VN VP Commodore Calais Workshop Manual

! : r : : i : r r . :

Lexcen Station Wagon

Commodore Executive Station Wagon

Commodore S

Not for distribution outside of AllCarManuals.com

CONTENTS

INTRODUCTIONVEHICLE IDENTIFICATION ANDGENERALSPECIFICATIONS . . .Vehicle identificationGeneral vehicle specifications . .

GENERAL INFORMATIONTools and equipmentSafetyGeneral repair procedures

LUBRICATION AND MAINTENANCESpecifications . . .How to grease and oil changeService schedule

WHEELS AND TYRESS p e c i f i c a t i o n s . . . .How to change a wheelTyre wear trouble shootingCare and maintenance . .

ENGINE TUNE-T'PTune-up specifications . .Tune-up operations

ROADSIDE TROUBLE SHOOTINGTrouble shootingTo check ignition and electrical systemTo check the fuel sYstemTo check the mechanical sYstem

ENGINESpecifications . .Engine mechanical trouble shootingDescriptionEngine assemblyDrive belt tensioner assemblYManifoldsRocker arms and Pushrods

EMISSION CONTROLIntroduction . . .Positive crankcase ventilation (PCV) system

Evaporative control sYstemExhaust control sYstem

CLUTCHSpecificationsClutch trouble shootingDescriptionClutch unit and release mechanism

122122

777

E8

1011

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125125r25126126128129

131131

l4145145147t4it14E148

151151151153153

balance shaft gears

ptpe .

Clutch cableClutch pedal

MANUAL TRANSMISSIONSpecificationsTransmission trouble shootingPropeller shaft trouble shootingDescriptionT r a n s m i s s i o n a s s e m b l y . - - . : . t . : . .

Propeller shaft assemblY . .

AUTOMATIC TRANSMISSIONSpecificationsDPglllr!4nvut

Automatic transmission troubltrouble shootingDescriptionTransmission fluidKickdowncable . . .Selector linkageNeutral safety switchTransmission assemblY

REAR AXLESpecifications . . .Rear axle trouble shootingDescriptionAxle shaft and bearingDrive pinion oil sealCover plate gasketDifferential and Frnal drive assemblyRear axle assemblyLimited slip differential

STEERINGPART 1. STEERING TROUBLE SHOOTINGFaults, causes and remediesPART 2. POWER STEERINGS p e c i f i c a t i o n s . . . . .DescriptionPreliminary inspectionand testing

minor repairsIn car adjustments andSteering wheelSteering columnIntermediate shaft assemblYPower steering gear assemblYPower steering PumPPART 3. MANUAL STEERINGSpecifrcationsSteering gear assembly . . .Steering wheelSteering columnIntermediate shaft assemblY

FRONT SUSPENSION .SpecificationsFiont suspension trouble shootingDescriptionF r o n t h u b . r . .

Suspension unitLower control armBall jointRadius rod . .Stabiliser barSuspension crossmemberSuspension and steering angles

REAR SUSPENSION .Specifications

131132133133t{r14t4

Hydraulic tappetsCvlinder heads

r54155155155157

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Timing cover .Timing chain, sprockets andCamshaft and balance shaftOil pumpSump and oil pump Pick-uPCrankshaft oil sealsPistons, connecting rods and cylinder bores .

Crankshaft and bearingsFlywheeUdrive plateEnginemountings . . . !Exhaust system

COOLING AND HEATING SYSTEMSSpecifications . . .Cooling system trouble shootingHeater and air conditioning trouble shooting

DescriptionRadiatorCooting fan and coolant temperature sensor

Thermostat . . .Water pumpWelch plugsIleater unit and blower motorHeater and air conditioning controlsAir conditioning

FUEL AND ENGINE MANAGEMENTSpecifications . . .Fuel and engine management trouble shooting

DescriptionService precautions and proceduresSystem diagnosisFuel supply comPonentsAir flow componentsElectronic componentsCruise control

16116116216216316t6168170t70170173r73r73

t74r741741751761771791791791E0180181

183183


Contents

Rear suspensionDescription . . .Shock absorbers

trouble shooting Sump and oil pump pick-up pipe .Crankshaft oil sealsSupport brace .Pistons, connecting rods and cylin6sr bores .Flywheel/Drive plate

COOLING AI\D IIEATING SYSTEMSDescriptionRadiatorHeater and air conditioning controlsAir conditioning. .

CLUTCII AND AUTOMATICTRANSMISSIONClutchAutomatic transmission

REAR AXLE, STEERING ANDFRONT SUSPENSION .Rear axleIteerinSFront suspension

REAR SUSPENSION AND BRAKESRearsuspension. ..Brakes

ELECTRICAL SYSTEMStarter motorC o m b i n a t i o n s w i t c h : : : : : : : : : : : : ' ' 'l l andb rakewarn ing lampsw i t ch . : : : : : : . : : . : : :Radio/CassetteTo check and renew fuses and fusible links.Windscreen wiper arms . . . .Lamp unitsWiring diagrams

BODY.Front and rear doors .Tailgate

PART z.I99IMODELS

E N G I N E . ! . .Specifications . .DescriptionDrive belt tensionerInletmanifold. . .Exhaust manifoldsRocker arms and pushrodsCylinder headsTiming cover

Tfuning qh.io, sprockets and balance shaft gearsCamshaft and balance shaft .Oil pumpSump and oil pump pick-up pipe .Crankshaft oil sealsPistons, connecting rods and cylinder hores .Crankshaftand bearings . . .Exhaust system

COOLING AND HEATING SYSTEMSSpecifications . .Desc r i p t i on ! . , .R a d i a t o r . . . .Thermostat

FUEL AND ENGIIYE MANAGEMENT ANDEMISSION CONTROLFuel and engine management . . .Emission control

CLUTCH, MANUAL TRANSMISSION, AUTOMATICTRANSMISSIONANDELECTRICAL SYSTEM. . . . .Clutch and manual transmlssionAutomatictransmission . r . .Electrical system

COIYVERSION TABLES

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Coil springs . .Upper suspension armsLower suspension armsStabiliser barPanhard rodBRAKESSpecificationsBrakes trouble shootingDescriptionMaster cylinderFront disc brakesRear disc brake assemblyHandbrake lever and cable .B,rake adjustmentsHydraulic systemBrake servo unitB rakepeda l . , . .ELECTRICAL SYSTEM .Specifications. . . -. . . :: : : : : : : : : : : : : : : : : : : : :lattery and charging system trouble shootingI*!"ry aud starting system trouble shootingLighting system trotble shootingTurn signal lamp trouble shootingTest equipment and some applicahonsB{teryAlternatorStarter motor - automatic transmission modelsStarter motor - manual transmission models!t"."itrg wheel and horn pad .Ignition systemSwitches and controls . . .rnstrument clusterRadior/cassette

lqnp unlts .Wiper motors and armsHeater blower motorFuses, fusible links and relaysTrailer wiringWiring diagra+sBODYWindscreen and rear glassFront doors . U0Rear doorsEngine bonnet ZMLuggage compartment lid . .Tailgate 248Radiator grille .Centre consoleS e a t s ! . . .Seat belts ?.SlDashboard

ST]PPLEMENT . 254PART 1. l99O MODELS

279

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VEHICLE IDENTIFICATION, GENBRAL SPECIFICATIONS,LUBRICATION AND MAINTENANCE, WHEELS AND TYRES,ENG_INE TUNE.TTP, ROADSIDE TROUBLB SHOOTING ANDFUEL AIID ENGINE MANAGEMENT. .Vehicle identification and general specifrcationsLubrication and maintenanceWheels and tyresEngine tune-up, roadside trouble shmting and fueland engine msnagement . . .

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ENGINESpecificationspecriptionIocker arms and pushrodsTimingcover . i . . .Camshaft and balance shaft


Refer to supplementfor more information.

I

VEHICLE IDENTIFICATION ANDGENERAL SPECIFICATIONS

1. VEHICLE IDENTIFICATION

When purchasing spare parts or when registeringor insuring a vehicle, it may be necessary to quotevarious identification codes. The locations of thesecodes are as follows.

The Engine Number is stamped on the front lefthand side of the cylinder block. Refer to the side viewof the engine in the Engine section for the exactlocation.

The Vehicle Identification Number is locatedunder the left hand lower corner of the windscreen.

The Compliance Plate is affixed to the left handside of the vehicle bulkhead and contains informationon the vehicle make, model, date of manufacture,identification number and seating capacity.

The Body and Option Identification Plate isaffixed to the right of centre of the vehicle bulkheadand contains information on model identification.paint and trim colours, paint number, engine, trans-mission and axle codes, suspension options and dateof manufacture.

The Tyre Placard is affixed to the inside of theglove compartment or the radiator support panel andcontains information of tyre size, rim size and tyrepressures.

2. GENERAL VEHICLE SPECIFICATIONS

Length:Sedan, except Calais and GLX . 4 850 mmCalais and GLX . . 4 865 mmStation Wagon . . . . 4 896 mm

Wheelbase:S e d a n . . 2 7 3 1 m mStation Wagon 2 822 mm

Front wheel track:Except Calais and GLXCalais and GLX . . I 453 mm

Rear wheel track:Except Calais and GLX . I 478 mmCalais and GLX . . I 480 mm

Location of the various identification plates, refer tothe side view of the engine in the Engine section for

the location of the engine number.

Turning circle (kerb to kerb) . . . . 10.4 metresFuel tank capacity:

f S e d a n . ! . . . . . 6 3 l i t r e sStation Wagon 68 litres

Towing capacity:Standard towbar . 500 kgLoad equalising trailer hitch I 200 kgBody side bracing, trailer brakes,heavy duty towbar, equalising hitch. . . I 590 kg

*Fuel consumption:L/l 00 km L/ 100 km

(City) (Highway)Automatic transmission 12.5 8.0Manual transmission I 1.5 7.6

*The fuel consumption information is based on testsmade according to Australian Standard 2877. Theactual fuel consumption obtained will depend onmany factors including prevailing conditions, drivinghabits, load and the vehicles equipment and con-dition.t85 litre fuel tank optional on some models.


GENERAL INFORMATION

1. TOOLS AhrD EQUIPMENT

To successfully perform any maintenance or re-pair work on a motor vehicle, suitable hand tools areessential. The use of tools for other than their intend-ed purpose or the use of incorrectly fitting tools cancause damage to the component and/or injury to theoperator.

BASIC TOOL KIT

The following is a suggested list of tools andequipment for the majority of the maintenance andrepair procedures described in this manual. Of course,not all of the tools are required for all the jobs, so it iswise to purchase tools on an'as needed'basis.

Set ofoBen ended spanners.Set of ring spanners.Set of socket spanners.Spark plug spanner.Assorted bladed screwdrivers.

Assorted Philips screwdrivers.Assorted pliers combination, long nose, multi-grip, vice grip, snap ring (internal and external).Assorted adjustable spanners.Ball pein hammer.Cold chisels.Pin punches and centre punch.Assorted files.Scraper.Feeler gauges.Torque wrench.Hydraulic jack.Chassis stands.Car ramps.Grease gun.Oil can.Oil gun.Oil filter removal tool.Funnel.Containers for draining oil and washing compon-ents.

A comprehensive tool kit showing a wide range of general hand tools.


Slide hammer, ball ioint puller' assortedpress Plates.

General Information

Assorted test equipment - dwell tachometer, digitalmultimeter, timing light and test lamp.

Inspection lamp.Test lamp.Tachometer.Timing light.Digital multimeter.Piston ring compressor.Valve spring compressor.Micrometer - inside, outside, multi range.Vernier calipers.Assorted pullers.

When purchasing tools, it is sound advice to selectthe highest quality that can be afforded, as theworking life of cheaper tools is often very short.

Tension wrench, piston ring compressor and valvespnng compressor.

Assorted measuring devices - inside and outsidemicrometers, vernier calipers, wire gauges and feeler

gauges.

Ensure that the tools are suitable for the system ofbolt and nut sizing on the vehicle. The range ofvehicles covered by this manual use a combination ofmetric and A/F sizes.

TOOL CARE

To ensure the longest possible life for hand tools,it is important that time be spent maintaining them.

At the conclusion of each job, all tools used shouldbe washed thoroughly in kerosene or similar cleaningsolvent. Ensure that all dirt and grease is removed,particularly from tools with moving parts such aspliers and adjustable spanners. The tools should thenbe wiped dry with a clean cloth.

Measuring devices should be given particularattention as their accuracy can be affected if notproperly maintained. Feeler gauges should be keptclean at all times and the blades should be wiped withan oily cloth after use to prevent rusting.

Views showing the correct tip profiles for a bladedscrewdriver. Bladed screwdrivers should not be

ground to a sharp point.

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I

pullers and


1 0 General Information

If tools are to be stored for any length of time, it isgood policy to wipe them with an oily cloth.

Bladed screwdrivers should be checked for dam-age to the tip. If necessary, the tip can be returned toits original profile by careful grinding. Do not grindscrewdriver tips to a sharp point.

Hammer heads should be secure on their handlesand shoutd be regularly checked for cracking or otherdamage.

Chisels and punches should be checked for dam-age or 'mushrooming' of the head. Any faults shouldbe rectified by grinding.

Hydraulic jacks should be regularly checked forfluid leaks. Chassis stands and car ramps should bechecked for damage and cracks. Any equipment thatis suspect should not be used.

STORES

For routine maintenance, stores of automotiveoils, greases and additives should be kept on hand.The following is a suggested list.

Engine oil.Brake fluid.Manual transmission or automatic transmissionoil - automatic transmission oil is also used inthe power steering system.Rear axle oil.Cooling system corrosion inhibitor/antifreeze.Chassis grease.High melting point grease, for hub bearings etc.Penetrating oil or spray.Kerosene or similar cleaning solvent.Methylated spirits.

Oils and greases are available in handy pack size fordo-it-yourself lube jobs.

2. SAFETY

PERSONAL SAFETY

Safety when working on a motorvehicle is basical-ly a matter of commonsense. Some safety precautionsto prevent personal injuries are as follows.

Raising a VehicleAlways jack a vehicle on firm, level ground and at

the specified jacking points. Ensure that the wheelsremaining on the ground are fully chocked.

After raising the vehicle, place chassis standsunderneath and allow the weight of the vehicle to reston them. Do not use bricks, blocks of wood or similarmaterial.

NOTE: Never work under a vehicle which isonly supported by a jack.

Electrical SystemAlways disconnect the negative battery terminal

when working on any electrical components. Avoidwearing metal watches, rings and chains which mayshort across live terminals.

As battery gases are explosive, keep naked flamesand sparks clear of the work area. When connectingand disconnecting jumper leads, use extreme cautionto avoid sparking.

Electronic lgnition SystemsElectronic ignition systems produce dangerous

high tension voltages in both the primary and second-ary circuits which can be fatal. Exercise extremecaution when working on or near any ignition systemcomponents. Do not disconnect high tension leadswhile the engine is running.

Work AreaDo not run the engine in a confined space. Ensure

that the work area is adequately ventitated.Spilt oil or water should be cleaned immediatelv

to avoid the possibility of slipping.

Fuel SystemAlways disconnect the negative battery terminal

when working on any fuel components. Do not smoke.Keep naked flames and sparks clear of the work area.

Do not syphon fuel using the mouth. Use a handpump or suitable syphon.

Do not attempt to repair a fuel tank by welding it.This is an extremely hazardous procedure and shouldbe entrusted to a specialist.

Cooling SystemTo avoid scalding, use caution when releasing the

radiator cap on an engine which is at normal operatingtemperature. Turn the cap anti-clockwise to the firststop and allow any pressure in the system to release.When the pressure is released, remove the cap fromthe radiator.

BrakesAs asbestos is used in some brake lining material,

avoid inhaling brake dust. Do not use compressed airto remove the dust. Gentle brushing with a smallbrush or using a vacuum cleaner with a hose attach-ment are the safest methods of cleaning the brakes.The above precautions also apply to the clutch platelining material.


General Information 1 l

Lifting EquipmentWhen using lifting equipment to lift heavy com-

ponents such as the engine and/or transmission, usemetal slings or chain in preference to rope. If ropemust be used, ensure that it is not placed against sharpedges on the component.Automotive Lubricants and Solvents

Avoid prolonged skin contact with oils, greasesand solvents as some can cause skin irritations anddermatitis.

Exercise caution when using cleaning solvents asmany are inflammable. Do not smoke. Keep nakedflames and sparks clear of the work area.Compressed Air

Never point an air hose at another person or allowcompressed air to blow onto your skin. High pressureair forced against the skin can enter the bloodstreamand prove fatal.Suspension and Steering Components

Damaged suspension and steering componentsshould not be welded. Many of these components arefabricated from toughened metals. If welded they maylose their strength or become brittle. Damaged com-ponents should be renewed.

Air ConditioningAvoid disconnecting air conditioning hoses as

escaping refrigerant can cause frostbite. The refriger-ant is highly flammable and when burnt, a poisonousgas is produced

VEHICLE SAFETY

To prevent damage to the vehicle during servicingor repair work, note the following precautions.

Brake FluidIf spilt on the vehicle paintwork, brake fluid

should be immediately washed away with clean waterand allowed to dry naturally, not wiped with a cloth.

Catalytic ConverterThe following should be observed to prevent

damage to the catalytic converter:Do not operate the vehicle on leaded fuel.Do not push or tow start the vehicle.Do not allow the engine to idle for prolonged

periods.Do not switch the ignition off while the vehicle is

in motion and the transmission is in gear.Do not'prime'the engine by pouring fuel into the

inlet manifold.Do not operate the vehicle if the engine is

misfiring.Avoid running the vehicle out of fuel.Ensure that the engine oil is formulated to contain

low phosphorus levels.Electronic Components

The electronic components of the ignition andfuel injection systems can be damaged by the use ofincorrect testing equipment.

It is essential in all tests where voltage or resrs-tance is to be measured that a digital display multi-meter with a minimum l0 megohm input impedencebe used.

Some types of tachometers, timing lights andignition system analysers are not compatible withcertain engine electronic systems. It is thereforerecommended that the manufacturer of the test equip-ment be consulted before using the equipment.

Jump starting, or being jump started by anothervehicle can cause damage to the electronic compon-ents of the vehicle. Refer to the Roadside TroubleShooting section for the correct jump starting proce-dure.

3. GENERAL REPAIR PROCEDURES

SEIZED FASTENERS

Seized bolts, nuts or screws should first have aliberal amount of penetrating oil applied. The fastenershould be left for a period of tirne to allow the oil topenetrate and soften the corrosion which is causingthe binding.

Often, a sharp hammer blow to the head of thefastener can dislodge the corrosion and permit it to beloosened.

An impact driver, which can be fitted with asocket or screwdriver bit, can be used to loosen aseized fastener.

Another method is to heat the component inwhich the fastener is seized. However, extreme cau-tion should be exercised when heating aluminiumalloy components as the melting point is much lowerthan that of steel.

If the above methods fail to free a seized nut,carefully hacksaw through one side of the nut until itcan be split. Care should be taken that the threads ofthe bolt or stud are not damaged.

Should a bolt or stud break below the surface ofthe component, it will be necessary to use a screwextractor to remove the remaining part. Follow thescrew extractor manufacturers instructions.

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Tap and die set and assorted screw extractors.


General Information

Damaged threads can be repaired using a die nuton studs and bolts, and a tap on nuts and threadedholes in castings. If the threads of a threaoJo t tte aredamaged leyon{ repair, it will be necesrurv io AriU31d tap the hole to u larger size. Alternatively, aHelicoil insert can be usedlo restore the hole to theoriginal thread size.

STUDS

The simplest method for removing studs is to locktyo lyts together on the threaded section. The studshould then be able to be removed by applyirrg "r,unscrewing action to the lower nut.

Alternatively, there are various makes of studextracting tools available.

Using two nuts locked together to remove a stud.

OIL SEALS

Oil seals can usually be removed by levering outwith a flat screwdriver or other suitabie lever. careshould be taken not to damage the surface of thecomponent which the seal lip runs on.

Seals can also be removeo uy inserting a numberof self tapping screws into rhe s"il body. ii; seat canthen be withdrawn using pliers gripping- ihe selftapping screws.

. Always apply a smear ofgrease or oil to the seal lipprior to installation to prorride initial tuuricaiiln.unless otherwise stated, oil seals should ahvays be

installed with the lip facing inwards or towards thesubstance to be sealed. During installation, the seal lipshould be protected from dimage from .tt"rp com-ponents such as shaft splines by wrapping tape iroundthe sharp edges.

Instal the new_ seal using a wooden block, or asocket or length of tube of rh"e "ppi"p.i"tr JilL"r.r.Ensure that the seal is installed squarity or distortionand subsequent leakage may occ.rr. If an initaliation9"pJh isnot specified, rhe seal shouto u.

-iirtalled

flush with the component surface.

GASKETS

. Ih"," separating mating components (ie cylinderhead and cylinder block), do not rnsert screwdrivers or

similar levers between the components in an attemptto lever them apart. This can cause severe damage tothe sealingsurfaces, particularly if the.o-pon.nts aremade of alloy compounds.. Th9 components can be separated by tapping

along tLe ioint with a soft faced hu-mer or piece ofwood. Before installing a new gasket, the matingsurfaces should be cleaned of a[ Iraces of old gaskelmaterial and sealant.

check that the new gasket is correct by comparingthe bolt holes and passages on the componen't facewith_the openings in the fasket.^ cork and paper gask-ets which have been storedtor some time may suffer from shrinkage. This can berectified by soaking the gasket in water.

BEARINGS AND BUSHESIf the correct equipment is not available when

removing and installing bearings and bushes, it isoften possible to improvise.

Bearings can often be removed from shafts bytapping alternately on opposite sides with a hammerand drift.

A simple bush instailing tool using a bort, nut and twowashers.

_ Ifu press is unavailable, bushes can be instailed byplacing the bush and component between the jaws of avice and screwing the jaws together until th6 6ush isfully inserted. A vice can alio be used to rlmovebushes by using suitably sized spacers against eithervice jaw, one bearing onthe bush ano trrittrrei on thecomponent. This method can also be used with a Gclamp.

A simple removing and installing tool can bema$e usinq a long bolt, large and small-washers, a nutand-a tubular spacer. Refei to the illustrations-for themethod and applications.

Rubber bushes and bushes in blind holes can belgmoyed- gsing . a3 expanding type masonry bolt(Rawlbolt Loxin). Instal a neat fitting -u*ry6olt tothe bush. Insral and tighten the boliuntillirir,ip, tt"bush. The bolt and bush can then be remov"i.*i"g uslide hammer or levers.


General Information l 3

LARGE \I/ASHER

A simple bush removing tool using a bolt, nut, suitablespacer and large and small washers. .

Bushes in blind holes can also be removed usinghydraulic foqce, With the hole packed with grease,insert a neat fitting drift and tap the drift into the hole.

The pressure of the grease on the rear of the bushshould force it from the hole.

ROTATING THE CRANKSHAFT

There are many occasions when it is necessary torotate the crankshaft to a certain position. Theseinclude timing and valve adjustment and checkingvalve timing.

To make the engine easier to rotate, remove thespark plugs. This will relieve compression pressure.

The simplest method is to use a socket or ringspanner on the crankshaft pulley nut and turn theengine in the normal direction of rotation.

On vehicles with manual transmission, the enginecan be turned by selecting top gear and rolling thevehicle forward. A variation of this method is toiaiseone of the driving wheels and, with top gear selected,rotate the driving wheel in a forward direction to turnthe engine.

Alternatively, the engine can be brought to thedesired position by briefly actuating the starter motor.


l 4 Refer to supplementfor more information.

LUBRICATION AND MAINTENANCE

SPECIFICATIONS

CAPACITY AND GRADE

Engine:Lubr i can t . . . I 5W/40SFSump capacity -W i t h f i l t e r . . . . . 4 . 1 l i t r e sWithout filter . . 3.8 litres

Cooling system capacity. . . . Approximately l0litresManual transmission:

Lubr i can t . . . .She l lXGOT5/90Capac i t y . . . . 2 l i t res

Automatrc transmission:Lubricant . . . . . . . Dexron I lDCapacity -Total dry refill I I litresServ iceref i l l . . .4 .8 l i t res

Rear axle:L u b r i c a n t . . . . . S A E 9 0 L SCapacity . I.7 litres

Steering:Steering gear lubricant EP Semi-fluid

lithium based type O greasePower steering lubricant Dexron I lD

Brake fluid type. Dot 3 disc brake fluid

NOTE: Lubricant capacities shown are ap-proximate only. The correct lubricant levelshould be checked at the level plug ordipstick. The specified lubricants for themanual transmission and rear axle havebeen changed during production. If uncer-tain about which oil is currently in use,drain and refill with the specffied oil.

1. HOW TO GREASE AND OIL CHANGE

(1) Run the front of the vehicle onto car rampsand stop the engine.

(2) Raise the rear of the vehicle with a jack untilthe vehicle is level and place chassis stands under therear axle assembly.

(3) Using a wire brush and a cloth, clean aroundthe engine sump drain plug and the transmission andrear axle filler plugs.

(4) Place a drain tin under the engine sump,remove the engine sump drain plug with the appro-

Location of the engine sump drain plug.

priate size ring spanner and allow the engine sump tocompletely drain. The oil will drain more freely if thecap on the rocker cover is also removed.

NOTE: It is best to drain the engine sumpwith the oil at operating temperature.However, if the oil is hot take care to avoidscalding.

When the engine sump has completely drained,instal and firmly tighten the sump drain plug. Wipearound the drain plug after installation.

NOTE: Before installing the sump drainplug check the plug sealing gasket to ensurethat it is serviceable.

Removing the engine oil filter using a filter removaltool.


Lub ri,cati,on and Maintenance 1 5

(6) Remove the filler plugs flom the manual

tranimission and the differential. Use a finger or a

ffitpiece of wire to check the oil levels. The correct

level is when the oil is level with, or fractionally b-.19*

ihe Uottom of the plug hole. Overfilled units should be

diained until the oil is level with the bottom of the

plug hole.^ Ir the oil level is low use the oil gun to fill the

transmission or rear axle to the correct level with the

specified oil.-r When satisfied that the levels are correct instal

anO nrmly tighten the plugs. Wipe around the plugs

with a cloth after installation.

lnstalled view of the manual transmission drain andfiller Plugs.

(5) Remove the oil filter with a filter removal

toot anO allow the residual engine oil to drain into the

drain tin. Smear oil onto the sealing gasket of the new

fiIt., and tighten the filter by hand as D€r the

til6t.ttittg inJtructions supplied with the new filter.

NOTE: Before installing the new , filte.rensure tha{ the sealing gasket from the old

filter has not come awa! frqm the old filter"a.nd adhered itself to thefilter sealing seat

on the engine. lnstalled view of the differential filler plug'

view of the engine compartment showing the various maintenance items. automatic transmission model'


1 6

NOTE: If an automatic transmission isinstalled to the vehicle, refer to the Auto-matic Transmission section for the correctprocedure to check and top up the hydraulicfluid level.

(7) Using a funnel, fill the engine with thespecified amount and grade of engine oil. Start andrun the engine for a few minutes.

Ensure that the oil pressure warning lamp goesout. Stop the engine, wait for a few minutes and checkthe oil level on the dipstick. If necessary, add oil tobring the level to the full mark on the dipstick.

NOTE: To prevent overfilling initially, it is

Lubrication and Maintenance

2. SERVICE SCHEDULE

good policy not to pour all of the specifiedamount of oil into the engine in one go assometimes the amounts specffied are onlyapproximate. It is best to hold back at leasthal-f a litre and top up to the level mark onthe dipstick after the engine has been runfora few minutes.

(8) Check thoroughly for oil leaks at the enginesump plug and engine oil filter.

(9) Referring to the following Service Schedule,lubricate and check all other items which coincidewith the oil change intervals.

(10) Lower the vehicle to the ground.

JOB Weerkly

I OOO km

THOUSAND KILOMETRES

5 1 5 25 35 45 55 65 75 85 95

ENGINE

(l) Check the oil level on the dipstick weekly oreach time the fuel tank is topped up. Top up asnecessary with the correct grade of engine oil.

(2) Drain and refill the crankcase and renew theoil filter initially at 5 000 km or 3 months then everyl0 000 km or 6 months.

NOTE: When operating under dusty con-ditions, predominately short trips, inner citydriving, towing or high speed heavy loadconditions at high temperatures, it is re-commended that the engine oil andfilter arechanged every 5 000 km or 3 months.

(3) Check the condition of the engine drive beltand the position of the belt wear indicator everyl0 000 km or 6 months.

(4) Check the engine compartment hoses andfittings every l0 000 km or 6 months.

(5) Check the condition of the exhaust systemevery 10 000 km or 6 months.

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COOLING SYSTEM(l) Check the coolant level in the surge tank

weekly or each time the fuel tank is topped up.

NOTE: On rnodels where the COLD markon the surge tank is below the join in thetank, the coolant level has been revised toapproximately 25 mm above the join in thetank.

(2) Drain, flush and refill the cooling systemwith the recommended coolant and check the con-dition of the hoses and clamps initially at 35 000 kmor 2l months then every 40 000 km or 24 months.

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Lubrication end Maintenance

JOB

(3) Pressure test the cooling system and thesurge tank cap every 10 000 km or 6 months.

(4) Clean the outside of the radiator and ifapplicable, the air conditioning condenser initially at35 000 km or 21 months then every 40 000 km or 24months.

FUEL AND ENGINE MANAGEMENT(1) Renew the air cleaner element initially at

35 000 km or 21 months then every 40 000 km or24 months.

NOTE: If the vehicle is operating in dustyconditions, renew the air cleaner elementevery 20 000 km or I2 months.

(2) Renew the fuel filter initially at 35 000 km or2l months then every 40 000 km or 24 months.

(3) Check the oxygen sensor operation initiallyat 35 000 km or 2I months then every 40 000 km or 24months.

(4) Check the position and security of the crank-shaft sensor every l0 000 km or 6 months.

(5) Check all the vacuum hoses and fittingsinitially at 15 000 km or 9 months then every 20 000km or l2 months.

CLUTCH AND MANUAL TRANSMISSION

( l) Lubricate the clutch cable initially at 25 000km or I 5 months then every 20 000 km or l2 months.

(2) Check the transmission for oit leaks initiallyat I 5 000 km or 9 months then every l0 000 km or6 months.

(3) Check the transmission oil level initially atI 5 000 km or 9 months then every 20 000 km or t 2months.

NOTE: If the vehicle is used for caravan ortrailer towing, change the manual trans-mission ail every 40 000 km or 24 months.

AUTOMATIC TRANSMISSION

(1) Check the fluid level on the dipstick weeklyor each time the fuel tank is topped up.

(2\ Renew the automatic transmission fluid andthe filter initially at 35 000 km or 21 months thenevery 40 000 km or 24 months.

(3) Renew the automatic transmission filterevery 75 000 km or 45 months.

NOTE: If the vehicle is used for caravan ortrailer towing or inner city driving with longidling periods, the automatic transmissionfluid and filter should be renewed every20 000 km or I2 months.

L7

THOUSAND KILOMETRES


1 8 Lubrication and Maintenance

JOB

(3) Lubricate the transmission shift linkage ini-tially at 25 000 km or \5 months then every 40 000 kmor 24 months.

REAR AXLE(l) Check the rear axle for oil leaks initially at

I 5 000 km or 9 months then every l0 000 km or6 months.

(2) Check the rear axle oil level initially at15 000 km or 9 months then every 20 000 km orl2 months.

(3) If the vehicle is equipped with a limited slipdifferential, change the rear axle oil at 5 000 km or3 months.

NOTE: If the vehicle is used for towing orhigh speed heavy load conditions at hightemperatures, change the limited slip differ-ential oil every 20 000 km or 12 months.The limited slip dffirential can be identi-fied by the red/brown level Plug.

STEERING

(1) Check the fluid level in the power steeringreservoir weekly or each time the fuel tank is toppedup.

(2) Check the steering gear and linkage forsecurity, damage and leaks initially at 15 000 km or9 months then every 10 000 km or 6 months.

NOTE: Check the steering gear and linkagefor security, damage and leaks every 5 000km or 3 months if the vehicle is operating onunsealed roads.

FRONT SUSPENSION

( I ) Inspect the front suspension components forsecurity, damage, wear or leaks initially at 15 000 kmor 9 months then every l0 000 km or 6 months.

NOTE: Reduce the above period to every5 0a0 km or 3 months if the vehicle isoperating on unsealed roads.

(2) Repack and adjust the front hub bearingsinitially at 25 000 km or I 5 months then every 40 000km or 24 months.

BRAKES

(l) Check the fluid level in the master cylinderreservoir weekly or each time the fuel tank is toppedup.

(2) Inspect the brake pads and discs for wearinitially at I 5 000 km or 9 months then every l0 000km or 6 months.

(3) Inspect the handbrake shoe linings anddrums for wear initiallv at 35 000 km or 2l months

THOUSAI\TD KILOMETRES


Lubrication und Maintenance l 9

JOBWeerkly

I OOO kr

THOUSAND KILOMETRES

5 1 5 25 3s 45 55 65 75 85 95

then every 40 000 km or 24 months.NOTE: Reduce the above period to 20 000km or 12 months if the vehicle is operatingon unsealed roads.

(4) Drain, refill and bleed the hydraulic systeminitially at 35 000 km or 2l months then every 40 000km or 24 months.

(5) Inspect all the hydraulic brake lines fordamage or chafing paying particular attention to theflexible hoses initially at l5 000 km or 9 months thenevery 10 000 km or 6 months.

(6) Check the handbrake operation initially atI 5 000 km or 9 months then every l0 000 km or6 months. Adjust as necessary.

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ELECTRICAL SYSTEM(1) Check the battery electrolyte level initiaily at

000 km or 3 months then every l0 000 km ormonths.

56

(2) Renew the spark plugs initially ar l5 000 kmor 9 months then every 20 000 km or 12 months.

(3) Check the high tension lead resistance andcontinuity initially at 7 5 000 km or 45 months thenevery 80 000 km or 48 months.

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BODY(1) Lubricate the door hinges, locks, strikers and

check straps initially at 15 000 km or 9 months thenevery 20 000 km or l2 months.

(2) Inspect the seat belts and check the seat beltoperation initially at 15 000 km or 9 months thenevery 20 000 km or l2 months.

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EMISSION CONTROL(1) Check the operation of the PCV valve initial-

ly at 35 000 km or 2l months then every 40 000 km or24 months.

(2) Check the charcoal canister for damage orleaks initially at 45 000 km or 27 months then every40 000 km or 24 months.

(3) Check the condition and attachment of allthe emission control hoses initially at 15 000 km or9 months then every 10 000 km or 6 months.

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WHEELS AND TYRES(l) Inspect the wheels and tyres, including the

spare wheel for wear and damage, and torque thewheel nuts every l0 000 km or 6 months.

(2) Check the tyre pressures, when the tyres arecold, weekly. Reduce this period to dai[y if the vehicleis constantly driven on long trips or on rough roads.

(3) Rotate the wheels to equalise the tyre wear asrequired.

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20

SPECIFICATIONS

*TYRE PRESSURES

Up to three passengers . . . 180 kPaFully loaded . . 240 kPa*Increase the tyre pressure by 30 kPa if the vehicle isconsistently driven at high speed.

TORQUE WRENCH SETTINGS

Wheel nuts. . . 125 Nm

NOTE: Always refer to the tyre placardlocated on the inside of the glove compart-ment or on the radiator support panel fortyre and wheel sizes and inflation pressures.Refer to local regulations for maximumwheel and tyre sizes if installing optionalequipment.

1. HOW TO CHAI{GE A WHEEL

(l) Ensure that the vehicle is level, on firmground; clear from any passing traffic and contains nopassengers.

(2) If necessary switch on the hazard flashers.(3) Place the transmission in the P (Park) posi-

tion on automatic transmission models or reverse gearon manual transmission models.

(4) Firmly apply the handbrake.(5) On Sedan models, remove the spare wheel,

jack and wheel spanner as follows:(a) Raise the luggage compartment lid and re-

move any loose items that obstruct access to the sparewheel.

(b) Release the retaining strap buckle and pullthe retaining strap away from the spare wheel.

(c) Where installed, remove the spare wheelcover.

(d) Lift up and remove the wheel spanner andthe spare wheel from the luggage compartment.

(e) Using the wheel spanner, lower the jack andremove the jack from the storage bracket.

(6) On Station Wagon models, remove the sparewheel, jack and wheel spanner as follows:

(a) Open the tailgate, roll back the luggagecompartment mat and fully open the spare wheelcompartment cover.


Chock the front and rear of the wheel diagonallyopposite the wheel being changed.

(b) [Jnscrew the spare wheel retaining nut andremove the spare wheel from the vehicle.

(c) Remove the wheel spanner from the storageclips.

(d) Using the wheel spanner, lower the jack andremove the jack from the storage bracket.

(7) When changing a wheel always chock thewheel diagonally opposite to the wheel being re-moved. Ensure that the wheel is chocked at the frontand rear.

(8) Where full wheel trims are installed, removethe wheel trim by inserting the bladed section of thewheel spanner in between the outer edge of the wheeltrim and the wheel.

Pry the wheel trim off the wheel, using the wheelas a levering point. Repeat the above procedure atseveral points around the wheel trim.

Where centre wheel trims are installed, gentlylever the centre trim off the wheel by placing thebladed end of the wheel spanner into the slot in thetrim.

(9) Instal the wheel spanner to a wheel nut insuch a manner that the bar end of the spanner ishorizontal and on the left hand side of the wheel.Apply pressure to the end of the spanner in an anti-clockwise direction and slacken the wheel nut approx-imately half a turn. Carry out the above procedure onthe remaining wheel nuts.

WHEELS AND TYRES


Wheels and Tyres 2r

View of the jack correctly positioned to the rearjacking point.

(10) Instal the jack to the relevant jacking pointunder the body sill panel.

NOTE: The jacking points are identrfied bycutouts in the underbody sill panel. Thecutout must be located in the slot of the jackhead.

(l l) Using the wheel sBanner, raise the vehicleslightly and check that the jack base is flat on theground and that the jack is vertical.

(12) Ensuring that the jack is correctly posi-tioned, raise the vehicle so that the wheel and tyreclear the ground. Allow enough clearance between thetyre and the ground for the spare wheel to be installed.

NOTE: Under no circumstances get underthe vehicle whilst the jack is the only meansaf support.

(13) Unscrew the wheel nuts and remove thewheel.

(14) Instal the spare wheel to the hub and looselyinstal the wheel nuts.

(15) Using the wheel spanner tighten the wheelnuts as much as possible.

View of the jack correctly positioned to the frontjacking point.

(16) Using the wheel spanner to operate the jack,lower the vehicle to the ground.

(17) Using the wheel spanner tighten the wheelnuts in a diagonal sequence. It will be necessary torepeat the above procedure several times until thewheel nuts are securely tightened.

( I 8) Remove the chocks ffom the opposite wheel.(19) Instal the wheel, jack and wheel spanner to

their original storage positions.

NOTE: Repair the flat tyre or damagedwheel as soon as possible and check the tvrepressure on the wheel just installed.

Tightening the wheel nuts using the wheel spanner.

2. TYRE WEAR TROUBLE SHOOTING

ABNORMAL WEAR ON BOTH SIDES OFTREAD

(1) Under inflation of the tyres: Check andinflate to the recommended pressures.

(2) Overloading: Reduce the maximum loading.

ABNORMAL WEAR IN CENTRE OF TREAD(l) Over inflation of the tyres: Check and reduce

to the recommended pressures.


22

ABNORMAL WEAR ON INSIDE OF TREAD

Front Tyres(1) Insufficient camber angle: Check the front

end alignment.(2) Sagging front coil springs: Check and renew

the faulty springs..(3) Loose orworn front hub bearings: Check and

adjust or renew the hub bearings.(4) Bent stub axle: Check and renew the faulty

components.(5) Loose or worn suspension arm components:

Check and renew the faulty components. Align thefront end.

Rear Tyres( I ) BeRt rear axle housing: Check and straighten

or renew the axle housing.(2) Bent suspension arm: Check and renew the

suspension arm.

ABNORMAL WEAR ON OUTSIDE OF TREAD

Front Tyre.s(l) Excessive camber angle: Check the front end

alignrnent.(2) Incorrect coil springs installed: Check and

instal the recommended replacement springs.

Rear Tyres(1) Eicessive speed when cornering: Revise

driving habits.(2\ Bent axle housing: Check and straighten or

renew the axle housing.

SPOTTY OR IRREGULAR WEAR

(l) Static or dynamic unbalance of the wheeland tyre assembly: Check'and balance the wheel andtyre assembly.

(2) Lateral run-out of the wheel: Check andstraighten or renew the wheel.

(3) Excessive play in the hub bearings: Checkand adjust or renew the hub bearings.

(4) Excessive play in the front suspension balljoints: Check and renew the ball joints.

LIGHTLY WORN SPOTS AT CENTRE OFTREAD

(l) Static unbalance of the wheel and tyre as-sembly: Check and balance the wheel and tyre assem-blv.

(2) Radial run-out (eccentricity) of the wheel:Check and renew the wheel.

FLAT SPOTS AT CENTRE OF TREAD

(l) Repeated se' ire brake application: Revisedriving habits.

(2) Lack of tyre rotation: Periodically rotate thewheel and tyre assemblies.

HEEL AND TOE WEAR (SAWTOOTH EFFECT)

(1) Overloading: Revise the maximum loading.(2) High speed driving: Avoid as far as possible.(3) Excessive braking: Revise driving habits.

FEATHERED EDGE ON THE SIDE OF TREADPATTERN

Front Tyres(l) Sharp inside edge - excessive toe-in: Check

and adjust the wheel alignment.(2) One tyre sharp inside edge other tyre sharp

outside edge: Check for a bent steering arm or tie rodand renew.

Rear Tyres

( 1) Worn suspension arm bushes: Check andrenew the bushes.

(2) Suspension arm bent: Check and renew thesuspension arrn.

(3) Bent rear axle housing: Check and straightenor renew the axle housing.

3. CARE AND MAINTENANCE

STEEL WHEELS

Steel wheels should be regularly cleaned of allforeign matter, such as dirt and mud. If foreign matteris allowed to build up it will affect the balance of the

Wheels and Tyres


Wheels and TtresJ

wheel and may cause vibrations and uneven tyre wear.If the paint has been chipped or scratched it should betouched up as soon as possible to prevent rust.

Any minor damage to the wheel rim can usuallybe removed using a suitable hammer after the wheelhas been removed from the vehicle. However, anymajor rim damage or buckling of the wheel willnecessitate the renewal of the wheel. It is good policyto occasionally remove the wheels from the vehicleand inspect them for damage, cracks or corrosion.

ALLOY WHEELS

Alloy wheels should be regularly cleaned of allforeign matter, such as dirt and mud. If foreign matteris allowed to build up it will affect the balance of thewheel and may cause vibrations and uneven tyre wear.

The alloy wheels are coated with a clear protectivefinish. Do not use abrasive cleaner, polishing com-pounds, steel wool etc. when cleaning the wheels. Onlymild soap and warm water are recommended. Alloywheels are particularly susceptible to corrosion dam-age particularly if exposed to salt water.

Alloy.wheels being relatively soft in comparisonto steel are easily scuffed, however this will not affectthe serviceability of the wheel. Where major damagehas been sustained to the wheel it should be renewed.Buckling or cracking of an alloy wheel cannot berepaired.

TyresThe depth of the tyre tread grooves should never

be allowed to be less than 1.5 mm before the tyres arerenewed. The tyres should also be renewed when anydamage, whether it be internal or external, is evident.Minor punctures or leaks should be properly repaired.Refer the tyre to a tyre specialist if there is any doubtabout the serviceabilitv of the tvre.

Tyre rotation diagram. lf desired, the wheel and tyreassemblies may be rotated in the manner shown.

2 3

When the tyre tread groove depth is less than 1.5mm, or when the tyre is worn to the point where thetyre wear indicators are level with the tread surface,

the tyre should be renewed.

The tread, tread grooves and sidewalls should beregularly inspected for foreign matter, ie: nails, stonesetc. Where foreign matter is detected it should beremoved from the tyre and if necessary the puncturerepaired.

The tyre valves should always have the capsinstalled, be regularly cleaned of dirt or dust and beinspected for wear, leaks or damage every time thetyre pressures are checked.

Regularly inspect the tread of the tyres for signs ofuneven wear, if uneven wear is apparent refer to theheading Tyre Wear Trouble Shooting in this sectionfor possible causes and cures. If the uneven tyre wearis noticed early enough, the cause correctly identifiedand the necessary repair or adjustment carried out,the life of the tyre should be extended.

To preserve tyre life it is good policy to periodical-ly have the front wheels balancetl and the front endalignment checked on a reliable wheel alignmentmachine.

The air pressure in the tyre is probably the singlemost important aspect of tyre care. Too little or toomuch pressure in the tyre can cause rapid wear orcomplete failure through overheating. Where possiblethe tyre pressures should be checked and adjustedwhen the tyres are cold.

As a rule, different tyre types, tread patterns orsizes should never be used on the vehicle at one time.All the tyres on the vehicle, including the spare,should be a matched set to prevent the vehiclebehaving erratically under certain conditions. IJnderno circumstances mix radial ply and conventional plytvres.

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24 Refer to supplementfor more information.

ENGINE TUNE.UPCAUTION: To prevent severe electrical shock, extreme c&re must be taken wlworking on or near the electronic ignitian system as dangerous high tension volta.are produced in both the primary and secondary circaits.

1. TUNE-UP SPECIFICATIONS

F i r i n g o r d e r . . . . L - 6 - 5 - 4 - 3 - 2

Spark plug:Type . AC R44 LTS6Gap . 1 .5 mmT i g h t e n i n g t o r q u e . . . . . . 3 0 N m

*Engine id le speedi n N e u t r a l . . . . . 7 0 0 * 1 0 0 r p m*Base igni t ion t iming . . . 10" BTDCHigh tension leadresistance l imi t : L7 kOCompress ion pressure (min imum) . . . .689 kPaDrive bel t def lect ion Sel f adjust ing

*Non adjustable

2. TUNE.UP OPERATIONS

Special Equiprnent Required:To Test Compression - Compression gauge

TO SERVICE AIR CLEANER

The air cleaner is equipped with a paper typeelement. The element should be renewed at the

recommended intervals of 40 000 km. This distance isonly a guide for normal operating conditions andshould be reduced accordingly if the vehicle is operat-ing under extremely dusty conditions.

NOTE: Paper air cleaner elements shouldnot be washed in petrol or any other type ofcleaning solvent. If the element has beenwashed in solvent or has become oil soakedit should be discarded and a new elementinstalled.

(1) Release the clamp securing the air intakehose to the upper air cleaner housing.

(2) Disengage the clips retaining the upper aircleaner housing to the lower housing.

(3) Raise the upper housing and remove the aircleaner element from the air cleaner housing.

Installation is a reversal of the removal procedurewith attention to the following points:

(1) When renewing the air cleaner element, useonly the manufacturers specified element.

(2) Clean the air cleaner upper and lower hous-ings thoroughly taking care not to allow any dirt toenter the air intake hose.

(3) Ensure that the air cleaner element is seatedcorrectly before installing the top housing.

TO RENEW FUEL FILTER

(1) Raise the rear of the vehicle and support iton chassis stands.

(2) Depressurise the fuel system using the fol-lowing procedure:

(a) Remove the fuel pump fuse from the enginecompartment relay housing.

(b) Start the engine and allow it to idle until theengine stalls. Operate the starter motor for ten sec-onds to ensure that the fuel pressure has been relieved.

(3) Disconnect the negative battery terminal.(4) Place a fuel resistant container under the fuel

filter.(5) Release the hose clamps securing the fuel

hoses to the filter, disconnect the hoses and removethe filter.

Installation is a reversal of the removal procedurewith attention to the following points:The air cleaner should be serviced at regular intervals.


Remove the fuel pump fuse when depressurising thefuel system.

Installed view of the fuel filter, located forryvard of therear axle on the right hand side of the vehicle.

( I ) Instal the fuel filter with the direction arrowfacing towards the engine.

(2) Ensure that the fuel clamps are correctlypositioned and tightened securely.

(3) Instal the fuel pump fuse.(4) Test the fuel system for external leakage as

described in the Fuel and Engine Management sec-tion.

(5) Start the engine and increase the enginespeed above 3 000 rpm to reset the idle air controlvalve, thereby controlling the engine idle speed.

On models equipped with a radio cassette usingPIN security, enter the PIN code as described underthe Radio/Cassette heading in the Electrical Systemsection.

25

TO TEST COMPRESSION

(1) Start and run the engine until the normaloperating temperature is obtained.

(2) Switch off the engine and disconnect thehigh tension leads from the spark plugs ensuring thatthe leads are disconnected by pulling on the boots andnot the high tension leads.

(3) Ensure that the area around each spark plugis clean to prevent foreign matter entering the cy-linders and remove all the spark plugs.

(4) Remove the fusible links marked ENG. INJand ENG. COMP from the fusible link housinglocated adjacent to the relay housing.

(5) Instal a suitable compression gauge tonumber one spark plug hole. Refer to the compressiongauge manufacturers instructions if necessary.

Remove the ENG INJ and ENG COMP fusible l inksprior to performing a compression test.

Checking the compression pressure using a compres-ston gauge.

Engine Tune-up


26 Engine Tune-up

(6) Have an assistant fully depress the throttlepedal and operate the starter motor. Observe thecompression gauge and stop the engine when thegauge has reached the highest reading.

(7) Record the reading and check the compres-sion of the remaining cylinders in the same manner.

(8) Compare all the readings taken. Variationbetween the highest and lowest readings should notexceed 70 kPa and all readings must be above 689kPa.

(9) If a low reading is taken on one or morecylinders the trouble may be isolated as follows:

(a) Inject a small amount of engine oil into thespark plug hole of the low reading cylinder ensuringthat the oil is evenly distributed within the cylinder.

(b) Repeat the compression test on the cylinderconcerned.

A substantial increase of compression pressureindicates faulty or worn piston rings, piston or cy-linder. No increase of compression pressure indicatesburnt, obstructed or sticking valves or a leaking orblown head gasket.

TO SERVICE HIGH TENSION LEADS

( I ) Check the leads for perishing or cracking andrenew as required. Never attempt to repair defectivecarbon impregnated core leads.

The leads may be cleaned using a cloth moistenedwith kerosene, then wiped completely dry.

Using an ohmmeter, check the electrical resis-tance of the high tension leads as follows:

(a) Disconnect one high tension lead at a timefrom the spark plug and the ignition coil. Whendisconnecting the high tension lead from the sparkplug pull on the boot, not the high tension lead.

(b) Connect the ohmmeter terminals to each

Check the high tension lead terminals for corrosion orburning.

Overhead view showing the cylinder numbersequence and the correct high tension lead routing.

end of the high tension lead and measure the resis-tance. If the resistance exceeds Specifications, renewthe high tension lead.

(2) Check the coil terminals for corrosion orburn marks and clean as necessary.

(3) When renewing a high tension lead ensurethat the lead is routed correctly and fastened to theretainers to prevent possible chafing, burning ormisfiring.

(4) When connecting the high tension lead to thespark plug ensure that the terminal is connectedsecurely to the spark plug and the boot has not movedon the lead. Also ensure that the metal locating tabsare completely seated over the hexagonal rim of thespark plug.

TO SERVICE SPARK PLUGS

The spark plugs should be renewed at intervals of20 000 km.

Remove the high tension leads, pulling on theboot only, to prevent damage to the leads.

Before removing the spark plugs, ensure that thearea around each spark plug is clean to prevent foreignmatter entering the cylinder when the plug isremoved.

Spark plugs removed from an engine in goodmechanical condition should have light powderydeposit ranging from light brown to greyish tan incolour. After considerable service the electrodes willshow signs of wear or normal burning.


Engi,ne Tune-uP

Black damp deposits can be caused by excessive oilconsumption or incorrect plug type. Spark plugs in

this condition are usually not f ir ing.

ELECTRODES

Cutaway view of a spark plug showing a crack in theinsutator nose which can be caused by exerting pres-sure against the centre electrode when adiusting thegap. The other crack shown on the insulator is caused

by tilting the Plug sPanner.

Spark plug with burnt electrodes and white blisteredappearance, possibly due to incorrect plug type, loose

plug or the engine running too hot.

Due to the type of ignition system, normal sparkplug wear may be indicated by the spark plugl- frombnJ Uant having worn centre electrodes while theplugs from the other bank have worn outer electrodes.^ -Spark

plugs showing a thick black oily depositindicite arrenfine with worn piston rings or possibly aspark plug with the incorrect heat range has beeninstalled.

Spark plugs showing a white or yellowish depositindicite sustiined high speed driving or possiblyspark ptugs with a heat range that is too high haveb-een instilled, particularly when these deposits areaccompanied by blistering of the porcelain and burn-ing of the electrodes.

When plug electrodes are eroded to this degree thespark plug can be considered worn out and should bereplaced using a plug of the recommended heat range.

27


28 Engine Tune-up

Checking the spark plug electrode gap with a wiregauge.

Before installing the spark plugs measure the gapbetween the electrodes, preferably with clean wiregauges. If wire gauges are unavailable use clean feelergauges. Move the side electrode towards or away fromthe centre electrode to obtain the correct gap.

Screw the plugs into the cylinder head finger tightand use a torque wrench to tighten the plugs to thespecified torque.

TO ADJUST DRIVE BELT

The drive belt tension is controlled by a tensionerassembly which maintains the correct tension on thedrive belt and compensates for wear and stretch.

The tensioner assembly is equipped with a tensionindicator that shows when the tensioner is exertingminimum pressure on the drive belt due to excessivebelt wear, necessitating renewal of the drive belt.

Check the drive belt for cracks or separationbetween the rubber and the fibre belt by examiningthe portion of the belt that is positioned around thewater pump pulley.

Installed view of the drive belt tensioner showing thetension indicator. Renew the drive belt when the

indicator is outside the normal operating range.

Examine the drive belt for cracks or deteriorationwhere the drive belt is positioned around the water

pump pulley.

NOTE: If the drive belt is slipping and thetension indicator is within the normal oper-ating range, remove the drive belt and checkthat the pulleys operated by the drive beltincluding the tensioner pulley rotatesmoothly without binding.

If no fault can be found renew the drivebelt tensioner as described in the Enginesection.

TO RENEW DRIVE BELT

(1) Place an 18 mm ring spanner on the drivebelt tensioner pulley bolt and rotate the pulley assem-bly anti-clockwise, raising the pulley away from thebelt.

(2) Hold the pulley in this position and remove

Correct method of releasing the drive belt tensioner.Rotate the pulley assembly in the direction illustrated.


Schematic diagram showing the drive beltinstallation.

the drive belt from the water pump pulley. Return thepulley to its previous position.

(3) Disconnect the drive belt from the enginepulleys and remove the drive belt.


29

( 1) When installing the drive belt ensure that thegrooves in the drive belt and engine pulleys align.

(2) Rotate the tensioner pulley and position thedrive belt onto the water pump pulley.

(3) Start the engine and check the drive belt andtensioner operation.

NOTE: It is normal for the drive belt to emita squeak when the engine is started orstopped.

TO ADJUST IDLE SPEED

The engine idle speed is controlled by the idle aircontrol (IAC) valve and is not adjustable.

If the idle speed is incorrect, check the IAC valvefor correct operation as described in the Fuel andEngine Management section.

TO CHECK AND ADJUST IGNITION TIMINGThe ignition timing is controlled by the electronic

control unit, eliminating the need for adjustment tothe ignition timing.

NOTE: If, at the completion of the enginetune-up, there ,s reason to suspect thatthe engine is not performing satisfactorily,refer to the Engine and Fuel and EngineManagement sections.

Engine Tune-up



ROADSIDE TROUBLE SHOOTINGCAUTION: To prevent severe electrical shock extreme care must he taken wlworking on or near the electronic ignition system as dangerous high tension volta)are produced in hoth the pyl*ary and secondary circuits. See text for precautiontnotes.

This section deals with the common causes ofengine failure to start, as inevitably there will come atime when every driver will experience this problemand will therefore need to call upon his own resourcesto rectify the trouble. Roadside breakdowns otherthan engine failure can be identified by reference tothe Trouble Shooting section on the particular com-ponent affected.

1. TROUBLE SHOOTING

Trouble shooting is only a process of eliminationand provided the procedure is carried out correctlyand systematically an accurate diagnosis of the trou-ble can be made in the minimum amount of time.

For an internal combustion engine to run thereare three basic requirements, these are ignition, fueland compression. There are other factors of coursebut as a rule an engine's failure to start can beattributed to a fault in one of these three systems.

Reports from field engineers of motoring organi-sations prove that the biggest percentage of enginebreakdowns are in the order of ignition or electricalfailure first, followed by fuel, with mechanical orcompression failure the least common.

Should the engine fail to start, first check thatthere is adequate fuel in the tank and if so, carry outthe following checking procedures in the orderdescribed.

SERVICE PRECAUTIONS

To protect the catalytic converter, the followingprecautions should be observed:

(1) Do not operate the vehicle on leaded fuel.(2) Do not push or tow start the vehicle.(3) Do not operate the vehicle if the engine is

misfiring.(4) Avoid running the engine out of fuel.(5) Ensure that the engine oil is formulated to

contain low phosphorus levels.

TO JUMP START A VEHICLE

NOTE: Jump starting a vehicle can bedangerous if the procedure described below

View showing the correct jumper lead connectionswhen iump starting a vehicle. lf available use leadsequipped with a surge protection device as shown in

the illustration.

Jumper leads courtesy of Comproof Sales.

,s not performed coruectly. If any doubtexists, it is recommended that the services ofa competent mechanic be obtained.

The range of vehicles covered by thismanual is equipped with complex electroniccircuitry which can be damaged by toltagesurges. These voltage surges can be gener-ated when jump starting, or being jumpstarted by, another vehicle. If available usejumper leads equipped with a surge protec-tion device and follow the lead manufac-turers instructions carefully, particularlyregarding the connection and disconnectionof the leads.

(1) Ensure that the booster battery is 12 voltsand the negative terminal is earthed.

(2\ Ensure that the vehicles are not touching andthat the ignition and all accessories on both vehiclesare switched Off.

(3) Ensure that the transmission on both vehi-


Roadside Trouble Shooting 3 I

cles are in Park or Neutral and the handbrakes arefirmly applied.

(4) Remove the vent caps from the battery andcheck the electrolyte level. Replenish with distilledwater as necessary.

(5) Place the vent caps loosely over the cellapertures.

(6) Connect one end of the red jumper lead tothe positive (+) battery terminal of the boosterbattery and the other end of the red lead to thepositive (+) battery terminal of the dischargedbattery.

NOTE: The battery emits hydrogen gaswhich is explosive. Do not expose the batteryto naked flames or sparks.

Do not lean over the battery whenconnecting the jumper leads.

Do not allow the ends of the jumperleads to touch one another or any part of theengine.

(7) Connect one end of the black jumper lead tothe negative (-) battery terminal of the boosterbattery and the other end of the black lead to a goodearthing point on the engine of the vehicle with thedischarged battery.

NOTE: Do not connect the jumper leaddirectly to the negative (-) battery terminalof the discharged battery.

(8) Start the engine onbooster battery and run thespeed.

(9) Start the engine ondischarged battery.

the vehicle with theengine at a moderate

the vehicle with the

(10) If possible, leave the engines of both vehiclesrunning for l0 minutes.

(11) Disconnect the jumper leads in the reverseorder of the sequence in which they were connected.

2. TO CHECK IGNITION AND ELECTRICALSYSTEM

(l) Switch on the ignition and check for warninglamp illumination on the dashboard.

(2) Operate the starter and check that the srarrerrotates the engine at a steady speed.

(3) Switch on the headlamps and check for goodlight intensity.

Should the lamps not illuminate or the startermotor not turn the engine, carry out the followingsteps:

(a) Disconnect the battery terminals and cleanboth terminals and posts. Connect the terminals andwhere applicable tighten firmly but not excessively.

NOTE: When disconnecting or connectingthe battery terminals or fusible linl<s ensure

Remove all dirt and corrosion from the battery'terminals.

that the ignition switch is in the Offpositionto prevent damage to the electronic controlunit.

If the engine does now start, increase the speed to3 000 rpm for l0 seconds allowing the idle air controlvalve to reset.

On models equipped with a radio cassette usingPIN securityn it will be necessary to enter the PIN codeas described under the Radio/Cassette heading in theElectrical System section.

(b) Check that the earth lead from the battery tothe engine or body frame is not broken and that theconnections are clean and secure.

(c) Check that the lead from the battery to thestarter motor or starter solenoid is intact and has aclean and secure connection.

(d) Where necessary carry out repairs to (b) and(c).

Again carry out the check procedure. Should thestarter motor still not operate or the lamps notilluminate, one or more of the following faults may bethe cause:

No starter motor operation or lamps: Battery flator defective.

Lamps illuminate but no starter operation: Startermotor drive jammed in mesh with flywheel ring gear.Starter motor or solenoid defective. Ignition/starterswitch faulty. On automatic transmission models,faulty neutral safety switch.

Lamps dim and starter operation sluggish: Dis-charged battery or fault in starter motor. Battery flatdue to broken fan belt or defective alternator. Faultybattery due to cell breakdown.

If the battery and starter motor operation provessatisfactory but the engine still fails to start, continueas follows:

NOTE: Electronic ignition systems can pro-duce dangerously high voltages in both theprimary and secondary circuits. For this


32

Securely earth the body of a test spark plug to checkfor spark at the high tension leads.

reason, extreme care must be taken whenperforming these checks. When disconnect-ing the wiring from any component ensurethat the ignition switch rs Off and thenegative battery terminal is disconnected toprevent damage to the solid state circuitry.

(1) Open the electrode gap of a serviceable sparkplug to 6 mm. Securely earth the spark plug using ajumper lead or by tying the plug to an earthed enginecomponent.

(2) Disconnect the high tension lead from aspark plug and connect it to the test spark ptug.

(3) Have an assistant operate the starter motor.(4) Check that a spark, if any, jumps the gap on

the test spark plug.


Roadside Trouble Shooting

Check that all electrical connections are clean andsecure.

(5) If the spark is sufficient but the engine is stillnot operating satisfactorily, remove the spark plugsand check the condition and electrode gap as de-scribed in the Engine Tune-up section.

(6) If there is no spark, check the high tensionleads to ensure that they are dry and that the in-sulation is not cracked or perished. Check the ends ofthe leads for burning or corrosion. Refer to the Fueland Engine Management section for further ignitionsystem checks.

(7) Ensure that all electrical connections andearth leads are clean and secure.

NOTE: On Calais models ensure that theanti-theft system has not been accidentlyturned on. If necessary turn the overrideswitch, located in the glove box, counterclockwise to turn the system off,

3. TO CHECK THE FUEL SYSTEM

Due to the complex nature of tle EFI system, it isrecommended that should the following checks provesatisfactory but the engine fails to start, reference bemade to the Fuel and Engine Management section ofthismanual or an authorised workshop be consulted.

(l) Check that the fuel tank contains a reason-able amoulnt of fuel.

(2) Squeeze the fuel supply hose, located adja-cent to the brake servo unit, between the thumb andforefinger.

(3) Turn the ignition switch On. The fuel pumprelay will be heard to activate and the fuel supply hosewill pressurise. The pressure will be most noticeablewhen the fuel pump relay deactivates within 2 secondsof operation.

NOTE: If the fuel pump relay fails, powerwill be supplied to the fuel pump via the oilpressure switch. When starting the engine,


Roadside Trouble Shooting 3 3

Squeeze the fuel supply hose to check for fuel pumpoperation.

Check for leaks at all fuel line connections.

Ensure that the fusible links are intact and the asso-ciated wiring is securely connected.

the fuel pump will not operate until the oilpressure is sufficient to extinguish the oilpressure warning lamp. Therefore it will benecessary to operate the starter motor for a

r longer period than usual to start the engine.

(4) Check that all fuel supply connections aresecure.

(5) Remove the spark plugs and check for petrolsaturation of the electrodes. Thoroughly clean and drythe spark plugs before replacement.

(6) If flooding is suspected, turn the ignitionswitch to the Start position while maintaining thethrottle in the wide open position.

(7) Check the fusible links and ensure that allwiring connectors are clean and secure.

Check the MAP sensor vacuum hose for splits,obstructions and a secure connection.

(8) Ensure that the MAP sensor vacuum hose issecurely connected and is not split, perished orobstructed.

NOTE: If the Check Engine warning lampon the instrument cluster is illuminated, afault exists in the fuel and engine manage-ment system. Refer to the Fuel and EngineManagement section for information onsystem faults.

4. TO CHECK THE MECHAhIICAL SYSTEM

The following check procedure assumes that thestarter motor will rotate the engine. If not, on manualtransmission models depress the clutch pedal todisengage the engine from the transmission in case thefault lies within the transmission.

If the starter will not rotate the engine it will benecessary to remove the starter motor and attempt to


34

turn the engihe over manually. This will establishwhether the fault lies with the starter motor, whichcould be jammed or defective, or with the engine,which could be seized or have broken internal com-ponents such as connecting rods, pistons and crank-shaft etc.

If the starter motor is not at fault and the enginewill not rotate manually, refer to the Engine Mechani-cal Trouble Shooting heading in the Engine section.

It should be noted that the only way that cylindercompression can be accurately tested is with acompression gauge. The method described in thefollowing procedure is only intended to give a roughindication when checking for causes of engine break-down.

(1) Check the coolant surge tank for loss ofcoolant. If coolant loss is evident, check carefully forany indication of external leakage and remove theengine oil dipstick and check for emulsification of theoil. When oil mixes with water it will turn creamy andthe oil level will also have increased. If the oil isemulsified, proceed to operation (5).

(2) Remove the fusible links marked ENG.INJand ENG.COMP from the fusible link housing locat-ed adjacent to the relay housing.

(3) Remove all of the spark plugs except one.(4) Have an assistant operate the ignition switch

to rotate the engine and listen to the sound that the en-gine makes as it is being turned over. Move the sparkplug to a different cylinder and repeat the test.

By performing the same test on all cylinders, arough comparison of compression can be made todeterrnine if there is any loss of compression in anycylinder. This will be apparent by the different soundthe engine will make as it is being turned over.

Normally, if the compression is satisfactory thecylinder with the spark plug installed will create aresistance to the rotating engine.

However, if the compression is low in a particularcylinder, the engine will turn over easily and smoothlywhen that spark plug is in place.

(5) If the above checks show a loss of coolantand this is present in the engine oil or on the sparkplug, one or more of the following faults may be thecause:

Blown cylinder head gasketCracked cylinder or cylinder headWarped cylinder head and/or cylinder block facesIf the compression check showed any weak or

inconsistent compressions, in addition to the abovefaults any of the following could also be the cause:

Roadside Trouble Shooting

Check the engine oil for correct level and dilution onthe dipstick.

Broken piston(s)Burnt or broken valve(s)Provided the previous checks do not indicate an

internal leakage of coolant, proceed with the follow-ing:

(6) Remove a rocker cover and, again with anassistant operating the ignition switch, check that allthe valves open and close as the engine turns over.

If the valves do not operate with engine rotation,one of the following faults may be the cause:

Broken camshaft drive chain or a sheared crank-shaft timing sprocket drive key. Refer to the Enginesection of this manual.

Remove the ENG INJ and ENG COMP fusible l inksprior to performing a compression test.



35

ENGINE

SPECIFICATIONS

ENGINE ASSEMBLY

Type 6 cylinder 90" Vee with OHV andbalance shaft

C a p a c i t y . . . . . 3 7 9 l c cB o r e . . . : . . 9 6 . 5 2 m mStroke 86.36 mmCompression ratio 8.5:1Firing order l-6-5-4-3-2

NOTE: Specifications regarding engine tun-ing are listed in the Engine Tune-up section.

CYLINDER BLOCK

Cylinder number sequence (front to rear):Left bank t-3-5Right bank . 2-4-6

Standard bore diameter 96.507-96.533 mmMaximum ovality 0.010 mmMaximum taper. . 0.013 mmCylinder block face machining limit 0.08 mm

CYLINDER HEAD

Valve seat angle. . . . 45"Valve seat width:

I n l e t . . . . 1 . 5 2 - 2 . O 3 m mExhaust . 2.29-2.79 mm

Surf,ace machining limit 0.30 mmMinimum cylinder head face thickness . . 1.072 mm

VALVES AND SPRINGS

Valve head diameter:Inlet. 43.307-43.561 mmE x h a u s t . . . 3 7 . 7 1 9 - 3 7 . 9 7 3 m m

Minimum valve head thickness (margin). . 0.63 mmValve faceang le . . . . 45"Valve stem diameter:

I n l e t . . . 8 . 6 4 1 - 8 . 6 6 6 m mE x h a u s t . . . . . 8 . 6 4 8 - 8 . 6 6 6 m m

Valve stem to guide clearance:I n l e t . . 0 . 0 3 8 - 0 . 0 8 9 m mE x h a u s t . . . . 0 . 0 3 8 - 0 . 0 8 2 m m

Valve stem installed height . 49.1 5-50. 17 mm

Valve stem oversize 0.254 mmMaximum valve spring end distortion 1.60 mmValve spring installed height 42.93-44.45 mm

PISTONS AND RINGS

Piston diameter 96.477-96.497 mmPiston to cylinder bore oilclearance 0.010-0.056 mmGudgeon pin diameter . 22.995-23.000 mmGudgeon pin to piston boreoil clearance. . 0.010-0.020 mmPiston oversizes 0.250, 0.508 mmNumber of rings:

Compression . 2Oil control

Piston ring end gap. 0.254-0.635 mmPiston ring side clearance:

C o m p r e s s i o n . . . . . 0 . 0 3 9 - 0 . 0 7 9 m mOil control . . 0.028-0.206 mm

CONNECTING RODS AND BEARINGS

Maximum connectingrod bend . . 0.020 mm per 25.4 mmMaximum connectingrod twist . . 0.038 mm per 25.4 mmConnecting rod big end borediameter 60.294-60.313 mmMaximum big end boretaper and ovality. . 0.008 mmConnecting rod bearing oilclearance 0.008-0.071 mmConnecting rod side clearance 0.10-0.38 mm

CRANKSHAFT AND MAIN BEARINGS

Number of main bearings. . . . . . . 4Main bearing journal diameter . 63.470'

63.495 mmMaximum journal ovality and taper. . . . . 0.008 mmMain bearing oil clearance. . 0.013-0.51 mmCrankshaft end float:

Taken at . No. 2 main bearingR a n g e . . . 0 . 0 8 - 0 . 2 8 m m

Crankpin journal diameter 57.117-57.147 mmMaximum journal ovality and taper. . . . . 0.008 mm


36

Main bearing undersize (i'efer text) . 0.025 mmMaximum crankshaft runout (bend) 0.008 mmMaximum flange runout ., 0.05 mm

CAMSHAFT AND BEARINGS

Number of bearing journals. . . . . . . . .. 4Bearing journal diameter . 45.339-45.364 mmCamshaft journal oil clearance . . . 0.013-0.089 mmCamshaft lobe lift 6.909 mmMaximum timing chain movement. . . . . . 25.40 mm

BALANCE SHAFT

Maximum balance shaft end float 0.203 mmBalance shaft gear backlash . 0.050-0.127 mmMaximum front bearing radialclearance 0.028 mmMaximum rear bearing radial clearance. . 0. I 19 mm

LUBRICATION

O i l p u m p t y p e . . . . . G e r o t o rMaximum regulated oil pressure 340 kpaMinimum oil pressure at I 850 rpm(normal operating temperature). 27 5 kpaOil pressure switch contact pressure . . . 4l kpaMaximum inner gear tip to outergear clearance 0.15 mmOuter gear to timing coverclearance 0.203-0.381 mmInner and outer gearto timing cover end clearance . . . . 0.025-0.089 mmPressure regulator valveclearance 0.038-0.076 mmPressure regulator spring free length 64.8 mm


Crankshaft pulley bolt . . . 325 NmMain bearing cap bolts . . . 127 NmConnecting rod cap bolts 30 Nm + 50"C a m s h a f t g e a r b o l t s . . . . . . . 4 0 N m*Cylinder head bolts:

First stage 34 NmSecond stage. + 90"Third stage 8l Nm

Rocker arm pivot bolts . . . 44 NmRocker cover bolts I I NmHydraulic tappet retainer plate bolts . . 40 NmInlet manifold bolts. . 12 NmExhaust manifold studs . . . 60 NmExhaust manifold flange bolts . . . . . . . . 27 NmT i m i n g c o v e r b o l t s . . : . . . : . . .Oil pump pick-up pipe bolts 12 NmOil filter adaptor bolts . . . . 40 NmEngine sump bolts 12 NmBalance shaft gear retaining bolt. 22 Nm* 35"Balance shaft retainer bolts 40 NmFlywheel/drive plate bolts . 90 Nm

*Tension must not exceed 81 Nm during second stage.

1. ENGINE MECHANICAL TROUBLESHOOTING

ENGINE MISFIRES AT IDLING SPEED

(l) Blown head gasket: Check the cylindercompressions and renew the head gasket as necessary.

(2) Burnt valves or seats in the cylinder heads:Check the cylinder compressions and overhaul thecylinder heads as necessary.

(3) Broken or worn piston rings: Check thecylinder compressions and renew the piston rings asnecessary.

(4) Weak or broken valve springs: Remove therocker covers and check the condition of the valvesprings.

(5) Air leak at the inlet manifold gasket: Checkfor air leaks by running oil around the manifold joints.If an air leak is detected and cannot be rectified bvtightening the manifold bolts, renew the gasket.

Check the compression pressure using a compressiongauge.

Check the inlet manifold gasket for leaks by running oilalong the gasket joint.

Engine


Engi,ne

NOTE: Use a compression gauge to checkthe compression pressure in each cylinder asdescribed in the Engine Tune-up section.For other causes of engine misfire refer tothe Fuel and Engine Management section.

NOISY VALVE OPERATION

(l) Faulty hydraulic tappets: Remove and dis-mantle the hydraulic tappets and renew as necessary.

(2) Weak or broken valve springs: Remove therocker covers and check the condition of the valvesprings.

(3) Worn valve guides: Overhaul the cylinderhead(s).

(4) Worn rocker gear: Remove the rocker gearand check the components for wear.

(5) Worn camshaft lobes: Renew the camshaft.(6) Low oil pressure: Refer to the Low Oit

Pressure heading.

BIG END BEARING NOISE

(1) Low oil pressure: Refer to the Low OilPressure heading.

(2) Excessive bearing clearance: Renew thebearing shells. Renew the crankshaft if the big endjournals are oval, tapered or scored.

(3) Misaligned big end bearings: Align the con-necting rods and renew the big end bearing shells.

NOTE: Big end bearing noise is indicatedby a metallic knock which is usually loudestat approximately 60 km/h with the throttleclosed. Before dismantling the engine toinspect the big ends, check the engine oil forcorrect level and dilution on the dipstick.Also remove the oil pressure switch andconnect an oil pressure gauge into the oilgallery to check the oil pressure readings.

MAIN BEARING NOISE (APPARENT)

(1) Loose flywheel: Tighten the flywheel bolts tothe specified torque.

(2) Low oil pressure: Refer to the Low OilPressure heading.

(3) Excessive crankshaft end float: Renew themain bearings.

(4) Excessive bearing to journal clearance:Renew the bearing shells. Renew the crankshaft if thejournals are oval, tapered or scored.

NOTE: Main bearing noise is indicated by aheavy but dull knock when the engine isunder load. A loose flywheel is indicated bya thud or dull click when the ignition isturned of. It is usually accompanied byvibration.

Cranl<shaft end float noise is indicatedby a sharp rap at idle speed. The uanlcshaftcan be readily checked for excessive end

37

float by levering the cranl<shaft backwardsand forwards.

Ifthe oil pressure is satisfactory, removethe main bearing caps and assess the bear-ing clearance using the Plastigage methodas described in this section. Ovalitv andweer on the main bearing journals can onlybe checked with a micrometer after thecranl<shaft has been removed.

EXCESSIVE OIL CONSUMPTION

(1) Oil leaks: Check and renew the engine gas-kets or seals as necessary.

(2) Damaged or worn valve stem oil seals: Dis-mantle the cylinder head and renew the damaged orworn oil seals.

(3) Excessive clearance, valve stem to valveguide: Ream the valve guides and renew the valves asnecessary

(4) Worn or broken piston rings: Renew thepiston rings on all the pistons.

(5) Rings too tight or stuck in the grooves:Renew the rings and clean out the ring grooves.

(6) Excessive wear in the cylinders, pistons andrings: Recondition the cylinders and renew the pistonsand rings.

(7) Coqnpression rings incorrectly installed. Oilrings clogged or broken: Renew the piston rings.

(8) Faulty PCV system operation: Check thePCV system as described in the Emission Controlsection.

NOTE: Before checking the engine for oilleal<s the engine should be completely de-greased and cleaned. Run the engine atoperating temperature for a period andvisually check for oil leakage. By placingwhite paper on thefloor directly beneath theengine any excessive leak can be readilypinpointed.

Damaged or worn valve stem oil sealswhich allow oil to be drawn down past the

Run the engine over white paper to check for engine oilleaks.


38

valve stems into the combustion chamberscan be diagnosed by allowing the engine te-idle for a few minutes and then opening thethrottle. If oil is being drawn down past thevalve stems a heavy discharge of blue smokewill be seen at the tailpipe.

Piston, ring and cylinder bore troublesare normally accompanied by a /oss ofcompression. Cylinder compression canonly be accurately assessed by using acompression gauge.

LOW OIL PRESSURE

( I ) Oil level low in the sump: Check and replen-ish the oil to the full mark on the dipstick.

(2) Thin or diluted oil: Change to the correct oilgrade and rectify the source of the dilution. Ensurethat the engine is not overheating.

(3) Blocked oil filter: Renew the oil filter.(4) Oil pump relief valve stuck or spring broken:

Free the relief valve or renew the relief valve spring.(5) Blocked oil pump pick-up pipe: Remove the

pick-up pipe and remove the obstruction.(6) Excessive bearing clearance: Renew the

bearing shells and check the condition of the crank-shaft journals.

(7) Excessive wear of the oil pump components:Dismantle the oil pump and renew the components asnecessary.

NOTE: If the vehicle is not equipped with anoil pressure gauge, remove the oil senderunit and connect a pressure gauge into theoil gallery. Check the oil pressure with theengine cold and hot.

If the oil pump or relief valve arefaulty,low pressure will be indicated with theengine both hot and cold. However, if thebearings are at fault a fairly high oil pres-sure will be indicated when the engine iscold but a marked fall in pressure will benoted when the engine is hot.

Check the engine oil for correct level and dilution onthe dipstick.

ENGINE WILL NOT ROTATE

(l) Starter motor drive jammed: Remove thestarter motor, check and renew the damaged driveand/or the flywheel ring gear.

(2) Engine overheated and seized: Remove anddismantle the engine, check and renew the damagedcomponents. Refer to the following note.

(3) Water in the cylinders due to a blown headgasket or cracked cylinder block or head: Remove thecylinder head. If the gasket is blown, check forcylinder block and head distortion, reface if necessary.Renew the cylinder head and/or the cylinder block ifthey are cracked.

(4) Broken crankshaft, connecting rod, pistonetc. due to overheating, fatigue etc: Remove anddismantle the engine, examine and renew the com-ponents as necessary.

(5) Valve head broken off due to overheating,fatigue etc: Remove the cylinder head, check the head,piston and cylinder for damage and repair or renew asnecessary.

NOTE: Frequent jamming of the startermotor drive with the flywheel ring gear canbe due to a bent starter armature shaft,damaged teeth on the drive and/or ringgear. With the starter motor removed, theflywheel ring gear teeth can be examinedthrough the starter motor mounting aper-ture. Renewal of the ring gear requiresremoval of the clutch and flywheel on man-ual transmission models. The checkingfor abent armature shaft can be done by rotatingthe shaft by hand while the end is held inclose proximity to a fixed object.

Invariably when an engine seizes, be--,cause of overheating due to lack of oiland/or water, damage is done to the bear-ings, pistons etc. Although there may be

A blown head gasket is indicated by bubbles in theradiator coolant with the engine running.

Engine


instances where an engine will restart andrun after it has cooled down and the oil andwater have been replenished, it will general-ly be found that oil consumption increases,oil pressure drops and the engine will benoisier, depending upon the degree of da-mage.

When a cylinder head gasket blowsallowing water into the cylinders, orcompression /oss between cylinders, it lsessential to check the gasket faces on thecylinder block and cylinder head for distor-tion. Sufficient water can enter a cylinderdue to a blown gasket, cracked cylinder orhead to prevent an engine from rotating.Normally this is preceded by dfficult start-ing, misfiring, excessive steam from theexhaust and loss of water from the surgetank.

By filling the surge tank with coolantuntil the level is halfway up the neck of thesurge tank, bubbles may be seen in the neckof the surge tank when the engine is fastidling, indicating a blown head gasket.

2. DESCRIPTION

The engine installed to the range of vehiclescovered by this manual is a cast iron, water cooled V6with pushrod operated valves. A feature of this engineis the inclusion of a balance shaft, located above thecamshaft, to reduce engine vibration.

The crankshaft is supported by four replaceableprecision insert main bearings and the end float iscontrolled by the number two main bearing. Theconnecting rod journals are offset to allow the cylin-ders to fire at equal intervals. The connecting rodbearings are replaceable precision inserts. The manu-facturer recommends that should the crankshaft jour-nals require machining, the crankshaft be renewedand standard size bearings installed. Undersize bear-ings are not available.

The camshaft is driven by a timing chain from thecrankshaft. The timing chain tension is controlled bya spring tensioned damper. Hydraulic tappets with anintegral needle bearing supported roller provide auto-matic adjustment of the valves by eliminating clear-ances in the valve train and provide a hydrauliccushion to absorb operating shock.

The balance shaft is housed directly above thecamshaft in the valley between each bank of cylindersand is driven by a gear mounted to the camshaftbehind the camshaft sprocket. It rotates at crankshaftspeed but in the opposite direction.

The oil pump is integral with the timing eover andis driven by the crankshaft.

The engine is supported by hydraulic enginemountings to reduce engine vibration. The enginemountings have two oil filled cavities which transfer

39

, oil from one cavity to the other through orifices insidethe mounting, absorbing the shock when vibration ormovement occurs.

3. ENGINE ASSEMBLY

Special Equipment Required:To Remove and Instal - Suitable lifting tackle

TO REMOVE AND INSTAL

(1) Depressurise the fuel system as described inthe Fuel and Engine Management section.

(2) Place suitable protection around the enginecompartment to prevent damage to the vehicle body.

(3) Disconnect the negative battery terminal.(4) Disconnect the windscreen washer tube from

the T junction.

Right hand side view of the engine separated from thetransmission.

(5) With the aid of an assistant, support theengine bonnet and remove the bolts securing thebonnet mounting brackets to the bonnet hinges.Remove the bonnet.

(6) Drain the cooling system and disconnect theradiator hoses from the engine and the radiator.Disconnect the overflow hose from the radiator.

(7) On models with automatic transmission,disconnect the oil cooler hoses from the radiator. Sealthe hoses and the radiator fittings to prevent the entryof dirt.

(8) Disconnect the engine cooling fan wiringconnector.

(9) Remove the radiator retaining clips, raiseand withdraw the radiator and fan assembly from thevehicle.

(10) Disconnect the coolant supply, the air bleedand the heater hoses from the engine.

Engine


40

Left hand side view of the engine separated from thetransmission.

(l l) Disconnect the main wiring harness connec-tors and the battery harness connector located to theside of the relay housing.

(12) Open the cover located at the front of thefusible link housing and disconnect the power supplywire.

(13) Remove the nut securing the battery earthwire to the right hand side inner mudguard. Discon-nect the wiring harness retaining clip from the fusiblelink housing mounting bracket.

(14) Disconnect the throttle cable from the throt-tle body linkage and the mounting bracket. If apptic-able, disconnect the cruise control cable from thethrottle body linkage and remove the cruise controlcable mounting bracket bolts. Place the cable to oneside.

(15) Release the clamps securing the air intakehoses to the throttle body and the air cleaner housing.Disconnect the wiring harness from the rear of the airintake duct. Remove the air intake duct retaining nutand remove the air intake duct and the air intakehoses from the vehicle.

(16) Open the glove compartment and prise thehinge pin from the right hand side of the glovecompartment. Remove the glove compartment fromthe vehicle.

( I 7) Remove the fasteners retaining the lowertrim panel to the underside of the dash panel and theleft hand kickpanel and remove the lower trim panel.

(18) Using a small screwdriver, prise the plasticstrip from the front section of the left hand side sillpanel cover. Disengage the front section of the sillpanel cover from the kickpanel and the sill panel.

(19) Disengage the lower front corner of the kickpanel from the locating stud positioned behind the

Engine

kick panel and manoeuvre the kick panel from thevehicle.

(20) Disconnect the control unit wiring connec-tors and the main wiring harness connector.

(21) Compress the lugs securing the wiring har-ness plug to the bulkhead and withdraw the wiringharness from the passenger compartment to the en-gine compartment. Disconnect the wiring harnessfrom the retaining straps located on the inner lefthand side mudguard and lay the wiring harness on theengine.

(22) Disconnect the wiring connectors from thethrottle body, MAP sensor and the oxygen sensor. Onmodels with air conditioning, disconnect the com-pressor clutch wiring connector.

(23) Where applicable, disconnect the coil packearth strap from the inner left hand side mudguard.

(24) Disconnect the vacuum hoses from thethrottle body and the inlet manifold adaptor.

(25) Suitably mark and disconnect the fuel supplyand return hoses. Seal the hoses to prevent the entry ofdirt.

(26) Disconnect the small vacuum hoses from thefront of the throttle body. Disconnect the vacuumlines from the fuel rail clips and place the vacuumlines away from the engine.

(27) On air conditioned models, remove the en-gine drive belt.

(28) Raise the vehicle and support it on chassisstands.

(29) Drain the engine oil into a container.(30) On models equipped with power steering,

note the installed position of the power steering hosesand disconnect the hoses from the steering gear. Drainthe fluid into a container and seal the hoses and thesteering rack to prevent the entry of dirt.

(31) Drain the transmission. Refer to the Manualor Automatic Transmission sections.

(32) Mark the rear axle pinion flange and thepropeller shaft flange to ensure correct alignment oninstallation. Remove the nuts and bolts securing thepropeller shaft to the pinion flange and remove thebolts securing the centre bearing support to the floorpan. Withdraw the propeller shaft from the vehicle.

(33) Remove the bolts securing the engine ex-haust pipes to the exhaust manifolds.

(34) On models with automatic transmission,proceed as follows:

(a) Remove the nut securing the selector lever tothe transmission selector shaft and disconnect theselector lever from the transmission.

(b) Disconnect the torque converter clutch wir-ing connector from the side of the transmission andthe vehicle speed sensor wiring connector.

(c) Ensure that all wiring is disengaged from thetransmission housing.

(35) On models with manual transmission, pro-ceed as follows:

(a) Release the clutch cable adjusting nut at theclutch housing.

IN1€T MANIFOLD

AUTO TRANS OIL COOLER PIPES


(b) Raise the rear of the clutch cable cover anddisconnect the cluth cable from the release lever.Withdraw the clutch cable towards the front of thevehicle.

(c) Disconnect the wiring connectors from thereverse lamp switch and the vehicle speed sensor.

(d) Ensure that all wiring is disengaged from thetransmission housing.

(36) Attach suitable lifting tackle to the enginelifting brackets and raise the engine slightly to take theweight offthe engine mountings.

(37) Remove the nuts securing the front enginemountings to the crossmember.

(38) Place a block of wood on a jack and raise therear of the transmission slightly.

(39) Remove the bolts securing the crossmemberto the transmission mounting bracket and the under-body and remove the crossmember. Lower the trans-mission.

(a0) On models with manual transmission,remove the bolts retaining the upper gear lever to thetransmission gear lever and raise the upper gear leverclear of the transmission.

(41) On models with manual transmission,remove the nuts and bolts securing the steering gear tothe crossmember and pull the steering gear from thecrossmember. Angle the front wheels fully towards theleft.

(a2) Raise the engine slightly and manoeuvre theengine and transmission forward slightly. On airconditioned models, remove the bolts securing thecompressor to the engine and tie the compressor clearof the engine.

(a3) Raise the engine and transmission assemblywith the front higher than the rear and manoeuvre it

View of the engine and transmission being removed.Note the angle required to enable the engine to clear

the front panel.

4 L

through the bonnet opening. During this procedureensure that the assembly is not fouling on any object.

NOTE: On air conditioned models, ensurethat the engine assembly does not contactthe condenser.


(1) Tighten all nuts and bolts securely.(2) Fill the engine and transmission with the

correct grade and quantity of oil. Fill the coolingsystem as described in the Cooling and HeatingSystems section.

(3) On models equipped with power steering, fillthe reservoir with oil and bleed the system as de-scribed in the Steering section.

(4) Ensure that all wiring connections aresecure.

(5) Check the fuel system for external leakage asdescribed in the Fuel and Engine Management sectionbefore starting the engine.

(6) Start the engine and increase the speed to3 000 rpm for 10 seconds, allowing the idle air controlvalve to reset. Check for oil and coolant leaks andrectify as necessary.

(7) On models equipped with a radio/cassetteusing PIN security, enter the PIN code as describedunder the Radio/Cassette heading in the ElectricalSystem section.

4. DRIVE BELT TENSIONER ASSEMBLY


(1) Disconnect the negative battery terminal.(2) Drain the cooling system. Refer to the Cool-

ing and Heating Systems section if necessary.(3) Loosen the power steering pump pulley re-

taining bolts. On models not equipped with powersteering, loosen the idler pulley retaining bolts.

(4) Remove the drive belt from the engine.Refer to the Engine Tune-up section if necessary.

(5) Remove the power steering pump pulleyretaining bolts and remove the pulley. On models notequipped with power steering, remove the idler pulleyretaining bolts and remove the pulley.

(6) If applicable, remove the screws securing thepower steering pump reservoir to the drive belttensioner mounting bracket.

(7) Remove the nut securing the heater pipesand the power steering pipe to the drive belt tensionerlower mounting stud.

(S) Remove the alternator retaining bolt locatedat the rear of the drive belt tensioner pulley. L.oosenthe alternator pivot bolt and raise the alternator.

(9) Remove the bolt securing the heater inletpipe to the front of the inlet manifold.

(10) Remove the bolt securing the heater outlet

Engine


42

COOLANT OUTLET iiPE

Front view of the engine showing the drive belttensioner assembly.

pipe to the coolant outlet pipe located adjacent to thelght hand rocker cover and remove the heater pipesfrom the timing cover and the inlet manifold.

(l l) Remove the power steering pump retainingbolts and carefutly place the pump to oni side. Onmodels without power steering, remove the idlerassembly retaining bolts and remove the idler assem-bly from the engine.

(12) Remove the bolts securing the drive belttensioner to the cylinder head and remove the drivebelt tensioner.


(l) Tighten all bolts securely.(2) Fill the cooling system with the recommend-

ed coolant:(3) Start the engine and increase the speed to

3 000 rpm for l0 seconds, allowing the idle aiicontrolvalve to reset. check for coolant leaks and rectifv asnecessary.

(4) On models equipped with a radio/cassetteusing PIN security, enter the pIN code as describedunder the Radio/Cassette heading in the ElectricalSystem section.

5. MANIFOLDS

INLET MANIFOLD

To Remove and Instal(l) Depressurise the fuel system as described in

the Fuel and Engine Management section.(2) Disconnect the negative battery terminal.(3) Mark the fuel supply and return hoses to

ensure correct installation. Disconnect the hoses fromthe fuel rail inlet pipe and the fuel pressure regulator.

Engine

(4) Disconnect the lower radiator hose anddrain the coolant into a clean container.

(5) Disconnect the coolant air bleed hose fromthe inlet manifold pipe.

(6) Disconnect the small vacuum hoses from thefront of the throttle body and disconnect the hosesfrom the fuel rail retaining clips.

(7) Slide the high tension lead retainers from thesupport brackets.

(8) Disconnect the vacuum hoses from thethrottle body and the inlet manifold adaptor.

