5?0,1 11,2&0,05 ~ 11,8*0,1

, Coi1 Springs Coi1 diameter mm 111

.-
Free length mm 310 302 313
,i;

Stiffness N/mm (kg/mm) 21,3 (217) 23,l (2.35) ~23,4 (2.39)

l e nStaticg load t h mm 204

l Boge
Tvpe
Hydraulic
Shock absprbers
81 Piston rod diameter mm 12(l), 11 (2)
~
1 8 0 (1)
S t r o k e mm 186 (l), 1 4 4 ( 2 )
8 132 (2)
I
1,
i
:i

INSPECTION AND ADJUSTMENT

DATA OF SHOCK ABSORBER SETTING

Versions 33e* ~ 3311.7 *

33 1.3 33ll.7 IE
33 1 . 3 s A 33 1.7 a
3 3 1 . 5 TI A 33; 1.7 IE 3 3 1.5 a x a
3 3 ya-r0

Shock absorber type BOGE SPICA BOGE SPICA

~
Alfa Romeo Part Number 581.052 549.141 549.134 549.142

~ Compression N (kg: lb) 10040 (10,2?4) 220 f 40 (22.4 f 4) 117240~(12+4) 180 k 40 (1#8,4 + 4)
Low, speed
Extension N (kg; lb) 90 k 40 (9.2 f 4) 200 f 40 (20,4 f 4) 157+401(16t4) 200 k 40 (20,4 -t 4)

Compression N (kg; lb) 400 f 50 (40.7 i: 5) 520+40~(53+4) 451 f 501(46 f 5) 520 f 40 (53 f 4)
High speed
Extension N ( k g ; lb) 730175 (74,4+7,6) 1160*40 (~118,3+4) 2 1 1 +78 (21,5+8) 116Oi40 (118,3*4)

VOTE:; VaLues to be measured with shock absorbers at 20 *29: (68 f 3.6F) temperature.
- () Net marketed in all countries with 1.2 engine.
(4 With electronic injection engine for countries where antipollution regulations are in force.

25-2 PA333500883300
~
,,
 CONTENTS ~
,DE$~Rl~PTI6N . . . . . . . . . . . . . . . . . . . . . . . .(*) Generabspecifications . . . . . . . . . . . . . . (*)
8
,REAR H U B ........................... (*)
Inspection and adjustment . . . . . . . . . . 2 5 - 3 1J
RE@ SUSPENSION . . . . . . . . . . . . . . . . . . (*)
TROUBLE DIAGNOSIS AND
SERVIC:E DATA AND CORRECTIONS . . . . . . . . . . . . . . . . . . . , . . (*)
SP~($lFICATIONS . . . . . . . . . . . . . . . . . . . . . 25-2
~
?&hnical: data SPECIAL SERVICE TOOLS . . . . . . . . . . . . (*)

Refer to Group,OO - Chassis and Body, Maintenance

for:
l Che,cking Rear Suspension yeight~ ~

~
(*) Refer to: Lr WORK$HOP, MANUAL [-33)
VOLUME I and VOLUME II - Groui, 25 ~

MAY 1988
,l,
~
;,~SERVICE DATA ANDY SPECIFICATIONS

1
~TECH$CAL DATA
j COIL %=RING, f%lOCK ABSORBER AND ANTI-ROLL BAR

CoilSprine Coi1 diameter mm (in) 111 ,(4.37)

I
Free length mm (in) 313 (12.32) 302 (11.89) 323 (12.72)

23,s !(2,?) ( 1 3 4 . 4 ) ,-- _,

StiffnessNlmm (kglmm) (loin)

~. S&ICA
~

Type B O G E

l I! HYDRAULIC
I

Shock abiodber, Piston rod diameter mm (in) 12 (1) (0.472) 11 (2) (0.433) 12 (1) (0.472)

~
180 (1) (7.086)
~ Stroke mm (in) 180 (1) (7.086)
144 (a), (5.67)

(1) For SPIEA shock absorbers only

(2) For S?G~E dock a b s o r b e r s only

25-2 ,,

8
 Iil%~ti~k?ikib ADJUSTMENT
DATA OF SHOCK ABSORBER SElTlNG

n TYPE

Alfa Romeo part No.

+

549137
3s 4.7 k3

BOGE

5491230
SPICA

549142
BOGE

549134 581052

Compression N (kg) 216+40 (22+4) 11716 f40 (12 54) 180540 (18,4&4) 117,8+40 (12+4) 1 OOf (10,2f4) 220+46 (22,4+4)
Low speed
Extension . N (kg) 196f40 (20f4) 117,6+40 (1254) 200f40 (20,4&4) 157f40 (16+4) 90f40 (9,2&4) 2OOz!z40 (20,4+4)

Compression N W 520+40 (53+4) 461 M9 (47t5) 52Or140 (53-14) 451+50 (46+5)~ 400f50 (40,7&5) 520+40 (53f4)
High speed
Extension N (kg) 760+40 (77.5+4) 853zt83 (87&8,5) 1160f40 (118,3-140) 799f78 (81,528) 73OC75 (74,4t7,6) 1180f40 (118,3&4)
C

NOTE: The shock absorbers are Integrated In the strut-tubes.

 C O N T E N T S
,m
,
~CHkCKING TIRE CONDITIONS . :. . . () Genera~l specifications . . . . . . . .. . . (*)
TIR~E~ REPLACEMENT . . . . , . . . . . . . , (*) Inspec$ion and adjustment . . . . . . . . ()
CHECKI~NGWHEELCONDITIONS , . . (*) Tightening torques . ; . . . . . . . . . . . ()
SEti\iIqE DATA AND Technkal data . . . . . ~. . . . . . . . . . . . 282
SPklFIICATIONS.. . . . , . . . . , . , . . ,
,
. 282
,:
,

~
(1 Refer ta WORKSHOP MANUAL c-33)
V O L U M E I a n d V6lhME I I -
Group 28

,l,
,,

PA$3+5?0883300 28-I May 1 9 8 8

!i

SERVICE DATA AiiD
8 TsEC~llNICAL D A T A
n
-

a
-
P
-
a
-
P
-
a
-
P
7
a
-
0.
-
a
-
a
-
a
-

m
x
-7
c
u-l

PA333500883300
 *
~
1

WHEELS: AND TXRES, 8 i

CONTENTS
CHECKjNG TIRE CONDiTIONS . . . . . . . . (*) General specificaticns . . . . . . . . . . . . . . (*)
Inspection and adjustment . . . . . . . . . . (*)
TIF& REPLACEMENT . . . . . . . . . . . . . . . . . (*) Tightening torques . . . . . . . . . . . . . . . . . (*)
8 Technical data . . . . . . . . . . . . . . . . . . . . . 28-2
CHECKING WHEEL CONDITIONS . . . . . . (*)
1; ,

