VN VP Commodore Calais Workshop Manual

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Commodore Executive Station Wagon
Lexcen Station Wagon
Commodore S
Not for distribution outside of AllCarManuals.com
CONTENTS
INTRODUCTION VEHICLE IDENTIFICATION AND GENERALSPECIFICATIONS . . .
Vehicle identification General vehicle specifications . .
EMISSION CONTROL
7 7 7 E 8 10 11 14 14 t4 t6 20 20 20 2l 22 24
Introduction . . . Positive crankcase ventilation (PCV) system Evaporative control sYstem
122 122
1?2 L23 125 125
r23
Exhaustcontrol sYstem
GENERAL INFORMATION
Tools and equipment
Safety General repair procedures
CLUTCH
Specifications Clutch trouble shooting
r25
126 126 128 129 131 131 131 132 133 133
Description mechanism Clutch unit and release

Clutch cable Clutch pedal
LUBRICATION AND MAINTENANCE

Specifications . . . How to grease and oil change Service schedule
MANUAL TRANSMISSION
Specifications Transmission trouble shooting Propeller shaft trouble shooting Description Transmissionassembly Propeller shaft assemblY . .
WHEELS AND TYRES

Specifications.... How to change a wheel Tyre wear trouble shooting . . Care and maintenance
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ENGINE TUNE-T'P
Tune-up specifications . .
Tune-up operations
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AUTOMATIC TRANSMISSION
Specifications DPglllr!4nvut trouble shooting Automatic transmission troubl Description Transmission fluid . . . Kickdowncable Selector linkage Neutral safety switch Transmission assemblY
ROADSIDE TROUBLE SHOOTING

Trouble shooting To check ignition and electrical system To check the fuel sYstem To check the mechanical sYstem
ENGINE
Specifications . . Engine mechanical trouble shooting Description Engine assembly Drive belt tensioner assemblY Manifolds Rocker arms and Pushrods
Hydraulic tappets Cvlinder heads

Timing cover . Timing chain, sprockets and balance shaft gears Camshaft and balance shaft Oil pump Sump and oil pump Pick-uP ptpe . Crankshaft oil seals Pistons, connecting rods and cylinder bores . Crankshaft and bearings FlywheeUdrive plate . . . ! Enginemountings Exhaust system
30 30 3l 32 33 35 35 36 39 39 4l 42 4 45 6 50 51 53 56 57 58 63 6 (I 68 70 70 70 72 72 73 75 77 77 7E 79 79 81 83 83 83 E5 88 E9 92 99 104 t?.o
REAR AXLE
Specifications . . . Rear axle trouble shooting Description Axle shaft and bearing Drive pinion oil seal Cover plate gasket Differential and Frnal drive assembly Rear axle assembly Limited slip differential
STEERING
PART 1. STEERING TROUBLE SHOOTING and remedies Faults,causes PART 2. POWER STEERING
Specifications.....
Description Preliminary inspectionand testing

In car adjustments and minor repairs Steering wheel Steering column Intermediate shaft assemblY Power steering gear assemblY Power steering PumP PART 3. MANUAL STEERING Specifrcations Steering gear assembly . . . Steering wheel Steering column Intermediate shaft assemblY . FRONT SUSPENSION Specifications Fiont suspension trouble shooting Description Fronthub Suspension unit Lower control arm Ball joint Radius rod . . Stabiliser bar Suspension crossmember Suspension and steering angles
COOLING AND HEATING SYSTEMS

Specifications . . . Cooling system trouble shooting Heater and air conditioning trouble shooting Description Radiator Cooting fan and coolant temperature sensor Thermostat . . .
Water pump
Welch plugs Ileater unit and blower motor Heater and air conditioning controls Air conditioning
FUEL AND ENGINE MANAGEMENT

Specifications . . . Fuel and engine management trouble shooting Description Service precautions and procedures System diagnosis Fuel supply comPonents Air flow components Electronic components Cruise control
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REAR SUSPENSION.
Specifications
14 t4 l4 145 145 147 t4it 14E 148 151 151 151 153 153 r54 155 155 155 157 159 159 159 161 t6l. 161 161 162 162 163 16 t6 168 170 t70 170 173 r73 r73 t74 r74 174 175 176 177 179 179 179 1E0 180 181 183 183
Contents
Rear suspensiontrouble shooting Description . . . Shock absorbers Coil springs . . Upper suspensionarms Lower suspensionarms Stabiliser bar Panhard rod BRAKES
Specifications Brakes trouble shooting Description Master cylinder
Front disc brakes Rear disc brake assembly Handbrake lever and cable . B,rakeadjustments Hydraulic system Brake servo unit Brakepedal . ,.. ELECTRICAL SYSTEM . Specifications.. . -. . . :: : : : : : : : : : : : : : : : : : : : : lattery and charging systemtrouble shooting I*!"ry aud starting systemtrouble shooting Lighting systemtrotble shooting Turn signal lamp trouble shooting Test equipment and someapplicahons B{tery Alternator Starter motor - automatic transmission models Starter motor - manual transmission models !t"."itrg wheel and horn pad . Ignition system Switchesand controls . . . rnstrument cluster Radior/cassette lqnp unlts . Wiper motors and arms Heater blower motor Fuses,fusible links and relays Trailer wiring Wiring diagra+s BODY
Windscreen and rear glass Front doors . Rear doors Engine bonnet Luggage compartment lid . . Tailgate Radiator grille . Centre console Seats Seat belts Dashboard
183 184 184 186 185 187 187 188 189 r89 1E9 r9l l9L 194 t96 198 r99 199 200 201 ?.02 202 202 203 204 205 205 ?.M 208 212
Sump and oil pump pick-up pipe . Crankshaft oil seals Support brace . Pistons,connectingrods and cylin6sr bores . Flywheel/Drive plate COOLING AI\D IIEATING SYSTEMS Description Radiator Heater and air conditioning controls Air conditioning. .
2ffi 260 2ffi
26r
261 262 262 262 263 2&
CLUTCII AND AUTOMATIC TRANSMISSION