(9) Remove the engine vent pipe from the lefthand rocker cover and the throttle body.

(10) Remove the engine drive belt. Refer to theEngine Tune-up section if necessary.

(11) Disconnect the wiring harness connectorfrom the alternator.

(12) Remove the alternator retaining bolt locatedat the rear of the drive belt tensioner pulley.

(13) Loosen the alternator pivot bolt, raise thealternator and disconnect the positive wire from thealternator.

(14) Remove the alternator pivot bolt and re-move the alternator._ (15) Disconnect the water pump by-pass hosefrom the front of the manifold.

(16) Remove the bolt securing the heater inletpipe to the front of the manifold.

( 17) Remove the nut securing the heater inletpipe to the drive belt tensioner lower mounting studand remove the heater inlet pipe from the inletmanifold.

( 1 8) Working at the rear of the engine, release thehose clamp and disconnect the coolant outlet hosefrom the thermostat cover.

(19) Release the clamps securing the air intake

ALTERNATOR P'VOTf,

AIR BLEED HOSE

Installed view of the inlet manifold.


View of the inlet manifold removed from the engine.

hose to the throttle body and the air intake duct andremove the air intake hose.

(20) Release the nuts securing the throttle cable tothe mounting bracket and disconnect the throttlecable from the throttle linkage. On models equippedwith cruise control, remove the bolts securing thecontrol cable mounting bracket to the inlet manifoldadaptor and the throttle body. Disconnect the controlcable from the throttle linkage.

(21) On automatic transmission models, discon-nect the inner kickdown cable from the throttlelinkage, compress the tangs securing the outer kick-down cable to the mounting bracket and remove thekickdown cable.

(22) Disconnect the wiring connectors from thethrottle body, fuel injectors, MAT sensor, coolanttemperature sensor and the temperature gauge sender

43

unit. Refer to the Fuel and Engine Managementsection if necessary.

(23) Disconnect the wiring harness retainers fromthe inlet manifold and place the wiring harness to oneside.

(24) Remove the inlet manifold retaining boltsand remove the inlet manifold from the engine.Remove and discard the seals and gaskets.


(1) Thoroughly clean the mating surfaces of theinlet manifold, the cylinder heads and the cylinderblock.

(2) Ensure that the inlet manifold retaining boltand cylinder head threads are clean.

(3) Apply RTV 732 sealant tp each end of therubber valley gaskets and ensure that they are posi-tioned firmly against the cylinder heads and thecylinder block.

(4) Instal the inlet manifold gaskets to the cyl-inder heads, ensuring that the dowels in each gasketlocate into the holes in the cylinder head.

(5) Coat the inlet manifold retaining bolts withLoctite 242 and tighten the bolts to the specifiedtorque in the sequence shown in the illustration.Repeat the tightening sequence.

(6) Ensure that att wiring connections are se-cure.

(7) Connect and adjust the throttle cable and ifnecessary, the cruise control cable as described in theFuel and Engine Management section.

(8) On automatic transmission models, instaland adjust the kickdown cable as described in theAutomatic Transmission section.

(9) Instal the drive belt as described in theEngine Tune-up section.

(10) Replenish the cooling system with the re-commended coolant as described in the Cooling andHeating Systems section.

(11) Check the fuel system for external leakage asdescribed in the Fuel and Engine Management seCtionbefore starting the engine.

(12) Start the engine and increase the speed to3 000 rpm for l0 seconds, allowing the idle air controlvalve to reset. Check for coolant leaks and rectifv asnecessary.

(13) On models equipped with a radiolcasserteusing PIN security, enter the PIN code as describedunder the Radio/Cassette heading in the ElectricalSystem section.

EXHAUST MANIFOLDS

To Remove and Instal(l) Disconnect the negative battery terminal.(2) Disconnect the high tension leads from the

spark plugs and remove the high tension leads fromthe retainers. Place the high tension leads on theengine.

Engine

View of the inlet manifold showing the bolt tighteningsequence.


44

lnstalled view of the left hand exhaust manifold.

(3) When removing the left hand exhaust mani-fold proceed as follows:

(a) Disconnect the oxygen sensor wiring connec-tor.

(b) Release the clamps securing the air inlethoses to the throttle body and the air cleaner housing.Remove the air inlet duct retaining nut, disconnectthe wiring harness fastener from the rear of the airinlet duct and remove the air inlet duct from thevehicle.

(4) When removing the right hand exhaust man-ifold proceed as follows:

(a) Remove the engine oil dipstick tube retain-ing nut and remove the dipstick tube from the engine.

(b) Disconnect the upper radiator hose andpartially drain the cooling system into a clean con-tainer. Remove the upper radiator hose.

(c) Working at the rear of the engine, release theclamp securing the coolant hose to the thermostathousing.

(d) Remove the bolt and nuts securing thecoolant outlet pipe to the rear engine lifting bracketand the exhaust manifold studs.

(e) Remove the coolant outlet pipe from theengine.

(0 Release the clamps and remove the coolantsupply hose from the surge tank and the heater inletpipe.

(5) Raise the front of the vehicle and support iton chassis stands.

(6) Remove the bolts securing the exhaust en-gine pipe to the relevant manifold.

(7) Remove the exhaust manifold retainingstudi and remove the manifold from the engine.


(1) If renewing the left hand manifold, removethe oxygen sensor from the manifold and instal thesensor to the new manifold, Refer to the OxygenSensor heading in the Fuel and Engine Managementsection.

(2) Ensure that the cylinder head and exhaustmanifold faces are clean.

(3) Coat the exhaust manifold studs with asuitable anti-seize compound.

(4') Instal the manifold and tighten the retainingstuds to the specified torque.

(5) Connect the exhaust engine pipe to themanifold and tighten the retaining bolts to the speci-fied torque.

(6) If necessary, replenish the cooling systemwith the recommended coolant as described in theCooling and Heating Systems section.

(7) Connect the high tension leads to the sparkplugs.

(8) Start the engine and increase the speed to3 000 rpm for 10 seconds to allow the idle air controlvalve to reset. Check for exhaust and coolant leaksand rectify as necessary.


6. ROCKER ARMS AND PUSHRODS

TO REMOVE

(l) Disconnect the negative battery terminal.

Engi,ne

COOLANT OUTLET PIPE:;;

Installed view of the right hand exhaust manifold.


Engine

ROOG*R o urr*r/

+GUIDE

Dismantled view of the valve train components.

(2\ Disconnect the high tension leads from thespark plugs.

(3) Release the lugs retaining the high tensionlead cover to the left hand rocker cover and slide thecover offthe rocker cover.

(4) Disconnect the engine vent pipe from the lefthand rocker cover.

(5) Remove the right hand high tension leadsfrom the retainers.

(6) Remove the bolts securing each rocker coverto the cylinder head and remove the rocker coversfrom the engine.

(7) Remove the rocker arm pivot bolts and therocker arrns from the cylinder head. Place the rockerarms and pivots in order of removal to ensure correctinstallation.

(S) Remove the pushrod guide plate from thecylinder head.

(9) Withdraw the pushrods from the engine andplace them in order of removal to ensure correctinstallation.

TO CTEAN AND INSPECT

(1) Wash all components in cleaning solvent anddry with compressed air.

(2) Clean the threads on the rocker arrn pivotbolts.

(3) Inspect the rocker arrn tip for deep scoring ordamage. Renew as necessary.

(4) Inspect the rocker arm pivot for scoring orcracks. Renew the rocker arm pivot and bolt asnecessary.

45

(5) Inspect the pushrods for distortion and wearon the spherical ends. Renew as necessary.

TO INSTAL


(1) Liberally coat the contact surfaces of thecomponents with clean engine oil prior to installation.

(2\ Instal the pushrods in their original loca-tions. Rotate the pushrod between the fingers andcheck for smooth movement. If the pushrod does notrotate smoothly the pushrod may not be locatedcorrectly in the hydraulic tappet.

On early production models, instal the guide plate asshown.

(3) Instal the pushrod guide plate to the cylinderhead ensuring that the words THIS SIDE UP arevisible and the pushrods are correctly positioned inthe guide.

(4) Apply Loctite 242 to threads on the rockerarm pivot bolts and instal the rocker arms and pivotsin their original location.

(5) Tighten the rocker arm pivot bolts to thespecified torque, ensuring that the pushrod remains incontact with the valve lifter and the rocker arm.

(6) Instal the rocker covers and tighten theretaining bolts to the specified torque, ensuring thatthe seals are seated in the rocker cover grooves.

(7) Start the engine and check for oil leaks andvalve train noise. Rectify as necessary. Increase theengine speed to 3 000 rpm for l0 seconds allowing theidle air control valve to reset.


7. HYDRAULIC TAPPETS

TO REMOVE AND DISMANTLE

( 1) Remove the inlet manifold and the rockerarms and pushrods as previously described.

WYH nodxenenn

H"rr"*OO*Fl

[N 24s*1s

H@

HYDRAULT. rAppEr F-l\Mta,


46

Dismantled view of a hydraulic tappet.

(2) Remove the bolts securing the hydrautictappet retainer plate to the cylinder block valley andremove the retainer plate.

(3) Remove the hydraulic tappet guides andplace them in order to ensure correct installation.

(4) Remove the hydraulic tappets from the cy-linder block and place them in the order of removal ioensure correct installation.

(5) Press the pushrod seat and plunger down andremove the snap ring with a small screwdriver.

(6) Remove the pushrod seat, metering valve,plunger assembly and the plunger spring from thetappet body.

NOTE: If the plunger assembly is dfficult toremove, turn the tappet upside down and tapsharply on a block of wood. If this fails todislodge the plunger assembly, soak thetappet in cleaning solvent.

(7) Using a fine bladed screwdriver, remove thecap, spring and ball from the plunger assembly.

TO CLEAN AND INSPECT

(1) Thoroughly wash all components in cleaningsolvent.

(2) Inspect the tappet body for wear or scuffmarks. If wear or scuff marks are evident, renew thehydraulic tappet assembly and examine the corre-sponding bore in the cylinder block for scoring.

(3) Renew the hydraulic tappet assembly if theroller has any of the following faults; binding or roughoperation, excessive play in the roller bearing, flatspots or pitting on the roller.

(4) Inspect the pushrod seat for wear. If thepushrod seat is worn renew hydraulic tappet assemblyand examine the corresponding pushrod for wear.Renew as necessary.

NOTE: The tappet must be renewed as anassembly if any of the components areunserviceable.

TO ASSEMBLE AND INSTAL

NOTE: When assembling the hydraulic tap-pets it is essential that the components andthe work area arefree of dirt or lint to avoidfailure or unsatisfactory operation of thetappets.

(1) Place the ball on the hole in the end of theplunger.

Engine

(2) Carefully place the spring and cap over theball and press the cap into position using a fine bladedscrewdriver.

(3) Half fill the tappet body with clean engine oiland instal the plunger spring.

(4) Align the oil feed hole in the plunger with thehole in the body and instal the plunger assembly intothe body. Fill the tappet with clean engine oil.

(5) Instal the metering valve and the pushrodseat, press the pushrod seat down arnd instal the snaprlng.

NOTE: If the snap ring cannot be installed,remove the pushrod seat and the meteringvalve and insert a I mm diam,eter pin intbthe centre of the plunger assembly anddepress the ball. Push the plunlier asiemblydown the required distance to alllow the snapring to be installed.

(6) Ensure that the tappet body, roller and boreare clean.

(7) Coat the tappet and the tappet bore withLUBRIZOL 6612 and instal the tappets to the cy-linder block.

(8) Instal the tappet guides, aligning the flatsegments on the tappet with the flat segments on theguide.

(9) Instal the hydraulic tappet netainer plate andtighten the bolts to the specified torrlue.

(10) Instal the pushrods, rocker arms and theinlet manifold as previously described.

8. CYLINDER HEADS

Special Equipment Required:To Dismantle - Valve spring cortrpr€SSorTo Inspect - Dial gauge and straight edgeTo Assemble - Valve spring compressor andvernier gauge


(l) Remove the inlet and exhaust manifolds andthe rocker arms and pushrods as prev'iously described.

(2) When removing the left hand cylinder head,proceed as follows:

(a) Release'the screw retaining the wiring har-ness connector to the ignition control module anddisconnect the wiring harness connector.

(b) Remove the nuts and disconnect the earthwire terminal and the wiring harnesr; support bracketfrom the alternator/ignition control nnodule mountingbracket studs.

(c) Remove the nut and disconnect the earthstrap from the ignition control module mounting stud.

(d) Remove the bolts retaining the alternator/ignition control module mounting bracket to thecylinder head and remove the mounting bracket.


Engine 47

(l) [Jse new gaskets during assembly.(2) Clean the cylinder headbolt and the cylinder

btock threads. Renew cylinder head bolts that havedamaged heads or threads.

(3) Position the head gaskets over the locatingdowels on the cylinder block face, ensuring that theside of the gasket marked TOP is facing uppermost.

(4) Coat the threads of the cylinder head boltswith Loctite 242 and tighten the lbolts finger tight.

NOTE: The cylinder head bolts are dffirentlengths. The four 59 mm bolts are installedin the external holes adjacent to the sparkplug holes. The two 82 mnn bolts are in-stalled at each end of the cylinder head,adjacent to the valve springs ttnd the two I l3mm bolts are installed in the centre holes.

(5) Apply an initial torque: of 34 Nm tocylinder head bolts in the sequence shown inillustration.

(6) Set the torque wrench ta, 8l Nm and furthertighten the bolts 90 degrees, Ibllowing the samesequence. Cease tightening the bolts if the torquewrench registers 81 Nm.

(7) Further tighten the cylinder head bolts to 8lNm.

(8) Ensure that the earth connections are tight-ened securely.

(9) Instal the pushrods, rocker arms and theinlet manifold as previously descr:ibed.

(10) Fill the cooling system with the recommend-ed coolant as described in the Cooling and HeatingSystems section.

(l l) Start and run the enginr: and check for oi[,coolant or exhaust leaks. Rectifv ias necessary.

TO DISMANTLE

(1) Clean the deposits from the combustionchamber. Do not contact the c),linder head gasketfaces with a rotary wire brush.

.(2) Compress the valve spr:ings using a valvesprlng compressor and remove the valve retainingcollets.

NOTE: If dfficulty is experienced in separ-ating the valve spring retainer from thecbllets, apply light pressur(? to the valvespring compressor and tap the edge of theretainer with a soft faced hammer.

(3) Release the spring compressor and removethe retainer, the valve springs anrl the valve stem oilseal.

(4) Remove any burrs from the end of the valvestem to prevent damage to the valrre guide as the valveis withdrawn.

(5) Remove the valves, keeping them in order toensure assembly in their original positions.

Underside view of the cylinder head showing the valvearrangement.

Cylinder head bolt tightening sequence.(e) Remove the bolts securing the alternator

mounting support bracket to the cylinder head andremove the bracket.

(3) When removing the right hand cylinderhead, proceed as follows:

(a) Remove the power steering pump pulleyretaining bolts and remove the pulley.

On models not equipped with power steering,remove the idler pulley retaining bolts and remove thepulley.

(b) Remove the nut securing the heater pipesand the power steering pipe to the drive belt tensionerlower mounting stud and disconnect the pipes fromthe mounting stud.

(c) Remove the bolts and stud and remove thedrive belt tensioner bracket and the power steeringpump assembly from the cylinder head.

On models not equipped with power steering,remove the drive belt tensioner bracket and the idlerassembly.

(4) Progressively loosen the cylinder head boltsin the reverse order to the tightening sequence.

(5) Remove the cylinder head bolts and removethe cylinder heads and gaskets.


thethe


Q dJ*ot rrs-gg

f f i q #- -RerArNERst L

. =

ffi-v-qg

Dismantled view of the inlet and exhaust valvecomponents.


(1) Clean the valves thoroughly and discard anyburnt, warped or cracked valves.

(2) Using a sharp scraper, carefully remove alltraceg of gasket from the cylinder heads. Remove allcarboR deposits from the cylinder head using a wirebrush and electric drill. Do not use the wire brush onthe cylinder head mounting faces. Clean the valveguides using a piece of wadded cloth or a suitablebrush and cleaning solvent.

(3) Thoroughly clean the cylinder heads incleaning solvent using a soft brush.

(4) Check the cylinder head mounting faces andthe inlet and exhaust manifold mating surfaces fordistortion using a straight edge and feeler gauges. If

48

checking the cylinder head for distortion using feelergauges and a straight edge.

Engine

.""-

Checking the cylinder block for distortion using feelergauges and a straight erdge.

Measure the cylinder head mountingl face thickness atthe three measuring pads as showrr, using a vernier

gauge.

the cylinder head is distorted it must be machined. Ifit is necessary to machine more tha.n 0.30 mm fromthe cylinder head, the cylinder head must be renewed.

NOTE: To determine if the q,linder headmounting face has sufficient ,thickness toallow machining, measure the depthbetween the cylinder head mctunting faceand the three measuring pads, as shown inthe illustration. From- this nreasurementsubtract the distortion measurement. If the.figure ls /ess than 1.072 mm ,the cvlinderhead will have to be renewed.

(5) Check the cylinder block faces for distortionusing a straight edge and feeler gauges. If the distor-tion is within the cylinder block face machining limit,remove the engine and machine th,e cylinder blockfaces. If the distortion exceeds the limit. renew thecylinder block.

NOTE: Machining the cylind,er head orcylinder block faces beyond Specfficationswill increase the compression ratio. This

F-/sEots--ffi

fl *..='uo..u= ffiI I ExHA,sr vALvE fi |

4,.,,.,d


may cause cylinder detonation or pinging,result in loss of performance and could afectemission levels.

(6) Check the cylinder heads for cracks in thevalve seats, combustion chambers and external cracksleading to the water jackets. Check the cylinder headmounting faces for corrosion.

(7) Check for bent valve stems using a dial gaugeand Vee blocks.

(8) To check the valve stem to valve guideclearance, measure the valve stem side movement asfollows:

(a) Install the valve to its original guide andsecure a dial gauge to the cylinder head so that theplunger is against the side of the valve stem approx-imately 8-12 mm above the top of the guide.

(b) Open the valve approximately 2 mm andmove the valve stem from side to side. If the dialgauge reading exceeds 0.25 mm, remove the valve andmeasure the valve stem using a micrometer. If thevalve stem diameter is within Specifications, it will benecessary to ream the valve guide and install anoversize valve.

(9) Check the con{ition of the valve seats and ifnecessary recut the seats with a valve seat cutter to thecorrect angle and width as specified.

(10) Inspect the valve faces for grooves or pittingand the valve tips for wear. If necessary, reface thevalves to the specified angle and machine the valvestem tip flat on a valve refacing machine.

If the valve head margin has been reduced to lessthan the specified thickness after refacing, the valveshould be renewed.

NOTE: If the valves or seats require machin-ing it is recommended that this be carriedoit by an engine reconditioning workshop.If a valve seat is cut, the corresponding valvemust be refaced.

(11) Inspect the valve spring contact surf,ace onthe cylinder head and the valve spring retainer forwear. Renew the faulty components as necessary.

(12) Check the valve springs for squareness. If

Engine 49

the ends of the valve spring coil are not parallelwithin Specifications, the spring is bent and must berenewed.

(13) Lap the valves to the valve seats with alapping compound. Apply a smeal of Prussian Blue tothe valves after lapping and checll< the seat to ensurethat a true and concentric seat has been gained.

NOTE: Do not lap new valt'es as this willdestroy the protective coating on the valveface.

TO ASSEMBLE

Assembly is a reversal of the dismantling proce-dure with attention to the followirng points:

(1) To ensure correct hydraulic tappet opera-tion, the valve stem installed height must be checkedusing the following procedure.

Measuring the valve stem ins-ta,llled height using avernrer gauge.

(a) Instal the valve to its oril;inal guide and holdit in the closed position.

(b) Measure the height between the valve springseat and the valve stem tip using a vernier gauge. If theheight exceeds Specifications, mar:hine the valve stemfip to achieve the correct dimensiron.

(2) Measure the valve spring installed heightusing the following procedure:

(a) Instal thd valve to its original guide andinstal the valve spring retainer and the retainingcollets.

(b) Place a finger under the retainer and raisethe valve against its seat. Ensure that the retainer andthe collets are fully seated.

(c) Measure the height betw,een the valve spring

Measuring the valve stem side movement.


50

Measuring the valve spring installed height using avernier gauge.

seat and the valve spring contact face on the retainerusing a vernier gauge. If the height exceeds Specifica-tions, instal valve spring seat shims to achieve thecorrect dimension.

(3) Thoroughly clean all the components anddry with compressed air.

(4) Lubricate the valve stems and valve guideswith clean engine oil and instal the valves intd theirguides.

(5) Instal the valve stem oil seals to the valveguides ensuring that the oil seals are installed to thecorrect valve guide as the seals for the inlet and theexhaust guides are different.

(6) Instal the valve springs and the retainer.Compress the valve springs and instal the retainingcollets, ensuring that the collets are correctly seatedbefore releasing the valve spring compressor.

(7) Lightly tap the top of the valve stem with asoft faced hammer to settle the collets in the retainer.

(8) Instal the cylinder heads as previouslydescribed.

,. TIMING COVER


(l) Disconnect the negative battery terminal.(2) Release the engine drive belt tensioner and

disconnect the drive belt. Refer to the Engine Tune-upsection if necessary.

(3) Raise the front of the vehicle and support iton chassis stands. Refer to the Wheels and

-Tvres

section if necessarv.

(4) On models with an automertic transmission,remove the torque converter inspection cover and,using a suitable implement, lock the drive plate or ringgear to prevent the engine turning. l'he manufacturerrecommends removing the starter motor and. placing alever between the engine block and the drive pliteteeth.

(5) On models with a manual transmission, fullyengage the handbrake, select top gear and chock therear wheels.

(6) Remove the crankshaft pultey retaining boltand remove the crankshaft pulley from the crankshaft.

(7) Drain the cooling system and disconnect theradiator hoses and the air bleed hose from theradiator.

(8) On models with an automatic transmission,disconnect the oil cooler hoses from the radiator. seaithe hoses and the radiator fittings to prevent the entryof dirt.

(9) Disconnect the engine cortling fan wiringconnector, remove the radiator retairring clips and liftthe radiator and fan assembly from rthe vehicle.

(10) Release the water pump by-pass hose clampand disconnect the hose from the water pump.

(l l) Release the lower radiator hose clamp anddisconnect the hose from the timing cover.

. (I2) Remove the nut securing the heater supplypipes to the drive belt tensioner mounting brackefanddisconnect the heater pipes and ii' applicable, thepower steering hose from the mounting stud.

. (13) Remove the bolt securing the heater supplypipe to the coolant outlet pipe located adjacent to itrbright hand side rocker cover and remove the heatersupply pipe from the timing cover.

(14) Disconnect the wiring contlectors from thecrankshaft sensor and the oil pressure switch.

(15) Disconnect the crankshaft sr3nsor wiring har-ness from the clamp located at the side of the timingcover. Remove the clamp retaining nut and remove

CRANKSHAFT PULLEY

View of the timing cover and associated componentsremoved from the eng,ine.

Engine


Engine 5 l

the clamp and the wiring harness earth connectionterminal.

( 16) Remove the crankshaft sensor retainingbolts and remove the crankshaft sensor from thetiming cover. Refer to the Fuel and Engine Manage-ment section if necessary.

( I 7) Remove the sump plug and drain the engineoil into a container.

(18) Remove the bolts securing the engine sumpto the timing cover. Loosen the remaining sump boltsand allow the sump to separate from the cylinderblock and the timing cover.

(19) Remove the timing cover retaining bolts andcarefully remove the timing cover from the engine. Itmay be necessary to remove the water pump pulleyretaining bolts and the pulley from the water pump.

(20) If necessary, to dismantle the oil pumpassembly, refer to the Oil Pump heading.

(21) If necessary, to remove and instal the waterpuffip, refer to the Cooling and Heating Systemssection.


(l) Remove the crankshaft oil seal from thetiming cover using a hammer and a suitable drift.Instal a new oil seal to the timing cover, ensuring thatthe lip of the seal faces the inside of the timing cover.

(2) Ensure that the timing cover and the cy-linder block surfaces and the timing cover retainingbolt threads are clean.

(3) Ensure that the camshaft thrust bearing andspring are correctly installed in the front of thecamshaft.

(4) Instal a new timing cover gasket to thecylinder block.

(5) Instal the timing cover, ensuring that the flatsegments on the crankshaft sprocket align with thoseon the oil pump inner gear. Ensure that the sumpgasket is located correctly between the timing coverand the sump.

(6) Coat the threads of the timing cover retain-ing bolts with Loctite 242 and instal the bolts fingertight.

(7) Instal the engine sump to the timing coversecuring bolts and tighten to the specified torque.

(8) Tighten the timing cover retaining bolts tothe specified torque.

(9) Tighten the remaining sump bolts to thespecified torque.

(10) Instal and if necessary, adjust the crankshaftsensor as described in the Fuel and Engine Manage-ment section.

(11) Instal the crankshaft pulley and tighten theretaining bolt to the specified torque.

(12) Instal a new O ring seal to the heater supplypipe and connect the pipe to the timing cover.

(13) Ensure that all coolant hose clamps aresecurely tightened.

(14) Fill the engine with the correct grade andamount of engine oil.


( l6) Ensure that all wiring connectors are secure-ly fastened.

(17) Start the engine and increase the speed to3 000 rpm for l0 seconds allowing the idle air controlvalve to reset. Check for oil and coolant leaks andrectify as necessary.


10. TIMING CHAIN, SPROCKETS AI\DBALANCE SHAFT GEARS


(l) Remove the timing cover from the engine aspreviously described.

(2) With the timing cover removed, hold thetiming chain damper away from the timing chain andmove the chain in and out between the camshaft andcrankshaft sprockets. If the movement exceeds Speci-fications, renew the timing chain and closely inspectthe sprockets for wear when removed.

(3) Measure the balance shaft gear backlashusing the following procedure:

(a) Mount a dial guage to the cylinder block andposition the plunger against the face of a balance shaftgear tooth.

(b) Partially rotate the balance shaft gear untilall clearance is removed and zero the dial gauge.

(c) Rotate the balance shaft gear in the oppositedirection and note the dial gauge reading.

Hold the damper away from the timing chain andmeasure the movement in the chain between thecrankshaft and camshaft sprockets. The movement

must not exceed 25.40 mm.


52

Repeat the above procedure at four points, turn-ing the balance shaft 90 degrees between each point.

(d) If the backlash exceeds Specifications at anypoint, renew the camshaft and balance shaft gears.

(4) Withdraw the camshaft thrust bearing andspring from the front of the camshaft.

(5) Rotate the crankshaft until the timing markson the camshaft and crankshaft sprockets are aligned.

(6) Remove the camshaft sprocket retainingbolts, hold the timing chain damper away from thetiming chain and remove the camshaft sprocket andtiming chain from the engine.

NOTE: After removing the timing chain donot attempt to turn the cranl<shaft or cam-shaft as damage to the pistons or valves mayresult.

(7) Slide the crankshaft sprocket from the crank-shaft. A puller should not be necessary to remove thecrankshaft sprocket, however, if the sprocket is diffi-cult to remove, carefully lever against the sprocketwith a large screwdriver.

View of the camshaft timing marks correctly aligned.

(8) Remove the damper tensioning spring fromthe damper retaining bolt. Remove the bolt and thedamper from the engine.

If necessary remove the balance shaft gears asfollows:

(a) Instal two bolts, approximately 35 mm long,into the camshaft gear and place a lever between thebolts to prevent the gear turning.

(b) Remove the balance shaft gear retaining boltand remove the gear.

(9) Remove the bolts from the camshaft gearand remove the gear from the camshaft.

(10) Clean all components in cleaning solventand dry with compressed air.

(11) Inspect the sprockets and gears for worn ordamaged teeth. Renew the sprockets or gears asnecessary.

View of the timing chain, sprockets and damperremoved from the engine.

(12) Inspect the timing chain roller links for wearor stretch. Renew the timing chain as necessary.


(1) If removed, instal the balance shaft andcamshaft gears, ensuring that the timing marks arealigned. Tighten the balance shaft gear retaining boltto the specified torque.

(2) Instal the crankshaft sprocket and temporar-ily instal the camshaft sprocket to ensure that thetiming marks are in alignment. If the marks are not inalignment, carefully rotate the crankshaft or camshaft.

(3) Remove the camshaft sprocket and instal thedamper and tensioning spring, ensuring that the endof the spring is located in the hole adjacent to thedamper retaining bolt. Tighten the damper retainingbolt securely.

(4) Instal the camshaft sprocket and the timingchain, holding the damper away from the chain. Wheninstalled, release the damper and check that thetiming marks are aligned.

(5) Tighten the camshaft sprocket retainingbolts to the specified torque.

View of the balance shaft timing marks correctlyaligned.

Engine

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Engine

(6) Instal the camshaft thrust bearing into thefront of the camshaft.

(7) Instal the timing cover as previouslydescribed.

11. CAMSHAFT AND BALANCE SHAFT

TO MEASURE CAMSHAFT LOBE LIFT

(1) Remove the rocker arms from the cylinderheads as previously described.

(2) Mount a dial gauge to the cylinder head andposition the plunger on the end of the pushrod.

(3) Rotate the crankshaft until the pushrod is atits lowest point and zero the dial gauge.

(4) Rotate the crankshaft and note the maxi-mum reading on the dial gauge.

Repeat the procedure on the remaining pushrods.If th€ maximum reading on any pushrod is below

Specifications, a worn camshaft lobe is indicated.Renew the camshaft as described under the followingheading.

If the reading is as specified, instal the rockerarms as previously described.

TO REMOYE

(l) Remove the inlet manifold, rocker arms andpushrods, hydraulic tappets, timing cover, timingchain and camshaft sprocket and the camshaft gear aspreviously described.

(2) Measure the balance shaft end float using thefollowing procedure:

(a) Mount a dial gauge to the cylinder block andposition the plunger against the end of the balanceshaft gear retaining bolt.

(b) Move the balance shaft fully towards thefront of the engine and zero the dial gauge.

(c) Push the balance shaft fully towards the rear

Measuring the balance shaft end float using a dialgauge.

5 3

Measuring the balance shaft bearing radial clearanceusing a dial gauge.

of the engine and note the dial gauge reading.If the reading exceeds Specifications, a worn front

balance shaft bearing is indicated. Renew the balanceshaft and front bearing assembly.

(3) Measure the balance shaft radial clearanceusing the following procedure:

(a) Mount a dial gauge to the cylinder block andposition the plunger against the top of the frontcounter weight on the balance shaft.

(b) Zero the dial gauge and raise the balanceshaft noting the dial gauge reading.

View of the camshaft components removed from theengrne.

If the reading exceeds Specifications, a worn frontbalance shaft bearing is indicated. Renew the balanceshaft and front bearing assembly.

(c) Repeat the previous operations on the rearcounterweight and note the dial gauge reading.

If the reading exceeds Specifications, a worn rearbalance shaft bearing is indicated. Renew the rearbearing as described under the heading To RenewBalance Shaft Rear Bearing.

(4) Temporarily instal the camshaft gear to thecamshaft using two bolts approximately 35 mm longand place a lever between the bolts to prevent thecamshaft gear turning. Loosen the balance shaft gearretaining bolt.

(5) Remove the bolts from the camshaft gearand remove the gear.

(6) Carefully withdraw the camshaft from theengine, ensuring that the camshaft lobes do notdamage the camshaft bearings as the camshaft is beingremoved.


54

(7) Remove the balance shaft retainer bolts andremove the retainer from the engine.

(S) Position two screwdrivers behind theshoulder on the rear of the balance shaft gear and leverthe balance shaft and front bearing from the engine.Do not lever against the gear teeth.

TO INSTAL

(l) Lubricate the balance shaft front bearing andthe rear bearing sleeve with clean engine oil.

(2) Instal the balance shaft and lightly tap thefront of the balance shaft until the front bearing isfully installed in the cylinder block. Ensure that thebalance shaft rotates freely.

(3) Instal the balance shaft retainer and tightenthe retaining bolts to the specified torque.

(4) Lubricate the camshaft bearing journals withclean engine oil and the camshaft lobes with LUBRI-ZOL 6612lubricant.

(5) Smear Molybdenum Disulphide greasearound the camshaft front bearing bore.

(6) Carefully instal the camshaft, ensuring thatthe lubricant on the lobes is not removed whenpassing through the camshaft bearings. Ensure thatthe camshaft rotates freely.

(7) Instal the balance shaft and camshaft gears,the camshaft sprocket and timing chain, the timingcover, hydraulic tappets, pushrods and rocker arms,and the inlet manifold as previously described.

TO RENEW BALANCE SHAFT REAR BEARING

(l) Remove the engine from the vehicle aspreviously described and separate the transmissionfrom the engine.

(2) Remove the balance shaft from the engine aspreviously described.

(3) Remove the flywheel or drive plate as de-scribed later in this section under the Flywheel/Driveplate heading.

(4) Using a suitable socket and bar, knock therear bearing and the welch plug from the rear of the cy-linder block.

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Instalthe balance shaft rear bearing until A: 22-18 -22-6A mm from the rear of the cylinder block.

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Engine

BALANCE SHAFT

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View of the batance shaft components removed fromthe engine.

NOTE: If the balance shaft cannot be re-moved using two screwdrivers, remove thebalance shaft gear, instal a suitable slidehammer to the balance shaft and withdrawthe balance shaft andfront bearingfrom theengine.

TO INSPECT

(1) Check the camshaft bearing journals andlobes for wear, damage and discolouration, which isan indication of overheating.

(2) Using suitable micrometers, measure thecamshaft bearing journals and the camshaft bearingbores and calculate the oil clearance using thesemeasurements. Renew the camshaft and/or the cam-shaft bearings as necessary.

NOTE: If the camshaft bearings are slightlyscored remove any burrs with emery paperand lightly polish the bearings with steelwool. Polish the camshaft bearing journalsif necessary.

If the camshaft bearings requirerenewal it is necessary to remove the engineand have the bearings removed and in-stalled by an engine reconditioning work-shop.

(3) Support the camshaft between two veeblocks placed under each end journal and mount adial gauge so that the plunger is resting on the back ofthe camshaft lobe. Zero the dial gauge. Rotate thecamshaft and note the maximum reading on the dialgauge. Repeat this procedure on the remaining lobes-

If a camshaft lobe lift does not meet Specifica-tions, renew the camshaft.

(4) Inspect the balance shaft rear bearing sleevefor wear or pitting. If the sleeve is worn or pittedrenew the balance shaft and front bearing assemblyand renew the balance shaft rear bearing as describedunder the appropriate heading.

CYLINDER BLOCK


Engine


(l) Liberally coat the rear bearing with cleanengine oil prior to installation.

(2) Using a suitable socket or tubular drift, instalthe bearing into the bearing bore from the rear of thecylinder block ensuring that the side of the bearingwith the flat face is towards the rear.

The rear bearing is correctly located in the bearingbore when the distance between the rear face of thebearing and the rear face of the cylinder block is22.18-22.68 mm.

(3) Coat the sealing edge of the new welch plugwith Loctite 620 and instal the welch plug into the rearof the cylinder block.

(4) Instal the flywheel or drive plate as describedunder the Flywheel/Drive plate heading.

(5) Instal the balance shaft as previously de-scribed.

(6) Instal the engine as previously described.

12. OIL PUMP


(l) Place a container under the oil filter andremove the oil filter.

(2) Remove the timing cover as previously de-scribed.

(3) Remove the bolts securing the oil filteradaptor to the timing cover and remove the oil filteradaptor. Remove and discard the gasket.

(4) Remove the pressure regulator valve andspring from the timing cover.

(5) Using a Torx T30 bit, remove the oil pumpcover plate retaining screws and remove the coverplate.

9 C

(6) Remove the oil pump gears from the timingcover.

(7) Remove and discard the timing cover gasketand the crankshaft oil seal.

TO INSPECT

(1) Wash all components in cleaning solvent anddry with compressed air.

(2) Inspect the timing cover and the oil pumpcover plate for cracks, excessive scoring or damage.

(3) Inspect the pressure regulator valve for scor-ing. Instal the valve in the timing cover and check forfree movement. Check the pressure regulator valvebore in the timing cover for burrs.

(4\ Measure the pressure regulator spring freelength. If the length is not as specified or the conditionof the spring is suspect, renew the spring.

(5) Check the oil pump gears for excessive wear,scoring or damage.

(6) Instal the oil pump gears into the timingcover and carry out the following checks:

Measuring the inner gear tip to outer gear clearance.

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Dismantled view of the oil pump assembly. Measuring the outer gear to housing clearance.


56

Measuring the inner and outer gear to timing coverend clearance.

(a) Measure the clearance between the innergear tip and the outer gear.

(b) Measure the clearance between the outergear and the timing cover.

(c) Measure the end clearance between the innerand outer gears and the timing cover.

(d) Using suitable micrometers, measure thepressure regulator valve and the corresponding borein the timing cover. Subtract the valve measurementfrom the bore measurement to calculate the pressureregulator valve clearance.

If any component is excessively worn or unfit forservice, or if any clearance exceeds Specifications,renew the timing cover and oil pump assembly.


(l) Using a tubular drift, instal a new crankshaftoil seal into the timing cover.

(2) Thoroughly coat the oil pump gears withPetroleum Jelly and instal the gears into the timingcover. The inner gear must be installed with'thechamfered inner edge facing away from the timingcover.

(3) Completely fill the oil pump cavities withPetroleum Jelly. Failure to do this will result indelayed lubrication of the engine when the engine isstarted.

(4) Instal the cover plate and tighten the retain-ing screws securely.

(5) Lubricate the pressure regulator valve withclean engine oil and instal the spring and valve intothe timing cover.

(6) Using a new gasket, instal the oil filteradaptor and tighten the retaining bolts to the specifiedtorque.

(7) Instal the timing cover to the engine, ensur-ing a new gasket is installed as previously described.Instal a new oil filter as necessary.

(S) Start the engine and check that the oil

Engine

pressure warning lamp does not remain illuminated.Check for oil and coolant leaks and rectify as neces-sary.

13. SUMP AT{D OIL PUMP PICK.UP PIPE

TO REMOVE

(1) Disconnect the negative battery terminal.(2) Raise the vehicle and support it on chassis

stands placed under the side frame members.(3) Remove the sump plug and drain the engine

oil into a container.(4) Remove the front suspension crossmember

as described in the Front Suspension section.(5) Place chassis stands under the front engine

mountings to secure the engine.

View of the engine with the sump removed showingthe oil pump pick-up pipe.

(6) Remove the bolts securing the wiring har-ness clamps to the front of the sump.

(7) On automatic transmission models, removethe screws securing the oil cooler pipes to the sump.

(8) Remove the sump retaining bolts and lowerthe sump from the engine. Remove and discard thesump gasket.

(9) Remove the bolts securing the oil pumppick-up pipe to the cylinder block and remove anddiscard the gasket.


( I ) Clean the cylinder block and sump matingsurfaces.

(2) Wash the inside of the sump to removecarbon and sludge deposits. Check for any metaldeposits which will indicate an imminent bearingfailure.

(3) Inspect the sump for dents, cracks or damage


Engi,ne

to the mounting surface. Inspect the threads on thesump plug and sump for damage or wear. Repair orrenew as necessary.

(4) Thoroughly clean the oil pump pick-up pipescreen with cleaning solvent and a brush.

(5) Inspect the oil pump pick-up pipe for cracksor dents. Renew as necessary.

TO INSTAL


( 1) Using a new gasket, instal the oil pump pick-up pipe and tighten the retaining bolts to the specifiedtorque.

(2) Place the new sump gasket onto the sump,aligning the recesses in the gasket with the corre-sponding dimples on the sump mounting surface.

(3) Instal the sump to the cylinder block andtighten the retaining bolts to the specified torque.

(4) Instal and tighten the sump plug to thespecified torque.

(5) Secure the wiring harness and, if necessary,the oil cooler pipes to the sump and tighten theretaining bolts securely.

(6) Instal the front suspension crossmember asdescribed in the Front Suspension section.

(7) Fill the sump with the correct grade andquantity of oil.

(8) Start the engine and check for oil leaks.Rectify as necessary.

Increase the engine speed to 3 000 rpm for 10seconds, allowing the idle air control valve to reset.


14. CRAhIKSHAFT OIL SEALS

FRONT CRANKSHAFT OIL SEAL

To Remove and Instal(1) Disconnect the negative battery terminal.(2) Release the engine drive belt tensioner and

disconnect the drive belt. Refer to the Engine Tune-upsection if necessary.

(3) Raise the front of the vehicle and support iton chassis stands. Refer to the Wheels and Tyressection if necessary.

(4) On models with an automatic transmission,remove the torque converter inspection cover and,using a suitable implement, lock the drive plate or ringgear to prevent the engine turning. The manufacturerrecommends removing the starter motor and placing alever between the engine block and the drive plateteeth.

(5) On models with a manual transmission, fullyengage the handbrake, select top gear and chock therear wheels.

View of the timing cover and associated componentsremoved from the erngine.

(6) Remove the crankshaft pulley retaining boltand remove the crankshaft pulley from the crankshaft.

(7) Drain the cooling system and disconnect theradiator hoses and the air bleed hose from theradiator.

(8) On models with an automatic transmission,disconnect the oil cooler hoses from the radiator. Sealthe hoses and the radiator fittings to prevent the entryof dirt.

(9) Disconnect the engine cooling fan wiringconnector, remove the radiator retaining clips and liftthe radiator and fan assembly from the vehicle.

(10) Using a punch, tap a small hole in the frontface of the oil seal.

(1 1) Insert a self tapping screw into the hole.(12) Grip the head of the screw with a pair of

pliers and pull the oil seal from the timing cover.Installation is a reversal of the removal procedure

with attention to the following points:(1) Instal a new crankshaf,t oil seal using a

tubular drift. Ensure that the lip of the oil seal facesthe inside of the timing cover. Check the seal contactarea on the crankshaft pulley for grooves or damageand renew the crankshaft pulley as necessary.

(2) Instal the crankshaft pulley and tighten theretaining bolt to the specified torque.

(3) Instal the radiator and fan assembly andconnect the engine cooling fan wiring connector.

(4) Ensure that all hose clamps are securelytightened.


(6) On models with an automatic transmission,check the transmission fluid levefi as described in theAutomatic Transmission section.

(7) Start the engine and increase the speed to3 000 rpm for 10 seconds allowing the idle air controlvalve to reset. Check for oil and coolant leaks andrectify as necessary.

5 l

CRANKSHAFT PULLEY


58


REAR CRANKSHAFT OIL SEAL

To Remove and InstalTo renew the rear crankshaft oil seal it is neces-

sary to remove the engine from the vehicle andremove the crankshaft. This procedure is describedunder the heading Crankshaft and Bearings.

It is possible to repair a leaking rear crankshaft oilseal without removing the engine as described underthe following heading.

To Repack Oil Seal(l) Disconnect the negative battery terminal.(2) Remove the sump from the engine as pre-

viously described.(3) Remove the rear main bearing cap bolts and

tap the cap with a soft faced hammer to break thesealing compound. Instal a slide hammer into thesump bolt holes and remove the main bearing cap.

(4) Using a suitable tool gently drive the oil sealrope into the groove in the cylinder block until it istightly packed. The amount the seal can be compactedwill vary between 6-9 mm. Repeat this operation onthe other end of the seal.

(5) Remove the oil seal from the rear mainbearing cap. Thoroughly clean and dry the oil sealgroove and remove all traces of sealant from thechannels on each side of the bearing cap.

(6) Measure the depth that each side of the sealhas been compacted in operation (4) and add 2.0 mm.

(7) Cut two lengths of seal to the dimensionscalculated in operation (6), from the old seal removedfrom the main bearing cap.

View of the rear main bearing cap removed showingthe crankshaft oil seal installed.

Engine

(8) Instal the appropriate lengths of seal into theoil seal grooves in the cylinder block and compactthem until the ends are flush with the cylinder block.If necessary, soften the rope seal with oil to aidinstallation. Trim the ends to ensure that no fibres orstrands are protruding in the joint face.

, (9) Remove the rear main bearing shell andapply an adhesive such as l.octite 401 to the inside ofthe oil seal groove.

(10) Place a new seal into the oil seal groove andpress firmly into place. Use a hammer handle or otherround smooth object in a rolling motion to ensure thatthe seal is tightly packed in the groove.

(l l) Use a razor blade or similar and trim theexcess seal flush with the bearing cap mating face.Firmly hold the oil seal in place when trimming theseal ends.

( 12) Apply a light film of Loctite 5 I 5 GasketEliminator to the main bearing cap mating face, instalthe bearing shell and lubricate the bearing shelt andthe crankshaft journal with clean engine oil.

(13) Instal the rear main bearing cap and tightenthe bolts finger tight. Tap the bearing cap into positionusing a soft faced hammer and tighten the bolts to thespecified torque.

(la) Inject RTV 732 sealant into thebearing cap side channels until the sealant

rear malnbegins to

extrude from the joint gaps.(15) Instal the sump to the engine as

described.previously

15. PISTONS, CONNECTING RODS ANDCYLINDER BORES

Special Equipment Required:To Remove - Ridge removing toolTo Measure Piston and Bore - Micrometer,cylinder measuring gaugeTo Deglaze Bores - Cytinder bore honeTo Instal - Piston ring compressor


(l) Drain the engine oil and coolant and removethe cylinder heads, sump and oil pump pick-up pipe aspreviously described.

(2) If a ridge is present at the top of the cylinderbores, remove the ridge with a ridge removing tool.Ensure that the piston is at the bottom of the cylinderand is covered with a cloth to collect anv metalshavings.

(3) Using a centre punch, carefully number theconnecting rods and connecting rod caps in relation tothe cylinders from which they are removed.

(4) Using feeler gauges, measure the side clear-ance of each connecting rod. If the side clearance isnot within Specifications, renew the connecting rod.

(5) With the pisron at the bottom of the cy-


Engine 59

linder, remove the connecting rod cap bolts andremove the cap and the lower bearing shell.

Wipe the bearing shell and the exposed part of thejournal with a piece of clean lint free cloth, insert apiece of Plastigage across the journal and instal theconnecting rod cap and lower bearing shell. Tightenthe bolts to the specified torque.

Remove the bolts and cap and measure the spreadwidth of the Plastigage to determine the bearingclearance.

Compare the measurement to Specifications andif the clearance exceeds the limit, use new bearingshells on installation.

Repeat the procedure on the remaining bearingsand note each individual bearing clearance for instal-lation purposes.

(6) Remove each connecting rod cap in turnkeeping them in order and, using a wooden hammerhandle, carefully push each piston assembly from thecylinder block.

Instal the cap and bearing shell to the correctconnecting rod after removal.

(7) Remove and discard the piston rings.

TO INSPECT PISTONS AND CONNECTINGRODS

(1) Inspect the pistons for scuffmarks, scoring,cracks or burning. Renew the piston(s) as necessary.

(2) Clean all carbon deposits from the pistoncrowns and using a piece of broken ring, clean out thering grooves.

(3) Remove any deposits from the piston skirtsusing a suitable cleaning solvent.

(4) Inspect the ring grooves of the pistons forexcessive wear. Use a new piston ring and check the

Measuring the piston ring side clearance using feeler9auges.

Measuring the connecting rod side clearance usingfeeler gauges.

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60

Measuring the piston diameter using a micrometer.

side clearance of the ring in the ring groove. If the sideclearance exceeds Specifications, renew the piston.

(5) Measure each piston at the top and bottomof the piston skirt, at right angles to the gudgeon pinaxis. Renew the piston if the diameter is not withinSpecifications.

(6) Inspect each pair of bearing shells for wear.If one or both of the bearing shells are worn on theouter edge it is likely that the connecting rod is bent. Ifnecessary, have the connecting rod alignment checkedat an engine reconditioning workshop.

(7) If the bearing clearance exceeded Specifica-tions when previously checked with Plastigage, mea-sure each crankpin journal diameter with a micro-meter. If the journal is worn beyond Specifications itwill be necessary to remove the engine and renew thecrankshaft.

(8) Before renewing a piston, inspect the cy-linder block to see if it requires machining or renewal.Cylinders that require boring will have to have newpistons installed.

(9) If it is necessary to renew a piston and/orconnecting rod, take the assembly to an engine recon-ditioning workshop

(10) Check the connecting rod cap bolts for wearand stretch by comparison with a new bolt.

TO INSPECT CYLINDER BLOCK AND BORES

With the pistons removed as previously de-scribed, carry out the following checks and measuringprocedures:

(l) Check the cylinder bores for cracks, scoresand scuffs.

(2) Using an accurate cylinder gauge, measureeach cylinder bore for wear, ovality and taper. Takethe measurements at the upper, middle and lowersections of the bore in two directions, along and acrossthe block.

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Check for cylinder bore wear. Difference between Aand B measurement at top of piston travel is out ofround dimension. Difference between A at top and at

bottom of piston travel is cylinder taper.

Checking the cylinder block for distortion using feelergauges and a straight edge.

If either the diameter, ovality or taper exceedsSpecifications, it will be necessary to rebore thosecylinders and instal oversize pistons.

NOTE: It ,s not necessary to rebore allcylinders if correction is required to one ortwo cylinders only, as oversize pistons aremanufactured to the same weight as stan-dard pistons.

(3) Check the top faces of the cylinder block fordistortion using a straight edge and feeler gauges. Ifdistortion is present and is within the machininglimit, remove the engine and machine the cylinderblock top faces. If the distortion exceeds the machin-ing limit, the manufacturer recommends renewing thecylinder block.

NOTE: Machining the cylinder block facesbeyond Specifications will increase thecompression ratio. This may ceuse cylinderdetonation or pinging, result in /oss of

Engine

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Engi,ne 6 l

performance and could afect AustralianDesign Rules emission requirements.

(4) Thoroughly clean the cylinder block with asuitable cleaning solvent and compressed air.

TO CHECK PISTON CLEARANCE

(1) Using an accurate cylinder measuring gauge,measure and note the diameter of each bore aspreviously described.

(2) Measure each piston skirt as previouslydescribed.

(3) Subtract the piston skirt diameter from thecylinder bore diameter to calculate the piston clear-ance.

(4) Cylinders that have been rebored and honedfor oversize pistons should also have the clearancechecked in the manner described.

TO DEGLAZF. CYLINDER BORES

Cylinder bores that are fit for further service withoriginal pistons but require re-ringing should bedeglazed with a hone.

( 1) Use a surfacing hone with 32A-400 gdtstones for deglazing.

NOTE: When deglazing cylinder bores withthe cranl<shaft installed, plenty of clean ragshould be placed over the uanl<shaft toprevent abrasive materials entering the oilways.

(2) Move the hone up and down the cylinderwalls fast enough to achieve a cross hatch pattern.

The cross hatch pattern most satisfactory forcorrect seating of the piston rings is when the ltonemarks intersect at 30-45 degrees.

' NOTE: When deglazing, the cylindershould be honed only sufficiently to elimin-ate the glazed condition. Excessive honingwill increase bore size and thus increasepiston clearance.

(3) Lubricate the bore with honing oil duringhoning. Do not use engine oil, transmission oil,mineral spirits or kerosene.

(4) When honing is completed ensure that thecylinder bore, crankcase area and oil ways are thor-oughly cleaned using a scrubbing brush with warmwater and detergent. Do not use solvents.

(5) After the cylinder block has been cleanedand dried, wipe the bores with a lint free cloth andcoat them with engine oil to prevent rusting.

TO FIT NEW PISTON RINGS AND INSTALPISTONS

Once the correct piston and bore relationship hasbeen determined and the pistons cleaned or renewedas necessary, proceed as follows:

Measuring the piston ring end gaP.

(1) Select a set of rings to suit the bore, standardor oversize, whichever is necessary.

(2) Place a compression ring into number onecylinder bore and using an inverted piston, push thering down the bore approximately 50 mm.

(3) Withdraw the piston and measure the gap inthe ring with feeler gauges. If the end gap does notmeet Specifications either substitute with another ringor file the ring to the specified gap.

(4) Repeat the previous procedures on the re-maining cylinders.

(5) Treat each ring and cylinder bore individ-ually and ensure that the rings are assembled to therespective piston from the cylinder bore in which therings were originally checked for end gap clearance.

(6) Prior to installing the rings to the piston, rollthe outer circumference of each compression ringaround its respective ring groove to ensure that it isfree. If the ring binds due to a high spot in the ringgroove, carefully file the ring groove until the pistonring is free'

FRoNT

z*ltnaltos

Diagram showing the installed position of the pistonring gaps. [ : Upper compression ring, B = Oil ringrail gaps, C : Lower compression ring, D : Oil ring

expander within this arc.


/LOWER COMPRESSION RING

AF ro**],',Jot

62

View of the piston rings showing the identificationmarkings.

If a ring has insufficient side clearance, place asheet of emery paper on a piece of flat glass and rubthe piston ring on the emery paper until the specifiedclearance is obtained.

(7) Instal the oil ring expander into the lowerring groove, ensuring that the ends of the expander arebutting together. Position the tang on the oil ringexpander in the hole or slot in the ring groove withinthe arc shown in the illustration.

(8) Instal one oil ring rail from the top of thepiston down into the oil ring groove.

(9) Instal the other oil ring rail from the bottomof the piston into the oil ring groove.

Check that the ends of the oil ring expander havenot overlapped.

(10) Using a piston ring expander, instal thelower and then the upper compression rings. The

Installed view of the pistons showing the directionarrows.

Instal the piston to the cylinder block using a ringcompressor and a hammer handle.

upper and lower compression rings are identified bymarkings on the ring adjacent to the gap. One markingidentifies the upper compression ring, two identicalmarkings identify the lower compression ring.

Instal the rings to the piston with the markingsfacing towards the top of the piston and position thegaps as shown in the illustration.

(11) Using the same procedure, instal the pistonrings to the remaining pistons.

(12) Remove the connecting rod cap bolts fromnumber one piston and connecting rod assembly andremove the connecting rod cap.

( 13) Rotate the crankshaft until the number onejournal is at the bottom of its stroke.

(14) Ensure that the bearing shell is correctlyinstalled in the connecting rod and liberally coat thepiston assembly and the bearing shell with engine oil.

(15) Instal the piston and connecting rod assem-bly into the cylinder bore with the arrow on the top ofthe piston facing the front. Instal a piston ringcompressor over the piston and compress the ringsinto their grooves.

NOTE: Connecting rod and piston assemb-lies must be replaced in the cylinders fromwhich they were removed.

(16) Carefully push the piston assembly down the

Engi,ne


cylinder bore and align the connecting rod on thecrankpin journal, ensuring that the bearing shell is notdislodged.

( l7) Instal the connecting rod cap and tighten thebolts. Loosen the bolts one turn and tighten to thespecified torque.

( l8) If new bearing shells were installed, recheckthe bearing clearance using Plastigage as previouslydescribed.

(19) Instal the remaining pistons in the samemanner.

(20) Prior to installing the oil pump pick-up pipeand sump, retighten the connecting rod cap bolts.

(21) Instal the various components, referring tothe appropriate headings.

16. CRANKSHAFT AND BEARINGS

Special Equipment Required:To Measure Journals - MicrometerTo Check Oil Clearance - Plastigage

TO REMOVE

(1) Remove the engine and transmission assem-bly from the vehicle.

(2) Remove the transmission from the engine.(3) Remove the sump and the oil pump pick-up

pipe.(4) Remove the timing cover, timing chain and

crankshaft sprocket. Refer to previous headings forthe correct procedure.

(5) Remove the spark plugs.(6) Remove the connecting rod cap bolts and the

connecting rod caps. Carefully push each connectingrod and piston assembly up the cylinder withoutexceeding the normal travel of the piston.

To measure the crankshaft end float, lever the crank-shaft forward and measure the clearance between the

front of the No. 2 main bearing and the crankshaft.

63

View of the No. 2 main bearing cap removed showingthe bearing shell.

NOTE: Ensure that the bearing caps andconnecting rods are numbered in relation toeach other to facilitate correct assembly.

(7) Prise the crankshaft forward and using feelergauges, measure the crankshaft end float between thefront of the No. 2 main bearing thrust face and thecrankshaft. If the end float exceeds Specifications,renew the No. 2 main bearing shells.

(8) Check the main bearing oil clearance usingPlastigage as follows:

(a) Remove the bearing cap and with a piece oflint free cloth, wipe the journal and bearing clean.

(b) Position a piece of Plastigage the approxi-mate length of the bearing width onto the mainbearing journal, parallel to the centreline of thecrankshaft. Ensure that the Plastigage is not over theoil hole.

(c) Instal the bearing cap and tighten the bolts tothe specified torque.

NOTE: Do not rotate the crankshaft whilethe Plastigage is in position.

(d) Remove the bearing cap bolts and carefutlyremove the cap and the lower bearing shetl.

(e) With the Plastigage scale, measure the com-pressed Plastigage strip to determine the oil clearance.

(0 The widest point of the strip will indicate theminimum clearance and the narrowest point themaximum clearance.

(g) The remaining bearings can be checked inturn using the same procedure.

(9) On manual transmission models, remove theclutch assembly and the flywheel. On automatictransmission models, remove the drive plate. Refer tothe following heading if necessary.

(10) Remove the bearing cap bolts and removethe bearing caps. To remove the rear bearing cap,remove the bolts and tap the cap with a soft facedhammer to break the sealing compound. Instal a slidehammer into the sump bolt holes and remove the cap.

Engine


64

(l l) Carefully lift the crankshaft from the cy-linder block, taking care not to dislodge or damage tlieupper halves of the main bearing shels if they are tobe used again.

If new bearings are to be installed, remove theupper halves of the bearing shells from the cylinderblock.

(12) Remove the rope crankshaft seals from therear main bearing cap and the cylinder block.

(13) Remove all traces of sealant from the cvlin-der block and the rear main bearing cap.

TO CHECK AND INSPECT(l) Thorouehly wash the crankshaft in a suitable

cleaning solvent and blow out the oilways with com-pressed air. Dry completely with compressed air.. (2) Inspect the bearing journals for cracks, scor-ing, roughness or discolouration. The crankshafi mustbe renewed if cracks, scoring or discolouration arepresent. Slight roughness of a journal may be removedwith a fine emery cloth soaked in engine oil. Removeburrs with a fine oil stone.

(:l Measure the main bearing and connectingrod journals for wear, taper and ovility. If any of th6measurements exceed Specifications, renew thecrankshaft.

(4) Support the crankshaft at each end in Veeblocks and, using a dial gauge, check the crankshaftfor bend at No. 2 and No. j main bearing journals.Renew the crankshaft if the bend exceedJSpecifica-tions.

(5) With the crankshaft still supported in Veeblocks, position a dial gauge against th-hywheel/driveqlate mo-unting flange and measure the fl-ange runout.Ensure that the crankshaft is prevented froir movingtowards or away from the dial gauge while performin[this check._ (6) Check the No. 2 main bearing thrust facesfor w_ear or pitting. If wear or pitting is evident, renewthe No. 2 main bearing shells.

(7) Check the bearing shells for uneven wear,scores, flaking and general deterioration of the bearingsurface. Renew the bearing shells as necessary.

TO INSTAL


(l) Thoroughly clean and dry the rear oil sealgrooves in the main bearing cap and the cylinderblock.

(2) Apply an adhesive such as Loctite 401 to theinside of the oil seal grooves.

(3) Place the rope seals in their respectivegrooves and press them firmly into place using ahammer handle or other ro,md r-ooth object in arolling motion to ensure that the seals urb tighttypacked into the grooves.

(4) Use a razor blade or similar and trim the

Engine

excess seal flush with the bearing cap and cylinderblock mating faces.

- Firmly hold the oil seal in place when trimmingthe seal ends and pack any loose strands or fibres intSthe rope seal grooves.

(5) Thoroughly clean the crankshaft journalsand oilways, the bearing caps and the cylindLr blockbearing bores.

(6) Ensure that the bearing shells are clean anddry ang install them to their respective positionsensuring that the oil feed holes in the upper shellsalign with the holes in the cylinder block.

NOTE: The bearing shells are not inter_changeable and must be installed in thecoruect location. To determine the correctlocation, compare the part number stampedon the rear of the shells with the identifica_tion chart. The grooved main bearing shellsmust be installed in the cylinder btock.

_ (7) Lubricate the No. Z main bearing thrustfaces with Molybdenum Disulphide grease and themain bearing shells with clean engine oit.

(8) carefully lay the crankshlft into the cylinderblock, guiding the connecting rod journals into theirrespective connecting rod.

(9) Instal the main bearing caps to their correctposition in the cylinder block. instil the bearing capbolts loosely_ and tap the bearing cap into positionusing a soft faced hammer. when the bearing cap issecurely seated tighten the retaining bolts finger tight.Prior to installing the rear main bearing capl apply alight film of Loctite 515 Gasket Elimittuto. to itremounting face of the bearing cap.

NOTE: The -dimples on the main bearingcaps must,fq.ce towards the front of thbengine and the number of ribs on the side ofthe main bearing caps indicate its numbiror position.

lnstalled view of the crankshaft showing the mairdbearing caps installed with the dimplesfaJing forwardand the ribs on the side of the tap indiciting the

correct location.


MAINBiEAF,,NG

| 988/90MODEL YEAR

N O 1

UPPERCOLOUR

24500076MAGENTA

LOWERCOLOUR

24500077MAGENTA

N O 2

UPPERCOLOUR

N/A

LOWERCOLOUR

N/A

N O 3

UPPERCOLOUR

1 8001 490L IME GREEN

LOWERCOLOUR

1 8001 492LIME GREEN

N O 4

UPPERCOLOUR

24500076MAGENTA

LOWERCOLOUR

2450AO78N/A

Main bearing identification chart.

(10) Recheck the bearing oil clearance using Plas-tigage as previously described.

If the clearance is not within Specifications,remove the bearing shell from the bearing cap andexamine the rear of the shell. An undersize bearing isidentified by the size stamped on the rear of thebearing shell. If the bearing shell is not undersize,instal an undersize bearing shell to the main bearingcap and recheck the clearance.

If the clearance is not as specified, renew thecrankshaft.

NOTE: The cranl<shaft has rolledfillet jour-nals and the manufacturer states that thecranl<shaft cannot be machined but must berenewed if the specified clearances cannotbe obtained.

( I I ) To align the No. 2 main bearing thrust faces,loosen the main bearing cap retaining bolts and leverthe crankshaft backwards and forwards several timeswith the final movement being forward.

( 12) Tighten the main bearing cap bolts to thespecified torque.

(13) Inject RTV 732 sealant into the rear mainbearing cap side channels until the sealant begins toextrude from the joint gaps.

( I a) Pull the connecting rods onto the crankshaftjournal and instal the connecting rod cap and bolts.Tighten the connecting rod bolts, loosen them oneturn and tighten to the specified torque.

(15) Rotate the crankshaft to check for free opera-tion. If the crankshaft does not rotate freely, check

65

that the main bearing caps and connecting rod capsare installed to their original positions. Check thecrankshaft end float as previously described.

(16) Instal the remaining components as de-scribed under the relevant headings and instal theengine in the vehicle as previously described.

TO RENEW MAIN BEARINGS

Crankshaft Installed(l) Disconnect the negative battery terminal.(2) Remove the sump and oil pump pick-up

pipe as previously described.(3) Check the main bearing oil clearance as

follows:(a) Remove the main bearing cap.(b) Place a hydraulic jack under the adjacent

crankshaft web and raise the jack until it is just takingthe weight of the engine.

(c) Wipe the main bearing shell and the crank-shaft journal with a piece of clean, lint free cloth.

(d) Place a piece of Plastigage across the bearingshell and instal the main bearing cap to the cylinderblock. Tighten the bolts to the specified torque.

(e) Remove the bearing cap and measure thespread width of the Plastigage to determine thebearing oil clearance.

Compare the measurement to Specifications andrenew the bearing shells as necessary.

Repeat the procedure on the remaining bearingsand note each individual bearing oil clearance.

(4) Remove the hydraulic jack and remove thebearing cap in which the shells are to be renewed.Remove the lower bearing shell-

(5) Instal a suitable rivet into the crankshaft oilhole and slowly rotate the crankshaft counter-clock-wise when viewed from the front. As the crankshaftturns the upper bearing shell will roll out of thecylinder block bearing bore.

(6) Remove the upper bearing shell and therivet. Thoroughly clean the crankshaft journal, thecylinder block bearing bore and the bearing cap.

(7\ Lubricate the upper bearing shell with en-gine oil. The upper bearing shells are identified by thegroove in the centre of the shell.

(8) Insert the flat end of the bearing shell overthe journal and partially slide the shell into thebearing bore from the side which has the locating tang.

(9) Instal the rivet into the crankshaft oil holeand rotate the crankshaft until the bearing shell is inposition. Remove the rivet from the crankshaft.

(10) Lubricate the lower bearing shell and instalthe bearing cap. Tap the bearing cap into position andtighten the bolts to the specified torque.

( I I ) Renew the remaining bearings using thesame procedure, with attention to the followingpoints.

(12) To remove the rear main bearing cap, re-move the bolts and tap the cap with a soft faced

Engi,ne

tr':I


66Engine

hammer to break the sealing compound. Instar a slidehammer ro the sump boli holes ;il ;;;ove thebearing cap.(13) When installing the No. 2 rna)n bearingghgllg, coat the th.u.i ib."., *i,t Motybdenum Disul-phide grease prior ro instailution.-iigr,l;;;. bortsfinger tight and lever the crankshaft backwards andforwards several times with the nttai -;;;;;"t beingforward. This procedure will arign the thrust faces.Tighten the bolts to the specified ?..;;

!.r s\

NOTE: The ̂ dimples on the main bearingcaps must face towards the front ij tneengine.

(14) Prise the crankshaft forward and using feelergauges' measure the crankshaft end float between thefront of the No. 2 main uea.i"g trr-ri-r"ie and thecrankshaft. If the end float is not-witrri" sp."ifications,repeat t!. previous operation to align tt. mainbearing thrust faces.

(15) Prior to installing the rear main bearing cap,remove all traces of sealant from the ctrann;6;" eachside of the cap. Applv a light nrm of-ioctite s t sGasket Eliminato. to the morinting ru.. ortil"L""rrrrgcap. Instal themain bearing cap aid tightenihe boltsto the specified torque.

(16) Recheck the bearing crearance as previouslydescribed. If the clearance ls not withinTpecifica-tions, remove the bearing shell from trttu*-ring capand examine the rear of ttre shell. a,, ""a.rsizebearing is identifi94 bv the size stamped on the rear ofthe bearing shell..If the bearing sheliis noi.rrrdrrrire,instal an undersize bearing sf,eil to the-u.arirrg ,apand recheck the clearance.

If the clearance is not as specified, renew thecrankshaft.

- ( I 7) with the main bearing cap borts tightened tothe specified torque, rotate ttre crinkshaft ind checkfor free operation without binding ut u"V poirrt.

If the crankshaft binds check that tie bea.ingshells and cap are installed correctly and check thecrankshaft end float as previously descriUeO.

--

(.18) Instal tl.re oil pump pick_up pipe and sump aspreviously described.

17. FLYWHEEL/DRIVE PLATE

TO REMOVE

(l) Remove the transmission from the vehicle asdescribed in the Manual or Automati. i;;;issionsections, whichever is applicable.

(2) On manual transmission models, remove theclutch pressure plate and driven prate is describedunder the clutch Unit and Release Mechanism head-ing in the Clutch section. Ensure that the

-pi.rrur.

plate - and flywheel are marked to r"rui.-.Lrr..tinstallation.

(3) On automatic transmission models, mount a

Installed view of the drive plate assembly.dial gauge in a position where the plunger will restagainst the driveTlate adjacent to the Iorqu. con-verter bolt holes. check the runout at each of the boltholes. If the runout exceeds 0.20 --, li^ may bepossible to correct using a mallet. If thi;'f;ir, renewthe drive.plate.

(4) Remove the flywheel or drive plate retainingbolts and remove the flywheel or drive irr"iilrom ttrecrankshaft.

TO CHECK AND INSPECT

. (l) Inspect the flywheel face for cracks or exces-slve scorrng.

(2) Inspect the ring gear for damaged, cracked orworn teeth- If ne,cessary, the ring gear on the flywheelpay be renewed separately as described under thefollowing heading, lio*"rrer, if the ,i6;;in ttredrive plate requires renewal, the drive piut. urr.mblymust be renewed.

. (3) Inspect the drive plate bolt holes for elonga_tion, caused by loose retaining bolts.

(4) Inspect the drive plate for cracks.NOTE: The flywheel and drive plate are(es.igned and .manufactured rc 5, iri- ofbalance and should-not be balanrra ii i"individual component.

TO RENEW FLYWHEEL RING GEAR

- . ( 1) with the flywheel removed from the vehicle,drill a 3 mm diameter hole between two teeth of thering gear.

NOTE: Do not drill right throush the rinsgear as this will damage the flinge on th"eflywheel.

(2) Secure the flywheel, with the drilled holeuppennost, in a vice_ equipped with soft jaw guards.

(3) Place a cold chisel above the hoie in",h. ringgear and hit it sharply to split the ring gear.(4) observe the direction of trie-teeth leading


Engine

edges of the old ring gear. The new gear must beinstalledto the flywheel with the teeth leading edges inthe same direction.

(5) Remove the ring gear, clean the mountingface on the flywheel and remove any burrs.

(6) Polish a few spots of the new ring gear withemery cloth and heat the ring gear evenly until thepolished spots turn blue.

NOTE: Do not heat the ring gear past thepoint required to achieve a blue colour or thetempering of the gear teeth will be impaired.

(7) With the flywheel suitably supported, pickthe ring gear up using pliers and place it evenly ontothe flywheel.

NOTE: Allow the ring to cool slowly. Do notquench in water.

TO INSTAL


(1) As the flywheel or driveplate retaining boltholes are offset, the flywheel or driveplate can beinstalled in one position only.

(2) Tighten the retaining bolts to the specifiedtorque.

(3) On manual transmission models, instal theclutch and pressure plate assembly as described in theClutch section.

(4) Instal the transmission to the vehicle asdescribed in the Manual or Automatic Transmissionsections.

18. ENGINE MOUNTINGS

FRONT MOUNTINGS

To Remove and Instal(1) Disconnect the negative battery terminal.(2) Release the clamp securing the air inlet hose

to the throttle body and disconnect the hose.(3) Raise the front of the vehicle and support it

on chassis stands.(4) Remove the nuts securing the engine mount-

ing to the crossmember and the engine bracket.(Sl Using suitable lifting tackle, raise the engine

until the weight is taken off the engine mountings.(6) When removing the left hand engine mount-

ing proceed as follows:(a) On automatic transmission models, remove

the bolt securing the front of the starter motor to theengine bracket.

(b) On air conditioned models, remove the airconditioner compressor retaining bolts and secure thecompressor away from the engine.

(7) Remove the engine bracket retaining bolts,raise the engine slightly and remove the enginebracket and engine mounting.

67

Dismantled view of the right hand engine mountingcomponents.

esf

Dismantled view of the left hand engine mbuntingcomponents. Air conditioned model shown.


(l) Ensure that all bolts are tightened securely.(2) Start the engine and increase the speed to

3 000 rpm for 10 seconds, allowing the idle aircontrolvalve to reset.


68


REAR MOUNTING

To Remove and Instal( I ) Raise the front of the vehicle and support it

on chassis stands placed under the front jackingpoints.

(2) Position a jack underthe transmission with asuitable piece of timber placed between the head ofthe jack and the bottom of the transmission and raisethe transmission slightly to relieve the weight from therear mounting.

(3) Remove the bolts retaining the transmissioncrossmember to the vehicle underbody and the nutsand bolts retaining the crossmember to the mountingbracket.

CROSSUEMBER

Hur+@

&-r,rUrS

(2) When installing the crossmember to themounting bracket ensure that the insulating washersare correctly positioned at each end of the insulatingbushes and tighten the nuts and bolts finger tight.

(3) Instal the crossmember to the vehicle under-bodv and tighten the bolts securely.

(4) Remove the jack and tighten the cross-member to mounting bracket nuts and bolts securely.

19. EXHAUST SYSTEM


(1) Raise the vehicle and support it on chassisstands.

(2) Remove the clamp securing the rear mufflerand tailpipe assembly to the intermediate muffler.

(3) Remove the bolts securing the rear mufflersupport bracket to the tailpipe. If necessary removethe support bracket and rings.

(4) Separate the rear muffler and tailpipe assem-bly from the intermediate muffler.

NOTE: Should dfficulty be experiencedwhen separating the exhaust pipes from themufrler, they may be cut with a hacl<saw orpipecutter when a replacement system is tobe installed. When heating "frozen" jointsto loosen them, take extreme cere nearfloorpanels, fuel and brake lines and electricalwiring.

(5) Support the engine pipes in front of thecatalytic converter.

(6) Remove the bolts retaining the intermediatepipe to the catalytic converter.

(7) Remove the support insulator from the bodybracket and manoe-uvre the intermediate pipe andmuffler from the underbody.

(8) Remove the bolts securing the left handexhaust engine pipe to the left hand exhaust manifoldflange.

(9) Remove the clamp securing the right handexhaust engine pipe to the left hand exhaust enginepipe junction.

(10) Separate the left hand exhaust engine pipeand. catalytic converter from the right hand exhaustengine pipe and remove the catalytic converter andengine pipe assembly.

(l l) Remove the bolts securing the right handexhaust engine pipe to the right hand exhaust mani-fold flange and remove the right hand engine pipefrom the vehicle.

( 12) If necessary, remove the bolts securing thecatalytic converter to the left hand exhaust enginepipe and separate the pipe from the converter. Dis-card the gasket,

NOTE: Do not drop or hit the catalytic

Engine

t\"ot 4

-"t,,o24gt238t6f'8�

Dismantled view of the rear engine mountingassembly.

(4) Withdraw the transmission crossmemberfrom the vehicle.

(5) Working through the holes provided in therear mounting bracket, remove the bolts retaining themounting to the extension housing and withdraw themounting.

(6) If necessary, remove the nuts retaining themounting bracket to the mounting and separate thetwo components.


(l) If the rear mounting and mounting bracketwere separated, instal the mounting bracket to the rearmounting ensuring that the arrow on the top of themounting bracket is facing to the left side of thevehicle when installed.

I

#


converter or damage to the ceramic core willresult.


(l) [Jse new gaskets when installing the catalyticconverter.

(2) Instal all components of the exhaust systemto the underbody but do not tighten any nut or bolt.

Engine

lnstalled view of the exhaust system.

69

(3) Check the system for correct positioning.Ensure that all components clear the underbodysufficiently.

(4) Progressively tighten the exhaust system,starting from the exhaust manifold flanges and work-ing towards the tailpipe.

(5) Start the engine and check for exhaust leaks.Rectify as necessary.



COOLING AND HEATING SYSTEMS

SPECIFICATIONS

Coolant capacity Approximately 10 litresCoolant . . 50% ethylene glycol corrosion

inhibitor and 5070 clean waterThermostat:

Opening temperature . 89 - 93 deg CValve lift at 106 deg C . . . . . . More than 9 mm

Fan cut in temperature Above 102 deg CFan cut out temperature Below 99 deg CSurge tank pressure cap opening pressure . . . . l2O -

I 50 kPa


Engine drain plugsWater pump bolts:

Long boltsShort bolts

Thermostat cover bolt .Water pump pulley boltsFan to motor shaft nut.Fan shroud to radiator bolts

Check the radiator hoses for cracks or deterioration.

NOTE: Check the cooling system for exter-nal leakage by running the engine to operat-ing temperature over a dry floor andchecking for the source of a leak. Also checkthe vehicle interior below the heater unit formoisture. If a welch plug is found to berusted, it is recommended that all the welchplugs be renewed.

COOLANT LEAKAGE - INTERNAL

(l) Cylinder head gasket leak due to warpedcylinder head or cylinder block gasket faces: Refacecylinder head(s) or cylinder block and renew cylinderhead gasket(s).

(2) Crack in the cylinder head or cylinder block:Repair or renew the faulty components.

NOTE: Check the engine for internalleakage by withdrawing the dipstick andinspectinsfor emulsffied oil. Run the engineand checkfor excessive steam at the exhaustpipe which would indicate water leakageinto the combustion chamber. Check thecompression as described in the EngineTune-up section to locate a leaking cylinderhead gasket.

54 Nm

40 Nml4 Nm34 Nml6 Nm

2.5 Nm4.5 Nm

1. COOLING SYSTEM TROUBLE SHOOTING

COOLANT LEAKAGE - EXTERNAL

(l) Loose hose clip or faulty hose: Tighten thehose clip or renew the faulty hose.

(2) Leaking radiator core or tanks: Repair orrenew the radiator.

(3) Worn or damaged water pump seal as-sembly: Renew the water pump assembly.

(4) Worn or damaged water pump bearing as-sembly: Renew the water pump assembly.

(5) Loose or damaged coolant drain plugs:Tighten or renew the coolant drain plugs.

(6) External crack in the cylinder block or cy-linder head: Repair or renew any faulty components.

(7) Leaks at the thermostat cover or waterpump: Renew the gaskets or O rings as required.

(8) Leaking heater core or valve: Repair orrenew any faulty components.

(9) Loose or rusted welch plugs: Renew thewelch plugs.


Cooling and Heating Systems 7r

ENGINE OVERHEATING

(1) Surge tank pressure cap defective: Renew thepressure cap.

(2) Insufficient coolant: Replenish the coolant,check the cooling system for leakage and repair asnecessary.

(3) Obstructed air passage through the radiatorcore: Blow out the obstruction by applying air or waterpressure from the rear to the front of the radiator core.

(4) Faulty coolant temperature sensor, electriccooling fan or wiring: Check and renew the coolanttemperature sensor or electric cooling fan or repair thewrrrng.

(5) Leaking cylinder head gasket: Check andrectify as described under Coolant LeakageInternal.

Check the condition of the valves and the seal on thesurge tank cap.

Ensure that the wiring connections to the cooling fanare clean and secure.

A blown head gasket is indicated by bubbles in theradiator coolant with the engine running.

(6) Faulty thermostat: Check and renew thethermostat.

(7) Faulty water pump: Renew the water pump.(8) Engine tight after overhaul: Check and if not

unduly tight, stop the engine and allow it to cool.(9) Poor coolant circulation: Check and rectify

as under Coolant Circulation Faulty.(10) Restricted exhaust system: Remove the

restriction or renew the restricted component.(11) Incorrect fuel mixture: Check the fuel

system as described in the Fuel and Engine Manage-ment section and rectify as necessary.

(12) Low engine oil level: Stop the engine im-mediately and replenish the oil in the sump to thecorrect level.

(13) Incorrectly adjusted or dragging brakes:Check and rectify by adjustment or renewal ofcomponents as described in the Brakes section.

(14) Slipping clutch: Repair the clutch asnecessary.

NOTE: Engine overheating is usuallyaccompanied by steam emitting from theengine compartment. A leaking cylinderhead gaiket ls sometimes indicated bybubbles in the coolant when the engine isrunning.

COOLANT CIRCULATION FAULTY

(1) Insufficient coolant in the system: Replenishthe coolant and check for leaks.

(2) Partial blockage of the radiator core tubes:Reverse flush or renew the radiator.

(3) Sludge deposits in the engine water passages:Clean and reverse flush the engine cylinder block.

(4) Faulty thermostat: Check and renew thethermostat.

(5) Collapsingradiatorthe radiator hose.

(6) Faulty water pump:

hose: Check and renew

Renew the water pump.


72 Cooling and Heati,ng Systems

NOTE: This condition is best checked byremoving the surge tank cap and runningthe engine until it reaches the normaloperating temperature. Check for waterturbulence in the tank. A normal systemshould show turbulence at part throttle.

As most adverse conditions can becaused by more than one fault, diagnosiscan only be made after checking the itemsby process of elimination in the ordershown. If blocked radiator core tubes aredetected, it li recommended that theradiator be taken to a reliable specialist forrepair.

2. HEATER AITD AIR CONDITIONINGTROUBLE SHOOTING

NO HOT AIR INSIDE VEHICLE

(l) Faulty thermostat: Renew the thermostat.(2) Faulty heater valve: Check and renew the

valve.(3) Blocked heater hoses: Remove the blockage

or renew the hose.(4) Blocked heater core: Clean or renew the core.(5) Heater controls inoperative: Check the va-

cuum hoses for leaks.(6) Lack of coolant in engine: Check the surge

tank coolant level.

NOTE: Ensure that the engine is reachingnormal operating temperature. If in doubtcheck the operation of the thermostat asdescribed under the Thermostat heading inthis section.

When the engine is at normal operatingtemperature and the heater valve is open, allthe heater hoses shouldfeel warm/hot. If thevalve is not allowing the coolant to flow, the

View of the heater shut off valve. The valve shouldclose when the heater control is moved to the full coldjrcsition. Adjust the heater control rod if necessary.

heater hoses will remain cold. With the aidof an assistant, and with the engine running,check that the valve operates when thecontrol inside the vehicle is moved from thecold position.

If the heater core is blocked, the hose onone side will be hot while the other will becold.

NO COOLED AIR INSIDE VEHICLE

(l) Engine drive belt slipping: Check and renewthe drive belt as described in the Engine Tune-upsection.

(2) Insufficient refrigerant: Check the system forleaks and top up as necessary. Refer to the AirConditioning heading in this section for informationon checking the refrigerant level.

(3) Compressor inoperative: Check for power tothe compressor before removing the cornpressor forrepair by a specialist.

(4) Heater system allowing warm air to mix withcooled air: Check the operation of the heater system.

NOTE: The above trouble shooting pro-cedures are basic checlcs only. If the airconditioning system li suspect, it l's re-commended that the vehicle be taken to anauthorised dealer for testing and repair.

It is normal for water to be seen drain-ing under the vehicle from the evaporatorafter the vehicle has been operated with theair conditioning on.

3. DESCRIPTION

ENGINE COOLING SYSTEM

The cooling system uses the thermo-siphon prin-ciple with a water pump and an electric cooling fanproviding assistance. The system is pressurised inorder to raise the boiling point of the coolant and soincrease the efficiency of the engine.

A lightweight aluminium crossflow radiator isused with plastic radiator tanks. On automatic trans-mission models the left hand side radiator tank housesthe transmission oil cooler.

Provision for pressure and vacuum relief of thesystem is incorporated in the surge tank pressure cap.

The surge tank has three hose connections, an airbleed port from the inlet mainfold, a coolant overflowfrom the top of the radiator and a coolant supply port.

Temperature within the cooling system is con-trolled by a thermostat located at the rear of the inletmanifold. The function of the thermostat is to preventthe circulation of the coolant through the radiatoruntil the engine has reached operating temperature.This restricted circulation allows the engine to warmup more quickly improving driveability and fueleconomv.


Cooling a,nd Heati'ng Systems 73

The water pump is driven by the automaticallyadjusted engine drive belt. The body of the waterpump is made from aluminium alloy to assist ingnging lyeight roduction, It is equipped with a doubleto* bull bearing and a spring loaded seal assembly.The water pump is a disposable unit and thus cannotbe repaired.

The electric cooling fan is mounted on the rear ofthe radiator and its operation is regulated by thecoolant temperature sensor and the engine controlunit. Power is supplied by a relay and fuse which arelocated in the engine compartment relay housing. Thecontrol unit also operates the fan when the attconditioning is switched on and vehicle speed is below55 km/h, or if the coolant temperature sensor is faulty.

To avoid accidental scalding, exercise cautionwhen releasing the surge tank pressure cap on anengine that is at normal operating temperature.

4. RADIATOR

TO CHECK COOLANT LEVEL

NOTE: On models where the COLD markon the surge tank is below the join in thetank, the coolant level has been revised toapproximately 25 mm above the join in thetank.

(l) With the engine cold, check the level of thecoolant in the surge tank. The level should be at thecold mark on the surge tank.

(2') If the level is below the cold mark. removethe surge tank pressure cap and add the recommendedcoolant and clean water mixed in a ratio of 50Vo coolantto 5006 water until the level is correct.

(3) Run the engine and check for coolant leaks.If necessary, pressure test the surge tank cap to checkfor serviceabilitv if coolant loss occurs and leaks arenot apparent.

TO DRAIN AND REFILL

(l) Set the heater controls to the hot position.(2) Position a suitable container under the

cylinder block drain plugs and remove the surge tankcap. The drain plugs are located on each side of thecylinder block.

(3) Remove the cylinder block drain plugs, dis-connect the lower radiator hose and drain the coolantinto the container.

(4) When the coolant has drained clean thecylinder block drain plugs, apply Loctite 242 orequivalent to the threads and tighten the drain plugsto Specifications. Connect the lower radiator hose.

(5) Disconnect the water pump bypass hosefrom the front of the inlet manifold, and the overflowhose from the radiator.

(6) Loosen the clamp retaining the thermostatcover outlet hose to the pipe at the rear of the engineand insert a blunt nose screwdriver between the hoseand pipe using care not damage the hoss.

(1) Slowly fill the surge tank with the specifiedcoolant until the coolant begins to flow from thebypass and radiator overflow hose connections. Con-nect the hoses securely.

(8) Continue filling the surge tank until coolantflows from the hose where the screwdriver is installed.Remove the screwdriver and tighten the clamp se-curely.

(9) Fill the surge tank with the specified coolantas previously described and install three coolingsystem pellets, available from the vehicle manufac-turer, into the surge tank.

NOTE: The pellets are required to preventdeposits forming on the water pump sealwhich may cause coolant leakage.

(10) Start and run the engine for 20 minutes todissolve the pellets and purge any air that may betrapped in the cylinder heads. Check the coolant levelas previously described.

TO REMOVE

(l) Disconnect the negative battery terminal.(2) Drain the coolant as previously described.(3) Disconnect the wiring connector for the

electric cooling fan.(4) Loosen the hose clamp and disconnect the

overflow hose from the radiator.

View of the radiator and associated componentsremoved from the vehicle.


74 Cooling and Heating Systems

(5) Disconnect the upper and lower radiatorhoses.

(6) On automatic transmission models, loosenthe hose clamps and disconnect the oil cooler hosesfrom the left hand side radiator tank. Plug the hosesand the fittings to prevent the loss of fluid and theentry of dirt.

(7) Using a pair of pliers, squeeze the radiatorretaining clips and remove them from the radiatorsupport panel.

(8) Lift the radiator upwards and out of theengine compartment. Plug the radiator inlet andoutlet hose fittings and fill the radiator with coolant.

NOTE: When a radiator that has been inuse for some time ,J removed from thevehicle to enable repairs to be carried out tothe engine, it should not be allowed to standempty for any length of time. The radiatorshould be kept full. Failure to observe thisprecaution may result in overheating whenthe engine is put back into service. This iscaused by internal deposits in the radiatordrying and flaking and so obstructing thecirculation of the coolant in the system.

TO FLUSH AND CLEAN

(1) With the radiator removed as previouslydescribed, block off the overflow passage and placethe radiator on its side.

(2) Insert a hose in the radiator outlet fitting,seal the gap around the hose with suitable waste clothand reverse flush the radiator until the water flowingfrom the inlet fitting is clean.

NOTE: If excessive back pressure ordiminished flow indicates severely blockedradiator core tubes, which cannot be cleanedby reverse flushing, it is recommended thatthe radiator be repaired by a radiatorspecialist.

(3) Apply a stream of water or compressed air tothe radiator core from the rear to the front.

Cleaning the radiator core using a garden hose.

To avoid damage to the radiator core maintain adistance of 40 - 50 cm between the cleaning nozzLeand the radiator core.

Continue the cleaning procedure until all dirt andforeign matter is removed from the radiator core.

TO REPAIR

The aluminium core of the radiator can be re-paired using an Aluminised Silicon material availablefrom an authorised dealer.

If the plastic side tanks develop a leak, the tanksmust be renewed. When renewing side tanks alwaysuse a new seal.

If a leak is apparent in the join between the sidetanks and the core assembly, tighten the clinch tabsevenly using vice grip type pliers. If the leak is stillpresent remove the side tanks for inspection.

To prevent damage to the engine the followingprecautions should be observed:

Do not remove more than 25 mm of the total finarea of the radiator.

Do not block off more than two tubes of theradiator.

Replace the radiator core if there are more thanthree clinch tabs broken on one side of the header ormore than two adjacent tabs broken.

When the side tanks are removed for any reasonalways use new seals during assembly.

To Repair Core(l) Remove the radiator from the vehicle, flush

it out and thoroughly clean the area to be repaired.Dry the radiator using a hot air gun or hair dryer.

NOTE: If the repair area is not clean therepair will fail when the radiator is put intoservice.

(2) If necessary cut away approximately 6 mm ofthe fin material beyond the area to be repaired toexpose the damaged area.Reverse flushing the radiator using a garden hose.


Cooling and Heating Systems t 5

(3) Clean the damaged area with a small amountof petrol to remove any traces of oil.

(4) Thoroughly stir the contents of the repairagent.

(5) Apply the repair agent sparingly using awooden spatula or similar to drip the agent onto theradiator core.

(6) Allow the radiator to stand clean and dry in awell ventilated area for a minimum of three hours. Donot apply heat to promote drying.

(7) Instal the radiator as described later in thissection.

To Repair Tube(1) Remove the radiator from the vehicle.(2) Cut the broken tube 6 mm from the header

and pinch the tube shut before following the corerepair procedure.

To Renew Side Tank(l) Remove the radiator from the vehicle and

flush it out thoroughly.(2) Pry open the clinch tabs using a suitable tool

or screwdriver. Lift the tabs only enough to allowremoval of the side tanks.

(3) Lift the side tank from the core using lighttaps of the palm of the hand to release seal adhesion ifnecessary.

(4) Remove and discard the seal. Clean thesealing surfaces of the core and tank.

(5) Check the header area of the core for burrsand other damage and repair the area as necessary.

(6) If the oil cooler is to be removed from the lefthand tank and installed in a new one proceed asfollows:

(a) Remove the oil cooler nuts and washers fromthe oil cooler fittings.

(b) Remove the oil cooler from the radiatortank.

(c) Instal new seals to the new radiator tank andslide the oil cooler through the seals.

(d) Instal the nuts and washers then torque thenuts to 20 Nm.

(7) Instal the tank and the seal to the core andsecurely clamp it in position using adjustable buildersclamps ensuring a 30o/o compression of the seal.

(8) Clamp the clinch tabs to the tank using vicegrip type pliers. Start at the centre of the radiator andwork outwards in a circular sequence.

(9) Instal the radiator as described later in thissection.

To Renew Oil Cooler SealsIt is not necessary to remove the side tank from

the radiator if the oil cooler seals are being renewed.(1) Remove the radiator from the vehicle and

flush it out thoroughly.(2) Remove the oil cooler nuts and washers and

push the oil cooler into the side tank.

NOTE: Lay the radiator down so that the oilcooler does not slide to one end.

(3) Remove the seals using a small wire hook.(4) Instal new seals withor.rt any lubrication

ensuring that the inner lip is positloned correctly.

NOTE: Prior to installation of the seals, drythe tank and cooler seal areas using a hot airgun or hair dryer.

(5) Using long nose pliers in conjunction with astrong wire hook pull the oil cooler through the rubberseals. IJse care to ensure that thre rubber does notbecome dislodged during this operration.

(6) Instal the oil cooler nuts and washers andtighten the nuts to 20 Nm.

(7) Instal the radiator as des,cribed later in thissection.

TO INSTAL


(l) Instal the shroud and fern assembly to theradiator.

(2) Carefully instal the radiator, ensuring thatthe pegs on the bottom of the radiator are fullyinserted in the lower mountings.

(3) Instal the radiator retaining clips and con-nect the fan wiring connector.

(4) Instal all radiator hoses and hose clamps.(5) On automatic transmission models connect

the oil cooler hoses.(6) Refill the cooling syst,sm as previously

described and check for leaks.(7) Connect the negative battery terminal.Start the engine and increase the speed to 3 000

rpm for 10 seconds allowing the id,le air control valveto reset.

On models equipped with a radio cassette usingPIN security, it will be necessary to enter the PIN codeas described under the Radio/Cassiette heading in theElectrical System section.

(8) Road test the vehicle and check for correctoperation.

(9) On automatic transmissrion models checkand if necessary top up the transnnission fluid to thecorrect level. Refer to the Autonratic Transmissionsection for the correct procedure.