I.. #
; SEi3kE DATA AND
SPECIPICATIONS . . . . . . . . . . . . . . . . . . . . . 28-2

(*) Refer to: WORKSHOP MANUAL[m]

VOLUME I and VOLUME II - Gioup 28

PA3335OQOOS W O O MARCH 1988

 TYRES RIM of
measurement A P A

165/70 RI 376s
165170 RI 379T 5 1/2 J x 13 1.8 1.8

- -

2!I
175i70 R_l3 82T 5 1/2 J x 13 Kg/cm2 - 1.8 1.8

- 2.0 2.0 -
185/60 R14 82H 5 1/2 J x 14

Balance (max. allowed residual balance) 9 8

% Balance weights Cl 10 i 40 (at 10 g-intervals)

63 _ ,-------_\ .~~
Snow chains
Chain S max. dimensions mm 16
(for tyres 165/70 R13)

[(A) With eiectronic injection engine for countries where antipollution regulations are in-force.

S rating F~Up~to 180 Km/h (112 m.p.h.)

T rating = Up ton 196 Kmlh (y 18 m.p.h.)
H rating = Up to 210 Km/h (130 m.p.h.)

[l) Inflatjng pressure measured with cold tyres,

In particularly heavy operating conditions (max. load, high temperatures, high speeds, etc...) it is advisable to increase inflating pressures by 0.2 kg/cm (0.2 bar; 20 kPa; 2.84
p.s.i.).
2
In the event of rear axle overloading (trailer hauling. (L.P.G. tank, etc...),it is advisable to increase rear tyre inflating pressure by 0.6 kglcm (0.6 bar; 60 kPa; 8.53 p.s.i.).
0
Unit of measurement conversion:
2
2.2 kg/cm = 2.16 bar = 216 kPa-= 31.30 p.s.i.
8
1.8 kg/cm2 = 1.76 bar = 176 kPa = 25.6 p.s.i.
z
1.6 kg/cm2 = 1.57 bar = 157 kPa = 22.76 p.s.i.
s
 , ~ r

ELECTRICAL SYSTEM ~ ~, , ~

,
~
All information contained in this group is applicable fo
1.7 electronic injection engiries with cata!ytic convertdr only
;
8 CONyiENTS ~
HOWVTOREAD THE WIRING DIAGRAM (*) Cl&ter . . . . . . . . . . . . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-9
Carburettor power supply and rpm puiser
FUEL~ DI~STRI~BUTION . . . . . . . . . . . . . . . . 40-2 (wiring diagram) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-I 2
Fiel lwiring diagram . . . . . . . . . . . . . 40-2 Engine, cooling, lubrication, brake, pad
~FUses ......................... 40-3 wear sensor, minimum level, brake
Idnition switch ................. (O) clutcher (wiring diagram) . . . . . . . . . . . . . . . . . . . . . 40-I 3
~ELKfROMECHANICAL AND WINDSCREEN WASH/WIPER
ELECTR~ONIC DEVICES, . . . . . . . . . . . . . . 40-5 HEADLIGHT WASHIWIPER AND
Relays, timer, and electronic devices and REARS WINDOW WASH/WIPER . . . . . . . . . . . . . . . 40-14
intermittences ...................................... 40-5 Witidscreen wash/wiper, headlight
~ wash/wiper and rear window
Ll@H~;rl$lG SYSTEM ................................. 40-8 8 wash/wiper (wirin,g diagram) . . . . . 40-14
y?ylp? ,,, . . . . . . . . . . . . . . . . . . . . . . (1 ,Windscreen wiper~ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (*)
,&bjnation switch assembly . . . . . (*) He~adlight w a s h e rl................................. C*l
~OCt$de ~{ront lighting ~ Wihdscreen washer . . . . . . . . . . . . . 40-I 5
;($ri:ng diagram) . . . . . . . . . . . . . . . . ()
~ Rear wtndow washlwiper . . . . . . . . . . . . . . . . . . . . . (*)
,Rear combination lamps (wiring
,.Rear w i n d o w w i p e r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (7
;,
d/agram) .............................................. 40-8
Rear window washer electric pump . . . . . (*)
Front optical groups ............................. (*)
EL+TRIC ~ACCESSCRIES . . . . . . . . . . . . . . . . . . ..a. (0)
Rear ~optical groups ............................. (1
Fcg/ights and rear foglights 8 KEY h0 WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . 40-17
,

(wir~ing diagram) . . . . . . . . . . . . . . . . (O) ,,
8,
Ihside lightening (wiring diagram) . (O)

BO?+ INSTRUMENTS AND SENSORS

AND~TRANSMITTERS . . . . . . . . . . . . . . . 40-9
:,
~ i
~
1
1,

1, (*) FIefer to WORI<SHOP

MANUAL (Alfa) VOLUME I AND VOLUME11 -~Group 40
,l,
1 (0) qefer to WORKSHOP M A N U A L @$$@j Models - Group 40 1 ~ ~
i ! ~ ,
,N
,m ,
,i
;,
,. ~

~P A Q335008l73300 May 1 9 8 8
 ~
l

8, E L E C T R I C A L S Y S T E M ~

i ,

POWER SUPPL.Y R0~UTI.W

8, ~
For 1.7 electronic injection engine. with catalytic donvertor bnly
POWiR DISTRIBUTION WIRING DIAGRAM (wiring d i a g r a m )

May 1988 PA333500883300

 SERVICES PROTECTED
LOCA~TION CAUTION: IhY FUSES
The fusebox is an integral part of the a. Should a fuse blow, before replbc-
terminal board support and is located ing it, make sure that the cause of
on left ~side, of the intermediate bulk- failure has been removed.
headl in the engine compartment. b. Use fuses with the specified
Furthler,mdre t h e r e a r e t w o f u s e s . amperage only. Never use fuses
relating to Injection wiring in rightfront with an amperage greater than
area ;of engine compartment close to that specified.
relative lighting unit. c . Correctly insert f u s e i n t o fusebox; ~
aligning it carefully in its sating: i

d. Should dar rbmain statiOnaIy \Or

a long tirne, remove fuse pro-
tecting supply circuit of clock.

In the~following table, for each model, it is specified which are the services proteoted by eqch fuse.

Models ~

~ i,
Fuse~ Protected Service Ampere ~
:l
,

Front power Windows

I 16 X
1 ~ 1 Heedlight washer timer - Headlight washer
electric pump (1
I
2 Door lock control unit --36 X
,l Front fog Irghts

31 Heated rear window 1 6 X

C a r r a d i o -
4i , Cigar lighter - Horns 16
X
I

Passenger compartment roof lamp-Intermittence 8 X

of direction and hazard lights - Stop switch

8, ~~Windscreen wiper - Windscreen wiper electronic

intermittence generator - Windscreen wiper
control - Windscreen washer pump control - 8
~6
~ Cluster
Windscreen washer electric pump

~ Haated raar window switch -

~ Heater switch - Rear window relay
8
Power window relay - electronic injection relay - clock

~ Rear window washlwiper

(1 Only fer Sweden version

;

May 1988
 Models

Protected Service Ampere

33 1.7 IE 3 3 1.7 +
Injection

Reverse switch - H,azard light switch lighting

X X
8
ALFA ROMEO Control
- -

~ Sida light left front and right rear - RH.

X X
~~~number plate light
Drawer light x X
8
( ALFA ROMEO Control (Side light left front
and right rear - RH. number plate light) x
Cigar lighter
X X

Side light: right front and left rear - L.H.

X X
I number plate light

ALFA ROMEO Control (Side light! right

~
, front and left rear - L.H. number plate light) X
8
Heater control lighting lamp - Cluster
lighting lamp X X

Front fog light relay - front fog light switch lighting X X

Right low beam 8 X

~Left fow beam - Rear fog light, switch 8 X

~
8
~Right full beam 8

Left full beam - Full beams warning lamp 8

Lsmbda sensor resistance 7.5 X

Fuel pump 1.5 X

(*) Otily for Sweden version.

() These; fuses are focated on right front area of engine room close to optical groups.

40-4 PA333500883300
Y
 r
,.

ELECTRICAL S Y S T E M ~~

ELECTROMEC~HANICAL AN~D ELECTRONIC DEVICES

Only for 1.7 electronic injection engine with catalytic convertor
RECAYS, ~ELECTRONIC AND INTERMITTENCE DEVICES
~LOC&T(,ON
.,
To &ate komponents, see following figures and the two tables remote control switches and electronic devices and intermittences.
1

1 Fuseholderbox 5 Lamp washing remote control switch 9 Lamps and beam switching device
2 i3eam excluding remote control switch 6 Front wihdow llifting remote controli$witch 10 Main injection remote control switch
~ 3 Horn; remote control swltcb 7 Foglamps remote control switch 11 Fuel pump remote control switch
4 Thermal winqlow remote control switch 9 Electronic window iritermittence
il ~
,
1,
;,
~ ~,
,l

CHFCK
Al/ com&onents must be of the type stated on the specification table

PA333~00883300
81 40-s ~ ~ May 1 9 8 8
, 1
 Position
External view Symbols (See fig.
pag. 40-5)

43
30

86 87 85 2
8 7

3
,Horns! relay

il 3 0
Heated \eer window
86 87 85 4
relay ~ 1 2
,

30
6
86 87 85

~ %b 87

1
Front f*glamp
117 7
relay
:
,,
8,

i.,

May 19b8 40-6 PA333500883300

1
,,
~
R@&s and Timer (Table corhnued)

-Position
Component ,External ;view !Symb& i :(Sec f i g .
, ,pag. 40-5)

Main &je?ion arelay S12b i -10

,

S12a

Yntetyi~tences :and ,electronic devices Table

.Position
:Com.ponent ;External r i e w Bymbols ,(See fig.
;pag. 40~5)
8:
~ ~
1
..i
1 1,
,l ,

Windscree~.wiper .electronic
,inter,mittence ;N14

Electronic ,device for ~headlights 2

,and Nflashing changeover ,<N18

i
,:
~
!Mazard;,and.dire.ction
ligh? .iqtertiittance ;Nd3
1
! )
~

,(*j) lLoc+ed,,in compartment, under .the dashboard, at the sright:of steering!XYkrmn, .aS:per i[m] .~

i,
 1 ,:
~
E L E C T R I C A L S Y S T E M ~~
.

LIGHTING SYkTEM,
For 1.7 electronic injection engines with catalytic convertor; only
EXTERNAL REAR LIGHTIiNG (wiring d i a g r a m )

May 1988; PA333500tj83300

i, ,
 i,
i
r
i
ELECTRICAL S Y S T E M ~

PAN~EL~ I N S T R U M E N T S, SENSORS~ AND TENDERS

For 1.7 electronic injection engine. with catalytic convertor only

CL+TE,R

Front ;view

Rear view

Tachometer - odometer 8 Brake fluid insufficient level warning lamp

Fuel level gauge
Fuel reserve warning lamp
Max coolant temperature warning lamp
Coolant temperature gauge
Rev. counter
Hand brake warning lamp
9 Headlight warning lamp
10 Direction light warning lamp
11 Alternator charge warning lamp
12 Lights warning lamp
13 Insufficient oil pressure Warning lamp
14 Tripodometer reset knob

PA3~3+0,0883~00 40-9 May 1 9 8 8

Cl Electronic rev. counter D7 Hand brake warning lamp
C2 Electronic tachometer DE Fuel reserve warning lamp
c4 Fuel. Ievef gauge. D1~1 Engine oil min.; pressure warning lamp
C6 Coolant temperature- gauge D13, Engine coolanti max. temperature warning
Dl Alternator- charge: warning: lamp l a m p
D2 Direction, light warning. lamp. F12 Cluster lighting, lamg
D3, Side light warning: lamp G5, Connecter ,N
D4 Full- beam warning: lamp G3 Cluster B. connecter
D5 Brake fluid level warning lamp: 67 Cluster R connecter
 ~ ,

kIN-$lT~ LOCATION
For,lo$a\ion of pin-ou& of connectors 1, 2 and 3, refer to the followifx$ figures and tables.
~

Cluster rear view

Borletti type Jaegqr type

8:

Conpector 1 : white Connecter 1 : white

Pin Service, Pin Ser\iice

Connecter for tachimetric pulse generator InterTediat wiring oohneotor

Connecter for tachimetric p+e generator EngiRe Wirihg conheirtsr

- Availabie Engihe wiring Mnnector

Engine wirihg cbnnector