5. COOLING FAI{ AI{D COOLI\NTTEMPERATURE SEI\ISOR

TO TEST COOLING FAN AND SYSTEM

(l) With the cooling system cold, switch on theignition and confirm that the coolinLg fan is stationary.

(2) If the cooling fan rotates, proceed as follows:(a) Remove the cooling fan relay from the

engine compartment relay housing.(b) Check for continuity betrveen the relay ter-

minals 30 and 87 using an ohmmeter. If continuity isdisplayed, renew the relay.


KEYl :/ -$ :Q , '$ =$ :J _$ :

76

COLOUR CODEF u s e S B - B l a c kF u s e 2 3 L - B l u eCooling fan relay Y - YellowCool ingfan W-WhiteCoolant temperature sensor O - OrangeControluni t K -PinkTo throttle position switchGonnector

Schematic layout of the cooling fan and coolant tem-perature sensor showing the cooling fan relay ter-

minal numbers.

If continuity is not displayed, proceed as follows:(c) Switch the ignition Off and disconnect the

engine control unit wiring connector. If necessary,refer to the Fuel and Engine Management section.

(d) Using an ohmmeter, check for continuitybetween the relay connector terminal 85 and earth.

If continuity is displayed, rectify the short to earthin the wiring harness between the relay connectorterminal 85 and the control unit connector terminalc l .

If continuity is not displayed, renew the controlunit.

(3) In step (1) if the cooling fan is stationaryproceed as follows:

Location of the diagnostic link connector. lnset showsthe terminal identification. The connector may be con-

cealed behind the kick panel.

Cooling and Heating Systems

(a) Connect a jumper lead between the terminalsA and B of the diagnostic link connector (ALDL).

(b) If the fan runs, the fan circuit is satisfactory.If the engine is overheating check the coolant tem-perature sensor as described in the Fuel and EngineManagement Section, code 14.

(c) On air conditioned models a further check onthe fan is possible. Remove the jumper lead from theALDL, start the engine and allow it to idle. Switch theair conditioning on and ensure that the cooling fanruns.

If the fan does not run, check the f,an relay asdescribed in the Fuel and Engine Management sectionunder the EFI and Fuel Pump Relays heading.

TO REMOVE AND INSTAL COOLING FAN

( I ) Disconnect the negative battery terminal.(2\ Separate the cooling fan wiring harness con-

nector adjacent to the top radiator hose.(3) Remove the bolts retaining the fan shroud

assembly to the radiator and manoeuvre the assemblyfrom the vehicle.

Dismantled view of the cooling fan assembly.

(4) If necessary, the fan and motor assembly canbe separated. from the shroud assembly by removingthe fan nut and the motor retaining screws.

NOTE: If thefan will not come offthe motorshaft, place the fan nut back on the motorshaft and lightly tap the fan shaft with a softfaced hammer while holding the fan blades.


(l) Ensure that the fan does not contact theshroud when rotating.

(2) Tighten all screws and bolts securely.(3) Connect the negative battery terminal.Start the engine and increase the speed to 3 000


Cooling and Heating Systems 77

rpm for l0 seconds allowing the idle air control valveto reset.

On models equipped with a radio cassette usingPIN security, it will be necessary to enter the PIN codeas described under the Radio/Cassette heading in theElectrical System section.

(4) Road test the vehicle and check for correctoperating temperature.

TO TEST COOLANT TEMPERATURESENSOR

Testing and renewal of the coolant temperaturesensor is covered in the Fuel and Engine Managementsection.

6. THERMOSTAT

Special Equipment Required:To Check Thermostat - Thermometer


(l) Drain the cooling system to a level below thethermostat as described under the Radiator heading.

(2) Remove the throttle body and the inletmanifold adaptor as described in the Fuel and EngineManagement section.

(3) Loosen the hose clamps and disconnect thecoolant hose from the thermostat cover.

(4) Remove the thermostat cover retaining boltand pull the cover from the inlet manifold. Discardthe O ring.

Installation is a reversal of the re,moval procedurewith attention to the following Foints:

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249/515

THEnuosrar+

(1) Ensure that the mating surfaces of the ther-mostat cover and inlet manifold are clean and freefrom corrosion. Use a new O ring during installation.

(2) Instal the throttle body and the inlet mani-fold adaptor as described in the Fuel and EngineManagement section.

(3) Fill the cooling system as previously de-scribed, run the engine and check for coolant leaks.

TO CHECK

(1) Check that the thermostat is fully closedwhen cold.

THERII,PMETER

THERMOSTA

WATER FILLED AINER

HEAT SOURCE

Line drawing showing the correct method used to testa thermostat.

(2) Suspend and immerse the thermostat to-gether with a reliable thermometer, in a vessel of50/50 glycol/water, ensuring that neither the thermos-tat nor the thermometer are touching the sides orbottom of the vessel.

(3) Progressively heat the coolant mixture not-ing the temperature reading on the thermometer asthe thermostat valve commences to open. See Specifi-cations for the correct opening temperature. Heat thecoolant to 106 degrees C and check that the thermos-tat valve opens more than 9 mm.

A thermostat which does not perform as describedabove should be renewed.

7. WATER PUMP


(1) Disconnect the negative battery terminal.(2) Drain the cooling system as described pre-

viouslv in this section.

/CONT

View of the thermostat and associated components.


'uI."

6ry@ililqt

78

{

Cooling and Heating Systems

Dismantled view of the water pump components.

(3) Before removing the drive belt loosen thewater pump pulley retaining bolts.

(4) Using an 18 mm ring spanner, loosen thedrive belt tensioner and remove the drive belt.

(5) Remove the water pump pulley bolts andwithdraw the pulley from the pump.

(6) Remove the water pump retaining bolts andusing a soft faced hammer lightly tap the oiate, pumpto remove it.

(7) If necessary remove the water pump spacerplate and discard the gasket.

(8) Inspect the water pump for cracks anddamage to the gasket surfaces. Check the water pumpbearing for roughness or noisy operation. Inspect thewafer pump drain hole for signs of coolant leakage. Ifdefects are found, renew the water pump as anassembly.


(t) Ensure that all mating faces are clean andfree. from old gasket material. Always use new gasketsduring installation.

(2) Clean the threads of the water pump retain_ingbolts and apply Loctite sealant 242 or equivalentto the threads.

NOTE: Do not apply sealant to thefirst I - 2threads of the bolts.

(3) Instal the bolts and tighten progressively.The shorter water pump retaining bolts have a muihsmaller torque than the longer bolts, refer to Speci-fications.

(4) Instal the water pump pulley and tighten theretaining bolts securely but not exceisively.

-

(5) Instal the drive belt as descriLed in theEngine Tune-up section.

(6) With the drive belt installed check the torqueof the water pump pulley bolts.

(7) Fill the cooling system as previously de-scribed, run the engine and check for ioolant leaks.

(8) Connect the negative battery terminal.Start the engine and increase the speed to 3 000

rpm for 10 seconds allowing the idle air control valveto reset.

On models equipped with a radio cassette usingPIN security, it will be necessary to enter the pIN codeas described under the Radio/cassette heading in theElectrical System section.

8. WELCH PLUGS

To facilitate the casting of the cylinder block andcylinder head, a number of openings had to be madeat manufacture. These openings are plugged withwelch plugs. The plugs may have to be renewed when-cleaning th_e engine water jackets or when the plugsbecome defective due to corrosion.

TO RENEW

NOTE: If one welch plug is found to bedefective it is good policy to ienew all thewelch plugs.

(1) Drain the radiator and cylinder block aspreviously described.

(2) Remove the necessary engine components oraccessories to gain ample working space around theplug.

(3) Using a suitable punch and hammer, tap thewelch plug on its outer circumference into its opening.

(4) Grasp the edge of the welch plug with a piirof multigrip pliers and using the shoulder of themultigrip pliers, lever the plug out of its opening.

(5) Thoroughly clean and dry the welch plugopening.

(6) Lightly smear the edge of the new welch plugand its opening with o'Stag" jointing compound.

(7) Place the welch plug into the opening andusing a suitable tube or socket fitting the rim of tneplug, drive the plug squarely into the opening.

NOTE: The plug must be driven into theopening sqparely or leaks may occur.

,..1,,:'.:i';,Iiii r:'o.*,r",.-;+

lnstalled view of the engine welch plugs.


(8) Instal the components which were removedto gain access to the Plug.-(9)

Fill the cooling system as previousty d9-

s"riUed. With the surge tank pressure cap installed,mn the engine until it reaches normal operatingtemperature and check for coolant leaks.

9. HEATER UNIT AI{D BLOWER MOTOR


NOTE: On air conditioned models, removalof the heater unit requires the disconnectionof tne air conditioner evaporator lines. Thiswill necessitate the evacuation and recharg-ing of the system by an authorised dealer.nifer to the Air Conditioning heading.

(l) Remove the dashboard from the vehicle asdescribed in the Body section.

(2) Drain the cooling system as previously de-scribed.

(3) Disconnect the water hoses from the heaterpipei in the engine compartment adjacent to thebulkhead.

(4) Disconnect the vacuum hose from the heaterwater valve in the engine compartment.

(5) Remove the screws retaining the vent anddemisting ducts to the heater unit. Disconnect theducts from the heater unit.

Cooling and Heating SYstems 79

(6) Working in the engine compartment, removethe heater unit retaining screws.

(7) Working inside the vehicle, remove thescre*s retaining ihe heater unit to the bulkhead.

(8) CarefJlly withdraw the heater unit from thevehitle, using care not to drip coolant on the interior

of the vehicle.(9) If necessary, the blower motor can be re-

morred from the heaier unit by removing the retainingscrews and unplugging the motor cooling hose.


(1) Moisten the heater hose fittings with waterprior to installation through the bulkhead grommets.

(2) Tighten all screws securelY(l) Eniure that the heater hoses are pushed fully

onto the fittings prior to installing the clips.(4) Fill the cooling system as previously de-

scribed in this section.(5) Bring the engine to operating temperature

and check the operation of the heater unit.

10. HEATER AND AIR CONDITIONINGCONTROLS

DESCRIPTION

The heater controls use three adjustments todirect air through the vehicle at the most comfortabletemperature.

View of the heater unit with the dashboard removed and the vent and demisting ducts removed.


80 Cooling and Heati,ng Systems

Installed view of the heater and air conditioningcontrols.

The air flow control directs air to the vehicle floor,windscreen or dashboard outlets as required. Thiscontrol also has a biJevel position and a recirculateposition. On bi-level, the air from the dashboardoutlets is cooler than the air from the floor outlet. Onthe recirculate position, the air from within thevehicle is recirculated. This position is for use in dustyconditions or to allow rapid heating or cooling of thevehicle.

The temperature control opens or shuts the heaterwater valve as it moves offthe full cold position thenoperates a flap within the heater unit to regulate thetemperature. A vacuum switching shut off valve isused to control the heater water valve.

The fan speed control switches the fan on and offand is used to select the desired fan speed.

The air flow and temperature controls usevacuum servos to adjust and direct the air flow

lf the heater controls are not working, check allvacuum hoses and connections for damage, kinking orleaks starting at the vacuum tank under the front of

the vehicle.

through the vehicle. Vacuum is supplied by the engineand stored in a vacuum tank located under the frontleft hand side of the vehicle. For proper operation ofthe heater and air conditioner controls it is importantthat all vacuum hoses, the vacuum tank and all con-nections remain in good condition.

Air conditioned models use identical controlswith the addition of an air conditioner On/Offbutton.The fan must be set on I or above before the airconditioning will operate.

TO REMOVE, INSTAL AND ADJUST

(1) Disconnect the negative battery terminal.(2) Prise up the rear of the centre console cover

panel and pull the panel rearwards slightly to allowaccess to the radio/cassette surround screws.

(3) Remove the screws from the lowerpart of theradio/cassette surround and pull the surround rear-wards carefully until the locating lugs at the toprelease from the dashboard.

Disconnecting the vacuum block from the heatercontrols.

(4) Disconnect the electrical connectors fromthe radio/cassette surround panel noting their posi-tions as an aid to assembly.

(5) Working in the drivers footwell, disconnectthe heater control rod from the control lever at theright hand side of the heater unit.

(6) Rernove the screw retaining the heater con-trols to the dashboard and pull the heater controlrearwards.

(7\ Disconnect the vacuum block and the electri-cal connector from the heater controls and withdrawthe heater controls from the vehicle.


(l) Ensure that the heater vacuum hoses are ingood condition and that they are not pinched orkinked when installing the heater controls.

(2) Turn the temperature control to the full coldposition and ensure the heater control lever is also in

a

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e


Cooling a,nd Heati,ng SYstems

t*\

View of the heater unit showing the position of the heater shut off vatve and lever when the heater controls atthe full cold position.

8 1

the full cold position before installing the snap-in rod.Operate the temperature control several times.

(3) Turn the temperature control knob to the fullcold position again and ensure that the heater controllever is pushing in on the vacuum shut off valve.Adjust the heater control snap-in rod if necessary.

NOTE: If the rod cannot be adiusted tooperate the shut of valve properly, removethe shut of valve and elongate the holesslightly using a small round file. The valvecan then be positioned closer to the lever.



On models equipped with a radio cassette usingPIN security, it will be necessary to enter the PIN codeas described under the RadiolCassette heading in theElectrical System section.

(5) With the engine running and with the aid ofan assistant operating the temperature control, ensurethat the heater water valve is shut when the tempera-ture control is in the fully closed position. Adjust therod and the shut off valve again if necessary.

11. AIR CONDITIONING

DESCRIPTION

The air conditioning systern removes heat andmoisture from the air within the vehicle-

The system may be operated alone during warmweather or in conjunction with the heater during coldweather. When used in conjunction with the heater,the system will provide warm, dry air which willrapidty demist the interior glass of the vehicle.

The basic components of the air conditioningsystem are an evaporator, condenser, compressor,accumulator, expansion valve and pipes and hosescarrying the refrigerant through the system. Varioussubsidiary controls and sensors are used to monitorhigh and low pressure within the system, and toprevent the engine stalling at idle.

The refrigerant will boil at a very low temperature(-33"C), therefore it must be contained under pres-sure. Escaping refrigerant can cause frostbite and eyedamage, and will produce a poisonous gas when burnt.

View of the air conditioning condenser and the highpressure switch.


82 Cooling and Heating Systems

Installed view of the air conditioning accumulator andthe low pressure switch.

If the system suffers a rapid loss of refrigerant, oilfrom the compressor will be lost with the refrigerant.It is recommended that any work requiring disconnec-tion of the refrigerant lines be referred to an autho-rised dealer or an air conditioning specialist.

MAINTENANCE

The air conditioning system reqruires little main-tenance other than the following. Where applicable,refer to the Lubrication and Maintenance section forthe recommended service intervals.

(1) Inspect the air conditioner pipes arid hosesfor leaks, deterioration and alignmenrt. Evidence of oilleakage is an indication of leakage of refrigerant.Repair or renew as necessary.

(2) Inspect the evaporator drain tube and thecondenser cooling fins for blockage. Clean as neces-sary.

(3) Check the drive belt for deterioration and forcorrect tension. Refer to the Engine Tune-up sectionfor the correct procedure.

(4) Operate the system at least once every twoweeks for approximately 10 minurtes to keep thecompressor seals lubricated.



8 3

Manifold air temperature(MAT) sensor. Hand tighten

plus one turnD e t o n a t i o n s e n s o r . . . . . . . . 2 2 N m

1. FUEL AI{D ENGINE MANAGEMENTTROUBLE SHOOTING

NOTE: The fottowing Trouble Shootingprocedures are basic checks onlv. If theseprocedures fail to locate the fauit, iompr"-hensive fault diagnosis procedures aredescribed under the System Diagnosis head-ing.

Faults in the Fuel and Engine Manage-ment system can be divided into threecategories: fuel supply, electrical connec-tions and electrical componentfailure. Elec-trical component failure accounts for lessthan ten percent offaults.

Prior to performing any of thefollowingoperations, refer to the Service Precautionsand Procedures heading.

ENGINE WILL NOT START OR HARD TOSTART

(l) Fault in the fuel supply system: Check thefuel pump fuse and relay. Check the fuel filter forblockage. Check the fuel pressure. Check the ftelpump connections. Check for water in the fuel. Checkthe fuel injector circuit.

(2) Fault in the power supply: Check the battery,fusible links and fuses. Check for clean secure connec-tions, particularly the earth connections. Check theEFI relay.

(3) Fault in the ignition system: Check that thehigh tension leads are clean, dry and securely connect-qd to the coil pack terminals and the spark plugs.Check that the spark plugs are not faulty, fouled brincorrectly gapped. Check the ignition control moduleand the coil pack.

(4) Faulty engine management component wir-ing connections: Check that all component wiringconnections are clean and secure.

FUEL AND ENGINE MANAGEMENTCAUTION: To prevent severe electrical shock, extreme care must be taken n lworking on or neer the electronic ignition system as dangerous high tension volta)are produced in both the primary and secondary circuits. See text for precautionrnotes.

SPECIFICATIONS

FUEL INJECTION

Type . . Electronic controlled multi-point

FUEL PUMP

High pressure:Type Electric, roller vaneFuel pressure with ignition On . . . 280-320 kpaFue[ pressure at idle 240-260 kpa

*Low pressure:Type Electric CentrifugalFuel pressure 20-25 kpa

FUEL FILTER

Type .. . Disposablepaperelement

AIR FILTER

Type .. . Disposablepaperelement

IGNITION SYSTEM

Type . . . Direct Fire Ignition (DFI)Firing order l-6-5-4-3-2Coil primary resistance ... 0.3-1.5 ohmsCoil secondary resistance . . . . . 10 000-14 000 ohmsHigh tension leadresistance limit 17 000 ohms*Long range fuel tank only.


Air cleaner housing retaining nuts . . . . . 7 NmThrottle body retaining nuts . . . . 20 NmThrottle body adaptor retaining nuts . . 20 NmFuel rail retaining bolts . . . 30 NmThrottle cable mounting bracket bolts . 34 NmIgnition control module retaining nuts. 1l NmCrankshaft sensor adjusting bolt. . 5 NmCrankshaft sensor retaining bolts 40 NmCrankshaft pulley retaining bolt . . . . . 325 NmCoo lan t tempera tu resensor . . . . . 12NmOxygen sensor . 46 Nm


84

Check that all electrical connections are clean andsecure.

Check the MAP sensor vacuum hose for splits,obstruction and a secure connection.

(5) MAP sensor vacuum hose blocked or discon-nected: Clear or connect the vacuum hose.

(6) Engine flooded: Fulty depress the throttlepedal until the engine starts. Check the coolanttemperature sensor circuit. Check the injectors forleakage.

NOTE: If the fuel pump relay fails, powerwill be supplied to the fuel pump via the oilpressure switch. When starting the engine,the fuel pump will not operate until the oilpressure is sufficient to extinguish the oilpressure warning lamp. Therefore it will benecessary to operate the starter motor for alonger period than usual to start the engine.

ENGINE STARTS THEN STALLS

(1) Fault in the fuel supply system: Cheek for

Fuel and Engine Managernent

water in the fuel. Check the fuel pressure. Check theinjectors for faulty operation.

(2) Faulty, fouled or incorrectly gapped sparkplugs: Renew or clean and adjust the spark plugs.

(3) Vacuum leak at the inlet manifold: Check alljoints and hoses for vacuum leaks.

(4) Faulty engine management component wir-ing connections: Check that all component wiringconnections are clean and secure.

(5) MAP sensor vacuum hose blocked or discon-nected: Clear or connect the vacuum hose.

(6) Faulty MAP sensor operation: Check theMAP sensor circuit.

(7) Faulty idle air control (IAC) valve operation:Check the IAC valve circuit. Check the alternatorvoltage output.

(8) Faulty throttle position sensor operation:Check the throttle position sensor circuit.

(9) Loose or corroded battery terminals andearth straps: Clean and tighten the battery terminalsand earth straps.

ENGINE MISFIRES


(2) Weak or inconsistent spark: Check the hightension leads for moisture, dust, cracks and burns.Check the resistance of each lead.

(3) Weak ignition coil output: Check the igni-tion system circuit.

(4) Faulty fuel injector operation: Check the fuelinjection circuit.

(5) Faulty crankshaft sensor: Check the crank-shaft sensor and the crankshaft pulley blades fordamage, Renew as necessary.

(6) Fault in the fuel supply system: Check thefuel supply system for a blocked fuel filter, incorrectfuel pressure or water in the fuel.



Fuel and Engine Managernent 85

Refer to the

(7) Vacuum leak: Check for vacuum leaks at thevacuum hoses, the throttle body and the inlet mani-fold.

NOTE: To check if a fuet injector is func-tioning, hold the blade of a long screwdriveragainit the body of the fuel injector whilethe engine is idling. Listen to the oppositeend of the screwdriver for a clicking sound,indicating that the fuel iniector is function-ing.

ENGINE LACKS POWER

(l) Fault in the fuel supply system: Check thefuel supply system for a blocked fuel filter, water inthe fuel or incorrect fuel pressure.

(2) Blocked air cleaner: Check the element andclean or renew as necessary.


(4) Excessive high tension lead resistance: Testeach lead and renew as necessary.

(5) Incorrect alternator voltage output: Checkthe alternator operation.

(6) Loose control unit earth connections: Ensurethat all connections are secure and clean.

(7) Incorrectly adjusted throttle cable: Checkand adjust the throttle cable as necessary.

EXCESSIVE FUEL CONSUMPTION

(1) Incorrect fuel pressure: Check the fuel pres-sure with a pressure gauge.

(2) Leaks in the fuel system: Check the connec-tions and components for leakage.

(3) Faulty coolant temperature sensor operation:Check the coolant temperature circuit.

(4) Faulty manifold air temperature (MAT) sen-sor operation: Check the MAT sensor circuit.

Check all fuel lines and connections for leakage.

(5) Faulty manifold absolute pressure (MAP)sensor operation: Check the MAP sensor circuit.

(6) Faulty fuel injector operation: Check the fuelinjection circuit.

(7) Vacuum leaks: Check for vacuum leaks atthe vacuum hoses, the throttle body and the inletmanifold.

(8) Faulty thermostat operation:Cooting and Heating Systems section.

(9) Faulty engine cooling fan operation.the Cooling and Heating Systems section.

Refer to

2. DESCRIPTION

The engine management system on the range ofvehicles covered by this manual controls the operationof the following systems; Fuel injection, Ignition,Engine cooling fan and if equipped, the Automatictransmission torque converter clutch and the Airconditioning compressor clutch.

The central component ofthe engine managementsystem is the control unit. The control unit is amicrocomputer which controls the ignition timingand the amount of fuel injected according to signalsreceived from various sensors. As changes are detect-ed in engine load and speed, coolant temperature, airtemperature, barometric pressure, throttle position,vehicle speed and exhaust oxygen content, the controlunit alters the ignition timing and the fuel injection toachieve optimum engine efficiency under those condi-tions.

The control unit also incorporates a self diagnosismode which stores and displays codes relating tocertain system malfunctions. Whenever power is sup-plied to the control unit, the control unit performs aseries of tests on various components in the systemand records the results. If a fault is discovered, the

The air cleaner should be seruiced at regular intervals-


86

Check Engine warning lamp will illuminate on theinstrument cluster while the engine is running. Whenthe self diagnosis mode is activated, the Check Enginewarning lamp will flash coded signals indicating thearea in which the fault has occurred.

This function is very useful in locating systemfaults, particularly intermittent problems. However,the self diagnosis mode does not provide comprehen-sive testing of the engine management system, andtherefore should always be used in conjunction withthe test procedures described later in this section inorder to accurately locate system faults.

When a fault is discovered, the control unit willby-pass the fault and substitute a signal calculated bythe control unit, allowing near normal operation ofthe system until the fault is rectified.

The direct fire ignition (DFI) system consists of acontrol module, coil pack assembly containing threeignition coils, crankshaft sensor and crankshaft pul-ley. The feature of this system is the absence of adistributor.

The control module controls the primary circuitto the coils and the ignition timing when a fault isdiscovered in the Engine Management system.

Each coil fires two spark plugs simultaneously,however, the firing sequence ensures that one sparkplug fires on the compression stroke and the otherspark plug fires on the exhaust stroke. The spark plug

Fuel a,nd Engine Ma,nagernent

cooLANT TEMPERATUBE SENSOR (HTDDEN)

View of the engine showing the engine management components.

firing on the compression stroke receives most of theavailable voltage as the spark plug firing on theexhaust stroke requires little voltage to spark.

The crankshaft sensor is made up of three seg-ments. The centre segment is a magnet and thesegments on either side are sensors. A magnetic field iscreated between the sensors and the magnet. Whenthe interrupter blades on the rear of the crankshaftpulley pass through the channels between the magnetand the sensors the magnetic field is broken and pulsesignals are produced. The signals are supplied to thecontrol module to determine the position of thepiston. The control module then supplies signals tothe control unit which calculates engine speed andcontrols ignition timing. If detonation is detected bythe detonation sensor, the control unit retards theignition timing up to 8' and slowly reverts to theappropriate ignition timing when detonation hasceased.

The electronic fuel injection system uses multi-point injection, where a metered amount of fuel isinjected into the air stream at the inlet ports of thecylinder head. The airlfuel mixture then enters thecombustion chamber via the inlet valves.

The fuel is supplied under pressure by a highpressure electric fuel pump which is mounted to thefuel gauge sender unit inside the fuel tank. The fuel ismaintained at a constant pressure, relevant to var-


1. Fuel l ine2. Vacuum line3. Electrical circuit4. Air cleaner element5. Throttle body6. Manifold absolute pres-

sure (MAP) sensor7. High pressure fuel pump

(Standard fuel tank)7. Low pressure fuel pump

(Long range fuel tank)


Schematic diagram of the engine management system.

8. High pressure fuel pump(Long range fuel tank)

9. Fuel damper (Longrange fuel tank)

10. Fuel f i l ter1 1. Pressure regulator12. Fuel injector13. Oxygen sensor14. Detonation sensor1 5. Goolant temperature

sensor

16. Manifold air tempera-ture (MAT) sensor

17. ldle air control (lAC)valve

18. Throttle position sensor19. Control unit20. lgnition control module21. Crankshaft sensor22. Spark plug23. Fuel tank24. Yehicle speed sensor25. Neutral safety switch

87


88

iances ln manifold pressure, by the fuel pressureregulator. Excess fuel is returned to the fuel tank viathe fuel return line.

Models equipped with a long range fuel tank havethe high pressure pump mounted externally and anadditional low pressure pump is mounted to the fuelgauge sender unit inside the fuel tank. A fuel damperis installed between the external high pressure fuelpump and the fuel filter to suppress fuel pulsationscreated when the two fuel pumps are in operation.

The amount of fuel injected is relevant to the timethe injectors remain open. The basic time the injectorsremain open is controlled by the control unit, whichuses information from the various sensors to giveoptimum engine efficiency for the relevant condi-tions.

The idle air control (IAC) valve controls the idlespeed during engine warm up and maintains the basicidle speed at a set value by compensating for loadssuch as air conditioning or the selection of Drive onautomatic transmission models.

The throttle body is mounted to the rear of theinlet manifold and controls the amount of air enteringthe engine by the action of the throttle pedal.

Efficient operation of the EFI system depends onaccurate signals being received by the control unit andcontrolled air flow beyond the throttle valve. There-fore it is essential that all air, fuel and electricalconnections are clean and secure.

3. SERVICE PRECAUTIONS ANDPROCEDURES

Electronic ignition systems can produce danger-ously high voltages in both the primary and secondarycircuits. For this reason, extreme care must be takenwhen working on or near the ignition system.

Do not start the engine if the battery terminals arenot clean and tight

Do not use the fast charge or boost settings on abattery charger to start the engine.

Do not disconnect the battery terminals while theengine is running.

Disconnect the battery terminals before chargingthe battery.

Disconnect the negative battery terminal beforeworking on the engine management system.

Do not subject the control unit to temperaturesabove 80 deg C.

Ensure that all wiring connectors are clean andtight.

Ensure that the ignition is Off before disconnect-ing any engine management component.

Depressurise the fuel system before removing anyfuel supply components. The fuel system maintains ahigh residual pressure at all times.

Disconnect the battery terminals and the controlunit wiring connector and remove the control unit


from the vehicle before attempting any welding opera-tions.

Do not direct a steam cleaning or pressure wash-rng nozzle at engine management components whencleaning the engine.

Handle all engine management component withcare, particularly the control unit and oxygen sensor.

At the completion of a self diagnosis test proce-dure or the repair or renewal of a component, clear thefault codes, run the engine for 2 minutes and test forfault codes to ensure that the fault has been rectified.

Do not attempt to dismantle the control unit orair flow meter. If faulty, these components must berenewed as complete assemblies.

Do not directly apply battery voltage to theinjectors.

NOTE: If the power supply to the controlunit has been interrupted by disconnectingthe negative battery terminal or the ENG.COMP fusible link, it will be necessary torun the engine at 3 000 rpm for l0 secondsto allow the idle air control valve to reset.

If the battery has been disconnected onmodels equipped with a radio/cassette usingPIN security, enter the PIN code as de-scribed under the Radio/Cassette headingin the Electrical System section.

TO CONNECT ELECTRICAL TESTEQUIPMENT

NOTE: Some types of tachometers and igni-tion system analysers ere not compatiblewith this engine management system. It istherefore recommended that the manufac-ture of the test equipment be consultedbefore proceeding to use the test equipment.

MultimeterIt is essential that in all tests where voltage or

resistance is to be measured a digital display multi-meter with a minimum l0 megohms impedance beused.

All meter readings are to be performed with thecomponent wiring connectors installed unless other-wise instructed. This can be done by inserting themeter test probes from the wiring harness side of theconnector, or back probing. If the test probes are notthin, they should be modified by attaching a thin pieceof wire to the end of the probe, giving a fine point thatwill not damage the connector. Ensure that the wire ismaking good contact with the probe.

To facilitate testing of the control unit wiringconnectors, disconnect the connectors from the con-trol unit, remove the plastic retaining clips from bothsides of the connectors and instal the connectors to thecontrol unit. Ensure that the retaining clips areinstalled to the connectors at the completion of thetest procedure.'



The correct method of backprobing the wiring harnessconnections. The meter test probe should be modified

with a piece of thin wire as shown.

Remove the retaining clips from the control unit wiringconnectors to facilitate backprobe testing.

If sealing plugs or boots are removed from thewiring connectors to facilitate backprobing, ensurethat they are correctly installed at the conclusion ofthe test procedure.

To identify wiring connector terminals, refer tothe fuel and engine management wiring diagram andnote the wiring colour codes to the various compon-ents.

Test lampWhen a test lamp is specified, it is essential that

the test lamp does not draw a current of more than 0.3amp to avoid damage to the electronic components.

To check the current draw of the test lamp,connect an accurate ammeter, such as the multimeterdescribed previously, in series with the test lamp. Testthe assembly across the vehicle battery.

If the ammeter reads less than 0.3 A or 300 ma thetest lamp is suitable.

If the test lamp is not suitable, fabricate an LED(light emitting diode) test lamp as described in theElectrical System section.

TachometerTo measure engine rpm an inductive pick-up

tachometer must be used and set on 2 cycle operation.If the tachometer does not have cycle adjustment,halve the indicated rpm.

Connect the tachometer to the engine followingthe instrument manufacturers instructions.

4. SYSTEM DIAGNOSIS

NOTE: Due to the use of complex electroniccomponents in the engine management sys-tem, the diagnosis and testing proceduresdescribed in this section should not becarried out by persons lacking an under-standing of electronics and the precautionsassociated with the servicing of electroniccomponents. It is recommended that shoulda Jirult arise in the system, the vehicle betaken to an authorised dealer for rectifrca-tion.

The control unit can be damaged bycomponent faults not indicated by the selfdiagnosis codes and the renewal of thecontrol unit without locating the cause offoilure will result in the failure of thereplacement unit. It is for this reason thatthe practice of substituting components toisolate faults is not recommended.

Prior to performing any of thefollowingoperations, refer to the Service Precautionsand Procedures heading.

PRELIMINARY CHECKS

Prior to performing the Self Diagnosis Test Proce-dure, catry out the following preliminary checks andrectify as necessary.

(1) Check for fuel in the fuel tank.(2) Check the wiring connectors and eafth

points of all engine management components forclean, secure connections. To prevent damage to thecontrol unit, disconnect the negative battery terminalbefore disconnecting any engine management wiringconnectors.

(3) Check the condition of the battery. Refer tothe Electrical System section in this manual forchecking procedures. Rectify any faults as necessary.

(4) Check the air cleaner element for restriction.(5) Check for air leaks at the throttle body, inlet

manifold and all related hoses.(6) Ensure thai the control unit wiring harness is

routed away from all other wiring harnesses.(7) Check the fuel pump pressure as descdbed

later in this section.(8) Ensure that the engine is in satisfactory

mechanical condition and is in tune. Refer to theEngine and Engine Tune-up sections as necessary.


90 FueI and Engine Management

ENG. COMPFUSIBLE LINK 30 A

MAIN FUSIBLELINK 60 A

Anti-ThetlCircuit

FUSE No.95 A

EFIRELAY

"_j

+ +COOLANTTEMP

SENSOR a A,iC Relay

,,

MAP SENSOR

< Tachometer

N

Starter Circuit

BR -BR

D B - D B

- TriD Comouler{#

- Auto Trans 4th Gear/femp Switch -

COLOUR CODE

The first letter ot the code represents themain wire colou( the other letters represenlthe trace colours.

B . B L A C K V . V I O L E TL . B L U E P - P U R P L EG - G R E E N X - L I G H T G R E E NR . R E D Z - L I G H T B L U EY . YELLOW M. DARK GREENW. WHITE T - DARK BLUEN - B R O W N A - L I G H T B B O W NO - O R A N G E E . S L A T EK - P I N K D . T A NS . GREY

-.1

INJECTORS

ELECTRONICCONTROL UNIT

D7

8 1 1

D l 0

A9

A5

A7

A't2

D6

o3

D1

CA

UO

c5

A 1 0

c't2

A l l

c 1 1

c14

c 1 3

02

c 1 0

c 1

8 1 0

6d

82

A2

B5

B3

D4

D5

ALARM OVERRIDE

FUSE No. 211 5 A

To Oil Pressure Lamp

DETONATION

GW

ZB

- Cooling Fan Relay

Neutral Safety Switch (4,/T)

249t452MD144

Fuel and engine management system circuit diagram.


Fuel and Engine Managernent 9 l

SELF DIAGNOSIS

This function is very useful in locating systemfaults, particularly intermittent problems. However,the self diagnosis mode does not provide comprehen-sive testing of the engine management system, andtherefore should always be used in conjunction withthe other test procedures described later in thissection in order to accurately locate system faults.

To Interpret Self Diagnosis CodesOnce the self diagnosis mode is activated, various

fault codes will be displayed as a series of flashes bythe Check Engine warning lamp on the instrumentcluster.

To identify the code number, count the number oftimes the Check Engine warning lamp flashes. Eachfault code comprises two groups of flashes separatedby a 1.2 second pause. The first group represents tensand the second group represents single units. Forexample I flash followed by a 1.2 second pausefollowed by 4 flashes would be code number 14.Similarly, 4 flashes followed by a 1.2 second pausefollowed by 2 flashes would be code number 42.

The code will be displayed three times. If morethan one fault code is present, the self diagnosissystem will indicate each one in numerical order, witha3.2 second pause between each code and then repeatthe sequence.

The fault codes can be identified as follows:

CODE NUMBER

r 213 ,44 ,4514,15

21, 222 3 , 2 52433,344 l

42

435 l55

FAULT AREA

Satisfactory operationOxygen sensor circuitCoolant temperature sensorcircuitThrottle position sensor circuitMAT sensor circuitVehicle speed sensor circuitMAP sensor circuitNo crankshaft input signals(engine will not start)Electronic spark timing (EST)circuitDetonation sensor circuitMem-Cal unitControl unit input circuits

Test Procedure(l) Perform the following checks:(a) Ensure that the battery voltage is above I I

volts.(b) Ensure that the throttle valve is fully closed.(c) Place the transmission in neutral.(d) Ensure that the air conditioner, fan, lights

and all other accessories are switched off.(2) Turn the ignition On and confirm that the

Check Engine warning lamp on the instrument clusteris illuminated but not flashing.

If code 55 is displayed, refer to the Control Unit

heading, perform the circuit test procedure and rectifythe cause of the code before proceeding.

If the Check Engine warning lamp flashes codesother than code 55, check the wiring harness betweenthe diagnostic link connector terminal - and thecontrol unit wiring connector terminal A.9 for shorts.Repair or renew the wiring harness as necessary.

If no fault can be found, renew the control unit.If the Check Engine warning lamp does not

illuminate, proceed as follows:(a) With the ignition switched On, check that

the instrument cluster warning lamps light. If they donot light check that the instrument cluster wiringconnectors are securely installed.

Also check the instrument cluster printed circuitfor damage or open circuits.

(b) Check the condition of fuses 9 and 11 andthe fusible links. Renew the components as necessary.

(c) Check the wiring harness connectors to theinstrument cluster. Ensure'that the wiring harnessconnector terminals are secure and clean.

(d) Check the Check Engine warning lamp bulb.Renew as necessary.

(3) Connect a jumper lead across terminals Aand B on the diagnostic link connector.

Location of the diagnostic link connector. Inset showsthe terminal identification. The connector may be con-

cealed behind the kick panel.

(4) Note the codes indicated by the flashingCheck Engine warning lamp.

If code 12 is displayed, the system is operatingcorrectly.

If codes other than code t2 are displayed, refer tothe component or circuit test procedure under theappropriate heading as indicated by the code number.

If more than one code is being displayed, test eachindicated fault working in the order of display of thecode numbers.

(5) After completing the self diagnosis test pro-cedure, remove the jumper lead fiom the diagnosticlink connector.

(6) After repairing or renewing the necessary


92

components, erase the self diagnosis memory asdescribed later in this section.

(7) Repeat the self diagnosis test procedure andensure that code 12 is displayed.

To Erase Memory(l) With the ignition Off, remove the ENG.

COMP fusible link, located adjacent to the relayhousing, for at least l0 seconds.

(2) Instal the fusible link.(3) Start the engine and increase the speed to

3 000 rpm for l0 seconds, allowing the idle air controlvalve to reset.

5. FUEL SUPPLY COMPONENTS

Special Equipment Required:To Check Fuel Pressure - 600 kPa pressuregauge, suitable T piece fitting

NOTE: Before proceeding with any of theoperations in this section, refer to the Ser-vice Precautions and Procedures headings.

TO DEPRESSURISE FUEL SYSTEM

( 1) Remove the fuel pump fuse from the enginecompartment relay housing.

(2) Start the engine and allow it to idle until theengine stalls.

(3) Operate the starter motor for 10 seconds toensure that the fuel pressure has been relieved.

(4) Replace the fuse.

Remove the fuel pump fuse when depressurising thefuel system.

TO TEST FOR EXTERNAL LEAKS

(l) Ensure that the fuel tank has a sufficientamount of fuel.

(2) Connect a jumper lead between terminals Cand D in the diagnostic link connector which islocated at the top of the pasbenger side kick panel andturn the ignition On.


(3) Check the fuel system for leaks at all connec-tions from the fuel tank to the injectors.

(4) If renewal of any component is required, thefuerl system must be depressurised as previouslydescribed.

NOTE: Use only hoses and clamps as speci-fied by the manufacturer.

(5) Turn the ignition Offand remove the jumperlead from the diagnostic link connector.

TO TEST FOR INTERNAL LEAKS

(l) Depressurise the fuel system as previouslydescribed.

(2) Disconnect the negative battery terminal.(3) Disconnect the fuel supply hose from the

fuel supply pipe located under the throttle cablemounting bracket.

Testing the fuel system for correct pressure andinternal leakage.

(4) Using a suitable T piece, a short length offuel hose and hose clips, instal the T piece and the fuelhose to the fuel supply hose and the fuel supply pipe.

(5) Instal a suitable pressure gauge to the Tpiece, ensuring that all connections and test equip-ment are capable of withstanding pressures up to 600kPa.

(6) Instal the fuel pump fuse and connect thenegative battery terminal. Check the fuel system forexternal leaks as previously described.

NOTE: To prevent misleading pressuregauge readings, ensure that the ignition isOnfor 15 seconds to purge the fuel system ofair.

(7) Remove the jumper lead from the diagnosticlink connector and turn the ignition Off for l0seconds.

(8) Turn the ignition On and note the reading onthe pressure gauge.


If the pressure does not decrease, no internalleakage is indicated.

NOTE: There may be a small initial de-crease in pressure when the fuel pumpswitches off. This is acceptable and does notindicate a fault in the system.

(9) If the pressure decreases, clamp the fuelsupply hose between the T piece and the fuel rail andnote the reading on the pressure gauge. If the pressurestops decreasing the high pressure fuel pump may beconsidered faulty and should be renewed as describedlater in this section.

NOTE: If the fuel pressure has decreased alarge amount, turn the ignition On forapproximately I0 seconds to pressurise thesystem. This should be done be:hre the fuelhose is clamped. Pressurise the system asnecessary during the testing procedure.

(10) If the pressure continues to decrease, releasethe clamp from the fuel supply hose and clamp thefuel return hose from the pressure regulator. Pressur-ise the fuel system if necessary.

( I I ) Note the reading on the pressure gauge. If thepressure stops decreasing, the pressure regulator maybe considered faulty and should be renewed as de-sc.ribed later in this section.

(12) If the pressure continues to decrease, releasethe clamp from the fuel return hose.

(13) Remove the fuel rail and injector assemblyfrom the inlet manifold as described later in thissection. Connect the fuel pipe and hoses to the fuel railensuring that the joints are secured firmly.

(14) Pressurise the fuel system and observe whichinjectors are leaking, Renew the faulty injector(s) asnecessary.

(15) Pressurise the fuel system and check for anypressure decrease.

(16) Depressurise the fuel system as previouslydescribed and remove the pressure gauge and fittings.

(17) Instal all components and connect all fuelhoses and clamps securely.

(18) Test the system lbr external leaks as pre-viously described.

(19) Start the engine and increase the speed to3 000 rpm for 10 seconds, allowing the idle air controlvalve to reset.

(20) On models equipped with a radio/cassetteusing PIN security, it will be necessary to enter thePIN code as described under the Radio/Cassetteheading in the Electrical System section.

TO TEST FUEL PRESSURE

High Pressure Fuel Pump(1) Depressurise the fuel system as previously

described.(2\ Disconnect the negative battery terminal.(3) Disconnect the fuel supply hose from the


fuel supply pipe located under the throttle cablemounting bracket. Disconnect the pressure regulatorvacuum hose.

(4) Using a suitable T piece, short length of fuelhose and hose clips, instal the T piece and the fuelhose to the fuel supply hose and the fuel supply pipe.

(5) Instal a suitable pressure gauge to the Tpiece, ensuring that all connections and test equip-ment are capable of withstanding pressures up to 600kPa.

(6) Instal the fuel pump fuse and connect thenegative battery terminal. Check the fuel system forexternal leaks as previously described.

(7) With the jumper lead remaining connectedto the diagnostic link connector, turn the ignition Onfor one minute until the fuel pressure reading stabi-lises. The pressure gauge should read 280-320 kPa.

(8) If the fuel pressure is as specified, test thepressure regulator as follows:

(a) Connect a hand vacuum pump to the pres-sure regulator vacuum connection.

(b) Switch the ignition On and note the fuelpressure. Apply 50 kPa vacuum to the pressureregulator. The fuel pressure should decrease 15 kPa ormore.

If the pressure did not decrease, renew thepressure regulator.

(9) If the fuel pressure is below the specifiedreadings, carry out the following procedure:

(a) Check the fuel lines for blockages and kinks.Also check for a blocked fuel filter or fuel pump pick-up strainer.

(b) If no fault can be found in the previouschecks clamp the fuel return hose from the pressureregulator.

(c) Turn the ignition On and note the pressuregauge reading.

If the pressure is less than 320 kPa the fup! Fumpmay be considered faulty. If the pressure is greaterthan 320 kPa the pressure regulator may be consi-dered faulty.

(10) If the fuel pressure is above the specifiedreading as described in operation (7), carry out thefollowing procedure:

(a) Disconnect the fuel return hose from the:pressure regulator.

(b) Connect a suitable length of fuel hose to the,pressure regulator and place the opposite end of theihose into a petroleum resistant container.

(c) Turn the ignition On and note the pressuregauge reading.

If the pressure is within 280-320 kPa locate andremove the restriction in the fuel return pipe. If thepressure is greater than 320 kPa the pressure regulatormay be considered faulty.

(11) Remove the pressure gauge and fittings,connect all fuel hoses and tighten the clamps securely.

(12) Test the system for external leaks as pre-viously described.


94

(13) Start the engine and increase the speed to3 000 rpm for l0 seconds allowing the idle air controlvalve to reset.


Low Pressure Fuel Pump: LonB Range Fuel Tanlt(l) Depressurise the fuel system as previously

described.(2) Disconnect the negative battery terminal.(3) Raise the rear of the vehicle and support it

on chassis stands.(4) Using a hand pump or suitable siphon, drain

sufficient fuel from the fuel tank to reduce the fuellevel to below the fuel gauge sender unit. Do notsiphon fuel using the mouth.

(5) Disconnect the fuel supply hose from thefuel gauge sender unit.

(6) Disconnect the fuel return hose from the fueltank.

(7) Using a suitable T piece, two lengths of fuelhose and hose clips, instal the T piece and the fuelhoses between the fuel gauge sender unit and the fuelreturn hose tank connections.

(8) Instal the pressure gauge to the T piece andensure that there is sufficient fuel in the tank to coverthe fuel pick-up.

(9) Disconnect the external fuel pump wiringconnections.

(10) Connect the negative battery terminal.(11) Connect a jumper lead across terminals C

and D on the diagnostic link connector, located at thetop of the passenger side kick panel.

(12) Turn the ignition On and note the reading onthe pressure gauge. The pressure shouldbe2}-25 kPa.

If the fuel pressure is less than the specifiedpressure, remove the low pressure fuel pump asdescribed later in this section and check the strainerfor blockage. If the- strainer is not blocked the lowpressure fuel pump should be renewed.

(13) Remove the pressure gauge and connect thefuel supply and return hoses.

(14) Start the engine and increase the speed to3 000 rpm for l0 seconds, allowing the idle air controlvalve to reset.


TO RENEW FUEL FILTER

The procedure to renew the fuel filter is describedin the Engine Tune-up section.

FUEL PUMP

To Test Operation(1) Check the fuel pump fuse located in the

Fuel end Engine Managernent

engine compartment relay housing. Renew the fuse ifnecessary.

(2) Switch the ignition On. If the fuel pump fuseblows, refer to the heading EFI and Fuel Pump Relaysand carry out the test procedures.

(3) Switch the ignition Off. Connect a test lampbetween the diagnostic link connector terminals Dand B.

(4) After ten seconds switch the ignition On andnote the test lamp. It should illuminate for 2 seconds.If the test lamp illuminates as specified, proceed to thefollowing operation.

If the test lamp does not illuminate, a fault in thefuel pump relay or the fuel pump relay circuit isindicated. Refer to that heading and carry out the testprocedures.

If the test lamp remains illuminated after 2seconds, disconnect the oil pressure switch wiringconnector. If the test lamp goes out, renew the oilpressure switch.

If the test lamp remains illuminated, a fault in thefuel pump relay or the fuel pump relay circuit isindicated. Refer to that heading and carry out the testprocedures.

Squeeze the fuel supply hose to check for fuel pumpoperation.

(5) Remove the test lamp from the diagnosticlink connector.

(6) Connect a jumper lead between terminals Cand D on the diagnostic link connector and switch theignition On.

(7) Squeeze the fuel supply hose adjacent to thebrake seryo unit and feel for pulsations which indicatefuel pump operation. It should also be possible to hearthe fuel pump operating in the fuel tank.

If the fuel pump is operating, the fuel pumpcircuit is serviceable.

If the fuel pump is not operating, disconnect theround wiring connector at the fuel pump/tank senderunit and connect a test lamp between the two termin-als in the wiring connector. If the test lamp illumin-ates, renew the fuel pump.



If the test lamp does not illuminate, check thewiring harness between the fuel pump wiring connec-tor, the diagnostic link connector terminal D and theearth connection for continuity. Repair or renew thewiring harness as necessary.

Ifno fault can be found, check the fuel pump relaycircuit as described under the heading EFI and FuelPump Relays.

To Remove and Instal High Pressure Fuel Pump -Standard Fuel Tank

(l) Depressurise the fuel system as previouslydescribed.

(2) Disconnect the negative battery terminal.(3) Raise the rear of the vehicle and support it



(5) Disconnect the wiring connectors from thefuel gauge sender unit.

(6) Loosen the hose clamp and remove the fuelhose from the fuel gauge sender unit.

(7) Remove the screws retaining the fuel gaugesender unit and manoeuvre the sender unit and thefuel pump assembly from the fuel tank, being carefulnot to damage the strainer.

(8) Disconnect the wiring connector from thefuel pump.

(9) Remove the strainerinlet.

from the fuel pump

Viewof the high pressurefuel pump removed from thefuel tank. Standard fuel tank.

Installed view of the fuel gauge sender unit.

(10) Slide the pulsator along the pick-up tubeuntil it is clear of the fuel pump outlet.

( I I ) Manoeuvre the fuel pump from the mount-ing bracket.


(1) Ensure that the fuel pump wiring is woundaround the fuel pump outlet pipe to prevent it foulingthe fuel gauge float arm.

(2) Ensure that the strainer is installed securely.(3) Use only hoses and clamps as specified by

the manufacturer and ensure that all fuel clamps areproperly seated and tight.

(4) Test the fuel system for external leakage aspreviously described.



To Remove and Instal High Pressure Fuel Pump -Long Range Fuel Tank

(1) Depressurise the fuel system as previouslydescribed.




(5) Note the installed positions of the wiringconnectors. Disconnect the wiring connectors fromthe fuel pump.

(6) Place a suitable drain tray below the fuelpump.

(7) Remove the fuel pump clamp retaining boltand remove the clamp.


96 FueI and Engine Management

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High pressure fuel pump and damper removed fromthe vehicle.

(8) Loosen the hose clamps and disconnect thefuel hoses from the fuel pump. Remove the fuel pumpfrom the vehicle.


(1) Use only hoses and clamps as specified bythe manufacturer and ensure that itt fuel tlamps ateproperly seated and tight.

@ Test the fuel systems for external leakage aspreviously described.

(3) Start the engine and increase the speed to3 000 rpm for l0 seconds, allowing the idle speedcontrol valve to reset.

(4) On models equipped with a radio/casserreusing PIN security, enter the pIN code as describedunder the Radiolcassette heading in the ElectricalSystem section.

To Remove and Instal Low Pressure Fuel pump -Iong Range Fuel Tank

The procedure for the removal and installation ofthe low pressure fuel pump is the same as the highpressure fuel pump installed to the standard fuel tankwith attention to the following points:

( I ) When removing the fuel pump from the tanksender unit note the installed position of the fuelpump wires to ensure correct installation. Remove thenuts retaining the fuel pump wires to the terminalsand remove the wires.

(2) Remove the clip retaining the rubber con-nector to the pick-up tube and slide the rubber

connector along the pick-up tube until clear of the fuelpump. Manoeuvre the fuel pump from the mountingbracket.

F'UEL DAMPER

To Remove and Instal(1) Depressurise the fuel system as previously

described.

Installed view of high pressure fuel pump, damper andfuel gauge sender unit.


on chassis stands.(4) Place a suitable drain rray beneath the fuel

damper.(5) Loosen the hose clamps retaining the fuet

hoses to the fuel damper and disconnect the hoses.(6) Remove the nut and washer retaining the

fuel damper to the mounting bracket and removi thefuel damper from the vehicle.


(1) Use only hoses and clamps as specified bythe manufacturer and ensure that all fuel clamps areproperly seated and tight.




FUEL PRESSURE REGULATORTo Remove and Instal

(1) Depressurise the fuel system as previouslydescribed.

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Dismantled view of low pressure fuelcomponents.

pump


Fuel end Engine Managernent e7

Installed view of the fuel pressure regulator.

(2) Disconnect the negative battery terminal.(3) Disconnect the fuel return hose and the

vacuum hose from the pressure regulator. Plug thefuel return hose to prevent the entry of dirt.

(4) Remove the bolts retaining the pressureregulator to the fuel rail and remove the pressureregulator.

(5) Seal the opening in the fuel rail to preventthe entry of dirt.


(l) Instal the regulator to the fuel rail ensuringthat a new O ring is installed and lubricated withengine oil.

(2) Connect the fuel return hose to the pressureregulator and tighten the clamp securely. Connect thevacuum hose to the pressure regulator.

(3) Test the system for external leakage as pre-viously described.

(4) Start the engine and increase the speed to3 000 rpm for 10 seconds allowing the idle air controlvalve to reset.

(5) On models equipped with a radio/cassetteusing PIN security it will be necessary to enterthe PINcode as described under the Radio/Cassette headingin the Electrical System section.

FUEL RAIL AND INJECTORS

To Test Iniector Circuit and Injectors(l) Disconnect the wiring connectors from the

injectors.(2\ Connect a test lamp between the terminals of

one injector wiring connector ensuring that the testlamp probes do not make contact with each other.

(3) Switch the ignition On and note the testIamp. It should not light. If the test lamp lights, checkthe wiring harness for shorts to earth between theinjector wiring connectors and the control unit wiringconnector terminals Dl5 and Dl6. Repair or renewthe wiring harness as necessary.

(4) With the aid of an assistant, operate thestarter motor and observe the test lamp. The test lampshould flash.

If the test lamp does not light, proceed to opera-tion (6).

ti the test lamp lights but fails to flash, connect anohmmeter between the terminals of each injector. Theresistance should be 15-17 ohms.

If the resistance of each injector is as specifiedrenew the control unit.

If the resistance of an injector is not as specified,renew the injector and repeat the test procedure.

(5) Repeat operation (2) to (4) on the remaininginjector wiring connectors. If the test lamp flashes*h.n connected to each injector wiring connector thecircuit can be considered serviceable.

If the test lamp does not flash when connected to aparticular injector wiring connector, check the wiringharness for continuity between the injector wiringconnector, the EFI relay and the control unit wiringconnector terminals D15 and D16.

Checking the resistance of a fuel injector.

(6) Switch the ignition On 4nd probe each ter-rninal of an injector wiring connector with a test lampto earth.

If the test lamp lights when the probe contacts thelight blue wire terminal, check the wiring harness forshorts to voltage between the injector wiring connec-tors and the control unit wiring connector terminalsD l5 and D16 .

If the test lamp does not light when the probecontacts the orange and red wire terminal, a fault inthe EFI relay or circuit is indicated. Refer to thatheading in this section and carry out the test proce-dures.

If the test lamp lights when the probe contacts theorange and red wire terminal proceed as follows:

(7) Switch the ignition Off and connect theinjector wiring connectors.

(8) Switch the ignition On and backprobe thecontrol unit wiring connector terminals D15 and Dl6with a test lamp to earth. The test lamp should lightwhen the probe contacts each terminal.

If the test larnp does not light as described check


98 Fuel and Engine Management

the wiring harness for continuitybetween the injector ,wiring connectors and the control unit wiring connec-

tor teminals Dl5 and D16. Repair or rinew thewiring harness as necessary.


described.(2) Disconnect the negative battery terminal.(3) Disconnect the fuel return hose and the

vacuum hose from the pressure regulator. plug thehoses to prevent the entry of dirt.

(4) Disconnect the vacuum hoses from the frontof the throttle body and the fuel rail.

(5) ' Disconnect the fuel supply pipe from the fuelrail. Plug the fuel pipe to prevent the

-entry of dirt.

I{OTE: When disconnecting the fuel supplypipe ensure that the fuel rail flange is

_ supported with the correct size spanner to- pieuent damage to the fuel rail.

(6) Slide the high tension lead retainers off thesupport brackets.

(7) Disconnect the wiring connectors from thefuel injectors.

(q) Ensure that the area around each injector isfree from dirt.

(9) Remove the bolts securing the fuel rail to theinlet manifold and carefully remove the fuel rail andthe injectors from the engine. Seal the openings in theinlet manifold to prevent the entry of foreign material.

(10) If necessary, remove the injector retainingclips and withdraw the injectors from the fuel rail.Discard the O ring seals.

Installation is a reversal of the removal procedurewith attention to the foltowing points:

(1) When installing the injectors, lubricate thenew O ring seals with clean engine oil.

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(2) Ensure thatcorrectly seated,

(3) Tighten th.especified torque.

the injector retaining clips are

fuel rail retaining bolts to the

(4) Connect the fuel supply p)pe to the fuet ra;landtighten the flare nut secuiely. Ensure that the fueirail flange is supported with the correct size spanner toprevent damage to the fuel rait.

(5) Connect the fuel return hose and the vacuumhose to the pressure regulator. Tighten the fuel returnhose clamp securely.

(6) Test the system for external leaks as pre_viously described.

O Start the engine and increase the speed to3 000 rpm for l0 seconds, allowing the idle aiicontrolvalve to reset.

(8) On models equipped with a radio/cassetteusing PIN security, enter the pIN code as describedunder the Radio/cassette heading in the ElectricalSystem section.

FUEL TANK


described.(2) Disconnect the negative battery terminal.(:l Raise the rear of the vehicle and support it

on chassis stands.(4) Drain the fuel from the fuel tank using a

hand pump or suitable siphon. Do not siphon fuetusing the mouth.

(5) Loosen the hose clamp and disconnect thefuel hose from the fuel gauge sender unit.

(6) Loosen the hose clamp and disconnect thefuel return hose from the fuel tank.

(7) Disconnect the wiring connectors from thefuel gauge sender unit.

(8) Remove the screws retaining the stoneguardand remove the stoneguard from under the right handside rear wheel arch.

(9) Disconnect the fuel vapour hose from themetal pipe which connects to the charcoal canister.

View of the fuel rail partially dismantled. Installed view of the fuel tank. Station Wagon model.


View of the fuel tank removed from the vehicle.Station Wagon model shown.

(10) Support the fuel tank and remove the boltsand nut retaining the support straps.

NOTE: If a jack is used to support the fueltank, place a block of wood between the jackand thefuel tank to prevent possible damageto the fuel tank.

( I I ) On Sedan models, lower the tank slightly anddisconnect the vapour hoses from the top of the fueltank and carefully pass the hoses through the vehiclechassis.

(12) Lower the fuel tank and filler neck assemblyfrom the vehicle.


(l) Apply petroleum jelly to the upper end of thefiller tube as an aid to installation.

(2) Ensure that all fuel clamps are properlyseated and tight.




6. AIR FLOW COMPONENTS

NOTE: Before proceeding with any of theoperations in this section, refer to theService Precautions and Procedures head-ing-

AIR CLEANER

To Remove and Instal Element(l) Release the clamp securing the air intake

hose to the air cleaner upper housing.(2) Disengage the clips retaining the air cleaner

upper housing to the lower housing.(3) Raise the upper housing and remove the air

cleaner element from the air cleaner lower housing.

Fuel a,nd Engi,ne Managernent 99


(1) When renewing the air cleaner element, useonly the manufacturers specified item.

(2) Clean the air cleaner housings thoroughly,taking care not to allow dirt to enter the air intakehose.

(3) Ensure that the air cleaner element is seatedcorrectly before installing the upper housing.

To Remove and Instal Air Cleaner Housing(1) Disconnect the negative battery terminal.(2) Release the clamp securing the air intake

hose to the air cleaner upper housing.

,/ INTAKE DUCT

Dismantled view of the air cleaner.

(3) Disengage the clips retaining the air cleanerupper housing to the lower housing.

(4) Raise the upper housing and disconnect theair intake hose. Remove the air cleaner element.

(5) Remove the nuts securing the air cleanerlower housing to the mounting insulators.


(l) Tighten the air cleaner lower housing retain-ing nuts to the specified torque.

(2\ Ensure that the air cleaner element is seatedcorrectly before installing the upper housing.

(3) Tighten the air intake hose clamp securely.


r00



AIR INTAKE DUCT

To Remove and Instal(l) Release the clamps retaining the air intake

hoses to the throttle body and the air cleaner upperhousing.

(2) Remove the nut securing the air intake ductto the mounting bracket.

(3) Remove the wiring clamp secured to the rearof the air intake duct.

(4) Remove the air intake duct and the airintake hoses from the vehicle.

Installation is a reversal of the removal procedureensuring that the air intake hose retaining clamps aretightened securely.

THROTTLE BODY

To Remove and Instal( I ) Disconnect the negative battery terminal.(2) Release the clamps securing the air intake

hose to the throttle body and the air intake duct andremove the air intake hose.

(3) Disconnect the engine vent hose from thethrottle body.

(4) Disconnect the vacuum hoses from the frontof the throttle body.

(5) Disconnect the MAP sensor vacuum hosefrom the rear of the throttle body.

(6) Disconnect the wiring connectors from thethrottle body.

(7) Disconnect the throttle cable from the throt-tle body linkage. If applicable, disconnect the cruisecontrol cable and the kickdown cable from the throttlebody linkage.

lAC VALVE

View of the throttle body and inlet manifold adaptorremoved from the engine.


(8) On models equipped with cruise control,remove the bolts retaining the cruise control cablemounting bracket to the throttle body and the inletmanifold adaptor. Place the cruise control cable andmounting bracket to one side.

(9) Remove the nuts retaining the throttle bodyto the inlet manifold adaptor and remove the throttlebody.

(10) If necessary remove the inlet manifoldadaptor using the following procedure:

(a) Remove the bolts retaining the throttle cablemounting bracket to the inlet manifold adaptor.

(b) Remove the nuts retaining the inlet manifoldadaptor to the inlet manifold and remove the inletmanifold adaptor.


(1) Ensure that all gasket faces are clean and newgaskets are installed.

(2) Tighten all nuts and bolts to the specifiedtorque.

(3) Ensure that the wiring connectors are fas-tened securely to the throttle body.

(4\ If removed, instal the throttle cable mount-ing bracket and connect the throttle cable and ifequipped, the kickdown cable and the cruise controlcable.

(5) Check and if necessary, adjust the throttlecable and if equipped, the cruise control cable asdescribed in this section. On models with automatictransmission, check the kickdown cable adjustment asdescribed in the Automatic Transmission section.

(6) Connect the air intake hose to the throttlebody and tighten the retaining clamp securely.

(7) Start the engine and increase the speed to3 000 rpm for 10 seconds allowing the idle air controlvalve to reset.


To Adjust Base ldle Speed

NOTE: The idle speed is controlled by theidle air control (IAC) valve and li notadjustable. The throttle stop screw controlsthe base idle speed and is factory set. Thefollowing base idle speed adjustment shouldonly be performed if the throttle body hasbeen renewed, or if comprehensive testing ofrelated components indicates that adjust-ment is required.

(l) Start the engine and allow it to reach normaloperating temperature.

Perform the following checks:(a) Check that the air cleaner element is service-

able.(b) Check the air intake system for leaks.

THROTTLE BODY


Fuel and Engine Managernent 1 0 1

View of the throttle body showing the throttle stopscrew, IAC valve and the throttle position sensor.

lnsert shows the IAC valve terminal identification.

NOTE: Vacuum leal<s will make the engineidle faster than it should.

(c) Ensure that all accessories are switched off.(d) Check that all wiring connectors and vacuum

hoses are securely connected.(e) Ensure that the transmission is in Park or

Neutral with the handbrake engaged and the rearwheels chocked.

(2) Stop the engine, switch the ignition On andconnect a jumper lead between terminals A and B onthe diagnostic link connector.

(3) After 30 seconds disconnect the idle aircontrol valve wiring connector.

(4) Ensure that the throttle valve moves freelyand returns to the fully closed position when slowlyreleased.

(5) Connect an inductive tachometer to a sparkplug lead and start the engine. If the engine will notstart, open the throttle slightly. Allow the throttle toslowly return to the fully closed position after starting.

(6) Allow the engine to idle for 2 minutes, ensurethat the cooling fan is stationary and note the idlespeed. The idle speed should be 500-600 rpm.

(7) If adjustment is necessary, remove the capfrom the throttle stop screw and turn the throttle stopscrew until an idle speed of 500-550 rpm is obtained.

NOTE: If the engine has completed lessthan 3 000 km, do not alter the throttle stopscrew if the idle speed is below 600 rpm.

(8) Instal a new cap to the throttle stop screw.(9) Stop the engine and connect the idle air

control valve wiring connector.( l0) Disconnect the jumper lead from the diag

nostic link connector and erase the memory codes aspreviously described.

(l l) Start the engine and increase the speed to3 000 rpm for 10 seconds allowing the idle air controlvalve to reset.

rDLE ArR CONTROL (rAC) VALVE

To Test(1) With the engine idling in Park or Neutral at

normal operating temperature, and if applicable, theair conditioner switched off, note the engine idlespeed with a suitable inductive pick-up tachometer.

(2) Switch the engine Offand disconnect the idleair control valve wiring connector.

(3) Start the engine and note the engine speed, itshould be over I 500 rpm.

If the engine speed has not increased proceed tooperation (4).

If the engine speed has increased switch theengine Off, connect the idle air control valve wiringconnector and start the engine. If the engine speeddoes not return to the idle speed noted in operation (1)proceed to operation (4).

If the engine speed returns to the idle speed notedin operation (1) the idle air control valve can beconsidered serviceable.

If the idle speed is not 650-750 {pm or is erratic,check the following possible causes:

(a) Vacuum leaks at the inlet manifold or thethrottle body.

(b) Sticking or binding throttle cable or linkages.(c) Loose or dirty bittery terminals & earttt

connections.(d) Worn or incorrectly gapped spark plugs.(e) Incorrect alternator output voltage.(0 Foreign material inside the throttle body

causing the idle air control valve to stick.(g) Incorrectly adjusted throttle stop screw.(h) Faulty neutral safety switch operation (Auto-

matic models).(i) Coolant temperature sensor resistance.0) Faulty throttle position sensor operation.(k) Incorrect fuel pressure or leaking injectors.0) Faulty air conditioner relay or circuit.(4) Stop the engine, switch the ignition On and

connect a jumper lead between terminals A and B onthe diagnostic link connector.

(5) Disconnect the idle air control valve wiringconnector and connecl a suitable test lamp betweeneach connector terminal and earth for 5 seconds.

If the test lamp flashes when connected to eachconnector terminal check for loose or broken terminalsin the idle air control valve. If the terminals aresatisfactory renew the idle air control valve.

If the test lamp does not light when connected tothe connector terminals proceed to operation (6).

If the test lamp lights and does not flash whenconnected to the connector terminals, proceed asfollows:

(a) Switch the ignition Off and disconnect thecontrol unit wiring connectors.

(b) Switch the ignition On.(c) Connect the test lamp between each terminal

on the idle air control valve connector and earth.(d) If the test lamp lights when connected to a


1 0 2 Fuel and Engine Management

terminal check the wiring harness for shorts to voltagebetween the idle air control valve connector and thecontrol unit wiring connector. Repair or renew thewiring harness as necessary and repeat the test pro-cedure.

(e) If the test lamp does not light when con-nected to the terminals check for loose or brokenterminals in the idle air control valve. If the terminalsare satisfactory renew the idle air control valve.

(6) Disconnect the control unit wiring con-nectors and check the wiring harness for shorts andcontinuity between the control unit wiring connectorterminals C4, C3, C5 and C6 and the idle air controlvalve connector terminals A, B, C and D. Repair orrenew the wiring harness as necessary and repeat thetest procedures.

If no fault is found with the wiring harnessproceed as follows:

(7) Connect an ohmmeter between terminals Aand B, and C and D on the idle air control valve andmeasure the resistance. If the reading is not 40-80ohms, renew the idle air control valve.

(8) Check that there is no continuity between theidle air control valve terminals A and D.

(9) Check for loose or broken terminals in theidle air control valve and the control unit. If theterminals are satisfactory, renew the control unit.

To Remove and Instal(l) Disconnect the negative battery terminal.(2) Remove the throttle body as previously

described.(3) Using a Torx No. 20 adaptor, remove the

screws retaining the idle air control valve to thethrottle body and remove the valve.

Instailation is a reversal of the removal procedurewith attention to the following points:

(l) Ensure that the area in the throttle bodywhere the idle air control valve seats is clean to ensurea full seal of the O ring.

(2) Prior to installing the valve to the throttlebody, measure the distance between the tip of thepintle and the flange mounting face. If the distance is

When installing the idle air control valve, ensure thatdistance A is less than 28 mm.

greater than 28 mm, push the pintle towards the valvebody while moving it slightly side to side until itretracts to a distance less than 28 mm.

(3) Lubricate the O ring with clean engine oil.(4) Tighten the Torx screws securely.(5) Instal the throttle body as previously de-

scribed.(6) Connect the negative battery terminal.(7) Remove the ENG. COMP. fusible link from

the fusible link housing for l0 seconds and replace thefusible link.

(8) Start the engine and increase the enginespeed to 3 000 rpm for 10 seconds, allowing the idleair control valve to reset.


MANIFOLD ABSOLUTE PRESSURE (MAP)SENSOR

To Test - Codes 33 and 34

NOTE: The following test procedure as-sumes that fault codes 33 or 34 have beendisplayed during the self diagnosis test pro-cedure. If no codes have been displayed butthe operation of the MAP sensor is suspectbegin the test procedure at operation (15).

(1) Erase the self diagnosis code memory aspreviously described.

(2) Start and run the engine at idle speed for60 seconds or until the Check Engine warning lampilluminates.

(3) Stop the engine, switch the ignition On andconnect a jumper lead between terminals B and A onthe diagnostic link connector. Note any fault codesdisplayed.

If code 33 is displayed, remove the jumper leadfrom the diagnostic link connector, erase the selfdiagnosis codes and proceed to operation (4).

If code 34 is displayed, remove the jumper leadfrom the diagnostic link connector, erase the selfdiagnosis codes and proceed to operation (7).

lnstalled view of the MAP sensor.


Fuel and Engi,ne Management 1 0 3

Check the MAP sensor vacuum hose for splits,obstructions and a secure connection.

If no codes are now displayed, but codes 33 or 34were displayed when the self diagnosis test procedurewas originally performed, an intermittent fault isindicated. Proceed as follows:

(a) Check for faulty wiring connections. Checkthat all wiring connectors are clean and secure.

(b) Check that all earth wires are secure.(c) Check the vacuum hose to the MAP sensor

for deterioration or restriction.(4) Disconnect the wiring connector from the

MAP sensor.(5) Start and run the engine at idle speed for 60

seconds or until the Check Engine warning lampilluminates.

(6) Stop the engine, switch the ignition On andconnect a jumper lead between terminals A and B onthe diagnostic link connector. Note any fault codesdisplayed.

If code 33 is displayed, connect a voltmeter acrossterminal B on the MAP sensor wiring connector andearth. If the voltmeter reads lower than I volt theelectronic control unit can be considered faulty.

If the voltmeter reads higher than I volt, check thewiring harness and wiring connectors for shortsbetween terminal B on the MAP sensor wiring connec-tor and terminal Cll on the control unit wiringconnector. Repair or renew the wiring harness asnecessary.

If code 34 is displayed, proceed as follows:(a) Check for a restricted or leaking MAP sensor

vacuum hose.(b) Check the wiring harness for continuity and

shorts between terminal A on the MAP sensor wiringconnector and terminal Al I on the control unit wiringconnector. Repair or renew the wiring harness asnecessary.

If no faults can be found proceed to operation(1s) .

(7) Disconnect the wiring connector from theMAP sensor and connect a jumper lead betweenterminals B and C on the wiring connector.

(8) Start and run the engine at idle speed for 60


(9) Stop the engine, switch the ignition On andconnect a jumper lead between terminals B and A onthe diagnostic link connector. Note any fawlt codesdisplayed.

If code 33 is displayed, proceed to operation ( I 5).If code 34 is displayed, proceed as follows:(10) Remove the jumper lead from the MAP

sensor wiring connector and measure the voltageacross terminals A and C on the MAP sensor wiringconnector.

If the voltage is below 4 volts, proceed to opera-t ion (12).

If the voltage is 4 - 6 volts proceed as follows.( I 1) With the ignition Off disconnect the wiring

connectors from the control unit and check the wiringharness for continuity and shorts between the MAPsensor wiring connector terminal B and control unitwiring connector terminal Cll. Check the wiringconnectors for faults also. Repair or renew the wiringharness as necessary.

If no fault is found, renew the control unit andretest for fault codes.

(I2) Disconnect the wiring connector from thethrottle position sensor.

(13) Measure the voltage across terminals A andC on the MAP sensor wiring connector.

If the voltage is 4 - 6 volts, renew the throttleposition sensor as described later in this section.

If the voltage is below 4 volts, proceed as follows:( 14) With the ignition Off, disconnect the wiring

connectors from the control unit and check the wiringharness for continuity and shorts between the MAPsensor wiring connector terminal C and control unitwiring connector terminal Cl4. Check the wiringconnectors. Repair or renew the wiring harness asnecessary.

If no fault is found. renew the control unit andretest for diagnosis codes.

(15) Test the MAP sensor as follows:(a) With the ignition On and the MAP sensor

wiring connector connected, measure the voltageacross terminals A and B by back probing the MAPsensor wiring connector. The voltage should be asfollows:ALTITUDE VOLTAGEBelow 305 m 3.8 - 5.5 volts305 - 610 m 3.6 - 5 .3 vo l ts610 - 914 m 3 .5 - 5 .1 vo l t s914 - l2l9 m 3.3 - 5.0 voltsI2l9 - 1524 m 3.2 - 4.8 volts1524 - 1829 m 3.0 - 4.6 volts1829 - 2133 m 2.9 - 4.5 volts2133 - 2433 m 2.8 - 4.3 volts2438 - 2743 m 2.6 - 4.2 volts2743 - 3048 m 2.5 - 4.0 volts

If the voltage is not as specified, renew the MAPsensor.


104

(b) If the voltage is as specified, apply a 34 kPavacuum to the MAP sensor using a vacuum pump.The voltage should be 1.2-2.3 volts lower than thatmeasured in operation (a).

If the voltage is not as specified, renew the MAPsensor.

If no fault is found, check the vacuum supply hosefor restriction or leakage.

To Remove and Instal

(1) Disconnect the negative battery terminal.(2) Disconnect the MAP sensor wiring connec-

tor and the vacuum supply hose.(3) Remove the retaining screws and remove the

MAP sensor from the vehicle.Installation is a reversal of the removal procedure

with attention to the following points:(1) Ensure that the vacuum hose is connected

securely to the MAP sensor.(2) Start the engine and increase the speed to

3 000 rpm for 10 seconds, allowing the idle air controlvalve to reset.


THROTTLE CABLE

To Remove and Instal(l) Loosen the adjusting nuts and disconnect the

outer throttle cable from the throttle cable bracket.(2) Disconnect the inner throttle cable from the

throttle body linkage.(3) Remove the clips retaining the drivers side

lower trim panel to the underside of the dashboardpanel and remove the trim panel from the vehicle.

(4) Remove the retainer from the top of thethrottle pedal and disengage the throttle cable fromthe pedal.

(5) Withdraw the throttle cable from the enginecompartment.

Installation is a reversal of the removal procedure.Adjust the throttle cable as described under thefollowing heading.

To Adjust(1) Remove the clips retaining the drivers side

lower trim panel to the underside of the dash paneland remove the trim panel from the vehicle.

(2\ Have an assistant depress the throttle pedalfully.

(3) Working in the engine compartment, adjustthe throttle cable adjusting nuts so that the throttlevalve is in the fully open position. Tighten theadjusting nuts securely.

(4) Release the throttle pedal and ensure that thethrottle valve is in the fully closed position, that thethrottle lever is touching the throttle stop screw andthe pedal is contacting the pedal stop.

Fuel and Engi'ne Managernent

lnstalled view of the throttle cable showing the adiust-ing nuts.

(5) Check that there is a minimum of pedal freeplay and approximately 10-15 mm deflection of theinner cable between the outer cable end and thethrottle body linkage.

(6) Instal the lower trim panel to the vehicle.

6. ELECTRONICCOMPONENTS

NOTE: Before proceeding with any of theoperations in this section, refer to the Ser-vice Precautions and Procedures heading.

IGNITION SYSTEM

To Test - Code 41(1) Attempt to start the engine.If the engine starts an intermittent fault is indicat-

ed. Proceed as follows:(a) Check for faulty wiring connections. Check

that all wiring connections are clean and secure.(b) Check that all earth wires are secure.If the engine does not start proceed as follows:(2) Remove the high tension leads from the

spark plugs on one side of the engine.(3) Connect a suitable conductor such as a split

pin to a high tension lead and secure the high tensionlead to a non-metallic object.

(4) Connect one end of a jumper lead to earthand connect the other end of the jumper lead to thenon-metallic object leaving a gap of 8 mm from theexposed end of the conductor to the end of the jumperlead.

(5) Operate the starter motor and check for astrong spark between the conductor and the jumperlead. Repeat the operation on the remaining hightension leads.

If there is no spark when connected to any leadproceed to operation (10).

If there is spark at one or two of the leads proceedto operation (20).

If there is spark when connected to each leadproceed as follows:



To test for sufficient coil output, insert a conductorinto the high tension lead and place a jumper leadconnected to earth 8 mm from the conductor. Crank

the engine and check for spark.

(6) Switch the ignition Off and disconnect thewiring connectors from the control unit.

(7) Backprobe the control unit wiring connectorterminal 85 with a voltmeter to earth.

(8) Switch the ignition On and note the voltage.It should be less than 1 volt or approximately 5 volts.

If the voltage is not as specified, check the wiringharness for continuity or shorts between the controlunit wiring connector terminal 85 and the ignitioncontrol module wiring connector terminal D. Repairor replace the wiring harness as necessary.

If no fault can be found, renew the ignition controlmodule.

(9) Observe the voltmeter and operate thestarter motor. The voltage should read between 2 and3 volts.

If the voltage is not as specified, replace theignition control module.

If the voltage is as specified, check the control unitterminal B5 and the corresponding wiring connectorterminal for a loose connection.

If no fault can be found, renew the control unit.( 10) Remove the ignition control module wiring

connector.(11) Connect a test lamp between the ignition

control module wiring connector terminal P and earthand switch the ignition On. The test lamp should lieht.

If the test lamp does not light, check the number1l fuse and the wiring harness for continuity andshorts between the ignition switch and the ignitioncontrol module wiring connector terminal P. Repairor replace the wiring harness as necessary.

(12) Switch the ignition Otr and connect a

jumper lead between the ignition control modulewiring connector terminals N and P. Connect ajumper lead between the ignition control modulewiring connector terminal M and earth. Ensure thatthe jumper leads do not contact each other.

(13) Connect a test lamp between the ignitioncontrol module wiring connector terminal H and thepositive battery terminal and switch the ignition On.

(14) Using a socket and bar, slowing rotate thecrankshaft pulley one revolution and observe the testlamp. The test lamp should go on and off 3 timesduring one revolution.

If the test lamp does not light as described, checkthe wiring harness for shorts and continuity betweenthe crankshaft sensor terminals B, A, C and D and theignition control module terminals G, H, M and N.Repair or renew the wiring harness as necessary.

If no fault can be found renew the crankshaftsensor.

(15) Switch the ignition Offand remove the testlamp probe from terminal H and connect it to terminalG.

(16) Switch the ignition On and slowly rotate thecrankshaft pulley one revolution and observe the testlamp. The test lamp should go on and off l8 timesduring one revolution.

If the test lamp does not light as described, checkthe wiring harness for shorts and continuity betweenthe crankshaft sensor terminals B, A, C and D and theignition control module terminalS G, H, M and N.Repair or renew the wiring harness as necessary.

(17) Switch the ignition Off and closely inspectthe crankshaft sensor for damage. Renewas necessary.

(18) Slowly rotate the crankshaft pulley andclosely examine the blades on the rear of the crank-shaft pulley as they pass through the channels of thecrankshaft sensor.

Rear view of the crankshaft pulley showing the inter-rupter blades.


106

If any of the blades are bent, renew the crankshaftpulley.

If any of the blades contact the crankshaft sensorrenew the crankshaft pulley and the crankshaft sensor.

(19) Disconnect the test lamp and the jumperleads from the ignition control module wiring con-nector and instal the connector to the ignition controlmodule.

(20) Disconnect the high tension leads from thecoil pack assembly and remove the Torx screwsretaining the coil pack assembly to the ignition controlmodule.

(21) Raise the coil pack assembly and discon-nect the three wires with black stripes from the coilpack assembly. Do not disconnect the blue wires.

(22) Connect a test lamp between one of the bluewire connectors and the disconnected blue and blackstriped wire connector. Operate the starter motor andobserve the test lamp. The test lamp should blink.

Underside view of the coil pack assembly showing thewiring connections.

(23) Repeat the previous operation on the dis-connected green and black and the yellow and blackstriped wires.

If the test lamp does not blink in the aboveoperations, renew the ignition control module.

(24) Switch the ignition Off and connect a digi-tal ohmmeter between the blue and black striped wireconnector and the blue wire connector and measurethe resistance. The resistance should be 0.3 - 1.5ohms.

(25) Repeat the previous operation between thegreen and black and the yellow and black striped wiresand its opposite blue wire connector.

If the resistance is not as specified, renew the coilpack assembly.

(26) Connect an ohmmeter between the coilpack high tension terminals 1 and 4,2 and5 and 6 and3. The resistance should be l0 - 14 k/ohms.

If the resistance is not as specified, renew the coilpack assembly.

Fuel and Engine Management

ELECTRONIC SPARK TIMING (EST)

To Check Operation(l) Start the engine and maintain the engine

speed at 1600-1 800 rpm. Do not adjust the throttlestop screw.

(2) Connect a jumper lead between terminals Aand B on the diagnostic link connector and note thedecrease in the engine speed.

If the engine speed does not decrease, a fault inthe EST circuit is indicated.

If necessary, carry out the following test proce-dure.

To Test - Code 42


(2) Start and run the engine at idle speed for 60seconds or until the Check Engine warning lampilluminates.


If code 42 is displayed, proceed to operation (4).If code 42 is not displayed, but was displayed

when the self diagnosis test procedure was originallyperformed, an intermittent fault is indicated. Proceedas follows:


(b) Check that all earth wires are secure.(4) With the ignition Off, disconnect the control

unit wiring connectors.(5) With the ignition On, measure the resistance

between control unit wiring connector terminal D4and a good earth point. The resistance should be lessthan 500 ohms.

If the resistance is more than 500 ohms, check thewiring harness between the ignition control modulewiring connector terminal A and the control unitwiring connector terminal D4 for continuity andensure that terminal A has a secure connection to theignition control module.

If no fault can be found, renew the ignitioncontrol module.

If the resistance is as specified, proceed as follows:(6) With the lead of a test lamp connected to the

positive battery terminal, probe the control unitwiring connector terminal D5.

If the test lamp does not light, proceed to opera-tion (7).

If the test lamp lights, disconnect the ignitioncontrol module wiring connector. If the test lampremains illuminated, check the wiring harnessbetween the ignition control module wiring connectorterminal B and the control unit wiring connectorterminal D5 for shorts to earth.

Repair or renew the wiring harness as necessary.



If the test lamp does extinguish, renew the igni-tion control module.

(7) Connect an ohmmeter between the controlunit wiring connector terminal D4 and a good earthpoint.

(8) With the lead of a test lamp connected to thepositive battery terminal, backprobe the control unitwiring connector terminal D5. As the test lamp probetouches the terminal, the ohmmeter reading shouldchange from less than 500 ohms to over 5 000 ohms.

If the reading is as specified, switch the ignitionOff, instal the control unit wiring connectors and runthe engine for I minute or until the Check Enginewarning lamp illuminates. Stop the engine, turn theignition On and check for fault codes as previouslydescribed. If code 42 is displayed, check for faultyconnections. If no fault can be found, renew thecontrol unit.

If the reading is not as specified proceed asfollows:

(9) Disconnect the ignition control module wir-ing connector.

(10) Check for continuity between the controlunit wiring connector terminal D4 and earth. Thereshould be no continuity.

If continuity exists, check the wiring harnessbetween the ignition control module wiring connectorterminal A and the control unit wiring connectorterminal D4 for shorts to earth. Repair or renew thewiring harness as necessary.

If there is no continuity, check the wiring harnessbetween the ignition control module wiring connectorterminal B and the control unit wiring connectorterminal D5 for continuity and ensure that terminal Bis a secure connection to the ignition control module.

If no fault can be found renew the ignition controlmodule.

IGNITION CONTROL MODULE AND COILPACK ASSEMBLY

To Remove and Instal(l) Disconnect the negative battery terminal.(2) LJnscrew the ignition control module wiring

connector retaining screw and remove the wiringconnector from the ignition control module.

(3) Disconnect the high tension leads from thecoil pack assembly.

(4) Remove the Torx screws retaining the coilpack assembly to the ignition control module.

(5) Tilt the coil pack assembly to one side andmark the wiring connectors to ensure correct connec-tion at installation.

(6) Disconnect the wiring connectors from thecoil pack assembly and remove the coil pack assemblyfrom the ignition control module.

(7) Remove the nuts securing the ignition con-trol module to the alternator mounting bracket andremove the ignition control module.

Dismantled view of the ignition control module and thecoil pack assembly.


(1) Where applicable, instal the earth lead to thecontrol module mounting stud, between the alternatormounting bracket and the retaining nut.

(2) When installing a new coil pack bend thewiring connector terminals inwards 90'.

(3) Instal the original gasket between the coilpack and the ignition control module.

(4) Connect the ignition control module wiringterminals to the coil pack, using the reference marksmade at removal to ensure correct connection.

(5) Connect the negative battery terminal andstart the engine. Increase the engine speed to 3 000rpm for l0 seconds allowing the idle air control valveto reset.


CRANKSHAFT SENSOR

To Remove and Instal(1) Disconneit the negative battery terminal.(2) Place an l8 mm ring spanner on the drive

belt tensioner pulley bolt and rotate the pulley assem-bly anti-clockwise, raising the pulley away from thedrive belt.

(3) While maintaining the pulley in this positionremove the drive belt from the water pump pulley.Return the pulley to its previous position and removethe drive belt from the engine.

(4) Using a 28 mm socket and bar, slowly rotatethe crankshaft pulley while closely inspecting each ofthe outer interrupter blades, located behind the crank-shaft pulley, as they pass through the crankshaft

TO$( SCREWS\g€$


108

sensor channel. Renew the crankshaft pulley if a bladeis bent.

(5) Remove the bolt retaining the crankshaftpulley to the crankshaft and slide the pulley off thecrankshaft.

(6) Disconnect the crankshaft sensor wiring con-nector.

(7) Remove the crankshaft sensorbolts and remove the crankshaft sensorengine.

retarnrngfrom the

Installed view of the crankshaft sensor. Crankshaftpulley removed for clarity.

Instatlation is a reversal of the removal procedurewith attention to the following points:

(1) [Jnscrew the crankshaft sensor clamp boltsufficiently to allow the sensor to move freely.

(2) Instal the crankshaft sensor to the engine,ensuring that the dowel pin locates in the crankshaftsensor bracket and tighten the retaining bolts to thespecified torque.

(3) Instal the crankshaft pulley onto the crank-shaft while positioning the crankshaft sensor to locatethe blades of the crankshaft pulley between thechannels on the crankshaft sensor.

(4) Carefully rotate the crankshaft pulley untilthe keyway aligns with the crankshaft key and pushthe crankshaft pulley against the stop.

(5) Instal the crankshaft pulley retaining boltand tighten to the specified torque.

NOTE: When tightening the crankshaftpulley retaining bolt, block the flywheel toprevent the crankshaft turning. If the crank-shaft turns, damage to the cranlcshaft sensorcould result.

(6) Slowly rotate the crankshaft pulley until oneof the outer blades is positioned in the outer channelof the crankshaft sensor.

(7) Insert a 0.5mm feeler gauge between theouter face of the blade and the outer segment on thecrankshaft sensor.

Fuel and Engine Management

(8) While maintaining a light pressure on thesensor, pushing it against the feeler gauge and theouter blade, tighten the clamp bolt to the specifiedtorque. If the clamp bolt is not tightened to thespecified torque the crankshaft sensor could move orthe crankshaft sensor bracket could be distorted.

(9) Remove the feeler gauge and check theclearance as described in operation (7) in threepositions around the crankshaft pulley, approxi-mately l20 apart.

If any of the blades contact the outer segment onthe crankshaft sensor during rotation of the crank-shaft pulley, loosen the crankshaft sensor clamp boltand repeat the previous three operations.

Measure the interrupter blade to crankshaft sensorclearance using feeler gauges.

If the clearance is still unsatisfactory, renew thecrankshaft pulley.

(10) Connect the crankshaft sensor wiring con-nector.

(l l) Instal the drive belt. Refer to the EngineTune-up section if necessary.

(12) Connect the negative battery terminal andstart the engine. Increase the speed to 3 000 rpm for l0seconds allowing the idle air control valve to reset.


EFI AND FUEL PUMP RELAYS

To Remove and Instal(1) Disconnect the negative battery terminal.(2) Remove the cover from the relay housing

which is located in the engine compartment forwardof the coolant surge tank.


Fuel and Engine Managernent r09

Continuity should exist between termilnals 86 and85 but should not exist between terminat! 30 and 87.

(3) Using suitable jumper leads, apfly 12 voltsto terminal 86 and connect terminal 85 to {he negativebattery terminal- '(4i

Using an ohmmeter, check for continuitybetween terminals 30 and 87.

If continuity exists, the relay can be consideredsatisfactory.

If continuity does not exist renew the relay.

To Test Relay Circuits

(l) Remove the relay from ttre 't eficle as pre-viously described. Connect the negative battery ter-minal.

(2) Connect a test lamp between thp relay con-nector terminal A and earth. The test lhmp shouldlight.

If the test lamp does not light when (hecking theView of the relay housing showing the location of the

EFi and fuel PumP relaYs.

(3) Remove the relevant relay from the connec-tion block.


(l) Connect the negative battery terminal andstart the engine. Increase the speed to 3 000 rpm for l0seconds, allowing the idle air control valve to reset.


To Test Relays(l) Remove the relay from the vehicle as pre-

viously described.(2) Using an ohmmeter, check for continuity

between terminals 86 and 85, and terminals 30 and 87on the relay.

EFI relay circuit, check the fusible link fo{ continuity.Renew the fusible link if necessary.

If the fusible link blows, check the wiling harnessbetween the relay connector terminal A and thefusible link for shorts to earth. Repair dr renew thewiring harness as necessary.

If the test lamp does not light when ghecking thefuel pump relay circuit, check the fuel pqmp fuse forcontinuity. Renew the fuse if necessary.

If the fuse blows, check the wiring harnessbetween the relay connector terniinal A, the oilpressure switch and the fuel pump fuse for shorts toearth. Repair or renew the wiring harndss as neces-sary-

(3) Switch the ignitioq On and cohnect a testlamp between the relay connector terr4inal B andearth. The test lamp should light. When dhecking thefuel pump relay circuit the test lamp should extinguish2 seconds after the ignition has been swi

If the test lamp does not light when ohecking thefuel pump relay circuit, check the wi{ing harnessbetween the control unit wiring connecfor terminalAl and the fuel pump relay connector tefminal B forcontinuity. Repair or renew the wirin$ harness asnecessary.

FUEL PUMPzasltos

lllustration showing the terminal iEFI and fuel pump relay connectprs.

fn leT'

Testing a relay using a multimeter.


1 1 0

If no fault can be found renew the control unit.If the test lamp does not light when checking the

EFI relay circuit, check the ignition fuse for contin-uity. Renew the fuse if necessary.

If the fuse blows, check the wiring harnessbetween the fuse panel, the diagnostic link connectorterminal C and the EFI relay for shorts to earth.Repair or renew the wiring harness as necessary.

(4) Switch the ignition Off and connect the leadof a test lamp to the positive battery terminal andprobe the relay connector terminal C. The test lampshould light.

If the test lamp does not light, check the wiringharness between the relay connector terminal C andearth for continuity. Check that all earth connectionsare clean and secure. Repair the wiring harness asnecessary.