SN Combination switch unit, windscreen

washlwipe pump

6 C N Engine Wiring connectdr

Cork t& 3 : white
7 Min. brake fluid level sensor eRd
Service ALFA~ ROMEO Control wrhirq lamp

Available 8 HN Power window wiring conheotol

B Engine wiring connecter

Ihtermecliate wiring connecter

Available
REtiOVE, AND ~INSTAL~ATION
N Direction indicator intermittence
A s p e r models w .
Fuseholder box to fuse 14 (full beam
warning lamp)

A N Direction indicator intermittence

REMOVE~ AND ~INSTALtiATION
tkJIIIinatiOh of heater fan swltch
As per modek v .

PA33350q8fI3300 iday 1988

40$1-l
~
ii,
11~ FUEL ~s;UPPLY AND REV. COUNTER PULSE ~GENERATOR (wiring diagram)
,s ;i
1,
r _ - - - - - - -y - -1

:
I 0u
1 ~
1, ,
1
I IL--- i .--. <

f- m 11
L- SCSEOS
ION --
lilsn

SLSS l
0Fi
Fr.4

ce
i , 8

May 1988 PA333500883300

l
,
 ELECTRIh SYSTEM :
,;
8

EN&N,E SPOOLING, LUBRICATI.ON; BRAKE P A D WEA~R s~NS~R,,~ BRAKE-CLUTCH

FLljlti MIN. LEVEL SENSOR (wiring diagran)
For 1.7 eledronic injection enghe with #catal,ytic convertor bonIy

PA33350(%?83300 May 1988

 -
7
-

- -

- -

1
-
-
~ -
-

My 1988 PA333500883300
 ELECTRIFAL SYSTEM

WINPSCREEN WASHER

1 Tank
2 Liquid level sensor
3 Windscreen washer pump
4 G a s k e t
5 Pump wiring
6 Delivery tube fo sprayers
7 Plug
8 Pump covering
9 Flller i&t
10 Gaskel
11 Lower fixing screw
12 Upper fixing screw
13 Grave1 guard pf right front wheel

PA333tjOO883300
May 1 9 8 8
 P U M P
8,
REMOVAL AND INSTALLATION
1 REMOVAL AND INSTALLATION
i 1. Remove tank.
:With referqnce to the figure, operate 2. With reference to figure, remove
a s follows:~ covering @ and pump @ press
1. Rembye front right wheel and its fitted into its relative gasket @
relevant grave1 Iguard 0.
3. For pump installation, reverse or&-
2. ,Disc?nnect right side d i r e c t i o n er of removal.
indicator ~
~3 . OpeLating,;from, e n g i n e compart-
, ment, rerhqve press~fit filler inletfitting
WINDSCREEN! WASHER
~l@. ~ ~,
;, 4. Unscr;ew~Uppe,r fixing screw 0. LIQUID LEVEL SENSOR
#i, 5. !Opei.a$ng froml under wheel arch,
,, unscrew~ +rew 0 a n d l o w e r t a n k
0. ~: REMOVAL AND INSTALLATION
,6. Discomnect level sensor @ wir- 1. Connect the two ends of tester to
;~ ing )and ki~ring @ from pump 0. As per figure, operate as follows: sensor connecter by operating as per
1. Disconnect tank @ and lower it, f\gure.
,;7. Disc@nekt tube cc> f r o m p u m p ,
as stated at tank pp toi step 0. ~ 2. Check sensor proper functioning
8, remove ta& and drain liquid.
2. Disconnect sensor @ wiring and , by verifying the following.
1 8 . I f ndcessery, r e m o v e pump @
remove it from tank.
completd $th gasket @ a n d sensor
3. Proceed to installation, operating Float liftes: 00
@ with qssociated gasket from tank
in reverse order to removal. FLoat lowered: 0 D
a, ,
9. For ta& installation, reverse order
of removal!

May 1988 40-l 6 PA333500883300

 E L E C T R I C A L SYSTEM~ ~~

A : STARTING - CHARGING 842 Lamp dimmer rheostat

843 Interna1 control switch for door unlock
A l Bttery 844 Rear spot light control switch
A2 Alternator 845 Identification light control switch
A3 Alternator with integral electronic voltage regulator 846 Two note,horns - normal lhorns control switch
A4~ Voltage regulator 047 Sun roof motor control switch
A5: Ignition distributor 848 Intercom system control switch
A59 Ighition distributor A 849 Speakllisten changeover switch
A5b Ignition distributor B 850 Sirencontrol. switch
A6 Pulse generator 851 Driver:s seat heater control switch
A 7 Rotor
A8 Ignition coil
Asa Ignition coil A c: INSTRUMENTS
A8b Ignition coil B
A9 Coi1 resistor Cl Electronic rev counter
A10 2-way connecter for coi1 c2 Electronic sp,eedometer
Al 1 Starter motor c3 Voltmeter
Al2 Spark plugs c4 Fuel level gauge
Al3 Pre-heating glow plugs c5 Oil pressure gauge
Al4 Alternator table terminal board C6 Coolant temperature gauge
c7 Clock
C8 Space free for instrument
B: MANUAL ELECTRIC CONTROLS c9 Turbocharger air pressure gauge
CIO Cluster (1
B Ignition switch Cl 1 ALFA RO,MEO Control display
82 Windscreen wiper control switch Cl2 Performancegauge display
83 Wfndshield washer and/or headlamp wash/wiper p u m p Cl3 Optoelectronic cluster
control switch Cl4 Warning lamp pane1
.B4 Control switch for side lights. flashing, lowlfull beam () CIO AIBICIDIEIF Cluster connectors
headlamps
B5 ~ Horncontrol switch
~ B6~ Direction indicator control switch D: WAR~NING LAMPS
87 Low beammflashing control switcfl
88 Fjllbeam flashing control switch Dl Alternator charge warning lamp
89 ~ Heated rear window control switch D2 Direction, indicator warnilng lamp
BIO Foglamp control switch D3 Side light warning lamp
Bli Raar fog lamp control switch D4 Full beam warning lamp
812 Road hazard lights control switch D5 Brake fluicl Ibw level warning lamp
813 Passenger compartment front roof lamp control switch D6 Heaterlventilation warning lamp
814 Passenger compartment rear roof lamp control switch D7 Handbrake warning lamp
815 Passenger compartment roof lamp control switch D8 Fuel reserve warning lamp
Bl Cluster lighting dimmer rheostat D9 Choke warning lamp
Bli Gearbox oil level warning lamp switch Dl0 Handbrake ON - brake fluid level warning lamp
SI8 Door,lock control switch on front right door Dl 1 Engine oil minimum pressure warning lamp