(5) When checking the EFI relay circuit proceedas follows:

(a) Disconnect the wiring connectors from thefuel injectors.

(b) Connect a jumper lead between the positivebattery terminal and the relay connector terminal D.

(c) With the lead of a test lamp connected toearth, probe the red wire terminal of an injectorwiring connector. The test lamp should light.

If the test lamp does not light, check the wiringharness between the relay connector terminal D andthe injector wiring connectors for continuity. Repairor renew the wiring harness as necessary.

(6) When checking the fuel pump relay circuit,proceed as follows:

(a) Disconnect the round wiring connector atthe fuel pump/tank sender unit and connect a testlamp between the two terminals in the wiring connec-tor.

(b) Connect a jumper lead between the positivebattery terminal and the relay connector terminal D.The test lamp should light.

If the test lamp does not light, check the wiringharness between the relay connector terminal D, thediagnostic link connector terminal D, the oil pressureswitch and the fuel pump wiring connector forcontinuity and shorts. Repair or renew the wiringharness as neccessary.

CONTROL UNIT

To Test Input Circuits - Code 55(1) Switch the ignition On and note the Check

Engine warning lamp. If the Check Engine warninglamp is illuminated and not flashing proceed tooperation (4).

If the Check Engine warning lamp is displayingcode 55 proceed as follows:

(2) Switch the ignition Off and disconnect thewiring connectors from the control unit.

(3) Switch the ignition On and check the follow-ing control unit wiring connector terminals for vol-tage , A9 , 811 , C l0 , C l l , C12 and C l3 .


lnstalled view of the control unit located behind thepassenger side kick panel.

If there is no voltage at any of the terminals renewthe control unit.

If there is voltage at any terminal, a short tovoltage in the particular wiring circuit is present.Repair or renew the wiring harness as necessary.

(4) Connect a jumper lead between terminals Aand B on the diagnostic link connector. Note any faultcodes displayed.

If code 55 is displayed proceed as follows:(5) Remove the jumper lead from the diagnostic

link connector and erase the self diagnosis codememory as previously described.

(6) Start and run the engine for 2 minutes andrepeat the test procedure.

If code 55 is displayed renew the control unit.

To Test Power Supply and Earth Circuit( 1) With the ignition switch turned off, back-

probe the control unit wiring connector terminals Bland Cl6 with a test lamp to earth.

The test lamp should illuminate.If the test lamp does not illuminate, check the

fusible link marked ENG. COMP for continuity. If thefuse is serviceable, an open circuit between the fusiblelink and the wiring connector terminals Bl and C16 ispresent.

Repair or renew the wiring harness as necessary.(2) Disconnect the control unit wiring connec-

tors and measure the resistance between terminalsA^l2, Dl, D3, D6 and Dl0 and earth. The resistanceshould be O ohms at each terminal.

If the resistance is not as specified, check that theearth connections located at the coil pack mountingbracket retaining bolt and the timing cover bolt,directly below, are clean and secure. If no fault can befound, an open circuit between the wiring connectorterminal(s) is present.

Repair or renew the wiring harness as necessary.To Remove and Instal

(1) Disconnect the negative battery terminal.(2) Remove the fastener securing the lower

dashboard trim panel to the left hand side kick panel.(3) Using a small screwdriver, prise the plastic


Fuel and Engi'ne

f l , i l t l " r I I

|.*q.

View of the control unit with the Mem-Cal removed.

strip from the front section of the left hand side sillpanel cover.

(4) Disengage the front section of the sill panelcover from the kick panel and the sill panel.

(5) Remove the lower front corner section of thedoor sealing rubber.

(6) Disengage the lower front corner of the kickpanel from the locating stud positioned behind thekick panel and manoeuvre the kick panel from thevehicle.

(7) Disconnect the wiring connectors from thecontrol unit.

(8) Lever the plastic tongues away from thecontrol unit and withdraw the control unit from themounting brackets.

(9) Remove the screws retaining the Mem-Calcover to the control unit.

(10) Release the Mem-Cal unit retaining clips,grasp the Mem-Cal unit at each end and remove itfrom the control unit.


( I ) When installing the Mem-Cal unit, align thenotches in the Mem-Cal unit with those in the controlunit and push on each end of the Mem-Cal unit. Donot push in the middte section of the Mem-Cal unit.

(2') Secure the Mem-Cal unit retaining clips.Ensure that the clips locate into the Mem-Cal unit.

Managernent I I I

(3) When installing a new control unit transferthe identification and bar code label to the newcontrol unit.

(4) Ensure that the control unit wiring connec-tors are securely installed to the control unit.

(5) Activate the self-diagnosis codes. If code 51is displayed or the Check Engine warning lamp isconstantly iltuminated, the Mem-Cal unit is not fullyinstalled. If the Mem-Cal unit is installed correctly afault in the Mem-Cal unit is indicated. Renew theMem-Cal unit as previously described.



MEM.CAL UNIT

To Test - Code 5lShould fault code 5l be displayed during the self

diagnosis test procedure, proceed as follows:(a) Check that the Mem-Cal is fully inserted in

the control unit.(b) Erase the fault code memory and retest for

fault codes.(c) If code 5l is still displayed, renew the Mem-

Cal.(d) Erase the fault code memory and retest for

fault codes.(e) If code 5l is still displayed, renew the control

unit.

To Remove and InstalThe Mem-Cal unit is incorporated within the

control unit. Refer to the previous heading for theremoval and installation procedure.

THROTTLE POSITION SENSOR

To Test - Codes 2l tnd,22

NOTE: The following test procedure as-sumes that fault codes 2I or 22 have beendisplayed during the self diagnosis test pro-cedure. If no codes have been displayed butthe operation of the throttle position sensoris suspect, begin the test procedure at opera-tion (23).


(2) Start and run the engine at idle speed for 60seconds or until the Check Engine warning lampilluminates. If the engine will not start proceed tooperation (4).

(3) Stop the engine, switch the ignition On andconnect a jumper lead between terminals B and A on


1 1 2

the diagnostic link connector. Note any fault codesdisplayed.

If codes 2l or 22 are displayed, proceed tooperation (4).

If codes 21 or 22 are not displayed, but weredisplayed when the self diagnosis test procedure wasoriginally performed, an intermittent fault is indicat-ed. Proceed as follows:


(b) Check that all earth wires are secure.

Installed view of the throttle body showing the throttleposition sensor. Engine vent pipe removed for clarity.

(4) Remove the jumper lead from the diagnosticlink connector.

(5) Erase the self diagnosis codes as previouslydescribed

(6) Disconnect the wiring connector from thethrottle position sensor.

If code 22was displayed in operation (3), proceedto operation (12).

If code 21 was displayed in operation (3), proceedas follows:

(7) Start and run the engine at idle speed for 2minutes or until the Check Engine warning lampilluminates. If the engine will not start, proceed tooperation (10).

(8) Stop the engine, switch the ignition On andconnect a jumper lead between terminals B and A onthe diagnostic link connector. Note any fault codesdisplayed.

If code 2 1 is displayed, proceed to operation ( l0).If code 22 is displayed, proceed as follows:(9) Connect the lead of a test lamp to the

positive battery terminal and insert the probe intoterminal B on the throttle position sensor wiringconnector.

If the test lamp lights, proceed to operation (23).If the test lamp does not light, check the wiring

harness between throttle position sensor wiring con-nector terminal B and control unit wiring connectorterminal D2 for continuity. Repair or renew thewiring harness as necessary and retest for fault codes.


( 10) With the ignition Off, disconnect the controlunit wiring connectors.

(11) With the ignition On, measure the voltage atthe control unit wiring connector terminal C13.

If the voltage is less than I volt, check the wiringharness for shorts between the throttle position sensorand the control unit. If no fault is found, renew thecontrol unit.

(12) Start and run the engine at idle speed.(13) With the engine idling, connect a jumper

lead across terminals A and C on the throttle positionsensor wiring connector and idle the engine for l0seconds.

( l4) Stop the engine, switch the ignition On andconnect a jumper lead between terminalsi A and B onthe diagnostic link connector. Note any' fault codesdisplayed.

If codes 2l and 22 are displayed, proceed tooperation (23).

If code 22 only is displayed, proceed as follows:(15) Remove the jumper lead from the throttle

position sensor wiring connector.( l6) Measure the voltage across the throttle posi-

tion sensor wiring connector terminals A and B.If the voltage is below 4 volts, proceed to opera-

t ion (19) .If the voltage is 4-6 volts, proceed as follows:(17) With the ignition Off, disconnect the control

unit wiring connectors.(18) Check the wiring harness between the con-

trol unit wiring connector terminal Cl3 and thethrottle position sensor wiring connector terminal Cfor continuity and shorts. Repair or renew the wiringharness as necbssary. Check the control unit wiringconnector terminals.


(19) Disconnect the wiring connector from theMAP sensor.

(20) Measure the voltage across the throttle posi-tion sensor wiring connector terminals A and B.

If the voltage is 4-6 volts, renew the MAP sensor.If the voltage is below 4 volts, proceed as follows:(21) With the ignition Off, disconnect the control

unit wiring connectors.(22) Check the wiring harness between the con-

trol unit wiring connector terminal Cl4 and thethrottle position sensor wiring connector terminal Afor continuity and shorts. Repair or renew the wiringharness as necessary.

Check the control unit terminals and the controlunit wiring connector terminals for damage or poorconnections.


(23) If removed, instal the wiring connector tothe throttle position sensor.

(24) With the ignition On, measure the voltage atthe control unit terminal Cl3 by backprobing thewiring connector. The voltage should be 0.2-1.2 volts.


Fuel and Engi,ne Managernent 1 1 3

If the voltage is as specified proceed to operation(30).

If the 'oltage is between 1.2 and 2.5 volts proceed

to operation (28).If the voltage is higher than 2.5 volts proceed as

follows:(25) Disconnect the wiring connector from the

throttle position sensor and repeat operation (24).(26) It the voltage is higher than I volt check the

wiring harness between the control unit wiring con-nector terminal C13 and the throttle position sensorwiring connector terminal C for a short to voltage.Repair or renew the wiring harness as necessary.

(27) lf the voltage is lower than 1 volt, check thewiring harness between the control unit wiring con-nector terminal D2 and the throttle position sensorwiring connector terminal B for continuity. Repair orrenew the wiring harness as necessary.

If no fault is found, renew the throttle positionsensor.

(28) Check the base idle speed as previouslydescribed. Adjust if necessary.

(29) Repeat operation (24).If the voltage is not as specified, renew the throttle

position sensor.If the voltage is as specified, proceed as follows:(30) With the voltmeter connected as described

in operation (24), slowly open the throttle. Thevoltage should increase steadily as the throttle pro-gresses to the wide open position. With the throttlewide open, the voltmeter should read over 4 volts.

NOTE: Ensure that there are no floor matsor carpet under the throttle pedal, prevent'ing the throttle from opening fully.

If the voltage is not as specified, renew the throttleposition sensor.


(1) Disconnect the negative battery terminal.(2) Remove thg throttle body as previously

described.(3) Remove the throttle position sensor retain-

ing screws using a number 20 Torx bit and remove thethrottle position sensor from the throttle body.


(1) With the throttle valve in the fully closedposition, instal the throttle position sensor onto thethrottle shaft at a position 30 degrees clockwise pastthe throttle position sensor retaining screw holes inthe throttle body.

(2) Align the holes in the throttle position sensorwith those in the throttle body, instal the retainingscrews and tighten securely.

(3) Instal the throttle body as previously de-scribed.


IDLE ArR coNTRoL vALvE o RING

\ \

wq

View of the throttle position sensor and the idle aircontrol valve removed from the throttle body.


COOLANT TEMPERATURE SENSOR

To Test - Codes 14 and 15(1) Erase the self diagnosis code memory as

previously described.(2) Start and run the engine at idle speed for 60


NOTE: If the engine is warm and will notstart, hold the throttle in the wide openposition until the engine starts.


If codes 14 or 15 are displayed, proceed tooperation (4).

If codes- 14 or 15 are not displayed, but weredisplayed when the self diagnosis test procedure wasoriginally performed, an intermittent fault is indicat-ed. Proceed as follows:

(a) Check for a faulty wiring connection. Checkthat all wiring connectors dre clean and secure.

(b) Check that all earth wires are secure.(4) Disconnect the wiring connector from the

coolant temperature sensor.(5) With the ignition On, measure the voltage

across the terminals on the coolant sensor wiringconnector. The voltage should be above 4 volts.

If the voltage is below 4 volts, proceed to opera-tion (9).

If the voltage is as specified, proceed as follows:(6) Remove the coolant temperature sensor

from the vehicle.(7) Connect an ohmmeter to the coolant temper-

ature sensor terminals.(8) Immerse the metal end of the coolant tem-

perature sensor in a 50/50 mixture of glycol and iced

.\& rffi


r t4 Fuel and Engine Management

If no fault is found. renew the control unit andretest for fault codes.To Remove and Instal

(1) Disconnect the negative battery terminal.(2) Disconnect the wiring connector from the

coolant temperature sensor.(3) Drain the cooling system to a level below the

coolant temperature sensor.(4) Unscrew the coolant temperature sensor

from the rear of the inlet manifold.rER Installation is a reversal of the removal procedure

with attention to the following points:(1) Coat the threads of the coolant temperature

sensor with Loctite 242 sealant.(2) Replenish the cooling system and check for

leaks. Refer to the Cooling and Heating Systemssection if necessary.



COOLANT TEMPERATURESENSOR --+

249t237tLD14

COOLANT

Schematic drawing showing the correct method usedto test the coolant temperature sensor.

water at a temperature of 0 deg C. The resistanceshould be 6 000 ohms.

Slowly heat the mixture and measure the resis-tance of the coolant temperature sensor at the follow-ing temperatures. Compare the results with thespecified values:

0 d e g C . . . a p p r o x 6 0 0 0 o h m s20degC. . . approx 2500 ohms3 0 d e g C . . . a p p r o x 1 8 0 0 o h m s4Odegc . . . approx l20O ohms7 0 d e g C . . . . . . a p p r o x 4 5 0 o h m s9 0 d e g C . . . . . . a p p r o x 2 5 0 o h m s

100 deg C. . . . . . approx 190 ohmsI l0 deg C. . . . . . approx 110 ohms

If the resistances obtained are not the specifiedvalue at any of the given temperatures, renew thecoolant temperature sensor and retest for fault codes.

(9) Disconnect the control unit wiring connec-tors.

(10) Check the wiring harness between the coo-lant temperature sensor wiring connector terminal Aand control unit wiring connector terminal ClO forshorts. Repair or renew the wiring harness as neces-sary.

lnstalled view of the coolant temperature sensor,MAT sensor and the temperature gauge sender.

MANIFOLD AIR TEMPERATURE (MAT)SENSOR

To Test - Codes 23 nd 25(l) Erase the self diagnosis code memory as

previously described.(2) Start and run the engine at idle speed for 60



If codes 23 or 25 are displayed proceedtion (4).

If codes 23 or 25 are not displayed,

to opera-

but were

TO OHMMETER

THERMOME

/

/

, / -

FILLED CONTAINEB

A

A +- HEAr souRcETEMPERATURE GAUGE SENDER

MAT SENSOR


Fuel and Engine Management 1 1 5

displayed when the self diagnosis test procedure wasoriginally performed, an intermittent fault is indicat-ed. Proceed as follows:


(b) Check that all earth wires are secure.(4) Disconnect the wiring connector from the

MAT sensor.(5) With the ignition On, measure the voltage

across the terminals on the MAT sensor wiringconnector. The voltage should be 4-6 volts.

If the voltage is below 4 volts proceed to operation(10) .

If the voltage is over 6 volts check the wiringharness between the MAT sensor wiring connectorterminal A and the control unit wiring connectorterminal Cl2 for shorts to voltage. Repair or renewthe wiring harness as necessary.

If the voltage is 4-6 volts proceed as follows:(6) Remove the MAT sensor from the inlet

manifold.(7) Connect an ohmmeter to the MAT sensor

terminals.(8) Immerse the metal end of the manifold air

temperature sensor in a 50/50 mixture of glycol andiced water at a temperature of 4 deg C. The resistanceshould be 7 500 ohms.

Slowly heat the mixture and measure the resis-tance of the MAT sensor at the following tempera-tures. Compare the results with the specified values.

4 d e g c . . . . : . 7 5 0 0 o h m s2 0 d e g c . . . . . . 3 4 0 0 o h m s3 8 d e g c . . . l 8 0 0 o h m s7 O d e g c . . . 4 5 0 o h m s

l 0 0 d e g c . . . l 8 5 o h m s

If the resistances obtained are not the specifiedvalue at any of the given temperatures, renew theMAT sensor and retest for fault codes.

(9) Check for loose terminals in the MAT sensorwiring connector and ensure that the terminals aremaking firm contact when connected to the MATsensor.


(10) Connect a voltmeter between the MAT sen-sor wiring connector terminal A and earth and mea-sure the voltage. The voltage should be 4-6 volts.

If the voltage is as specified, proceed as follows:(a) Check the wiring harness between the MAT

sensor wiring connector terminal B and the controlunit wiring connector terminal Al1 for continuity.Repair or renew the wiring harness as necessary.

(b) Ensure that the terminals are making firmcontact when connected to the control unit.

(c) If no fault can be found, renew the controlunit and retest for fault codes.

(11) If the voltage is not as specified, proceed asfollows:

(a) Check the wiring harness between the MATsensor wiring connector terrninal A and the controlunit wiring connector terminal C12 for continuity.Repair or renew the wiring harness as necessary.

(b) Ensure that the terminals are making firmcontact when connected to the control unit.


To Remove and Instal(1) Disconnect the negative battery terminal.(2) Disconnect the wiring connector from the

MAT sensor.(3) Llnscrew the MAT sensor from the rear of

the inlet manifold.Installation is a reversal of the removal procedure

with attention to the following points:( 1) Coat the threads of the MAT sensor with

Loctite 242 sealant prior to installation.(2) Connect the negative battery terminal.(3) Start the engine and increase the speed to

3 000 rpm for 10 seconds allowing the idle air co?rtrolvalve to reset.

(4) On models equipped with a radio/cassetteusing a PIN security, enter the PIN code as describedunder the Radio/Cassette heading in the ElectricalSystem section.

OXYGEN SENSOR

To Test - Codes 13, 44 and 45(l) Run the engine until the normal operating

temperature is obtained.(2) With the engine running connect a jumper

lead between terminals B and A on the diagnostic linkconnector.

(3) Increase the engine speed to I 600-1 800rpm for 2 minutes and note the flashing sequence ofthe Check Engine warning lamp.

If the Check Engine warning lamp flashes on andoffat equal intervals of approximately I per second orslower, the oxygen sensor is functioning correctly. Ifcode 44 or 45 are being tested an intermittant fault isindicated. Proceed to operation (4).

If code 13 is being tested proceed as follows:(a) Remove the jumper lead from the diagnostic

link connector.(b) With the engine running increase the speed

above 2 000 rpm for 2 minutes and note the CheckEngine warning lamp.

If the Check Engine warning lamp lights, switchthe engine Off and check for fault codes.

Perform the relevant code test procedure.If the Check Engine warning lamp does not light,

an intermittent fault is indicated.(4) When an intermittent fault is indicated,

proceed as follows:(a) Check for faulty wiring connections. Check

that all wiring connectors are clean and secure.(b) Check that all earth wires are secure.


I l 6

Installed view of the orygen sensor.

If, in operation (3) the Check Engine warninglamp flashes on and off at 2 flashes per second oiflashes an unequal sequence proceed as follows:

(5) If code 44 was originally displayed proceedto operation (11).

(6) Switch the ignition Off and disconnect theoxygen sensor wiring connector.

(7) Connect a jumper lead between the oxygensensor wiring connector and eafth.

(8) Start the engine and maintain the speed atI 600- I 800 rpm and note the Check Engine warninglamp.

If the warning lamp failed to light for approxi-mately 30 seconds proceed to operation (9) if code l3was originally displayed or operation (10) if code 45was originally displayed.

If the Check Engine warning lamp remainedilluminated, or flashes, proceed as follows:

(a) Check the wiring harness between the engineearth connection and the control unit wiring connec-tor terminal D6 for continuity. Ensure that the earthconnection at the engine block is clean and secure.Repair or renew the wiring harness as necessary.

(b) Check the wiring harness between the oxy-gen sensor wiring connector and the control unitwiring connector terminal D7 for shorts and contin-uity. Repair or renew the wiring harness as neiessary.


(9) If code l3 was originally displayed check thewiring harness between the engine earth connectionand the control unit wiring connector terminal D6 forcontinuity. Ensure that the earth connection at the


engine block is clean and secure. Repair or renew thewiring harness as necessary.

If no fault can be found, a faulty oxygen sensorconnector or oxygen sensor is indicated.

NOTE: A faulty oxygen sensor can becaused by contamination to the oxygensensor through the use of leaded fuel orunsuitable RTV silicone sealants on enginecomponents and may be identfied by awhite, powdery substance covering the tip ofthe oxygen sensor.

A contaminated oxygen sensor shouldbe renewed and the cause of the contamina-tion rectffied.

(10) If code 45 was originally displayed, check thefollowing possible causes:

(a) High fuel pressure.(b) Leakinginjector(s).(c) Charcoal canister saturated with fuel.(d) Faulty coolant temperature sensor circuit.(e) Faulty MAT sensor circuit.(0 Faulty MAP sensor circuit.G) Intermittent throttle position sensor.If no fault can be found renew the oxygen sensor

and retest for fault codes. Refer to the previous note.(l l) Switch the engine Off and disconnect the

oxygen sensor wiring connector.. (12) Start the engine and maintain the speed at

I 600-1 800 rpm for at least 30 seconds and note theCheck Engine warning lamp.

If the warning lamp failed to light for 30 seconds,switch the ignition Off and check the wiring harnessbetween the oxygen sensor wiring connector and thecontrol unit wiring connector terminal D7 for a shortto earth.

Repair or renew the wiring harness as necessary.If no fault can be found, renew the control unit

and retest for fault codes.If the warning lamp flashes on and offat 2 flashes

per second check the following possible causes:(a) Low fuel pressure.(b) Water in the fuel supply.(c) Left hand side exhaust manifold leak at the

cylinder head.(d) Faulty MAP sensor.(e) Obstructed oxygen sensor vent.(0 Restriction in fuel injector(s).If no fault can be found renew the oxygen sensor

and retest for codes.

To Remove and Instal(l) Disconnect the negative battery terminal.(2) Disconnect the oxygen sensor wiring connec-

tor.(3) Remove the oxygen sensor from the exhaust

manifold. If access to the oxygen sensor cannot begained, remove the exhaust manifold as described inthe Engine section.


Fuel and Engine Managernent rt7

View of the o)rygen sensor removed from the exhaustmanifold.

NOTE: It may be necessary to heat theexhaust manifuld if the oxygen sensor isdfficult to remove. Failure to heat themanifuld may result in damage to thethreads in the exhaust manifold.


(l) When installing an oxygen sensor that haspreviously been removed, ensure that the threads arecoated with an anti-seize compound.

(2) Tighten the oxygen sensor to the specifiedtorque.

(3) Connect the negative battery terminal andstart the engine. Increase the speed to 3 000 rpm for 10seconds, allowing the idle air control valve to reset.


DETONATION SENSOR

To Check Operation(1) Start the engine and increase the engine

speed to I 600-1 800 rpm and set the throttle tomaintain that engine speed.

(2) Using a small hammer, quickly and repea-tedly tap the engine block, cylinder head or inletmanifold. The engine speed should drop when tappingthe engine and slowly increase to the original speedwhen the tapping has ceased.

If the engine speed does not decrease, carry outthe following test procedure.

To Test - Code 43(l) Erase the self diagnosis code memory as

previously described.(2) Start and run the engine for 2 minutes or

until the Check Engine warning lamp illuminates.(3) Stop the engine, switch the ignition On and

connect a jumper lead between terminals B and A onthe diagnostic link connector. Note any fault codesdisplayed.

If code 43 is displayed proceed to operation (4).If code 43 is not displayedbut was displayed when

the self diagnosis test procedure was originally per-formed, an intermittent fault is indicated. Carry outthe following checks.


(b) Check that all earth wires are secure.(4) Disconnect the detonation sensor wiring

connector.(5) Connect an ohmmeter between the centre

terminal on the detonation sensor and earth. Theresistance should be 3 000-5 000 ohms.

If the resistance is not as specified, renew thedetonation sensor.

(6) Using a voltmeter, measure the voltage at thedetonation sensor wiring connector terminal.

If the voltage is less than 4 volts or more than 6volts, check the wiring harness between the detona-tion sensor and the control unit wiring connectorterminal Bl l for shorts to earth or voltage. Repair orrenew the wiring harness as necessary.

If the voltage is between 4-6 volts check that thesensor wire is not bare and ensure that the wire has notbeen chafing due to normal engine movement.

If no fault can be found, renew the control unitand retest for fault codes.

To Remove and Instal(l) Disconnect the negative battery terminal.(2) Squeeze the wide sides of the wiring connec-

tor together and remove the connector from thedetonation sensor.

(3) IJnscrew the detonation sensor from thecylinder block.


(l) Ensure that the threads of the detonationsensor and the cylinder block are clean.

(2) If the original sensor is being installed, applyLoctite 242 to the threads on the sensor.

(3) Tighten the detonation sensior to the speci-fied torque.lnstalled view of the detonation sensor.


1 1 8

(4) Connect the negative battery terminal andstart the engine. Increase the speed to 3 000 rpm for10 seconds, allowing the idle air control valve to reset.

(5) On models equipped with a radiolcassetteusing PIN security, enter the PIN code as describedunder the Radio/Cassette heading in the ElectricalSystem section.

VEHICLE SPEED SENSOR

To Test - Code 24

NOTE: If code 24 has not been displayed,but the operation of the vehicle speed sensoris suspect, perform operations (6) to (11).

(l) Check fuses 9 and 12. Renew if necessary. Ifthe fuses are serviceable proceed to operation (5).

(2) Erase the self diagnosis codes as previouslydescribed.

(3) Start and run the engine for 5 minutes anddrive the vehicle at a speed of at least 100 km/h and,

Installed view of the vehicle speed sensor. Automatictransmission model.


with the throttle closed, allow the vehicle to coast ingear until the engine speed is less than I 500 rpm.

(4) Check fuses 9 and 12.lf either of the fusesare blown, check the wiring harness for shorts to earthbetween the fuse panel, the instrument cluster and thevehicle speed sensor. Refer to the wiring diagrams inthe Electrical System section. Repair or renew thewiring harness as necessary.

If the fuses are serviceable, retest for fault codes.If code 24 is displayed proceed as follows:

(5) Check the operation of the speedometer andthe instrument cluster warning lamps.

If the speedometer is functioning, proceed tooperation (12).

If the speedometer and the instrument clusterwarning lamps are not operating, a fault in theinstrument cluster wiring harness is indicated. Referthe fault to an authorised dealer.

If the speedometer only is not operating, proceedas follows:

(6) Remove the vehicle speed sensor as de-scribed under the following heading.

(7) Remove the instrument cluster as describedin the Electrical System section.

(8) Connect the vehicle speed sensor wiringconnector.

(9) Connect the negative battery terminal.(10) Connect a 4.7 Vohm 0.5 watt resistor

between the blue instrument cluster wiring connectorterminals 7 and 11 and connect a digital voltmeterbetween terminal 7 and earth.

( I I ) Slowly rotate the vehicle speed sensor shaftand note the voltmeter reading.

It should pulse between zero and battery voltage.If the voltmeter does not read as specified, check

the wiring harness for continuity between the vehiclespeed sensor, the blue instrument cluster wiringconnector terminal7 and the earth connection.

If no fault can be found, renew the vehicle speedsensor.

(12) On models without a trip computer, raise therear of the vehicle, support it on chassis stands and

View showing the location and terminal numbers ofthe instrument cluster wiring connectors.

Installed view of the vehicle speed sensor.transmission model.

Manual


Fuel and Engine

shift the transmission to neutral. Proceed to opeiation( le) .

On models with a trip computer, proceed asfollows:

(13) With the ignition switch Off, depress andhold the trip computer RESET button. Switch theignition On and release the RESET button.

If the trip computer displays FAIL, a fault in thetrip computer circuitry is indicated. Refer the fault toan authorised dealer.

(1a) Switch the ignition Off.(15) Raise the rear of the vehicle and support it

on chassis stands.(16) Depress the trip computer RESET button

and start the engine. Release the button when theengine is running..'

( 17) Place the transmission in first gear and allowthe rear wheels to slowly spin.

( l8) Observe the trip computer display. It shouldact as a digital speedometer, indicating the speed ofthe spinning rear wheels.

If the trip computer is not displaying as specified,a fault in the trip computer circuitry is indicated.Refer the fault to an authorised dealer.

(19) Switch the ignition Off for 10 seconds andthen switch the ignition On.

(20) With the aid of assistants, slowly spin boththe rear wheels by hand while backprobing the controlunit wiring connector terminal Al0 with a digitalvoltmeter to earth.

The voltage should alternate from under I volt toover 10 volts.

If the voltmeter reads as specified, the vehiclespeed sensor is operating satisfactorily, indicating anintermittent fault was the cause of the fault code.Proceed as follows:


(b) Check that all earth connections are secure.If the voltmeter continually reads over 10 volts,

proceed to operation (25).If the voltmeter continually reads under 1 volt,

proceed as follows:(21) Switch the ignition Off and disconnect the

control unit wiring connectors.(22) Switch the ignition On and connect a 4.7

k/ohm resistor between the control unit wiring con-nector terminal A10 and a jumper lead connected tothe positive battery terminal.

(23) Connect a voltmeter between the controlunit wiring connector A10 and earth.

(24) Slowly spin the rear wheels and note thevoltmeter.

If the voltmeter-reads over 10 volts, renew thecontrol unit.

If the voltmeter reads under 1 volt, check thewiring harness for a short to earth between the controlunit wiring connector Al0 and the orange instrumentcluster wiring connector terminal 4. Repair or renewthe wiring harness as necessary.

Mana,gement 1 1 9

If no fault can be found in the wiring harness,check the flexible printed circuit on the rear of theinstrument cluster for damage. On models with a tripcomputer, ensure that the trip computer wiring con-nector is secure when installed to the instrumentcluster.

If no fautt can be found, renew the trip computer.On models without a trip computer, renew the speed-ometer.

(25) Switch the ignition Off and disconnect thecontrol unit wiring connectors.

(26) Switclr the ignition On and measure thevoltage at the control unit wiring connector terminalA l 0 .

If the voltage is over 10 volts, check the wiringharness for a short to voltage between the control unitwiring connector terminal Al0 and the orange instru-ment cluster wiring connector terminal 4. Repair orrenew the wiring harness as necessary.

If the voltage is under I volt, proceed as follows.(27) Switch the ignition Off.(28) Remove the instrument cluster as described

in the Electrical System section.(29) With an ohmmeter, check for continuity

between the control unit wiring connector terminalAl0 and the orange instrument cluster wiring connec-tor terminal 4.

If there is no continuity, repair or renew thewiring harness as necessary.

If continuity exists, check the printed circuit onthe rear of the instrument cluster for damage. Onmodels with a trip computer ensure that the tripcomputer wiring connector is secure when installed tothe instrument cluster.

If no fault can be found, renew the trip computer.On models without a trip computer, renew the speed-ometer.


(l) Disconnect the negative battery terminal.(2) Raise the vehicle and support it on chassis

stands.(3) Disconnect the vehicle speed sensor wiring

connector.(4) (Jnscrew the vehicle speed sensor from the

speedometer drive adaptor.Installation is a reversal of the removal procedure

with attention to the following points:

o::Y'o" "T: 'EAL sENsoR'@0#&wh.m

lI

Dismantled view of the vehicle speed sensor.


120 Fuel and Engine Management

( I ) Connect the negative battery terminal andstart the engine. Increase the speed to 3 000 rpm for 10seconds allowing the idle air control valve to reset.


NEUTRAL SAFETY SWITCH

To Test Circuit(l) Remove the centre console selector cover by

carefully raising the rear section of the cover todisengage the retaining clips. Disconnect the electricalconnectors, rotate the cover 90" and remove the coverfrom the console.

(2) Disconnect the neutral safety switch wiringconnector.

(3) Switch the ignition On and connect a digitalvoltr,neter between the neutral safety switch wiringconnector terminal B and earth. The voltmeter shouldread battery voltage.

If the voltmeter reads battery voltage, proceed tooperation (5).

If the voltmeter does not read battery voltage,proceed as follows:

(4) Backprobe the control unit wiring connectorterminal B10 with a digital voltmeter connected toearth. The voltmeter should read battery voltage.

If the voltmeter does not read battery voltage,check the control unit power supply.

If the voltmeter does read battery voltage, checkthe wiring harness for shorts and continuity betweenthe control unit wiring connector terminal Bl0 andthe neutral safety switch wiring connector terminal B.Repair or renew the wiring harness as necessary.

(5) Switch the ignition Off and connect theneutral safety switch wiring connector.

(6) Place the gear selector in Park or Neutral andswitch the ignition On.

Installed view of the neutral safety switch showingthe location of the wiring connector and the wiring

connector terminal identification.

(7) Backprobe the neutral safety switch wiringconnector terminal B with a test lamp connectedto 12volts. The test lamp should light.

If the test lamp does not light, check the wiringharness between the neutral safety switch wiringconnector terminal A and the wiring harness earthconnection for continuity. Ensure that the earthconnection is clean and secure. Repair or renew thewiring harness as necessary.

(8) Engage the parking brake and move the gearselector into D (Drive) position.

The test lamp should go out.If the test lamp remains illuminated, renew the

neutral safety switch as described in the AutomaticTransmission section under the Neutral Safetv Switchheading.

7. CRUISE CONTROL

DESCRIPTION

The electronic cruise control system enables thevehicle to maintain a preset speed without the driveroperating the throttle pedal. Cruise control is notavailable on models with manual transmission.

The system consists of an electronic control mo-dule and a control switch assembly. The electroniccontrol module receives a signal from the speedo-meter and activates an electric motor inside theelectronic control module. The motor adjusts thethrottle position via the control cable to maintain thepre-set speed.

The system is deactivated when the brake pedal orthe control switch is depressed. Two switches areinstalled on the brake pedal support bracket. Thelower switch is a combination stop lamp/cruise cancelswitch and the upper switch is a failsafe cruise cancelswitch, should the lowep switch fail. The cruise controlsystem will not activate until the vehicle speed isabove 40 km/h.

The cruise system incorporates complex electroniccircuitry, therefore it is recommended that the vehiclebe taken to an authorised dealer for testing and

Installed view of the cruise control module.


Fuel and Engine Managernent r2r

repair should the operation of the system be in doubtand the following procedures fail to rectify the prob-lem.

CONTROL CABLE

To Remove and Instal(l) Remove the retaining clip securing the inner

control cable to the throttle linkage and disconnect theinner control cable.

(2) Depress the edges of the outer control cableretaining clip and withdraw the control cable assem-bly from the mounting bracket.

(3) Remove the control cable retaining strapfrom the left hand side inner mudguard.

(4) Depress both sides of the outer control cableretaining clip and withdraw the control cable assem-bly from the control module. Disengage the innercontrol cable from the connecting strap and removethe control cable from the vehicle.


(1) Instal the inner cable to the connecting strapand pull the opposite end of the cable until tight. Ifnecessary rotate the connecting strap to remove anytwists.

(2) While holding the inner cable taut, instal theouter cable to the control module, ensuring that theretaining clip engages the control module.

(3) Instal the control cable to the mountingbracket, ensuring that the retaining clip locks theouter control cable mounting flange in position.

View of the cruise eontrol cable connected to thethrottle linkage.

(4) Raise the cable lock plate, located in theouter control cable mounting flange, and connect theinner control cable to the throttle linkage. Instal theretaining clip.

(5) Press the cable lock plate down firmly'(01 Adjust the cable as described under the

following heading.

To Adjust(l) Ensure that the ignition is switched Off'(2) Raise the cable lock plate located in the outer

control cable mounting flange.(3) Slowly pull the outer control cable until the

throttle linkage begins to move and slowly return theouter control cable until the throttle linkage is justtouching the throttle stop.

(4) While holding the cable in this position,press the cable lock plate down firmly.

CRUISE CANCEL SWITCHES

To Remove and InstalThe procedure for the removal and installation of

the combination stop lamp/cruise cancel switch andthe failsafe cruise cancel switch are identical. Proceedas follows:

(1) With the ignition switched Off, open the fusecover by turning the retaining clips 90 degrees.

(2) On models with power windows, remove thepower window module retaining bolts and move themodule to one side.

(3) Disconnect the electrical connectors fromthe relevant switch.

(4) Pull the switch assembly from its bracket toremove.

Installation is a reversal of the removal procedurewith attention to the following adjustment.

To Adjust(1) Hold the brake pedal in its depressed posi-

tion and instal the switches into the tubular clips untilthey stop. Audible clicks will be heard as the switchslides through the clips.

(2) Pull the brake pedal back against its stopuntil the audible clicking sounds can no longer beheard.

(3) Apply and release the brake pedal severaltimes to ensure that the adjustment is correct.

(4) If the combination stop lamp/cruise cancelswitch has been adjusted, ensure that the stop lampsoperate correctly.


122

INTRODUCTION

To reduce the output level of the three primaryautomotive emissions, carbon monoxide (CO), hydro-carbons (HC) and oxides of nitrogen (NOx), and thuscomply with legislation on the maintenance of cleanair, several different types of emission control systemsare used in the Commodore range of vehicles coveredby this manual.

The systems will be discussed under the headings(l) Positive Crankcase Ventilation (PCV) System, (2)Evaporative Control System and (3) Exhaust ControlSystem.

1. POSITIVE CRAI{KCASE VENTILATION(PCV) SYSTEM

DESCRIPTION

To prevent the emission of crankcase vapours tothe atmosphere, a closed PCV system is used.

Crankcase vapours are drawn into the inlet mani-fold from the engine via the PCV valve and hose, andare then consumed in the combustion process. Cleanair is drawn from the throttle body and enters the lefthand side rocker cover via the engine vent pipe.


If the engine is being operated under hard acceler-ation or heavy load conditions, and the generatedblow-by vapours exceed the capacity of the PCVvalve, the excess vapours flow back through the enginevent pipe to the throttle body and are drawn into theinlet manifold.

If the engine is excessively worn and blow-by is ata high level, a small amount of crankcase vapour willflow back through the rocker cover and into thethrottle body, irrespective of throttle position.

The engine oil dipstick and filler cap are sealed tothe atmosphere. These seals must be effective for thePCV system to operate correctly.

TO CHECK OPERATION OF PCV VALVE

( 1) With the engine running at idle, disconnectthe PCV valve and hose from the base of the inletmanifold.

(2) Place a finger over the PCV valve inlet. Astrong vacuum should be felt immediately as thefinger is placed over the valve inlet.

(3) Stop the engine, disconnect the PCV valvefrom the hose and shake it. A rattling noise should beheard.

Renew the PCV valve if it is found to be defective.

EMISSION CONTROL

Installed view of the PCV system components. Checking the PCV valve operation.


Emission Control r23

TO SERVICE THE SYSTEM

The system should be regularly serviced withparticular attention given to the following points:

(1) Check the condition of the rubber hoses,ensuring that they are not blocked, collapsed ordeteriorated. Renew the hoses if necessary.

(2) Check the seals on the engine oil filler cap,the dipstick and the PCV hose connections. Renewthe seals if damaged or if the sealing quality is suspect.

(3) Check the operation of the PCV valve aspreviously described.

2. EVAPORATIVE CONTROL SYSTEM

DESCRIPTION

The evaporative control system reduces theamount of hydrocarbons emitted to the atmospherethrough fuel evaporation.

Installed view of the charcoal canister.

The Commodore range of vehicles use the absorp-tion regeneration system to reduce vapour loss. Thesystem utilises a canister of activated charcoal to trapand hold the fuel vapours until they can be fed into theinduction system for burning in the combustionchambers.

The basic components of the evaporative controlsystem are:

(a) Fuel tank with integral expansion tank andsealed filler cap.

(b) Charcoal canister with integral purge valve.When the engine is at rest, vapour through eva-

poration gradually fills the air space in the fuel tankexpansion chamber. As the fuel tank is fitted with asealed filler cap, pressure builds up within the systemforcing the fuel vapour to flow into the charcoalcanister.

When the engine is started and run at medium tohigh speed, fuel vapour stored in the charcoal canisteris drawn into the engine via the purge hose. This iscontrolled by a vacuum signal from the throttle body.

TO SERVICE THE SYSTEMThe evaporative control system should be ser-

viced initially at 1 500 km or I month, and then every40 000 km or 24 months with attention to thefollowing points:

(1) Visually inspect all hoses and pipes ensuringthat they are not damaged or restricted and check allconnections for tightness.

(2) Check the fuel tank filler cap seal for damageand check the operation of the vacuum relief valve.

(3) Remove the charcoal canister from the vehi-cle. Inspect the charcoal canister for damage asfollows:

(a) Shake the canister. There should be no soundfrom within the canister.

(b) Using a vacuum pump, apply 20-35 kPa ofvacuum to the vacuum control port on the canister. Itshould be possible to blow low pressure air throughthe purge port, which is located directly under thevacuum control port.

(c) Release the vacuum to the control port. Itshould not be possible to blow low pressure airthrough the purge port.

Check the condition of the seal on the fuel filler cap.

(d) Apply compressed air at a pressure of 20-35kPa to the fuel tank port. Air should flow freely fromthe other ports.

(e) If air flow through the drain port on thebottom of the canister is restricted, clean the charcoalcanister filter by blowing compressed air at a pressureof 300 kPa into the purge port and suitably blockingthe fuel tank port. If air flow through the drain poft isstill restricted, the canister should be renewed.

(0 Apply compressed air at a pressure of 20-35kPa to one of the ports and suitably block the others. Ifany leaks are evident, the canister should be renewed.

3. EXHAUST CONTROL SYSTEM

The exhaust system is the greatest source ofpollutant emissions from the internal combustionengine.


r24

On the range of vehicles covered by this manual,the exhaust control system is largely controlled by theengine management system.

The control unit of the engine management sys-tem constantly monitors the exhaust gases via anoxygen sensor located in the exhaust manifold. Fuelinjection is then adjusted accordingly to give theminimum amount of exhaust emission.

For more comprehensive service procedures,refer to the Fuel and Engine Management section.

CATALYTIC CONVERTER

DescriptionA catalytic converter, which is located in the

exhaust system, converts harmful hydrocarbons,oxides of nitrogen and carbon monoxide present inthe exhaust gases into carbon dioxide, nitrogen, waterand heat.

Installcd view of the catalytic converter.

The catalytic converter does not require periodicmaintenance or replacement under normal circum-stances. However, it can be damaged or poisoned byexcessively high exhaust gas temperatures, raw fueland the use of leaded fuel.

To prevent the use of leaded fuels a small dia-meter fuel filler neck with a spring loaded trap door isused.

To prevent damage to the catalytic converter, thefollowing precautions should be observed.

Do not operate the vehicle on leaded fuel.Do not push or tow start the vehicle.Do not drop the converter as internal damage

could result.Do not allow oil, water or raw fuel to enter the

converter as this will cause contamination of thecatalyst.

Do not operate the vehicle for long periods if theengine is misfiring.

Do not instal used converter flange gaskets.Avoid running the vehicle out of fuel.Ensure that the engine oil and oil additives are

formulated to contain low phosphorus levels.If it is necessary to weld the converter housing, use

only MIG or TIG with stainless steel wire. Do not useoxy/acetylene welders.

To Inspect Catalytic Converter(l) Inspect the converter for dents and damage.

If the converter is excessively damaged, it should berenewed.

(2) Inspect the converter heat shield for damageand ensure that it is positioned correctly. Renew theconverter heat shield if necessarv.

To Remove and InstalTo remove the catalytic converter refer to the

Exhaust System heading in the Engine section.

Ernission Control



r25

CLUTCH

SPECIFICATIONS

Type . . . . . S ing ledryp la teOpera t ion . . . . . . Cab lePressure plate type . Diaphragm springRelease bearing type. . Prelubricated ballDriven plate:

Hub type. Spring cushionOutsidediameter . . .252.7 mmInside diameter 165. lmmT h i c k n e s s . . . 7 . 8 5 - 8 . 3 5 m m

compressed by 740 kg load*Clutch pedal height 168.0 + 2.0 mmRelease lever pivot ball height. . . . 102.0 mm*With pad removed from clutch pedal.


Pressure plate to flywheel bolts 25 NmRelease lever pivot ball locknut 34 NmClutch housing to engine bolts 90 NmClutch pedal pivot bolt 16 Nm

1. CLUTCH TROUBLE SHOOTING

CLUTCH SLIPPING

(l) Incorrectly adjusted clutch cable: Check andadjust the clutch cable.

(2) Weak or broken pressure plate diaphragmspring: Check and renew the pressure plate assembly.

Check the clutch driven plate for wear.

(3) Worn or scored flywheel face: Machine orrenew the flywheel.

(4) Worn or scored Bressure plate face: Renewthe pressure plate assembly.

(5) Worn driven plate facings: Renew the drivenplate.

(6) Oil on the driven plate facings: Renew thedriven plate and rectify the oil leak.

NOTE: In most cases clutch slippage is firstevident by a marked increase in engine revs,for no apparent reason, when pulling up asteep hill. The clutch condition can bepositively diagnosed as follows: With thehandbrake firmly applied and the wheelschocked, place the transmission in top gearand increase the engine speed to approxi'mately I 500 rprn. Slowly release the clutchpedal. Clutch slippage ,s evident if theengine does not stall. Make the test asquickly as possible to prevent any furtherclutch damage.

CLUTCH SHUDDER

(1) Oil on the driven plate facings: Renew thedriven plate and rectify the oil leak.

(2) Loose or broken engine mountings: Checkand tighten or renew the engine mountings as neces-sary.Check the clutch pressure plate for scoring.


r26

(3) Worn driven plate hub or transmission inputshaft splines: Renew parts as necessary.

(4) Loose diiven plate facings: Renew the drivenplate.

NOTE: Clutch shudder is usually mostevident when reversing up an incline. Asloose or damaged engine mountings a.re acause of clutch shudder, thoroughly checkthe engine mounting rubbers and mountinghardware for damage and looseness beforeremoving the clutch for inspection.

Check the engine mountings for deterioration.

INSUFFICIENT CLUTCH RELEASE

(l) Incorrect cltrtch pedal height: Check andadjust the clutch pedal height.

(2) Incorrect release lever pivot ball height:Cleck and adjust the release lever pivot ball height.

(3) Worn or damaged clutch release compon-ents: Check and renew parts as necessary.

(4) Worn pressure plate diaphragm fingers:Renew the pressure plate assembly.

(5) Driven plate hub binding on the transmis-sion input shaft splines: Remove the clutch assemblyand free up or renew parts as necessary.

NOTE: With the engine idling, disengagethe clutch,.wait at least nine seconds andselect reverse gear. Gear clash indicatesinsufrcient clutch release.

RELEASE BEARING NOISE

( I ) Dry or worn release bearing: Check andrenew the release bearing.

(2', Damaged pressure plate diaphragm spring:Check and renew the pressure plate assembly.

NOTE: Lightly depress the clutch pedal withthe engine running to check for release

Check the clutch pressure plate diaphragm fingers forscoring or other damage.

bearing noise. If the release bearing is faultyand has to be renewed alwavs check,theother clutch components.

2. DESCRIPTION

The clutch consists of a single dry driven plate,splined to slide on the transmission input shaft. Adiaphragm spring type pressure plate assembly isbolted to the engine flywheel.

The driven plate is sandwiched betweenpressure plate and the flywheel and transmitsdrive from the engine to the transmission.

Damper springs are interposed between thedriven plate hub and the driven plate facings in orderto cushion the drive.

The release mechanism is activated by the clutchpedal through the clutch cable. The release mechan-ism consists of the release lever, release bearing andthe diaphragm spring in the pressure plate assembly.

On some models, a steel mass damper is weldedto the release lever to suppress vibrations.

Operation of the clutch pedal moves the releasebearing and the diaphragm spring centre towards theflywheel. When the outer edge of the diaphragmdeflects, the clutch is caused to disengage.

3. CLUTCH UNIT AND RELEASE MECHANISM

Special Equipment Required:To Renew Spigot Bush - Suitable extraction toolTo Instal - Clutch aligning tool

TO REMOVE

(l) Remove the transmission from the vehicle asdescribed in the Manual Transmission section.

(2) Disconnect the left hand side engine exhaustpipe from the left hand side exhaust manifold flange.

(3) Disconnect the engine pipe flange at thefront of the catalytic converter.

(4) Loosen the clamp and disconnect the righthand side engine exhaust pipe from the left hand side

Clutch

thethe


engine exhaust pipe. Remove the left hand side engineexhaust pipe from the vehicle.

(5) Loosen the right hand side engine exhaustpipe flange at the right hand side exhaust manifoldand allow the right hand side engine pipe to hang clearof the clutch housing.

(6) Loosen the adjusting nut on the outer clutchcable at the lower end of the cable abutting the clutchhousing.

(7) Lift the rear of the clutch cable cover at theclutch housing and move the cover forward clear ofthe clutch housing.

(8) Disconnect the inner clutch cable from theend of the release lever and pull the clutch cableforward out of the clutch housing.

(9) Secure the clutch cable to one side clear ofthe work area.

(10) Remove the retaining bolts and remove thelower front coyer from the clutch housing.

(11) Remove the retaining bolts and remove theclutch housing from the rear of the engine.

(12) Mark the installed position of the pressureplate cover to the flywheel to aid installation andprogressively loosen the pressure plate retaining boltsusing a diagonal sequence across the assembly.

(13) Remove the pressure plate assembly and thedriven plate assembly from the vehicle noting theinstalled position of the driven plate hub.

(la) Working on the clutch housing, pull therelease lever off the pivot ball and withdraw therelease lever and bearing assembly from the clutchhousing.

(15) Clean the pressure plate and flywheel facesusing a soft cloth moistened with cleaning solvent.

NOTE: Do not use petroleum based solventto clean the above faces.

(16) By gentle brushrng, remove the accumulateddust from the inside of the pressure plate being carefulnot to inhale any of the dust which may containasbestos.

r27

( 17) Wash the release lever and the inside of theclutch housing using a suitable solvent.

NOTE: Do not immerse the release bearingin cleaning solvent as the factory installedlubricant will be destroyed.


(1) Check the driven plate facings for wear,glazing or oil contamination.

Check the hub for weak or broken cushion springsand wear in the centre spline.

Renew the driven plate if wear or damage isfound.

(2) Check the pressure plate assembly for wearon the diaphragm spring fingers, cracked diaphragmspring and a cracked or distorted cover. Check thatthe pressure plate face is not badly scored.

Check the clutch driven plate hub cushion springs forwear or breakage.

(3) Check the flywheel face for heat cracks, burnmarks or scoring. Should the flywheel have scores ordamage which cannot be corrected with emery paper,the flywheel can be removed and a light cut takenacross the face in a lathe.

(4) Check that the transmission input shaft spi-got bush in the end of the crankshaft is serviceable.If necessary renew the bush using the followingprocedure:

(a) Withdraw the bush using a suitable extrac-tion tool.

(b) Clean the bore for the bush and carefullyinstal a new bush using a close fitting mandrel and ahammer.

(c) Apply a few drops of SAE90 gear oil to thenew bush.

(5) Check the release lever for cracks, distortionand wear. Check the pivot ball for wear and measurethe installed height using the following procedure:

(a) Place a straight edge across the front face ofthe clutch housing.

(b) Measure from the top edge of the pivot ballto the straight edge.

Clutch

'ffi

PRESSURE PLATE ASSEIIBLY

DRIVEN PI.ATE

I xtsl376

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EF3-=*=,",o,od tnro**Vh&r

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View of the

DIAPHRAGM SPRING

clutch pressure Plate assemblY,plate and flywheel.


1 2 8

lllustration of the release lever pivot ball heightmeasuring point. Dimension A - 1O2.O mm.

(c) If necessary, loosen the locknut and raise orlower the pivot ball to obtain the specified height.

(d) Tighten the locknut to the specified torqueand check that the height is still correct.

(6) Check the release bearing for noise, wear orroughness.

If the bearing is to be renewed, support thebearing on its outer edge and tap the carrier out of thebearing.

Instal a new bearing so that the thrust face of thebearing is facing away from the lever end of thecatTrer.

TO INSTAL


(l) Sparingly lubricate the splines of the trans-mission input shaft with high melting point molyb-denum disulphide grease. Slide the driven plate ontothe input shaft, withdraw the driven plate and removeany excess grease from the hub and the input shaft.

(2) Position the clutch driven plate onto theflywheel with the cushion spring section towards thepressure plate and the long end of the splined hubtowards the flywheel, as noted on removal.

(3) Instal a clutch aligning tool through thedriven plate and into the spigot bush to hold thedriven plate in position.

(4) Instal the pressure plate to the flywheel,aligning the marks made on dismantling. Instal theretaining bolts finger tight.

NOTE: If installing a new pressure plateassembly, align the white paint marlcs onthe pressure plate with the white paintmarl<s on the flywheel as close as possible.

(5) Tighten the pressure plate retaining bolts

lllustration showing clutch aligning tool. The tool canbe readily fabricated from a length of round sectionwood or metal. Dimension A : diameter of trans-mission input shaft spigot. Dimension B : inside

diameter of driven plate hub.

progressively in a diagonal sequence to the specifiedtorque. Withdraw the clutch aligning tool.

(6) Sparingly lubricate the recess in the releasebearing carrier, the pivot ball groove in the releaselever and the carrier contact surfaces of the releaselever with high melting point molybdenum disulphidegrease.

(7) Instal the release bearing to the release leverand the release lever to the pivot ball.

(8) Ensure that the mating faces of the clutchhousing and the rear of the engine are clean and freefrom burrs and instal the clutch housing to the engine.Tighten the retaining bolts to the specified torque.

(9) Connect the clutch cable to the clutch hous-ing and the release lever and adjust the clutch pedalheight as described later in this section.

(10) Instal the left hand side engine exhaust pipeto the vehicle.

(11) Instal the transmission to the vehicle asdescribed in the Manual Transmission section.

( 12) Road test the vehicle and check for correctclutch operation.

(13) Check and if necessary adjust the clutchpedal height as described later in this section.

4. CLUTCH CABLE


(l) Disconnect the negative battery terminal.(2) Raise the front of the vehicle and support it

on chassis stands.(3) Loosen the adjusting nut on the outer clutch

cable at the lower end of the cable abutting the clutchhousing.

(4) Lift the rear of the clutch cable cover at theclutch housing and move the cover forward clear ofthe clutch housing.

(5) Disconnect the inner clutch cable from therelease lever and pull the clutch cable forward out ofthe clutch housing.

(6) Working inside the vehicle, remove the trimcover from the lower right hand corner of the dash-board.

Clutch

rr6/LD5


I'|

It

tl

Clutch

Viewof the innerclutch cable connectedtothe releaselever. Clutch cable cover removed prior to disconnec'

tion of the cable.

(7) On vehicles with power windows, removethe mounting screws from the power window electri-cal module, disconnect the wiring and remove themodule from the vehicle.

(8) Disconnect the wiring from the stop lampswitch.

(9) Remove the mounting screws from the fuseand electrical module panel and move the panel awayfrom the steering column.

(10) Lift the clutch pedal and disconnect theinner clutch cable from the hook on the top of theclutch pedal.

( 1 I ) Working in the engine compartment, dis-connect the coil spring from the outer clutch cable andpull the clutch cable out of the bulkhead. Note theinstalled positions of the components on the bulkheadend of the outer cable.

(12) Remove the clutch cable from the vehicle.(13) Check the clutch cable for wear, fraying,

kinks or damage. Renew the cable as necessary.Installation is a reversal of the removal procedure

with attention to the following points:(l) Ensure that the components on the bulkhead

end of the outer cable are positioned correctly asnoted on removal.

(2) Lubricate the clevises at both ends of theclutch cable with molybdenum disulphide grease.

(3) Ensure that adequate clearance existsbetween the cable and any exhaust system compon-ents.

(4) Adjust the clutch pedal height as describedlater in this section.

NOTE: Do not fully depress the clutch pedalprior to adjusting the clutch pedal height asdamage could occur to the pressure plateassembly.

(5) Start the engine and increase the speed to

r29

3 000 rpm for l0 seconds, allowing the idle air controlvalve to reset.

(6) On models equipped with a radio/cassetteusing FIN security, enter the PIN code as describedunder the Radio/Cassette heading in the ElectricalSystem section.

5. CLUTCH PEDAL

TO RE,MOVE AND INSTAL

(1) Disconnect the negative battery terminal.(2) Working inside the vehicle, remove the trim

cover from the lower right hand corner of the dash-board.

(3) On vehicles with power windows, removethe mounting screws from the power window electri-cal module, disconnect the wiring and remove themodule from the vehicle.

(4) Remove the screw retaining the right handside floor air duct to the heater assembly and removethe air duct from the vehicle.


(6) Remove the mounting screws from the fuseand electrical module panel and move the panel awayfrom the steering column.

(7) Remove the clutch pedal pivot bolt, lowerthe pedal slightly and disconnect the inner clutchcable from the hook on the top of the pedal.

(8) Disconnect the upper end of the clutch pedalreturn spring from the pedal mounting bracket andwithdraw the clutch pedal from the vehicle.

zoef loro

Dismantled view of the clutch pedal.


130

(9) Remove the bushes and spacer from theclutch Bedal.- (to) Examine the bushes and spacer for wear anddamage. Examine the clutch pedil and

-the leturn

spring for wear, bends, cracks and damage. Renewparts as necessary.


(1) Lubricate the spacer, bushes and pedal borewith molybdenum disulphide grease.

(2) Ensure that the clutch pedal return spring iscorrectly positioned on the pedal and the mountingbracket.

(3) Tighten the pivot bolt to the specified tor-que.

(4) Adjust the clutch pedal height as describedin the following text.



TO ADJUST CLUTCH PEDAL HEIGHT

( 1) Remove the rubber pad from the bottom ofthe clutch pedal.

(2) Roll back the floor covering to expose thefloor panel in the drivers footwell.

(3) Lightly depress the clutch pedal by handuntil resistance from the pressure plate assembly isfelt. Hold the pedal in this position.

(4) Measure the distance from the floor panel to

Clutch

lllustration of the clutch pedal height measuring point.Note that the pad is removed from the pedal. Dimen-

s i o n A - 1 6 8 . 0 + 2 . O m m .

the centre of the metal pad on the bottom of the clutchpedal at 90 degrees to the floor panel.

(5) If the above measurement is not as specified,adjust the outer cable nut at the clutch housing untilthe specified height is obtained.

(6) With the engine idling, operate the clutchand check for correct gear selection.

t



SPECIFICATIONS

Type . . . . 5 speed, synchromesh on all forward gearsModel Borg Warner T5Gear ratios:

First 3.25:lSecond. 1.99:1Third. 1.29:lFourth. 1.00: lFifth . 0.72:lReverse 3.15: I

Gear end float:F i r s t . . . . 0 . 1 8 - 0 . 3 3 m mSecond . 0.18 - 0.76 mmT h i r d . . . 0 . 1 8 - 0 . 6 9 m mF i f t h . . . . 0 . 0 4 - 0 . 9 8 m mLaygear . . . . 0 .013 - 0 .102 mm

Synchro ring to gear clearance:First and second gears.Third and fourth gears.. . . . 0.95 - 1.5 mmFifth gear . 0.7 - 2.0 mm

Mainshaft preload:I d e a l . . . . 0 . 0 5 m mAcceptable range . . 0.025 - 0. 13 mm


Transmission to clutch housing bolts . . 84 NmTop cover bolts 15 NmFiller and drain plugs 40 NmExtension housing to transmissionc a s e b o l t s . . . . . 6 0 N mCrossmember mounting bolts . . . 50 NmFi f th / reversep ivo tp in . . . . 68NmReverse lamp switch . 27 NmI-aygear retainer Tom bolts 20 NmInput shaft bearing retainer bolts 25 NmRear propeller shaft flange coupling bolts . . . 65 NmCentre bearing mounting bolts . . 25 NmSelector cover bolts . 20 Nm

1. TRANSMISSION TROUBLE SHOOTING

DIFFICULT GEAR CHANGE

(1) Worn selector mechanism: Check and renewthe faulty components in the selector mechanism.

1 3 1

(2) Faulty gear synchroniser mechanism: Over-haul the transmission assembly.

(3) Faulty clutch or clutch release mechanism:Check and overhaul the clutch and/or adjust therelease mechanism.

(4) Excessive end float in the transmissionmainshaft: Renew the worn or damaged componentsin the transmission.

NOTE: First check the clutch fo, correctoperation. If reverse gear can be selectedwithout any sign of gear 'clash' this is afairly good indication that the clutch lsfunctioning normally.

Check that the coruect type and viscosityoil is used in the transmiiiion as this canalso cause difficult gear changing.

GEAR CLASH ON CHANGING DOWN

(l) Faulty clutch or clutch release mechanism:Overhaul the clutch and/or adjust the release mechan-ism.

(2) Faulty synchro rings and cones: Check andoverhaul the transmission.

Check the friction surfaces of the synchro rings andcones for wear and damage.

MANUAL TRANSMISSION


r32

(3) Engine idle speed too high: Check the idlespeed.

(4) Broken or incorrect positioning of thesynchro shift plate retaining springs: Check and over-haul the transmission.

(5) Lubricating oil too heavy: Drain the trans-mission and refill with the correct quantity and gradeof oil.

NOTE: Check the clutch for correct opera-tion as previously described before removingthe transmission for dismantling and in-spection. Also check that the correct type oflubricating oil is being used.

SLIPPING OUT OF GEAR

(l) Weak or broken detent springs or compon-ents: Check and overhaul the transmission.

(2) Worn synchroniser assembly, worn synchroring or teeth: Check and overhaul the transmission.

Check the synchronising teeth on all gears andsynchro rings for damage or wear.

(3) Excessive laygear end float: Check andrenew the laygear bearings.

(4) Worn input shaft or mainshaft bearings:Check and renew any faulty components as necessary.

(5) Worn shift forks or selector mechanism:Check and renew any faulty components as necessary.

NOTE: In most cases, slipping out of gear iscaused by wear or damage to internal com-ponents. However, prior to dismantling thetransmission, check that the gear selectormechanism is nat excessivelv worn and isoperating correctly.

TRANSMISSION NOISE (IN NEUTRAT)

(l) Worn transmission front bearing: Overhaulthe transmission and renew the bearing.

(2\ Chipped or pitted constant mesh gears (lay-gear, front drive gear or lst, 2nd, 3rd or 5th speedmainshaft gears): Overhaul the transmission.

Manual Transrncsseon

Check the extension housing oil seal as a likely sourceof leakage if the lubricant is low.

(3) Excessive laygear end float: Check andrenew the laygear bearings.

(4) Insufficient lubricant: Fill the transmissionwith the correct quantity and grade of oil.

NOTE: First check the lubricant level in thetransmission. Transmission front bearingor layshaft bearing noise can be isolated bydepressing the clutch and placing the trans-mission in any gear.

TRANSMISSION NOISE (FORWARD GEARSENGAGED, VEHICLE MOVING)

(l) Worn transmission bearings: Overhaul thetransmission and renew the bearings.

(2) Chipped or pitted gears: Overhaul the trans-mission.

(3) Lack of lubricant: Fill the transmission withthe correct quantity and grade of lubricant.

NOTE: Check the oil level in the transmis-sion before dismantling.

2. PROPELLER SHAFT TROUBLE SHOOTING

SHAFT VIBRATION

(l) Bent propeller shaft: Renew the propellershaft as an assembly.

(2) Excessive wear in the universal joint trun-nion and bearings: Renew the complete universaljoint (trunnion and bearings).

(3) Propeller shaft out of balance: Balance orrenew the complete propeller shaft.

(4) Excessive wear of the front joint sleeve in therear extension housing: Renew the transmission ex-tension housing bush and sleeve.

(5) Rear universal joint to pinion flange boltsloose: Renew and tighten the loose flange bolts.


Manual Transrnrss?on

Checking the rear universal ioint for wear by manualmanipulation.

NOTE: First check that all coupling boltsand nuts are tight. Check the universaljoints for wear by manual manipulation. Itwill be necessary to use a dial gauge orpointer if propeller shaft run out is suspect-ed. Check that the propeller shaft is stillcarrying its balance weights.

EXCESSIYE BACKLASH

( I ) Worn universal joint trunnion and bearings:Renew the joint trunnion and bearings as an assem-blv.

(2) Worn mainshaft and universal joint sleeve:Renew the worn components.

NOTE: Check the universal joints and uni-versal joint splined sleeve for wear by man-ual manipulation. The test should be madewith the transmission in neutral and therear of the vehicle clear of the floor so thatthe rear road wheels are free to turn.

3. DESCRIPTION

The five speed Borg Warner transmission, modelT5, has five forward gears and one reverse gear. Fullsynchromesh is available in all forward gears. Allforward gears are helical cut and in constant meshwith the laygear to provide smooth and quiet opera-tion.

The reverse idler gear is of the sliding gear typeand on engaging, slides into mesh with its matinggears on the mainshaft and laygear.

The laygear nrns on two sets of tapered rollerbearings and end float is adjustable by means of ashim at the front of the transmission.

The mainshaft assembly is supported by a taperedroller bearing located at the rear of the transmission,and a needle roller bearing inside the rear of the input

shaft. End float preload is adjustable by means of ashim at the front of the input shaft.

The input shaft is supported on a tapered rollerbearing located at the front of the transmission and abearing installed in the rear of the crankshaft.

Gear lever movement is transferred to the selectorforks via the gear lever and a single selector rail.

All gears, forward and reverse, with the exceptionof the fifth gear are located inside the transmissioncase. The fifth gear assembly is located in the exten-sion housing.

The first, second and third gears, when notengaged are free to rotate on the mainshaft.

4. TRANSMISSION ASSEMBLY

Special Equipment RequiredTo Dismantle - Suitable Torx sockets and adap-tors, suitable laygear bearing puller, press andpress platesTo Assemble - Dial indicator gauge, micrometer,suitable Torx sockets and adaptors


(1) Disconnect the negative battery terminal.(2) Raise the front and rear of the vehicle and

support it on chassis stands.(3) Drain the transmission oil into a clean drain

tin. Check the oil for foreign particles to assist inlocating worn components if the transmission is to bedismantled and overhauled.

(4) Place mating marks on the propeller shaftrear flange and the differential drive pinion flange toensure replacement to the original position

(5) Remove the coupling bolts from the pro-peller shaft rear flange.

(6) Remove the propeller shaft centre bearingmounting bolts.

(7) Lower the centre bearing and separate thepropeller shaft rear flange from the differential drivepinion flange.

(S) Slide the propeller shaft out of the rear of thetransmission and remove the propeller shaft from thevehicle.

(9) Disconnect the wiring from the vehicle speedsensor located on the extension housing and thereverse lamp switch located on the side of the trans-mission. Secure the wiring to one side clear of thetransmission.

(10) Remove the bolts retaining the stiffener tovehicle underbodv and remove the stiffener fromvehicle.(l l) Disconnect the engine exhaust pipe from the

front of the catalytic converter.(12) Support the transmission on a jack with a

block of wood interposed between the head of the jackand the bottom of the transmission.

1 3 3

thethe


r34

lnstalled view of the manual transmission.

( l3) Working in the engine compartment, discon-nect the air flow duct from the throttle body.

(14) Remove the mounting bolts from the trans-mission rear crossmember.

(15) Remove the nuts retaining the rear transmis-sion mounting to the crossmember and remove thecrossmember from the vehicle.

(16) Carefully lower the jack and remove thebolts retaining the upper gear lever to the transmis-sion gear lever. Raise the upper gear lever clear of thetransmission.

(17) Remove the bolts retaining the transmissionto the clutch housing.

(18) Slide the transmission rearwards clear of theclutch housing. Lower and remove the transmissionfrom under the vehicle.

NOTE: Do not allow the weight of thetransmission to hang on the clutch drivenplate at any time during the removal proce-dure as damage may occur.


(l) Ensure that the mating faces of the clutchhousing and the transrnission are clean and free fromburrs.

(2) Sparingly lubricate the input shaft spigotwith SAE90 gear oil and the splines with high meltingpoint grease prior to installation.

1xn F

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ste%ii,

EXTENSION HOUShIC24s12261615

Manual Transrnosseon

FILLER PU'G

Right hand side view of theremoved from the

DRAIN PLUG

manual transmissionvehicle.

(3) Ensure that the weight of the transmissiondoes not hang on the clutch driven plate at any timeduring installation.

(4) Tighten all bolts to the specified torque.(5) If the transmission has been overhauled and

new paper lined synchro rings were installed, add 150mls of Lubrizol 7906 to the oil when filling thetransmission.

(6) When-1 the engine is started, increase thespeed to 3 000'rpm for 10 seconds, allowing the idleair control valve to reset.

(7\ On models equipped with a radio/cassetteusing PIN security, enter the PIN code as describedunder the Radio/Cassette heading in the ElectricalSystem section.

TO DISMANTLE

(1) Remove the transmission from the vehicle aspreviously described and thoroughly clean the outsideof the transmission.

(2) Remove the retaining bolt and clamp plateand remove the vehicle speed sensor from the trans-mission extension housing.

(3) Remove the retaining bolts and remove theselector cover from the extension housing.

(4) Using a suitable pin punch, remove the rollpin retaining the linking joint to the shift rail.

NOTE: Do not attempt to remove the link-ing joint from the extension housing. Adetent lug on the linking joint prevents itsremoval.

(5) Remove the bolts retaining the extensionhousing to the transmission case.

(6) Separate the extension housing and linkingjoint assembly from the transmission case.

NOTE: Careful taps with a soft faced ham-mer may be necessary to separate the mat-ing faces.

(7) Remove the linking joint, roll pin, detentball and spring from the extension housing.

(8) Remove the top cover retaining bolts. Notethe location of the two dowel bolts.

(9) Carefully lever the top cover away from thetransmission case mating face.

(10) Lift the top cover slightly and slide the covertowards the filler plug side of the transmission case toallow the shift mechanism to clear the groove in thefifth/reverse shift lever.

Remove the top cover from the transmission case.(l l) Depress the clip retaining the speedo drive

and slide the speedo drive rearwards off the main-shaft. Remove the clip from the mainshaft.

(12) Carefully prise the plastic oil guide from therear of the laygear.

(13) Remove the snap ring and the fifth gearsynchro shift plate retainer from the rear of thelaygear.


Manual Transmission

(1a) Support the rear of the shift rail and removethe roll pin from the fifth gear shift fork.

(lstRemove the fifth gear synchro a-s9embly,shift fork and fifth driving gear as an assembly from

the rear of the laygeat.(16) Using long nosed pliers, remove the C clip

retaining the fifth/reverse shift lever to the lever pivotpin.^

(17) Remove the reverse lamp switch from thetransmission case.

(18) Using a suitable Torx socket and adaptor,remove the fifih/reverse pivot pin from the transmis-sion case.

(19) Disengage the fifth/reverse shift lever fromthe fifth/reverse shift mechanism and remove the shiftlever from the transmission case.

(20) Remove the retaining bolts and remove theinput shaft bearing retainer from the front of thetrinsmission case. Note the position of the word TOPstamped on the bearing retainer.

(21) Remove the bearing cup, preload shims andthe seal from the bearing retainer. Note the numberand thickness of the shims to aid assembly.

(22) Rotate the input shaft until the cut awaysection aligns with the laygear and remove the inputshaft and fourth gear synchro ring from the transmis-sion case. Do not drop the thrust bearing or the rollerbearing located in the rear of the input shaft.

(23) Pull the mainshaft rearward and remove themainshaft rear bearing cup from the transmissioncase. It may be necessary to use the mainshaft to jarthe cup loose if difficulty is encountered.

(2a) Raise the front of the mainshaft and lift themainshaft assembly out of the transmission case.

(25) Unhook the reverse inhibitor spring fromthe anchor inside the transmission case.

(26) Pull the fifth/reverse shift rail out of thetransmission case.

(27) Remove the reverse shift fork and the re-verse inhibitor spring from the transmission case.

1 3 5

sTH SHIFT FORK-r-

INHIBITOR

TRANSMISSION CASE

sTH/REV SHIFT RAIL

GEAR SYNCHRO SLEEVE

sTH/REV.SHIFT LEVER

PIVOT PIN

/ - ,

EAR sTH DRIVING GEAR

lllustration of the transmission components removed from the transmission housing. Note that the reverse igear and shaft are not shown.

249tz26tl-Itz8. j t

W -M"ruh, LAMP swtrcH

View of the fifth/reverse shift components.

(28) Remove the roll pin from the front of thereverse idler shaft using a suitable pin punch.

(29) Straighten the tabs on the laygear rear bear-ing retainer and remove the retaining bolts using asuitable Torx socket and adaptor.

(30) Remove the laygear rear bearing retainerand shim from the transmission case.

(31) Remove the laygear rear bearing cup fromthe transmission case. It may be necessary to use thelaygear to jar the cup loose if difficulty is encountered.

(32) Remove the reverse idler shaft out the rear ofthe transmission case. Remove the O ring, gear androll pin from the transmission case.


1 3 6

(33) Using a suitable puller, remove and discardthe laygear rear bearing from the laygear.

(34) Move the laygear rearward, lift the front ofthe laygear and withdraw the laygear from the trans-mission case.

(35) Using feeler gauges, measure the end float ofthe first, second and third mainshaft gears.

To measure the third gear end float use thefollowing procedure:

(a) Ensure that the secoird gear is held against thefirst/second synchroniser and push the third geartoward the second gear.

(b) Holding the gears in the above position,measure the distance between the second and thirdgears.

(c) Pull the third gear away from the second gearand measure the distance between the two gears.

(d) The difference between the two measure-mgnts is the third gear end float.

(36) Using suitable press plates to support third

Manual Transmiss'ion

gear, press the mainshaft out of the third/fourthsynchroniser assembly. Remove the third gear, needleroller bearing and spacer from the mainshaft.

(37) Remoye the snap ring retaining the'fifth gearto the mainshaft.

(38) Using suitable press plates to support firstgear, press the mainshaft out of the fifth gear, the rearbearing and first gear.

(39) Remove the first gear needle roller bearingand sleeve from the mainshaft.

(40) Remove the first gear bearing sleeve locatingpin from the mainshaft.

(41) Remove the first gear synchro ring assembly.(42) Remove the snap ring retaining second gear

to the mainshaft.Remove the thrust washer, second gear, needle

roller bearing and spacer from the mainshaft.(a3) Using a small screwdriver, remove the spiral

snap ring retaining the first/second synchroniser as-sembly to the mainshaft. Remove the thrust washer.

T}IRT'ST WASI{ER

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SPEEDoGEAR

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5TH ORIVING GEAR

lllustration of the mainshaft and laygear components dismantled.


SELECTOR ARM

Manual Tronsmission

IST/2ND SHIFT FORK

INTERLOCK PLATE

249tatt17

r37

points for the first/second synchro ring to gear clear-ance.

(5) Check each synchro assembly for wear anddamage paying particular attention to the shift platesand springs. Renew worn components as necessary.

(6) Check all the roller bearings and cups forpitting and wear. Renew worn bearings as necessary.

NOTE: Do not spin the bearings with com-pressed air as damage to the bearingsand/or injury to the operator could result.

(7) Check all the needle roller bearings fordistortion pitting or wear. Check the running surfacesof the mainshaft and renew parts as necessary.

(8) Check the shift forks and rail for bend, wearand damage. Renew parts as necessary. Check theshift forks for excessive clearance in the synchrosleeves. Renew parts as necessary if excessive clear-ance exists.

24�elLDls

lllustration showing the correct measuring points forthe first/second synchro ring to gear clearance. Xcfearance should be 1 .1 -2.1 mm. Y clearance should

be 2.4 - 3.2 mm.

(9) Where applicable, check the detent springand ball for damage, wear and breakage and renew asnecessary. These components can be deleted withoutaffecting transmission operation.

(10) Check the reverse idler components for wearand damage. Renew parts as necessary.

(l l) Check the transmission breather located inthe extension housing for blockage. Clean as neces-sary.

(12) Renew all the oil seals and O rings.

TO ASSEMBLE

(l) Lubricate all the transmission componentswith the recommended grade of lubricant prior toassembly.

(2) If new paper lined synchro rings are beinginstalled, soak the rings in transmission lubricant forat least ten minutes prior to installation.

(3) Working on the top cover, carefully instal anew O ring to the rear of the cover and assemble usingthe following procedure:

(a) Instal the shift plates and nylon inserts to theshift forks.

NOTE: The shift plates are interchangeable.

Dismantled view of the top cover.

(44) Suitably mark the sleeve in relation to thehub and remove the first/second synchroniser assem-bly from the mainshaft being careful not to lose thedetent ball and spring, where applicable.

NOTE: The Jtrst/second synchroniser hubcannot be separated from the mainshaft.

(45) Suitably mark the sleeves in relation to thehubs and dismantle the third/fourth and fifth gearsynchroniser assemblies. Keep the components ofeach synchroniser assembly separate from the otherassemblies.

(a6) Working on the top cover assembly, markthe position of the shift mechanism components as anaid to assembly.

(47) Position the interlock mechanism in neutraland rotate the shift rail counter clockwise. When theselector arm disengages from the shift plates pull theshift rail rearwards as far as possible.

(48) Using a hammer and punch, remove the nowaccessible shift rail roll pin and withdraw the shift iailfrom the top cover.

(49) Remove the shift forks, shifl plates, interlockplate and selector arm from the top cover.

(50) Remove the O ring from the rear of the topcover.


(l) Wash all the transmission components thor-oughly in suitable cleaning solvent.

(2) Check all the gears for toothwear and renew if necessary.

(3) Check all the shafts for wearRenew worn or suspect shafts.

damage and

and damage.

(4) Check each synchro ring for wear on thecontact face and teeth. Push the synchro ring onto itsrespective gear cone and measure the ring to gearclearance. Renew the synchro rings as necessary.

Refer to the illustration for the correct measuring


1 3 8

(b) Instal the selector arln and interlock plate tothe top cover ensuring that the interlock plate ispositioned in the top cover slot with the selector armroll pin hole towards the rear of the cover.

(c) Position the shift forks in the top cover. Thefirst/second shift fork is the larger and the offset ofboth forks must face the rear of the cover.

The third/fourth shift plate must be positionedunderneath the first/second shift plate.

(d) Instal the shift rail ensuring that the flat isfacing upwards, away from the cover. Align the rollpin hole and instal the roll pin until it is flush with theend of the hole.

(4) Assemble the third/fourth and fifth gearsynchroniser components to the positions marked ondismantling. Ensure that the tangs on the ends of eachshift plate spring locate in the same shift plate and thatthe springs rotate away from the shift plate in oppositedirections.

z+s | r ra

lllustration showing the correct positioning of thesynchroniser shift plate springs.

(5) Where applicable, instal the detent ball andspring to the first/second synchro hub. Instal the shiftplates and the synchro sleeve to the marked positions.

(6) Instal the shift plate springs to the first/second synchro shift plates ensuring that the tangs onthe ends of each shift plate spring locate in the sameshift plate and that the springs rotate away from theshift plate in opposite directions.

(7) Instal the three piece second gear synchroring assembly to the mainshaft ensuring that the outerring slots engage the shift plates and the inner ringsplines engage the mainshaft splines.

(8) Instal the thrust washer and the spiral snapring to the mainshaft.

(9) Instal the spacer, needle roller bearing andsecond gear to the mainshaft. Ensure that the slots inthe gear align with the tab on the synchro ring.

(10) Instal the thrust washer and a new snap ringto the mainshaft.

NOTE: Do not stretch the snap ring as

Ma,nual Transmission

damage could occur to the inner surface ofthe third gear.

(1 l) Instal the first gear bearing sleeve locatingpin to the mainshaft.

(12) Instal the three piece first gear synchro ringassembly to the mainshaft ensuring that the outer ringslots engage the shift plates and the inner ring splinesengage the mainshaft splines.

(13) Instal the first gear bearing sleeve ensuringthat the slot in the sleeve engages the locating pin.

(14) Instal the needle roller bearing and first gearto the mainshaft ensuring that the slots in the gearalign with the tab on the synchro ring.

(15) Instal the rear mainshaft bearing ensuringthat the bearing taper faces the rear of the mainshaft.

(16) Lubricate the splines of fifth gear and themainshaft with transmission lubricant and instal thegear to the mainshaft using a press. Ensure that thefirst gear and rear bearing are held in position whilepressing and that the squared edge of the fifth gearteeth are facing the rear of the mainshaft.

(17) Instal a new snap ring adjacent to fifth gear.(18) Instal the spacer, third gear needle roller

bearing and third gear to the front of the mainshaft.(19) Instal the third gear synchro ring to the

third/fourth synchroniser assembly ensuring that theslots in the ring engage the shift plates.

(20) Press the third/fourth synchro assembly ontothe mainshaft ensuring that the hub offset and the sideof the sleeve with the machined groove or the widechamfer is facing the front of the mainshaft and thatthe third gear synchro ring remains in position.

(21) If necessary to renew the front laygear bear-ing, use the following procedure:

(a) Remove the bearing cone from the front ofthe laygear using a suitable puller.

(b) Support the transmission case around thelocation of the bearing cup using a suitable pipe andpress the cup from the transmission case.

(c) Instal a new O ring to the new bearing cupand coat the cup with Loctite 620 or equivalent.

(d) Support the front face of the transmissioncase on press plates and press the cup into the

z4st226lLD25

/ \I

I

lllustration of the input shaft components dismantled.


Manual Transrnessoon

transrnission case using a suitable mandrel. Instal thecup so that the flange is level with the end of the bore.

(e) Using a suitable tube, press a. new bearingcone onto the front of the laygear.

(22) lf necessary to renew the input shaft bearing,use the following procedure:

(a) Remove the bearing cone from the inputshaft using a suitable puller.

(b) Support the end of the input shaft on pressplates and press the new bearing cone onto the inputshaft using a suitable tube.

(23) Instal a new oil seal to the input shaft bearingretainer ensuring that the lip of the seal faces thetransmission case. Lubricate the seal lip with'trans-mission lubricant.

(24) Prise the oil seal from the extension housingand instal a new oil seal ensuring that the lip of the sealfaces the transmission case. Lubricate the seal lip withtransmission lubricant.

(25) Manoeuvre the laygear into the transmissioncase and place the transmission case upright with thefront face supported on flat, clean press plates.

(26) Position two spacers, 7 mm thick, 15 mmwide and 100 mm long between the front of thelaygear and the transmission case and press a newbearing cone onto the rear of the laygear. Remove theassembly from the press and remove the spacers.

(27) Instal the reverse idler gear to the transmis-sion case with the selector groove towards the rear andinstal the reverse idler shaft through the gear.

(28) Instal a new O ring to the front of the reverseidler shaft and push the shaft fully into the frontsupport aligning the roll pin hole.

(29) Instal the laygear rear bearing cup to thetransmission case.

(30) Instal the shim and the laygear rear bearingretainer, tighten the retaining bolts to the specifiedtorque.

(31) Using a dial gauge with the plunger contact-ing the end of the laygear, measure the laygear endfloat. If necessary, adjust the end float by changing theshims under the laygear rear bearing retainer.

NOTE: Shims are available from 2.55 mmto 3.85 mm in increments of 0.007 and0.008 mm.

(32) When the laygear end float is correct, bendthe lock tabs over the retainer bolts.

(33) Instal the reverse idler shaft roll pin so thatthe pin protrudes equally from each end of the hole.

(34) Connect the long end of the reverse inhibitorspring to the reverse shift fork tang and position thereverse shift fork onto the reverse idler gear.

(35) Manoeuvre the mainshaft assembly into thetransmission case.

(36) Apply multi-purpose grease to the inputshaft bore and instal the roller bearing and the thrustbearing to the input shaft.

(37) Instal the fourth gear synchro ring to the

1 3 9

third/fourth synchroniser assembly ensuring that theslots in the ring are aligned with the shift plates.

(38) Instal the input shaft to the transmissioncase aligning the cut away section with the laygear.

(39) Instal the input shaft bearing cone to thebearing retainer without the preload shim.

(40) Temporarily instal the input shaft bearingretainer to the position noted on removal and tightenthe retaining bolts to the specified torque.

(41) Instal the mainshaft rear bearing cup to thetransmission case.

(42) Instal the fifth driving gear to the end of thelaygear.

IIFT FORK INHIBTTOR SPRING

249ln6lLDttA

lllustration of the transmission case showing thelayout of various components.

(43) Slide the fifth/reverse shift rail through therear of the transmission case, through the reverse shiftfork and inhibitor spring and into the front of thetransmission case.

(aa) Using a pair of long nosed pliers connect thefront of the reverse inhibitor spring to the anchorinside the transmission case.

(45) Instal the synchro ring and the shift fork tothe fifth gear synchroniser assembly and instal theassembly to the rear of the laygear ensuring that thehub offset and the side of the sleeve with the widechamfer is facing towards the rear of the laygear.

(46) Align the holes in the fifth gear shift forkand while supporting the end of the shift rail, instalthe roll pin.

(47) Instal the shift plate retainer and new snapring to the rear of the laygear.

(48) Carefully tap the plastic oil guide into therear of the laygear.

(49) Instal the speedo drive retaining clip to themainshaft and instal the speedo drive ensuring that itis securely held in position by the clip.

(50) Instal the fifth/reverse shift lever to thetransmission case ensuring that the lever correctlyengages the fifth/reverse shift mechanism.


140

(51) Apply Loctite 620 or equivalent to thethreads of the fifth/reverse pivot pin and instal the pinto the transmission case. Tighten the pin to thespecified torque using a suitable Torx socket andadaptor.

(52) Apply sealant to the threads of the reverselamp switch and instal the switch to the transmissioncase. Tighten the switch to the specified torque.

(53) Instal the C clip to the fifth/reverse pivotpin.

(i(-cur

Manual Transmission

Dismantled view of the extension housing.

(5a) Apply a 3 mm bead of RTV Silastic 1080 orequivalent to the top cover mating face and instal thetop cover from the filler plug side of the transmissioncase until the shift forks and the fifth/reverse shiftlever are correctly engaged.

NOTE: Ensure that all the synchronisersand shift forl<s are in neutral to facilitateinstallation of the top cover.

(55) Instal and tighten the top cover retainingbolts to the specified torque. Ensure that the dowelbolts are installed to the positions noted on removal.

(56) Apply a 3 mm bead of RTV Silastic l0E0 orequivalent to the extension housing mating face.

(57) Instal the extension housing over the main-shaft and shift rail until the shift rail just enters theselector housing on the rear of the extension housing.

(58) Coat the detent ball and the detent springwith multipurpose gease and instal the ball to thedetent plate.

(59) Instal the detent spring to the linking jointand push the linking joint into position on the shiftrail while pushing the extension housing into positionagainst the transmission case.

(60) Apply RTV Silastic 1080 or equivalent to thethreads of the two upper extension housing retainingbolts. Instal and tighten all the retaining bolts to thespecified torque.

(61) Instal the linking joint roll pin using asuitable pin punch.

(62) Position the transmission case upright withthe front face resting on the open jaws of a vice.

(63) Mount a dial gauge to the extension housingso that the plunger is contacting the rear of themainshaft.

(64) Push the mainshaft downwards and zero thedial gauge.

(65) Push the input shaft upwards and measurethe mainshaft end float.

(66) Add 0.05 mm to the end float measurementobtained to ascertain the shim thickness requiredbehind the input shaft bearing cup.

(67) Remove the input shaft bearing retainer andremove the input shaft bearing cup.

(68) Instal the required shim behind the inputshaft bearing cup and instal the cup to the bearingretainer.

(69) Apply a 3 mm bead of RTV Silastic 1080 orequivalent to the input shaft bearing retainer matingfaces and instal the bearing retainer to the transmis-sion case.

NOTE: Ensure that the sealant does notcover the oil return slots in the bearingretainer.

(70) Instal and tighten the bearing retainer boltsto the specified torque.

(71) Apply a 3 mm bead of RTV Silastic 1080 tothe selector cover mating face and instal the cover tothe extension housing ensuring that the end of thelower gear lever engages the linking joint.

(72) Instal and tighten the selector cover retain-ing bolts to the specified torque.

(73) Instal the speed sensor and clamp plate tothe extension housing. Instal and tighten the retainingbolts securely.

(74) Select each gear in turn and ensure that thetransmission rotates freely in each gear.

Investigate and rectify any malfunctions.(75) Instal the transmission as previously de-

scribed.

SEI..ECTOR COVER

ttn\..6 S;"""


Manual Transrncssoon

5. PROPELLER SHAFT ASSEMBLY

Special Equipment Required:To Remove and Instal Constant Velocity Joint -

Press and press PlatesTo Renew Centre Bearing - Press and pressplates


( I ) Raise the vehicle to a suitable working heightand support it on chassis stands.

(2) Suitably mark the rear propeller shaft flangeand the differential drive pinion flange to ensurereplacement to the original location, remove thecoupling bolts and nuts from the flanges and separatethe propeller shaft flange from the differential flange.

NOTE: It may be necessary to lightty tap theend of the shaft with a soft hammer to freethe shaft assembly from the drive pinionflange.

(3) Remove the bolts retaining the centre bear-ing support bracket to the vehicle underbody, slide thefront propeller shaft out of the transmission extensionhousing and remove the propeller shaft from thevehicle.

NOTE: Take care when removing the pro-peller shaft from the transmission not tomark or damage the front sleeve as this canlead to rear transmission oil seal failure onassembly.

(4) Plug the end of the transmission extensionhousing to prevent the loss of lubricant and the entryof dirt.

NOTE: A used propeller shaft yoke sleevecan be used for this purpose or a length ofplastic or metal pipe sealed at one end andwith a diameter the same as the yoke sleeveof the propeller shaft. Rag should not bejammed in the end of the transmissionextension housing as this could distort theseal lip causing failure.


(l) Apply Loctite 242 to the centre bearingretaining bolt threads and tighten to the specifiedtorque.

(2) Check and if necessary top up the transmis-sion with the specified lubricant.

UNIVERSAL JOINTS

To Renew

NOTE: Each universal joint is serviced as akit which includes trunnion, seals, snaprings and the needle roller bearings andcups.

t4r

Do not dismantle a universal joint un'less the components are to be renewed. Donot hold the sleeve of the front universaljoint in the unprotected jaws of a vice,otherwise damage will result.

( I ) Remove the propeller shaft assembly fromthe vehicle as previously described.

(2) Remove the snap rings securing the needleroller bearings of the front universal joint.

(3) Support the propeller shaft on a partiallyopened vice and using a metal drift, tap one of thebearing cups in to drive the other bearing cup out ofthe yoke.

BEARING CUPS

BEARING CUPS

Dismantled view of universal joint.

(4) Again using the drift, tap the trunnion of thebearing just removed to drive the other cup back intoand then out of the yoke.

NOTE: The prapeller shaft is balanced tofine tolerances and must not be dented orotherwise damaged.

(5) Manoeuvre the front yoke and trunnion outof the propeller shaft.

(6) Treat the other two bearings of the frontuniversal joint and the bearings of the rear universaljoint in a similar manner to completely dismantle theuniversal joints.

Installation is a reversal of the dismantling proce-dure.

CONSTANT VELOCITY JOINT

To Remove and Instal(1) Remove the propeller shaft frorn the vehicle

as previously described.(2) Mark the front and rear shafts and the

SNAP RINGS


r42 Manual Transrm,sscon

constant velocity joint to ensure correct relocation onassembly.

(3) Remove the six socket head screws securingthe rear shaft to the constant velocity joint.

NOTE: If it is necessary to clamp theassembly in a vice use soft protective vicejaws. Clamp the shaft only on the extrem-ities outward of the weld beads and use onlysufficient pressure to provide a stable work-ing unit. Support the protruding section ofthe shaft.

Do not tighten the vice up to prevent theoverhanging weight of the shaft from rotat-ing the unit in the vice jaws. If pressure ofthe vice is used to do this, distortion of theshaft will occur.

(4) IJse a soft punch and tap the rear propellershaft flange off the constant velocity joint.

(5) Remove the rear snap ring from behind theconstant velocity joint.

(4) Apply sealant to clean, grease free matingareas on the constant velocity joint and dust bootretainer.

(5) Apply sealant to the rear shaft flange and thethreads of the socket head screws.

(6) Tighten the socket head screws securely.

CENTRE BEARING ASSEMBLY

To Renew

NOTE: The centre bearing should not beremoved unless it is faulty. If the centrebearing is removed a new bearing and reardust slinger must be installed.

(l) Remove the constant velocity joint as pre-viously described.

(2) Remove the bolts and nuts from the cupguides and remove the bracket. Straighten the tabs onthe lower cup guide and separate the guides from therubber mounting cup.

(3) Using a suitable punch tap off the bearingrear dust slinger.

(4) Remove the bearing retainer snap ring.(5) Using suitable adaptor plates to fit as Close to

the centre line of the shaft as possible, press off thecentre bearing and mounting cup assembly.

(6) Using a hammer and punch, remove therubber dust slinger from the front shaft.

NOTE: During the above operations takecare not to damage the metal dust slingerwhich is fixed to the shaft.


(1) Instal the rubber dust slinger to the frontshaft using a hammer and tube.

(2) Keep the bearing and shaft clean and freefrom dirt.

T"-t scREwscAsKEr W*=Z[srANr vElocrrY JotNr

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scREws

Dismantled view of constant velocity joint compon-ents.

(6) Tap the dust boot retainer away from theconstant velocity joint and remove the gasket.

(7) Using suitable adaptor plates to providecontact with the inner section of the constant velocityjoint, press the constant velocity joint from the frontshaft.

(8) Remove the thrust washer and remainingsnap ring.

(9) If the dust boot is split or damaged releasethe holding clamps and remove the dust boot.

Installation of the constant velocity joint is areversal of the removal procedure with attention tothe following points:

( I ) Ensure that the parts are clean and free fromdust and foreign matter.

NOTE: It is essential that extreme cleanli-ness is used at assembly of the unit if a fullservice life is to be obtained. If the dust bootis split or perished it must be renewed.

(2) Pack the assembly with 80 g of molybdenumdisulphide grease, working it well into the joint.

(3) Align and instal the parts as marked duringdisassemblv.

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BOL

1241il5

FRONT SHAFT TET BEARING

SHAFT

Dismantled view of centre bearing components.


Manual Transrnesscon

(3) Press the centre bearing and mounting cupassembly onto the shaft by applying pressure to theinner race only.

(4) Instal the retaining snap ring and instal anew rear dust slinger. Use care not to push the reardust slinger too far onto the shaft.

It is important that a small amount of clearance

be maintained betweenslinger.

(5) Instal the uppermounting cup. Bend theguide.

(6) Instal the constant velocity joint as previ-ously described.

r43

the mounting cup and the

and lower cup guides to thetabs over on the lower cuP



AUTOMATIC TRANSMISSION

SPECIFICATIONS

Model Turbo Hydra-Matic 700 R4Type Four forward gears with overdrive,

reverse gear and lock up torque converter

StJI*i,:s: Automatic, hydraulic

First 3.06: ISecond 1.63: IThird 1.00: IOverdrive 0.7:lReverse : .. .

_. 2.29:l

TORQUE WRENCH SETTINGSConverter to drive plate 75 NmConverter housing to engineSelector rod trunnion lock bolt . . 24 NmOil pan bolts il NmC o n v e r t e r h o u s i n g c o v e r . . . . . . . l 0 N mCrossmember mounting bolts 5l NmMounting to crossmember 40 NmKickdown cable retaining bolt . . . l0 Nm

I. AUTOMATIC TRANSMISSION TROUBLESHOOTING

NOTE: The following transmission faultscan be caused by conditions that may berectified within the scope of the infurmationgiven in this section.

NO DRIVE IN ANY RANGE

(1) Low fluid level in the transmission: Checkthe fluid level in the transmission and top up ifnecessary

(2) Incorrectly adjusted selector linkage: Checkand adjust the selector linkage.

(3) Incorrect or contaminated transmissionfluid: Drain and refill the transmission with therecommended grade of fluid.

Check the extension housing oil seal as a likely sourceof leakage.

NO TRANSMISSION KICKDOWN

(l) Incorrectly adjusted throttle cable: Checkand adjust the cable as described in the Fuel andEngine Management section.

(2) Incorrectly adjusted kickdown cable: Checkand adjust the cable as described in this section.

(3) Broken kickdown cable: Renew the cable andadjust as described.

NOTE: Check the throttle cable and kick-down cable for fraying: Adjust the throttlecable before adjusting the kickdown cable.

SLIPPING OR ROUGH IN UPSHIFT

(l) Incorrectly adjusted throttle cable: CheckCheck the oil cooler hose connections fur leaks.


Automatic Tr ansmis sion

and adjust the cable as described in the Fuel andEngine Management section.

(2) Incorrectly adjusted kickdown cable: Checkand adjust the cable.

(3) Kickdown cable sticking: Disconnect thekickdown cable and check for smooth movement.

STARTER MOTOR WILL NOT OPERATE IN PoR N POSITIONS, OR WILL OPERATE IN ANyPOSITION

(l) Incorrectly adjusted or worn selector linkageand bushes: Adjust the selector rod or renew thelinkage and bushes.

(2) Neutral safety switch faulty: Check andrenew as necessary.

NOTE: Check possible causes in the ordergiven.

2. DESCRIPTION

The Turbo Hydra-Matic 700 R4 automatic trans-mission consists of a lock up type torque converterand a hydraulically controlled epicyclic gear systemwhich provides four forward and one reverse gear.

The hydraulic system consists of a pump and avalve body.

The hydraulic fluid is circulated through an oilcooler located in the radiator. The oil cooler isconnected to the transmission by pipes.

The fluid level is checked by a dipstick located inthe filler tube.

The floor mounted selector lever has a lockmechanism to prevent accidental selection of Park orReverse when the vehicle is moving forward.

The overdrive position gives the best vehicleperformance for normal travelling. However, D(drive) position improvesthe perfornance when over-taking or negotiating hilly terrain. 2 (second) or I(first) can be selected when increased engine brakingis required.

It is necessary to select P (park) or N (neutral)when starting the engine.

When tuning or testing the engine, the handbrakemust be firmly applied and the transmission must bein P (park) or N (neutral) otherwise the vehicle maymove when the engine speed is increased.

The vehicle may be towed in N (neutral) fordistances under 55 km at speeds not exceeding55 km/h. If the vehicle has transmission damage, thepropeller shaft must be disconnected from the differ-ential and secured to the underbody, leaving thetransmission sealed against dirt and contamination.

The transmission can be removed from the vehi-cle as an assembly without removing the engine.

NOTE: As extensive knowledge and equip-ment is required to overhaul the automatictransmission, it is not considered a viable

r45

repair proposition for the average person.However, if the transmission must be re-moved for overhaul by a specialist or re-placement by an exchange unit, the removaland installation procedure is described atthe end of this section.

3. TRANSMISSION FLUID

Only the recommended automatic transmissionfluid should be used when topping up or changing thetransmission fluid. Refer to the Specifications in theLubrication and Maintenance section of this manualfor the recommended fluid.

TO CHECK AND TOP UP

(l) Bring the transmission to the normal operat-ing temperature, by idling the engine for 15 minutesor driving the vehicle on the road until the enginetemperature gauge registers the normal temperature.

(2) Park the vehicle on a level surface. With theengine idling and the handbrake firmly applied, movethe selector lever through all the gear positions and

Location of the automatic transmission dipstick.

Checking the automatic transmission fluid level on thedipstick.


146 Automatic Tr a,nsmis sion

select P (Park). Allow the engine to idle in this rangethrouglrout the checking procedure.

(3) Clean around the filler tube and the top ofthe dipstick to ensure that dirt cannot enter thetransmission when the dipstick is withdrawn.

(4) Withdraw the dipstick and wipe it clean on apiece of lint free cloth. Replace the dipstick fully intothe filler tube.

(5) Withdraw the dipstick and check the levelwhich must be at the Full Hot mark on the dipstick.Check the fluid for contamination. discolouration orburnt smell.

NOTE: Dfficulty can be encountered whenjudging the actualfluid level on the dipstick.Repeat operations (4) and (5) above andcheck both sides of the dipstick until the truefluid level is ascertained. Fluid which ,scontaminated, discoloured or smells burntusually indicates a mechanical problemwithin the transmission requiring specialistattention.

(6) If necessary, add a sufficient quantity of therecommended fluid through the filler tube to bring thelevel to the Full Hot mark on the dipstick. Allow areasonable period of time for the fluid to drain out ofthe filler tube to avoid a false reading when the level ischecked.

NOTE: Do not overfill the transmission orfoaming and unsatisfactory operation of thetransmission may result. If it has beennecessary to add a substantial quantiiy ofJluid to the transmission the cause of thefluid loss should be immediately in-vestigated and rectified.

It is difrcult to gain an accurate fluid level checkif the vehicle has been operated in ambient tempera-tures above 32 deg C, at sustained high speeds, in citytraffic in hot weather, or as a towing vehicle.

In any of the above circumstances, allow thetransmission to cool for approximately 30 minutesbefore checking the fluid level.

TO DRAIN AND REFILL I

(l) Ensure that the transmission is cold, raise thevehicle and support it on chassis stands placed clear ofthe work area.

(2) Clean the outside of the transmission oil panand the area of the transmission housing around theoil pan mating face.

(3) Position a suitable drain tin under the trans-mission oil pan, prefqrably the drain tin should belarger in area than the oil pan to avoid fluid spills.

(4) Remove the oil pan retaining bolts in adiagonal sequence leaving the front bolts loosely inposition.

(5) Carefully tap the corner of the oil pan to

View of the transmission with the oil pan removed.

Removing the filter from the transmission.

separate the oil pan from the transmission housingand tilt the oil pan to allow the fluid to drain.

(6) Remove the remaining front bolts from theoil pan and remove the oil pan from the transmission.Drain the remaining fluid into the drain tin. Checkthe fluid and the bottom of the oil pan for abnormalmetal and friction material particles which would'indicate an internal mechanical problem.

(7) Clean the inside of the oil pan and the oil panand transmission housing mating faces.

(8) If necesSsry, remove the filter from thetransmission.

(9) Instal the new filter and O ring, ensure thatthe filter is correctly located.

(10) Instal the oil pan, using a new gasket, instaland tighten the retaining bolts to the specified torquein a diagonal sequence.


Automatib Tr ansrnis slon

View of the transmission with the filter removed.

(l l) Lower the vehicle to the ground and refillthe transmission with new fluid approximately thesame amount as drained. Refer to the Lubrication andMaintenance section. Carry out the procedure de-scribed previously under the heading To Check andTop Up.

4. KICKDOWN CABLE


(1) Disconnect the inner cable from the throttlelinkage.

(2) Disconnect the outer cable from the mount-ing bracket on the throttle body.


Disconnecting the inner kickdown cable from thetransmission link.

(4) Remove the kickdown cable retaining boltfrom the transmission housing.

(5) Lift the kickdown cable out of the trans-mission and disconnect the inner cable from the trans-mission link.

(6) Remove the kickdown cable from the ve-hicle.


(1) Renew the seal at the transmission end of thecable prior to installation of the cable.

(2) Tighten the retaining bolt to the specifiedtorque.

(3) Adjust the cable as described in the followingtext.

TO ADJUST

(1) Ensure that the throttle cable is correctlyadjusted as described in the Fuel and Engine Manage-ment section.

(2) Depress the metal tab and pull the outercable away from the throttle linkage until the end ofthe cable contacts the adjuster fitting. Release themetal tab.

Installed view of the kickdown cable showing thelocation of the metal tab.

(3) Fully open the throttle valve. The cable willmove through the adjuster fitting and automaticallystop at the correct position when the throttle valve isopened fully.

5. SELECTOR LINKAGE

TO ADJUST

(1) Raise the front of the vehicle and support iton chassis stands. Securely apply the handbrake.

(2) Loosen the bolt retaining the trunnion to thetransmission selector lever.

(3) Working inside the vehicle, place the vehicleselector lever in P (park).

(4) Working Uineaftr the vehicle, place the trans-mission selector lever in P (park).

147


148

View of the selector linkage adjustment point.

(5) Tighten the trunnion retaining bolt to thespecified torque.

(6) Remove the chassis stands and carefullylower the vehicle to the ground.

(7) Road test the vehicle and check for correcttransmission operation.

(8) Check that the neutral safety switch is oper-ating correctly.

6. NEUTRAL SAFETY SWITCH


(1) Disconnect the negative battery terminal.(2) Carefully prise the rear of the console cover

from the centre console. Disconnect the wiring con-nectors, turn the cover 90 degrees and manoeuvre itover the selector lever handle.

(3) Remove the gear position scale and trim, theslide indicator and the indicator support.

(4) Remove the screws retaining the support

Automatic Tr ansrnts st on

assembly to the centre console, disconnect the qua-drant lamp connector and remove the support assem-bly from the vehicle.

(5) Disconnect the wiring connector from theneutral safety switch.

(6) Remove the neutral safety switch retainingscrews and manoeuvre the switch from the vehicle.


(l) Ensure that the switch operates correctly andthat the reverse lamps operate when reverse gear isselected.

NOTE: The neutral safety switch is notadjustable. Adjustment is automatic whenthe prevtously desuibed selector linkageadjustment is performed.



7. TRANSMISSION ASSEMBLY

Special Equipment Required:To Remove and Instal - Suitable trolley jack towhich the transmission can be secured.


(1) Disconnect the negative battery terminal.(2) Raise the front and rear of the vehicle and

support it on chassis stands.(3) Drain the transmission fluid as previously

described.(4) Remove the bolt retaining the filler tube to

the converter housing and pull the filler tube out of thetransmission. Remove the filler tube from the vehicle.Plug the hole in the transmission to prevent the entryof dirt.

(5) Remove the propeller shaft from the vehicleas described in the Manual Transmission section.

(6) Remove the engine exhaust pipes from thevehicle as described in the Engine section.

(7) Remove the retaining bolt and disconnectthe kickdown cable from the transmission. Secure thecable to one side clear of the transmission.

(8) Remove the bolt retaining the trunnion tothe selector lever.

(9) Disconnect the wiring from the speed sensoron the transmission extension housing.

(10) If applicable, disconnect the speed sensorwiring from any clips on the transmission and securethe wiring to one side clear of the transmission.

(l 1) Remove the retaining bolts and remove thecover from the bottom of the converter housing.Installed view of the neutral safety switch.


Right hand side view of the automatic transmissionremoved from the vehicle.

KICKDOWN CABLE ADJUSTER

Automati,c Tr ansmis sion 149

Attach a strap to the torque converter housing toretain the converter during removal and installation of

the transmission.

(20) Remove the bolts retaining the converterhousing to the rear of the engine.

(21) Instal a metal strap to the converter housingto retain the converter in position.

(22) Carefully manoeuvre the transmission rear-wards until the torque converter is clear of the driveplate, lower the transmission and withdraw the trans-mission from under the vehicle.

NOTE: The transmission and convertermust be removed from the engine as anassembly.


( 1) Ensure that the converter housing and enginemating faces are clean and free from burrs.

(2) Ensure that the torque converter is installedto the marked position on the drive plate.

(3) To prevent damage to the seals on assembly,instal the new kickdown cable and filter tube seals intothe transmission.

(4) Tighten all bolts to the specified torque.

ELECTRICAL CONNECTOR

Left hand side view of the automatic transmissionremoved from the vehicle.

(12) Mark the torque converter in relation to thedrive plate and remove the bolts retaining the torqueconverter to the drive plate.

NOTE: Rotate the engine by means of thecranl<shaft pulley to gain access to theconverter bolts.

(13) Disconnect the wiring from the electricalconnector on the left hand side of the transmission.

(14) Remove the stiffener retaining bolts andremove the stiffener from the underbody.

(15) Remove the bolts retaining the rear mount-ing to the transmission.

(16) Support the transmission on a trolley jackwith a piece of timber interposed between the head ofthe jack and the oil pan. Secure the transmission to thejack.

(17) Remove the crossmember mounting boltsand remove the crossmember from the vehicle.

( l8) Lower the trolley jack and support the rearof the engine using a chassis stand and timbercontacting the sump mounting rail.

(19) Disconnect the oil cooler pipes from thetransmission. Plug the ends of the pipes and thetransmission fittings to prevent the entry of dirt. lnstalled view of the driveplate.


1 5 0

(5) Adjust the kickdown cable and selector lin-kage as previously described.

(6) If the transmission has been overhauled or ifan exchange unit is being installed, pour approximate-ly I I litres oftransmission fluid into the transmission.Refer to the Lubrication and Maintenance section.

With the engine cold (running in Park) the levelshould be 16 mm below the Full Hot mark on thedipstick.

Increase the engine speed to 3 000 rpm for l0

Aut om a tic T r an s rnls s r,o n

seconds, allowing the idle air control valve to reset.(7) On models equipped with a radiolcassette

using PIN security, enter the PIN code as describedunder the Radio/Cassette heading in the ElectricalSystem section.

(8) Road test the vehicle. Check that the level ison the Full Hot mark on the dipstick with thetransmission at the normal operating temperature.Refer to the heading To Check and Top Up for thecorrect procedure.



l 5 l

REAR AXLE

SPECIFICATIONS

Type . . Salisbury type, semi-floating axleshafts with hyPoid final drive

Model Borg Warner 78 seriesPinion bearing preloadadjustment.. . Col lapsiblespacerPinion and carrier bearing types . . . . Tapered rollerPinion preload:

Old bearings without pinion seal . . 0.8-1.4 NmNew bearings without pinion seal . 1.6-2.8 Nm

Carrier bearing preload adjustment . . . . ShimsCarrier preload:

Old bearings without axlesor pinion installed . 0.5-1.4 NmNew bearings without axlesor pinion installed . 1.1-2.8 Nm

Axle shaft bearing type . . . Tapered rollerAxle shaft end float:

Old bearings . . . Maximum 0.76 mmNew bearings . . 0.40-0.48 mm

Crownwheel to pinion backlash 0.10-0.18 mmRatio . . 3.08:1Fluid:

Type . . . Hypoid gear oil LS 90 GL5Capacity

TORQUE WRENCH SETTINGS*Crownwheelbol ts . . .Bearing cap bolts . . . 60 NmDifferential carrier cover bolts. . . 3l NmAxle shaft retaining plate nuts.Limited slip differential case bolts . . . . 45 NmUpper suspension arrn to axle housingb o l t s . . . . 7 5 N mLower suspension ann to axle housingb o l t s . . . 1 1 0 N mLower shock absorber mountings . . . . . 29 NmPanhard rod to axle housing nut . 70 NmStabiliser lower mounting nut . . . 10 NmStabiliser bar to axle housing nut 18 Nm

*Left hand thread

1. REAR A}GE TROUBLE SHOOTING

REAR WHEEL NOISE

(1) Wheel loose on the axle flange: Check the

condition of the axle and wheel and tighten or renewthe faulty components.

(2) Defective brake components: Overhaulbrakes as described in the Brakes section.

(3) Defective axle shaft bearing: Removeaxle shaft and instal a new bearing.

(4) Bent axle housing or shaft: Renew thehousing or shaft.

the

the

axle

With the axle shaft removed, turn the bearing by handto check for roughness.

(5) Wheel bent or out of balance: Renew thewheel or balance the wheel and tyre assembly.

NOTE: Check the wheel nuts for tightness.Raise and support the rear of the vehicle andspin the wheels to check for run out. Axleshaft bearing noise can be diagnosed byspinning one wheel at a time and listeningfor a rumble. When carrying out the bearingtest place the transmission in neutral andstop the other side wheelfrom turning. If theaxle shaJt is suspected of being bent removethe axle shaft and checkfor run out betweencentres.

FINAL DRIVE GEAR NOISE

(1) Lack of lubricant: Rectify the leak and top upwith the correct grade of lubricant.

(2) Loose bearing cap bolts: Torque the bolts toSpecifications.

(3) Loose pinion nut: Tighten the pinion nut.Check the pinion preload.


r52

Final drive gear noise can also be caused by internaldamage or wear.

NOTE: Check possible causes in the ordergiven. Final drive gear noise can also becaused by internal damage or wear, inwhich case the rear axle assembly will haveto be removed for overhaul. In most cases ifthe dffirential assembly is damaged it isbest to instal an exchange unit.

REPEATED AXLE SHAFT BREAKAGE

(l) Bent axle housing: Renew the housing.(2) Repeated overloading: Revise the load

capacity.(3) Abnormal clutch operation: Revise driving

habits or check the clutch condition.

NOTE: If the clutch is operating coruectlyand overloading is not the cause check therear axle housing for bend.

PINION SHAFT WILL ROTATE BUT NOTDRIVE VEHICLE

(l) Broken axle shaft: Check and renew the axleshaft.

(2) Sheared crownwheel bolts: Renew thecrownwheel bolts.

the crownwheel and bearing caPtightness.

NOTE: Withdraw the axle shafts and checkfor breakage. Remove the dffirential coverand check the crownwheel bolts. It lsimperative that all foreign metal particlesare removed from the rear axle beforerefilling with oil.

LOSS OF LUBRICANT

(l) Leaking drive pinion oil seal: Renew the oilseal and inspect the flange.

(2) Leaking axle shaft oil seal: Renew asnecessary.

Check the rear axle breather for blockage as internalpressure can force lubricant out of the seals.

(3) Leaking cover plate gasket: Renew thegasket.

(4) Porous or cracked rear axle assembly: Repairor renew as necessary.

NOTE: Check the breather for cloggingbefore thoroughly washing down the rearaxle assembly and checking for leaks. If oilleakage is not apparent when the rear axle iscold, run the vehicle on the road until therear axle reaches ,operating temperature.

Rear Axle

Check the drive pinion oil seal as a l ikely source of oilleakage.

Check bolts for


Rear Axle

Check thoroughly for small craclcs in therear axle housing. Normally small craclcs donot open up and leak oil until the rear axlereaches operating temqerature.

LIMITED SLIP DIFFERENTIAL OPERATINGNOISE

(1) Whirring sound: This noise does not indicatefailure of the differential, it is usually caused byseverely unbalanced drive conditions.

(2) Groaning or chattering noise: Possible lubri-cation failure. Drain and refill the differential usingthe correct lubrication. Road test, if the noise remainsremove the differential and inspect.

NOTE: If a limited slip dffirential rsinstalled ensure that both rear tyres areexactly the same size.

2. DESCRIPTION

The Borg Warner 78 series Salisbury type rearaxle is of the semi-floating type with hypoid finaldrive gears.

The crownwheel and differential assembly is car-ried on tapered roller bearings. Axial adjustment ofthe assembly controlling the bearing preload andcrownwheel to pinion backlash is obtained by the useof spacer shims installed between the bearing outercups and the differential housing abutments. Shimsare also used to obtain pinion height position.

Pinion bearing preload is controlled by a collap-sible spacer installed between the inner cones of thefront and rear pinion bearings.

Axle shaft and bearing assemblies and axle shaftand pinion oil seals can be removed and installedwithout removing the axle housing from the vehicle.

Removal and installation of the axle assembly isrecommended to facilitate the dismantling, assem-bling and adjusting procedures of the differential.

The tapered roller type axle shaft bearings areinstalled from the splined end of the shaft to abut alocating shoulder on the shaft, and are retained by acollar which is an interference fit on the shaft andwhich bears against the bearing inner race.

The axle shaft oil seals are located outboard of theaxle bearing assemblies on the axle shafts, therefore ifthe oil seal is faulty the bearing must be removed togain access to the oil seal. It is recommended that oncethe axle bearing assembly has been pressed from theaxle shaft it should be discarded and a new bearinginstalled in its place.

The oil seals have a sleeve built into the outercircumference which contacts the retaining plate andthe bearing rib ring to retain the bearing cup intoposition in the axle tube flange.

1 5 3

3. AruE SHAFT AND BEARING

Special Equipment Required:

To Remove Axle Shaft - Slide hammerTo Renew Bearing - Vertical press and pressplates


(1) Raise the rear of the vehicle, support it onchassis stands and remove the relevant wheel.

(2) Remove the caliper anchor plate retainingbolts and lift the caliper off the brake disc.

(3) Place a spacer approximately as thick as thebrake disc between the brake pads and support orsuspend the caliper out of the way without stretchingthe brake hose.

(4) Remove the brake disc from the axle.(5) Prior to removal of the axle shaft, measure

the axle shaft end float. Mount a dial gauge with theplunger positioned against the axle flange and movethe axle shaft in and out. If the end float exceeds themaximum end float Specification the axle bearingmust be renewed.

(6) Working through the access hole in the axleflange, remove the nuts from the axle shaft retainer.

(7) Using a slide hammer secured to the axleshaft, remove the axle shaft.

NOTE: If a puller is not available, reversethe brake disc and loosely instal it on theaxle flange bolts with the wheel nuts. Usethe disc assembly as a slide hammer typepuller. Under no circumstances may the discbe hammered.

(S) If necessary, carefully remove the bearingcup from the axle housing using a slide hammer anda suitable adaptor.

Installation is a reversal of the removal proceduretaking care to engage the axle shaft with the dif-ferential side gears.

NOTE: On vehicles equipped with a limitedslip differential, ensure that the axle shaft isnot rotated until the opposite rtxle shaft isinstalled or misalignment of the cone andside gears will result.

TO RENEW BEARING AND OIL SEAL

(l) Remove the axle shaft as previously de-scribed.

(2) Drill a 6 mm hole into the bearing retainer atright angles to the axle shaft ensuring not to drillcompletely through the retainer as damage to the axleshaft will result.

(3) Resting the bearing retainer on an anvil, splitthe retainer with a cold chisel across the hole pre-viously drilled.

(4) Using a press and press plates, support the


t54

. .i_"]t*{+iisn+*_

BEARING

Removing the rear axle bearing retaining col lar.

bearing inner cone and press the axle shaft from thebearing. Discard the bearing.

(5) Remove the oil seal and retaining plate fromthe axle and discard the oil seal.

(6) Check the retaining plate for wear or dis-tortion, renew if necessary.

(7) Clean the axle shaft and inspect the bearingseat surface and oil seal surface to ensure that there isno damage.

NOTE: Use of a suitable press and pressplates are essential when renewing the bear-ing. If these are not available the shaftassembly should be taken to a reliableworlcshop for bearing installation.

(8) Instal the retaining plate to the axle shaftwith the flat side facing away from the axle flange.

B E A R I N G

Dismantled view of axle shaft.

Rear Axle

(9) Apply grease to the cavity between the seal-ing lips of the new oil seal and instal it to the axle shaftwith the lips facing away from the axle flange.

(10) Position the new bearing on the axle shaftensuring that the machined groove on the outer race istowards the axle flange.

(l l) Check that the bearing is squarely posi-tioned on the axle shaft and instal the new bearingretainer.

(12) Press the bearing and retainer on the axleshaft simultaneously using the press and press plates.

(13) Lubricate the bearing with the specifiedlubricant.

(14) Instal the axle shaft as previously describedin this section.

4. DRIVE PINION OIL SEAL

TO RENEW


(2) Mark the relationship between the propellershaft and the pinion flange, remove the retaining boltsand nuts and disconnect the propeller shaft from thepinion flange.

223t735

",!*,ffi,P-COLLAPSIBLE SPACER

!il*ffiJ;" "l c(

Dismantled view of the drive pinion.

(3) Mark the pinion nut, the pinion flange andthe pinion shaft to ensure correct assembly.

(4) With the aid of an assistant applying thebrakes, remove the pinion nut and washer.

(5) Place a container beneath the pinion flangeand remove the pinion flange and dust cover.

NOTE: If difficulty is encountered in remov-ing the pinion flange, a suitable puller willbe required.

(6) Prise the oil seal from the rear axle housingand discard.

(7) Allow the lubricant to drain then clean theseal surface and inspect for damage.

(8) Lubricate the lip of the new seal with grease.Lightly coat the outer surface of the new seal with anon-hardening sealant and tap the seal squarely intothe axle housing.

(9) Coat the pinion flange splines and seal sur-face with grease and instal the pinion flange to thepinion shaft ensuring that the marks made on removalare aligned.

R E T A I N I N G


Rear Axle

(10) Instal the pinion nut and washer andtighten the nut until the marks made on removal atealigned then tighten to a position not more than fivedegrees past the alignment setting.

(11) Instal the propeller shaft to the pinionflange aligning the marks made on removal. Instal theretaining bolts and tighten to 65 Nm.

NOTE: It is imperative that all markedcomponents are assembled in the sameposilion as they were prior to dismantling. If-the

pinion flange nut is tightened exces-sively then the collapsible spacer may col'lapsb, causing excessive preload on thepinion bearings.

(12) Check and if necessary top up the rear axlewith the correct grade of lubricant.

(13) Remove the chassis stands and lower thevehicle to the ground.

(14) Road test the vehicle and check that thereare no oil leaks at the oil seal.

NOTE: If renewal of the oil seal fails torecttfu the oil leakage, thoroughly clean therear axle housing in the vicinity of the oilseal and check for a porous axle housing.

5. COVER PI.ATE GASKET

TO RENEW


(2) Remove the Panhard rod lower mountingnut and washer. Disconnect the Panhard rod from therear axle housing and push the rod out of the way.

(3) Remove the securing bolt from the brakeunion bracket and unclip the brake pipe from thecover plate.

(4) Place a container beneath the cover plate andloosen the retaining bolts sufficiently to allow the oilto drain.

1 5 5

Underbody view showing the rear axle assembly.

(5) Remove the cover plate bolts and man-oeuvre the cover plate from the vehicle.

(6) Clean all traces of gasket from the axlehousing and cover plate ensuring that no pieces of thegasket fall inside the axle housing.

(7) Coat both sides of the new gasket with asuitable sealer and place the gasket on the axlehousing.

(8) Instal the cover plate and retaining bolts andtighten the bolts to the specified torque.

(9) Instal the brake union to the bracket and clipthe brake pipe to the cover.

(10) Instal the Panhard rod nut and washer, donot tighten at this stage.

(1 l) Fill the rear axle with the correct grade andquantity of lubricant. Remove the container frombeneath the vehicle.

(12) Lower the vehicle to the ground and tightenthe Panhard rod retaining nut.

6. DIFFERENTIAL AI{D FINAL DRIVEASSEMBLY

Extensive knowledge and specialised equipmentis required to carry out internal repairs to the dif-ferential and final drive assembly.

As the cost of the equipment required normallyexceeds repair costs by a specialist or a factoryexchange unit, it is not a worthwhile proposition forthe owner/driver or the person of limited knowledgeand equipment to attempt the overhaul procedure.


1 5 6 Rear Axle

OR|lJE

'.r/ ToE oF ToorH-

Ol|tRDRIUt

Crownwheel Tooth Marking for Correctly Adiusted Crownwheel and Pinion. Marking will be slightly Closer toof Tooth on Overdrive or Concave Side. Changes in Thickness of Pinion Positioning Shims will Afrect Tooth Maron Overdrive to Greater Extent than on Drive oi Con""r Side of Tooth. Changes in-Backlash have a more Pronour

E$ect on Drive Side Markings (All models.)

CENTRE i lARKING CENTRE TOE

80/P83

HEEL HIGH TOE HIGH

Hieh Pro{ile Markins on Both Sides of Crown"!:"J*lfftti[T:[t?I In"'".sins of Pinion Posiiionins Shims and R

TOE OF TOOTH

HEEL SLIGHTLY HIGH

TOE LOIV HEEL LOIV

Low Profile Marlcing on Both Sides of Tooth. Rectify by Reducing Thickness of Pinion Positioning Shims and RBacklash (Al l models.)

/1-

, \

TOE CENTRE. TOE SLIGHTLY LOW

Toe Marking on Drive Side and Low Profile Marking on Overdrive Side of Crownwheel Toofh. To Reciify, IncrBacklash. lt

-may be Necessary fo Increase Thickness of Pinion Posiiioning Shims to Maintain Backlash within Spec

Limitr (All models.)

HEEL CENTRE

Heel Marking on Drive Side and High Profile Marking on Overdrive Side of Crownwheel Tooth. To Rectify, Re<Backlash. lt fiay be Necessary to DJcrease Thickness if Pinion Positioning Shims to Maintain Backlash within'Speci

Limik (All models.)


Rear Axle

Specifications, illustrations and a tooth markingchart are included in the section for those who mayfeel competent and sufficiently equipped to undertakethe operation.

7. REAR A)(LE ASSEDIBLY


(l) Raise the rear of the vehicle and support iton chassis stands placed under the jacking points.Chock the front wheels.

(2) Remove the rear wheels.(3) Remove the propeller shaft as described in

the Manual Transmission section.(4) Disconnect both handbrake cables from the

actuating levers. Refer to the Brakes section forfurther information.

(5) Disconnect the hose from the underbodybrake pipe union and plug the pipe and hose toprevent fluid loss and the entry of dirt.

(6) Remove the brake hose retaining clip anddisconnect the hose from the bracket.

(7) Raise the rear axle slightly using a trolleyjack, disconnect the shock absorber lower mountingbolts and push the shock absorber up to clear the axlehousing.

(8) Remove the nuts, washer and the rubberbushes from the lower ends of the stabiliser bar linksand pull the stabiliser bar clear of the links. Removethe nut and washer from the Panhard rod lowermounting and push the rod up out of the way.

(9) Lower the jack and axle assembly sufficientlyto remove the coil springs. Remove the coil springsand insulators from the vehicle.

(10) Remove the botts and nuts securing the rearaxle assembly to the upper and lower suspensionarrns.

(l l) Ensure that the rear axle is securely sup-ported by the trolley jack. Disconnect the uppersuspension anns from the axle housing, slightly raiseand move the assembly rearwards to clear the lowercontrol arms. l,ower the jack and remove the assem-bly from the vehicle.

Rear suspension and axle assembly removed from thevehicle.

r57


NOTE: If an exchange or secondhand rearaxle assembly is being installed, ensure thatthe correct assembly is obtained.

(1) Instal the upper suspension arm bolt towardsthe centre of the vehicle but do not tighten.

(2) Ensure that the propeller shaft is installed tothe mark made on removal.

(3) Bleed the brakes as described in the Brakessection.

(4) Tighten all the bolts and nuts to the specifiedtorque with the weight of the vehicle on the suspen-sion.

(5) Fill the rear axle with the specified grade andquantity of lubricant.

8. LIMITED SLIP DIFFERENTTAL

Special Equipment Required:To Test - Axle shaft adaptor

DESCRIPTION

The limited slip differential unit is almost identi-cal with that of the conventional unit regarding gearand preload settings and general maintenance aspects,but testing, operating procedures and precautions areslightly different.

The differential case, in addition to the normalconventional components, houses two cone typeclutches splined to the axle shaft and positionedbehind the side gears and these correspond withmatching faces machined into the differential case.

Three preload springs enclosed in the centre of thepinion cross shaft and interposed between the twoside gears, preload the gears and cones and force thetapered face of the cones into contact with the matingfaces in the case.

The cone arrangement directs the major drivingforce to the rear wheel with greater traction, but itdoes not interfere with either the differential action orsteering characteristics.

The partial locking action resulting from thespring load on the cones is increased by the inherentseparating forces between the side gears and pinionswhich progressively increase the resistance as thetorque is increased. Where there are extremely un-balanced traction conditions between the wheels, suchas one wheel on hard or dry surface and the other onslippery or soft material, a conventional differentialwill tend to transmit the bulk ofthe power to the wheeloffering the least resistance if over acceleration isattempted, resulting in wheel spin and loss of vehiclemotion. With the limited slip differential unit how-ever, when there is any tendency for wheel spin tooccur the increased friction generated by the conestransfers the bulk of the driving force to the non-

ROD


1 5 8

spinning wheel providing continued traction andvehicle motion.

TO TEST (PRIOR TO DISMANTLING)

Any chatter emanating from the differential sidecones may be due to lack of lubricant between thecone friction surfaces. To ensure lubrication of thefriction surfaces proceed as follows:

( t ) Drive the vehicle at approximately ten kilo-metres per hour and execute five left and right handturns on full steering lock.

(2) If the chatter is still noticeable, it may benec.essary to change the lubricant.

(3) Should the chatter still persist, after carryingout operations (1) and (2) it will be necessary todismantle the differential for further examination.

To check the differential for correct operationcarry out the following test:

(l) Raise one side of the vehicle at the rear andsupport it on a chassis stand. Remove the wheel.

(2) With the transmission in neutral, chock thefront wheels and release the handbrake.

Rear Axle

Dismantled view of the limited slip differential.

(3) Remove the rear brake disc as described inthe Brakes section.

(4) Instal the special tool (which is an adaptor toenable a standard torque wrench to be attached) onthe wheel studs.

(5) Using a torque wrench of sufficient range,rotate the axle and note the torque required to do so.

NOTE: Rotation of the axle should require aminimum of 68 Nm.

(6) In the event of the torque not being asspecified, it will be necessary dismantle the differentialfor further examination.

(7) Carry out the same test on the opposite siderear wheel.

NOTE: Never run the engine with the trans-mission in gear and one wheel raised. Thedriving force transmitted by the cone ar-rangement may cause the vehicle to move.

#p1'e r#

cr@;

{@d:*ffi#

lpwsryr

b @O @



1 5 9

STEERINGPART I. STEERING TROUBLE SHOOTING

FAULTS, CAUSES AND REMEDIES

EXCESSIVE PLAY OR LOOSENESSIN STEERING

(1) Tie rod end loose or worn: Tighten or renewthe worn tie rod end.

(2) Steering gear assembly loose on cross-member: Inspect for damage and tighten the steeringgear mounting bolts.

(3) Steering gear worn: Overhaul the steeringgear.

(4) Worn or loose intermediate shaft couplingassembly: Tighten or renew the worn couplingassembly.

NOTE: Looseness in the steering linkage isbest assessed with the weight of the vehicleon the front wheels.

Have an assistant turn the steeringwheel from left to right while the inspectionfor wear is being made. If looseness is foundto be in the steering gear, then it will benecessary to overhaul the steering gear o,s-sembly.

HEAVY STEERING

(l) Low or uneven type pressures: Check the

Check for fluid leaks at the pipe fittings.

tyres and inflate to the recommended pressure.(2) Low fluid level in the power steering reser-

voir: Check for leakage, repair and/or renew the faultycomponents, top up the fluid level.

(3) Suspension worn or out of alignment: Checkthe front suspension for wear, renew the worn com-ponents and realign.

(4) Misalignment between the steering gear andcolumn mountings: Check and align the steering gearand column mountings.

(5) Binding in the intermediate shaft joints:Check the joints and renew the intermediate shaftcoupling assembly if necessary.

(6) Insufficient power steering pump pressure:Check the pump drive belt tension and the reservoirfluid level, if necessary renew the pump assembly.

NOTE: Ensure that both front tyres haveample depth of tread and are inflated to thecorrect pressure. Check the front suspensioncomponents for wear before having thesteering geometry checked. See the FrontSuspension section for component checkingprocedure.

STEERING PULLS TO ONE SIDE

(1) IJneven tyre wear or pressure: Check thecondition of the tyres and inflate to the recommendedpressures.

Check the tie rod end rubber boot for deterioration andthe tie rod end ball joint for wear.


160

(2) Incorrect front wheel alignment: Check andalign the front end.

(3) Dragging brakes: Check each wheel for drag-ging brakes. Overhaul the brakes as necessary.

(4) Damaged suspension or crossmember: In-spect and renew the damaged components.

(5) Faulty hydraulic valve in the power steering:Check and renew the pinion valve assembly.

NOTE: If the tyre condition and wheelalignment are satisfactory, raise thefront ofthe vehicle and spin both front wheels tocheck for brake drag.

FRONT WHEEL WOBBLE OR SHIMMY

(l) IJneven tyre wear or incorrect tyre pressures:Check the condition of the tyres and inflate to therecommended pressures.

(2) Tyre or wheel unbalance: Check and balanceas necessary.

(3) Worn of badly adjusted hub bearings: Checkthe condition and adjust the front hub bearings.

(4) Faulty or worn suspension units. Check andoverhaul or renew as a pair.

NOTE: Check the steering linkage as pre-viously desuibed. Raise the front of thevehicle and check the adjustment of the hubbearings by working the road wheel in andout at the top and bottom. No perceptiblemovement in the bearings should be felt.Check the suspension uiits as outlined inthe Front suspension section

STEERING ERRATIC OR WANDERING

(l) Incorrect or uneven wheel alignment setting:Check and adjust the steering geometry.

(2) Smooth front tyres: Check and renew thetyres as necessary.

(3) Steering gear assembly loose on cross-member: Inspect for damage and tighten the steeringgear mounting bolts.

(4) Wear in the tie rod assembly: Renew theworn tie rod assembly.

(5) Wear in the rack and pinion: Overhaul therack and pinion assembly.

(6) Loose or incorrectly adjusted hub bearings:Check and adjust the front hub bearings.

Check the steering gear mounting bolts for tightness.

NOTE: Incorrect or uneven camber is in-dicated by uneven wear of the tyres. Thevehicle will have to be set up on a reliablewheel alignment machine and the errorcorrected.

Loss of lubricant due to deterioratedrubber boots will cause premature wear tothe tie rod ball joints.

FAILURE OF POWER ASSISTANCE

( I ) Loose or broken engine drive belt: Renew theengine drive belt as described in the Engine Tune-upsection.

(2) Low fluid level in the power steering reser-voir. Check for leakage, repair or renew the fuultycomponents. Top up the fluid level.

(3) Insufficient power steering pump pressure:Check the engine drive belt tension indicator and thereservoir fluid level, if necessary renew the pumpassembly.

(4) Faulty power steering gear assembly: Re-move and overhaul the power steering gear assembly.

NOTE: When a power assistancefailure hasoccurred, the vehicle should only be driventhe minimum distance necessaryfor repairsto be carried out.

Steering - Part I


l 6 l

PART 2. POWER STEERING

SPECIFICATIONS

Steering gear type . . . Variable ratio rackand pinion with integral

power cylinderSteering column type . Collapsible energy

absorbingLinkage

tie rods and steering armsTurns lock to lock. 2.68Ratio

Rack centre 17.2:lRack ends 11.8:1

, Steering pump:Make SaginawType Droop flow vane impellerPressure at idle speed . 9 300 - l0 000 kPaDrive. PulleyBelttension. . . . Self adjusting

Fluid:Type . . . Dexronl lCapacity Approximately 650 mls

Rack pad adjustment Tighten to 12 Nmthen loosen 25 - 30 deg


Pump mounting bolts 54 NmReservo i rmoun t ingsc rews . . . . . 2 .5NmPump pulley bolts . . . 20 NmS t e e r i n g g e a r m o u n t i n g n u t . . . . . 5 6 N mTie rod assembly to rack . 100 NmTie rod end castellated nut. . . . . . 7l NmRack pad locknut . . . 65 NmRack bearing retaining screw . . . . 60 NmPinion bearing nut . . 45 NmPinion bearing screw. 60 NrnPinion valve housing screws 6 NrnIntermediate shaft upper bolt and nut . 30 NmIntermediate shaft lower bolt and nut . 22 NmSteering column mounting nut 16 NmSteering wheel nut. . . 22 Nm

1. DESCRIPTION

The power steering gear is a variable ratio rack,and pinion type incorporating a torsion bar and rotarycontrol valve and spool to control and direct'thehydraulic pressure to the appropriate side of thepower piston which operates in a cylinder incor-porated in the rack housing.

Hydraulic pressure is supplied to the power steer-ing gear by a pump which is belt driven from theengine crankshaft pulley. A fluid reservoir is mountedto the top of the pump assembly.

No lubrication of the steering gear is required inservice and in the event of a loss of power assistance

the steering will continue to operate but with greatlyincreased effort. However, as the steering gear andpump are lubricated by the power steering fluid, thecause of the fluid ,loss must be determined andrepaired promptly to prevent damage to the powersteering pump and, to a lesser extent, the steering gear.

The steering gear is connected to the steering armsby tie rods which have non-repairable ball jointsattached to the rack and sealed non-repairable tie rodends attached to the steering arms.

The assembly is protected against the entry ofwater and dust by a seal on the pinion shaft and bycomrgated rubber boots which are clamped at one endto the steering gear housing and at the other end to thetie rod. The boots expand and contract with themovement of the rack.

The steering column shaft is connected to thesteering gear by a flexible intermediate shaft and thesteering column assembly is a collapsible typedesigned to absorb secondary impact in the event of asevere front end collision.

2. PRELIMINARY INSPECTION AND TESTING

If the power steering system becomes partially orfully inoperative it is most important that the follow-ing preliminary inspection and testing procedure beperformed prior to undertaking any trouble shootingor repair operations.

ENGINE DRIVE BELT

Inspection, adjustment and renewal of the enginedrive belt is fully covered in the Engine Tune-upsection.

TO CHECK FLUID LEVEL

The fluid level is checked at the fluid reservoirwhen the fluid is at operating temperature. The fluidlevel must be at or slightly below the H indicatormarked on the reservoir dipstick.

(l) Ensure that the vehicle is level. Inspect thelevel indicated on the reservoir dipstick.

(2) If the fluid level is low top up with thespecified fluid. Do not overfill.

(3) If the reservoir is dry, the system must bebled as described under In Car Adjustments andMinor Repairs in this section.

TO CHECK FOR FLUID LEAKS

(1) Using a suitable solvent clean around allpower steering assemblies and hose fittings wherefluid leakage may occur and then start the engine.

(2) Turn the steering wheel from lock to lockseveral times, contacting the lock stops lightly andstop the engine.


r62

Checking the power steering fluid level. The fluid mustbe at or slightly below the indicator at operating

temperature.

Check for fluid leaks at the pipe fittings.

(3) Check for leakage. Where leakage is found atthe pipe fittings, tighten and recheck. Where leakage isfound at the steering pump specialist attention isnecessary. Where leakage is found around the top ofthe reservoir, remove the cap and check the capbreather holes for blockage.

3. IN CAR ADJUSTMENTS AI{DMINOR REPAIRS

TO BLEED SYSTEM

(1) Check the fluid level and top up if necessaryas previously described.

(2) Raise the front of the vehicle so that the frontwheels are clear of the ground and support it onchassis stands.

(3) With the engine stopped, turn the steeringwheel from lock to lock several times. Top up the fluidas necessary. Repeat until the fluid level remainsconstant.

Steering - Part 2

(4) Start the engine. With the engine at idlespeed, turn the steering wheel from lock to lockseveral times, contacting the lock stops lightly.

(5) When no air bubbles appear in the fluidreservoir and the fluid level remains constant, thesystem can be considered bled.

(6) Turn the wheels to the straight ahead posi-tion, stop the engine and lower the vehicle to theground.

TO REMOVE AND INSTAL POWER STEERINGLINES

(l) Raise the front of the vehicle and support iton chassis stands.

(2) Position a container under the steering gear.(3) Disconnect the fluid lines from the steering

gear and allow the fluid to drain into the container.(4) Loosen the hose clamp and disconnect the

hose from the reservoir.(5) Disconnect the high pressure line from the

pump. Plug the pump and steering gear to prevententry of dirt.

(6) Manoeuvre the lines from the vehicle.(7) Remove and discard the O rings from the

power steering lines.Installation is a reversal of the removal procedure

with attention to the following points:(l) Ensure that new O rings are installed to the

power steering lines.(2) Tighten the unions and hose clamp securely.(3) Ensure that the lines are routed correctly.(4) Refill and bleed the power steering system

and check for leaks as previously described in thissection.

4. STEERING WHEEL

Special Equipment Required:To Remove Steering Wheel - Steering wheelpuller.


(l) Disconnect the negative battery terminal.(2) Remove the horn pad by pulling the pad

from the steering wheel.(3) Remove the steering wheel retaining nut and

mark the relationship of the steering wheel to thesteering shaft to aid in the correct positioning oninstallation.

(4) Using a suitable puller, remove the steeringwheel from the steering shaft. Remove the spring.

NOTE: Do not strike the end of the puller orthe steering shaft as sharp blows can causeirreparable damage to the collapsible steer-ing shaft.


Steeri,ng - Part 2

Installed view of a steering wheel puller.


(1) Lubricate the horn contact with a suitablegrease prior to installation.

(2) Ensure that the mark on the steering wheeland steering shaft are aligned.

(3) Apply Loctite 242 to the threads of theretaining nut and tighten to the specified torque.

View of the steering wheel and components removedfrom the vehicle.

(4) Connect the negative battery terminal andcheck the operation of the horn. Ensure that the turnsignal switch self cancels.

Start the engine and increase the speed to 3 000rpm for 10 seconds allowing the idle air control valveto reset.


5. STEERING COLUMN

Special Equipment Required:To Remove Steering Wheel - Steering wheelpuller.

TO REMOVE

(1) Disconnect the negative battery terminal.(2) Remove the steering wheel as previously

described.(3) Open the fuse cover by turning the retainer at

each side 90 degrees.(4) Using aflatbladed screwdriver, prise out the

hinge pin at the left hand side and remove the cover.(5) From under the dashboard remove the

screws and fasteners securing the lower trim panel andremove the panel.

Installed view of the power window module.

Mark the relationship of the intermediate shaft to theclamp prior to removal.

1 6 3

HORN PAD


t64

INTERMEDIATE SHAFTMOUNTING

,/

IGNITION SWITCH

rcMNON

ff\PwSTEERING COLUMN LQryVER BEARING

The asterisk indicates late model components

CKI,IG PLUG

HOUSTNGft:

UPPER BEARING

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! ^ | 6 I st;ryryPI*V1' 'WASHERS

UPPER

LOCK[,lG

Steering - Part 2

BRACKETS

\

Steering column removed from the vehicle.

(6) On vehicles equipped with power windows,remove the mounting screws from the power windowmodule. Lower the module and disconnect the wiringharness. Remove the module from the vehicle.

(7) Remove the screws retaining the upper andlower covers to the steering column, maneouvre thecovers from the vehicle.

(8) Disconnect the wiring harness connectorsfrom the ignition switch, combination switch andhorn contact. Release the wiring harness from thesteering column and move it to one side.


(10) From under the vehicle mark the relation-ship of the intermediate shaft to the lower clamp.

( I I ) Remove the upper bolt and nut on thelower clamp.

(12) Remove the steering column mounting nutsand manoeuvre the steering column from the vehicle.

TO DISMANTLE, INSPECT .A,ND ASSEMBLE

(l) Remove the boot from the lower end of thesteering column.

(2) Remove the intermediate shaft upper clampbolt and nut and slide the intermediate shaft from thesteering shaft.

(3) Remove the retaining snap ring and washerwhere applicable, and withdraw the spring and washerfrom the upper end of the steering shaft.

(4) Remove the locking plugs retaining the up-per bearing housing to the steering column, turn the

SNAP RING LOCKhtc pLUG

STEERING SHAFT

I

S*,TCH BO"-B

housing anti-clockwise and withdraw it from thecolumn.

(5) Turn the ignition switch to the On positionand withdraw the steering shaft from the column.

NOTE: Do not strike or apply load to thesteering column or shaft as this may causeirreparable damage to the collapsible com-ponents.

(6) If the steering column lower bearing is to berenewed proceed as follows:

(a) Securely hold the lower end of the steeringcolumn tube in a vice equipped with soft jaws.

(b) Using a drift, drive the bearing and sealassembly from the lower end of the steering columntube and discard.

(c) Instal the new bearing assembly ensuring thatthe sealing lips are facing away from the steeringcolumn. The bearing is correctly installed when theouter edge is 9-11 mm from the lower end of thesteering column tube.

(d) Instal a new seal assembly to the lowersteering column tube. The seal assembly is correctlyinstalled when the metal cap is flush with the end ofthe steering column tube.

(7) Inspect the steering column tube for collapseby measuring from the end of the lower column tubeto the top of the upper bracket. Dimension should be356.5-359 ffirn, if not within Specifications thecolumn tube must be renewed.

INTERMEDIATE SHAFT

Dismantled view of the s-teering column components.


356.5to 359mm

Steering - Part 2 1 6 5

Check the steering column and

(8) Inspect the steering column shaft for collapseby measuring from end to end. Dimension should be662 ffiD, if not within Specifications the steeringcolumn shaft must be renewed.

(9) Inspect the intermediate shaft universal jointfor wear, damage or binding and renew as necessary.

(10) Inspect the rubber boot for cracks ordeterioration and renew as necessary.

(l 1) Check that the steering lock operates freely.(12) Inspect the steering column upper bearing

and if necessary renew as described in this section.Assembly is a reversal of the dismantling pro-

cedure with attention to the following points:(1) Ensure that the steering column lower bear-

ing assembly is not disturbed when installing thesteering shaft.

(2) Instal new locking plugs to the upper bearinghousing.

(3) Instal the intermediate shaft ensuring thatthe bolt hole aligns with the groove in the steeringshaft.

(4) Tighten the bolts to the specified torquesettings.

(5) Ensure that the steering column boot iscorrectly installed.

(6) Instal the steering column as described underthe following heading.

TO INSTAL


(l) Instal the steering column and intermediateshaft ensuring that the marks made on removal arealigned.

(2) Ensure that the steering column boot iscorrectly installed to the floor panel.

(3) Tighten the steering column mounting boltsto the specified torque settings.



steering shaft for collapse.


TO RENEW STEERING COLUMN UPPERBEARING

(l) Remove the steering wheel as previouslydescribed in this section.

(2) Remove the screws retaining the upper andlower covers to the steering column, manoeuvre thecoYers from the vehicle.

(3) Depress the retaining clips on the com-bination switch and remove it from the bearinghousing.

(4) Remove the wiring from the horn contact.(5) Remove the retaining snap ring and washer

where applicable, and withdraw the spring and washerfrom the upper end of the steering shaft.

(6) Remove the locking plugs retaining the up-per bearing housing to the steering column, turn thehousing anti-clockwise and withdraw it from thecolumn.

(7) Mount the housing in a soft jawed vice.(8) Prise the locking tangs away from the bearing

using a fine bladed screwdriver.(9) While applying pressure to the bearing, dis-

Dismantled view of the steering column upper bearinghousing.


r66

Cross sectional view of the steering column upperbearing housing showing the location of the locking

tangs and locating lugs.

engage the locating lug from behind the bearing anddrive the bearing from the housing.

(10) Instal the new bearing ensuring that thelocating lugs are correctly seated behind the bearing.

( I 1) Using a pin punch and hammer, locate bothlocking tangs to the groove in the upper bearing.

(12) Instal the upper bearing housing and instalnew locking plugs.

(13) Instal the turn signal switch and horn wire.(14) Instal the upper and lower covers.(15) Instal the spring and steering wheel.(16) Tighten the steering wheel retaining nut to

the specified torque setting.

6. INTERMEDIATE SHAFT ASSEMBLY


(1) Remove the steering column as previouslydescribed in this section.

(2) Remove the boot from the lower end of thesteering column.

(3) Remove the intermediate shaft upper clampbolt and nut and slide the intermediate shaft from thesteering shaft. i

Installation is a reversal of the removal procedureensuring that the bolt hole in the intermediate shaftaligns with the groove in the steering shaft.

7. POWER STEERING GEAR ASSEMBLY

Special Equipment Required:To Remove Tie Rod Assembly - Suitable spanneror large StillsonsTo Instal Tie Rod Assembly - Suitable torquewrench adaptor

As extensive knowledge and specialised equip-ment is required to overhaul the power steering gear,it is not a worthwhile repair proposition for theaverage person.

However, if the power steering gear is to beremoved for overhaul by a specialist or if it is to bereplaced by an exchange unit, the removal and in-stallation procedures are described in this section.

The procedures to renew the corrugated rubberboots, the tie rod ends and the tie rod assemblies aredescribed later in this section.


(l) Raise the front of the vehicle and support iton chassis stands. Remove the front wheels.

(2) On manual transmission models disconnectthe clutch cable as follows:

(a) Back offthe adjusting nut on the clutch cableat the clutch housing.

(b) Lift the rear of the clutch cable cover andmove it to one side to allow access to the clutch cable.

(c) Disengage the cable from the clutch releaselever.

(d) Remove the clutch cable by pulling towardsthe front of the vehicle. Remove the cover.

(3) Place a container under the power steeringgear.

(4) Disconnect the power steering lines from thesteering gear and allow the fluid to drain into thecontainer. Plug the lines and steering gear to preventthe entry of dirt.

(5) Mark the relationship of the intermediateshaft lower clamp to the steering gear pinion andremove the lower clamp lower bolt and nut.

(6) Remove the split pins and castellated nutsfrom the tie rod ends.

(7) Place a hammer or dolly against one side ofthe steering arm and strike the other side with ahammer. Disconnect the tie rod end from the steeringarm. Ensure that the nylon spacers on the tie rod endstuds are in good condition and secure. If necessaryrenew the nylon spacers.

(8) Remove the bolts, nuts and washers retain-ing the steering gear assembly to the front suspensioncrossmember.

(9) Manoeuvre the steering gear away from thesuspension crossmember and slide the steering gearpinion from the lower clamp.


Steering - Part 2

NUT NTERMEDIATE SHAFTg'r' - --7

HWB 24el6e8B

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lntermediate shaft removed from the vehicle.


Steering - Part 2 r67

lnstalled view of the power steering gear.

(l) Ensure that the power steering gear is centra-lised, this is achieved by rotating the pinion from lockto lock and halving the rotations. The white lines onthe pinion and the steering housing should align.

(2) Ensure that the steering wheel is centralised.(3) Ensure that new O rings are installed to the

power steering lines.(4) Tighten all bolts, nuts and lines to the

specified torque setting where applicable.(5) Instal new split pins to the tie rod end

castellated nut.(6) On vehicles equipped with manual trans-

mission, connect and adjust the clutch cable.(7) Refill and bleed the power steering system


(8) Check and if necessary adjust the toe in asdescribed in the Front Suspension section.

TO RENEW TIE ROD END

(1) Raise the front of the vehicle and support iton chassis stands. Remove the front wheel.

(2) Loosen the tie rod end locknut.(3) Remove the split pin and castellated nut

from the tie rod end.(4) Place a hammer or dolly against one side of

the steering arm and strike the other side with ahammer. Remove the tie rod end from the steeringarm. Ensure that the nylon spacer on the tie rod end isin good condition and secure. If necessary, renew thenylon spacer.

(5) Mark the installed position of the tie rod endon the tie rod and remove the tie rod end.


(1) Ensure that the new tie rod end is positionedto align with the marks made on removal.

(2) Tighten the tie rod end castellated nut to thespecified torque setting.

(3) Instal a new split pin to the castellated nut.(4) Check and if necessary adjust the toe in as

described in the Front Suspension section.

TO RENEW CORRUGATED RUBBER BOOT

(1) Remove the tie rod end as previouslydescribed.

(2) Remove the tie rod end locknut.(3) Remove the clip retaining the rubber boot to

the tie rod by sliding the ends of the clip sideways todisengage the locking teeth.

(4) Remove the clip retaining the rubber boot tothe steering gear by pushing out the centre pin using athin pin punch.

(5) Slide the rubber boot along the tie rod andremove the rubber boot from the vehicle.

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Tie rod dismantled showing components.


r68

(6) Turn the steeringgear to full lock and checkthat the rack lubricant is not contaminated or gritty,indicating the presence of dirt.

(7) If necessary, clean the rack and coat thesliding surfaces and the teeth with EP Semi fluidlithium'based type O grease.

Apply the grease to the corrugations in the rubberboot and instal the rubber boot to the steering gear byreversing the removal procedure. Ensure that therubber boot retaining clips are installed correctly andsecure.

NOTE: Position the front wheels straightahead before installing the outer ends of therubber boot in the machined groove in thetie rod and tightening the outer retainingclips.

(8) Instal the tie rod end as previously described.

TO RENEW TIE ROD ASSEMBLY

(1) On some models it may be necessary toremove the steering gear as previously described. Ifthis is not necessary, remove the tie rod end aspreviously described.

(2) Remove the comrgated boot as previouslydescribed.

(3) To remove the right hand tie rod turn thesteering to full left hand lock.

(4) Straighten the tabs of the lockwasher on theright hand tie rod.

(5) Using a suitable spanner grip thesection of the steering rack.

(6) Using a suitable spanner or largeloosen and remove the right hand tie rodrack and discard the lock washer.

exposed

Stillsons,from the

(7) To remove the left hand tie rod rotate thesteering until the left hand tie rod joint is exposed.

(8) Using the method described in operations(4), (5) and (6) remove the left hand tie rod from therack.


(1) Instal the new lock washers to the steeringrack ensuring that the tangs are located in the slots ofthe rack ends.

(2) Using a suitable adaptor, tighten the tie rodassembly to the specified torque setting.

(3) Bend the tabs of the lock washer against theflats of the tie rod to secure.

(4) Instal the rubber boots and tie rod ends aspreviously described.

8. POWER STEERING PUMP

As extensive knowledge and equipment is re-quired to overhaul the power steering puhp, it is not aworthwhile repair proposition for the average person.

However, if the power steering pump is to be

Dismantled view of the power steering pump andcomponents.

removed for overhaul by a specialist or it is to bereplaced by an exchange unit, the removal and instal-lation procedures are described as follows.


(1) Loosen the power steering pump pulley re-taining bolts.

Steering - Part 2

o R'NG--S

+CAP

PUMP ASSEMBLY

PUMP PULLEYBOLTS

Installed view of the power steering pump.


(2) Using a ring spanner, rotate the tensioneranti-clockwise and remove the engine drive belt fromthe vehicle, release the tensioner.

(3) Remove the power steering pump pulleyretaining bolts and remove the pulley.

(4) Place a container beneath the power steeringpump assembly.

(5) Loosen the low pressure hose clamp anddisconnect the hose from the reservoir.

(6) Loosen the high pressure line union anddisconnect it from the power steering pump. Discardthe O ring.

(7) Plug the hoses and pump to prevent the entryof dirt.

Steering - Part 2

Dismantled view of the power steering pump.

r69

(8) Remove the reservoir mounting screws anddisconnect the reservoir from the pump assembly.

(9) Remove and discard the reservoir O ring.( l0) Remove the power steering pump mount-

ing bolts and remove the pump from the vehicle.Installation is a reversal of the removal procedure

with attention to the following points:(l) Ensure that a new O ring is installed to the

reservoir and high pressure line.(2) Tighten all mounting screws and bolts to the

specified torque settings.(3) Refill and bleed the power steering system


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170

PART 3. MANUAL STEERING

SPECIFICATIONS

Steering gear type . . . Variable ratio rackand pinion

Linkage . . . . Direct from rack ends to tierod and steering arms

Turns lock to lock. 4.48Ratio:

Rack centre 19.7:lRack ends. . 23.3:l

Rack pad adjustment Tighten to 12 Nmthen loosen 25 - 30 degrees

TORQUE WRENCH SETTINGSSteering gear mounting nut .Rack pad locknut . . . 65 NmP i n i o n r e t a i n i n g s c r e w . . . . 6 0 N m

1. STEERING GEAR ASSEMBLY

Special Equipment Required:To Remove and Instal Pinion Retaining Screw -Suitable tanged socketTo Measure Pinion Rotating Torque - Suitabletorque gaugeTo Instal Tie Rod Ball Joint - Suitable torquewrench adaptor


(l) Raise the front of the vehicle and support iton chassis stands. Remove the front wheels.

(2) On manual transmission models, disconnectthe clutch cable as follows:

(a) Back offthe adjusting nut on the clutch cableat the clutch housing.

(b) Lift offthe rear of the clutch cable cover andmove it to one side to allow access to the clutch cable.

(c) Disengage the clutch cable from the clutchrelease lever.

(d) Remove the clutch cable by pulling the cabletoward the front of the vehicle. Remove the cover.

(3) Mark the relationship of the inrermediateshaft lower clamp to the steering gear pinion andremove the clamp lower bolt and nut.

(4) Remove the split pins and castellated nutsfrom the tie rod ends.

(5) Place a hammer or dolly against one side ofthe steering arm and strike the other side with ahammer to disconnect the tie rod ends from thesteering arms. Ensure that the nylon spacers on the tierod end studs are in good condition and secure. Ifnecessary, renew the nylon spacers.

(6) Remove the bolts, nuts and washers retain-ing the steering gear assembly to the front suspensioncrossmember.

(7) Manoeuvre the steering gear away from thesuspension crossmember and slide the steering gearpinion from the intermediate shaft lower clamp.


(1) Ensure that the steering gear is centralised.This is achieved by rotating the pinion shaft until it ismidway between its lock to lock rotations. The whitelines on the pinion and steering housing should align.

(2) Ensure that the steering wheel is centralised.(3) Tighten all bolts and nuts to the specified

torque settings.(4) Instal new split pins to the tie rod end

castellated nuts.(5) On manual transmission models, connect

and adjust the clutch cable.(6) Check and if necessary adjust the toe in as

described in the Front Suspension section.

TO DISNIANTLE

(l) Remove the steering gear assembly from thevehicle as previously described and clean the outsideof the assembly using a suitable solvent.

(2) Mount the steering gear assembly in a viceequipped with soft jaws, gripping the left hand sidemounting boss.

(3) Remove the corrugated rubber boots as pre-viously described in the Power Steering section.

(4) Rotate the pinion fully anti-clockwise andgrip the exposed section of the rack ensuring that thevice is equipped with soft jaw guards.

(5) Straighten the lock washer on the tie rodjoint and disconnect the joint from the rack using asuitable spanner. Remove the right hand side tie rodand joint assembly.

/ 238/693

View of the manual steering gear removed from the vehicle.

TlE ROD


Steering - Part 3 1 7 r

(6) Rotate the pinion clockwise, grip the lefthand end of the rack in the vice and repeat operations(4) and (5). Remove the left hand side tie rod and jointassembly.

(7) Grip the left hand side mounting boss in thevice and loosen the rack pad adjusting screw locknut,remove the locknut and remove the rack pad adjust-ing screw. Discard the O ring from the rack padadjusting screw.

(8) Remove the spring, nylon washer and rackpad from the steering gear housing.

(9) Using a suitable tanged socket, remove thepinion retaining screw from the steering gear housing.

( l0) Remove the pinion and bearing assemblyfrom the steering gear housing. If necessary, positionthe jaws of a l3 mm open end spanner in the piniongroove and tap on the spanner with a soft facedhammer to remove the pinion.

NOTE: The pinion and bearing are servicedas an assembly and no attempt should bemade to separate the bearing from thepinion.

(l 1) Partially slide the rack out of the right handside of the steering gear housing until the rack end isfree of the bush in the left hand end of the steering gearhousing.

(12) Position the steering gear housing uprightresting on one end of the rack and the other end of therack positioned against the bush in the left hand endof the steering gear housing.

(13) Using suitable snap ring pliers in the holes

provided in the rackbush, compress the rackbush anduse the rack to push the bush out of the steering gearhousing. Discard the O rings from the bush.

(14) Remove the rack from the steering gearhousing.

(15) Remove the oil seal from the pinion retain-ing screw.


(1) Clean all the components of the steering gearin suitable solvent and blow dry with compressed air,if available.

(2) Inspect the pinion bearing for wear androughness while turning the bearing by hand. Do notspin the bearing with compressed air. Renew thepinion and bearing assembly if the bearing is worn ordamaged.

(3) Inspect the pinion teeth for wear and da-mage.

(4) Inspect the rack teeth and sliding surfaces forwear and damage. Do not mistake the normal lightlypolished surfaces on the rack for wear.

(5) Inspect the lower pinion bearing in thesteering gear housing for wear and damage. Thebearing cannot be removed from the steering gearhousing. Renew the steering gear housing assembly ifthe bearing is unserviceable.

(6) Inspect the steering gear housing for cracks,wear and damage. Renew the steering gear housing ifcracks, wear or damage are detected.

(7\ Inspect the rack pad, the nylon washer and

FFSz- LOCKNUT

w

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o- oRING

spRrNG -*Qtg F | r r r l v f f i

NYL.N *ASHER -&-

JF- NYLoN TNSERT O RINGS

/ \$ry0

SPLIT PIN

Dismantled view of the manual steering gear.


172 Steering - Part 3

the rack bush for wear and damage. If necessary,renew the rack pad nylon insert.

(8) Renew all the O rings previously discardedand instal a new oil seal to the pinion retaining screwusing a suitable punch. Renew all components foundto be unserviceable in the above inspections.

TO ASSEMBLE

(l) Mount the steering gear housing in a viceequipped with soft jaws, gripping the left hand sidemounting boss.

(2) Lubricate the rack bush and O rings with thespecified lubricant. Refer to the Lubrication andMaintenance section.

(3) Using suitable snap ring pliers in the holesprovided in the rack bush, compress and instal thebush into the end of the steering gear housing.

-(4) Liberally coat the rack teeth and slidingsurfaces with the specified lubricant._ (5) Slide the rack into the steering gear housingfrom the right hand end aligning the rack teeth withthe position occupied by the pinion and centralise therack in the housing by measuring from the end of therack to the machined shoulder inside each end of thesteering gear housing. The measurements at each endwill be equal when the rack is centralised.

(6) Pack fifty grams of the specified lubricantinto the steering gear housing through the pinionaperture ensuring that the lower pinion bearing islubricated.

(7) Lubricate the upper pinion bearing with thespecified lubricant and instal the pinion into thesteering gear housing ensuring that the flat on thepinion is parallel with the rack teeth and away fromthe rack pad aperture.

(8) Lubricate the pinion oil seal with the speci-fied lubricant, instal and tighten the pinion retainingscrew to the specified torque. Stake the steering gear

Using a torque wrench and adaptor to tighten the rackpad adjusting screw-

Special seruice tools courtesy of Kent-MooreAustralia.

Using a torque wrench and tanged socket to tightenthe pinion retaining screw.

Speciat seruice tools courtesy of Kent-MooreAustralia.

Using a torque wrench and adaptor to tighten the rackpad adjusting screw locknut.

'speciat service T;"r::,i!*,

or Kent-Moore

housing into the retaining screw at two positions usinga suitable punch.

- - (gl Lubricate the rack pad with the specifiedlubricant, instal the rack pad, the nylon waslrer andthe spring to the steering gear housing.

( 10) Instal the rack pad adjusting screw and withthe rack centralised as previously deicribed, tightenthe screw to 12 Nm loosen the sciew 25 - 30 degrees,instal and tighten the rack pad adjusting screw toitcnuito the specified torque while holding the adjustingscrew in the adjusted position.

(l l) Attach a suitable torque gauge to the pinionand measure the pinion rotating torque. The iorqueshould not exceed 2.5 Nm over-the full travel of itrerack. If necessary, repeat the rack pad adjustmentdescribed in operation (10) and rent* parts as re-quired if rack pad adjustment is not the cause ofvariations in the pinion rotating torque.


Steering - Part 3

Using a torque wrench and adaptor to tighten the tierod joint.

spociat service ,T;"r::;:"* of Kent'Moore

(12) Instal new lock washers to the tie rod jointsensuring that the pressed dimples on the centre of thelockwasher are facing the rack.

(13) Rotate the pinion fully anti-clockwise andgrip the exposed section of the rack ensuring that thevice is equipped with soft jaws.

(14) Instal the right hand side tie rod and jointassembly to the end of the rack, tighten the joint to thespecified torque using the illustrated adaptor or equi-valent ensuring that the pressed dimples on the lockwasher are positioned in the slots in the end of therack and bend the lock washer over both flats on thejoint.

(15) Rotate the pinion clockwise to expose theleft hand end of the rack, change the assembly in thevice and grip the exposed end of the rack.

(15) Instal the left hand side tie rod and jointassembly to the end of the rack, tighten the joint to thespecified torque using the illustrated adaptor or equi-valent ensuring that the pressed dimples on thelockwasher are positioned in the slots in the end of therack and bend the lock washer over both flats on thejoint.

173

( 17) Instal the comrgated rubber boots to thesteering gear as previously described.

(18) Instal the locknuts and tie rod ends to themarked positions. Do not tighten the locknuts.

(19) Instal the steering gear assembly to thevehicle as previously described and adjust the toe in asdescribed in the Front Suspension section. Ensurethat the nylon spacers are in position on the tie rodend stud. Renew the nylon spacers if they are worn ordamaged.

TO RENEW TIE ROD END

The procedures for renewing a tie rod end arefully covered in the Power Steering section under thePower Steering Gear assembly heading.

TO RENEW CORRUGATED RUBBER BOOTS

The procedures for renewing the comrgated rub-ber boots are fully covered in the Power Steeringsection under the Power Steering Gear assemblyheading.

TO RBNEW TIE ROD ASSEMBLY

The procedures for renewing a tie rod assemblyare fully covered in the Power Steering section underthe Power Steering Gear assembly heading.

2. STEERINb WNEET

The procedures for removing and installing thesteering wheel are fully covered in the Power Steeringsection under the Steering Wheel heading.

3. STEERING COTUMN

The procedures for removing, dismantling,assembling and installing the steering column are fullycovered in the Power Steering section under theSteering Column heading.

4. INTERMEDIATE SHAFT ASSEMBLY

The procedures for removing and installing theintermediate shaft assembly are covered in the PowerSteering section under the Intermediate Shaft Assem-bly heading.


174

SPECIFICATIONS

Type Independent MacPherson struttype with coil springs and

lower control armCoil spring free length:

Standard models 360 mmModels with V5W option 363 mmSedans with FE2 option . . 315 mm

Shock absorber:Type Wet strutFluid capacity 350 mlFluid type. . . HMC 1588

*Wheel alignment:Caster angle -Modelswith FE2 option.. . 2 deg t I degModels without FE2 option. . . . . . I deg 30 min

t l d e gCamber angle -Models with FE2option minus 30 min + 30 minModels without FE2 option minus I deg

+ 30 minT o e i n . . . 4 m m + 2 m m

* Measurements should be taken with theunladen and the fuel tank full.


Pibton rod nutGfand packing nut. .Tib rod end castellated nut. .Su]spension unit to upper body nuts .I-qwer control arm pivot bolt nut .Stabiliser bar bracket bolts.Stabiliser bar link nuts .Rddius rod nuts:

FrontRear

Bdll joint to suspension unit nut:

vehicle

85 Nm120 Nm71 Nml6 Nm

1 1 0 N m25 Nml0 Nm

155 Nml l 0 N m

* S e l f l o c k i n g n u t . . . . 1 1 0 N mCastellated nut . . 95 Nmiper mounting bolts 90 Nm * 50 degpension crossmember mounting nuts . . . . 80 Nm

*New nut must be installed.


I. FRONT SUSPENSION TROUBLE SHOOTING

FRONT END NOISE

(1) Loose upper suspension unit mounting orpiston rod: Tighten the mounting or piston rod nuts.

(2\ Loose or worn suspension unit lower balljoint: Tighten or renew the lower ball joint.

(3) Noise in the suspension units: Overhaul thesuspension units.

Check the ball joints for wear and deterioration.

Checking the lower control arm inner pivot bolt fortightness.

FRONT SUSPENSION


Front Suspension 175

Check the stabiliser bar mounting for deterioration.

(4) Worn or loose steering gear: Overhaul thesteering gear assembly.

(5) Incorrectly adjusted front hub bearings: Ad-just the hub bearings.

(6) Loose or defective stabiliser bar or radiusrod mountings: Check, tighten or renew the mountingrubbers.

NOTE: To check the front suspension .com-ponents for wear, first raise the front of thevehicle, support it on chassis stands andallow both front wheels to hang free. Withan assistant pushing and pulling the frontroad wheels in and out at the top and then atthe bottom, check for excessive looseness at

check the lower controlbushes for wear.

the front hub bearings and lower controlarm inner pivot bushes. The suspension balljoint is spring loaded in its socket to com-pensate for normal wear, therefore if anymovement can be detected then the balljoint should be renewed. As a further checkon the inner pivot bushes and to check theradius rod front mounting bushes, have theassistant push the wheels firmly towards therear and then the front of the vehicle.Stabiliser bar mounting rubbers can bevisually checked for damage or deteriora-tion.

POOR OR ERRATIC ROAD HOLDING ABILITY

(1) L,ow or uneven tyre pressures: Inflate thetyres to the recommended pressures.

(2) Defective suspension unit: Check, overhaulor renew the faulty unit, preferably in pairs.

(3) Incorrect front end alignment: Check andadjust the alignment as necessary.

(4) Loose or defective stabiliser bar mountingrubbers or link nuts: Check and tighten or renew themounting rubbers.

(5) Weak or uneven front coil springs: Checkand renew front coil springs as a matching pair.

(6) Broken or weak rear spring: Renew both rearsprings as a matching pair.

NOTE: As a quick guide to suspension unitcondition, bounce thefront of the vehicle upand down (one side at a time), the vehialeshould come to rest in a single movement. Ifit bounces two or three times before stop-ping, the suspension unit should be removedand overhauled. If the front of the vehicle islaying down further on one side than theother, remove the coil spring and check itsfree length against a new spring. If thespring is found to be unserviceable it is goodpractice tofit two new springs as a matchingpair. This also applies to the springs on therear of the vehicle.

2. DESCRIPTION

Each front suspension unit comprises a verticaltubular strut and shock absorber unit, surrounded atthe upper end by a coil spring on the top of which isthe upper mounting attached to the underside of thefront wheel housing.

The piston rod of the shock absorber is in turnattached to the upper centre of the spring uppermounting by a rubber mounted thrust bearing assem-blv.

The lower end of the suspension unit is mountedto the outer end of the lower control arm by a swivelball joint. The lower control arm pivots at its inner

Using a lever to arm pivot


1 7 6

Installed view of the right hand side front suspensioncomponents.

end on a bolt and rubber bush in the channel sectionof the front crossmember. A stabiliser bar, attached tothe body sub-frame forward of the suspension andconnected to each suspension unit by a link bolt andrubber bushes contributes considerably to the hand-ling quality of the vehicle.

In order to maintain the lower control arm in thecorrect relationship with the other suspension com-ponents in service, a radius rod is mounted betweenthe lower control arrn and the front suspensioncrossmember.

Caster and camber may be adjusted marginally byrotating the upper mounting. Rotation toward thefront will increase the camber and decrease caster,rotation toward the rear will increase the camber andcaster.

3. FRONT HUB


(1) Raise the front of the vehicle and support iton chassis stands. Remove the front wheel.

(2) Remove the caliper retaining bolts and re-

Fron't Suspension

move the caliper. Suspend the caliper from a conven-ient point by tying it with a piece of wire. This willensure that no damage is done to the flexible brakehose.

(3) Remove the dust cap, split pin and castel-lated nut from the hub assembly.

(4) Withdraw the hub assembly from the stubaxle, taking care not to drop the bearings and damagethem. Remove the washer and outer bearing from thehub.

(5) Remove the inner bearing and the grease sealfrom the stub axle.

(6) Where necessary, using a suitable drift, drivethe two bearing cups from the hub. The inner bearingcup is driven towards the inside of the hub and theouter bearing cup towards the outside of the hub.


(l) Remove all the old grease and wash all partsin a suitable solvent.

(2) Inspect the bearings and cups for scoring,chips and pitting. If damaged, renew the bearings ascomplete assemblies comprising cup and cone.

(3) Inspect the brake disc for distortion, chip-ping or cracking.

(4) Check the inner surface of the hub whichrotates on the grease seal. Remove small scores andburrs with emery paper.

(5) Renew the grease seal.


( I ) Where removed , t&D the two hub bearingcups into position in the hub so that their tapers areopposed to each other.

(2) Apply wheel bearing grease (suitable for discbrake application) to the rollers of the inner bearingcone assembly. Smear the cup with grease and slidethe cone into position in the hub.

(3) Place a new grease retafiing seal onto thestub axle. The seal should be firmlv seated on the stubaxle.

NOTE: The new grease retaining seal lipshould be lightly coated with grease beforeinstalling the hub. Do not pack the space inthe hub between the two bearings withgrease.

(4) Apply grease to the cone and rollers of theouter hub bearing. Smear the cup with grease, placethe hub assembly on the stub axle, and position theouter cone and roller assembly in the outer end of thehub.

(5) Instal the flat washer and castellated nut onthe stub axle and, while rotating the hub, tighten thenut to 18 Nm.

(6) Slacken off the nut until there is slight endfloat, then tighten the nut to 13 Nm.

(7) Slacken the nut one to one and a half slotsand instal a new split pin. Replace the dust cap.

; - \ ** INGCONEil \iS^ &

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HUA AND DIS ASSY

OUTER BEARING CONE

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Dismantled view of front hub components.


Front Suspenseon 177

Pack the hub bearings by thoroughly working greasebetween the rollers and the inner race and roller cage.

(8) Instal the caliper, tighten the bolts to Specifi-cations and pump the brake pedal two or three times.

(9) Instal the front wheel and lower the vehicleto the ground.

4. SUSPENSION UNIT

Special Equipment Required:To Remove - Ball joint removing toolTo Dismantle - Spring compressor, gland packingnut wrench or StillsonTo Assemble - Spring compressor, gland packingnut wrench or Stillson

TO REMOVE

(l) Raise the front of the vehicle 4nd support iton chassis stands. Do not support the vehiclb underthe lower control arms.

(2) Remove the front wheel.(3) Remove the brake caliper and hub assembly

as previously described under the heading Front Hub.

NOTE: Turn the sleeve on the brake hosebracket and disengage the hose from thesuspension unit.

(4) Remove the upper nut, washer and bushfrom the stabiliser bar link bolt.

(5) Take out the split pins and remove the nutsfrom the steering tie rod end and the lower controlarm ball joint.

(6) Disconnect the tie rod end ball joint stud byplacing a suitable dolly or hammer against one side ofthe steering ann eye and striking the opposite sidewith a hammer.

Insert the ball joint removing tool and disconnectthe lower control arm ball joint.

(7) Using a suitable lever, prise the lower controlarm and the ball joint bolt from the suspension unit.

(S) Support the suspension unit on a iack, raisethe engine bonnet and working in the engine compart-ment, remove the retaining nuts securing the suspen-sion unit to the upper support member.

NOTE: Observe the position of the uppersuspension mounting in the upper srypportmember. It wiil be seen that between theinner two studs there is a mark on thesuspension mounting and the upper supportmember. This is a factory setting for casterand camber: Ensure the suspension unit isreturned to the same position or the wheelalignment will be altered.

(9) Lower the jack and remove the suspensionunit from the vehicle.

TO DISMANTLE

(l) Prior to dismantling the suspension unit,clean it thoroughly and ensure that a clean workingarea is available. Clamp the assembly upright in avice.

NOTE: Clamp the suspension unit by thesteering knuckle only.

(2) Instal a coil spring compressor to the suspen-sion unit. Compress the spring, remove the dust sealand the piston rod nut.

(3) Remove the upper support bearing assem-bly, washer, spring seat and insulator.

SPRING COMPRESSOR

Suspension unit with spring compressor installed.


1 7 8

STBUT BODY

. Dismantled view of suspension unit.

(4) Remove the spring compressor and the coilspring. Remove the rubber bump stop and dust coverfrom the suspension unit.

NOTE: The dust cover is retained at thebottom by a plastic tie. This tie will have tobe cut.

(5) Push the piston rod down until it bottoms,clean the gland nut and surrounding area and usingthe special gland packing nut wrench or a Stillson,remove the gland packing nut.

(6) Pull the piston rod slowly upwards, removethe O ring from the top of the piston guide andwithdraw the piston rod and cylinder assembly.

NOTE: Do not remove the piston rod andguide from the cylinder as they are servicedas an assembly.


(l) Drain all oil from the suspension unit body.Wash components and dry with compressed air. Nonmetallic parts should be cleaned by air only.

(2) Renew the gland packing nut, O ring and tie.Inspect and clean the filter and dust cover. Renew thefilter and dust cover if necessary.

(3) Check the suspension unit body for distor-tion and cracks. Inspect the stub axle for distortion.Check the base and threaded section for fatigue anddamage.

(4) Test the coil spring for sag and fatigue andcheck the rubber components.

(5) Check the support bearing for roughness andgeneral wear.

(6) Renew all worn or damaged parts wherenecessary.

TO ASSEMBLE

(1) Prior to assembly, ensure that all parts areclean. Do not use cotton waste for wiping down asparticles could lodge in the cylinder and result infaulty operation.

(2) Place half the quantity of the specified fluidin the suspension unit body.

(3) Instal the kit from the sealed package but donot tighten the gland nut.

(4) Operate the unit up and down until an evenresistance is felt.

(5) Raise the unit slightly and add the remainderof the fluid.

(6) Instal the unit with the new O ring and glandnut and using the gland nut wrench or Stillson, tightenthe gland nut to the specified torque.

(7\ Instal the dust cover, bump rubber and filterto the suspension unit. Position the dust cover so thatthe bottom of the filter assembly is approximately 20-25 mm above the lowest part of the spring seat then in-stal and tighten a new tie.

(8) Operate the suspension unit fully severaltimes and ensure that the dust cover does not move onthe suspension unit body.

(9) Replace the compressed spring on thesuspension unit, instal the insulator and the springseat and instal the washer and upper support bearingassembly.

NOTE: Ensure that the notch on the springseat flange faces the stub axle and that theedge of the washer faces upward.

(10) Instal and tighten the piston rod nut to thecorrect torque, ensure that the spring is aligned withthe spring seat and release the spring compressor.

TO INSTAL


( I ) Working below the front mudguard, placethe suspension unit in the same position as it wasremoved, see note in removal section. Instal thewashers and nuts but do not tighten the nuts at thisstage.

NOTE: Ensure that the underside of thewheel housing is clean before ofering up thesuspension unit.

(2) Engage the control arm ball joint bolt in thebottom of the suspension unit, instal and tighten thenut to the specified torque and, if applicable, instal anew split pin. If a locking nut is installed to the balljoint bolt, it must be renewed each time it is removed.

(3) Fully tighten the three nuts securing thesuspension unit to the upper support member.

Front Suspenseon

sp',rf e eEAr + 8,_ry*-*?*-

DUSTSEAL ,r"rrror? ill\c' \ffir ttl*r,nurs

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ffi7t'""""W\/p^'"'"'W''"'"Hlaeanr{drssY ry -.E

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PISTON ASSEMBLY


(4) Instal the stabiliser link bush, washer andnut.

(5) Engage the steering tie rod end stud into thesteering arm, instal and tighten the nut to the specifiedtorque and instal a new split pin.

(6) Instal the hub and brake caliper assembliesas previously described.

(7) Instal the front wheel and lower the vehicleto the ground.

5. LOWER CONTROL ARM

Special Equipment Required:To Remove - Ball joint removing tool


(l) Raise the front of the vehicle and support iton chassis stands. Do not support the vehicle underthe lower control arms.

(2) Remove the front wheel.(3) Remove the radius rod nut and washer at the

control arm.(4) Remove the split pin, where applicable, and

remove the nut from the ball joint. Using a ball jointremover, disconnect the ball joint from the suspensionunit.

(5) Remove the nut and washer from the controlarm pivot bolt.

(6) Withdraw the pivot bolt and remove thecontrol arm from the vehicle.

(7) Clean the control arm and inspect for distor-tion and fatigue. Check the pivot bush, the ball jointand radius rod bush for damage or wear. Renew partsas necessary.

NOTE: Special equipment is required torenew the pivot bush and the radius rod

S--nut *rr,rr,"

179

bush. If these special tools are not used inthe removal and replacement of thesebushes, serious distortion of the lower con-trol arm may occur.

For this reason, if replacement of thesebushes is necessary the complete lower con-trol arm should be taken to an authoriseddealer for renewal of the bushes.


(l) Instal the radius rod onto the lower controlarm with the convex side of the front washer towardthe bush, instal but do not tighten the nut at this stage.

(2) Instal the lower control arm into the cross-member and insert the pivot bolt from the front.Instal the nut loosely. With the vehicle on the ground,bounce it a few times at the front to settle the bushesthen tighten the control arm nut and the radius rodnut to the specified torque.

6. BALL JOINT

TO REMOVE AND INSTAL(l) Remove the lower control arm as previously

described.

NOTE: The ball joint is an interference fitin the lower control arm and any attempt toremove or replace it without the use ofspecial tools will seriously distort the lowercontrol arm. It is therefore recommendedthat should replacement of this part becomenecessary, the complete lower control armbe taken to an authorised workshop forrenewal of the ball joint.

Installation is a reversal of the removal procedure.

7. RADIUS ROD


(l) Remove the lower control arm as previouslydescribed.

(2) Remove the nut and washer at the cross-member mounting bracket and withdraw the radiusrod from the vehicle. Check the radius rod fordistortion and renew the rubber bushes and washerswhere necessary.

NOTE: When removing the radius rod notethat the longer shouldered end is installed tothe crossmember and the shorter end to thelower control arm.


(l) It is important that on installation of theradius rod the concave side of the front washer is

Front Suspension

BALL JOINT 12413f,.2

View of lower control arm and associated components.Model with castellated nut and split pin.

BALL JOINT BOLT


r80 Front Suspensron

^ \61w w/n

9.


, tBOLTS .

^6

dqtDismantled view of radius rod components.

placed toward the bush. And that on installation of thelower control arm the convex side of the front washeris toward the bush.

(2) Before final tensioning of the radius rod nutsthe vehicle should be lowered to the ground andbounced at the front to settle the bushes.

NOTE: If the radius rod bushes in thecrossmember need to be renewed specialtools are needed. For this reason the vehicleshould be taken to an authorised dealer forrenewal of the bushes.

8. STABILISER BAR


(1) Raise the front of the vehicle and support iton chassis stands. Do not support the vehicle underthe lower control arms.

(2) Remove the lower nuts, washers and bushesfrom the stabiliser bar links.

(3) Take out the retaining bolts from the front ofeach stabiliser bar mounting bracket and loosen thebolts at the rear of each bracket.

(4) Mark the stabiliser bar on one side so that itcan be replaced in its original position, lift it off thelinks and remove it from the vehicle. '

NOTE: Use a daub of paint to mark the bar.Do not make a file mark or cut of qnydescription as this would set up fatigae dndlead to failure of the stabiliser bar.

Installation is a reversal of the removal prpcedurewith attention to the following points:

(1) Ensure that the rubber bushes on lhe con-necting links are in good condition and tighten thelink nuts to the specified torque.

(2) Ensure that the front mounting rubbers arein a serviceable condition and a good frl in themounting brackets, The open ends of the mountingrubbers must face the front of the vehicle.

(3) Instal the stabiliser bar so that the paintmark made on removal is in the same position.

Special Equipment Required:To Remove - Overhead engine lifting gear

(l) Disconnect the negative battery tprminal.Remove the engine bonnet as described in the Bodysection of this manual.

(2) Raise the front of the vehicle and sdpport iton chassis stands located under the front jackingpoints. If necessary, refer to the Wheels and Tyressection for the location of the front jacking foints.

(3) If applicable, remove the retaining bolts andremove the engine sump guard from the vehicle.

(4) Remove the inner pivot bolts and nuts fromboth lower control arms.

(5) Remove the radius rods from both sides ofthe vehicle as previously described and sep4rate thelower control arms from the crossmember.

(6) Remove the steering gear mounting boltsfrom the crossmember.

(7) Raise the engine slightly using qverheadlifting gear and remove the bolts retaining the enginemountings to the crossmember. Loosen the boltsretaining the engine mounting brackets to the cylinderblock.

(8) Support the crossmember on a trofley jackand remove the nuts retaining the crossmember to thevehicle subframe.

(9) Lower the jack and remove the crossmemberfrom the vehicle.

Installation is a reversal of the removal pfocedurewith attention to the following points:

(l) Refer to the lower control arm installation

ROD

mffi

ffiI

enrbxer

24n11241382

Dismantted view of one end of the stabiliser barshowing the mounting components. procedure prior to tightening the inner pivotlbolts.


Front Suspenston

lnstalled view of the front suspension crossmember.

1 8 1

(2) Ensure that the weight of the engine is restingon the mountings prior to tightening the retainingbolts.

(3) Tighten all bolts to the specified torque.(4) Start the engine and increase the speed to

3 000 rpm for l0 seconds allowing the idle air controlvalve to reset.


10. SUSPENSION AND STEERING AhIGLES

NOTE: Extensive knowledge and specia-lised equipment is required to measure andcorrect the suspension and steering anglesexcept the front wheel toe in. It is thereforenot a worthwhile propositions for the lay-man to do a complete wheel alignment andthe vehicle should be taken to a wheelalignment specialist.