SI9 Door lock control switch on front left door Dl2 Pre-heating glow plug waining lamp
BT? Interior door locking,switch Dl3 Engine coolant high temperature warning lamp
821 Front right power window control switch Dl4 Maximum air pressure warning lamp
822 Fr,ont left power window control switch Dl5 Minimumfuel pressure warning lamp
823 Rear right powar windbw control switch Dl6 Free warning lamp
824 Rear left power window control switch Dl7 Gear position warning lamp
825 Rear power window inhibitor switch Dl8 Manual injection advance, warning lamp
826 ~Rear power window and rear cigar lighter inhibitor swifch Dl9 Brake ,pad wear warning lamp
827 ~ Fr,ont seat height control switch D20 Rear drive engagement warning lamp
828 Front left backrest control switch D21 ALFA ROMEO Control warning lamp
829 ~ Front right backrest control switch D22 Heated rear yindow warning lamp
B3o Door mirror control switch D23 Hazard light warning lamp
B31 Antenna control switch D24 Rear fog light warning lanp
832 ~W/ndshield washer pump control D25 Fog light warning lamp
833 Fr#ont spot light switch D2fS Injection diagnosis warning lamp
834 Rear left spot light switch D27 A.B.S. system warning lamp
835 ~Rear right spot light switch D28 Ident,i/ication light warning lamp
839 Door mirror double control switch D29 Ignitidn diaghosis warning lamp (antiknocking)
637 , Parking light control switch
638 Rear window wiper control switch
839 Trip odometer recall microswitch E: EXTERNAL LIGHTS
840 Tr:ip odometer reset microswitch
841 VF electronic rheostat E l Front direction indicator

PAb;35&?883300 '40-17 ~ ~ May 1988

 E:~ EXTERNAL LIGHTS fcontinued) GI2 Connectai b e t w e e n b o a r d w i r i n g a n d courtesy m i r r o r
88 shitch: I ,
:
1 E2 Front side light GI3 Connecter between board wiring and console wiring
E 3 Front direction indicator and side light GI4 3-way connecter ~ between board wiring and door wiring
;: E4 Frdnt side marker light GI5 2,,way connectorbetween board wiring and door wiring
E5 Loy beam light G16 6-way connecter between board wiring and door wiring
E 6 Low bea,m light with incorporated side light GI7 Connecter b e t w e e n b o a r d w i r i n g a n d f r o n t r i g h t door
, E7 Ful~l beam light wiring
: E8 $0~ and fullbeam light G18 Connecter between board wiring and front left door wiring
E9 Side repaater GI9 Connecter between board wiring and pessenger compart-
E l 0 ,Fog light ment roof lamp
~', Eil Rear direction indicator G20 Connecter for front right door - locking motor
El2 Rear side marker light G21 Connecter for front right door wiring
G22 Connecter for front left door - locking motor ~
El3 Rear parking light
E l 4 Re~ars~in~glight G23 Connecter for front left door wiring
8 E l 5 Sto,p liglit G24 Connecter for rear right door T locking motor
, El6 Rear fbg lamp G25 Connectorl for rear right door hiring
E l 7 Numberplate l i g h t G26 Connecter forrear left door - locking motor
El8 Stop and rear side light G27 Connecter for reai left door wiring
El 9 Rear right light G 2 8 Connecter, between front right door w i r i n g a n d p o w e r
E20 Rear left ligh,t window switch
~ E21 Inspection light G28a Connecter between rear right door w i r i n g a n d p o w e r
,# window switch:
E 2 2 Ide(ntif,ication l i g h t
1 G 2 9 Connectai b e t w e e n door Iock w i r i n g a n d r e a r p o w e r
~; 1
1, ,, Windows ~ ~
INTERIOR LIGHTS G30 Connecter for,power Windows and door lock
1 F: l, ,,
! G31 Connecter, b e t w e e n f r o n t l e f t door w i r i n g mand p o w e r
FI Passenger compartment front roof lamp window yitch
F2 Passenger compartment rear roof lamp G31a Connecter between rear left door wiring and power window
F 3 Pas~senger compartment roof lamp switch
F 4 5ngine compartment lamp G 3 2 Connecter between console wiring and rear right door
F5 Luggage compartment lamp wiring
F 6 Dobr op,en si,gnalling light G33 Connecton between console wiring and rear left door wiring
,; Fuse li:ght G34 Connecter, for power window supply table
F!
Heaterlventilation control lighting lamp G35 Connecter betweien rear wi(ing and rear right tail light
F?
F9 Glovebo,x light wiring, ~i
1,:,
G36 Connectoq forspower window switch tables
~, Fi; b;;;hl
G 3 7 Connectai for combmation switch on steering column
, FI2 Cldster l i g h t G 3 8 Connectai forlair conditioner wiring
,l Fi 3 Front spot light G39 Connecta; for clock
~ FI4 Rer right spot light G40 Connecter for door lock control unit
ml FI5 Rear lefi s p o t l i g h t G41 Connecter f o r t a c h y m e t r i c switch _ r e v counter puise
FI6 Ign~ition s w i t c h l i g h t generator
F17 Swhch illumination light G42 Connecter between alternator and min engine oil pressure
FI8 Rear spot light switch
FI9 Passenger compartment roof lamp - right side G43 Connecter for heater/ventilation control tables
F20 Passenger compartment roof lamp - left side G44 Connecter for rear fog lamp
F21 Readingspot light with switch - right side G45 Connecter for headlight washlwipe tables
F22 ~Reading light with switch - left side G46 Connecter for headlights
F23 Floor !ighting lamp on right interna1 valance pane1 G 4 7 Connecter for right side - repe~ater tables
F24 Floor lighting lamp on left interna1 vafance pane1 G48 Connecter between electric ldoor, mirror and left side .