Prior to carrying out a wheel alignment the frontsuspension should be completely checked to ascertainthat it is in a serviceable condition.

Carry out a thorough inspection of the steering

linkage, front hub bearing adjustments, suspensionjoints and rods, springs and suspension unit recoilaction. Renew or repair components where necessary.

The tread of the front tyres should be examinedfor excessive or uneven wear as certain conditions oftyre wear are indicative of damaged or worn compon-ents in the suspension, steering linkage or the wheelsand bearings.

Refer to Tyre Wear Trouble Shooting in theWheels and Tyres section.

If tyres are found to be defective renew withserviceable tyres.

The vehicle should be unladen except for a fulltank of fuel, with the tyres inflated to the normalpressures.

TO CHECK AND ADJUST TOE IN

(1) With the vehicle on a level floor, raise thefront of the vehicle and support it on chassis stands.

(2) Spin each front wheel in turn and using apiece of chalk, mark a thin line around the peripheryof each tyre as near to the centre as possible.

(3) Lower the front of the vehicle to the floorandbounce the vehicle up and down several times andlet it find its own level. Set the front wheels in thestraight ahead position.

(4) Mark the centre line on both tyres in front ofthe suspension at the height of the wheel centres.


1 8 2

R E A R W H E E L S

L D / 1 2

Diagram indicating front wheel toe in. Distance Ashould be less than distance B. See Specifications.

(5) Using a telescopic gauge or rule, measureand record the distance between the two marks on thetyre centres.

Front Suspenseon

(6) Maintain the wheels in the straight aheadposition, roll the vehicle forward until the marks arethe same distance above the floor, but to the rear ofthe front suspension.

(7) Again, use the telescopic gauge, or rule tomeasure and record the distance between the markson the tyres. The distance measured at the front of thewheels must be less than the measurement taken at therear of the wheels. See Specifications for correct toe insetting.

(8) If adjustment of the toe in is required pro-ceed as follows:

(a) Remove the outer clips from the rack bootsand loosen the tie rod end locknuts.

(b) Adjust the tie rods as required until thecorrect toe in is reached.

NOTE: It is important to make equal ad-justments to each tie rod to maintain thecentral position of the steering gear.

(c) Tighten the tie rod end locknuts and instalthe outer clips to the rack boots.

(d) Check the position of the steering wheel withthe front wheels in the straight ahead position. Ifnecessary remove and reposition the steering wheel.Refer to the Steering section for the correct steeringwheel removal and installation procedure.

W H E E L S



SPECIFICATIONS

Type Live axle with locating arms,coil springs, telescopic shock absorbers,

stabiliser bar and Panhard rodShockabsorber type. . . . . Doubleact ingCoil spring type Progressive rateStabi l isertype. . .Decoupled

TORQUE WRE,NCH SETTINGS*Lower suspension arm mountingbolt nuts I l0 Nm*Upper suspension arm mountingbolt nuts . 75 Nm*Shock absorber upper nut. . 16 Nm*Shock absorber lower bolt nut . . 29 Nm*Panhard rod:

Axle housing attaching nut. . 70 NmBody attaching nut . I 10 Nm

Stabiliser bar:Bracket to axle housing bolts l8 NmStabiliser link nuts l0 Nm

Wheel nuts. . . 125 Nm*Torque these nuts to Specifications only when thevehicle has been lowered to the ground.

1. REAR SUSPENSION TROUBLE SHOOTING

NOISE IN SUSPENSION

(1) Defective shock absorber or mountings:Renew faulty components.

Gheck the shock absorber mounting rubbers for wearand deterioration.

1 8 3

(2) Loose or defective suspension arm bushes:Check, tighten or renew as necessary.

(3) Worn coil spring insulator: Renew theinsulator.

(4) Worn stabiliser or link rubbers: Renew therubber components.

(5) Loose or defective Panhard rod bushes:Renew the bushes.

(6) Broken coil spring: Renew the coil spring.

NOTE: As a quick guide to shock absorbercondition, bounce the vehicle up and down(one side at a time) and observe if the vehiclecomes to rest in a single movement. If thevehicle bounces two or three times beforecoming to rest the shock absorber is suspect.

If suspect, remove the shock absorberand test and check as described under theappropriate heading.

To check the suspension arm bushesand pins, insert a lever between the suspectunit and its mounting and lever the unitback and forth checking for excessive move-ment. Check the rear spring coils visuallyforbrealcs. Also check the insulatorsfor damageor distortion. If a coil spring is found to beunserviceable it is good practice to instal twonew springs as a matching pair.

REAR WHEELS NOT IN ALIGNMENTWITH FRONT WHEELS

(1) Spring badly sagging on one side: Renew thedefective coil spring.

(2) Sprung or bent axle housing: Renew the axlehousing.

(3) Distortion of body and subframe: Check andrectify the body alignment.

(4) Upper or lower suspension arm bolt brokenor missing: Renew the suspension arm bolt.

(5) Panhard rod mounting bolt missing orbroken: Renew the bolt.

NOTE: To check this condition measurefrom the centre of the front wheels to thecentre of the rear wheels on both sides.Compare the measurements which must be

REAR SUSPENSION


1 8 4

A worn suspension arm bush wil l readily show up bylevering between the suspension arm and the axle

housing bracket.

equal. Before measuring ensure that thefront wheels are in the straight aheadposition.

2. DESCRIPTION

The rear axle is located by four trailing arms and aPanhard rod and is sprung by progressive rate coilsprings. Shock absorbers are installed between theouter suspension arm rear brackets and the vehicleunderbody.

The suspension arms hold the axle square to thevehicle and share in controlling axle reactions todrive, braking and acceleration forces.

The upper arms carry rubber bushes at both ends.The lower arrns incorporate bushes at their front end.The lower arrn rear bushes are located in brackets onthe axle housing. The forward ends of all arms mountto brackets on the vehicle underbody.

The axle housing has mountingbrackets welded toit to provide mounting points for the rear ends of theupper and lower suspension arms. The springs areinsulated from the underbody and suspension armseats by means of rubber insulators.

View of the rear suspension components and axleassembly removed from the vehicle.

Rubber bump stops are fitted totions of the underbody to limit the travel of thousing during compression of the springs.

A stabiliser bar attached to the axle housithrough links and rubber insulators, connectunderbody is installed. It reduces roll and ihandling.

A Panhard rod is installed to controlmovement of the axle housing. Abell shaped rinstalled to the Panhard rod retaining nut athousing point. This is to prevent damage totank in the case of a rear end collision.

3. SHOCK ABSORBERS

TO REMOVE

Sedan(1) Raise the rear of the vehicle and su

on chassis stands placed beneath the rear axleas close as practicable to the road wheels.

(2) Working inside the luggage comremove the protective cap from the upperand remove the nut securing the shock absobody. Remove the washer and rubber insula

(3) Working underneath the vehicle,the shock absorber clear of the body andlower retaining bolt and nut.

(4) Withdraw the shock absorber fimounting bracket.

NOTE: Gas filled rear shock absorbersbe installed on some vehicles. As this type

Rear Suspenston

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Rear Suspension

shock absorber is difrcuh to compress, it willbe necessary after removing the top mount-ing nut, rubber insulator and washer, toremove the lower retaining bolt and nut andmanoeuvre the shock absorber from thevehicle.

Station Wagon(1) Raise the rear of the vehicle and support it

on chassis stands placed beneath the rear axle housingas close as practicable to the road wheels.

(2\ Working inside the load area lift back thefloor covering to expose the shock absorber uppermounting covers.

(3) Remove the retaining screws and remove thecover. Remove the nut securing the shock absorber tothe body and remove the washer and rubber insulator.

(4) Working underneath the vehicle, compressthe shock absorber clear of the body and remove thelower mounting retaining nut and washer.

(5) Withdraw the shock absorber from themounting.

View of Station Wagon rear shock absorber uppermounting.

TO TEST AND BLEEDThe extent to which a shock absorber can be

tested without special equipment is limited to thefollowing:

(1) Check the body of the shock absorber fordents or damage and for fluid leaks. The shockabsorber cannot be repaired and should be renewed ifdefective.

(2) Check the rubber bushes and grommets forwear and deterioration. Renew as necessary.

(3) Mount the shock absorber upright in a viceby the lower mounting eye.

(4') Grasp the upper half of the shock absorber,pull up to the fully extended position and then slowlypush down until the shock absorber is fullycompressed.

(5) Repeat operation (4) six to eight times toremove any slack spots caused by air in the system. Ifslack spots exist and cannot be removed by this

method, the shock absorber is evidently defective andshould be renewed.

NOTE: If gas filled shock absorbers areinstalled to the vehicle, inspect visually forleal<s which will indicate a faulty shockabsorber. Excessive noise will also indicatea faulty unit. If either of these faults areevident the shock absorber should berenewed.

Do not puncture or incinerate gas filledshock absorbers

TO INSTAL


(1) Ensure that the rubbers and bushes are in aserviceable condition.

(2) Bleed the shock absorbers prior to installa-tion and keep the shock absorber in an uprightposition during installation.

(3) The weight of the vehicle must be taken bythe wheels prior to torquing the shock absorbermountings to Specifications.

SUPERLIFT SHOCK ABSORBERS

Optional shock absorbers with built in pressurisedair bags assisting the springs can be fitted to allmodels.

The air bags in both shock absorbers are inflatedfrom a common tee valve, the pressure depending onthe load of the vehicle. The valve assembly is situatedat the rear of the vehicle.

NOTE: Pressure in the vehicle air bagsshould not exceed I 034 lcPa and should notbe below 103 kPa. Do not operate thevehicle in a lightly laden condition with theair bags inflated to I 034 kPa.

To Remove( 1) Loosen the air pipe at the shock absorber and

let the air escape.(2) Remove the fitting and the air pipe from the

shock absorber and remove the shock absorber fromthe vehicle as previously described for standard typeshock absorbers.

To Test and BleedSuperlift shock absorbers are tested in the same

manner as conventional shock absorbers.When the shock absorber is extended and com-

pressed, air will flow through the pipe connector as aresult of the movement in the air bag.

To Instal(l) Instal the shock absorber as previously

described for standard type shock absorbers.

1 8 5


1 8 6

Dismantled view of Superlift rear shock absorbercomponents.

(2) Connect the air pipe and tighten the fittings.(3) Inflate the shock absorber air bags to 1 034

kPa and check the air pipes, connections and shockabsorbers for air leaks. This can be done with soapywater brushed onto the components.

4. COIL SPRINGS

TO REMOYE AND INSTAL

(1) Raise the rear of the vehicle and support iton chassis stands placed under the jacking points.

(2) Remove the rear wheel.(3) With the jack placed beneath the lower

suspension arm directly under the spring, lift the armenough to remove the rear lower suspension armretaining bolt.

Rear Suspension

(4) Slowly lower the jack and remove the springand insulators from the vehicle.

NOTE: If a spring is found to be unservice-able it is good practice to instal two newsprings as a matching pair.


(1) Place the jack beneath the lower suspensionarm.

(2) Instal the lower insulator and spring to thesuspension arm.

(3) Place the upper insulator onto the spring andraise the jack and spring into the upper spring seat.

ITIOTE: The coil spring is tapered and isinstalled with the taper at the top.

(4) Continue to lift the suspension arm until therear retaining bolt can be install-ed.

(5) Lower the vehicle onto car ramps and torquethe rear retaining bolt to the specified torque.

5. UPPER SUSPENSION ARMS


(l) Raise the rear of the vehicle and support iton chassis stands placed under the jacking points.

(2) Raise the rear axle assembty with a jack totake the spring load off the upper suspension arm.

(3) Remove the front and rear attaching boltsand withdraw the arm from the vehicle.

NOTE: Check the condition of the bushes.Special tools are required to renew the

bushes in the arm. For this reason shouldthe bushes require renewal the units shouldbe taken to an authorised dealer or theproper tools obtained.

To remove both upper suspension arms

INSULATORS

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Rear suspension coil spring components. Upper suspension arm removed from vehicle.


Rear Suspensoon r87

at the same time it will be necessary to placea jack directly under each coil spring tominimise the movement of the axlehousing.


(1) The upper suspension arms are to be in-stalled with the lips facing outwards and the attachingbolts must be installed with the heads facing theoutside of the vehicle.

(2) The weight of the vehicle must be taken bythe rear springs before torquing the arm mountingbolts as specified.

6. LOWER SUSPENSION ARMS


(1) Raise the rear of the vehicle and support iton chassis stands placed under the jacking points.

(2) Remove the rear wheel.

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Lower suspension arm removed from the vehicle.

(3) With the jack placed beneath the lowersuspension arm directly under the spring, lift the armenough to remove the rear lower suspension armretaining bolt.

(4) Slowly lower the jack and remove the springand insulators from the vehicle.

(5) Remove the front retaining bolt and removethe suspension arm.

NOTE: The front bush will remain in thesuspension arm whilst the rear bush willremain in the bracket on the rear axlehousing.

Check the condition of the bushes.Special tools are required to renew the

bushes in the arm or the axle housing. Forthis reason should the bushes require

renewal the units should be taken t0 anauthorised dealer or the proper tools ob'tained.


(1) Place the front of the lower suspension armin the body mounting bracket and instal the bolt butdo not tighten.

(2) Place the jack beneath the lower suspensionarm.

(3) Instal the lower insulator and spring to thesuspension arm.

(4) Place the upper insulator onto the spring, raisethe jack and guide the spring into the upper springseat.

NOTE: The coil spring is tapered and isfitted with the taper at the top.

(5) Continue to lift the suspension arm until therear retaining bolt can be installed.

(6) Lower the vehicle onto car ramps and torquethe retaining bolts to the specified torque.

7. STABILISER BAR

TO REMOVE AND INSTAL(1) Raise the rear of the vehicle and support it

on chassis stands placed beneath the rear axlehousing.

(2) Hold each link and remove the lower nut.Remove the washers and rubber insulators.

(3) Swing the stabiliser bar downwards andremove the remaining bottom insulators and washersfrom the links.

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Dismantled view of rear stabil iser bar and right handside mounting components.

ARM

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1 8 8

(4) Remove the bracket attaching bolts and nutson the rear axle housing, remove the biackets and thestabiliser bar. open and remove the split mountingbracket rubbers.

(Sl To renew the link or upper link insularors,hold the link and remove the top nut at the uppermounting bracket.

(6) Withdraw the link, washers and insulators.Installation is a reversal of the removal procedure

with attention to the following points:(l) Ensure that all rubber mountings and insula_

tors are in a serviceable condition.- - (2) Tighten the link nuts and bracket attachingbolts to Specifications.

8. PANHARD ROD

TO REMOVE AND INSTAL(U Raise the rear of the vehicle and support it

on chassis stands placed beneath the r"ui axlehousing.

\Zl Remove the nut and fuel tank protectivewasher securing the Panhard rod to the axle housing.

(3) Remove the upper body mounting nut andbolt and remove the Panhard rod.


(l) The eye with the sleeve must be installed tothe body bracket.

(2) Ensure that the fuel tank protective washer isinstalled.

Rear Suspension

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Dismantled view of Panhard rod mountingcomponents. Body bracket side.

TO RENEW BUSHES

(l) Remove the panhard rod as previouslydescribed and clamp it securely in a vice.

(2) Remove the sleeve from the bush using asuitable punch and hammer.

(3) Remove the bushes, if necessary cut thebushes with a sharp knife or hacksaw blade.

(4) Clean the eyes of the panhard rod andlubricate the new bushes and the eyes with soapywater.

(5) Press the new bushes into the eyes by handand then instal the sleeve.

(6) Instal the Panhard rod to the vehicle.

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1 8 9

BRAKES

SPECIFICATIONS

Type front

TyBe rear . . Solid disc with single pistoncaliper incorporating drum type handbrake

Handbrake . . Mechanical on rear wheelsMaster cylinder bore diameter:

Standardbrakes . . .23.81 mmHeavy duty brakes . . 25.4 mm

Front disc:Diameter (nominal) -Standardbrakes . . . .270.8-271 mmHeavy duty brakes . . 288.8-289 mmTh ickness(min imum) . . . . . 21 .0 mmRunout limit . . 0.10 mm

Front caliper bore diameter 54.0 mmRear disc:

Diameter (nominal) . . 278.8 - 279 mmThickness (minimum). 9.5 mmRunout limit . . 0.13 mmHandbrake diameter. . 160 mmHandbrake maximum out of square. . . 0.05 mmHandbrake maximum out of round . . . 0.08 mm

Rear caliper bore diameter 38 mm


Front caliper to steeringknuckle bolts 90 Nm * 50 degRear caliper to brakesupport plate bolts. . . 70 NmGuide pin self locking bolt . . . . . 34 NmMaster cylinder end plug

1. BRAKES TROUBLE SHOOTING

BRAKE PEDAL HARD

(1) Incorrect brake pads installed: Check andreplace with the recommended type.

(2, Frozen pedal pivot: Rectify or renew thepivot pin and bushes.

(3) Restricted brake line from the master cy-linder: Check the brake lines and remove the restric-tion, or renew the line.

(4) Frozen caliper pistons: Check and overhaulthe calipers.

(5) Vacuum servo system inoperative: Checkthe servo system and rectify.

NOTE: The vacuum servo system can bechecked as follows: With the engineswitched off, pump the brake pedal s,everaltimes to deplete any vacuum in the sltstem.With the engine still switched ofr pressdown firmly on the brake pedal and hold itthere, noting the position and presst4re re-quired. Holding down on the Qrake pedal,start the engine. Ifthe servo unit is apd,ratingcorrectly, the brake pedal will sink slightlyand the pressure required to hold it mayeven reduce. If the pedal does not sinkslightly when the engine is started, the,brakeservo unit can be considered inoperalive.

BRAKE DRAG

(l) Clogged master cylinder ports: Check andclean the master cylinder and the fluid reservoir.


(3) Frozen handbrake linkage: Free up or renewthe linkage.

(4) Frozen handbrake cables: Renew the cables.

NOTE: To check this condition, raise thevehicle and support it an chassis stands.Spin the wheels one at a time to check forbinding. If the wheels are not binding, havean assistant apply the brakes and qeleasethem. Check if the brakes release immedia-tely. A clogged master cylinder Bort willcause binding on the two wheels fed bv thatparticular circuit from the master cylinder.Open the bleeder valve on one of the otfftnd-ing wheels to check if pressure build up is thecause of the blinding. A frozen handbrakecable will usually cause binding on a rearwheel. To check this condition disconnectthe handbrake cable at the support plate andcheck if the wheel will then turn freely.


190

LOW SPONGY BRAKE PEDAL

(l) Lack of sufficient fluid in the system: Checkfor leaks, replenish the fluid and bleed the system.

(2) Air in the brake hydraulic system: Bleed thehydraulic system.

NOTE: A spongy brake pedal in most casesis caused by air in the hydraulic system. Forair to enter the system one or more of thesealing rubbers or pipes must be sucking inair. Always recttfu the cause of the troublebefore bleeding the brake system. Faultycomponents usually show up as fluidleakage.

Check the disc for scoring and wear.

BRAKES LOCK ON APPLICATION

( I ) Gummy brake pads due to oil or fluidcontamination: Renew the brake pads.

(2) Distorted brake disc: Check and renew anyfaulty disc.

(3) Incorrect brake pads installed: Check andrenew the pads as a set, with the recommended type.

NOTE: If this condition arises, first removeall the wheels and check the condition of thefriction material for both oil contaminationand excessive wear. A distorted brake discwill be indicated by pulsating on the brakepedal when the brakes are lightly applied.

BRAKE PEDAL PULSATES

(1) Distorted brake disc: Check and renew thebrake disc as required.

(2) Loose or worn hub bearings: Adjust or renewthe bearings.

NOTE: Adjust or renew the hub bearings asoutlined in the relevant suspension section.Brake discs that prove to bb distorted mustbe machined. This job is best entrusted to a

Brakes

brake specialist who will also be ahle todetermine if a new disc needs to be installed.

BRAKE FADE

(1) Brake pads saturated with hydraulic fluid:Renew, as a complete set, all the brake pads andrectify the leak.

(2) Incorrect pads installed: Check and instalnew recommended pads in sets.

Check the brake pads for serviceability through theinspection hole in the caliper.

NOTE: In most ca,ses brake fade is causedby overuse of the footbrake, which in turncauses a build up of heat at the frictionmaterial and discs. Once this excessive buildup of heat is allowed to dissipate the brakesshould again function normally.

BRAKES OVERHEATING

(l) Faulty handbrake cables or adjustment:Check the cables, renew or adjust.


(3) Obstructed or damaged hydraulic hose orline: Remove the obstruction or renew the hydraulichose or line.

(4) Obstructed master cylinder compensatingport: Clear the compensating port.

(5) Blocked vent in the master cylinder reservoircap: Check and remove the obstruction in the vent.

(6) Broken rear suspension arm: Check andrenew faulty components.

(7) Overuse of footbrake: Revise driving habits.NOTE: To checkfor brake binding, raise thevehicle and spin each wheel in turn by hand.If it is found that one caliper piston l'ssticking then it is advisable to overhaul allthe calipers and the master cylinder.


Bra,kes

BRAKE FAILUW(1) Faulty master cylinder: Remove and over-

haul the mast er cylinder(2) Loss of brakc fluid due to a leaking caliper:

Overhaul or renew the caliper assembly and bleed thehydraulic system.

Check the brake system for leaks.

(3) Loss of brake fluid due to a fractured hose,pipe or faulty union: Renew the faulty components asnecessary and bleed the hydraulic system.

(4) Air in the hydraulic system: Locate the sourceof the air leak and rectify. Bleed the hydraulic system.

(5) Water in the hydraulic fluid: Drain, flush,refill and bleed the hydraulic system.

NOTE: To locate the source of a brake fluidleak, refill the master cylinder and reservoirwith brake fluid and have an assistant pumpthe brake pedal. Check for obvious signs ofexternal leakage, prior to dismantling andoverhauling the braking system.

l 9 I

BRAKE NOISE

(1) Brakes squeal on application: Glazed fric-tion material. Remove and inspect the brake pads anddeglaze the friction material with emery paBgr.

(2) Grinding noise on application: Friction ma-terial worn away. Inspect the friction material on thebrake pads and renew the brake pads as necessary.Machine or renew the brake disc if it is scored.

NOTE: Brake squeal in most cases is causedby the friction material on the brake padsbecoming glazed. Unsuitable friction mater-ial or the omission of anti-rattle springs mayalso cause brake noise.

If the brake pads are worn, alwaysrenew the pads as a complete set.

2. DESCRIPTION

The front and rear disc brakes are applied byindependent circuits, by means of the dual circuitmaster cylinder. The two front outlets are connectedto the left and right hand front calipers. The rearoutlet is connected to the rear brakes.

Should a malfunction occur in one circuit, theremaining circuit is capable of stopping the vehiclesafely.

The disc calipers are of the floating type and areself adjusting. The single piston hydraulic brakecaliper automatically compensates for brake pad wearby the sliding caliper feature. The caliper slides onguide pin sleeves located on the anchor plate. Whenthe brakes are in the offposition, a constant clearanceis maintained between the pads on the disc.

Elastic deformation of the piston seal on thepiston takes place when the brakes are applied andreturns the piston to its normal off position when thebrakes are released.

Some models are equipped with heavy dutybrakes which are identified by cooling fins on the frontbrake caliper body.

Should the master cylinder be renewed, the newcylinder must have the same proportioning valvenumber stamped on the front of the cylinder.

The handbrake is operated by a lever located inthe centre console which is connected to the rearhandbrake drums via flexible cables. The small dia-meter drums are incorporated within the rear discassembly.

3. MASTER CYLINDER


(1) Working in the engine compartment, instalcovers to the mudguards to prevent damage to thevehicle paintwork.

(2) Disconnect the wiring from the pressuredifferential switch.Check the brake hoses for deterioration.


r92

(3) Disconnect the brake fluid pipes from theoutlet ports on the master cylinder. Plug the pipes toprevent the entry of dirt.

(4) Remove the support bracket to master cy-linder retaining bolt.

(5) Remove the retaining nuts holding the mas-ter cylinder support bracket to the body side memberand remove the bracket.

(6) Remove the nuts and lock washers securingthe master cylinder to the brake servo unit andwithdraw the master cylinder.

NOTE: Care should be exercised when re-moving or installing the master cylinderassembly to ensure that brake fluid is notpermitted to drop onto the surroundingpaintwork of the vehicle. Do not apply thebrake pedal when the master cylinder isremoved or the servo unit may be damaged.


(l) If the master cylinder has been renewedensure that it has the same proportioning valvenumber stamped on the end of the cylinder as thecylinder removed.

Installed view of the master cylinder showing thelocation of the proportioning valve number.

(2) Pour a small amount of new brake fluid intothe reservoirs and pump the piston assemblies with asuitable blunt rod until fluid begins to emerge fromthe outlets.

(3) Loosely instal the master cylinder to thebrake servo unit.

(4) Loosely instal the brake fluid pipes andtighten the master cylinder retaining nuts.

(5) Instal and tighten the support bracket.(6) Tighten the brake pipe union nuts and con-

nect the wires to the pressure differential switch.(7) Bleed the brakes as described under the

heading Hydraulic System.

TO DISMANTLE

(l) Remove the master cylinder as previouslydescribed.

(2) Remove the reservoir cap and seal and drainthe fluid from the reservoir.

Dismantled view of the brake master cylinder. pn somemodels the washer marked with an asterisk is]replaced

by an O ring. ]

(3) Remove the reservoir retaining nut andwasher.

(4) Separate the reservoir from the rcylinderbody and remove the two reservoir sealing gfommetsfrom the cylinder body.

(5) Remove the snap ring from the rear of thecylinder bore.

(6) Withdraw the primary piston together withthe return spring from the cylinder bore. l

(7) Using a suitable blunt rod, press the secon-dary piston into the cylinder bore and at the sametime remove the retaining stud and coppe{ washerfrom the cylinder body.

(8) Tap the cylinder gently on a block of woodand allow the secondary piston and return spring to bedislodged from the cylinder bore.

(9) Remove the pressure differential sqitch andcontact spring from the cylinder body. l

( l0) Carefully remove the end plug froml the rearof the cylinder body.

NOTE: When the end plug has been |oo-sened unscrew by hand to prevent the inier-nal components from springing out. l

( I I ) Withdraw the bore plug and the aluminiumseal block. If the assembly cannot be readily removedby hand, lightly tap the cylinder body on a block ofwood.

(12) Withdraw the large spring and thel pressedsteel poppet valve retainer.

( I 3) Withdraw the plastic poppet valve and spoolassembly using long nose pliers, gripping tde outeredge of the poppet valve. Should the valve lseparatefrom the spool, remove the spool by gripping thepoppet valve retaining extension on the end of thespool using long nose pliers.

(14) Remove the return springs from thetprimary. and secondary piston assemblies, the rubber O ringfrom the bore plug and the seal from the reser{'oir cap.

Brakes

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(l 5) If the pistons are to be reused, cut the plasticcup retainers with a sharp knife and remove the pistoncrrps using a blunt instrument. Ensure that the pistonsare not damaged during this operation.


( I ) Wash all components thoroughly in methyl-ated spirits. Do not use petrol, kerosene or othercleaning solvents.

(2) Check the master cylinder bores for wear,corrosion or pitting.

NOTE: Do not hone the master cylinderbore.

If the bore is pitted or worn renew themaster cylinder as an assembly.

(3) Ensure that all inlet and compensating portsbetween the reservoirs and the cylinder bore are freeof any obstruction.

(4) Discard all rubber parts.

TO ASSEMBLE

NOTE: Always use a genuine major repairkit which contains preassembled rubberseals and pistons. The use of a major kit willensure a thorough overhaul and long servicefrom the unit.

Assembly is a reversal of the dismantling proce-dure with attention to the following points:

(l) Liberally lubricate the cylinder bores and allinternal parts with clean brake fluid.

NOTE: Instal all the parts supplied with therepair kit. The aluminium seal block andbore plug supplied in the sealed plastic bagmust not be washed. They are prelubricatedand no further lubrication on assembly isnecessary.

(2) Hold the cylinder body vertical with theopen end to the top and carefully instal the plasticpoppet valve and spool assembly with the poppetvalve uppermost into the cylinder bore.

(3) Lower the pressed steel poppet valve retaineropen end first into the cylinder bore. Ensure that thevalve retainer is positioned correctly over the poppetvalve.

(4) Push down on the poppet valve retaineruntilthe spool is correctly positioned in the bore. Themeasurement, from the top of the bore to the top ofthe small end of the poppet valve retainer, should be44.5 mm when positioned correctly.

(5) Instal the large spring over the poppet valveretainer.

(6) Carefully instal the seal block, washers endfirst, into the bore and onto the large spring.

(7) Instal a new O ring onto the bore plug andposition the bore plug ensuring the slotted end abutsthe seal block.

193

(8) With the end plug installed onto aPhillips screwdriver, carefully depress the boreinto the cylinder bore.

(9) Using finger tension only, instal the end plugand tighten until the head of the plug is below thecylinder mounting flange. Using the correct sizespanner tighten the end plug to the specified torque.

(10) Place the switch contact spring onto thepressure differential switch plunger, small end first.Ensure that the spring stays on the plunger by invert-ing the switch, if not close the small end.

(11) Instal the pressure differential switch to theside of the cylinder body.

(12) Instal the new O ring seal onto the middlegroove of the secondary piston.

(13) Instal one of the three identical cup sealsonto the groove adjacent to the O ring seal ensuringthat the lip of the cup seal faces away from the O ringseal.

(14) Instal the second of the three identical cupseals onto the groove at the return spring side of the se-condary piston, ensuring that the seal lip faces awayfrom the O ring seal installed previously.

(15) Instal the last of the three identical cup sealsonto the groove at the return spring side of theprimary piston. Ensure that the lip of the seal facesaway frorn the piston pushrod end.

(16) Instal the secondary seal into the groove atthe pushrod end of the primary piston. Ensure that thelip of the seal faces away from the piston pushrod end.

(17) Instal a plastic cup retainer to the front endof the primary and the secondary pistons. Engage theretainer to the retainer groove and using a small bluntinstrument, push the retainer completely into thegroove. Take care not to damage the cup seals on thepiston.

(18) Slide the secondary return spring into theend of the secondary piston and carefully instal thepiston assembly, spring first, into the master cylinderbore.

(19) Using a suitable blunt rod, push the second-ary piston down to its full travel and instal thesecondary piston stud with a new copper washer or Oring. Screw the piston stop down by hand and tightenthe piston stop securely. Instal a new O ring to thestud.

(20) Instal the primary piston return spring to thefront end of the primary piston and carefully instal thepiston assembly, spring first into the master cylinderbore.

(21) Push the piston assemblies into the cylinderbore and instal the snap ring into the groove in the endof the cylinder bore.

(22) Place the reservoir sealing grommets into therecess on top of the master cylinder body.

(23) Place the reservoir into the sealing grom-mets. Instal the reservoir retaining nut and washer.

(24) Instal a new seal assembly to the reservoircap.

Brakes

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194 Brakes

(25) Instal the master cylinder to the vehicle aspreviously described.

4. FRONT DISC BRAKES

TO RENEW BRAKE PADS

Brake pads should be examined regularly andrenewed if the pad linings are excessively worn.

(1) Raise the front of the vehicle, support it onchassis stands and remove the front wheels.

Installed view of the front brake caliper.

(2) Drain approximately two thirds of the brakefluid from the master cylinder reservoir. This can bedone by loosening the brake line at the master cylinderand draining the fluid into a container. Do not reusethis fluid.

NOTE: Do not completely remove the brakeline or drain off all the fluid from thereservoir otherwise it will be necessary tobleed the hydraulic system. The fluid isdrained from the reservoir to prevent over-flow when the caliper piston is pushed backinto its bore to facilitate pad renewal.

Complete work on one caliper at a timeand replace brake pads as sets of four.

(3) While holding the guide pin hexagon with asuitable spanner, remove the self locking bolts retain-ing the caliper housing to the guide pins.

NOTE: Renew the self locking bolts retain-ing the caliper housing to the anchor plategaide pins. They must be renewed as theyare designed to be used once only.

(4) Remove the caliper housing and suspend orsupport the caliper housing in such a manner that thecaliper weight is not taken on the brake hose.

(5) Note the position of the brake pads and theanti-rattle springs . Lift the pads from the anchor plate.

Dismantled view of the front brake caliper.

(6) Ensure that the guide pins move freely in theanchor plate and that the dust covers are in goodcondition.

NOTE: Never lubricate the guide pins wiithmineral oil or grease. Use only a silicqnetype grease.

(7) Clean any dirt from the piston face contactarea and the caliper to pad contact area.

(8) Push the piston squarely by hand ,into thecaliper bore and check for fluid leaks.

NOTE: Overhaul the caliper if lealcs qreevident or the dust seals are deteriorated

(9) On models without heavy duty brakes, applybrake pad adhesive to the back of the brake pads andthe corresponding caliper and piston contact surfaces.

(10) Place the new brake pads onto the anchorplate, with the anti-rattle springs parallel with the padsand their open ends facing outwards. If the brake padsare marked Inner, Outer or Piston Side, ensureinstallation to the correct side of the anchor plate.

(11) Instal the caliper housing to the anchor plateand instal and tighten the new retaining bolts.

(12) Top up the brake master cylinder reservoirwith the recommended brake fluid and pump thebrake pedal to bring the pads to their normal positionalongside the disc.

(13) Instal the front wheels.

TO OVERHAUL CALIPER

(1) Raise the front of the vehicle, support it onchassis stands and remove the front wheels.

(2) Disconnect the brake hose from the brakecaliper by removing the banjo bolt holding the hose tothe caliper. Plug the brake hose to prevent the loss offluid and entry of dirt.

(3) Remove the bolts retaining the caliper hous-ing to the anchor plate guide pins and withdraw thecaliper. Discard the retaining bolts.

(4) Place a piece of soft cloth in front of the

rO


Brakes

piston and using a low air pressure applied to thehydraulic brake hose aperture, gently force the pistonfrom the caliper bore.

NOTE: If dfficulty is experienced in remov-ing the caliper piston, remove the brakehose, instal it to the caliper and apply the airthrough the brake hose.

(5) Disengage the dust seal from the locatinggroove in the end of the caliper bore and remove itfrom the caliper.

(6) Using a thin blunt probe, perferably madefrom wood or plastic, lift and remove the piston sealfrom its groove in the caliper bore.

(7) Pull the guide pins and their dust coversfrom the anchor plate.

(8) Clean all parts except the brake pads inmethylated spirits and examine carefully for wear andcorrosion. Renew any corroded, worn or doubtfulparts. Discard the piston seal and the dust seal.

Assembly and installation is a reversal of thedismantling and removal procedure with attention tothe following points:

(l) Check the brake pads on the anchor plate forwear and renew where necessary.

(2) Instal the dust covers to the guide pinsensuring that they are correctly seated in the guide pingroove.

(3) Lubricate the guide pins with a silicone typegrease and push the guide pins into the anchor plate.Seat the dust covers in the grooves on the anchorplate.

NOTE: Do not use mineral oil or grease tolubricate the gaide pins.

(4) Dip the new piston seal in clean brake fluidand instal the seal into the groove in the caliper bore.Ensure that the seal is not twisted and is correctlyseated in the groove.

(5) Smear the caliper bore with clean brake fluidand instal the new dust seal to the outer groove of thebore. Ensure that the dust seal is squarely and firmlyseated in its groove.

(6) Smear the outside of the piston with cleanbrake fluid. Guide the lip of the dust seal over thepiston and push the piston into the bore. Push thepiston by hand completely into the bore and instal theouter lip of the dust seal squarely into the pistongroove.

(7) Instal the caliper over the brake pads anddisc and instal and tighten the new retaining bolts.

(8) Instal new copper washers to the brake hosebanjo bolt and secure the brake hose to the caliper.

(9) Bleed the hydraulic system as outlined underthe heading Hydraulic System.

(10) Start the engine to activate the brake servounit and press the brake pedal hard. Check for fluidleaks.

1 9 5

TO REMOVE AND INSTAL BRAKE DISC

(1) Raise the front of the vehicle, support it onchassis stands and remove the front wheel.

(2) Remove the caliper anchor plate to stub axleflange retaining bolts and lift the caliper assembly offthe disc.

(3) Place a spacer approximately as thick as thebrake disc between the brake pads and support orsuspend the caliper out of the way without stretchingthe brake hose.

(4) Remove the grease cap from the hub and thesplit pin from the stub axle.

HUB AND DISC ASSY

\..r

OUTER BEARING CUP

\ clst.rLArED NUT

\ ,r*.* \ orr, "o,'ffiffibb&

OUTER BEARING CONE

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ffi ){G, t&a,EE l l *a , : : . t ,

ffi 'In #wf f i ' *R t f f iffi \Gy A,ffi

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|NNER BEARTNG CUP

Dismantled view of the front hub components.

(5) LInscrew the adjusting nut on the end of thestub axle, remove the thrust washer and the outerbearing cone and roller assembly.

(6) Withdraw the hub and disc assernbly fromthe stub axle.

(7) Clean the disc with solvent and examine forwear, damage or scoring.

(8) If necessary the hub bearings and seal can beserviced as described in the Front Suspension section.


(1) Adjust the front hub bearings as described inthe Front Suspension section.

Checking the brake disc for runout using a dial gauge.


196

(2) Instal the brake caliper and tighten themounting bolts to Specifications.

(3) Pump the brake pedal to relocate the brakepads after installation.

TO CHECK BRAKE DISC

(l) Raise the front of the vehicle, support it onchassis stands and remove the front wheel.

(2) Remove the grease cap from the front hub.Remove the split pin and tighten the front hub bearingnut until the front hub bearings are preloaded.

(3) Rotate the front hub and measure the runoutof the brake disc machined surface.

(4) Machine or renew the brake disc if therunout exceeds Specifications.

5. REAR DISC BRAKE ASSEMBLY

TO CHECK AND RENEW PADS

To inspect the rear brake pads follow operations(l) and (2).

(l) Raise the rear of the vehicle, support it onchassis stands and remove the rear wheels.

(2) Look through the square hole in the caliperhousing and note the thickness of the friction materialremaining on the pad.

(3) Drain approximately two thirds of the brakefluid from the master cylinder reservoir. This can bedoneby looseningthe brake line at the master cylinderand draining the fluid into a container. Do not reusethis fluid.

NOTE: Do not completely remove the brakeline or drain off all the fluid from thereservoir otherwise it will be necessary tobleed the hydraulic system. The fluid isdrained from the reservoir to prevent over-,flow when the caliper piston is pushed backinto its bore to facilitate pad renewal.

(4) Remove the bolts retaining the caliper hous-ing to the anchor plate guide pins.

Brakes

NOTE: Renew the self locking bolts retain-ing the caliper housing to the anchor plategaide pins. They must be renewed as theyare designed to be used once only.

(5) Remove the caliper housing and suspend orsupport the caliper housing in such a manner that thecaliper weight is not taken on the brake hose.

(6) Note the position of the brake pads and theanti-rattle springs. Lift the pads from the anchor plate.

(7) Ensure that the guide pins move freely in theanchor plate and that the dust covers and seals are ingood condition.

NOTE: Never lubricate the gvide pins withmineral oil or grease. Use onllt a siliconetype grease.

(8) Push the piston squarely by hand into thecaliper bore and check for fluid leaks.

NOTE: Overhaul the caliper if fluid lealcsare evident or the dust seals are deterior-ated.

(9) Place the new brake pads onto the anchorplate. The anti-rattle springs should be parallel withthe pads, their open ends facing outwards.

(10) Instal the caliper housing to the anchor plateand instal and tighten the attaching bolts.

(l l) Top up the brake master cylinder reservoirwith the recommended brake fluid and pump thebrake pedal to bring the pads to their normal positionalongside the disc.

( l2) Instal the rear wheels and lower the vehicle tothe ground.

TO OYERHAUL CALIPER

(l) Raise the rear of the vehicle, support it onchassis stands and remove the rear wheels.

(2) Disconnect the brake hose from the brakecaliper by removing the banjo bolt holding the hose tothe caliper. Plug the brake hose to prevent the loss offluid and entry of dirt.

(3) Remove the bolts retaining the caliper to theanchor plate guide pins and withdraw the caliper.

NOTE: Renew the self locking caliper re-taining bolts.

(4) Place a piece of soft cloth in front of thepiston and using a low air pressure applied at thehydraulic brake hose aperture, gently force the pistonfrom the caliper bore.

(5) Disengage the dust seal from its locatinggroove in the end of the caliper bore and remove itfrom the caliper.

(6) Using a thin blunt probe, perferably madefrom wood or plastic, lift and remove the piston sealfrom its groove in the caliper bore.

(7) Pull the guide pins and their dust coversfrom the anchor plate.Installed view of the rear brake caliper.


Brakes r97

(10) Start the engine to activate the brake servounit and press the brake pedal hard. Check for fluidleaks.

TO REMOVE AND INSTAL BRAKE DISC

(1) Raise the rear of the vehicle, support it onchassis stands and remove the rear wheels.

(2) Remove the caliper and anchor plate tobrake support plate retaining bolts and tift the caliperoff the disc.

(3) Place a spacer approximately as thick as thebrake disc between the brake pads and support orsuspend the caliper out of the wiy without sfritchingthe brake hose.

(4) Withdraw the disc assembly from the axleshaft.

NOTE: If difficulty is experienced in remov-ing the brake disc, ensure that the hand-brake ,s in the released position anddisconnect the handbrake cable from thehandbrake relay rod.

(5) Clean the disc with solvent and examine forwear, damage or scoring.


(l) Instal the brake caliper and tighten themounting bolts to Specifications.

(2) Pump the brake pedal to relocate the brakepads after installation.

TO CHECK AND OVERHAULHANDBRAKE ASSEMBLY

(1) Raise the rear of the vehicle, support it onchassis stands and remove the rear wheels.

(2) Remove the brake caliper and disc assemblyas described under To Remove and Instal Brake Disc.

NOTE: Checkthe liningsfor excessive wear,oil saturation or gumminess and renew aspairs with the corresponding lining and shoeassembly on the other wheel. If the liningsare to be renewed proceed with thefollowingsteps.

(3) Disconnect the lower return spring from bothbrake shoes.

(4) Disconnect the upper return spring fromboth brake shoes and remove the brake adjuster.

(5) Remove both brake shoe retaining springs bycompressing the spring and rotating the pin 90'.Rotate the axle flange as required.

(6) Remove the handbrake shoesvehicle.

(7\ If necessary, remove the reactionpin from the vehicle.

from the

plate and

(8) If necessary, disconnect the return spring andhandbrake cable and remove the actuating lever fromthe vehicle.

BLEEDER VALVE

&M*ffi &

Dismantled view of the rear caliper and anchor plate.

(8) Clean all parts except the brake pads inmethylated spirits and examine carefully for wear andcorrosion. Renew any corroded, worn or doubtfulparts. Discard the piston seal and the dust seal.

Assembly and installation is a reversal of thedismantling and removal procedure with attention tothe following points:

(1) Check the brake pads on the anchor plate forwear and renew where necessary.

(2) Lubricate the guide pins with a silicone typegrease and push the dust covers into the grooves in theguide pins.

NOTE: Do not use mineral oil or grease tolubricate the guide pins.

(3) Push the guide pins into the anchor plate.Ensure that the dust covers are seated correctly in thegrooves on the anchor plate.

(4) Dip the new piston seal in clean brake fluidand instal the seal into the groove in the caliper bore.Ensure that the seal is not twisted and is correctlyseated in the groove.

(5) Smear the caliper bore with clean brake fluidand instal the new dust seal to the outer groove of thebore. Ensure that the dust seal is squarely and firmlyseated in its groove.

(6) Smear the outside of the piston with cleanbrake fluid. Guide the lip of the dust seal over thepiston and push the piston into the bore. Push thepiston by hand completely into the bore and instal theouter lip of the dust seal squarely into the pistongroove.

(7) Instal the caliper over the brake pads anddisc and instal and tighten the new retaining bolts.

(8) Instal new copper washers to the brake hosebanjo bolt and secure the brake hose to the caliper.

(9) Bleed the hydraulic system as outlined underthe heading Hydraulic System.

lII

%


198 Brakes

(9) Check the inside of the brake disc assembly rfor cracks, scoring or ovality and renew or regrind asnecessary.

(10) Ensure that there are no burrs on the brakesupport plate where the shoes slide.

(11) Check the tension of the brake shoe returnsprings by comparison with new springs and renew asnecessary.

(12) Check the actuating lever assembly for wear.(13) Check that the adjuster thread is not burred

or damaged and turns freely by hand.(1a) Check the operation of the handbrake cabie.(15) Check the retaining springs and pins for wear

or damage.Installation is a reversal of the removal procedure

with attention to the following points:(1) Install the brake shoes with the longest step

between the friction material and the end of the brakeshoe at the bottom.

(2) Lubricate all metal to metal contact surfaceswith a light smear of zinc oxide grease.

(3) Sparingly lubricate the adjuster assembly andthe reaction plate pin with Molybdenum disulphideglease.

Installed view of the handbrake assembly.

(4) Position the brake shoes on the support plateand install the retaining springs and pins. Ensure thatthe pins are correctly locked.

(5) Install the brake adjuster and the upper andlower return springs to the brake shoes.

(6) Loosen the handbrake cable adjusting nutsuntil there is no tension in the handbrake cable andthe actuating levers are fully retracted.

(7) Extend the brake adjuster until the brakedisc slides neatly over the brake shoes. Ensure that thebrake shoes are centralised by firmly operating thehandbrake several times.

&- t'*

249t261t3,j,9

of the handbrake assembly

(8) Set the adjuster length to obtain minimumclearance between the brake shoes and the disc withno drag when the disc is rotated.

(9) Install the caliper assembly and tighten theanchor plate bolts to the specified torque. Install therear wheel. If applicable, connect the shock absorberlower mounting.

(10) Check the handbrake operation and ifnecessary, adjust the handbrake cable as describedunder the Brake Adjustments heading.

6. HANDBRAKE LEVER AI{D CABLE

TO REMOVE AND INSTALHANDBRAKE LEVER

(l) Raise the rear of the vehicle and support iton chassis stands.

(2) Remove the handbrake cable adjusting nuts,cable and equaliser from the handbrake relay rod.

ADJUSTER ASSEMBLY/ \

ffiffi# 'm

M

@-",,1".-I

z- PaN

It

@Dismantled view

LEVER ASSY

+ B O L T

Dismantled view of the handbrake lever and associ-ated components.


(3) Remove the retaining clip and the rubberboot assembly from the handbrake relay rod.

(4) Remove the centre console as described inthe Body section.

(5) Remove the handbrake lever securing bolts.To gain access to the securing bolts lift and supportthe carpet so that it does not interfere with furtheroperations.

(6) Manoeuvre the lever assembly up far enoughto permit the removal of the handbrake warning lampswitch.

(7) Remove the handbrake lever assembly fromthe vehicle. Where necessary remove the damper andwasher from the relay rod.


(l) Lubricate all working points of the hand-brake mechanism when assembling.

(2) Ensure that the rubber boot sealing the relayrod is correctly installed.

(3) Adjust the handbrake as described underBrake Adjustments.

TO REMOVE AND INSTALHANDBRAKE CABLE

(l) Raise the rear of the vehicle and support iton chassis stands.

(2) Remove the handbrake cable adjusting nut,cable and equaliser from the handbrake relay rod.

(3) Pull the outer cable to the rear of the vehicleand disconnect it from the retaining clips on the bodyfloor.

(4) Remove each handbrake cable return springfrom its actuating lever and disconnect the hand6rakecable from the levers.

(5) Pull the cable toward the front of the vehicleand slide out of the retainers.


(1) Lubricate all working points of the hand-brake mechanism when assembling.

(2) Adjust the handbrake as outlined under theappropriate heading.

7. BRAKE ADJUSTMENTS

TO ADJUST HANDBRAKE


(2) Remove any slack from the handbrake cableby adjusting the relay rod nuts.

(3) Mark the positions of the rear wheels inrelation to the rear hubs and remove the rear wheels.

(4) Remove the rear brake disc as previouslydescribed.

(5) Adjust the handbrake shoes to 159.5 mmoutside diameter using the adjuster and measuringwith a pair of calipers.

r99

View showing the handbrake cable adjusting point.

NOTE: If a pair of calipers is not availableadjust the brake shoes until the disc is aneat, slidingfit on the brake shoes and turnswith no drag.

(6) Instal the disc, rear brake caliper and rearwheel as previously described.

(7) Operate the handbrake lever several times toset the brake shoes.

(8) From the fully released position pull thehandbrake lever up six notches.

(9) Check that there is a moderate drag at therear wheels, approximately 20 - 40 Nm.

(10) Release the handbrake and check that therear wheels rotate freely.

(11) If necessary, repeat steps (5) to (10) andlower the vehicle to the ground.

8. HYDRAULIC SYSTEM

TO BLEED

Bleeding the hydraulic system is necessary whensome portion of the system has been disconnected orair has been allowed to enter the svstem.

The brake fluid in the hydraulic system should bechanged at regular intervals, refer to the Lubricationand Maintenance section. The procedure for changingthe brake fluid and bleeding the hydraulic system aresimilar with attention to the notes in the text.

There are four points in the system where bleedervalves are installed; one on each brake caliper.

(l) Fill the fluid reservoir on the master cylinderwith clean hydraulic brake fluid and maintain at leasthalf full throughout the entire bleeding operation.

(2) Attach a rubber bleeder tube to the left rearbleeder valve and immerse the other end of the tube ina small amount of brake fluid contained in a cleanglass jar.

Brakes


200

Method of bleeding air from the brake hydraulicsystem.

(3) Pump the brake pedal several times and withthe brake pedal depressed, open the bleeder valve.Close the bleeder valve whilst air, or fluid and air is es-caping from the bleeder valve. Allow the brake pedalto return slowly and repeat this step until air bubblescease to flow from the bleeder tube.

NOTE: If changing the brakefluid, continuebleeding the system until clean new fluidflows from the bleeder tube.

(4) Carry out the bleeding operations, in thesame manner, on the remaining bleeder valves in thesystem. Always work from the longest line in thesystem down to the shortest.

NOTE: Do not allow the fluid in the reser-voir to fall below the haA full level at anytime during the bleeding operation or airmay enter the system and a fresh start willhave to be made. Always use new fluid whentopping up the reservoir.

(5) After bleeding the system the brake pedalshould be firm when depressed with no evidence ofsponginess. Ensure that all the bleeder valves are tight.

NOTE: If sponginess is evident in the brakepedal after the bleeding operations are com-pleted it may be necessary to pressure bleedthe system to expel all traces of air from thelines. This is best left to an authorised dealeror brake specialist.

(6) Top up the master cylinder reservoir withclean brake fluid.

9. BRAKE SERVO UNIT

DESCRIPTION

The brake servo unit is installed between thebrake pedal and the brake master cylinder.

The valve and rod assembly of the servo unit andthe pedal pushrod are on the same axis and in the case

of a vacuum failure act as a single pushrod withoutassistance.

The servo unit is connected by a hose to the inletmanifold.

On models with heavy duty brakes, a tandembrake servo unit is installed.

TO CHECK OPERATION

( I ) With the engine switched off, apply thefootbrake several times to exhaust all vacuum fromthe system.

(2) Again apply the footbrake, but this time holdthe brake pedal fully depressed.

(3) Start the engine. If the servo unit is function-ing satisfactorily a distinct downward movement ofthe brake pedal should be noticed.

Should the pedal fail to fall away when the enginehas been started, the vacuum system can be con-sidered inoperative.

Checking for vacuum at the servo unit vacuum hoseconnection.

NOTE: If the pedal continues to fall awaythere is a fault in the hydraulic system.

(4) Ensure that the brake pedal is fully off, startthe engine and run it at medium speed. Stop theengine.

Let the vehicle stand for 1-2 minutes, then pressthe brake pedal two or three times and check itsoperation.

If there is no vacuum assistance, the vacuumsystem has developed a leak or the one way checkvalve is defective.

NOTE: Before removing the servo unitfromthe vehicle for inspection, disconnect thevacuum supply hose at the unit, start theengine and check that manifold vacuum isin fact reaching the servo unit. Also checkthe one way check valve as described below.

TO TEST ONE WAY CHECK VALYE

(1) Release the hose clip and disconnect the hosefrom the check valve. Carefully lever the check valvefrom the servo unit.

Brakes


(2) Check the valve for sticking- Suction-on themanif'otd side should allow air to flow freely. Airblown into the valve from the manifold side shouldnot be able to flow through the valve.

(3) Check the rubber seal for deterioration andrenew if necessary.

(4) Instal the valve and check the operation ofthe servo unit as previously described.

NOTE: Check that there are no air lealcs atthe hose connections and that the hose clipsare tight. Also check that the hose is nolbulged or collapsed due to deterioration.

TO REMOVE AND INSTAL SERVO UNIT

(l) Remove the brake master cylinder as pre-viously described

(2) Disconnect the vacuum hose from the checkvalve.

(3) Working inside the vehicle, remove the re-taining clip and washer from the brake pedal clevispin and slide the pushrod from the clevis pin.

(4) Remove the nuts securing the servo unit tothe bulkhead and manoeuvre the servo unit with thebracket from the engine compartment.

Installation is a reversal of the removal procedurebut it will be necessary to bleed the hydraulic system.

Brake seruo unit removed from the vehicle.

10. BRAKE PEDAL


(l) Working inside the vehicle, remove the

207

lower trim panel retaining screws and fasteners and

withdraw the trim panel from the drivers footwell.(2) Open the fuse cover by turning the retainers

90 degrees, prise out the left hand side hinge pin andwithdraw the fuse cover from the vehicle.

(3) Remove the nuts retaining the throttle pedalassembly to the bulkhead and place the assembly toone side.

(4) Remove the retaining clip and washer fromthe brake pushrod clevis Pin.

(5) Slide the pushrod from the clevis pin andcollect the remaining washers.

(6) Remove the nut securing the brake pedalshaft to the pedal support.

Installed view of the brake Pedal.

(7) Tap the shaft through the brake and'ifapplicable, the clutch pedal components noting thelocation of all springs, washers and spacers.

(8) Manoeuvre the throttle pedal assembly clearto allow the pedal shaft to be withdrawn sufficiently toallow pedal removal.

(9) Withdraw the pedal and return spring assem-blv.

(10) Inspect the components for wear, bending orcracks. Check the tension of the return spring.


(l) Apply a coating of multi-purpose grease tothe outer faces of the pedal shaft.

(2) Manoeuvre the pedal and spring into posi-tion and instal the pedal shaft.

(3) Instal the nut and washer to the pedal shaftand tighten securely. If the shaft turns it can be heldusing a suitable spanner on the flats provided.

(4) If necessary adjust the brake pedal switch orswitches as described in the Electrical System section.

Brakes


202

BATTERY

Type 12 volt lead acidPolaritv Negative earthSpecific gravity:^

Fu[f charged Above 1.250 - 1.270Fu l l yd ischarged . . . Be low l . l 30

ALTERNATOR

MakeMaximum output 85 ampsVoltage 14.25 - 14.55 voltsBrush length:

Standard 9.3 mmMinimum 4.0 mm

STARTER MOTOR

Manual TransmissionMake Delco RemyType Four pole, four brush solenoid

operated pinion with reduction gearand overrunning clutch

Commutator:Maximum out of round 0.05 mmMinimum diameter 27.0 mmMinimum depth of undercut 0.2 mm

Brushes:Minimum length 9 mmSpring tension 15-17 N

Automatic TransmissionMake BoschType Four pole, four brush solenoid

operated pinion with overrunning clutchCommutator:

Maximum out of round 0.05 mmMinimum diameter 33.5 mmMin imum dep th o f undercu t . : . . . . . . 0 .7 mm

IGNITION SYSTEM

.The ignition system is an integral part of theengrne management system. The specifications, test-ing and overhaul procedures are fully covered in theFuel and Engine Management section.

Refer to supplementfor norc intomation,


Starter motor retaining bolts . . . . 50 NmStarter motor brace bolt. . . 35 NmAlternator pulley retaining nut . . 68 NmAlternator mounting bolts . 34 NmW i p e r p i v o t b o l t s . . . . 2 N m

1. BATTERY AND CHARGING SYSTEMTROUBLE SHOOTING

BATTERY UNDERCHARGED

(l) Loose or slipping engine drive belt: Renewthe engine drive belt and check the adjuster.

(2) Faulty alternator voltage regulator: Renewthe regulator.

(3) Faulty battery: Instal a new battery of therecommended type and capacity.

(4) Faulty alternator: Overhaul or renew thealternator.

(5) Fault in the charging circuit wiring: Checkand repair or renew the wiring harness.

Examine the drive belt for cracks or deteriorationwhere the drive belt is positioned around the water

pump pulley.

ELECTRICAL SYSTEM

SPECIFICATIONS


Electrical S,tstem

NOTE: Check t;he state of charge (specrficgravity) of the battery as described under theBattery heading in this section. If the bat-tery rs undercharged, check the possiblecauses in the order given.

BATTERY OVERCHARGED(l) Faulty alternator voltage regulator: Renew

the regulator.(2) Faulty battery: Renew the battery.(3) Faulty alternator: Overhaul or renew the

alternator.(4) Faulty charging circuit wiring or con-

nections: Check and renew or repair any faultycomponents.

NOTE: An overcharged battery is indicatedby continual loss of water through boiling.This l's usually accompanied by dis-colouration of the electrolyte.

CHARGE INDICATOR LAMP REMAINS ON

(l) Broken engine drive belt: Renew the enginedrive belt.

(2) Faulty regulator: Check and renew the regu-lator.

(3) Faulty alternator: Check and overhaul thealternator.

(4\ B* lead from alternator broken: Repair orrenew the B* lead.

(5) S lead from alternator broken: Repair orrenew the S lead.

(6) Short to earth in the lamp circuit: Check andrepair the circuit.

(7) Battery overcharged: Refer to the previousheading.

CHARGE INDICATOR LAMP DOES NOTOPERATE

( I ) Charge indicator lamp bulb blown: Checkand renew the faulty bulb.

(2) Charge indicator lamp bulb holder faulty:Check the bulb holder and renew if necessary.

(3) Open circuit in the wiring: Check and rectifythe open circuit.

(4) Open circuit in the rotor windings: Checkand overhaul the alternator.

NOISE IN DRIVE BELT OR ALTERNATOR

(l) Drive belt frayed: Renew the drive belt.(2) Loose alternator mounting bolts or worn

bearings: Tighten the mounting bolts or renew thebearings.

(3) Loose alternator pulley: Tighten the pulleyretaining nut.

(4) Faulty alternator: Overhaul or renew thealternator.

203

Spin the alternator pulley by hand to check the bear-ings for roughness.

NOTE: To check if the noise is in thealternator or drive belt, remove the drivebelt.

If the noise is gone when the engine isrunfor a short time, check the serviceabilityof the belt and alternator components.

2. BATTERY AND STARTING SYSTEMTROUBLE SHOOTING

STARTER LACKS POWER TO CRANK ENGINE

(l) Battery undercharged: Check the chargingsystem and rectify as necessary.

(2) Battery will not hold charge: Check andrenew the battery.

(3) Battery terminals loose or corroded: Cleanand tighten the terminals.

(4) Faulty starter motor: Check and overhaul thestarter motor.

(5) Faulty starter or dirty solenoid switch orcontacts: Check and renew the solenoid as necessarv.

Remove all din and corrosion from the battery ter-minals.


204 Electrical System

NOTE: Check the state of charge of thebattery and check all terminals for cleanli-ness and security. If necessary, test andoverhaul the starter motor as described inthis section.

STARTER WILL NOT ATTEMPT TOCRANK ENGINE

(l) Open circuit in the starting system: Checkfor dirty or loose terminals, dirty commutator, faultysolenoid or faulty switch.

(2) Discharged battery: Check for a fault or ashort circuit in the system.

(3) Battery fully charged but will not crankengine: Check for a locked drive and ring gear,internal starter fault or a seized engine.

(4) Automatic neutral safety switch faulty:Check the switch and renew if necessary.

(5) Faulty starter or dirty solenoid switch orcontacts: Check and renew the solenoid as necessary.

NOTE: Turn the engine over by hand toensure that the starter drive is not lockedwith the flywheel ring gear and that theengine is not seized. Ensure that the ignitionis switched Off before turning the engine.

3. LIGHTING SYSTEM TROUBLE SHOOTING

LAMP OR LAMPS FAIL TO LIGHT

(l) Faulty bulb: Check and renew the faultybulb.

(2) Open circuit in the wiring or connections:Check and rectify the fault.

(3) Faulty lamp switch: Check and renew theswitch.

Engine compartment relay housing and fusible links. 1: Fuel pump relay fuse - 15 amp, 2 : Hom relay fuse- 15 amp, 3 : Engine cooling fan relay fuse - revisedto 3O amp, 4 : low beam headlamp relay fuse - 15amp, 5 : High beam headlamp relay fuse - 25 amp.

Using a test lamp to check for power at the headlampwiring connector.

(4) Fuse or fusible link blown: Rectify the faultand renew as necessary.

(5) Headlamp relay or relay fuse faulty: Checkand renew as necessary.

(6) Tail lamp fuse blown: Renew the fuse.

NOTE: Switch on the headlamps and usinga test lamp, check that the lamp circuits areoperating. This is best done by starting atthe lamp wiring connector and workingback to the power source.

LAMP OR LAMPS INCORRECTLYILTUMINATED

(1) Lamp or lamps incorrectly earthed: Checkthe lamp earth for looseness or poor contact, either atthe lamp body or the wire and repair as necessary.

(2) Incorrect bulbs installed: Check the bulbwattage and voltage and renew with the correct type ifnecessary.

(3) Dirty or damaged lamp reflector: Clean orrenew the lamp reflector.

(4) Faulty bulbs: Check with a known ser-viceable unit and renew if necessary.

(5) Dirty lamp lens: Clean or renew the lamplens.

NOTE: The most common cause for thiscondition is incorrect lamp earthing. Checkthe lamps at their earthing points.

LAMPS FLARE WITH ENGINE SPEEDINCREASE

( 1) Faulty battery: Check and renew the battery.(2) Battery in a low state of charge: Recharge the

battery and check the charging system.(3) High resistance or faulty connections be-

tween the battery and the alternator: Check the circuitand rectify the condition.

(4) Poor earth connection between the battery


Electrical System 205

and the engine: Check the battery earth lead and theearth between the engine and the body.

(5) Faulty alternator voltage regulator: Renewthe regulator.

(6) Alternator faulty: Check and repair or renewas necessary.

NOTE: The most common cause for thiscondition is dirty terminals on the earthleads. Check all earth leads at their earthingpoints.

4. TURN SIGNAL LAMP TROUBLE SHOOTING

TURN SIGNAL LAMP DOES NOT LIGHT ANDNO AUDIBLE NOISE FROM FLASHER UNIT

(1) Fuse blown: Rectify the fault and renew thefuse.

(2) Flasher unit faulty: Renew the flasher unit.(3) Turn signal switch faulty: Renew the switch.(4) Fault in the wiring circuit: Check and repair

the fault.

TURN SIGNAL WARNING LAMP DOES NOTFLASH BUT AUDIBLE CLICKING FROMFLASHER UNIT

( I ) Warning lamp bulb blown: Check and renewthe bulb.

Turn the retaining clips 9O degrees and open the fusecover to gain access to the flasher unit.

(2) Fault in the warning lamp wiring: Check andrepair the fault.

NOTE: When renewing bulbs ensure that anew bulb of the coruect wattage is used.

TURN SIGNAL LAMPS FLASH WEAKLY ANDAT GREATER THAN NORMAL SPEED

(1) Faulty flasher unit: Check and renew theflasher unit.

(2) Front or rear bulb blown on the turn side:Check and renew the bulb.

NOTE: If the flasher unit is to be renewedalways try to obtain a genuine replacementpart.

HAZARD WARNING LAMPS DO NOTOPERATE

(1) Fuse blown: Rectify the fault and renew asnecessary.

(2) Flasher unit faulty: Renew the flasher unit.(3) }{azard warning switch faulty: Renew the

switch.(4) Fault in the wiring circuit: Check and repair

the fault.

5. TEST EQUIPMENT AND SOMEAPPLICATIONS

Special Equipment Required:To Make Test Lamp or Jumper Lead - Solderingiron

When working on the electrical system, a testlamp and jumper leads can be very useful to checkcircuits.

TO MAKE A JUMPER LEAD

The minimum materials required to make ajumper lead are one length of 4 mm wire and twosmall alligator clips.

(l) Bare both ends of a suitable length of 4millimetre wire.

(2) Connect a small alligator clip to each end ofthe wire. Solder and tape the connections.

(3) Test the jumper lead for continuity by re-moving one battery cable and connecting the leadbetween the cable and the battery terminal. Turn the

Assembldd view of the various sized jumper leads.



ignition key to On, the dashboard warning lampsshould operate indicating a completed circuit throughthe jumper lead.

(4) Remove the jumper lead from the circuit andreconnect the battery.

NOTE: Make a few jumper leads of variouslengths using dffirent sizes and types ofalligator and battery clips.

TO MAKE A TEST LAMP

Due to the extensive use of electronic componentsin the electrical system, an LED (light emitting diode)test lamp is recommended. A simple LED test lampcan be made from a suitable length of 3 mm wire, analligator clip, an LED, a t/q wafi 560 ohm resistor, asuitable case such as an old ball point pen case and alength of rod or wire sharpened to form a probe.

( I ) Solder the length of wire to the K (cathode)lead of the LED, The K lead is the shorter of the twoleads and is adjacent to the flat on the LED.

(2) Solder the 560 ohm resisror to the A (anode)lead of the LED.

(3) Solder a short length of wire to the other leadof the resistor and to the probe.

(4) Drill a hole in the side of the case to acceptthe wire attached to the K lead of the LED.

y'wtRE

(5) Mount the probe in the case. If using a pencase, push the probe through the lower end of the penafter removing the refill.

(6) Push the lead attached to the K lead of theLED through the hole made in the side of the case andsolder the alligator clip to the lead.

(7) Mount the LED to the case. If using a pencase, the LED may be mounted in the plug at the topof the pen after drilting the plug to accept- the LED.

(8) Suitably attach the probe to the case usingadhesive or tape.

TO TEST SWITCHES

(l) Disconnect the wires from the switch.(2) Using a test lamp, test each wire to locate the

power wire. It may be necessary to turn the ignitionswitch On as the switch may be wired throrfih theignition circuit.

(3) Disconnect the test lamp and connect ajumper lead between the power wire and the wirefrom the other side of the switch.

If the circuit functions, the switch can be consi_dered faulty and should be renewed. Refer to theheading Switches and Controls.

TO TEST BULBS

( I ) Remove the bulb from the bulb holder.(2) Connect a jumper lead between the positive

terminal of a battery and the base of the bulb.(3) Connect another jumper lead between the

negative battery terminal and the contact on the baseof the bulb. The bulb should illuminate.

If the bulb has two filaments, connect the jumperlead to the second contact on the base of the bulb. Thesecond filament should illuminate.

If the bulb fails to light. It should be renewed witha bulb of the correct voltage and wattage.

TO TEST CIRCUITS

( I ) Turn the circuit switch On.(2) Using a test lamp, check for power at one of

the circuit connections. A fuse is a good starting point.If power is available, reconneci the corrr"cior and

continue checking towards the motor or bulb end ofthe circuit.

If power is not available, continue checkingtowards the battery or switch end of the circuit.

6. BATTERY

Special Equipment Required:To Test - HydrometerTo Charge - Battery charger


NOTE: Prior to disconnecting the batterydetermine if the vehicle radioTcassette unit

PEN CASE

451 /LDs

Schematic of an LED test lamp. Ensure that theconnections to the K (cathode) lead and A (anode) lead

of the LED are as illustrated.



is equipryd with a PIN number securitycode. If the radio/cassette is equipped with aPIN number it will be necessary to ltave tltenumber and instruction sheet supplied withthe vehicle so that the radio/cassette me-mory and security code can be reset. If thenumber has been lost it may be obtained bycontacting an authorised dealer and provid-ing proof of ownership.

After connecting the battery, start andr4n the engine at 3 000 rpm for l0 secondsto reset the idle air control valve.

(l) Disconnect the negative and positive batteryterminals.

(2) Remove the battery holding clamp and liftthe battery from the vehicle.


(l) Ensure that the terminals and posts areclean.

(2) When connecting the leads to the battery,ensure that the polarity is correct. Connect the posi-tive lead first.

(3) Do not overtighten the terminal clamp nuts.(4) Apply petroleum jelly to the battery ter-

minals to prevent corrosion.

MAINTENANCE

Battery maintenance should be performed at thescheduled services.

NOTE: Keep naked flame away from thebattery as the battery gases are hishlyexplosive.

(l) Keep the battery and the surrounding areaclean and dry. In particular, ensure that the top of thebattery is free from dirt and moisture to preventvoltage flow between the terminals.

If necessary, clean the battery case as follows:

Remove all dirt and corrosion from the batteryterminals.

(a) Remove the battery from the vehicle aspreviously described.-

(b) Pour hotwater over thebattery beingcarefulnot io-allow any water to enter the battery through thefiller cap vent holes.

(c) Wipe the battery case clean.(2) Clean the battery terminals and posts using a

battery post cleaner, wire brush or emery cloth.Remove all dirt and corrosion.

(3) Remove the filler caps and check that thevent holes are clear.

(4) Check the electrolyte level and replenishwith distilled water as necessary. The correct level isjust above the top of the plates. Do not overfill thebattery. Do not transfer electrolyte from one cell toanother.

(5) If the battery electrolyte requires frequentreplenishing, check the battery case for cracks. If thecase is damaged, renew the battery.

Check for overcharging by measuring the outputof the alternator as described later in this section.

(6) Apply petroleum jelly to the battery ter-minals to prevent corrosion.

(7) If the electrolyte has overflowed and con-taminated the battery carrier and surrounding bodypanels, proceed as follows:

(a) With the battery removed from the vehiclesprinkle bicarbonate of soda over the corroded areas.

(b) Pour hot water over the bicarbonate of soda.The bicarbonate of soda will react with the water andbegin to foam.

(c) When the bicarbonate of soda has stoppedfoaming, rinse the area with clean water and allow todry.

(d) Remove any blistered paint from the con-taminated areas.

(e) Paint the contaminated areas with a cor-rosion inhibiting paint.

TO TEST AND CHARGE

(l) Using a hydrometer, test the specify gravityof the battery electrolyte. Refer to the following chartwhich shows charge conditions for various specificgravity readings:1.110-1.130 Ful lyd ischarged1 . 140- 1. I 60 Nearly discharged1. 170- I . 190 Approximately one quarter chargedr.200-r.2201.230-1.250 Approximately three quarter charged1.260-1.280 Fully charged

These readings are for electrolyte at atemperatureof 20 deg C. For every l0 deg above 20 deg C, add0.007. For every l0 deg below 20 deg C, substract0.007.

NOTE: An accurate specific gravity readingcannot be obtained if distilled water hasrecently been added to the electrolyte. If the



electrolyte level is below the battery plates,replenishwith distilledwater and charge thebattery before testing the specific gravity.

(2) If a low state of charge is indicated, or if thespecific gravity readings vary more than 0.030between cells, the battery should be charged using acommercially available battery charger with attentionto the following points:

(a) Disconnect the negative and positive batteryterminals.

(b) Check the battery electrolyte level and re-plenish as necessary.

(c) Remove the filler caps from the battery.(d) Follow the battery charger manufacturers

instructions.(3) Should the battery fail to operate satisfacto-

rily after charging, it is recommended that it be takento an authorised dealer with necessary equipment toperform a load test. Load testing, when performed inconjunction with the specific gravity tests describedabove, will give an accurate indication of the service-ability of the battery.

7. ALTERNATOR

Special Equipment Required:To Test - 100-0-100 Ammeter, voltmeter, aI 000 watt (min) lamp bank with switching,tachometer, ohmmeterTo Dismantle Soldering iron, press, pressplates, bearing pullerTo Assemble - Soldering iron, press, press plates

DESCRIPTION

The Bosch alternator installed in the range ofvehicles covered by this manual has an internalvoltage regulator which is battery voltage sensitive,this ensures that the alternator charying rate is directlydetermined by the condition of the battery.

The alternator consists of a fixed coil winding orstator, a shaft wound coil or rotor, a rectifier or diodepack and an internal voltage regulator.

A magnetic field is produced in the rotor byelectrical current fed into the rotor windings bybrushes bearing on slip rings mounted on the rotorshaft. Three phase alternating current (AC) is pro-duced in the star wound stator by the rotation of themagnetic field.

As it is not possible to charge a storage batterywith alternating current (AC), it is necessary to rectifythe output of the stator windings to direct current(DC). This is done by using a bank of diodes or diodepack, mounted within the alternator slip ring endbracket.

The current output of the alternator is governedby the inbuilt characteristics of the alternator. Thevoltage output of the alternator is governed by the

internal integrated circuit regulator. The voltage regu-lator is not adjustable.

An electrical cut out unit is not necessary as thediodes prevent a reverse current flow through ttrealternator.

SERVICE PRECAUTIONS

(1) Ensure that the battery is connected with thenegative terminal to earth.

(2) Do not short circuit or ground any terminalscommon to the charging circuit.

(3) Always disconnect the battery before con-necting a battery charger.

(4) If a booster battery is used, always connect itin a parallel circuit i.e. positive to positive (+ to *)and negative to negative (- to -) to maintain a 12volt supply.

(5) Never disconnect the battery or terminals inthe charging circuit while the engine is running.

(6) Regularly check the drive belt tension.(7) Keep the battery terminals clean and all

electrical connections tight.(8) Disconnect the battery and alternator when

electric welding on the vehicle.

TO TEST ON VEHICLE

If the warning lamp stays on after the engine hasbeen started and run at approximately I 000 rpm orthe charge rate is suspected of being outside thespecified range, indicated by a discharged or over-charged battery, carry out the following tests.

(l) Stop the engine, do not open circuit any partsof the charging circuit whilst the engine is running.

(2) Check the condition and adjustment of thedrive belt.

(3) Clean the battery terminals, tighten all theelectrical connections, checking the wiring for shortcircuits to earth and/or bridged circuits, ensure thatthe battery is fully charged. If the battery is in a lowstate of charge, either recharge it or replace it with afully charged battery.

(4) Start the engine and allow it to run untilnormal operating temperature is reached, then stopthe engine.

NOTE: Whilst performing thefollowing testan the alternator, do not attach leads withalligator clips.

All cannections should be made withclamp or bolted type connectors. This willprevent leads becoming detached during thetest and open circuiting the alternator whichwould result in failure of the diodes.

(5) Disconnect the negative terminal from thebattery. Refer to the note under the Battery heading inthis section. Remove the nut and washer from thealternator output terminal (B+) and disconnect thealternator output lead.


(6) Connect one lead of a 100-0-100 ammeterto the output terminal (B+) and the other lead of theammeter to the lead removed from the outputterminal.

(7) Connect the negative battery terminal andthe I 000 watt lamp bank to the battery.

(8) If necessary, connect an inductive tacho-meter to one of the high tension leads following themanufacturers instructions.

NOTE: Ensure that the tachometer to beused is of the inductive pickup type and thatthe scale is set for 2 cycle operation.

If no 2 cycle position is available thetachometer reading will have to be halved.

(9) Start the engine and increase the enginespeed to 1 480 rpm.

(10) Adjust the lamp bank and engine speeduntil the voltmeter is showing 14 volts and enginespeed is I 480 rpm.

(l l) The ammeter should now indicate 85 ampsat 2O degrees C.

NOTE: If the temperature is more than 20deg C engine rpm will have to be increasedslightly to a maximum of 2 200 rpm at 60deg C.

(12) Overhaul or renew the alternator if a fault isindicated.

(13) Return the engine to idle speed prior toswitching off the lamp bank.



NOTE: Refer to the note under the Batteryheading in this section prior to disconnect-ing the battery.

(2) Disconnect {he terminal blogk from the alter-nator by pulfing on the terlninal block, not the wires

209

and remove the terminal nut and lockwasher toremove the wiring from the B * terminal.

(3) Using an 18 mm ring spanner rotate thedrive belt tensioner pulley anti-clockwise and removethe drive belt from the alternator pulley.

(4) Remove the alternator mounting bolts, liftthe alternator upward and remove the nut and lock-washer retaining the B* terminal wiring. Disconnectthe wiring from the alternator and withdraw thealternator from the engine.


(1) Instal the B* terminal wire to the alternatorand tighten the retaining nut securely.

(2) Instal the alternator to the support bracketsand tighten the retaining bolts to the specified torque.

(3) Connect the terminal block and place thedrive belt around the alternator pulley while holdingpressrire on the belt tensioner. Refer to the EngineTune-up section for further information regarding thedrive belt adjustment.

TO DISMANTLE

(1) Remove the alternator from the vehicle aspreviously described.

(2) Scribe a mark across the drive end bracket,stator and slip ring end bracket to facilitate correctalignment during assembly.

(3) Remove the screws and washers securing theregulator and brush holder assembly. Withdraw theregulator and brush holder assembly from the alter-nator.

(4) Remove the long screws securing the driveend bracket to the slip ring end bracket and withdrawthe drive end bracket, rotor and pulley assembly.

NOTE: Ensure that the sealing O ringbehind the rotor shaft rear bearing in thbslip ring end bracket is not mislaid.

(5) Holding the rotor in a suitable soft jawedvice to protect the rotor, unscrew and remove thedrive pulley retaining nut and the spring washer fromthe rotor shaft.

(6) Remove the drive pulley, spacer, platewasher and fan from the rotor shaft.

(7) Using a suitable press and press plates,support the drive end bracket with the pulley end ofthe rotor shaft uppermost and carefully press the rotorshaft from the Spacer, bearing and the drive endbracket.

(8) Remove the spacer and the bearing retainerplate screws from the drive end bracket.

(9) Remove the bearing retainer plate and thebearing from the drive end bracket.

(10) If necessary, using suitable pullers, removethe rear bearing from the rotor shaft.

Electrical System

-.f4ffi, .-.:iOUTPUT TERIIB{AL B}

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END BRAGKET

SENS,SIG TERMINAL S

WARNB{G LAMP TERIIhIAL t

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View of the ahernator removed from the vehicle.



View of the stator assembly and the slip ring endbracket.

NOTE: When removing the rotor bearinss.note the position of theleating shields o;;;aid to assembly.

(J tl Remove the nut, spring washer and outputterminal gomponents from tire (i+) t.;i;; ln theoutside of the slip ring end bracket.'

(12) Working inside the slip ring end bracker,remove the screws securing the diodi pack to thebracket and withdraw the stitor and diod-e pult ur unassembly. Remove the insulating spacer and washerfrom the (B*) terminal.

NOTE: The diode pack rs supplied esan integral ,unit and in the event'6f o ,oi-ponent {ailure, the diode pack *"il i"renewed as a complete unit.

(13) Jag and mark all wiring connections priorto removal to avoid incorrect connections duringassembly.

( 14) Where necessary, using a very hot solderingiron and a pair of rong tror.d pliers, unsolder the statorleads from rhe connector terminais i;;;;;;ir" ,t.diode pack.

NOTE: Do not apply undue heat rcconnections as damage may result toterminal insulator and/o, diodes.

TO CLEAN PARTS

- (l) Do not immerse units of the alternator incleaning solvents as damage to the windinls willresult.@ Thoroughly clean and dry the end brackets in

a suitable solvent. after. they have been .o-pr"t"rvdismantled from the unit.- (3) Check the rear bearing sealing O ring for

damage and deterioration and renew as necessary.(4) compressed air can be carefully ur.o io blow

thethe

PLATE WASHERwAsHER I

/ t'f'"

/ FAN,i, l/,k#M,.^",.* dffi-/ffi,Www

ffi"ROTOR

SLIP RING END BRACKET

DIODE PACK

0I

O RING

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BEARING

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Dismantled view of the alternator.


out the dust from the stator windings and the fieldwinding on the rotor.

(5) Slip rings that are burned or scored should bepolished using very fine glass paper.

(6) Clean the brushes and the brush holdersusing a petrol damp rag, check and remove any burrsfrom the holder.

(7) Check the rotor shaft bearings for wear androughness and renew as necessary.

TO CHECK AND TEST COMPONENT PARTSAll parts being electrically tested should be resting

on a non-conductive pad.

Field Windings and Rotor Assembly( I ) The insulation to earth test is done with an

ohmmeter. Connect one of the test prods to one of thefield wires or slip rings and the other test prod to onepole piece of the rotor.

2rr

use an on'lT:l,l'? :;:1"':J,jJ#:xl:n!r

internat

(4) If there is any variation in resistance be-tween phases it will be necessary to renew the statorassembly.

(5) Connect a jumper lead from the negativeterminal of a charged 12 volt battery to the statorwinding frame. Connect one end of a test lamp to thebattery positive terminal, the other end of the testlamp to the stator lead, one at a time.

(6) Should the test lamp lighr or burn dimly ashort circuit is indicated and the stator assemblv mustbe renewed.

DiodesThe diodes may be tested after their disconnec-

lio_n, testing can be done by using a l2 volt battery and1.5 watt bulb in series with a jumper lead.

(l) Connect a jumper lead from the negativeterminal of a charged battery to the carrier/biacketholding the diode to be tested.

(2) Connect one end of a test lamp to the batterypositive terminal and the other end of the lamp to th6diode lead. Note whether the lamp is illuminated andthen reverse the connections on the battery.

(3) If the lamp was illuminated in both direc-tions or was not illuminated at all the diode is faultvand the diode pack/heat sink must be renewed.

Brush Spring and Brushes(l) Unsolder and remove the brushes from the

holders.(2) Check the brush springs for overheating and

distortion, check for binding in the brush holders.(3) Check the brush length and renew as neces-

sary. Refer to the Specifications.

TO ASSEMBLE

The assembling procedure is a reversal of thedismantling operation with attention to the followingpoints:

Electrical System

&;i,

Checking rotor windings for shon to earth.

(2) If the ohmmeter shows a reading and novisual earthing can be seen and rectified, a new rotorassembly will have to be installed.

(3) To check for bridged or internal shorring ofthe rotor windings, check the resistance between the sliprings. The resistance should be2.47 -2.l3ohms. A lowreading indicates a bridged circuit internally, a highreading indicates an open circuit or high resistancelnthe windings. In both cases a new rotor assembly willhave to be installed.

Stator WindingsThe stator test is carried out using an ohmmeter.(l) The stator leads must be detached from the

diode pack.(2) Connect one test prod of the ohmmeter to

one stator lead and the other test prod to anotherstator lead. Note the ohmmeter reading.- (3) Repeat the operation on the remaining leads

alternately to check each phase.

S L I P R I N G S


212

(l) If previously disconnected, using a hot sol-dering iron and a long nosed pair of pliers as a heatsink, solder the stator leads to their respective ter-minals on the diode pack.

(2) Instal the insulating washer and spacer to the(B+) terminal post and position the diode pack andstator assembly onto the slip ring end bracket. Instalthe diode pack retaining screws and tighten themsecurely.

(3) Working on the exterior of the slip ring endbracket, instal the output terminal components to the(B+) terminal and secure with the retaining nut.

(4) Position the bearing retainer, bearing andspacer on the rotor shaft.

(5) Using a suitable press and press plates,support the rotor shaft on the front face of the spacerand carefully press the rotor shaft fully into thebearing and spacer.

(6) Position the rotor shaft assembly into therear of the drive end bracket and instal and tighten thebearing retainer plate screws.

(7) Instal the fan, plate, spacer and drive pulleyto the rotor shaft and secure them with the retainingwasher and nut.

(8) If necessary, using a suitable press and pressplates, support the rotor shaft rear bearing and care-fully press the rotor shaft fully into the bearing.

NOTE: Ensure that pressure is applied onlyto the inner race of the bearing.

(9) Ensure that the rotor shaft bearing O ring issecurely located in the slip ring end bracket and insertthe rotor in the stator and slip ring end bracketassembly.

( 10) Align the marks made on dismantling andinstal and tighten the through screws.

(11) Position the regulator and brush holderassembly to the slip ring end bracket and instal andtighten the retaining screws.

(I2) Instal the alternator to the vehicle and testthe operation as previously described.

8. STARTER MOTOR - AUTOMATICTRANSMISSTON MODELS

Special Equipment Required:To Renew Brushes - Soldering iron

DESCRIPTION

The Bosch starter motor fitted to automatictransmission models is the induced pole type withfour brushes and four pole shoes with field coils.

A solenoid switch is attached to the starter driveend bracket. The solenoid plunger is connected to theoverrunning clutch and drive pinion assemblythrough a link, lever and pivot bolt arrangement.

When the solenoid windings are energised, theplunger acting on the lever and pivot engages the drive

pinion with the flywheel ring gear and at the $ametime closes the switch supplying power from thepositive lead of the battery to the starter motor fieldcoils and the armature to operate the motor.

As the engine fires, the ovemrnning clutch of thedrive pinion assembly prevents higl speed rotation of,and possible damage to, the starter armature if thesolenoid windings are not immediately de-energisedby releasing the ignition key.

The starter solenoid switch windings are ener-gised by the key operated combination ignition andstarter switch.

TO TEST ON VEHICLE

Should the starter fail to operate when the ignitionswitch is moved to the Start position, check thefollowing points:

(1) Check the battery condition and state ofcharge. Refer to the Battery heading.

(2) Clean the battery terminals, taking particularcare to remove the scale from the positive (+)terminal post and terminal.


(3) Check the earth connections for tightnessand cleanliness.

(4) Switch on the headlamps and turn the igni-tion switch to Start. If the lamps dim but the starter isnot heard to operate, it could indicate that a shortcircuit has developed in the starting system whichcould be either external or internal.

Also check that the engine is not seized or lockedup as this condition would give the same indication asabove.

(5) If the lamps do not dim and the starter doesnot operate, this would indicate dirty or contaminatedstarter solenoid contacts in which case the solenoidshould be renewed or an open circuit such as a brokenor disconnected wire, or a switch not operating. Turnthe ignition switch to Start and move the transmissionselector lever through all the gear selection ranges. Ifthe starter operates in any position other than N or P,the neutral safety switch is faulty.

(6) Check all the external wiring to ensure thatthe fault is not external. If the external circuit provessatisfactory, indicating that the problem is in thestarter assembly, the unit will have to be removed andoverhauled.TO REMOVE AND INSTAL

(1) Disconnect the negative battery terminal.

NOTE: Refer tu the note under the Batteryheading in this section prior to disconnect-ing the battery.


Electrical System


(3) On vehicles equipped with air conditioning,remove the left hand exhaust manifold. Refer to theEngine section if necessary.

NOTE: Removal of the exhaust manifoldenables access to the solenoid terminals andthe starter motor support bracket.

(4) Remove the nut and washer retaining thebattery lead to the starter motor. Pull the switch wirefrom the solenoid by pulling on the connector not thewiring.

(5) Remove the bolts, nuts and washers retain-ing the steering gear assembly to the front cross-member and allow the steering gear assembly to hangfreely.

(6) Remove the starter motor retaining bolts andthe support bracket bolt, lower the starter motor andallow it to rest on the front suspension crossmember.

(7) Remove the torque converter housing coverretaining bolts and withdraw the cover from thetorque converter.

(8) Withdraw the starter motor rearwards.Installation is a reversal of the removal procedure

with attention to the following points;(l) Ensure that the starter motor battery lead

and switch wire are making a good connection to thestarter motor terminals before installing the exhaustmanifold.

(2) Torque all nuts and bolts to Specifications asdescribed in the relevant sections.

(3) After reconnecting the negative battery ter-minal, start the engine and increase speed to 3 000

PINION AND CLUTCH ASSIY

Electrical System

eotts ,-

2r3

HEAT SHIELD

View of the starter motor removed from the vehicle.

rpm for l0 seconds to allow the idle air control valveto reset.

(4) On models equipped with a security codedradio enter the PIN code as described under theRadio/Cassette heading in this section.

TO DISMANTLE

( 1) Remove the starter motor from the vehicle aspreviously described and mount the starter motor in asoft jawed vice.

(2) Disconnect the field connector strap fromthe lower terminal on the solenoid switch.

(3) Rernove the heat shield retaining screw fromthe drive end bracket and remove the heat shield.

BRACKET

WASHERS

BRUSH HOLDER

END BRACKETDRIVE

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Dismantled view of the Bosch starter motor.

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(4) Remove the solenoid retairting screws andwithdraw the solenoid leaving the solenoid plungerand spring on the drive end bracket.

(5) Disconnect the solenoid plunger from thepinion fork and remove the plunger and spring fromthe bracket.

(6) Remove the end cover cap retaining screwsand remove the cap and seal from the commutatorend cover.

(7) Remove the C clip and thrust washers fromthe rear of the armature shaft, noting the number ofwashers installed.

(8) Remove the through bolts and remove thebolts and the support bracket from the starter endcover.

(9) Separate'the commutator end cover from thestarter yoke.

(10) Withdraw the yoke and brush holder as-sembly from the armature and drive end brackets.

(11) Remove the sealing block from the driveend bracket and withdraw the armature and pinionfork from the drive end bracket.

(12) Carefully spread the pinion fork arms anddisconnect the pinion fork arms from the drive piniondowels. Remove the pinion fork.

(13) Support the armature in a vertical positionwith the drive pinion uppermost:.

(14) Using a suitable drift, tap the stop collartowards the drive pinion and clutch assembly andremove the snap ring from the armature shaft.

(15) Remove any burrs from the shaft andwithdraw the stop collar and the drive pinion andclutch assembly from the armature shaft.

( 16) Clean all parts thoroughly but do not im-merse the yoke, armature or drive clutch in cleaningsolvent.

(17) Ifthe field coils are to be removed, markthelocation of each individual pole shoe before removingthe mounting screws.

NOTE: Do not remove the field coils unlessthey are suspected of being unserviceable.The pole shoes must be replaced in the sameposition from which they were removed toavoid the possibility of the armature polingwhen the starter motor is assembled.


(l) With the starter motor dismantled, check thebrush holder insulation using an ohmmeter.

Connect one test prod to the brush holder positiveside and the other prod to the negative side. If theohmmeter reading is other than infinity, repair orrenew the brush holder.

(2) Check the brushes for adequate length.Brushes should be renewed when their length is belowSpecifications. They should be a free sliding fit in thebrush holders.

(3) Check the brush springs, and cornpare withnew springs.

(4) Check that the commutator ig free frompitting and burning. Clean the commutator with apetrol moistened cloth and polish with a strip of fineglass paper.

A badly worn commutator may be cleaned bymounting in a lathe, spinning at high speed, andtaking a light cut with a very sharp tool. After turning,undercut the insulation between the segments toSpecifications.

(5) Check the armature for short circuit, usingan ohmmeter.

Place one of the test prods on the armature shaftor core and move the other prod around the circum-ference of the commutator. If the ohmmeter shows areading at any point the armature is faulty and shouldbe renewed.

(6) Test the field coils for continuity by connect-ing the test prods in series with the field windings.

Failure of the ohmmeter to show a reading indi-cates an open circuit in the wiring of the field coils.

(7) Check the field coil for ground by placingone test prod on the field coil lead and the other prodon the yoke. If the ohmmeter shows a reading the fieldcoils and yoke assembly are faulty and will have to berenewed.

(8) Check the drive clutch assembly pinion teethfor wear, scoring or chipping. A clutch in goodcondition should take up the drive in one directiononly. It should rotate easily and smoothly in the non-drive direction and the assembly should movesmoothly along the armature helical splines.

(9) Check the armature shaft bushes for wearand renew as necessary. The old bushes must beremoved and the new ones pressed into the endbrackets using a polished mandr6l of the exactdiameter of the armature shaft.

NOTE: The new bushes must not be reamedto size, as reaming will impair the porosityof the bushes and cause early failure. Newbushes should be allowed to stand immersedin clean light engine oil for one hour beforeinstallation.

TO ASSEMBLE

Assembly is a reversal of the dismantling pro-cedure with attention to the following points:

(l) Sparingly lubricate the armature helix andpinion clutch assembly interior with MolybdenumDisulphide lithium based grease.

(2) Instal the stop collar to the armature shaftand position the snap ring in the locating groove onthe armature shaft.

(3) Rotate the drive pinion to push the stopcollar over the snap ring until the collar is locked onthe snap ring.



(4) Sparingly lubricate the armature shaftbushes with engine oil.

(5) Position the armature and the pinion forkinto the drive end bracket.

(6) Engage the solenoid plunger on the pinionfork. Instal the plunger spring, sealing block andsolenoid to the drive end bracket. Secure the solenoidwith the retaining screws.

(7) Instal the yoke over the armature.(8) Instal the brush holder with brushes in-

stalled. It is necessary to push the brushes against thespring tension into the holder and then slide theassembly onto the commutator.

(9) Instal the commutator end cover, the sup-port bracket and the through bolts. Ensure that thefield connector strap and insulators are seated cor-rectly.

(10) Instal the thrust washers to the end of thearmature shaft and secure them with the C clip.Adjust the armature end float to 0.05-0.30 mm byadding or subtracting thrust washers.

(l l) Place the end cover cap and gasket over thearmature shaft and instal the retaining screws.

(12\ Instal the heat shield to the starter motorand instal the starter motor to the vehicle as pre-viously described.

9. STARTER MOTOR - MANUALTRANSMISSION MODELS

DESCRIPTION

The Delco Remy reduction gear starter motorfitted to manual transmission models is the inducedpole type with four brushes and four pole shoes withfield coils

A solenoid switch is attached to the starter driveend bracket. The solenoid plunger is connected to theovemrnning clutch and drive pinion assemblythrough a link and lever assembly.

When the solenoid windings are energised, theplunger acting on the lever and pivot engages thp drivepinion with the flywheel ring gear and at the sametime closes the switch supplying power from thepositive lead of the battery to the starter motor fieldcoils and the armature to operate the motor.

As the engine fires, the ovemrnning clutch of thedrive pinion assembly prevents high speed rotation of,and possible damage to, the starter armature if thesolenoid windings are not immediately de-energisedby releasing the ignition key.

The starter solenoid switch windings are ener-gised by the key operated combination ignition andstarter switch.

TO TEST ON VEHICLE

Should the starter fail to operate when the ignitionswitch is moved to the Start position check thefollowing points:

(1) Check the battery condition and state ofcharge. Refer to the Battery heading.

(2) Clean the battery terminals taking particularcare to remove the scale from the positive (+)terminal post and terminal.


(3) Check the earth connections for tightnessand cleanliness.

(a) Switch on the headlamps and turn the igni-tion switch to Start. If the lamps dim but the starter isnot heard to operate, it could indicate that a shortcircuit has developed in the starting system whichcould be either external or internal.

Also check that the engine is not seized or lockedup as this condition wodld indicate an open circuitsuch as a broken or disconnected wire or a switch notoperating.

(6) Check all the external wiring to ensure thatthe fault is not external. If the external circuit provessatisfactory, indicating that the problem is in thestarter assembly, the unit will have to be removed andoverhauled.





(3) Remove the nut and washer retaining thebattery lead to the starter motor, putl the switclr-wirefrom the solenoid by pulling on the connector not thewiring.

(4) On vehicles equipped with air conditioning,remove the bolts, nuts and washers retaining thesteering gear assembly to the front crossmember andallow the steering gear assembly to hang freely.

NOTE: On models without air condit,ioningthere is sufficient space to remove the ptartermotor by sliding it towards the front of theengine and out between the stabiliser barand the front engine mount.

(5) Remove the starter motor retaining bolts andif applicable the starter motor mesh adjusting shim(s).

(6) Withdraw the starter motor from the engine.Installation is a reversal of the removal procedure

with attention to the following points:(l) Ensure that the starter motor mesh adjusting

shim(s) are in position if removed.(2) Torque all nuts and bolts to Specifications as

described in the relevant sections.(3) If the original starter motor is replaced by a

new or exchange unit or if the starter motor operation


2 1 6 Electrical System

is noisy, check and adjust the pinion mesh as de-scribed under the following side heading.

(4) After reconnecting the negative battery ter-minal start the engine and increase the speed to 3 000rpm for 10 seconds to allow the idle air control valveto reset.

(5) On models equipped with a security codedradio enter the PIN code as described under theRadio/Cassette heading in this section.

TO CHECK AND ADJUST PINION MESH

Incorrect starter pinion mesh is usually indicatedby a high pitched whine during cranking whichindicates that there is too much clearance between thestarter pinion and the ring gear or a high pitchedwhine after starting which indicates that there is toolittle clearance between the starter pinion and the ringgear.

Two starter motor shim sizes are available; 1.0mm and 2.0 mm. Washers can be used but total shimthickness must not exceed 3.0 mm.

(l) Remove the transmission from the vehicle asdescribed in the Manual Transmission section.

(2) Remove the clutch housing from the vehicleas described in the Clutch section.

(3) Using a dial indicator or a suitable pointerrotate the flywheel and mark the high point of the ringgear runout.

(4) Rotate the flywheel until the high point ispositioned adjacent to the starter motor.

(5) Pull the pinion gear into mesh with theflywheel using a suitable lever and hold.

(6) Using wire gauges measure the clearancebetween the top of the pinion teeth and the ring gear.

(7) If the clearance is less than 0.5 mm. shim-

ming the starter motor away from tho flywheel isrequired, refer to step (9).

(8) If the clearance is more than 1.5 mm, shim-ming the starter motor towards the flyvheel is re-quired, refer to step (9).

(9) If shimming is required loosen the inboardstarter mounting bolt and remove the outboardmounting bolt. Shims can be added and srbtracted asnecessary to achieve the desired clearance.

If it is necessary to move the starter motor closerto the flywheel, a 0.4 mm shim inserted at theoutboard mounting bolt location will decrease pinionclearance approximately 0.3 mm.

TO DISMANTLE

( I ) Remove the starten motor from the vehicle aspreviously described and mount the starter motor in asoft jawed vice.

(2) Disconnect the field connector strap fromthe lower terminal on the solenoid switch.

(3) Remove the solenoid retaining screws andunhook the solenoid from the pivot lever. Note anyshims that may be between the solenoid and the endbracket and place the shims to one side.

(4) Remove the starter motor brush cover re-taining bolts and the small screws retaining the brushholder.

(5) Remove the brush covef from the field coilyoke.

(6) Remove the armature and field coil yoke asan assembly from the centre housing.

(7) Using a fine bladed screwdriver prise backeach brush spring in turn so that each brush can bepulled away from the armature approximately 8 mm.Use the spring pressure on the side of the brush tohold the brush in the released position.

) q -"Jo",*o

1\

I

- J

CENTRE HOUSING-(I

\\

.L

t - ' o )/ l

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Dismantled view of the Delco Remy starter motor.


Electrical System 2r7

(8) Rbmove the armature from the yoke andfield coil assembly.

(9) Remove the cover retaining screws andremove the cover from the centre housing.

(10) Remove the C clip and the shim from thecentre housing.

(11) Remove the bolt retaining the centre hous-ing to the end bracket.

(12) Remove the centre housing from the endbracket. Note the shims installed on the pinion shaftas an aid to assembly. These shims control pinionshaft end float.

(13) Remove the reduction gear, the rubberspring holder and the two springs from the endbracket.

(14) Using a suitable diameter mandrel or a 16mm socket installed over the end of the pinion shaftand a hammer, release the stop collar from the clip.

(15) Using a pair of snap ring pliers, remove theclip from the end of the pinion shaft.

( 16) Using a small file, remove any burrs fromthe end of the pinion shaft.

(17) Remove the stop collar, spring and pinionfrom the pinion shaft.

(18) Remove the pinion shaft and pivot leverassembly from the end bracket.

(19) If necessary, the pivot lever can be removedfrom the pinion shaft after noting the installed direc-tion of the lever.

(20) Clean all parts thoroughly but do notimmerse the yoke, armature, drive clutch or bearingsin cleaning solvent.

If the field coils are to be removed mark thelocation of each individual pole shoe before removingthe mounting screws.

NOTE: Do not remove the field coils unlessthey are suspected of being unserviceable.The pole shoes must be replaced in the sameposition from which they were removed toavoid the possibility of the armature polingwhen the starter motor is assembled.


(l) With the starter motor dismantled, check thebrush holder insulation using an ohmmeter.

Connect one test prod to the brush holder positiveside and the other prod to the negative side. If theohmmeter reading is other than infinity, repair orrenew the brush holder.

(2) Check the brushes for adequate length.Brushes should be renewed when their length is belowSpecifications. They should be free sliding fit in thebrush holders.

NOTE: The vehicle manufacturer states thatbrushes are not available separately. Thepositive brushes are incorporated as part of

the yoke assembly and the negative brushesare incorporated as part of the brush holderassembly. However, brushes may be avail-able from automotive electrical suppliers.

(3) Check the brush springs and compare withnew springs.

(4) Check that the commutator is free frompitting and burning. Clean the commutator with apetrol moistened cloth and polish with a strip of fineglass paper.

A badly worn commutator may be cleaned bymounting in a lathe, spinning at high speed and takinga light cut with a very sharp tool. After turning,undercut the insulation between the segments toSpecifications.

(5) Check the armature for short circuit, usingan ohmmeter.

Place one of the test prods on the armature shaftor core and move the other prod around the circum-ference of the commutator. If the ohmmeter shows areading at any point the armature is faulty and shouldbe renewed.

(6) Test the field coils for continuity by connect-ing the test prods in series with the field windings.

Failure of the ohmmeter to show a reading indi-cates an open circuit in the wiring of the field coils.

(7) Check the field coil for ground by placingone test prod on the field coil lead and the other prodon the yoke. If the ohmmeter shows a reading the fieldcoils and yoke assembly are faulty and will have to berenewed.

(8) Check the drive clutch assembly pinion teethfor wear, scoring or chipping. A clutch in goodcondition should take up the drive in one directiononly. It should rotate easily and smoothly in the non-drive direction and the assembly should movesmoothly along the helical splines.

(9) Check the reduction gear for wear and renewif necessary.

(10) Check the armature and pinion shaft bear-ings for wear and renew if the bearings are rough ornoisy.

TO ASSEMBLE

Assembly is a reversal of the dismantling pro-cedure with attention to the following points:

(l) Lubricate the pinion shaft splines withMolybdenum'Disulphide grease and instal the pinionshaft, spring, pinion and stop collar.

(2) Instal the stop collar clip and using a smallpuller on the pinion, slide the stop collar over the clipto lock the clip in position.

It may be necessary to lightly tap the stop collarclip inwards with a punch to assist in installation.

(3) Lubricate the pivot lever fingers with Molyb-denum Disulphide grease and instal it to the pinionshaft with the lug towards the end bracket.

(4) Instal the gear, shims, pivot lever, springs


2 1 8 Electrical System

and the spring rubber and instal the centre housingand the retaining bolt.

(5) Instal the shim and the C clip to the end ofthe pinion shaft and check the pinion shaft end floatas follows:

(a) Push the pinion shaft towards the centrehousing and using feeler gauges under the C clipmeasure the end float.

(b) If end float is not 0.5 mm, instal shims whichare available in two thickness, 0.25 and 0.5 mm, untilthe end float is correct.

(6) Half fill the cover with Molybdenum Disul-phide grease and instal the cover to the centre housingand retain with the retaining screws.

(7) Instal the armature to the centre housingensuring that the'splines engage properly.

(8) Instal the yoke assembly to the centre hous-ing. The field coil lead must be positioned in thecentre housing locating tabs.

(9) Instal the brush holder ensuring that thebrushes are a free sliding fit in the brush holder andthat the brush holder screw holes will align with thebrush cover when the brush cover is installed.

(10) Instal the brush cover/brush holder screwsensuring that the drain tube is at the bottom when thestarter motor is mounted on the vehicle. Tighten thethrough bolts securely.

(l l) Instal the solenoid and if applicable, theshims. Tighten the solenoid attaching screws securely.

(12) Check the pinion position using the follow-ing procedure:

(a) Connect the positive lead from a 12 voltbattery to the switch terminal of the starter solenoid.

(b) Momentarily touch the negative lead fromthe battery to the starter motor to bring the pinioninto the mesh position.

(c) Push the pinion back and forth by hand andmeasure the amount of pinion shaft movement,0.5-2.0 mm is acceptable. Disconnect the negativebattery terminal.

NOTE: Do not have the battery connectedfor more than 30 seconds at a time.

(d) If necess?ry, add shims to decrease thepinion clearance or remove shims to increase theclearance. The shims are located between the solenoidand the centre housing.

(13) Instal the starter motor to the vehicle aspreviously described.

10. STEERING WHEEL AND HORN PAD


The removal and installation procedures for thesteering wheel and horn pad are fully covered in theSteering section.

11. IGNITION SYSTEM

The ignition system is fully covered in the Fueland Engine Management section.

12. SWITCHES AND CONTROLS

IGNITTON SWITCH AND LOCK CYLINDER

To Rernove and Instal(l) Disconnect the negative battery terminal.

NOTE: Refe, to the note under the Batteryheading in this section prior to disconnect-ing the battery.

(2) Twist the fuse panel cover retaining clips 90degrees and allow the cover the swing down.

(3) Loosen the lower steering column coverretaining screws and rernove the lower steeringcolumn cover from the vehicle.

(4) Insert the ignition key into the lock cylinderand turn the key to the On position.

View of the ignition switch and lock cylinder.

(5) Insert a 3 mm wire into the locking pin holeand depress the locking latch. Withdraw the lockcylinder from the steering column.

NOTE: It is not necessary to remove the lockcylinder if only the ignition switch is to berenewed.

(6) Disconnect the wiring harness connectorfrom the ignition switch.

(7) Using a small bladed screwdriver remove theignition switch retaining screws. Withdraw the switchfrom the steering column.


(l) When installing the lock cylinder ensure thatthe ignition key is in the On position, marked II on theswitch.

(2) When installing the ignition switch ensurethat the slot in the switch aligns with the stepped endof the lock cylinder shaft.

I.OCK CYLINDER

COLUMN



i

headingbattery

COMBINATION SWITCH

To Remove and Instal(1) Disconnect the negative battery terminal.


(2) Remove the steering wheel as described inthe Steering section.

(3) Remove the lower steering column coverretaining screws and withdraw the lower steeringcolumn cover from the vehicle.

(4) Manoeuvre the upper steering column coverfrom the vehicle.

(5) Depress the lock tangs and withdraw theswitch assembly slightly. Disconnect the wiring con-nector from the switch assembly and withdraw theassembly from the vehicle.


(l) Ensure that the switch assembly wiring con-nector is properly connected.

(2) Check the operation of the switch assemblybefore installing the column covers.

Removing the combination switch from the steeringcolumn.

SATELLITE SWITCH BANKS

The satellite switch banks are mounted to the lefthand and right hand sides of the instrument clustersurround. The switch bank on the right hand sideoperates the headlamps and hazard warning lampsand on some models the power aerial and the cruisecontrol.

The switch bank on the left hand side operates thewipers and washers, the rear demister, instrumentlamp dimmer, interior lamp and on some models thetrip computer.

The individual switches are not available separa-tely, if a switch is faulty the entire switch bank must berenewed.

To Remove and Instal(1) Refer to the note under the Battery

in this section and disconnect the negativeterminal.

(2) Remove the screws securing the instrumentcluster surround to the instrument cluster.

(3) Withdraw the surround slightly and dis-connect the wiring connectors at the rear. Mark or tageach connector as an aid to assembly.

(4) Remove the nut and bracket securing theswitch bank to the rear of the instrument cluster.

Installati"",:::::Jersal of the removal procedure.

Rear view of the instrument cluster surround showingthe satellite switch banks.

REAR WIPEWWASHE& AIR CONDITIONINGAND FOG LAMP SWITCHES

To Remove and Instal(1) Refer to the note under the Battery heading

in this section and disconnect the negative batteryterminal.

(2) Prise up the rear of the centre console coverpanel and pull the panel rearwards slightly to allowaccess to the radio/cassette surround screws.

(3) Remove the screws from the lower part of theradio/cassette surround and pull the surround rear-

Removing the connectors from the rear wiper/washer,air conditioning and fog lamp switches when remov-ing the radio/cassette surround. Not all switches are

installed to all models.



wards carefully until the locating lugs at the toprelease from the dashboard.

(4) Disconnect the electrical connectors fromthe switches noting their positions as an aid toassembly.

(5) To removp the switches depress the switchretaining tangs and slide the switches out of the frontof the panel.


COURTESY LAMP DOOR SWITCH

To Remove and Instal(l) With the door fully open, remove the retain-

ing screw from the switch mounting flange.(2) Partially withdraw the switch from the door

pillar.(3) Disconnect the wiring from the switch and

remove the switch from the vehicle.Installation is a reversal of the removal procedure.

View of the courtesy lamp door switch removed fromthe door pillar.

RE\rERSE LAMP SWITCH

On vehicles equipped with an automatic trans-mission, a combined neutral safety switch and reverselamp switch is installed on the side of the selectorlever. The renewal procedure is described in theAutomatic Transmission section.

On vehicles equipped with a manual trans-mission, use the following procedures.

To Test(l) Switch on the ignition and select reverse

gear. The reverse lamps should operate.(2) If the reverse lamps do not operate, raise the

front of the vehicle and support it on chassis stands.(3) Disconnect the wiring from the reverse lamp

switch on the side of the transmission.(4) Connect a jumper lead between the ter-

minals of the reverse lamp switch wiring conilector.(5) Switch on the ignition and check the reverse

lamps. If the reverse lamps now operate, the reverselamp switch can be considered faulty and should berenewed.

NOTE: If the reverse lamps still fail tooperate with the switch connector teryminalsjumped, check the condition of the lampsand the fuses.

To Remove and Instal(l) Raise the front of the vehicle and support it

on chassis stands.

View of the manual transmission showing the reverselamp switch.

(2) Disconnect the wiring from the reverse lampswitch on the side of the transmission.

(3) Remove the reverse lamp switch from thetransmission housing.


(l) Instal teflon tape to the threads of the reverselamp switch.

(2) Tighten the switch to a torque of 27 Nm.

STOP LAMP SWITCH

To Test(l) With the ignition switched on, depress the

brake pedal and have an assistant check if the stoplamps operate.

(2) If the stop lamps do not operate, switch offthe ignition open the fuse cover and working throughthe fuse cover aperture, disconnect the stop lampswitch wiring connectors.

NOTE: On models with power windows itwill be necessary to remove the power win-dow module retaining bolts and move themodule to one side to allow access to thestop lamp switch wiring connector.

(3) Connect a jumper lead between the wiringconnector terminals and switch on the ignition. If the


Electrical System 22r

SOp hfip*,operat€ the switch is incorrectly adjustedor requirm renewal.

To Rwve end Instel( I ) With the ignition switched off, open the fuse

cover by turning the retaining clips 90 degrees.(2) On models with power windows, remove the

power window module retaining bolts and move themodule to one side.

(3) Disconnect the electrical connectors fromthe stop lamp switch. On models with cruise controlthe stop lamp switch is combined with an electricalrelease switch and it has four terminals.

View of the

(4) Pullremove.

stop lamp switch with the fuse coverremoved.

the switch assembly from its bracket to

Installation is a reversal of the removal procedurewith attention to the following adjustment:

To Adjust - Models Without Cruise Control(l) Hold the brake pedal at its normal rest

position.(2) Push the stop lamp switch in until the switch

plunger protrudes 3-4 mm.(3) Apply and release the brake pedal several

times and ensure that the stop lamps are operatingeorrectly.

To Adjust - Models With Cruise Control(l) Hold the brake pedal in its depressed posi-

tion and instal the switches into the tubular clips untilthey stop. Audible clicks will be heard as the switchslides through the clips.

(2) Pull the brake pedal back against its stopuntil the audible clicking sounds can no longer beheard.

(3) Apply and release the brake pedal severaltimes and ensure that the stop lamps are operatingcorrectly.

HANDBRAKE WARNING LAMP SWITCH

To Renew(1) Remove the handbrake lever assembly as

described in the Brakes section.(2) Disconnect the Switch wiring and remove the

switch.(3) Instal the new s{"itch to the handbrake lever

and instal the lever assembly to the vehicle asdescribed in the Brakes section.

(4) Adjust the handbrake as necessary.

Dismantled view of the handbrake lever showing thewarning lamp switch location.

13. INSTRUMENT CLUSTER



NOTE: Refer to the note under the Batteryheading in this section prior to disconnect'ing the battery.

(2) Remove the steering wheel from the steeringcolumn as described in the Steering section.

(3) Remove the screws retaining the instrumentcluster surround, slide the instrument cluster sur'round rearwards slightly and disconnect the electricalconnectors.

(4) Withdraw the instrument cluiter surroundfrom the instrument cluster.

(5) On Calais models open the fuse cover andreach up on the right hand side of the instrumentcluster and disconnect the connector that passesthrough the hole in the dashboard assembly.

VOLTAGE REGULATOR

Rear view of the instrument cluster.



$""=,n.

INSTRU ENT CLUSTER

View of the instrument cluster with the lens andspeedometer removed.

(6) Remove the screws retaining the instrumentcluster to the dashboard and withdraw the instrumentcluster.

Installation is a reversal of the removal proced'rewith attention to the following points:

(l) Run the engine at 3 000 rpm for l0 secondsto allow the idle air control valve to reset.

(2) On radio/cassettes incorporating a securityPIN number enter the security code ai describedunder the Radio/Cassette heading in this section.

14. RADIO/CASSETTE

TO REMOVE AND INSTAL(1) Disconnect the negative battery terminal.

NOTE: Refer to the note under the Battervheading in this section prior to disconneci-ing the battery.

(2) Prise up the rear of the centre console coverpanel and pull the panel rearwards slightly to allowaccess to the radio/cassette surround screws.

(3) Remove the screws from the lowerpart of theradio/cassette surround and pull the surround rear-wards carefully until the locating lugs at the toprelease from the dashboard.

(4) Disconnect the electrical connectors fromthe radio/cassette surround panel noting their posi-tions as an aid to assembly.

(5) Working in the drivers footwell, disconnectthe heater control rod from the control lever at theright hand side of the heater unit.

(6) Remove the screw retaining the heater con-trols to the dashboard and pull the heater control,rearwards.

Removing the connectors from the rear wiper/washer,air conditioning and fog lamp switches when remov-ing the radio/cassette surround. Not all switches are

installed to all models.

Disconnecting the vacuum block from the heatercontrols.

(7) Disconnect the electrical connectors and thevacuum block from the heater controls and removethe heater controls from the dashboard.

(8) Reach in beside the right hand side of theradio and using a short Phillips head screwdriver,loosen the anti-theft screw a few turns.

(9) Drill out the pop rivets or shear-off screwsretaining the radio/cassette to the instrument panel.

(10) Slide the radio/cassette unit rearwardsslightly. If necessary, loosen the anti-theft screw togain access to the electrical connectors at the rear ofthe radio/cassette.

(l l) Disconnect the aerial connector and theelectrical connector from the rear of the radio/cassetteunit. Remove the unit from the dashboard.


(l) (Jse new pop rivets or shear-off screws oninstallation.


Disconnecting the radio aerial connector from theradio/cassette unit.

(2) Ensure that the heater control rod is posi-tioned correctly. Refer to the Cooling and HeatingSystems section if necessary.

(3) Connect the negative battery terminal andwhere applicable, enter the radio security code usingthe procedure described under the following sideheading.

(4) Start the engine and run at 3 000 rpm for10 seconds to allow the idle air control valve to reset.

TO ENTER SECURITY CODE

On some models a radio/cassette security codemust be entered whenever the power supply is inter-rupted, such as when the vehicle battery is dis-connected.

The code is given to the original owner on deliveryof the vehicle. If necessary, the code can be obtainedfrom an authorised dealer on production of proof ofvehicle ownership. The code comes with the informa-tion necessary to enter it into the radio.

15. LAMP UNITS

COMBINATION HEADLAMP, PARK LAMPAND TURN SIGNAL LAMP ASSEMBLY

To Remove and Instal(l) Disconnect the negative battery terminal.

NOTE: Refer to the note under the Battetryheading in this section prior to disconnect-ing the battery.

(2) Remove the screws retaining the upper partof the radiator grille to the radiator support panel. Liftthe grille out from the body and place to one side.

(3) Disconnect the wiring from the headlampand the front turn signal lamp.

(4) Remove the retaining nuts from the loweredge of the headlamp and the bolts from the radiatorsupport panel.

223

DUST COVER

View of the headlamp assembly r€trtrov€d from thevehicle.

(5) Withdraw the headlamp and turn signallamp assembly from the body ensuring that the turnsignal lens is not scratched by the mudguard peak.

Installation is a reversal of the rem<>val procedurewith attention to the following points:

(l) Hold the headlamp in position and tightenall nuts and bolts securely.

(2) Check and if necessary adjust the headlampaim as described later in this section.

To Adjust Headlamp Aim(l) Ensure that the tyres are irrflated to the

correct pressure and that the vehicle is positioned onlevel ground.

(2) Ensure that the vehicle is unlarden.(3) When using headlamp aiming equipment

refer to the manufacturers instrucrions for theappropriate instructions for that equipment.

(4) When using an aiming board position thevehicle 7.6 metres from and square to the board.

(5) Mark a reference line on the board to cor-respond with the horizontal centre line of theheadlamps.

CORRECT LIGHT PATTERNS

Diagram showing the method of adjusting headlampaim using an aiming board. Dimenslon R to be 7.6

metres.

Electrical System



Rear view of the headlamp showing the adjustingscrews.

(6) Mark two reference lines on the board tocorrespond with the vertical centre lines of theheadlamps.

(7) Switch on the headlamps and select low, beam.

(8) Adjust the headlamps by turning the adjust-ing screws at the rear of the headlamp assemblies.

(9) Adjust the headlamps to comply with localregulations. As a guide, adjust the lamps so that thelow beam pattern strikes the aiming board with thehorizontal cut off point 105 mm below the horizontalcentre line and the point where the beam raises fromhorizontal is on or to the left of the vertical centre line.

To Dismantle and Assemble Headlamp( I ) Remove the headlamp assembly as pre-

viously described. Rotate and remove the turn signalbulb sopket from the turn signal lamp assembly.

(2) Remove the turn signal lamp retaining screw

clrPs\--- \ r n x,,*n nxnil il

Dismantled view of the headlamp assembly.

and slide the turn signal lamp unit fornlards and offthe headlamp assembly. I

(3) Remove the dust cap from th4 rear of theheadlamp assembly, disconnect the wiriqg connector,disengage the bulb retaining clips andiremove thebulb. I

(4) Remove the dust cover froni above thedriving lamp. Remove the bulb partially and discon-nect the electrical connector from the bulb.

(5) Carefully prise the retaining spring clipsfrom the headlamp body and separate the lens andseal from the headlamp.

(6) If necessary the headlamp adjusting screwscan be loosened sufficiently and the reflector can beremoved as an assembly.

Assembly is a reversal of the dismantling proce-dure with attention to the following points:

(l) Ensure that the reflector and lens are se-curely located prior to installing the lens retainingclips.

(2) Ensure that the lens retaining clips are in-stalled by entering them first on the headlamp lensand then onto the body otherwise damage to the lensmay occur.

(3) Instal the headlamp as previously described.

To Renew Headlamp Bulb( I ) Working inside the engine compartment,

unscrew the dust cover from the rear of the headlampassembly.

(2) Remove the wiring connector from the rearof the bulb.

(3) Unclip the spring retainer from the bulb andwithdraw the bulb.

NOTE: Care must be taken not to handlethe glass portion of the bulb as this willshorten the life of the butb. Accidentalfingerprints can be removed by applyingmethylated spirits to the bulb ani dryingwith a clean tissue or cloth.

(4) Carefully instal the bulb and the retainingclips to the headlamp body.

(5) Instal the wiring connector to the bulb andthe dust cover to the headlamp body.

(6) Check the operation of the headlamp andadjust the aim if necessary as described in this section.

To Renew Driving Lamp Bulb(1) Remove the retaining screws and remove the

dust cap from above the bulb.(2) Disconnect the spring clip from the bulb, lift

the bulb upwards with the wiring attached and dis-connect the wiring connectors.

(3) Withdraw the bulb.

NOTE: Care must be taken not to handlethe glass portion of the bulb as this will

B

cl

REW

\4r


shorten the life of the bulb. Accidentalftngerprints can be removed by applyingmethylated spirits to the bulb and dryingwith a clean tissue or clath.

(4) Connect the wiring connectors to the bulbbefore installing the bulb retaining clip.

(5) Ensure that the bulb operates correctly andthat the dust cap is located securely.

To R.enew Park Lamp Bulb( 1) Working inside the engine compartment,

unscrew the dust cover from the headlamp body.(2) Pull the park lamp bulb holder from the lamp

and remove the bulb from the socket.(3) Instal the bulb into the bulb holder and push

the holder into the rear of the headlamp unit.(4) Instal the dust cover to the headlamp unit

and check the park lamp operation.

To Renew Turn Signal Lamp Bulh(1) Working in the engine compartment rotate

the turn signal lamp bulb holder and remove theholder from the lamp assembly.

Renewing the front turn signal lamp bulb.

(2) Rotate the bulb and remove it from theholder.

(3) Instal the bulb in the holder and instal theholder into the turn signal lamp.

To Remove and Instal Turn Signal Lamp(1) Remove the headlamp assembly as pre-

viously described.(2) Rotate the turn signal lamp bulb holder and

remove it from the headlamp assembly.(3) Remove the screw retaining the turn signal

Iamp to the headlamp body and slide the turn signallamp forwards and remove it from the headlamp.

Installation is a r.eversal of the removal procedure.

REAR COMBINATION LAMP - SEDAN

To Renew Bulb( I ) Working inside the luggage compartment

225

Removing the bulb from the Sedan combination lamp.

rotate the appropriate bulb holder and remove thebulb holder.

NOTE: The spare wheel must be removed togain access to the left side bulb holders.Where installed, rotate the holder retaininglever in an anti-clockwise direction andremove the bulb holders from the lamp.

(2) Depress and rotate the bulb in an anti-clockwise direction and remove the bulb from theholder.

(3) Installation is a reversal of the removalprocedure ensuring that the bulb holder is free fromcorrosion.

'NOTE: When installing new bulbs, ensurethat they are of the correct voltage andwattage.

REAR COMBINATION LAMP STATIONWAGON

To Renew Bulb(l) Open the tailgate and remove the screws

retaining the lamp to the vehicle body.

Renewing a bulb in the Station Wagon rear combina-tion lamp.

Electrical System


226

(2) Depress the small lever and turn the bulbholder in the direction of the arrow to remove.

(3) Depress and rotate the bulb in an anti-clockwise direction and remove it from the bulbholder.

(4) Instal the bulb in the reverse manner toremoval ensuring that the bulb holder is free fromcorrosion and that the bulb has the correct pinconfiguration.

(5) Instal the combination lamp to the rear ofthe vehicle and check for correct lamp operation.

NUMBER PLATE LAMP - SEDAN

To Renew Bulb(1) Using care, prise the snap fit lamp assembly

from the rear bumper.(2) Twist the bulb holder assembly and remove

it from the lamp assembly.(3) Pull the bulb from the bulb holder.(4) Instal the bulb in a reverse manner to re-

moval ensuring that the bulb holder is free fromcorrosion.

NUMBER PLATE LAMP - STATION WAGON

To Renew Bulb(1) Using a suitable screwdriver, remove the

number plate lamp lens retaining screws and removethe lens and bulb.

Removing the bulb from the Station Wagon numberplate lamp.

(2) Remove the bulb from the lens assembly.(3) Instal a new bulb to the lens ensuring that the

bulb holder is free from corrosion and that theterminals have sufficient tension to ensure a goodelectrical contact with the bulb.

(4) Instal the lens to the tailgate and tighten theretaining screws securely.

COURTESY LAMPS

To Renew Bulb(l) Carefully prise the lamp lens from the lamp

cover.

Removing the courtesy lamp lens.

(2) Carefully remove the festoon bulb ensuringthat the terminals have sufficient tension to provide agood electrical contact.

GLOVE COMPARTMENT LAMP

To Renew Bulb(1) Using a suitable screwdriver carefully prise

the lamp from the inside of the glove compartment.(2) Remove the festoon bulb from the rear of the

lamp.(3) Instal the bulb to the lamp ensuring that the

terminals are free from corrosion and that the ter-minals have sufficient tension to ensure good electri-cal contact.

LUGGAGE COMPARTMENT LAMP

To Renew Bulb( I ) Working in the luggage compartment

remove the festoon bulb from the lamp.(2) Instal the festoon bulb ensuring that the

terminals have sufficient tension to provide goodelectrical contact.

16. WIPER MOTORS AITD ARMS

WINDSCREEN WIPER ARM

To Remove and Instal(1) Raise the engine bonnet and support

the bonnet stay.(2) Raise the cover on the wiper arm

access to the retaining nut.

it with

to gain

(3) Lift the blade away from the windscreenuntil the retainer pin hole aligns with the hole in thewiper head.

(4) Insert a suitable piece of wire or a nailthrough this hole to hold the blade offthe windscreen.

Electrical System


(5) Remove the nut retaining the arm to thepivot shaft.

(6) Carefully prise the wiper arm from the pivotshaft taking care not to damage the vehicle paintwork.

Installation is a reversal of the removal procedurewith attention to the following point:

When the wiper is in the park position the righthand wiper blade should be 45-55 mm from thewindscreen surround'and the left hand wiper bladeshould be 25 mm from the windscreen surround.

Removing the windscreen wiper arm from the pivotshaft.

WINDSCREEN WIPER BLADE

To Remove and Instal( I ) Remove the wiper ann as previously

described.

. (2) Depress the retaining.clip at the end of thewiper arrn and slide the wiper blade from theU-shaped end of the wiper ann.

Installation is a reversal of the removal procedureensuring that the retaining clip is located correctly.

WIPER RUBBER

To Renew( I ) Remove the wiper blade as previously

described(2) Squeeze the sides of the retaining clip

together and slide the wiper rubber and spiner assem-bly from the wiper blade.

NOTE: It is advisable to instal a new rubberand spine as an assembly to ensure correctcontact between the rubber and the wind-screen.

(3) Slide the new rubber and spine into the wiperblade ensuring that the spine enters all the lugs on theblade and that the retaining clip locks into the wiperblade.

(4) Instal the wiper blade to the wiper ann.

227

WIPER MOTOR AND LINKAGE

To Remove and Instal(1) Remove the wiper arms as previously

described.(2) Remove the nuts from the wiper pivot shafts.(3) Using a flat bladed screwdriver remove the

plenum chamber water deflector clips.(4) Carefully manoeuvre the water deflector

from the plenum chamber.(5) Remove the screw retaining the wiper motor

eafth lead to the body.(6) Disconnect the wiper motor wiring con-

nector.(7) Remove the bolts retaining the wiper motor

and linkage assembly to the plenum chamber.

View of the wiper motor and linkage assembly withthe plenum chamber water deflector removed.

(gl Manoeuvre the wiper assembly and linkageout from the plenum chamber.

(9) The wiper motor may now be removed fromthe linkage and serviced as necessary.


(l) Tighten the wiper pivor assembly bolts to thespecified torque.

(2) Ensure that the wiper arms are installed tothe correct dimension as previously described.

TAILGATE WIPER MOTOR AND ARMTo Remove and Instal Wiper Btade and Rubber

The removal and installation procedure for thetailgate wiper blade and rubber is very similar to thewindscreen wiper blade and rubber except that theblade is located to the arm with a snap in shaft.

To Remove and Instal Wiper Arm(l) Raise the cover on the wiper ann to gain

access to the retaining nut.(2) Remove the nut retaining the arm to the

pivot shaft.(3) Carefully prise the wiper arm from the pivot

shaft taking care not to damage the paintwork.Installation is a reversal of the removal procedure

Electrical System


228

ensuring that the wiper blade is approximately 22 mmfrom the glass weatherstrip in the park position.

To Remove and Instal Wiper Motor( I ) Remove the wiper arm

described.(2) Remove the cap hexagon

spacer from the wiper pivot shaft.(3) Raise the tailgate and remove the push-in

trim retainers using a flat bladed screwdriver.(4) Remove the lower screw from the window

surround trim panels and lift the lower edge of thepanels to gain access to the hidden triJn retainers.

(5) Remove the retainers and carefully peel theedges of the trim away from the tailgate. The edges areretained with glue.

(6) Remove the tailgate trim completely andplace to one side ensuring that dirt etc is not allowedto contact the glue,

Installed view of the rear wiper motor.

(7) Disconnect the wiring connector from thewiper motor.

(8) Remove the bolts retaining the wiper motorto the tailgate and withdraw the wiper motor, washerand spacer rubber.


(l) Ensure that the wiper motor earth leadterminal is lobated under one of the retaining bolts.

(2) Test the oBeration of the wiper motor beforeinstalling the tailgate trirn.

17. HEATER BLOWER MOTOR


The removal and installation procedures for theheater blower motor is described in the Cooling andHeating Systems section.

18. FUSES, FUSIBLE TINKS AI{D BEIAYS

TO CHECK AND RENEW A FUSE

NOTE: If a fuse is found to be faulty orburnt out, use a replacement fuse of thespecified amperage only. The spectfiedamperage is marked on the fuse. The use ofa higher amperage fuse than that specifiedcould cause damage to the vehicle wiringharness.

Turn the retaining clips 9O degrees and open the fusecover to gain access to the interior fuses, relays and

the flasher unit.

View of the fuse cover label. The letters and numbercorrespond to those marked on the fuses and relays.

Electrical System

as previously

nut, washer and


The fuses are mounted in a fuse boxlocated below and slightly to the right of thest€ering eolumn and under the bonnet in theengine compartment.

(l) Turn the fuse cover retainers 90 degrees,open the fuse cover and using the information markedon the cover, locate the fuse protecting the circuit atfault.

(2) Pull the fuse out of the fuse box and inspect itfor serviceability.

(3) Should the fuse appear to be in a serviceablecondition, test its iontinuity with an ohmmeter or testlamp.

(4) Should the fuse appear to be faulty or burntout, instal a fuse of the same amperage.

(5) If the circuit is still inoperative or the fuse '

burns out again, refer the problem to an automotiveelectrician or an authorised dealer.

TO CHECK AND RENEW FUSIBLE LINKS

NOTE: If a fusible link is found to be faultyor burnt out, use a genuine replacementfusible link of the specified amperage only.The use of a higher amperage fusible linkthan that specified could cause damage tothe vehicle wiring harness.

A new fusible link should not be in-stalled until the fault which cqused theoriginal link to fail has been repaired.

(l) Release the retaining clips and open thefusible link cover.

(2) Inspect the condition of the fusible linkthrough the window in the top.

(3) To disconnect all fusible links except themain one pull the fusible links out of the holder.

22e

(4) To renew the main fusible link proceed asfollows:

(a) Disconnect the negative battery terminal.(b) Remove the screws retaining the fusible link

assembly and raise the assembly upwards to gainaccess to the fusible link terminal bolts.

(c) Remove the bolts from the fusible link,withdraw the link and insert a new main fusible link.

(d) Further installation is a reversal of theremoval procedure.

(5) Should the fusible link app€ar to be in aserviceable condition, test its continuity using anohmmeter or a powered test lamp.

(6) If the fusible link is faulty, instal a newfusible link and check the circuit for correct operation.

RELAY LOCATIONS

The various relays ernployed in the vehicle electri-cal system are located adjacent to the battery in theengine compartment and in the fuse box below and tothe right of the steering column.

The engine compartment relays power the elec-tronic control unit (ECU), air conditioning com-pressor, horn, fuel put'np, engine fan, starting, lowbeam, high beam, warning check lamp, anti-theft hornand fog lamp circuits.

The interior fuse box relays power the ignitionsystem, heated rear window, blower fan and the turnsignal circuits.

Not all vehicles are equipped with all relaysbecause of different equipment levels.

To renew a relay, pull the relay out of its socket.When installing a relay, ensure that the relay ter-minals are making good electrical contact.

19. TRAILER WIRING

There are several brands of trailer wiring con-nectors with a variety of pin configurations. The mostcommon is the seven pin type which provides for twoauxiliary circuits, usually used for reverse lamps andelectric trailer brakes.

Useful connections which can be used if the trailer tobe towed is equipped with a different type plug to the

towing vehicle socket.

Electri,cal System

Engine compartment relay housing and fusible links. 1: Fuel pump relay fuse - 15 amp' 2 : Horn relay fuse- 15 amp, 3 : Engine cooling fan relay fuse - revisedto 3O amp, 4 : Low beam headlamp relay fuse - 15amp, 5 : High beam headlamp relay fuse - 25 amp.

FOR CONNECTING UTILUX SOCKET TO BRYLITE PLUG

FOR CONNECTTNG FIVE PIN UTILUX SOCKET TO SIX PIN UTILUX PLUG


230 Electrical S^tstem

When installing a trailer socket, it may be neces-sary to replace the original vehicle flasher unit with aheavy duty unit to maintain the flash rate in accor-dance with local regulations. Local regulations mayalso require the installation of a dashboard mountedrepeater lamp.

Should the trailer socket and plug not be matched,adaptors can be made or obtained to facilitateconnection.

TO INSTAL'TRAILER SOCKET

The minimum material required are a trailersocket, mounting bracket, seven core flex, insulatedwiring connectors and a rubber grommet.


NOTE: Refer to the note under the Batteryheading in this section prior to disconnect-ing the battery..

(2) Locate the wiring harness for the lamps at therear of the vehicle.

(3) Identify the wires for the right turn signallamp, left turn signal lamp, tail lamp, stop lamp,reverse lamp and earth. Use the vehicle wiring dia-gram in this section to determine the wire colour foreach lamp circuit.

(4) Connect the seven core flex to the variouslamp wires using insulated connectors.

For seven pin sockets and plugs, use the followingstandard trailer wiring code:

Terminal No. Circuit ColourI Left turn signal lamp Yellow2 Reversing lamp Black3 Earth White4 Right turn signal lamp Green5 Electric brakes Blue6 Stop lamp Red7 Tail lamp Brown

For six pin sockets and plugs, use the followingstandard trailer wiring code:

Circuit ColourTail lamp BrownLeft turn signal lamp YellowRight turn signal lamp GreenStop lamp RedAuxiliary circuit BlueEarth White

For five pin sockets and plugs, use the followingstandard trailer wiring code:

Terminal No. Circuit

Minimum material needed for installing a trailersocket and plug. Utilux trailer socket and plug shown.

(5) Drill a suitable sized hole through the vehiclefloor and instal a rubber grommet to the hole.

NOTE: Before drilting the hole, checkwhether there is an existing hole whic'h maybe used. Ensure th;at a rubber grommet isinstalled to prevent chafing of the wires.

(6) Pass the seven core flex through the rubbergrommet.

(7) Cut the seven core flex to the reqruired lengthand slide the dust cover onto the flex.

(8) Remove approximately l5 mm o,f insulationfrom each wire in the flex.

(9) Connect the wires of the seven core flex tothe terminals of the socket, using the standard wiringcode and following the socket manufacturers connec-tion procedure.

(10) Assemble the socket and instal the dustcover to the rear of the socket.

(11) Instal the mounting bracket ,as close aspossible to the tow bar ball and high enough tomaintain vehicle ground clearance.

(12) Instal the socket to the mounting bracket.(13) Connect a trailer plug to the socket and test

for correct lamp operation.

TO INSTAL TRAILER PLUG

The minimum materials required are a trailerplug, seven core flex and insulated wiring connectors.

The installation procedure for the trailer plug is

FLE' t^l;__*,

t tt-II

DUST COVER

Terminal No.I23456

23567

Left turn signal lampEarthRight turn signal lampStop lampTail lamp

ColourYellowWhiteGreenRedBrown The Brylite seven pin trailer plug and socket.


simllar to that for ttre socket with attention to thefollowing pqints:

( 1) Connect the trailer wiring to the plug accord-ing to the standard wiring colour code and the plugmanufacturers instructions. Use a suitable length ofseven core flex and insulated connectors should thetrailer wiring not be long enough.

(2) trf the trailer wiring does not conform to thestandard colour code, identify each circuit as follows:

(a) Locate the trailer earth wire.

Electrical S'tstem

20. WIRING DIAGRAMS

To vehicle wiringharness7 pin socket - Bosch,Hella, Utilux7 pin plug - Bosch,Hella, UtiluxTra i l e rRHtums igna llampTrailer tail lamp

(b) Connect a lumper tead ftom the negativeterminal of a 12 volt battery to the earth wire.

(c) Connect a jumper lead to the positive ter-minal of a 12 volt battery and connect each of thetrailer lamp wires in turn to the positive batteryterminal jumper lead, noting the colour of the wireand the lamp circuit operated.

(3) After installation, connect the trailer plug tothe socket on the vehicle and check for correct lampoperation.

23r

tssToP- R

G- IEFT TUnN - YFREVEISE:- B. r -TA|L- N

G- EARIH- w.F-RtGHr IURN - G

o- BRAKE - L

cotouR coDE

B. : BlackG : GreenL : BlueN : BrownR : R e dW: WhiteY : Yellow

11

o l o l o l @ l o l o l o

Vehicle and trailer wired to conform to Australian Standard AS2513. Sockets and plug shown are as viewed fthe terminal side of the component. Refer to the text for the correct terminal applications when using a 5 or 6

socket and plug.

1 .

2.

3 .

4.

5 .

6.7 .8.

9.10 .

Trailer stop lampTrailer reverse lampTra i l e rLHtu rns igna llamp6 pin socket - Utilux5 pin socket - Bosch,Hella

11. 7 pin socket - Brylite12. Trailer electric brakes

243 TWD 1

68'



Wiring diagram for the starting, charging, engine cooling, air conditioning, heating, crube contrrand radio cassette. Wire colours in brackets indicate models from October 1989.

COLOURCODEThe first letter of the code

represents the main wire colour,the other letters represent thetrace colours.

B - BLACKL - BLUEG - GREENR . R E DY - YELLOWW - WHITEN - BROWNO - ORANGEK - PINKS - GREYV - VIOLETP - PURPLEX - LIGHTGREENZ - LIGHT BLUEM - DARKGREENT - DARKBLUEA - LIGHTBROWNE - SLATED - T A N

KEY1. Fusible link - main 60 AMP2. Fusible link - alternator

30 AMP3. Battery4. To flasher relay5. To radio/cassette6. Radio suppressor7. Ahernatorg. To ahernator warning lamp9. Starter motor

10. Starter relay11. lgnition switch12. lgnition relay13. To brake fail warning switch14. Warning lamp check relay15. Neutral safety switch

(automatic transmissionl16. To EFI control unit17 . To cigarette lighter18. To rear demister switch19. Fuse No 23 - engine cooling

fan relay 30 AMP20. Engine cooling fan relay21.To EFI control unit22. Auxiliary cooling fan (V8

with air conditioningl23. Engine cooling fan (V6l24. Air conditioner compressor

clutch25. Air conditioner compressor

relay26. To EFI control unit27. To EFI control unit

28. Air conditioner highpressure switch

29. Air conditioner lowpressure switch

30. Air conditioner evaporatorswitch

31. Air conditioner switch32. Fuse No 8 - blower fan,

air conditioner, rear demisterrelay 25 AMP

33. Heater blower motor switch34. Heater blower motor

resistorc35. Heater blower motor36. Heater blower motor relay37. To anti-theft module38. Fusible link - heater blower

motor 30 AMP39. To fuse No 1040. Gruise control module41. To cruise control sngage

indicator lamp412.To trip computertlil. Cruise control brake switchtl4. Cruise control brake switch45. Cruise control switch46. To fuse No 747. Fuse No 13 - radio, power

antenna module5 AMP (pre Oetober 1989110 AMP (Oetober 1989 onl

tl8. To fuse No 149. To earth50. Radio/casset.te

5l .LHfrontspeaker52.RHfrontspeaker53.LHrearspeaker54.RHrearspeaker55. To fuse No 356. Power antenna module57. Fuse - powcr antenna

motor 6 AIIP {some modelsl58. Power antenna motor59. Power antenna switchdl. Main wiring harness earth61. Gruise control and rear wiper

switch illumination lamps62. Circuit applicable to models

from November 1989 withouta power antenna module

t-f


Electri,cal System 233

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KEY1. To fuse No 122. Overdrive switch (automatic

transmission)3. Oil temperature svvitch

{automatic transmissionl4. Transmission lock-up

solenoid {automatictransmissionl

5. Fuel pump - internal6. Fuel pump - external

llong range fuel tankl7. MAT sensol8. MAP sgnsor9. EFI control unit

10. To check engine waminglamp

11. To EFI control unit -refer No 38

12. Diagnostic link conneetor13. Fuse No 21 -fuel pump

relay 15 AMPltl. Oil pressure switch15. Fuel pump relay16. EFI relay17. Fusible link - ENG.INJ

30 AMP18. To engine cooling fan relay19. Fuel iniector No 120. Fuel iniector No 221. Fuel injector l\&o 3

39 1II

I

I

22.Fuel iniestor No 423. Fuel injector ilo 524. Fueliniector No 625. Fuel injector l{o 7 lV8 only}26. Fuel injector No 8lV8 onlyl27. Throttle position sensor28. Coolant tomperature sensor29. Detonation gensor (VG onlyl30. Oxygen sensor31. To starter relay32. To air conditioner

compressor clutch relay33. To air conditioner

compressor clutch relay34. To brake fail warning lamp35. To trip computer36. To trip computer37. ldle air controlvalve38. To diagnostic link

connector - refer No 1139. To anti-theft module40. Anti-theft override switch41. To anti-theft moduletP. Tachometer signal wirerti}. Fusible link ENG.COMP

30 AMP44. Fuse No 11 - ignition system

lOAMP45. To tachometert[6. Crankshaft sensor47. lgnition control module

?'W24',"4NilD2A

1989 models.

48. EFI control unit49. lgnition control module50. To tachometer51. Hall Effect device52. Radio suppressor53. lgnition coil54. Distributor55. Tachomcter signal wire56. Main wiring harneas earth

V6 V8I

Wiring diagram for the engine management system. Pre Ostober

COLOURCODEThe first letter of the mde

represents the main wire colour,the other letters represent thetrace colourc.

B - BI.ACKL - BLUEG - GREENR - R E DY - YELLOWW - WHITEN - BROWNO - ORANGEK - PINKS - GREYV . VIOLETP - PURPLEX - LIGHTGREENZ - LIGHT BLUEM - DARKGREENT - DARKBLUEA - LIGHTBROWNE - SLATED - T A N



ABcDE

5 0 + r R

25afi24tJ.4nNmB

ltooELs FRolt l(rvErSEF t990 - - -

53. lgnition coil54. Distributor55. Tachometer signal wire56. Main wiring harness earth57. To anti-theft module58. To fuel pump relay and

fuse 2159. To instrunrent cluster

ltKEY

1. To fuse No 12 -2. Overdrive switch

(automatac transmissionl3. Oil temperature switch

(automatic transmission I4. Transmission lockup

solenoid {automatictransmission)

5. Fuel pump - internal6. Fuel pump - external7. MAT sensor8. MAP sensor9. EFI control unit

10. To check enginewarning lamp

11. To EFI control unit -refer No 38

12. Diagnostic link connector13. Fuse No 21 - fuel pump

relay 15 AMP14. Oil pressure switch15. Fuel pump relay16. EFI relay17. Fusible link - ENGINE

30 AMP18. To engine cooling fan relay19. Fuelinjector No 120. Fuelinjector No 221. Fuelinjector No 322. Fuel injector No 423. Fuel injector No 524. Fuel iniector No 6

? t

d

59

31 33 35 V8

Wiring diagram for the engine management system. Models from October 1989.

V6I

- - J

COLOUR CODEThe first letter of the code

represents the main wire colour,the other letterc represelil thetrace colours.

B - BLACKL - BLUEG - GREENR - R E DY - YELLOWW - WHITEN - BROWNO . O R A N G EK - PINKS . GREYV - VIOLETP _ PURPLEX - LIGHTGREENZ - LIGHT BLUEM - DARKGREENT - DARKBLUEA - LIGHTBROWNE - SLATED - T A N

25. Fuel injector No 7 (VB only)26. Fuelinjector No 8 (V8 onlyl27. Throttle position sensor'...28. Coolant temperature sensol29. Detonation sensor (VG onlyl30. Oxygen sensor31. To starter relay32. To air conditioner

compre*sor clutch relay33. To air conditioner

compressor clutch relay34. To brake fail warning lamp35. To trip computer36. To trip computer37. ldle air control valve38. To diagnostic link connector

,- refer No 1139. To anti-theft module40. Anta-theft override switch41. To anti-theft module42. Tachometer signal wiret|i|. To instrument cluster

(trip computer)44. Fuse No 9 - ignition system,

instruments 7.5 AMP45. To tachometer46. Crankshaftsensor47. lgnition control module48. EFlcontrol unitt[9. lgnition control module50. To tachometer51. Hall Effect device52. Radio suppressor

l s 7i AB I

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KEY1. Luggage compartment lamp

(Sedanl2. Luggage compartment lamp

switch (Sedanl3. Luggage compartment lamp

switch (Station Wagonl4. Luggage compartment lamp

(Station Wagon)5. Fuse No t[ - interior, luggage

compartment and stop lamps20 AMP {pre Oetober 1989}interior and luggagecompartment lamPs 10 AMP{October 1989 onl

6. L H rear courtesy lamp7. L H rear courtesy lamp

switch8. R H rear courtesy lamp9. R H rear courtesy lamp

switch10. L H map lamp switchl l . L H m a p l a m p12. R H map lamp switch1 3 . R H m a p l a m pItl. Courtesy lamp15. To courtesy lamp switch16. R H Gourtesy lamp door

switches17. L H courtesy lamp door

switches18. To power window module19. Glove c-ompartment lamp

switch20. Glove compartment lamp21.To lights on warning lamp,

instrument and switchillumination lamps

22. Automatic transmissionindicator lamp

23.f o cigarette lighter lamp24.To cruise control and power

antenna switch lamps25. Fog lamp switch lamp26. Rear washer switch lamp27. Rear wiper switch lamp28. Fuse No 7 - instrument

illumination lamps 5 AMP29. Air conditioner switch lamp30. Heater control illumination

lamp31. L H front parking lamp32. R H front parking lamp33. High mounted stop lamp34. To fuel gauge sender unit

and rear washer motor35. Fuse No 1 -parking and

instrument, illuminationlamps, trip Gomputer, radio15 AMP

36. To radio/cassette, tripcomputer and high beamindicator lamp

37. Headlamp switch38. Stop lamp switch39. Stop and tail lamp

(Sedan onlyltl{). Stop and tail lamp41. Number plate lamp

(Station Wagon and Utilityl42.To rear wiper motor4il. Number plate lamp (Sedanl44. High beam switch45. To fog lamp indicator lamptl6. Fog lamp switch47. Fog lamp relay

48. Headlamp relay49. Fusible link - headlamps

30 AMP (Pre October 19891t10 AMP (October 1989 on)

50. Fuse No 18 - headlamp relay15 AMP

51. Fuse No 19 - high beamrelay 25 AMP

52. High beam relay53. To high beam indicator

lamp54. Fog lamp55. Fog lamp55. To parking lamps57. L H headlamp58. L H high beam lamp59. R H high beam lamp60. R H headlamp6 l .LHreverse lamp62 .RHreverce lampGf. To reverse indicator lamp64. Reverse lamp switch

(automatic transmission )65. Reverce lamp switch

(manual transmissionl66. To transmission lockup

solenoid (automatictransmissionl

67. To vehicle speed sensor68. Fuse No 12 - automatic

transmission, reverse lamps,vehicle speed sensor 10 AMP

69. Fuse No 2.- hazard lamps,turn signal lamps, anti-theftsystem 20 AMP

70. To anti-theft module, anti-theft horn relay and luggagecompartment lock switch

ocroBEnr$001tS DEIETED FH([ . * P

JIN O,I

71. Fuse No 14 - wipers, turnsignal lamps, hazard lamps15 AMP

72.To wiper switch and motor73. Hazard lamp switch74. Flasher relay75. To anti-theft module and

L H turn signal indicator76. To earth77. Turn signal switch78. L H front turn signal lamp79. Vacant connector80. L H rear turn signal lamp81. R H rear turn signal lamp82.To anti-theft module and

R H turn signal indicator83. R H front turn signal lamp84. Main wiring harness earth85. To anti-theft module86. lgnition lock illumination

lamp87. To anti-theft module88. Fuse No 16 - stop lamps

15 AMP {October 1989 onl

2fit2494nilD3

Wiring diagram for the interior lamp+ parking lamps, stop and tail lamps, headlamps, reverse lamland turn signal lamps. Wire colours in brackets indicate models from October 1989.



ABcDE

iIi

18

Wiring diagram for the rear demister, front and rear wipers, instruments, instrument illumination rtrip computer. Wire colours in brackets indicate models from Oetober 1989.

KEY1. Fuse No 3 - rear demister,

power antenna 25 AMP2. To power antenna module3. To fuse No 94. Rear demister relay5. To rear demister nrarning

lamp6. Rear demister7. Neutral safety switch

(automatic transmissionl8. To automatic transmission

indicator lamp9. Cigarette lighter

10. Gigarette lighter lamp11. To fuse No 712. Fuse No 15 - cigarette

lighter, rear wiper andwasher 20 AMP

13. Rear wiper switch14. Rear wiper motor15. Rear washer motor16. To earth17. Rear washer switch18. To Gourt€sy lamp door

switch19. Warning lamp check relay20. Rear demister switeh21. Gourtesy lamp switch22. Dimmerswitch23. Ingtrument illumination

resistor24. Windscreen washer switch25. Windscreen wiper switch26. Trip computer switch27.Tsig computer switch lamp28. Rear demister and power

' antenna switch lamp29. Electronic module

30. To fuse No 1431. Windshield wiper motor/rear

wiper motol32. Windshield washer motor33. To earth34. To fuse l\l,o 1235. Vehicle speed sensor36. To earth37. To earth38. Fuel gauge sender unit39. To cruise control module40. To fuge No 141. To EFI control unit42. lnstrument cluster(3. Trip computer44. Trip computer display lamp45. Fuel gauget16. Speedometer47. Tachometertl8. Temperature gauge49. Instrument cluster lamps50. High beam indicator lamp51. Gruise control engage

indicator lamp52. Rear demister indicator lamp53. Fog lamp indicator lamp54. Lights On indicator lamp55. Ahernator warning lamp56. Reverce indicator lamp

(Pre October 1989);Engine disabled warninglamp (Ostober 198!l onl

57. L H turn signal indicator lamp58. R H turn signal indicator

lamp59. Brake failure warning lamp60. Check Engine warning lamp61. Oil pressure warning lamp62. Park brake warning lamp

2*nllJ-4'NU)A

6il. Coolant temperaturewarning lamp

64. Overcpeed warning lamp65. To fuse l\lo 766. To high beam relay67. To cruise control module68. To rear demister relay69. To fog lamp switch70. To alternator71. To revGrse lamp switch (Pre

october 19891; To anti-theftmodule and trip computer(Ostober 19&l onl

72.To turn signal switch73. To warning lamp check relay74. Brake fail warning switch75. To EFI control unit76. Oil pressure switch77. Park brake warning lamp

switch78. To EFI control unit79. To earth80. Temperature gauge sender81. To ignition control module82. To EFI control unitIXl. To rear demister relay and

EFI relay8t[. Fuse No f - inst]ument

warning lamps 5 AMP (Preoctober 198917.5 AMP(October 1989 on|

85. Main wiring harness earth86- To engine disabled warning

lamp {anti-theft systeml87. Lowfuel warning lamp88. Vohage rogulator

COLOURCODEThe first lgtter of the code

reptesents the main wire colour,tho othor letters replesent thetrace colourc.

B - BLACKL . BLUEG - GREENR - R E DY - YELLOWW - WHITEN - BROWNO - ORANGEK . PINKS - GREYv - vtorETP - PURPLEX . LIGHTGREENZ - LIGHT BLUEM . DARKGREENT - DARKBLUEA - LIGHTBROWNE . SLATED - T A N

86 65

f +t :r l

37 PnEocrotEnrs--36 ; ; -d ; ; - - - - -



II

II

iiL.l - 'II lll

KEY1. To electric door lock

switch LHfront2. L H front power window

switch3. L H front power window

motor4. L H rear power window

motor5. L H rear power window

switch6. R H front power window

switch7. R H rear power window

switch8. R H rear power window

motor9. Circuit breaker

10. Powerwindow module11. To courtesy lamp door

switch12. R H front power window

motol13. Luggage @mpartment lock

solenoid14. Luggage compaftment lock

solenoidswitch15. To fuse ilo 216. Fuse ib 10 - cruisa control,

electrh mirrors, powerwindows, eleqtric doorlocks 10 AMP

17. To eruise control €ngageswitch

Wiring diagram for the po{rer windows and elestric mirrors on all models and t{re electric door locanti:thedsJstem and homs on all models prior to kober 1!189. Wire coldurs in brackets ind-rcatr

models from October l$f.

COLOUR CODEThe first letter of the eode

represents the main wire colour,the other letters repr€sgnt thetrace colourS.

B . BLACKL - BLUEG - GREENR - R E DY - YELLO]'I'W. WHITEN - BROWNO - ORANGEK . PINKS - GREYv - vtoLETP . PURPLEX - LIGHTGREENZ - LIGHT BLUEM - DARKGREENT - DARKBLUEA . LIGHTBROWNE . SLATED - T A N

18. Eleetric mirror switah19. L H electric miror -

horizontal motor20. L H electric mirror *

vertical motor21. R H electric mirror -

horizontal motor22. RH electrh mirror -

vertical motol23.To powgr window switch24. Elecrie door lock switch

L H front25. Door lock anti-theft switch26. Fuse lUo 6 - electric door

locks 15 AMP27. Eleqtricdoor lock module28. L H front door lock switch29. L H front electric door lock30. R H front door loc* switch31. R H front electric door lock32. L H rear electrie door lock33. R H rear electric door lock34. Anti-theft override switch35. Anti-theft bonnet switch36. To R H turn signal lamPs37. To L H turn signal lamps38. To fusible link - heater

blower motol39. To anti-theft override switch40. To fuse No 241. Fuse t[o 22 - hom 15 AMPt12. Anti-theft horn relayrlil. Horn relay44. Anta-theft horn diode

45. Horn contact46. Anti-theft homtl7. Horn48. Horn€. Main wirlng hamess earth50. Anti-theft module


238 Electri,cal System

t ++r l9 =

i l r4

17* '+-L

it

-rr'-T-I


represents the main wire colour,the other letterc represent thetrace colours.

B - BLAGKL . BLUEG - GREENR - R E DY - YELLOWW - WHITEN - BROWNO - ORANGEK - PINKS - GREYV - VIOLETP - PURPLEX - LIGHTGREENZ - LIGHT BLUEM - DARKGREENT - DARKBLUEA - LIGHTBROWNE . SLATED . T A N

c c c c o i@ z z 6

J__]__l i II ze I ) >

o o

I6

Wring diagram for the anti-theft system, elestric door locks and horns. Models from October lgg:f

2s8WD2A

KEY1. Fuse No 6 - electric door

locks 15 AMP2. To rear companment lock

solenoid switch3. To anti-theft ultrasonics

connector - main wiringharness

4. To anti-theft ultrasonicsconnector - main wiringharness

5. To anti-theft ultrasonicsconnegtor - main wiringharness

6. To fuse No 147. To anti-theft override switch8. To anti-theft override switch9. To front courtesy lamp

switch10. To fuse No 211. To rear compartment lamp

switch12.To front courtesy lamp

switch13. To EFI control unit14. To trip computer module15. To engine disabled warning

lamp16. Fuse No22- horn 15 AMP

17. To turn signal switch18. Anti-theft LED indicator19. Anti-theft module20. Door lock module21. L H front electric door lock

key switch22. RH front electric door lock

key switch23. L H front elestric door lock

motor24. R H front electric door lock

motol25. L H rear electric door lock

motor26. R H rear electric door lock

motor27. Anti-theft bonnet switch28. Anta-theft override switch29. Anti-theft horn relay30. Horn relay31. Horn contact32. Anti-theft horn33. Horn, low note34. Horn, high note35. To fuse No 2136. Anti-theft horn diode37. Main wiring harness earth38. To fuse No 10

ABcDE

23aAI

Y12AI

_.1


Electri,cal System 239

ABcDE

n r-TtU I P qi l tro t t lt 6 t l

N i I I? l r lL J.I

E

F

Wiring diagram for the electronic climate oontrol system.

I.J

Itoo

Tr

2494n58,fiND4A


represents the main wire colour,the other letters represent thetrace colours.

B - BLACKL - BLUEG . GREENR - R E DY - YELLOWW - WHITEN - BROWNO . O R A N G EK - PINKS - GREYv - vtoLETP - PURPLEX . LIGHTGREENZ - LIGHT BLUEM - DARKGREENT - DARKBLUEA - LIGHTBROWNE - SI.ATED - T A N

KEY1. Fuse No 23 - engine cooling

fan 30 AMP2. Engine cooling fan relay3. A/C auxiliary fan4. AIC low pressure sritch5. A/C high pressure switch6. A/C relay7. AlCcompreslxrl8. Fuse No 8 - air conditioning

10 AMP9. Fusible link - heater blower

motor 30 AMP10. Heater blower motor11. Heater blower motor relay12. Heater blower motor switch13. Fuse No 17 - climate control

5 AMP14. Vacuum solenoid pack15. Climate control module16. Air mix motor17. Thermosensor18. Air temperature sensor19. A/C evaporator inlet control

switch20. lntake air temperature sensor

21. Ambient air temperaturesensor

22. Solar sensor23. To radio amplifier24.To fuse No 725. To fuse No 126. To EFlcontrol unit27.To ignition relay28. Main wiring harness earth

l l? lr l

i lt o

R'"+j"Q

III

' ?t t

+


240

lOOmm


,IItt-

I_9mm

t3mm WIRE 24efLD8

BODY

I. WINDSCREEN AI{D REAR GI.ASS

The renewal or replacement of the windscreenand the rear glass follows the same basic procedure.

The successful fitting and sealing of the wind-screen or rear glass will depend to a large extent on thetechnical knowledge and experience of the operatorand it is not recommended that rear glass or wind-screen replacement be attempted by anyone lackingprevious experience.

2. FROhIT DOORS

Special Equipment Required:To Remove Snipper Button - Removal tool

INTERIOR HANDLES AND TRIM PANEL

To Remove and Instal(1) On vehicles equipped with power windows

or electric mirrors disconnect the negative batteryterminal.

(2) On vehicles not equipped with power win-dows, lever back the regulator handle and using asuitable wire hook, withdraw the handle retainingclip, then remove the handle and washer.

Alternatively, slide a piece of sturdy cloth underthe handle and pull on each corner to release theretaining clip.

(3) Prise the cover from the armrest handle andremove the securing screws.

(4) Remove the handle from the door trim andwhere applicable, disconnect the electric exteriormirror wiring.

. (5) On vehicles equipped with manual exteriormirrors, remove the plug from the control knob. Openthe tabs on the control knob and carefully pull theknob offthe shaft.

(6) Remove the screw from the mirror innercover. Carefully pull the cover away from the doorand move it rearward to remove the cover from thevehicle.

(7) Fabricate a special tool to the dimensionsshown in the illustration.

Insert the tool down the left hand side of thesnipper button and locate it behind the orange insert.Pull the tool sharply to disengage the insert from thesnipper button. Slide the snipper button up off thecontrol rod.

(8) Remove the screw retaining the snipperbutton escutcheon and remove the escutcheon.

(9) Using a flat bladed screwdriver, carefullydisengage the trim panel retaining clips from the door.Starting at the lower rear corner, work across then up

Snipper button removed from the vehicle showing theinsert disengaged.Line drawing of the snipper button removing tool.


both sides alternately. Remove the trim panel fromthe door.

(10) Carefully peel the plastic sealing panel awayfrom the door while cutting the sealant using a sharpknife. Remove the plastic sealing panel from thevehicle.


(l) Use a suitable sealant to adhere the plasticsealing panel to the door.

(2) Instal the trim panel to the door, carefullylocating the trim panel clips in the door.

View of the front door with the trim panel and plasticsealing panel removed.

(3) Instal the window regulator handle escut-cheon, handle and cllp to tfrg door ensuring that thehandle apd gl4ss are'posilioped as o$ the oppositedoor.

NOTE: The regulator handle retaining clipsshould be placed on the handle before in-stalling the handle to the regulator.

WINDOW GLASS

To Remove and Instal(l) Remove the trim panel and plastic sealing

panel as previously described.(2) Temporarily instal the window regulator

handle and lower the window fully. Using a flat bladedscrewdriver, carefully prise the inner window mould-ing from the door, working from the rear end of themoulding.

(3) Support the window glass and remove thepivot plate retaining bolts.

(4) Manoeuvre the window glass to disengagethe window lift channels from the regulator arms.

24r

(5) Raise the rear upper corner of the windowglass and remove the window glass through the glassopening at the top of the door.


(1) Ensure that the window glass is located in therun channels and correctly aligned. Adjust the posi-tion of the pivot plate retaining bolts in the slottedholes to align the window assembly in a parallelattitude.

(2) Instal the trim panel as previously described.

WINDOW REGULATOR

To Remove and Instal( I ) Remove the trim panel and plastic sealing

panel as previously described.(2) Remove the window glass as previously de-

scribed and on power operated window models,disconnect the regulator wiring connector.

(3) Using an electric drill remove the rivetsretaining the regulator to the door. Disengage theregulator from the pivot plate and remove the re-gulator through the lower aperture in the door.


NOTE: If installing new nylon sliders to thesupport and regulator arms, ensure that thesliders are soaked in hot water for a mini-mum of two minutes prior to installation.

( I ) Lubricate the regulator friction surfaces andassociated parts with lithium grease.

(2) Instal the regulator to the door and attachusing suitable screws.

window regulator and window glasscomponents.

Body

Front door


242

(3) On power operated window models, instalthe regulator wiring connector.

(4) Instal the window glass as previouslydescribed.

EXTERIOR DOOR HANDLE


panel as previously described.(2) Remove the lock security shield retaining

screw and by pushing the shield upwards, remove itfrom the door cavity.

(3) Disconnect the lock cylinder control rodfrom the door lock by releasing the retainer clip.

(4) Withdraw the slide clip from the rear of theexterior door handle.

(5) Manoeuvre the handle section from the es-cutcheon from inside the door, then remove theescutcheon and seal from the door.


(l) Tilt the top of the escutcheon away from thedoor to assist with installation of the handle section.

(2) Ensure that the escutcheon and seal arecorrectly installed prior to installing the slide clip.

REMOTE CONTROL AND DOOR LOCK


panel as previously described.(2) On vehicles equipped with electrically oper-

ated door locks, remove the actuator retaining screwsand disconnect the control rod from the lock.

(3) Remove the lock security shield retainingscrew and by pushing the shield upwards, remove itfrom the door cavity.

(4) Disconnect the lock cylinder control rod, thesnipper button control rod and the remote control rodby releasing the retaining clips.

(5) Remove the lock retaining screws from thedoor and remove the lock through the door aperture.

(6) If necessary, remove the remote control bydisengaging the control rod from the guide and liftingthe rear section from the door. Slide the remotecontrol assembly rearwardS:and remove the assemblyo"TJHrffrLl;

,, u r.r,.rsal of the removal procedurewith attention to the following points:

(1) Ensure that the control rodsinstalled.

are correctly

(2) If equipped, instal and connect the door lockactuator.

(3) Ensure that the door lock controls and theexterior handle operate correctly prior to installing thetrim panel.

NOTE: Tighten the lock retaining screws to3-5 Nm. Do not exceed this torque settingor damage to the door loclcs will result.

Body

sNrppER BurroN - m

CYLINDER

SLIDE CLIP }

CONTROL RODS-+

SECURITY SHIELD

DOOR LOCK

Dismantled view of the front door lock and remote control components. tt is important not to overtighten the tlock retaining screws or damage to the door locks will resutt.

LOCK

\ry/

SEAL

ADJUSTING NUT

scREw--_ _ g


LO,CXCYLINDER


panel as previously described.(2) Remove the exterior door handle as pre-

viously described.(3) Withdraw the retaining clip from the es-

cutcheon and remove the lock cylinder.Installation is a reversal of the removal procedure

with attention to the following point:Powdered graphite is the only lubricant re-

commended for the lock cylinders.

DOOR LOCK STRIKER

To Remove, Instal and Adjust(l) Mark the installed position of the striker

plate on the body pillar using a soft lead pencil.(2) Remove the striker plate retaining screws

using a Torx adaptor and remove the striker plate.Inspect the striker plate for wear or damage.

(3) Instal the striker plate to the body pillaraccording to the pencil marks made on removal.

(4) Close the door and observe the alignmentwith the rear door. If incorrect, loosen the striker plateretaining screws and move the striker plate in or out toachieve a flush fit.

If the door lifts or drops when the lock engages thestriker plate, loosen the screws and move the strikerplate up or down to eliminate the problem.

NOTE: After each adjustment tighten thestriker plate screws and check the adjust-ment. Readjust as necessary.

243

EXTERIOR MIRROR

To Remove and Instal( I ) On vehicles equipped with manual exterior

mirrors, remove the plug from the control knob. Openthe tabs on the control knob and carefully pull theknob off the shaft.

(2) On vehicles equipped with electric exteriormirrors, remove the trim panel and plastic sealingpanel. Disconnect the negative battery terminal andthe mirror door wiring.

(3) Remove the screw from the mirror innercover. Carefully pull the cover away from the doorand move it rearwards. Remove the cover from thevehicle.

(4) Remove the screws retaining the mirror tothe door and remove the mirror from the vehicle.


If applicable, connect the negative battery ter-minal and start the engine, increase the speed to 3 000rpm for 10 seconds to allow the idle air control valveto reset. On vehicles equipped with a radio/cassetteusing PIN security, enter the PIN code as describedunder the radio/cassette heading in the ElectricalSvstem section.

Dismantled view of a manual exterior mirror andassociated components.

3. REAR DOORS

Special Equipment Required:To Remove Snipper Buffon - Removal tool

INTERIOR HANDLES AND TRIM PANEL

To Remove and Instal( I ) On vehicles equipped with power windows,

disconnect the negative battery terminal.(2) On vehicles not equipped with Bower win-

dows, lever back the regulator handle and using asuitable wire hook, withdraw the handle retainingclip, then remove the handle and washer.

Alternatively, slide a piece of sturdy cloth underthe handle and pull on each corner to release theretaining clip.

(3) Prise the cover from the armrest handle andremove the securing screws. Remove the handle fromthe vehicle.

Body

lnstalled view of the front door lock striker.


244

View of the rear door with the trim panel and plasticsealing panel removed.

(4) Fabricate a special tool to the dimensionsshown in the illustration under the Front Doorsheading.

Insert the tool down the left hand side of thesnipper button and locate it behind the orange insert.Pull the tool sharply to disengage the insert hom thesnipper button. Slide the snipper button up off thecontrol rod.

(5) Remove the screw retaining the snipperbutton escutcheon and remove the escutcheon.

(6) Using a flat bladed screwdriver, carefullydisengage the trim panel retaining clips from the dooi.Starting at the lower rear corner, work across then uploth sides alternately. Remove the trim pangl fromthe door.

(7) Carefully peel the plastic sealing panel awayfrom the door while cutting the sealant using a sharpknife. Remove the plastic sealing panel from itre dooi.


(tl Use a suitable sealant to adhere the plasticsealing panel to the door.

(2) Instal the trim panel to the door, carefullylocating the trim panel clips in the door.

(3) Instal the window regulator handle escut-cheon, handle and clip to the door, ensuring thpt thehandle and glass are positioned as on ttre=oppoqitedoor.

NOTE: The regulator handle retaining clipshould be placed on the handle befoie ii-stalling the handle to the regulator.-

(4) Connect the negative battery terminal andstart the engine, increase the speed to 3 000 rpm forl0 seconds to allow the idle air control valve to reset.On vehicles equipped with a radio/cassette using pIN

Body

security, enter the PIN code as dessribed under theradio/cassette heading in the Electrical Systemsection.

WINDOW GLASS AND FIXED GLASSTo Remove and Instal

( 1) Remove the trim panel and plastic sealingpanel as previously described.

(2) Temporarily instal the window regulatorhandle and lower the window fully. Using a flat bladedscrewdriver, carefully prise the inner and outerwindow mouldings from the door, working from therear end of the mouldings.

(3) Remove the rear section of the run channelrubber and remove the screws retaining the rear runchannel to the door.

(4) Remove the rear run channel from the fixedwindow rubber.

(5) Carefully move the window glass rearwardsto disengage the window glass frorn the regulator.Remove the window glass through the opening at thetop of the door.

. (6) ,If necesssry, remove the fixed gnass by pris-ing the fixed glass rubber from the uppei door-frbmeand sliding forwards.

II'INDOW GLASS

window regulator and window glasscomponents.

Rear door



(l) Ensure that the fixed glass and rubber arecorrectly installed to the door frame.

(2) Ensure that the inner and outer windowmouldings are coffectly located prior to tapping theminto place.

(3) Check the window glass operation prior toinstallation of the plastic sealing panel and trim panel.

WINDOW REGULATOR


panel as previously described.(2) Remove the window glass as previously

described and on power operated window models,disconnect the regulator wiring connector.

(3) Using an electric drill, remove the rivetsretaining the regulator to the door. Remove theregulator through the lower aperture in the door.


( I ) Lubricate the friction surfaces and as-sociated parts with lithium grease.

(2) Instal the regulator to the door using suitablescrews.

(3) On power operated window modelsi instalthe regulator wiring connector.

EXTERIOR DOOR HANDLE

To Remove and Instal(1) Remove the trim panel and plastic sealing

panel as previously described.(2) Withdraw the slide clip from the rear of the

exterior door handle.

245

(3) Manoeuvre thp handle section from the es-cutcheon from inside the door, then remove theescutcheon and seal from the door.

Installation is a reversal of the removal procedurewith attention to the foflowing point:

Ensure that the escUtcheon and seal are correctlyinstalled prior to installflng the slide clip.

REMOTE CONTROL AND DOOR LOCK

To Remove and Instal(1) Remove the trim panel and plastic sealing

panel as previously desoribed.(2) On vehicles equipped with electrically oper-

ated door locks, remove the actuator retaining screwsand disconnect the control rod from the lock.

(3) Disconnect thg remote control rod and thesnipper button control rod by releasing the retainingclips.

(4) Remove the lock retaining screws from thedoor and remove the lobk assembly through the dooraperture.

(5) If necessary, rpmove the remote control bydisengaging the control fod from the guide and liftingthe rear section from the door. Slide the remotecontrol rearwards and remove it from the door.


(l) Ensure that the control rods are correctlyinstalled.

(2) If equipped, instal and connect the door lockactuator.

(3) Ensure that the door lock controls and theexterior handle operate correctly prior to installing the

Body

trim panel.

249t7344

SN.PPERBurroN *ffi

CONTROL ROD-_ _--.REMOTE CONTROL

\.*

CONTROL

plot . ' -

Dismantled view of the rear door lock and remo-te control components. lt is important not to overtighten the tlock retaining screws or damage to the door locks will result.

\SEAL

ADJUSTING NUT


246

(4) Tighten the lock retaining screws to 3-5 Nm.Do not exceed this torque setting or damage to thedoor locks will result.

DOOR LOCK STRIKER

To Remove, Instal and Adjust(1) Mark the installed position of the striker

plate on the body pillar using a soft lead pencil.(2) Remove the striker plate retaining screws

using a Torx adaptor and remove the striker plate.Inspect the striker plate for wear and damage.

(3) Instal the striker plate to the body pillaraccording to the pencil marks made on removal.

Installed view of the rear door lock striker.

(4) Close the door and observe the alignmentwith the body. If incorrect, loosen the striker plateretaining screws and move the striker plate in or out toachieve a flush fit.

If the door lifts or drops when the lock engages thestriker plate, loosen the screws and move the strikerplate up or down to eliminate the problem.

NOTE: After each adjustment tighte.n thestriker plate suews and check the adjust-ment. Readjust as necessary.

4. ENGINE BONNET


( 1) Raise the bonnet and support it with thebonnet stay.

(2) Disconnect the windscreen washer tube fromthe T piece.

(3) With the aid of an assistant, remove the boltssecuring the bonnet mounting brackets to the boanethinges. Carefully remove the bonnet from the vehicle.

Installation is a reyersal of the remova.l procedure.

TO ALIGN

(1) To align the bonnet fore and afr, loosen thebonnet hinge mounting bolts sufficiently to allow thebonnet to be moved.

Installed view of the bonnet hinge showing the loca-tion of the securing bolt.

To align the front of the bonnet loosen or tighten thelock bolt.

(2) To align the height of the rear of rhe bonner,loosen the bonnet bracket mounting bolts sufficientlyto allow the bonnet to be moved.

(3) To align the height of the front of'the bonnet,loosen or tighten the lock bolt. Lock bolt nominallength is 52 mm from the bonnet to the lock boltshoulder.

NOTE: Correct alignment is achieved whenthe spacing and height of the bonnet andadjacent components are even.

5. LUGGAGE COMPARTMENT LID


(1) Raise the luggage compartment lid and markthe installed position of the hinges using a soft lead

Body


Mark the installed position of the luggage compart-ment lid hinge prior to removal.

pencil. If applicable, disconnect the solenoid wiringconnector.

(2) With the aid of an assistant, remove thehinge mounting bolts and remove the luggage com-partment lid from the vehicle.

Installation is a reversal of the removal procedureensuring that the hinges are relocated to the pencilmarkings made on removal.

TO ALIGN

( I ) To align the luggage compartment lid foreand aft loosen the hinge mounting bolts sufficiently toallow the lid to be moved.

(2) To align the height of the front of the luggagecompartment lid, shims must be added or removed.

(3) To align the height of the rear of the luggagecompartment lid the lock striker must be raised orlowered.

LUGGAGE COMPARTMENT LOCK

To Remove and Instal( I ) Raise the luggage compartment lid and dis-

connect the lock cylinder control rod. On vehiclesequipped with remote release, disconnect the solenoidwiring and the control rod.

(2) Remove the screws retaining the lock to theluggage compartment lid and remove the lock fromthe vehicle.

(3) If necessary, on vehicles equipped with aremote release solenoid, remove the screws retainingthe solenoid to the luggage compartment lid andremove the solenoid from the vehicle.


LOCK CYLINDER

To Remove and Instal( I ) Raise the luggage compartment lid and dis-

connect the lock cylinder control rod from the lock.(2) Compress the lock cylinder retaining tangs or

remove the retaining clip and remove the lockcylinder from the luggage compartment lid.


247

lnstalled view of the luggage compartment lock, lockcylinder and striker with the lid closed.

LOCK STRIKER

To Remove and Instal( 1) Raise the luggage compartment lid and mark

the installed position of the lock striker using a softlead pencil.

(2) Remove the lock striker attaching bolt andremove the lock striker.

Installation is a reversal of the removal procedureensuring that the tock striker is located to the pencilmarkings made on removal.

lnstalled view of the luggage compartment lockstriker.

To Adjust(1) Loosen the lock striker attaching bolt suf-

ficiently to allow movement.(2) Close the luggage compartment lid and

observe the height in relationship to the rearmudguards.

(3) Lower or raise the striker plate so that a flushfit is achieved. Tighten the lock striker attaching bolt.

Body


248

6. TAILGATE


(1) Disconnect the negative battery terminal.(2) Raise the tailgate, remove the trim clips

retaining the trim panel to the tailgate and remove thetrim panel.

(3) Disconnect the electrical connectors fromwithin the tailgate and tie a piece of string to theconnectors. Separate the rubber tubing from the top ofthe tailgate.

NOTE: The string is used to draw the wiringthrough the tailgate on installation. If thewiring is pulledfrom the tailgate without thestring attached, installation will be dfficult.

(4) Pull the wiring from the tailgate leaving theends of the string exposed. Untie the string from thewiring.

Installed view of the tailgate showing a hinge andsupport.

(5) Carefully prise out the window washernozzle from the outer tailgate panel and disconnectthe washer hose. Tie a piece of string to the washerhose and remove it from the tailgate, as previouslydescribed for the wiring.

(6) With the aid of an assistant supporting thetailgate, using a thin bladed screwdriver, remove theretaining clips from the lower end of the tailgatesupports and disconnect the supports from the pivotball.

(7) With the assistant supporting the tailgate,remove the hinge pin retaining clips and remove thehinge pins. Remove the tailgate from the vehicle.


(l) Ensure that all electrical connectors areinstalled prior to installing the tailgate trim.

(2) Ensure that the tailgate lock engages thetailgate lock striker correctly. If necessary, loosen thelock striker retaining screws and adjust to altow thetailgate lock to engage freely.

Installed view of the tailgate lock striker.

(3) Connect the negative battery terminal andstart the engine, increase the speed to 3 000 rpm forl0 seconds to allow the idle air control valve to reset.On vehicles equipped with aradio/cassette using pINsecurity, enter the PIN code as described under theradio/cassette heading in the Electrical Systemsection.

TAILGATE LOCK

To Remove and Instal(1) Raise the tailgate, remove the trim clips

retaining the trim panel to the tailgate and remove thetrim panel.

(2) Remove the screws retaining the lailgate lockto the tailgate.

(3) Swing the lock up inside the tailgate andmanoeuvre the control rod from the lock. Remove thelock from the tailgate.


rtu4"\;

M- LocK BUrroN

+CONTROL ROD

view of the tailgate lock, handlecomponents.

Body

Dismantled and


Body 249

tCONSOLE

View of the automatic transmission centre consoleand components removed from the vehicle.

(4) Open the centre console compartment lid,lift the carpet and remove the retaining screws.

(5) Unzip the handbrake lever boot and onpower operated window models, disconnect thewiring connectors.

(6) Loosen the adjusting screws at the front ofthe console to lower the console. Disengage thelocating lugs and remove the console from the vehicle.


Connect the negative battery terminal and startthe engine, increase the speed to 3 000 rpm forl0 seconds to allow the idle air valve to reset. Onvehicles equipped with a radio/cassette using PINsecurity, enter the PIN code as described under theradio/cassette heading in the Electrical Systemsection.

9. SEATS

FRONT SEATS

To Remove and Instal(l) Adjust the seat to the fully rearward position

and remove the front securing bolts.(2) Adjust the seat to the fully forward position

and remove the rear securing bolts.(3) Lift the seat from the vehicle and place it on

a clean dry surface.

I{rcKCYLINDER AND HANDLE ASSEMBLY

To Remore rnd Instal(1) Remove the tailgate lock as previously

described.(2) Remove the nuts retaining the handle to the

tailgate and disconnect the wiring. Remove the handlefrom the vehicle.

(3) Remove the lock cYlinderand disconnect the control rod.


7. RADIATOR GRILLE


(1) Raise the engine bonnet and support it withthe stay.

(2) Remove the retaining screws from the top ofthe grille.

(3) Lift the grille up to disengage the locatinglugs from the bumper bar, remove the grille assembly.

(4) If necessary, remove the grille retainer plugsfrom the bumper bar.


e--'/ \r-

View of the radiator grille removed from the vehicle.

8. CENTRE CONSOLE


(1) Disconnect the negative battery terminal.(2) On manual transmission models, remove the

gear knob from the gear lever, carefully prise the rearof the console cover from the centre console. Dis-connect the wiring connectors and remove the coverfrom the vehicle.

(3) On automatic transmission models, proceedas follows:

(a) Carefully prise the rear of the console coverfrom the centre console. Disconnect the wiring con-nectors, turn the cover 90 degrees and manoeuvre itover the selector lever handle.

(b) Remove the gear position scale and trim, theslide indicator and the indicator support.

(c) Remove the screws retaining the supportassembly to the centre console, disconnect thequadrant lamp connector and remove the supportassembly from the vehicle.

from the handle

T

/

location of the front seat ]ear securing bolts.


250

Location of the front seat front securing bolts.


(l) Lubricate the seat slides with multi-purposegrease prior to installation of the seat.

(2) Apply Loctite 242 to the securing bolts priorto installation and torque the bolts to 35 Nm.

REAR SE.AT CUSHION - SEDANTo Remove and Instal

(l) Firmly bump the front of the seat cushionrearwards to release the retaining clips from the floorpanel brackets.

(2) With the retaining clips released, lift the seatcushion from the vehicle and place it on a clean drysurface.


(1) Fnsure that the seat belts are correctly posi-tioned prior to installing the seat cushion.

(2) Ensure that the retaining clips are properlyengaged to the floor panel brackets.

REAR SEAT CUSHION - STATION WAGONTo Remove and Instal

(l) Firmly bump the front of the seat cushionrearwards to release the retaining clips from the floorpanel brackets.

(2) With the retaining clips released, lift thefront of the seat cushion and remove the seat beltsfrom the elastic loops on the rear of the seat cushion.

Body

(3) Lift the seat cushion from the vehicle andplace it on a clean dry surface.

Installation is a reversal of the remotal procedurewith attention to the following points:

(1) Ensure that ther seat belts are positionedthrough the elastic loops rprior to installing the seatcushion.

(2) Ensure that the retaining clips are properlyengaged to the floor panel bracketi.

Location of the rear seat cushion retaining brackets,rear seat backrest retaining bolts and lower rear seat

belt mounting bolt. Station Wagon model shown.

REAR SEAT BACKREST - SEDANTo Remove and Instal

(l) Remove the rear seat cushion as previouslydescribed.

(2) Remove the bolts,retaining the seat backrestframe to the floor panel.

(3) Lift the seat backrest from the retainingbrackets.

(4) Remove the seat backrest from the vehicleand place it on a clean dry surface.


REAR SEAT BACKREST - STATION WAGONTo Remove and Instal

(l) Remove the rear seat cushion as previouslydescribed.

(2) Remove the lower seat belt mounting boltsand withdraw the seat belts from the elastic loops.

(3) Release the rear seat backrest lock button,then remove the bolts retaining the seat backrestbracket to the vehicle body.

(4) Remove the seat backrest from the vehicleand place it on a clean dry surface.



Body

10. SEAT BELTS ,:

The front and outer rear seats are equipped with ;lap/sash inertia reel seat belts, which are designed to ilock with any sudden change in vehicle motion.

The centre rear seat is equipped with a manually iadjustable lap seat belt. ,,

The seat belts should be periodically inspected asd e s c r i b e d b e l o w . A n y s e a t b e l t a s s e m b l y t h a t i s w o r n �or damaged, or has been subjected to abnormal '

loadings in a collision, should be renewed as a .lcomplete assembly

Only mild soap and water should be used to clean :

the webbing. Contamination with polish, oil, bleaches ',

and other chemicals should be avoided.

Installed view of the front seat belt showing themounting bolt locations.

TO INSPECT

( I ) Check the seat belt webbing for fraying, cuts,burns or other damage. On inertia reel seat belts,slowly pull the belt from the reel to allow the entirelength to be examined. If the webbing is damaged orworn, renew the seat belt assembly.

(2) Ensure that the belts are not twisted.(3) Check all retaining nuts and bolts for

security.(4) Inspect the belt buckles for correct and

secure engagement. If the buckles are damaged or donot function correctly, renew the seat belt assembly.

(5) On inertia reel seat belts, check the retractormechanism as follows:

(a) Pull the belt slowly from the reel and checkfor a smooth operation. Release the belt and ensurethat it retracts fully.

(b) Pull the belt rapidly from the reel. The reelshould lock.

25r

Check the seat belt webbing for fraying, cuts, burns,or other damage.

(c) Drive the vehicle at walking pace andattempt to withdraw the belt slowly while brakingsharply. The reel should lock.

If the retractor mechanism does not functioncorrectly, renew the seat belt assembll'.

11. DASHBOARD


(1) Disconnect the negative battery terminal.(2) Remove the centre console as previously

described in this section.(3) Remove the steering column as described in

the Steering section.(4) Remove the radio as described in the Electri-

cal System section(5) Remove the instrument cluster as described

in the Electrical System section.(6) Open the glove companment and using a flat

bladed screwdriver, prise out the hinge pin at the righthand side and remove the compartment.

(7) From under the dashboarcl, remove thescrews and fasteners securing the lower trim panel andremove the panel.

(8) Using a small screwdriver, prise the plasticstrip from the front section of the left hand side sillpanel cover.