, F25 Vanitymirror roof lighting on sun visor repeater tables
F26 Gearbox lever pane1 lighting lamp G49 Connecta( aveilable
G50 Provision for loud speaker tables
G 5 1 Provision for car radio tables
I
G; FUSEBOX - CONNECTORS - GROUNDS G52 Fusebox ground
G53 Engine compartment ground
GJ Fusebox G53a Engine compartment ground - right side
: G2 Atrlxiliar,y fusebox G53b Engine compartment ground - left side
G3 Fusebbx terminal G54 Passenger compartment ground
G4 Frke fhsebox G54a Passengercompartment ground - right side
GS Miltiple connecter G54b Passenger compartment ground - left side
G6 Multiple connecter 6 - cluster G55 Valance pane1 #ground
G 7 Miltiple connecter R - cluster G56 Branch terminal board
G8 Singleiconnector G57 Provision for fuel tut-off solenoid valve
G9 Coinnector between, front left door wiring and door mirror G58 Connecter for ciger lighter
swbl G 5 9 Connecter for,electric door miirror
G,l 0 Co~nnector between front right door wiring and door mirror G60 Injection biring ground
Switch G 6 1 Connecter forign~ition coil
Gil 1 Colnnector between board wiring and rear wiring G62 Clutch switch connecter :
,;,

G: ~FUSEBOX - C O N N E C T O R S - GROUNDS (continuedj G99e Connecter for engine dashboard (Ej

GI 00 Connecter for console - doors wiring
G63, Rear ground GlOl T r i p C o m p u t e r connecter
G63a Rear right ground G 1 0 2 Optoelectroniccluster connecter
G63b Rear left ground GI03 Connecter for ground. and brake fluid tank
G 6 4 ~ Connecter for Trip Computer - clock G104 Connector for roof pane1 left pillar
G 6 5 ~Coa:xial table G105 Connecter for ashtray lamp
G66 Motronic wiring ground G106 Seat grounds
G 6 7 Moyinic connecter GI07 Connecter for fuel pump
G68 Con,nector A with board wiring GI08 CEM wiring ground
G69 Connector#B with board wiring G109 Injection, wiring ground
,G79 Connecter C with board wiring Gl 10 Thermostat housing ground
G71 Con;necter for warning lamp on instruments GI 11 Connecter for deshboard instrument wiring
G72 Cormector for Seat back adjustment wiring GI 12aConnector A for roof wiring
G73 ~Connecter for rear services GI 12bConnector B for roof wiring
G73a Connector for right reer services G112cConnector C for roof wiring
G73b Con;necter for left rear services G112d Connecter D for roof wiring
G74 Co&ctors between Televel rear wiring and ALFA ROMEO GI 13 Connecter for front left-hand fender
Control G114 Connecter for outside temperature sensor
G75 Con,nector b e t w e e n r i g h t a n d l e f t r o o f pane1 s e r v i c e s GI 15 Connecter for tow bar vehicle socket
,G76 Connecto\ for roof pane1 services - right sida G116 Connecter for tow bar trailer plug
G77 Con~nactor for roof pane1 services- ieft side GI 17 Connectorfor engine compartment lamp
G78 Conlnector for front door services wiring GI 18 Connecter for luggage compartment lamp
#G79 ~Connectoi for rear door services wiring GI 19 Connecter for vanity mirroq roof lamp
G80 Corrnecton for board wirmg GI 20 Connecter for map reading lamp
G81 I Connector for front left Seat back adjustment G121 Connecter for vehicle wiring
G82 ~Connecter for front right Seat back adjustment GI 22 Connecter for ignition wiring
,G83 Rear connecter for fast idle device G123 Pedal assembly ground
G84 Consqle table connecter GI24 Connecter for A.B.S. system
,G84a Console table connecter (15 wayj G125 A.B.S. system free fuse holder
G84b Console table connecter (12-wayj GI 26 Fuse protecting A.B.S. system relays
IG85 I Front service connecter GI27 Free fuse holder for identification lights
G86 Connecter for passenger compartment roof lamp GI28 IFrea fuse holder fortransce(ver
,G87 Connecter for rear door. locking motors GI29 Connecter fpr ltwo-notehorns - normal horns in engine
G88 Conne.ctor for rear tail lights compartment laft side
G 8 9 mtermediate connecter A GI30 Switchesmconnector
G90 I)ntermediate connecter B G I 31 Groundion u,pper caver
G91 Rear#doorlsensor g r o u n d GI 32 Ground Ion manifold
:G92 ~Luggage.compartment ground G133aElectronic injection - ignitio~n wiring connecter A
G93 Windshiel,d frame upper cross member ground G133bElectronic injection - ignition wiring connecter B
G94 ~Eng/ne compartment connecter GI34 L e f t f r o n t pi!lar connecter
G94a~ !O-way connecter for engine compartment GI35 Rear window sfielf wiring connecter
G94b 8.wy connecter for engine compartment G136 Front side marker intermediate connecter
G94c Engine compartment connecter - right side GI37 Injectionsupply wiring connecter
G94d Engine compartment connecter - left side GI38 Headlights - combination switch connecter
sG95 ~ Central fusebox GI39 Intercom system control unit connecter
G95A Connecter for switches GI40 Petrol pump attachment Nto floor services intermediate
;G95B Connectorl for swirches connectbr
G95C Connecter for cluster warning lamps G141 Intermediata connecter for iear sidemarker
G95D Connecter, for ALFA ROMEO Control G142 Engine services connecter
G955 Connecter for console GI43 C e n t r a l bulkhead g r o u n d
G95F Connecter for fog light - rear fog light G 1 4 4 Backdoor w i r i n g connecter
G95G Cannector for combination switch G227 Mudguaid under! pane1 SecViCe connecter
G95H Connecter for LH interface H: SWITCHES
G951 Connecter for RH interface
G95L Conhector for clock . rheostats Hl Handbrake switch
;G95M Connecter for sun - roof H2 Reversing light switch
,,G95N Connecter for battery H3 Stop light switch
G95.0 Gonhector for ignition switch H4 Passenger compartment roof lamp switch on pillar
G95P Co.nnector for door services H5 Left front door open indicator switdh
G95Q Con.nectorl for performance gauge H6 Right front door open indicator switch
G95R Connecter, for heated rear window H7 Leftrear door open indicator switch
G95S onnector for cluster H8 Right rear door :open indicabor switch
G95V FL& H9 Right front brake pad switch
G 9 6 ~Single connecter for ALFA ,ROMEO C o n t r o l - c l u s t e r HI0 Left front brake pad switch
G97 Connect0.r for left doors services Hll Right rear braka pad switch i
698 i Connecter for right doors serv.ices HI2 Left rear brake pad switch
G99,ai Conoector for engine dashboard (A) H13 Choke switch
G99,b Connecter for engine dashboard (Bj H14 Injection ,advance switch
G99c. Co,nnec,tor for engine dashboard (Cj H15 Gearbox oil law, level switch, (magnetic bulbl
G9.9dI Conrtector for engine dashboard (D.) H16 Starting and back-up inhibitor switch
 H: SW~ITCHES fcontinued) 146 Siren relay
147 Oil radiator electr(c fan relay
Hi 7 Brake fluid minimum level check switch
H i 8 Fast-idle switch in gearbox
HI9 Low fuel pressure switch L: SENDERS
HZ0 Ine~rtiaswitch
HZ1 Clutch, pedal fast idle switch Ll Low fuel pressumsender
HZ2 Igniition microswitch L2 Low oit pressure sender
HZ3 Engine compartment lamp switch L3 Max air pressure sender
HZ4 Luggagecompartment lamp switch L4 Thermal switch for engine cooling electromagnetic coupling
HZ5 Glovebox light switch L5 Thermal switch for engine coolant max temperature
H i 6 Cohtact switfh on rear door for rear window wiper warning lamp
HZ7 Coptact switch on rear door for heated rear window L6 Thermal switch for engine cooling electric fan
HZ8 Cadbudettor contact/switch L7 ~ Engine coolant temperature gauge sender
HZ9 Switch, for rear drive engagement warning lamp L8 Oil pressure gauge sender
H30 R.p.ml -,activated microswitch L9 Fuel level gauge sender
H31 Swjtchfor idle r p.m. adjusting screw on carburettor LlO Sender for, engine coolant temperature gauge and max tem-
H32 Microswitch on carburettor for inserting timing variator perature warning lamp contact
H33 Numberplate lights contact switch Ll 1 Retarded rotor arm tut-out pressure switch
H34 A.B.S. system brake fluid tank switch L12 Engine oil level sensor
H35 Fuel pre-heating filter thermal switch L13 Windscreen washirtgliquid level sensor
H36 Diesel fuel post-heating microswitch L14 Engjne coolanti level sensor
~ L15 Fyelflow sensor
,
1: 1; L16 Rev counter ptilseigenerator
;,
,,: R,~
E~LAYS L17 Speedomefer pulse generator
,l L18 L o a d sender
II Engin4 cooling fan relay L19 External temperature sensor
12 Heated rear window relay L20 Photoelectsic cell
13 Horn relay L21 Pierburg valve (Solenoid valve regulating the supercharging
14 Headlamp wiper relay pressure)
15 Auxiliary relay for headlight wiper timer L22 Knocking sensor
16 Fa$t idle relay L23 Potentiometer
17 Fuel p/pe closing relay L24 Coolant temperature sensor for ignition advance adjustment
18 Relay excluding retarded rotor arm L25 Thermal switch fcir engine coolant temperature
19 Gldw plug relay L26 V a c u u m sensor ~
110 Sta~rter inhibitor relay L27 Teniperatuie,sensor
II 1Front power window and Seat raising relay L28 Fr,ont right,brake sensor
112 Front powar window relay L29 Fr,ont left (brake sensor
:! 11~3Rear power window relay L30 Rearrightbrake sensor
: 114 Brake fluid automatic warning lamp control relav .L31 Rear left brake, sensor
,l, Il5 Low friel pressure warning light relav L32 Supercharging,air pressure sender
,N 116 Headlight relay L33 Two-level thermal: switch
1 1 7 Fog light relay
118 Double contact relay
Il,,9 Headlight washer pump relay M: SOLENOIDS - SOLENOID VALVES
1 2 0 Beam charrgeover relay
121 Full beam exclusion relay Ml Fuel tut-off solenoid valve ,
122 Low beam exclusion relay M2 Injection pump solenoid valve
Supplementary engine cooling fan relay M3 Solenoid with injection pump fuel tut-off microswhch
Diiectjon and hazard lights relay M4 Fast idle solenoid
Rear fog light relay M5 Engine stop solenoid
@of lamp relay M6 Fuel pipe closihg solenoid ~
Seat height adjustment relav M7 Door opeiing/closing solenoid
Haiard light relay M8 Auxiliary air device (for A/C equipped car)
129 Fu!el pump relay M9 Pierburg solenoid valve (for idle r.p.m.1
130 Relay swith CEM diode Ml0 Brake fluid adjustment valves
131 Front ;powar windows/heater relay Ml 1 Main A!B.S. valve
f 132 Advaye variation control unit relay
Cabburetor microswitch relay
,, 133
, 134 Re,ar f,og light exclusion relay N: ELECTRONIC DEVICES - INTERMITTENCES- TIMERS
135 Ky operated supply relav
136 Re:layifor brake wear and liquid levi?l Nl Electronic ignitio? module
137 Relay~for A.B.S. system control unit Nla Electronic ignition module A
138 buxiliary A.B.,S. system relay Nlb Electronic ignition module B
139 Brakesfluid level warning lamp relay N2 Connecter for Marelli module,
140 A.B.SI system brake fluid pump relay N3 Capacitor,for electronic ignition
141 Two note horns - normal horns relay N4 Connecter for Bosch module ~
142 TWO note horns relay N5 Tachymet!ric switch device
1 4 3 Inspection lamp relay N6 Pre heating glow plug timer