(9) Disengage the front section of the sill panelcover from the kick panel and the sill.


252 Body

(10) Disengage the lower front corner of the kickpanel from the locating stud. Remove the kick panelfrom the vehicle.

(11) Disconnect the dashboard wir ing.(12) Remove the screw retaining the ientre fascia

panel to the dashboard and remove the panel from theveh ic le .

(13),Remove the screws retaining the dashboardend coversr ?trd remove the end covers.

(14) Remove the retaining screws from the sidevent housings and remove the side vent housings.

( 1 5 ) R e m o v e t h e r e t a i n i n g s c r e w s f r o m t h espeaker covers and remove the speaker covers.

(16) Remove the demister gri l le retaining screwsand remove the demister gri l le.

(17) Remove the speaker retaining screws andwithdraw the speakers sufficiently to disconnect thewiring. Remove the speakers.

side venthousing retaining screws removed showing thelocation of the speaker cover retaining screw.

One of the dashboard end cover retaining screws isaccessed from behind the lower trim panel. On thepassenger side, this end cover screw is accessed with the

glove compartment removed.

Dashboard end cover removed showing the location of theside vent housing retaining screws.

AIt

View of the dashboard removed from the vehic le wi th arrows showing the locat ion of the mount ingscrews and bolts. Bolts marked A are deleted from models iftet February f SgS. '


Rear v iew of the dashboard part ia l ly removed

(18) Disconnect the heater ducts from the aper-tures in the outer ends of the dashboard.

(19) Remove the dashboard mounting bolts fromthe outer ends of the dashboard.

(20) Remove the retaining screw and bolt fromthe lower centre dashboard at the heater assembly.

(21) Fully recline both front seats.(22) With the aid of an assistant, remove the re-

maining mounting screws adjacent to the windscreendemister ducting.

(23) Carefully swing the passenger side of thedashboard away from the bulkhead and support it onthe drivers seat, as i l lustrated.

(24) Separate the wiring from the dashboard not-ing the installed position of the connectors and thewiring retainers.

253

showing the wir ing rout ing dnd retainer locat ion.

(25) Remove the dashboard from the vehicle andplace it on a clean dry suqface.

Installation is a rever$al of the removal procedurewith attention to the following points:

(1) Ensure that the lviring is correctly routed asnoted during removal.

(2) Adjust the heatqr control cable as describedin the Cooling and Heating Systems section.

(3) Tighten al l the retaining nuts, bol ts andscrews securely.

(4) Check the operation of all the componentsdisturbed during removal;

NOTE: When instdll ing the dashboard,be careful not to trqp any wiring betweenthe dashboard and the bulkhead.


254

SUPPLEMENT

This supplement provides additional information pertaining to all models manufac-tured from 1990 and is presented in two parts.

Part 1 is applicable to all models manufactured from 1990 including the Com-modore VG series Utility which was introduced in August 1990.

The Utility is available in Ute (base model) and S variants with a five speed manualtransmission as standard equipment and a four speed automatic transmission availableas an option. A column shift is optional with an automatic transmission and a split benchseat is available on all models except those with a floor shift automatic transmission. Alimited slip differential is standard on S models.

Part 2 covers further changes applicable to models manufactured in l99L Allchanges covered in Part 1 also apply io tggl models unless revised rnPart2.

As some of the production changes were introduced prior to the model commence-ment dates and are therefore applicable to earlier models, it is recommended that thesupplement be thoroughly read in conjunction with the main part of the manual andcompared to the particular vehicle being serviced.

Specifications and procedures not listed in this supplement remain as described inthe main manual.


PART I. T99O MODELS

\TEHICLE IDENTIFICATION, GENERAL SPECIFICATIONS,LUBRIC.ATION AIND MAINTENAI\CEO WHEELS AI\D TYRESO

ENGINE TUNE.UR ROADSIDE TROLIBLE SHOOTINGAI\D FIJELAI{D ENGINE MANAGEMENT

1. VEHICLE IDENTIFICATION AND GENERALSPECIFICAf,IONS

GENERAL VEHICLE SPECIFICATIONS

Utility ModelsLength .4997 mmWidth . . '1 ,794mmWhee lbase . . .2822mmWheel track:

F r o n t . . . . 1 4 5 1 m mRear | 478 mm

Fuel tank capacityTowing capacity:

63 litres

Fully loaded -*Front 2I0 kPa

tRear . 27O kPa

*Increase the tyre pressure by 29 kPa if the vehicle isdriven constantly at high speed.

tlncrease the tyre pressure by 39 kPa if the vehicle isdriven constantly at high speed.

HOW TO CHANGE A WHEEL

Utility Models

The procedure remains as described in the mainmanual with attention to the following point.

(1) Remove the spare wheel as follows:(a) Remove the jack and handle, wheel spanner and

the spare wheel winch handle from behind the drivers seat.(b) Instal the winch handle through the aperture

adjacent to the rear number plate and engage the sparewheel winch shaft.

(c) Rotate the winch handle anticlockwise to lowerthe spare wheel. Remove the winch cable plate from thespare wheel and withdraw the wheel from beneath thevehicle.


4. ENGINE TUNE-UR ROADSIDE TROLJBLESHOOTING AITD FI.JEL AT{D ENGINE

MANAGEMENT

All procedures remain as described in the mainmanual with attention to the following points.

(1) On models manufactured from mid October1989, a number of changes have been made to the wiringharness. Due to these changes, the ENG COMP and ENGINJ fusible links have been deleted and replaced by one 30amp fusible link marked ENGINE.

Where reference is made in the main manual to thefusible links marked ENG COMP and/or ENG INJ, thisshould be read as the fusible link marked ENGINE.

(2) Power to the ignition control module is suppliedthrough the EFI relay circuit.

(3) On Utility models, the fuel tank is installed in

Load equalising trailer hitchTrailer brakes, heavy duty towbar,equalising hitch, auto trans oil cooler

1 200 kg

1 590 kg

2. LUBRICATION AND MAINTENANCE

SPECIFICATIONSRear axle lubricant:

Utilitv models . . . . . Mobilube SHC 80W140 IDor Castrol SAF-XA 80W140

synthetic hypoid gear oil

NOTE: Use of incorrect lubricant may resultin damage to the dffirential gears.

SERVICE SCHEDULEOn all models manufactured from 1990, it is not

necessary to check the operation of the oxygen sensor asdescribed under the Fuel and Engine Management headingin the service schedule of the main manual.

3. WHEEI-S AITD TYRES

SPECIFICATIONSTyre Pressures:

Up to three passengers -*Front 200 kPa*Rear .200 kPa


256 Supplement - Part l. 1990 Models

MAIN FUSIBLELINK 60 A

EFIRELAY

B8

82

A2

pnesslne f LUS! I- g-l^E,ct{swricH- I PUMP l--l EN-gl_{E

v{ r-, T\_-/- I LAMP

. ' D ' . . F R O M N O V . 1 9 9 0 . . . . a . . . . . . . 8 . . . . . . .

DETONATION

F C D B A E

DIAGNOSTIC CONNECTOR

GW'zB

- fuC Switch<ts-N

a A/C Relay

,"

- Inp Computer__, Aulo Trans 4th Gear/femD Switch

a

I

tl€

Ior

MAP SENSOF

COLOUR CODE

The first lener of the cod€ repr€sents themain wire colou( the other bners reDresentthe trace @lours.

B . B L A C K V - V I O L E TL . BLUE P. PURPLEG. GREEN X. LIGHT GREENB - R E D Z - LIGHT BLUEY. YELLOW M- DARK GREENW. WHITE T - DARK BLUEN . BROWN A. LIGHT BROWNO - O R A N G E E - S L A T E

-DA

SR

n

K - PINKS - GREY

D ' T A N

249t452/WD12A

INJECTORSaUN

ELECTRG.IICCONTROL UNIT

t

E

Fuel and engine management system circuit diagram. All models from October lggg.


Supplement - Part 1. 1990 Models 257

FILLER HOSE

Location of the ENGINE fusible l ink.

the load compartment under the front floor panel and thefuel pump is mounted inside the tank. If removing the fuelpump, it is necessary to remove the fuel tank from thevehicle as described under the following heading.

FUEL PUMP AND FUEL TANK

To Remove and Instal - Utility Models

(1) Depressurise the fuel system as follows:(a) Remove the fuel pump fuse from the engine

compartment relay housing.(b) Start the engine and allow it to idle until it stalls.(c) Operate the starter motor for 10 seconds to en-

sure that the fuel pressure has been relieved. Instal the fuelpump fuse.

(2) Disconnect the negative battery terminal.(3) Drain the fuel from the fuel tank using a hand

pump or siphon. Do not siphon fuel using the mouth.(4) Remove the retaining screws and remove the

front floor panel from the load compartment.(5) Remove the retaining screws and remove the

side cover panel from the front right hand side of the loadcompartment.

(6) Suitably mark and disconnect the vent hosesfrom the top of the fuel tank.

Location of the fuel tank with the floor panel removed.Utility model.

Fuel tank removed from the vehicle. Utility model.

(7) Loosen the clamp and disconnect the vapourseparator from the filler neck hose.

(8) Loosen the clamp and disconnect the hose fromthe filler neck.

(9) Remove the fuel tank retaining bolts and partial-ly withdraw the tank from the vehicle until access can begained to the front of the fuel tank.

(10) Suitably mark and disconnect the fuel supplyand retum hoses from the fuel tank.

(l 1) Disconnect the wiring from the front of the fueltank and withdraw the tank from the vehicle.

(I2) Remove the retaining screws and withdraw thefuel pump and fuel gauge sender unit from the fuel tankusing care not damage the strainer.

(13) If necessary, dismantle the fuel pump as fol-lows:

(a) Disconnect the fuel pump wiring, noting theinstalled position to ensure correct assembly.

(b) Remove the strainer from the fuel pump inlet.(c) Slide the hose along the pickup tube until it is

clear of the fuel pump and manoeuvre the pump from themounting bracket.

r1" WIRING CONNECTOR

t \ r\ ,'1\

\ l )

\FUELPUMP

High pressure, internal fuel pump. Utility model.


258 Supplement - Part

Installation is areversal of theremoval procedure withattention to the following points:

(l) Ensure that the wiring is wound around the fuelpump outlet pipe to prevent it fouling the fuel gauge senderunit float arm.

(2) Ensure that the strainer is installed securely.(3) Use only hoses and clamps as supplied by rhe

manufacturer and connect the hoses according to the

I. 1990 Models

marks made previously. Ensure that all bose cl,amps arecorrectly seated and secure.

(4) When installing the fuel rank, apply perroleumjelly to the filler hose to aid installation.

(!) Tighten the fuel tank retaining bolts securely.(6) Test the fuel sys(em for external leakage as

described in the main part of the manual before instillingthe front floor panel.


Supplement - Part 1. 1990 Models

ENGINE

259

SPECIFICATIONS


Rocker arm pivot bolts . .65 NmSupport brace to converter housing bolts . .60 NmSupport brace to clutch housing bolts 35 NmSupport brace to sump retaining stud nuts . 12 Nm

I. DESCRIPTION

A larger timing chain damper is installed on modelsmanufactured from July 1989 to reduce engine noise andcan be installed to previous models.

The following production changes to the engine applyto vehicles manufactured from mid October 1989:

(a) Moulded plastic rocker covers are installed withrevised seals and retainers which can be installed to earliermodels.

(b) The double valve springs installed to earliermodel engines are replaced by a single valve spring andthe shape of the retainer is modified to suit the single valvespring. The single valve spring can be installed to earliermodels providing that the colresponding retainer is alsoinstalled.

(c) The steel pushrod guide plate is replaced bythree alloy retainers which support revised rocker armpivots. The revised pivots can be installed to earliermodels providing the alloy retainers are also installed.

(d) The camshaft has decreased lobe lift, increasedvalve timing duration and has a thrust washer installedbetween the flange and the front of the cylinder block. Thecamshafts can be identified by measuring the distancebetween the rear face of the front flange and the end of thecamshaft. On early model camshafu the distance is 374.5 mmand on late model camshafts the distance is375.2 mm. The laternodel camshaft and thrust wastrer can be installed to the earlymo&l engirre providing tlre correqponding Mem-Cal unit isinsalled to the engine control unit

(e) On automatic transmission models, a retainingplate is installed to the drive plate and a support brace isinstalled between the engine and the front of the transmis-sion. On models with a manual transmission, the supportbrace is installed to models manufactured from April 1990.

(0 The gasket installed between the oil pump pick-up pipe and the cylinder block on previous models isreplaced by an O ring and the direction arrow on the top ofthe pistons is deleted.

During 1990, high flow hydraulic tappets were intro-duced which can be installed to previous models. Theimproved tappets are identified by the yellow snap ringabove the pushrod seat.

NOTE: If the cooling systemis drained,ensurethat it isfilled as described later in this supple-ment to prevent engine overheating.

2. ROCKER ARMS AND PUSHRODS


(1) Operation (3) of the installation procedureshould read as follows:

Instal the rocker ann pivot retainers ensuring that thearrows on the top of the retainers face towards the centreof the engine and the base of the pivots seat correctly inthe retainers.

g:)gW,@

?A*261ffi

RO R ARMS\

CKE

Rocker arm components removed from the engine.

(2) In Operation (4) of the installation procedure, itis not necessary to apply Loctite 242 to the rocker arrnpivot bolts. Ensure that the pivot bolts are tightened to65 Nm.

3. TIMING COVER

The procedure to remove and instal the timing coverremains as described in the main manual with attention tothe following points.


260

(1) Where applicable, remove the support brace asdescribed later in this supplement.

(2) If the sump gasket has separated from thecylinder block, remove the remaining sump retaining boltsand apply a 2-3 mm bead of Dow Corning RTV 732 orequivalent sealant over the timing cover and rear mainbearing cap joints.

(3) Apply a thin bead of the specified sealant to thesump mating face directly below the timing cover joints.

(4) If applicable, instal the support brace asdescribed later in this supplement.

4. CAMSHAFT AND BAIANCE SHAFT


(1) When the camshaft is withdrawn from thecylinder block, remove the thrust washer.

Sealant application points on the rear main bearing capand the timing cover joints.

Supplement - Part l. 1990 Models

(2) Prior to installing the camshaft, apply Molyb-denum Disulphide grease to both sides of the thrust washerand instal the washer to the camshaft.

5. SUMP AND OIL PUMP PICK.I.JP PIPE


(1) Where applicable, remove the support brace asdescribed later in this supplement.

(2) The O ring located between the pick-up pipeand cylinder block must be renewed.

(3) Prior to installing the sump, apply a 2-3 mmbead of Dow Corning RTV 732 or equivalent sedlant overthe timing cover and rear main bearing cap joints.

Apply a thin bead of the sealant to the sump matingface directly below the timing cover joints.

(4) If applicable, instal the support brace asdescribed later in this supplement.

6. CRANKSHAFT OIL SEAI-S

TO REMOVE AND INSTAL FRONTCRANKSHAFT OIL SEAL

The procedure remains as described in the mainmanual with attention to the following point.

(1) On automatic transmission models, operation(a) of the removal procedure requires that the drive platebe locked prior to removing the crankshaft pulley retainingbolt. This will necessitate the removal of the support braceas described later in this supplement.

7. SUPPORT BRACE

TO REMOVE AND INSTAL(1) On automatic transmission models, remove the

starter motor as described later in this supplement.

lnstalled view of the support brace. Automatictransmission model.Sealant application points on the sump mating face.


Supplernent - Part

(2) Remove the retaining bolts and withdraw theexhaust engine pipes from the vehicle.

(3) On manual transmission models, disconnect theclutch cable from the release lever as previously describedin the main manual.

(4) Remove the bolts and nuts and partiallywithdraw the steering gear from the front suspensioncrossmember.

(5) Remove the retaining nuts and bolts andmanoeuvre the support brace from the vehicle.


(l) If the sump retaining studs have been disturbed,check that the support brace mounting faces on the studsare level using a straight edge or rule.

If necessary, loosen or tighten the relevant stud(s)until the mounting faces are level, ensuring that the studsare tightened to 8-12 Nm.

(2) Retain the support brace in position by looselyinstalling the sump stud retaining nuts.

(3) Hold the support brace flush against the clutchor converter housing and tighten the support brace to sumpstud retaining nuts to the specified torque. Tighten the rearnuts first.

(4) Check that the gap between the support braceand the clutch or converter housing is not more than0.2 mm. If the gap is excessive, loosen the nuts and repeatthe previous operation.

If the correct gap cannot be achieved, renew the sup-port brace.

(5) Instal the support brace to clutch or converterhousing retaining bolts and tighten to the specified torque.

NOTE: If the retaining bolts cqnnot be in-stalled, remove the support brace and enlargethe bolts holes to 13 mm. If the bolts stillcannot be installed, renew the support brace.

(6) Where applicable, instal and adjust the clutchcable as described in the main manual.

(7) Instal the engine pipes ensuring that a new gas-

ket is installed at the catalytic converter joint.(8) Where applicable, instal the starter motor as

described in the main manual.

1. 1990 Models 26r

8. PISTONS, CONNECTING RODS ANDCYUNDER BORES

All procedures remain as described in the mainmanual with attention to the following point.

(1) The direction arrow on the top of the pistons hasbeen deleted. When installing the pistons into the cylinderbores, ensure that the letters and numbers stamped on thetop of the piston are facing towards the front of the engine.

9. FLYWHEEL/DRM PIATE


(1) On automatic transmission models, a retainerplate is installed between the drive plate and the retainingbolts. When the retainer plate is installed, ensure that thedimple is facing away from the drive plate.

Ensure that the drive plate retainer is installed with thedimple facing outwards.


262

1. DESCRIPTION

During April lgg},the following changes were madeto the cooling system.

An overflow cap is installed over the surge tank pres-sure cap and is sealed to the surge tank with in O ririg. Acoolant reserve tank is installed to the left hand innermudguard and an overflow hose is installed between thereserve tank and the overflow cap.

Installed view of the surge tank and reserve tank.

As the coolant volume expands due to a rise intemperature, the pressure valve in the surge tank pressurecap opens and allows the excess coolant to flow into thereserye tank via the overflow hose.

When the coolant temperature falls, the vacuum valvein the surge tank pressure cap opens, allowing the coolantto siphon back into the surge tank.

The design of the thermostat has been revised toimprove reliability, however the operating characteristicsare the same as earlier models.

2. RADIATOR

TO CHECK COOLANT LEVEL(1) With the engine cold, the coolant level in the

reserve tank should be between the Minimum and Maxi-mum marks.

(2) If the level is below the Minimum mark, removethe cap and add the specified coolant to the reserve tankuntil the level is correct.

(3) Check that the surge rank is completely full ofcoolant. If the surge tank requires topping up, proceed asfollows.


COOLING AI\D HEATING SYSTEMS

NOTE: If the reserve and surge tanks requirefrequent topping up, check the cooling systemfor leakage.

The surge tank should be completely full ofcoolant at all times. If the surge tank requirestopping up but the reserve tank does not, checkthat the surge tank overflow cap and O ringare sealing fully and that the overflow cap andhose are not blocked or damaged.

(a) Disconnect the overflow hose and unscrew thecap from the surge tank. Fill the surge tank with thespecified coolant.

(b) Remove the O ring from the surge tank andcheck for signs of wear and damage. Renew the O ring asnecessary.

OVERFLOW CAP

PRESSURE CAP

Surge tank overflow and pressure caps separated.

(c) Lubricate the O ring with soapy water and instalit to the surge tank.

(d) Instal the cap to the surge tank and tightensecurely. When the cap is installed, the overflow hoseconnection must be facing towards the front right handside of the vehicle at an angle of approximately 45".

_ If the angle is incorrect, lever the overflow cap fromthe.pressure cap using two screwdrivers and correctlyposition the overflow cap ensuring that the slots in the capalign with the lugs on the pressure cap. Unscrew thepressure cap sufficiently to allow the overflow cap to be



lnstalled view of the surge tank cap correctly installedwith the overflow hose connection at approximately 45".

installed and firmly push the overflow cap onto the pres-sure cap.

(e) Connect the overflow hose to the cap ensuringthat the hose is not kinked or restricted.

TO DRAIN AND REFILL

The procedure to drain and refill the cooling system isdescribed in the main manual. Check the coolant level aspreviously described in this supplement.

3. HEATER AND AIR COI\DITIONTNGCONTROI-S


Split Bench Seat Models(1) Disconnect the negative battery terminal.

NOTE: Prior to disconnecting the battery ter-

minal, refer to the note under the Battery head-ing in the main manual.

(2) Remove the radio/cassette surround panelretaining screws. Pull the top of the panel outwards andraise the panel to disengage the retaining lug.

(3) Disconnect the wiring connectors from theswitches noting their installed positions as an aid to as-sembly and withdraw the surround panel.

(4) Rotate the retaining pins 90 degrees and openthe fuse cover on the right hand side of the steeringcolumn. Remove the hinge pin and remove the cover fromthe dashboard.

(5) Open the glove compartment, remove the hingepin and remove the glove compartment from the dash-board.

(6) Remove the centre fascia panel retaining screwsand remove the centre fascia panel from the vehicle.

Radio/cassette and heater controls with the centrefascia panel removed. Split bench seat models.

(7) Remove the heatercontrol cable retaining screwlocated behind the heater controls assembly.

(8) Working in the drivers footwell, disconnect theheater control cable from the control lever at the right handside of the heater unit.

(9) Remove the retaining screw and partiallywithdraw the heater controls. Disconnect the wiring andthe vacuum block and remove the heater controls from thevehicle.


(1) Ensure that the heater vacuum hoses are in goodcondition and that they are not pinched or kinked wheninstalling the heater controls.

(2) Instal the heater control cable retaining screw.(3) Turn the temperature control to the full cold

position and ensure that the heater control lever is also inthe full cold position before installing the snap in cableend. Operate the temperature control several times.

I' i.ll} r*l{I,}i;.rrrl'

Location of the radio/cassette surround panel retainingscrews. Split bench seat models.


264

(4) Turn the temperature control knob to the fullcold position again and ensure that the heater control leveris pushing in on the vacuum shut off valve. Adjust theheater control snap in cable end if necessary.

NOTE: If the rod cannot be adjusted to operatethe shut offvalve properly, remove the shut offvalve and elongate the holes slightly using asmall roundfile. The valve can then be posi-tioned closer to the lever.

(5) Connect the negative battery terminal.Start the engine and increase the speed to 3 000 rpm

for 10 seconds allowing the idle air control valve to reset.On models equipped with a ndtolcassette using PIN

security, it will be necessary to enter the PIN code asdescribed under the Radio/Cassette heading in the Electri-cal System section.

(6) With the engine running and with the aid of anassistant operating the temperature control, ensure that the


heater water valve is shut when the temperature control isin the fully closed position. Adjust the rod ard the shut offvalve again if necessary.

4. AIR CONDMONING

DESCRIPTION

- Some models are equipped with Elecrronic ClimateControl, an automatic, ele^cironically controlled systemthat maintains the interior of the vehicle at a presetternpera-ture by activating the heater and air conditioner asnecessary.

Jhe system is controlled by an electronic control unitwhich receives signals from various sensors that monitorthe temperature and intensity of light inside the vehicle.

Due to the complexity of the system, it is recom-mended that the vehicle be referred to an authorised dealerif the operation of the system is suspect.


I. CLUTCH

All procedures rernain as described in the mainmanual with attention to the following points which relateto models from April 1990.

(1) When removing the clutch'unit and releasemechanism, remove the bolts retaining the clutch housingto the support brace prior to removing the lower frontcover from the clutch housing.

(2) When installing the support brace, follow theprocedure described in the Engine section of this supple-ment.

2. AUTOMATIC TRANSMTSSION

The following changes have been made to the auto-matic transmission.

(l) The transmission identification has changedfrom Turbo Hydra-Matic 700 R4 to Hydra-Matic 4L60and improvements have been made to some of the internalcomponents.

(2) When removing and installing the transmissionit is necessary to remove and instal the support brace aspreviously described in this supplement.

(3) On sorne models, a column shift transmission isavailable as an option.

All procedures remain as described in the mainmanual except for those under the following headingswhich apply to models with a column shift transmission.

SELECTOR LINKAGE - COLUMN SHIFT

To Adjust

The adjustment procedure for the selector linkage ,fitted to column shift models follows the same basic pro-cedure described forthe floor shift models described in themain part of the manual with attention to the followingpoint.

(1) If necessary, adjust the selector indicator asdescribed later in this supplement.


(l) Raise the front of the vehicle and support onchassis stands. Apply the handbrake and place the trans-mission in Park.

(2) Disconnect the negative battery terminal.(3) Working in the engine compartment, remove

and discard the nut retaining the lever to the lower end ofthe column selector shaft and separate the lever from theshaft.

(4) Remove the spring clip, washer and dishedwasher and withdraw the bellcrank from the shaft.

265

View of the selector linkage adjustment point.

(5) Working under the vehicle, remove the nutretaining the selector lever from transmission shaft.

(6) Remove the selector lever from the transmissionand manoeuvre the linkage from the vehicle using care toavoid damage to the wiring and hoses.

(7) Dismantle the selector linkage noting the in-stalled position of the components.

(8) Check the rods and the bellcrank for bends and


MTJTC.H AI\D AUTOI\,IATI C TRAD{SMISSION

TRUNNTON *% SLEEVEdl

eusx {- FLAT wASHER

( d /

Selector linkage components.


266

elongated holes. Check the pins and the bellcrank shaft forwear. Renew the worn components as necessary.

(9) Check the rubber bush in the transmission selec-tor lever for wear and deterioration. Renew the bush asnecessary.

Installation is areversal of the removal procedure withattention to the following points:

(1) Apply multipurpose grease to the contact pointsat the joints.

(2) Ensure that the linkage is assembled with thedished side of the washers facing towards the rods and thatthe number on the bellcrank is facing towards the front ofthe vehicle.

(3) Ensure that the sleeve is installed in the rubberbush.

(4) Renew the nut retaining the lever to the columnselector shaft and tighten to a torque of 35 Nm.

(5) Adjust the selector l inkage as previouslydescribed in this supplement.

(6) Road test the vehicle and check for correct trans-mission operation.

SELECTOR SHAFT - COLUMN SHIFT


(l) Place the transmission in Park.(2) Disconnect the negative battery terminal.(3) Working in the engine compartment, remove

the nut retaining the lever to the lower end of the selectorshaft. Discard the nut.

(4) Remove the steering wheel using a puller. Ifnecessary, refer to the Steering section in the main manual.

(5) Rotate the retaining pins 90 degrees and openthe fuse cover on the right hand side of the steeringcolumn. Remove the hinge pin and remove the cover fromthe dashboard.

(6) Remove the steering column lower cover retain-ing screws, disconnect the i l lumination lamp andwithdraw the lower cover.

(7) Remove the access cover and the selector leverboot from the upper steering column cover.

(8) Remove the indicator cable retaining screw.(9) Straighten the wiring harness retaining clamp

and disconnect the neutral safety switch wiring connector.


Installed view of the selector shaft and lever assemblywith the lower cover removed.

Removing the column shift selector shaft assembly.

(10) While supporting the selector shaft, remove thebolts retaining the selector shaft mounting bracket to thesteering column and lower the selector shaft sufficiently to

ROLL PINS

z6IlLD3 SELECToR LEVER

Sefector shaft measuring points. Dimension A = 23F.241mm. Dimension B = 344.5-347.5 mm. Dimension B shoul,measured between the centre of the universal joint and the centre of the roll pin.



(1) Adjust thethat follows.

267

selector cable using the procedureclear,the upper cov€r.:It rnay be necessary to disconnectthe wiring from the ignition switch.

(11) If necessary, remove the retaining screws andremove the neutral safety switch from the mountingbracket.

(12) Carefully withdraw the selector shaft from thevehicle ensuring that it is supported at each end.

(13) Check the selector shaft for damage, distortionand worn or binding universal joints. Renew as necessary.

(14) Measure the selector shaft as shown in the il-lustration. If the dimensions are not correct. renew theselector shaft.


(1) Ensure that the pin protruding from the selectorlever housing engages the neutral safety switch.

(2) Tighten the selector shaft mounting bracketbolts to a torque of 3 Nm.

(3) Renew the nut retaining the lever to the columnselector shaft and tighten to a torque of 35 Nm.

(4) Adjust the selector indicator as described laterin this supplement.

(5) Instal the steering wheel as described in themain manual.

SELECTOR INDICATOR - COLUMN SHIFT


(1) Place the transmission in Park.(2) Remove the access cover located at the side of

the steering column. Remove the indicator cable retainingscrew.

Removing the selector indicator assembly.

(3) Using a small flat bladed screwdriver, lever thecover from the selector indicator.

(4) Remove the indicator retaining screws andwithdraw the illumination lamp socket from the indicator.Remove the indicator from the vehicle.


To Adjust(l) Apply the handbrake and place the transmission

in Neutral.(2) Remove the access cover located at the side of

the steering column.

Installed view of the steering column covers.

(3) Loosen the indicator cable retaining screw andadjust the indicator cable until the indicator needle iscentrally aligned over the 'N' position. Tighten the cableretaining screw.

NOTE: The indicator cable is spring tensionedtowards the Park position. If the indicator isfixed in a position and cannot be adjusted, it islikely that the spring is broken.

(4) Instal the access cover.

Location of the indicator cable retaining screw.


268 Supplement - Part 1. 1990 Models

NEUTRAT SAFETY SWITCH - COLUMN SHIFT switch is previously described under the headinl

To Remove and Instar Remove and Instal selector shaft'

However, operations (3), (12), (13), and (14) shouldThe procedure to remove and instal the neutral safety be disregarded.

\-" \'-" \+r'



REAR A>(LE, STEERING AI{D FRONT SUSPENSION

1. REAR A}(LE

All procedures remain as described in the mainmanual with attention to the following point,

(1) On Utility models, ensure that Mobilube80W140 ID or Castrol SAF-XA 80W140 synthetichypoid gear oil is used in the rear axle.

NOTE: The use of incorrect lubricant maycause damage to the differential gears.

2. STEERING

TO REMOVE AND INSTAL STEERING COLUMN

Column Shift Models(1) Disconnect the negative battery tenninal.(2) Remove ttre steering wheel. If necessary, refer

to the Steering section in the main manual.(3) Rotate the retaining pins 90 degrees and open

the fuse cover on the right hand side of the steeringcolumn. Remove the hinge pin and remove the cover fromthe dashboard.

(4) On vehicles equipped with power windows,remove the power window module retaining screws, lowerthe module and disconnect the wiring. Remove the modulefrom the vehicle.


(6) Remove the screws retaining the fuse panelmounting bracket to the lower dashboard panel and posi-tion the mounting bracket to one side clear of the steeringcolumn.

(7) Pull back the rubber boot from the lower end ofthe steering column and remove the nut from the inter-mediate shaft upper clamp bolt. Open the clamp slightlyusing a screwdriver leaving the clamp bolt in position.Mark the steering shaft in relation to the intermediateshaft.

(8) Release the cable tie securing the wiring harnessto the steering column.

(9) Remove the steering column lower cover retain-ing screws, disconnect the illumination lamp and removethe lower cover and the access cover.

(10) Remove the indicator cable retaining screw.(11) Remove the cover from the selector indicator

and withdraw the illumination lamp socket from the in-dicator.

(12) Straighten the wiring harness clamp and discon-nect the neutral safety switch wiring connector.

Disconnect the wiring from the ignition switch, com-bination switch and the horn contact.

(13) While supporting the selector shaft, remove thebolts retaining the selector shaft mounting bracket to thesteering column and lower the selector shaft.

(14) Remove the steering column mounting nuts andpull the column rearwards to disengage the brake pedalbracket support stud.

(15) Remove the intermediate shaft upper clamp boltand remove the steering column from the vehicle.


Installed view of the steering column with the lowercover removed.

(l) Instal the steering column and intermediateshaft ensuring that the marks made on removal are aligned.

(2) Ensure that the steering column boot is colrectlyinstalled to the floor panel.

(3) Tighten all the bolts and nuts and ensure that allelectrical connections are secure.

(4) Adjust the selector indicator cable as previouslydescribed under the Automatic Transmission heading inthis supplement.

(5) Instal the steering wheel ensuring that the marksare aligned and that Loctite 242 is applied to the threadson the retaining nut.

3. FRONT SUSPENSION

SPECIFICATIONS

Coil spring free length:U t i l i t ymode ls . . . . 363mm


270

Wheel alignment:Caster angle -Utility models . . . I deg 30 min *Sedan and Station Wagonm o d e l s . . . . 2 d e g 3 0 m i n *Camber angle -Utility models . . .Minus I deg + 30 mmSedan and Station Wagonmodels with FE2 option . . . Minus 42 min + 30 minSedan and Station Wagonmodels without FE2 option . . .Minus I deg + 30 min


I deg

I deg

T o e i n 2 m m * 2 m m

DESCRIPTIONOn models manufactured from mid June 1989. the

wheel alignment specifications on Sedan and StationWagon models were changed due to the installation ofrevised suspension unit upper mounting and bearing as-semblies.

The revised mountings are identified by the L (left) orR (right) marking on the upper face of each assembly andmust not be installed to the opposite suspension unit.



REAR SUSPENSION AI{D BRAKES

27r

2. BRAKES

DESCRIPTION

On models manufactured from mid November 1989,brake shields are installed behind the front brake discs toreduce water entry to the discs in wet conditions.

On Utility models, the brake master cylinder propor-tioning valve is deleted and replaced by a load sensingvalve which is attached to the rear suspension panhard rod.The load sensing valve controls the amount of hydraulicpressure applied to the rear brakes depending on thevehicle load.

Onmodels with a splitbench seat, the handbrake leveris located at the right hand side of the drivers seat.

All procedures remain as described in the mainmanual except for those under the following headingswhich apply only to Utility models.

MASTER CYLINDER

When dismant l ing and assembl ing the mastercylinder on Utility models, note that the proportioningvalve seal block, spring, retainer and poppet valve assemb-ly has been replaced by a spacer with sleeve and O rings,and a spool with an O ring and a return spring.

Brake master cylinder components.

LOAD SENSING VALVE

To Remove and Instal(1) Raise the rear of the vehicle and support it on

chassis stands.(2) Disconnect the brake pipes from the load sens-

ing valve. Plug the ends of the pipes to prevent the loss offluid and the entry of din.

(3) Hold the load sensing valve operating armtowards the panhard rod and disconnect the anchor bracketfrom the panhard rod. Slowly release the arm.

1. REAR SUSPENSION


Utility Models

Assist spring mounting bolts . .35 NmShock absorber lower mounting nut .35 Nm

DESCRIPTION

The rear suspension on Utility models is the same asSedan and Station Wagon models except that the rubberbump stops are replaced by rubber assist springs whichcontact pads on the rear axle housing when the vehicle isloaded.

All procedures remain as described in the mainmanual except for those under the following headingswhich apply only to Utility models.

TO REMOVE AND INSTAL ASSIST SPRING

(1) Raise the rear of the vehicle and support it onchassis stands. Remove the rear wheel.

(2) Remove the bolts retaining the assist springmounting bracket to the vehicle underbody and remove theassist spring from the vehicle.

(3) Separate the mounting bracket from the assistspring outer sleeve and remove the inner sleeve from theassist spring outer sleeve noting the installed direction.

(4) Examine the assist spring components fordamage, deterioration and wear. Renew unserviceablecomponents as necessary.

lnstallation is a reversal of the removal procedurewith attention to the following points:

(l) Do not apply any type of lubricant to the assistspring components.

(2) Instal the inner sleeve to the direction noted onremoval.

(3) Tighten the mounting bolts to the specifiedtorque.

,m t

4p/mffirc" l*

-

Ub=-?Assist spring components.


272

Load sensing valve.

(4) Remove the retaining bolts and remove the loadsensing valve from the vehicle.

Installation is a reversal of the removal procedure withattention to the following points:

(1) Tighten the load sensing valve retaining bolts toa torque of 30 Nm.

(2) Bleed the brake hydraulic system as describedin the main manual.

(3) Adjust the valve anchor bracket as described inthe following text.

To Adjust

(1) Locate the anchor bracket U bolt 483 mm ro rheleft of the panhard rod mounting bolt on the rear axlehousing.

Load sensing valve adjustment. Dimension A =115.5-116.5 mm.

(2) Adjust the anchor bolt until a distance of I 15.5-116.5 mm exists between the upper face of the anchorbracket and the top edge of the operating arm where thechain is connected.

NOTE: If the operation of the load sensingvalve is suspected of being faulty, it is recom-mended that the vehicle be taken to anauthorised dealerfor the necessary repairs.


TO REMOVE AND INSTAL HANDBR,A.KELEVER AND CABLE

Split Bench Seat Models

(1) Raise the front and rear of the vehicle and sup-port it on chassis stands. Release the handbrake.

(2) Remove the screws and withdraw the coverfrom the handbrake lever.

(3) Squeeze together the tabs on the end of thehandbrake warning lamp switch plunger and remove thewiring terminal.

(4) Working under the vehicle, loosen the hand-brake cable adjusting nuts at the equaliser until the rearhandbrake cables are slack. Disconnect the return springfrom the relay lever.

(5) Move the relay lever towards the front of thevehicle and disconnect the front cable from the relay lever.

(6) Pull the front cable towards the front of thevehicle until the cable can be withdrawn through the open-ing in the retaining bracket.

(7) Remove the nut and bolt retaining the frontcable support clamp to the vehicle. Remove the screwsretaining the handbrake outer cable retaining plate to thefloor panel.

Front handbrake cable and associated components.

(8) Operate and release the handbrake lever to drawthe inner cable towards the handbrake lever and discon-nect the inner cable from the handbrake lever.

(9) Remove the snap ring from the outer cable andwithdraw the cable through the floor panel.

(10) Remove the retaining bolts and remove thehandbrake lever from the vehicle.

(11) Check the handbrake lever and cable for wear.Renew the worn parts as necessary.

Installation ii a reversal of the removal procedure withattention to the following points:

(1) Lubricate the lever, pivots and cable ends withmultipurpose grease. Ensure that the relay lever operatesfreely.

(2) Adjust the handbrake as described in the mainmanual.


S;upplement - Part 1. 1990 Models

ELECTRIC.AL SYSTEM

1. STARTER MOTOR


The removal and installation procedure has beenrevised and is applicable to all models.

(1) Disconnect the negative battery terminal.(2) Raise the front of the vehicle and support it on

chassis stands.(3) Remove the left hand exhaust manifold as

described in the Engine section of the main manual.(4) Disconnect the wiring from the starter motor

solenoid.(5) On models wi th automat ic t ransmission,

remove the bolt supporting the front of the starter motor.(6) Remove the retaining bolts and manoeuvre the

starter motor from the vehicle through the engine compart-ment. Where applicable, do not misplace the adjustingshims on models with manual transmission.

NOTE: On some models with manual trans-mission, it may be necessary to remove thesupport brace to allow the starter motor to bewithdrawn.


(1) Ensure that all starter motor retaining bolts aretightened securely. Ensure that the wiring is clean andsecure.

(2) On manual transmission models, if a new orexchange starter motor is installed or the starter motoroperation is noisy, check and if necessary adjust the pinionmesh as described in the Electrical System section in themain manual.

2. COMBINATION SWITCH


Column Shift Models(1) Disconnect the negative battery terminal.(2) Remove the steering wheel using a puller.If necessary, refer to the Steering section in the main

manual(3) Remove the steering column lowercoverretain-

ing screws, withdraw the illumination lamp and removethe lower cover and the access cover.

(4) Disconnect the wiring connector from the igni-tion switch.

(5) Open the fuse cover by turning the retainers 90degrees. Using a flat bladed screwdriver, prise out the lefthand side hinge pin and remove the cover.

273

(6) Remove the indicator cable retaining screw.(7) While supporting the selector shaft, remove the

bolts retaining the selector shaft mounting bracket to thesteering column and lower the selector shaft.

(8) Using a small flat bladed screwdriver, lever thecover from the selector indicator.

(9) Remove the steering column retaining bolts andlower the steering column sufficiently to allow the uppercover to be removed. Support the steering column in thisposition.

lnstalled view of the combination switch witfi the lowercover removed.

(10) Depress the tangs at the side of switch andwithdraw the switch assembly from the steering columnbearing housing. Disconnect the wiring and remove theswitch from the vehicle.


(1) Ensure that all wiring connections are secure.(2) Tighten all bolts securely.(3) Adjust the selector indicator cable as described

under the Automatic Transmission heading in this supple-ment.

3. HANDBRAIG WARNING I.AMP SWITCH



(1) Move the front seat fully forward.(2) Remove the retaining screws and withdraw the

cover from the handbrake lever.(3) Squeeze together the tabs on the end of the


274 Supplement - Part l. 1990 Models

Installed view of the handbrake warning lamp switch.

handbrake warning lamp switch plunger and remove thewiring terminal.

(4) Remove the warning lamp switch from themounting bracket.


4. RADTO/CASSETTE


Bucket Seat Models

The following procedure applies to models manufac-tured from mid September 1989, when the radio/cassettemounting brackets were revised to provide increasedsecurity.

(1) Disconnect the negative battery terminal.(2) Prise up the rear of the centre console cover

panel and pull the panel rearwards slightly to allow accessto the radio/cassette surround screws.

(3) Remove the screws from the lower part of the

The arrows indicate the centre fascia panel screwlocations.

radio/cassette surround and pull the surround carefullytowards the rear until the locating lugs at the top releasefrom the dashboard.

(4) Disconnect the electrical connectors from theradio/cassette surround panel, noting their installed posi-tions as an aid to assembly. Remove the surround panel.

(5) Working in the drivers footwell, disconnect theheater control rod from the control lever at the right handside of the heater unit.

NOTE: The heater control rod is not installedto models equipped with electronic: climatecontrol.

(6) Remove the screw retaining the heater controlsor the electronic climate control panel to the dashboardand partially withdraw the controls from the dashboard.

(7) Disconnect the electr ical connectors, thevacuum block and, on models with electronic climatecontrol, the aspirator tube and remove the heater con-trol/electronic climate control panel from the vehicle.

(8) On automatic transmission models, proceed asfollows:

Centre console front height adjusting screw locations. Radio/cassette mounting locations.


Supplement - Pa,rt 1. 1990 Models

(a) Diseonnect the centre console cover wiring con-nector, turn the cover 90 degrees and manoeuvre it overthe selector lever handle.

(b) Rernove the gear position scale and trim, theslide indicator and the indicator support.

(c) Remove the screws retaining the support as-sembly to the centre console, disconnect the quadrantlamp connector and remove the support assembly from thevehicle.

(9) Loosen the centre console front height adjustingscrews and lower the front of the centre console sufficient-ly to disengage the locating lugs at the bottom of the centrefascia panel.

(10) Rotate the retaining pins 90 degrees and openthe fuse cover on the right of the steering column, removethe hinge pin and remove the cover from the dashboard.


(I2) Remove the centre fasciapanel retaining screwsand remove the centre fascia panel from the vehicle.

(13) Remove the retaining screws and withdraw theventilation ducts from the heater unit.

(14) Remove the radio/cassette retaining bolts lo-cated behind the side brackets.

(15) Remove the radio/cassette front mountingscrews and partially withdraw the radio/cassette from thedashboard.

(16) Disconnect the wiring and the aerial from theradio/cassette and remove the radio/cassette from thevehicle.


(1) Ensure that all the wiring is securely connected.(2) Tighten all the retaining screws securely.(3) Run the engine at 3 000 rpm for l0 seconds to

reset the idle air control valve.(4) Where applicable, enter the security PIN code.


(1) Disconnect the negative battery terminal.

NOTE: Prior to disconnecting the battery ter-minal, refer to the note under the Battery head-ing in the main manual.

(2) Remove the radio/cassette surround panelretaining screws. Pull the top of the panel outwards andraise the panel to disengage the retaining lug from thecentre panel.

(3) Disconnect the wiring connectors from theswitches, noting their installed positions as an aid to as-sembly, and withdraw the surround panel.

(4) Rotate the retaining pins 90 degrees and openthe fuse cover on the right of the steering column. Removethe hinge pin and remove the cover from the dashboard.


275

Location of the radio/cassette surround panel retainingscrews. Split bench seat models.

(6) Remove the centre fascia panel retaining screwsand remove the centre fascia panel from the vehicle.

(1) Working from the lef t hand side of theradio/cassette, remove the wing nut and earth lead fromthe radio/cassette rear mounting stud.

NOTE: It may be necessary to use a longscrewdriver to loosen the wing nut.

(8) Remove the radio/cassette front mouhtingscrews and partially withdraw the radio/cassette from thedashboard.

(9) Disconnect the wiring and the aerial from theradio/cassette and manoeuvre the radio/cassette from thevehicle.


(1) Ensure that all the wiring is securely connected.

Radio/cassette with the centre fascia panel removed.Split bench seat models.


Supplement - Part 1. 1990 Msdels

(2) Ensure that the wingnut stud enters the hole inthe bracket and tighten the wingnut securely.

(3) Tighten all the retaining screws securely.(4) Run the engine at 3 000 rpm for 10 seconds to

reset the idle air control valve.(5) Where applicable, enter the security PIN code.

5. TO CHECK AND RENEW FUSES AI{DFUSIBLE UNKS

The procedure to check and renew the fuses andfusible links remains as described in the main manual withattention to the following point.

(l) On models manufactured from mid October1989, a number of changes have been made to the wiringhamess.

Due to these changes, the ENG COMP and ENG INJfusible links have been deleted and replaced by one 30amp fusible link marked ENGINE and the raring of thefusible link marked HEADLAMP is increased to 40 amp.

The fuses in the interior fuse box have been revised asfollows:

6. UNDSCREEN WTPER ARMS

The removal and installation procedure remains asdescribed in the main manual with attention to the follow-ing points.

276

(1) Disregard operarion (2) of the removal proce-dure.

(2) The wiper arrns are marked D (drivers side) andP (passengers side) adjacent to the retaining hole and arenot interchangeable.

(3) Insial the wiper arm to rhe pivot shaft so rhat thedistance between the left hand end of the wiper blade andthe windscreen surround is 61-71 mm on tire right handblade and 31-41 mm on the left hand blade in the parkposition.

7. I.AMP UMTS

REAR COMBINATION LAMP - UTILITY

To Renew BulbsThe rear combination lamp on Utility models is the

same as Station Wagon models. To renew the bulbs, referto the procedure in the main manual.

HIGH MOUNTED STOP LAMP

To Renew Bulb(l) Remove the retaining screw and remove the

cover from the lamp base.(2) Rotate the bulb holder anticlockwise and

withdraw it from the lamp.

Renewing the high mounted stop lamp bulb. StationWagon model.

(3) Pull the bulb from rhe bulb holder.(4) Ensure that the bulb holder is nor corroded and

push a new bulb into the holder.(5) Instal the bulb holder and rotate it clockwise

until it is locked in position.(6) Instal the cover and tighten the screw securely.

NUMBER PLATE LAMP _ UTILITY

To Renew Bulb

(l) Remove the retaining screws and withdraw thelens from the number plate larnp.

FuseNo

Circuit FuseRatingAMP

2345678

9

I

10

t l1 2

1 3t4

1 5l 6t 7

Parking lamps, trip computer, radio/cassette, power antennaHazard lamps, luggage compartment lockRear window demisterInterior lampsPower windowsElectric door locksInstrument and switch illumination lampsEngine cooling fan relay and airconditioningInstruments, rear window demister relay,fuel injection and ignition systemPower windows, electric mirrors anddoor locks and cruise controlVacantAutomatic transmission, reverse lampsand speed sensorRadio/cassette and power antennaWindscreen wiper motor and turn signallampsCigarette lighter and rear wiper motorStop lampsVacant

15

2025l 0201 5525

7.5

10

l0

10l 5

2015


Swpplcment - Part I. 1990 Models 277

Renewing the bulb in the Utility number plate lamp.

(2) Remove the bulb from the lamp base.(3) Instal a new bulb and ensuring that the terminals

are clean and have sufficient tension to retain the bulbsecurely and provide good electrical contact. If necessary,remove the bulb and bend the terminals towards the centreof the lamp.

(4) Check that the lens seal is not split or perishedand instal the lens to the lamp assembly.

(5) Instal the lamp to the vehicle and tighten theretaining screws securely.

8. WIRING DI.AGRAMS

The wiring diagrams covering all models are dis-played in the main manual.



BODY

.. i':. , ' : . ," .. o : '

" 4 r

1. FRONT AND REAR DOORS

REMOTE CONTROL AND DOOR LOCKSOn models manufactured from October 1989.

redesigned power door locks were introduced with theactuator integral with the lock assembly. With the intro-duction of the new type power door locks, the nylonsleeved door lock strikers were deleted. The proceduie toremove and instal the front and rear door remote controland door lock is basically the same as described in themain manual allowing for minor variation.

NOTE: Damage could result if nylon sleeveddoor lock strikers are installed to vehiclesoriginally equipped with plain door lockstrikers.

2. TAILGATE

UTILITY MODELS


(1) Operate the release handle and open the tailgate.(2) Support the tailgate on padded srands anddis-

connect the limit cables from each end of the tailgate.(3) Remove the tailgate hinge retaining bolts and

remove the tailgate from the vehicle.Installation is a reversal of the removal procedure

e.nsuring that the hinge retaining bolts are securelytightened.

To Remove and Instal Lock Mechanism(l) Operate the tailgate lock release handle and

lower the tailgate.(2) Support the tailgate on padded stands and dis-

connect the limit cables from each end of the tailgate.(3) Remove the release handle retaining screw and

remove the release handle from the lock shaft.

Location of the tailgate hinge retaining bolts.

(4) Remove the retaining screws and remove thecover surrounding the lock shaft from the tailgate.

(5) Disconnect the retaining clips from the operat-ing rods and lift the rods out of the lock lever.

(6) Remove the retaining screws from the limitcable brackets and remove the brackets and operating rodsfrom the tailgate.

(7) Hold the lock shaft to avoid dropping the lockmechanism inside the tailgate, remove lhe retainingscrews and manoeuvre the lock mechanism out of thetailgate.

Installation is a reversal of the removal procedure withattention to the following points:

(1) Priorto installation,lubricate all thr: moving andsliding surfaces using lithium based grease.

(2) Ensure that the operating rods enter: from the topof the lock lever and lock the retaining clips securely.

(3) Tighten all the retaining screws ser:urely.


NART 2. 199I MODELS

ENGINE

SPECIFICATIONS

CYLINDER HEAD

Minimum cylinder head face thickness . . . . .

PISTONS AND RINGS

Piston ring end gap:. . . . 0 . 3 0 5 - { . 5 5 9 m m. . . . 0 . 2 5 m . 6 3 5 m m

.0.A234.053 mm

.0.023-0.53 mm

1.12 mm

279

CAMSHAFT AND BEARINGS

Bearing journal diameter 45.33445.369 mmCamshaft journal oil clearance . .0.021-O.107 mmCamshaft lobe lift:

Inlet . 6.43 mmE x h a u s t . . . 6 . 4 8 m m

Camshaft end float . . . .0.164.27 mm

LUBRICATIONMaximum regulatedo i lp ressure . . . . . . .Approx imate ly4 I4kPaMinimum oil pressureat 1 850 rpm (normaloperat ingtemperature) . . . . . .375kPaPressure regulator spring free length . . . . 66.3 mm

Upper compression ringLower compression ring

CONNECTING RODS AND BEARINGS

Connecting rod bearingoil clearance .

CRANKSHAFT AND MAIN BEARINGS

Main bearing oil clearance . . .

@

t ' " ' ;

&",,, : : . . . , . , - : : : :&, ' : r : : , . . : : : t : : . : . . . : . . , . . ,i AIR INTAKE DUCT

View of the engine compartment.

OVERFLOW HOSE



TORQUE WRENCH SETTINGSMain bearing cap bolts . . 39 Nm + 48"Camshaft sprocket bolt 200 NmRocker arm pivot bolts . . 65 NmTiming chain damper retaining bolt . 26 NmOil filter adaptor bolts . .35 NmFlywheel/drive plate bolts . . . .22 Nm + 75"Camshaft thrust washer screws 18 Nm

1. DESCRIPTION

The following production changes to the engine applyto models manufactured from mid November 1990.

A redesigned inlet manifold is installed which cannotbe installed to previous models. To improve air distribu-tion, a hllmouth is installed between the inlet manifoldand the throttle body adaptor. To reduce noise and vibra-tion, cast iron exhaust manifolds are installed which areconnected to redesigned engine pipes. The oxygen sensoris installed to the left hand engine pipe.

The cylinder heads have revised coolant passages anda 20 mm hole is drilled in the inlet manifold face for thepositive crankcase ventilation system. The cylinder headgaskets are coated with an adhesive on one side and aremarked with an zurow which must face rearwards when thegaskets are installed. Due to the revised coolant passages,the cylinder heads and gaskets must not be installed on

FOWER STEERilG RESERVOIR INLET MANIFOLD

fL ALTERI{ATOR

DRIVE BELTTEN$OHER

WATER PUMP PULLEY

CRANKSHAFT'PULLEY

WIRING HARNESS

@rHRorrLE"""t-nQ@

Inlet manifold bellmouth, adaptor and throttle body.

earlier models. Improved valve stem oil seals are installedwhich are identified by the course sealing ribs and theletters IPC on the top the seals. These seals can be installedto earlier models.

The cylinder block, which is not compatible with

, /THROTTLEBODY

I&

EXHAUST IIAMFOLD

STARTER TSOTOR

ilOUilNNG

€N

E

Engine and transmission assembly.



earlier,itifdfi, ;hi'ffmd€siSxr aleradons and is iden-tified by the EV6 mark which is cast in each side of the

cylinder block. Stainless steel welch plugs are installed tothe cylirder block and cylinder heads.

'ihe pistons are redesigned with an oval shapedztopring land to provide improved piston clearance duringthermal expansion and are identified by the arrow on thepiston crown that is formed by a number of dots. Thepistons can be installed to previous models.

The oil pump is unchanged except for the installation ofa longer pressure regulator spring to increase oil pressure.

The camshaft sprocket and gear are secured to thecamshaft using a key and a single retaining bolt. Thetiming chain cannot be used on early models as it isincompatible with the tooth profile on the camshaft andcrankshaft sprockets.

The camshaft thrust bearing and spring installed toearlier models is deleted and the camshaft is retained by athrust washer which is secured to the front of the cylinderblock with three screws. The valve timing and lobe lift isthe same as 1990 models but the front of the camshaft isredesigned to suit the installation of the thrust washer andthe revised camshaft sprocket and gear.

The timing cover has redesigned coolant passages toimprove coolant circulation and cannot be installed onearlier models. A shield is installed to the timing cover toprevent foreign objects contacting the crankshaft sensorand the intemrpter blades at the rear of the crankshaftpulley.

To ensure security, the crankshaft pulley is now apress fit on the crankshaft and is identified by three elon-gated holes in the front face of the hub. The pulley can beinstalled to previous models if the corresponding retainingbolt and washer are installed.

Unlike previous models, the crankshaft is the same forautomatic and manual transmission models. On manualtransmission models, a redesigned spigot bearing is in-stalled which cannot be installed to earlier models. Thecrankshaft cannot be installed on earlier models due to theadditional flywheel/drive plate retaining bolt holes and theredesigned rear flange which is machined to suit a onepiece neoprene rear crankshaft oil seal.

Unless otherwise stated, all procedures remain asdescribed in the main manual and Part I of this supple-ment. However, due to a number of changes in the cooiingsystem, allowance should be made for variations whenreference is made to the coolant and heater hoses andpipes.

NOTE: If the cooling system is drained, ensltrethat it isfilled as described loter in this supple-ment to prevent engine overheating.

2. DRIVE BEI.JT TENSIOhIER

The procedure to remove and instal the drive belttensioner remains as described in the main manual withattention to the following point.

2 8 1

Drive belt tensioner and associated components.Power steering pump removed.

(1) Prior to installing the heater pipe, check thecondition of the O ring and renew as necessary. Applypetroleum jelly to the O ring and instal the heaterpipe fullyinto the timing cover.

3. IhILET IVIAMFOLD

The procedure to remove and instal the inlet manifoldremains as described in the main manual with attention tothe following points.

(1) Disregard operations (5) and (9) of the removalprocedure.

(2) Operation (17) of the removal procedure shouldread as follows:

Inlet manifold gaskets and seals correctly installed.



View of the inlet manifold showing the tighteningsequence of the retaining bolts.

Release the clamp and disconnect the heater hosefrom the rear of the inlet manifold.


Release the clamp and disconnect the upper radiatorhose from the thermostat cover.

(4) When installing the inlet manifold, ensure thatthe cut out portions of the rubber valley seals are sittingover the cylinder block protrusions.

4. D(HAUST MAMFOLDS

The procedure to remove and instal the exhaustmanifolds remains as described in the main manual withattention to the following points.

(l) Where applicable, remove the lock nuts andlock plates prior to removing the manifold retaining studs.

(2) When removing the left hand exhaust manifold,disregard operation (3) (a).

(3 ) When remov ing the r igh t hand exhausrmanifold, disregard operations (a) (b) ro (4) (0.

Installed view of the right hand side exhaust manifoldand the engine pipes.

5. ROCHER ARIftS AstD,PUSlnil)S

tescribedr in the mainmanual and Part I of this supplement with dtentisr ts thefollowing points.

(l) Disregard operation (a) of the removal proce-dure in the main manual.

Ensure that retainers are installed with the arrowsfacing towards the inlet manifold.

(2) When removing the left hand rocker cover,remove the lock nuts and withdraw the left hand enginelifting bracket from the exhaust manifold retaining studs.

(3) Prior to installation, liberally coat thelcontactsurfaces of the rocker arrns and pivots with a mixture ofmolybdenum disulphide grease and clean engine oil.

6. CYLINDER HEADS


The cylinder head gaskets must be installed with thearrow facing towards the rear of the engine, Tighten the

cylinder head bolts in numerical -equenIe.


Suf'plm,€nt - Part 2. 1991 Models

(1) When checking the cylinderhead mounting facethickness, refer to Specifications in this supplement.

(2) When installing the cylir&r head gaskets, useciEg&,Walscr*ftiag &e swf&es which are coatedwith an adhbsive and ensure that the arrow on the top ofthe gaskets is facing towards the rear of the engine.

7. TIMING COVER

The procedure to remove and instal the timing coverremains as described in the main manual and Part I of thissupplement with attention to the following points.

(l) It is necessary to use a suitable three jaw pullerto remove the crankshaft pulley.

(2) To remove the shield from the timing cover,insert a screwdriver behind the shield adjacent to theretaining studs and gradually lever the shield from thestuds.

Grankshaft pulley, timing cover and associatedcomponents.

(3) Where applicable, bend rhe lock tabs over therear sump bolts.

(4) Check the condition of the heater pipe O ringand renew as necessary. Apply petroleum jelly to theO ring and instal the heater pipe fully into the timingcover.

(5) Check the adlbstment of the crankshaft sensoras described later in this supplement.

(6) Prior to installing the crankshaft pulley, applyRTV 732 sealant to the keyway slot.

8. TIMING CHAIN, SPROCKETS AITDBAIANCE SHAFT GEARS

The procedure to remove and instal the timing chain,sprockets and balance shaft gears remains as described inthe main manual with attention to the following points.

(1) Disregard operation (a) of the removal proce-dure in the main manual.


Remove the retaining bolt and withdraw the damperassernbly from the engine, noting the installed position ofthe spring.

283

If necessary, remove the balance shaft gears, as fol-lows:

(a) Slide the balance shaft drive gear from the cam-shaft and remove the key from the end of the camshaft.

(b) Using a T30 Torx socket, remove one of thescrews retaining the camshaft thrust washerto the cylinderblock.

(c) Instal the balance shaft drive gear to the cam-shaft so that one of the holes in the face of the gear isaligned with the vacant thrust washer retaining screw holeand instal a5/rc UNC x 30 mm bolt finger tight.

(d) Instal al2mmthick spacer with an inside diam-eter of approximately 25 mm to the end of the camshaft.Instal the camshaft sprocket retaining bolt finger tight.

(e) Remove the balance shaft gear retaining boltand withdraw the gear from the balance shaft.

(0 Remove the lock bolt and the retaining bolt andwithdraw the gear from the camshaft.

(4) Remove all sealant from the threads on the cam-shaft sprocket and the balance shaft gear retaining bolts.

(5) Apply Loctite 242 or equivalent sealant ro the

Method of preventing the balance shaft turning whenremoving the retaining boh.

bre\CRANKSHAFT SENSOR

ffie"1"

@l/

Balance shaft timing marks correctly aligned.



scREws

-:T' $,.Em n'rE.#ff. i0"r *{u* }'o*

o/

THRUSTWASHER

Gamshaft and associated components.

Gamshaft timing marks correctly aligned.

threads on the balance shaft gear and the camshaft sprocketretaining bolts and to the thrust washer retaining screws.

(6) Ensure that the key is installed to the camshaftand that the balance shaft and camshaft timing marks arealigned.

(7) Instal the damper assembly ensuring that theend of the spring is located in the hole adjacent to theretaining bolt. Tighten the bolt to the torque specified inthis supplement.

(8) Disregard operation (6) of the installation proce-dure.

the retaining hole.

9. CAI}TSHAFT AI\ID BAI.ANCE SHAFT

All procedures remain the same as the main manualwith attention to the following points.

(1) When checking the camshaft lobe lift, journaldiameter and oil clearance, refer to Specifications in thissupplement.

(2) In operation (4) of the removal procedure loosenbut do not remove the balance shaft gear retaining bolt as

Camshaft thrust washers correctly installcd. The wordTOP must be uppermost and facing outwards.

previously described in this supplement under the TimingChain, Sprockets and Balance Shaft Gears heading.


Remove the remaining Torx screws and withdraw thecamshaft thrust washer.

(4) Remove all traces of sealant from the threads ofthe thrust washer retaining screws and the cylinder block.

(5) Apply clean engine oil to the camshaft andthrust washer contact surfaces and instal the thrust washerensuring that the word TOP is uppermost and is facingoutwards.

(6) Apply Loctite 242 or equivalent sealant to thethrust washer retaining screws and tighten to the torquespecified in this supplement.

10. OL PUMP


(1) When checking the oil pressure or the pressureregulator spring free length, refer to Specifications in thissupplement.

11. SUMP AND OIL PI.JMP PICK.UP PIPE

All procedures remain as described in the mainmanual and Part I of this supplement with attention to thefollowing points.

Ensure that the end of the damper spring is located in


Suppternent - Part 2. 199I Models

(f i'Pfidf torernQvfig fte fear sump bolts, straightenthe tabs'ontl ie krck pfate. r 'r 'r ' :: : : ' : :

(2)" ' EnSure thatttwtWo'yelbw bolts are installed to

the centre troles at the rearof the sump and bend the lockplate tabs over the bcilts.

12. CRANKSHAFT OIL SEAIS


Front Crankshaft Oil Seal

The procedure remains as described in the mainmanual with attention to the following points.

(l) On automatic transmission models, operation(4) of the removal procedure in the main manual requiresthat the drive plate be locked prior to removing thecrankshaft pulley retaining bolt. This will necessitate theremoval of the support brace as described previously inPart 1 of this supplement.

(2) It is necessary to use a suitable three jaw pullerto remove the crankshaft pulley.

(3) Prior to installing the crankshaft pulley, applyRTV 732 sealant to the keyway slot.

R,ear Crankshaft Oil Seal

(1) Remove the transmission as described in therelevant transmission section in the main manual.

(2) Remove the flywheel or drive plate as describedin the Engine section in the main manual.

(3) Using a screwdriver, lever the seal from theengine ensuring that a thin piece of shim brass or steel ispositioned between the screwdriver and the crankshaft toprotect the crankshaft surface.

(4) Check the seal recess for burrs and damage andrectify as necessary.

(5) Check the seal contact surface on the crankshaftfor burrs and repair or renew the crankshaft as necessary.

(6) Apply clean engine oil to the inner and outersealing surfaces on the new seal.

(7) Ensure that the seal lip is facing towards thefront of the engine and, using a mandrel, instal the seal

squarely into the recess until the distance the between therear face of the seal and the rear face of the crankshaftflange is 4.24.7 mm.

NOTE: The rear main bearing cap oil returnhole will be blocked if the seal is installed

further than 4.7 mm into the seal recess andwill result in oil leakage.

(8) Instal the flywheel or drive plate ensuring thatthe bolts are tightened to the torque specified in this sup-plement. On automatic transmission models, ensure thatthe retainer plate is installed with the dimple facing awayfrom the drive plate as shown in Part I of this supplement.

(9) Instal the transmission as described in therelevant transmission section in the main manual.

13. PISTONS, CONNECTING RODS ANDCYUNDER BORES


(1) Ensure that the connecting rod bearing oilclearance is within Specifications in this supplement.

(2) The piston diameter must be measured at a point44 mm below the top of the piston at a right angle to thegudgeon pin axis.

(3) The direction arrow on the top of the pistonsmust face towards the front of the engine as originallydescribed in the main manual.

(4) Ensure that the piston ring end gap is withinSpecifications in this supplement.

14. CRANKSHAFT AND BEARINGS


The main bearing caps must be installed in numericalorder and with the ribs facing towards the starter motor.

285

Method of removing the rear crankshaft oil seal.


286

Main bearing identification chart.

(l) The two piece rope crankshaft oil seal installedto previous models is replaced with a one piece neopreneoil seal.

(2) Disregard operations ( 1) to (4) of the installarionprocedure in the main manual.

(3) Ensure that the main bearing shells are installedin the correct location. Compare the part number on thebearing shells with the identification chart.

(4) Lubricate all bearing surfaces including theNo 2 main bearing thrust faces with clean engine oil.

(5) The main bearing caps must be installed in

Supplement - Part 2. 1991 Madel,s

numerical order and with the ribs on the side of the capsfacing towards the starter motor side of the iylinder block.

(6) Undersize mdn pearing sheUs can be identifiedusing the identification chart as previously described.

(7) Tighten the main bearing cap bolts using rhefollowing procedure:

(a) Tighten the bolts to a rorque of 3l*39 Nm.(b) Using an angle gauge, tighten the bolts and

additional45".(8) Instal a new rear crankshaft oil seal as pre-

viously described in this supplement.(9) Whenever the rear main bearing cap is removed,

the rear crankshaft oil seal must be renewed as previouslydescribed.

15. EXHAUST SYSTEM

The procedure to remove and instal the exhaust sys-tem remains as described in the main manual with atten-tion to the following points.

(1) The oxygen sensor is installed to the left handengine pipe. If the engine pipe reqqires renewal, theoxygen sensor must be removed. The removal and instal-lation procedure for the oxygen sensor is described in Fueland Engine Management section in the main manual.

(2) The engine pipes are secured to the exhaustmanifolds using studs and nuts.

(3) The rear muffler assembly is connected to theintermediate muffler using a flange type joint, gasket andbolts.

(4) On Sedan and Station Wagon models, a flexiblejoint is installed to the rear muffler inlet pipe to reduceresonance in the exhaust svstem.

MAIN BEARING STANDARD UNDERSIZE

N O 1UPPER 24500039 24500740

LOWER 24500640 24500741

N O 2UPPER 1 801 7978 1 801 7982

LOWER 1 801 7974 1 801 7983

N O 3UPPER 1 801 7975 1 801 7979

LOWER 1 801 7976 1 801 7980

N O 4UPPER 24500639 24500740

LOWER 24500641 24500742


SPECIFICAf,IONS

Coolant:Type . . . : . . . .S}Voethyleneglycolcorrosion

capacity lil':li:'1"0]*::i:11Y,?f:Radiator cap:

P r e s s u r e r a t i n g . . . . 1 3 5 k P aOperating pressure . . l20 kPa-150 kPa

r. DESCRIPTION

The following changes to the cooling system apply tomodels equipped with the revised engine described pre-viously.

The radiator has a conventional filler neck and aradiator cap and the surge tank installed to earlier modelshas been replaced with a reserve tank. An overflow hoseis connected between the radiator filler neck and thereserve tank. As the coolant volume expands due to a risein temperature, the pressure valve in the radiator cap opensand allows the excess coolant to flow into the reserve tankvia the overflow hose. When the coolant temperature falls,the vacuum valve in the radiator cap opens, allowing thecoolant to siphon back into the radiator.

Due to the redesign of the inlet manifold, the thermo-stat, coolant temperature sensor and the temperature gaugesender are located towards the front of the inlet manifold.

The water pump spacer plate has been deleted and thecoolant passages revised to suit the redesigned timingcover. The water pump pulley is narrower than previousmodels and neither the water pump or the pulley areinterchangeable with earlier models.

lnstalled view of the thermostat cover and the reservetank.

287

2. RADIATOR

TO CHECK COOLANT LEVEL

(l) With the engine cold, the coolant level in thereserve tank should be between the Minimum and Maxi-mum marks.

(2) If the level is below the Minimum mark. removethe cap and add the specified coolant to the reserve tankuntil the level is correct.

NOTE: Do not top up the reserve tank withcoolant containing a dtfferent type of cor-rosion inhibitor. If necessary, drain and refillthe cooling system using coolant containingthe correct type of inhibitor in the specifiedratio.

If the reserve tank requires frequent top-ping up, check the cooling systemfor leakage.

(3) If the reserve tank is completely empty, removethe radiator cap and check the coolant level.

If coolant cannot be seen in the filler neck, fill theradiator as described under the following heading.

NOTE: The coolant level in the radiatorshould be checked periodically when the en-gine is cold.

If the radiator requires topping up and thereserve tank is not empty, check for a faultyseal on the radiator cap or a loose or blockedoverflow hose.

TO DRAIN AND REFILL

This engine is equipped with an air bleeder valve. Thevalve is used when refilling coolant using the manufac-turers special tool AU425.

It is not necessary to open the valve when refilling thecoolant using the following procedure.

(1) Set the heater controls to the hot position.(2) Remove the radiator cap. Disconnect the lower

radiator hose and drain the coolant into a container.(3) Position a container under the cylinder block

drain plugs, located on each side of the cylinder block, andremove the drain plugs.

(4) When the coolant has drained, clean the cylinderblock drain plugs, apply Loctite 242 or equivalent sealantto the threads and tighten the drain plugs securely. Con-nect the lower radiator hose.

(5) Mix approximately 12 litres of coolant, consist-ing of 6 litres of the specified corrosion inhibitor and 6litres of clean water.

ent - Part 2. 1991 Models

,COOLING AI\D HEATING SYSTEMS


288 Supplement - Part 2. 1991 Moidels

(6) Disconnect the upper radiator hose from thethermostat cover and hold the hose verticaily, ensuringthat the end of the hose is higher than the thermostat cover.

(7) Fill the cooling system with coolant through theopen end of the upper radiator hose until coolant flo*sfrom the radiator filler neck. Instal the radiator cap.

(8) Continue to pour coolant into the op"n end ofthe upper radiator hose until coolant flows from thethermostat cover.

(9) If the _cooling system has been completely$1ai_ne$, place three cooling sysrem pellets (pirt NoM40124) into the upper radiator hose.

(10) Quickly connect the upper radiator hose to thethermostat cover to prevent excesiive coolant loss ensur-ing that the pellets are not displaced. Tighten the hoseclamp securely.

(ll) Fill the reserve tank to approximately 25 mmabove the Maximum mark and instal the cap.

(I2) Start and run the engine for 20 minutes to dis_solve the pellets and_purge any air that may be trapped inthe cylinder heads. check the coolant levei as previouslydescribed.

3. THERMOSTAT

The procedure: [o naneve, instal and check thethermostat remains as debcribed in the main manual withattention to the following points.

(1) The thermostat is located at rhe front of the inletmanifold.

(2) Disregard operation (2) of the removal and in-stallation procedure.

(3) The thermostat cover is retained to the inletmanifold using two bolts and a gasket. The gasket must berenewed.

THERIIOSTATI

I Ad f f i n' w E r y I N!.sI:-

tV261861

oL**

Thermostat and associated components.

II


FI.TEL AI{D ENGINE MAI.{AGEMENT AIND EMISSION CONTROL

I. FI.JEL AND ENGilNE MANAGEMEIYT

SPECIFICATIONS

Injectorresistance .. .15-17C,Coil secondary resistance . . . 5-7 kOHigh tension lead resistance limit:

No 1, 3 and 5 leads . 17 kC)No 2, 4 and 6 leads ' 25 kg'

Crankshaft sensor air gap Refer to text


Fuel rail retaining bolts . 11 NmOxygen sensor . . .60 NmCrankshaft sensor retaining studs . . . 30 NmCrankshaft sensor clamp bolt . .5 Nm

DESCRIPTIONThe following changes to the fuel and engine manage-

ment system apply to models equipped with the revisedengine described previously.

The fuel rail is redesigned and the flow rate of theinjectors has been altered. A special fuel hose is installedbetween the fuel supply pipe and the fuel rail to reduce fuelpulsations. The revised fuel rail and injectors are notinterchangeable with earlier models.

The Coil pack installed on previous models has beenreplaced by three individual ignition coils and the igniliolcontrol module has been revised to suit the individualcoils.

The oxygen sensor is installed in the left hand enginepipe and an earth wire is installed to ensure that the oxygensensor is earthed securely. To prevent foreign objectscontacting the crankshaft sensor and the interrupter bladesat the rear of the crankshaft pulley, a shield is installed tothe engine timing cover.

lnstalled view of the fuel rail and the fuel pressureregulator.

FUEL RAIL AND INJECTORS

The procedure to remove and instal the fuel rail andinjectors remains as described in the main manual with

attention to the following Point.Operation (5) of the removal procedure should read as

follows:Release the clamp and disconnect the fuel supply hose

from the fuel rail.PRESSURE REGULATOR ETAINER

#\BOLT

O RING

/

Fuel rail, iniectors and associated components.

IGNITION SYSTEM

To Test - Code 41

The procedure remains as described in the mainmanual with attention to the following points.

(1) If the test lamp does not light in operation (1 l)'check the EFI relay and associated circuits as described inthe main manual.

(2) Disregard operations (20) to (26) in the mainmanual and proceed as follows:

Installed view of the ignition control module and theignition coils.

Suppl,ement - Part 2. 1991 Models 289

l , wI 0 . p

i \/

BoLr

RETAINER


290 Supplement - Part 2. lgg l AMels

(a) Disconnect the remaining high tension leadsftgT the ignition coils, remove thJscrJws retaining thecoils to the ignition control module and pull each coil fromthe module using care not to damage th-e terminals.

(b) Connect a test lamp between a pair of theprimary terminals protruding from the top of ihe ignitioncontrol module and check that the test lamp flashei whenthe starter motor is operated. Repeat the tesion the remain-ing module terminals.

If the test lamp does not flash at each of the primaryterminals, renew the ignition control module.

Ghecking the ignition coil secondary resistance.

(c) Switch the ignition Off and using an ohmmerer,check the resistance between the primary te-rminals of eachcoil. Renew any coil which does not hive a resistance of0.3-1.5 ohms.

(d) Connect an ohmmeter between the high tensionterminals of each coil. Renew any coil which doer nothave a secondary resistance of 5-7'k/ohms.

IGNITION CONTROL MODULE ANDIGNITION COILS

The procedure to rernove and instal the ignition con-trol module and ignition coils remains as desJribed in themain manual with attention to the following points.

(l) To remove the ignition coils, remove the screwsretaining_the ignition coils to the ignition module and pulleach coil from the module using care not damage theterminals

(2) When installing the ignition control module,ensure that the retaining studs are correctly seated in themodule. Align the mounting lugs on the base of themodule with the corresponding holes in the mountingbracket and tighten the nuts securely.

(3) Ensure that the seals are installed to the moduleterminals. If the seals are damaged, they must be renewed.

(4) Instal the ignition coils using care not to bendthe terminals and tighten the screws.

(5) If an ignition coil has been renewed, it will nothave the cylinder identification numbers. If necessary,

lefer to the.cylinder numbers stamped on the rear upperface of the ignition control module adjacent to each coilwlren csnnecting.the. h[h,gT!ry1l@s".

i. . . ; i,

CRANKSHAFT SENSOR

Special Bquipment Required:

To Instal and Adjust Crankshaft Sensor * Speciattool4U423 (refer to text)


(1) Disconnect the negative battery terminal.(2) Remove the engine cooling fan as described in

the cooling and Heating Systems iection in the mainmanual.

. (3) Using an 18 mm ring spanner, rotate the ten_s.i9ne1 pulley bolt clockwise to raiie the pulley from thedrive belt and remove the belt from the engine.-

(4) On manual transmission models, apply thehandbrake fully, select top gear and chock the reai*heelsto prevent the crankshaft turning.

(5) On automatic transmission models, remove thesupport brace as previously described in part I of thissupplement and place a lever between the cylinder blockand the drive plate teeth to prevent the crantsnart turning.

(6) Remove the crankshaft pulley retaining bolt an?remove the crankshaft pulley using a puller.

(l) Disconnect the wiring connector from thecrankshaft sensor.

(8) Insert a screwdriver behind the shield adjacentto the retaining studs and gradually lever the shield fromthe studs.

(9) Remove the retaining studs and withdraw thecrankshaft sensor.

(10) Check the interrupter blades at the rear of thecrankshaft pulley for damage and signs of contact with thecrankshaft sensor. Renew the crankshaft pulley as neces-sary.

Installation is areversal of the removal procedure withattention to the following points:

(1) Apply Loctite 242 or equivalenr sealant ro theretaining studs, instal the crankshart sensor to the engineensuring that the dowel pin locates in the crankshaft sensorbracket and tighten the retaining studs finger tight.

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CRANKSHAFT SENSOR

Grankshaft pulley, timing cover and associatedcomponents.


Swfrlement - Part 2. 199 I Models

(2).. ,Unserew tharankshsftrs€rsor elamp bolt suffi-ciently to sllow, the senror.tc rnmre freely.

(3) Inssal the speial tool over the end of thecrankshaft so that the one of the ymes is located in thecrankshaft s€nsor outer clpnnel and tighten the retainingstuds to the specified torque.

NOTE: The special tool, Part No AU423, isavailable from Kent-Moore Australia Pty Ltd(NSW).

(4) Rotate the special tool several times and adjustthe position of the sensor until the vanes pass evenlythrough the sensor channel.

(5) Tighten the clamp bolt to 3-5 Nm and confirmthat the sensor is correctly adjusted.

NOTE: Overtightening the clamp bolt will dis-tort the mounting bracket and may causedamage to the sensor through contact with theinterrupter blades.

(6) Ensure that the terminals are clean and instal thewirias connector to the crankshaft sensor.

t?, Apply RTV 732 sealant to the crankshaft pulleykeyway and instal the crankshaft pulley.

(8) Rotate the crankshaft slowly and check that theintemrpter blades do not contact the crankshaft senor. Ifnecessary, remove the crankshaft pulley and check thecrankshaft sensor adjustment using the special tool. If theadjustment is correct, renew the crankshaft pulley.

(9) Tighten the crankshaft pulley reraining bolt tothe specified torque.

(10) Instal the engine cooling fan..r,,.'. (11) Raise the tensioner and instat the drive belt. If

riecessary, refer to the illustration in the Engine Tune-upsection in the main manual.

COOLANT TEMPERATURE SENSORAll procedures remain as described in the main

manual with attention to the following point.(l) To gain access to the coolant temperature sen-

29r

sor, it is necessary to remove the engine drive belt, removethe alternator retaining bolt and, ensuring that the negativebattery terminal has been disconnected, pivot the alter-nator upwards.

OXYGEN SENSOR

To Test - Code 13

(l) With the engine at operating temperature, runthe engine at 1 600-1 800 rpm for two minutes.

(2) Using the backprobing method, connect the posi-tive lead of a voltmeter to the control unit wiring connectorterminal D7 and the negative lead to terminal D6.

If the voltage is not 325475 millivolts, an intermit-tent fault is indicated. Check that all wiring and earthconnections are clean and secure.

(3) With the voltmeter remaining connected to thecontrol unit wiring connector, disconnect the oxygen sen-sor wiring connector and, using a jumper lead, connect theharness connector violet wire terminal to a good earthpoint.

If the voltage is less than 200 millivolts with theengine running, check the oxygen sensor and the harnessconnector for loose or dirty terminals. If no fault can befound, renew the oxygen sensor.

NOTE: A faulty orygen sensor can be causedby contamination to the orygen sensor throughthe use of leaded fuel or unsuitable siliconesealants on engine components and may beidentffied by o white, powdery substancecovering the tip of the oxygen sensor.

A contaminated orygen sensor should berenewed and the cause of the contaminationrectified.

(4) Stop the engine, disconnect the jumper leadfrom the harness connector terminal and connect avoltmeter between the violet wire terminal and earth.

(5) Switch the ignition On and check the voltage.If the voltage is 300-600 millivolts, renew the control

uni t .If the voltage is below 300 millivolrs, check the circuit

between the control unit terminal D7 and the oxygensensor for continuity and secure connections. If no faultcan be found, renew the control unit.

If the voltage is above 600 millivolts, check the cir-cuits and connections between the oxygen sensor, thecontrol unit terminal D6 and the engine earth terminals forcontinuity. If no fault can be found, renew the control unit.

To Test - Code 44

(1) With the engine at operating temperature, runthe engine at I 600-1 8fi) rpm for two minutes.

(2) Using the backprobing method, connect the posi-tive lead of a voltmeterto the control unit wiring connectorterminal D7 and the negative lead to terminal D6.

If the voltage does not remain constant below 300Location of the coolant temperature sensor.


2e2 Supplement - Part 2. Igg l Models

millivolts, an intermittent fault is indicated. check that allwiring connections are clean and secure.

(3) With the voltmeter remaining connected to thecontrol unit wiring connector, disconnect the oxygen sen-sor wiring connector and check the voltage with the engineidling.

If the voltage is not 300-550 millivolts, check thecircuit between the control unit terminal D7 and theoxygen sensor connector for a short to earth. If no fault canbe found, renew the control unit.

If the voltage is 300-550 millivolts, check the circuitsand connections between the oxygen sensor, the controlunit terminal D5 and the engine eirth terminals for con-tinuity. If no fault can be found, check the followingpossible causes:

Low fuel pressureBlocked injectorsContaminated fuelExhaust leaks ahead of the oxygen sensorMAP sensorBlocked oxygen sensor vent to atmosphere(4) If the above components and conditions are

satisfactory, renew the oxygen sensor.

To Test - Code 45(l) With the engine at operating temperature, run

the engine at I 600-1 800 rpm for two minuies.. \Zl Using the backprobing method, connect the posi-

tive lead of a voltmeter to the control unit wiring connectorterminal D7 and the negative lead to terminal D6.

If the voltage does not remain constant above 750millivolts, an intermittent fault is indicated. check that allwiring connections are clean and secure.

(3) With the voltmeter remaining connected to thecontrol unit wiring connector, disconnect the oxygen sen-sor wiring connector and, using a jumper lead, connect theharness connector violet wire terminal to a good earthpoint.

If the voltage is above 350 millivolts with the enginerunning, check the circuits and connections between theoxygen sensor, the control unit terminal D6 and the engineearth terminals for continuity. If no fault can be found,renew the control unit.

If the voltage is below 350 millivolts, check the fol-lowing possible causes :

High fuel pressureLeaking injector(s)Ignition control module earth circuit (ignitioncontrol module to control unit terminal 83)Charcoal canister saturated with fuelCoolant temperature sensorMAT sensorMAP sensorThrottle position sensor(4) If the above components and conditions are

satisfactory, renew the oxygen sensor.

NOTE: Afaulty orygen sensor can be causedby contaminationto the orygen sensor through

the xse of leded.fwl or unnitablesillconesealants on engirte avmponefis.andvtWy tnidentified by a white, pawdery subs&ncecovering the tip of tlre orygen sensor. ,

A contaminated oryg€n sensor should berenewed and the cause rectified.

2. EMISSION CONTROL

DESCRIPTIONThe emission control system remains as described in

the main manual except for the foltowing changes to thepositive crankcase ventilation (PCV) system which applyto models equipped with the revised engine describedpreviously.

Clean air is drawn from the throttle body into the lefthand side cylinder head via a vent hose and an internalpassage at the rear of the inlet manifold and the cylinderhead.

The PCV valve is installed inside the front of the inletmanifold in a passage that runs between the inlet manifoldplenum chamber and the right hand side cylinder head.

Location of the PGV valve and vent hose.

TO CHECK PCV VALVE(1) Unscrew the cap from the front of the inlet

manifold and withdraw the spring and the pCV valve.(2) Shake the PCV valve and check that the valve

rattles. Renew the PCV valve if it does not rattle.(3) Check the condition of the O ring and spring and

renew as necessary.(4) Instal the PCV valve and spring into the inlet

manifold.(5) Apply Loctite 242 or equivalent sealant to the

threads on the cap and tighten the cap securely.

W M , WpcvvAlve cAP

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PGV valve and associated components.

Not for distribution outside of AllCarManuals.comNot for distribution outside of AllCarManuals.com

1. CLUTCH AND IIANUAI TRANSMISSION

DESCR,IPTIONThe clutch and manual transmission is the same as

previous models except that the design and operatingcharacteristics of the clutch unit has ben revised toachieve smoother operation. The front bearing retainer onthe transmission is 9 mm shorter to suit the revised clutchunit.

The revised clutch unit can be installed to earliermodels provided that the transmission front bearingretainer is shortened by 9 mm. If the transmission is to beinstalled to an earlier model, the longer type front bearingretainer must be installed to the transmission if the revisedclutch unit is not also being installed.

All procedures remain as described in the mainmanual.

2. AUTOMATIC TRANSMISSION

DESCRIPTIONThe automatic transmission is the same as 1990

models except that the shift points have been altered to suitthe revised engine.

3' H PgaBICAL SYSTEM

ALTERNATOR

The alternator is same as the one instalted to previousmodels except that the installed position of the slip ringend bracket, stator and associated components are rotated90" in relation to the drive end brackef to improve accessto the altemator wiring and to accommodate the revisedinlet manifold.

All servicing procedures remain as described in themain manual.

293

STARTER MOTOR

On automatic transmission models manufacturedfrom August 1991, the Bosch starter motor is replaced bya Delco Remy starter motor. The Delco Remy startermotor is similar to the type installed to manual transmis-sion models as described in the main manual and is iden-tified by the NO SHIM imprint on the end bracket.

View of the Delco Remy starter motor removedthe vehicle.

For all servicing procedures refer to the main manual.However, it should be noted that on all models manufac-tured from August 1991 including those with a manualtransmission where the starter motor end bracket has theNO SHIM imprint, the pinion mesh must not be adjusred.

The Delco Remy and Bosch starter motors are notinterchangeable.

WIRING DIAGRAMS

The wiring diagrams covering all models are dis-played in the main manual.

- Part 2. 1991 Models

UAL TRAI{SMISSION, AUTOMATICTRANShfiIS$ON AI{D ELECTRICAL SYSTEM

from


294 CONVERSION TABLES

Quantity Imperial Unitc o nue rs io n Fac to rs r e piiffi-

-HtpfriMetricAnits ' ' i*iiiliu""u,

Metric Unit

LENGTH inch ( in)

foot (fr)yard (yd)furlong (fur)

mile(for navigation)

millimetre (mm) oreentimetre (em)eentimetre or metre (m)metre (m)metre (m) orkilometr.e (km)kilometre (km)

I ih-='S5.{ ffi

f ft : 30.b emr yd : 0.914 ml f u r : 2 0 1 m

I mi le - t .6t kml n m i l e :

I cm : 0.894 inlm : 3.28 f tlm : 1.09 yd

l k ml k m

1852 m

: 4.97 fur+ 0,62l.mileinternationallautieal mile

(n mile)MASS ounce (oz)

pound (lb)stoneton

gl'am (c)

Cram (g)kilogramtonne (t)

;;lilosram (ks)

oz : 28.8 gl b : 4 5 4 gstone : 6.85 kgton : 1.02 t

0.0353 oz: 2.20Ib

IIII

k g =k g =+ -

: 0.157 stoneAREA square inch

square foot

square yar.dperch (p)rood (rd)acre (ae)square mile

0.984 ton(inz;(ftz)

(yd2)

square eentimetr.e (emz)square eentimetre (cmz) orsquare metre (mz)square metre (mz)square metre (mz)heetare (ha)hectare (ha)square kilometre (kme)

1 inz : 6.4b cmzI fbz : 929 emz

I ydz : 0.886 mzlp : 25.3 mzI rd : 0.101 haI ae : 0.405 ha1 square mile : 2.bg kmz

cm2 : 0. lb5 inz

m 2 :m 2 :m 2 :h a :h a :k m z :

10.8 ftr7.2O ydz0.0395 p9.88 rd2.47 ae0.386 square mileVOLUME cubie inch (ina)

eubic foot (fts)cubic yard (yda)bushel (bus)

eubic eentimetre (cms)cubie metre (mr)cubie metre (rpe)eubie metre (ma)

l i n s :1 f t 3 :l y d a :l b u s :

16.4 em30.0283 m30.765 mg0.0364 mg

I em3 - 0.0610 inslm3 - 35.8 ftg1 m 3 :1 m 3 :

1.31 yds27.5 busVOLUME (fluids) fluid ounee (fl oz)

pint (pt)gallon (gat)acre foot

millilitre (mt)millilitre (mt) or litre (l)litre (/) or cubic metre im)cubic metr.e (m3) ormegalitre (Mt)

l f l o zr p t :

: 28.4 ml568 ml

: 4.55 litrefoot : l2B0 m3

: r .2B Ml

I ml : O.OB52 ft ozI l itre : l.?6 ptI ms : Z2O gil

I Ml : 0.811 acre foot

I galI acre

FORCE pound-foree (lbf)ton-foree (tonfl

newton (N)kilonewbon (kN)

r lbf : 4.45 N1 tonf : 9.96 kN

N : 0.225 lbfkN : 0.10O tonfPRESSURE pound per square inch

(psi)atmosphere (atm)

ton per square inch(ton/in2)

psi

kilopascal (kpa)

kilopascal (kpa) ormegapaseal (Mpa)megapaseal (Mpa)

kg/emz

I psi : 6.89 kpa

I atm : l0l kpa

I ton/in2 : 15.4 Mpa

I psi : 0.070 kg/cmz

I kPa : 0 .145 ps i

i

I MPa : 9.8? atmI MPa : 0.0G47 ton/in2

VEI,OCITY I kg/cmz: 14.22 psimile per hour (mph)(for navigation) Il3f&.;; Per hour (km/h) I mph : l .6 t km/h

I kn : 1 .85 km/hI km/h : 0.621 mph

TEMPERATURE temperature ("F) temperature ("C) "c :+ ( "F -sz ) 9 X " Cr. :_1- + 82DENSITY pound per cubic inch

(lblina)

ton per cubic yard

gram per cubie centimetre(g/cmB): tonne per cubic metre(t/ms)

1 lb/ in3 : 27.7 t/mg 1t/mr : 0.0361 lb/ in3

I t/mz : 0.752 ton/ydatonne per.cubic metre (t/m3) 1 ton/yda : l.BB t,/mgENERGY British thermal unit (Btu)

therm(for eleetrical energ-y)

kilojoule (kJ)megajoule (MJ)ki lowatt hour (kWh)

I Btu : 1.06 kJI therm : 106 MJ

r kwh

: 0.948 Btu:9.48 X l0stherm

l k Jl M J

: 3.60 MJPOWER horsepower (hp)

TIMEkilowatt (kW) I hp : 0.246 kW I kW : r.B4 hpseeond (s)minute (min)hour (h)

I m in ' : 60 st h : 3 6 0 0 sFREQUENCY cyele per second (c/s) hertz (Hz) l e l s : 1 H z L H z : l c / sANGUI.AR

VELOCITYrevolution per minute (rpm) radian per seeond (radls)

revolution per minute (rpm)1 rpm : 0.10b rad/s I radls : 9.55 rpm

TORQUE lb-f t Nm

VACUUM inches of mercury (in Hg) kilopaseal (kpa) I in Hg : 3.386 kpa I kPa : 0.295 in Hg

r lb-ft : 1.85582 Nm I Nm : o. iARz ru_ft


Conaersion Tables

Flt t l t t ' lETRES 70

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F A H R E N H E I T & C E L S I U S

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VN VP Commodore Calais Workshop Manual

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