144 Fu~el pre heating device relay N7 Trip Computer
145 External rearview mirrors defrosting relay N8 ALFA ROMEO Control

PA333500883300 <
40-20
A
 SAFETY DEVICES S12a Fuel pump Motronic relay
S12b Motronic relay withdiode
Seat belt device SI~C Timingjvariator devi,ce Motronic relay
Catalytic muffler temperature indicatbr S12d Auxfliary Motronlc relay
Thermocouple for catalytlc muffler temperature detection s13 Timfngsensor
Suzzer signalllng unfastened seatbelt SI4 ~Rev sensor
Ruuer signalllng open door S15 i ThhQ variator devlce
Ddometer Si6 Altitude compensation device
Seat belt warning lamp SI7 CEM control unit
30,000: mile warnlng lamp S17a CEM control unit whlte connecter
!Push-button switch on Seat belts S17b CEM control unit black connecter
&talytlc muffler maximum temperature warnlng lamp S16 Throttle angle sensor
!Front left door swltch for Seat belt device SI9 Hall sensor l
520 ,Deton lsensor ~
521 Throttle actuatoi
ELECTRONIC INJECTION s22 ; Electroinjector terminal
S23 ~Electroinjector resistor
Injection control unlt S24 ~Electroinjector terminal board
Relay set S26 Injection system
Electrolnjectors S27 Lambda probe resistance
Cold start electroinjectors S26 Injection control relay
Air flow sensor S29 Mlnim,um adjustment a c t u a t o r
Accelerator throttle switch S32 ) Lambda probe coder
, i
,Englne coolant temperature sensor ,
Thermo-time switch
Supplementary air valve T: ~DIAGNOSIS
Lambda probe
Motronic control unit Tl ALFA!TESTER connecter
Motronic relay T2 Flashing Code diagnosis connecter

gc:tober 1988 40=2? PA333500883301

i
 r

,l
BODY-SHEET METAL PANE,LS ~

GEI$ER~AL INFORMATION . . . . . . . . . 49-2 BODY CO~NSTRUCTION . . . . . . . . . . . (1

Identification codes ............ (*) BODY SEALIING . . . . :. . . . . . . . . . . . (1
Lifting points . . . . . . . . . . . . . . . . . (1 BODY ALIGNMENT . . . . . . . . . . . . . . (1
,Wheel ,alignment . . . . . . . . . . . . . . . 49-2 CAUTIONS FOR THE OPERATORS . . (1
BO& COMPONENT PARTS . . . . . . . . (1 REPLAmCEMENT OPERATIONS . . . . . . (1
1
88

(1 Refer to WORKSHOP MANUAL (A-) VOLUME I

and VOLUME II - Group 49

PA333500883300 May 1 9 8 8
 ,,

G E N E R A L INFO-R-MATION
l
WHEEL ALIGNMENT

CAUT&
The techmcians assigned to the repair and replacement operations of sheet panels,shall always take into account, content of
the remaining part of the Workshop Manual in order always to maintain original quality and functioning conditions of car
as a whole. As, restoration of car correct alignment is of particular importance, ~fn the~following part are provided the data
relevantto geometr,y of both front andmrear suspensions. For any further information. refer to the specific Groups.

,/ Whkel aligkment is measured with car under nominal height (sec: Group Coi.
0, !,
i;
8,

~ 1. Front &le qnd suspension
1, 1
33*x
Mode1
331.3 3 3 1.7 *

331.3 s 3 3 1.7 IE
33l.BTD
33 1 . 5 l-l

Feature; 331.5 a x a

~, ,,i

Toe-out
~ Toe-outiangle ,_

Rim diaineter
;,~ mm (in) 0 =, 34Q 0 = 365 0 = 340
8,
;, 1
1
C a m b e r :an~gle (3=-l30 (3 = - 10 55 i 30
,

Caster abgie y=,2Oi-30 y=lOk30

External angle 6, = 270 50 6, = 290 3 3

Max steering angle
~ Interna1 angle :6, = 330 45' 6;= 35010'

,i
,il i,

2. Rea( axl,e and s u s p e n s i o n

:
331.s l-l 331.5 axa
33l.eTD
33 1.7 * 33 q.7 +
Electronic
injection

,! T o e - i n anile u=-20*10 u=QO*25

1
,i ,i,
, Camb,eratgle ~ fi = 00 f 25

! (*) Not marketed in all countries with 1.2 engine.

~
i
~
f
,l,

, 1;

49-2 PA333500883300
 _.

, Y

BODY-SHEET MET& PAhELS

CONTENTS ~, ~
~
GEjrl+AL INFORMATION . . . . . . . . . . . . . 49-2 BODY CONSTRUGTION . . . . . . . . . . . . . . (*)
,,
~Identification codes . . . . . . . . . . . . . . . . (*) BODY SEALiNG .......... . . . . . . . . . . . (*)
~L(fting points . . . . . . . . . . . . . . . . . . . . . .(*) BODY ALIGNMENT ....... . . . . . . . . . . . (*)
~
Wheel alignment . . . . . . . . . . . . . . . . . . . 49-2 CAUTIONS FOR THE IOPERATORS . . . . (*)
,
, -_ B?D;~ CPMPONENT PARTS . . . . . . . . . . . (*) REPLACEMENT OPEijATIONS . . . .,. . . . . (*)

() Refer to: WORKSHOP MANUAL ~(Aifa33)

-VOLUME I and VOLUME II - Groqp 49 ~

PA3)335ooobswoo MARCH 1988

$,, m!,
GENERAL INFORMATION
! :

WHEEL ALIGNMENT
:i,
8

CAUTION:,
,1 In orde,r ~toi maintain the original quality and functioning of the vehicle as a whole. technicians must;always keeb in mind and refer to the other
;j parts of rthe Workshop Manual. However. as correct alignment of the vehicle is of particular importance, the data relating to the geometry of
both front and rear suspensions is given below. For any further information refer to the specific groups.
,

Wheel alignment ii measured with carat nominal height (see: Group 00).

,l ~ ~
1,s

1. Frotit laile and suspension.

Models

33 1.7 UXA A

Toe-ot mm M-H=212

a= 10 a= 10

R,im diamet+r mm 340 365 (1) 340 365 (1) 340

/
~
Ckmber angle (3 = -10 +-30 p = -1%5 f30
;,
: ,
~; Casteria/7gly ~ y=20 lrc30 y = 10 230
8
External angle 6, = 29O 33
Max sfedring angle
Interna1 angle 6, = 33O 45 6,=35OlO

(1) With 51/2 J rim x 14 rim

i

2. Re@l @xle and suspension

[[
I l

T o e - i n adgle, a = - 2 0 *lO a = 0 +25 1

Catynbqr ingle

(A) With: electronic injection engine for countries where antipollution regulations are in force:

, MAY lh8 49-2 PA3335OOOOS WO 1