Clutch Automatic transmission
x5 26s
269 269 269 269 271 271 271 273 273 273 273
265
Rear axle IteerinS Front suspension
REAR AXLE, STEERING AND FRONT SUSPENSION.
REAR SUSPENSION AND BRAKES Rearsuspension. .. Brakes ELECTRICAL SYSTEM Starter motor C o m b i n a t i o n s w i :t c :h :: ::: : : :: :''' llandbrakewarninglampswitch . : : : : ::.::. Radio/Cassette To checkand renewfusesand fusible links. Windscreen wiper arms . . . . Lamp units Wiring diagrams
: ::
n4
2ts 2r8
218 218 221 ?22 223 ?26 228 228 229 23r 240
U0 ZM 248
n6 2n
276
276 27E 278 278 279 219 279 ?aa 281 ?,81 282 282 282 283 283 2M & 2U 285 2E5 28s 286 ?37 2yr NI 2gl 2E8 2E9 2E9 ?.92
B OD Y .
Front and rear doors . Tailgate
PART z.I99IMODELS ENGINE.!.. Specifications . . Description Drive belt tensioner Inletmanifold. . . Exhaust manifolds Rocker arms and pushrods Cylinder heads Timing cover Tfuningqh.io, sprocketsand balanceshaft gears Camshaft and balanceshaft . Oil pump Sump and oil pump pick-up pipe . Crankshaft oil seals Pistons,connectingrods and cylinder hores . Crankshaftand bearings. . . Exhaust system COOLING AND HEATING Specifications . . Description Radiator Thermostat SYSTEMS !.,. .... AND
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ST]PPLEMENT . PART 1. l99OMODELS
254
Camshaft and balance shaft
VEHICLE IDENTIFICATION, GENBRAL SPECIFICATIONS, LUBRICATION AND MAINTENANCE, WHEELS AND TYRES, ENG_INETUNE.TTP, ROADSIDE TROUBLB SHOOTING AND FUEL AIID ENGINE MANAGEMENT. . 2s5 Vehicle identification and general specifrcations 2s5 Lubrication and maintenance 25s Wheelsand tyres 255 Engine tune-up, roadside trouble shmting and fuel and enginemsnagement . . . 255 ENGINE 259 Specifications 2s9 pecription 259 Iocker arms and pushrods 259 Timingcover. i . .. 2s9
FUEL AND ENGIIYE MANAGEMENT EMISSION CONTROL Fuel and enginemanagement . . . Emission control
2@
CLUTCH, MANUAL TRANSMISSION, AUTOMATIC TRANSMISSIONANDELECTRICAL SYSTEM. . . . . 293 Clutch and manual transmlssion 293 Automatictransmission . r . . 293 Electrical system 293 COIYVERSION TABLES 294
Referto supplement for more information.
VEHICLE IDENTIFICATION AND GENERAL SPECIFICATIONS

1. VEHICLE IDENTIFICATION When purchasing spareparts or when registering or insuring a vehicle, it may be necessaryto quote various identification codes. The locations of these codesare as follows. The Engine Number is stamped on the front left hand side of the cylinder block. Refer to the side view of the engine in the Engine section for the exact location. The Vehicle Identification Number is located under the left hand lower corner of the windscreen. The Compliance Plate is affixed to the left hand side of the vehicle bulkhead and contains information on the vehicle make, model, date of manufacture, identification number and seatingcapacity. The Body and Option Identification Plate is affixed to the right of centre of the vehicle bulkhead and contains information on model identification. paint and trim colours, paint number, engine, transmission and axle codes,suspension options and date of manufacture. The Tyre Placard is affixed to the inside of the glove compartment or the radiator support panel and contains information of tyre size, rim size and tyre pressures. 2. GENERAL VEHICLE SPECIFICATIONS . 4 850 mm . . 4 865 mm . ... 4 896 mm ..2731 mm 2 822 mm . . I 453 mm . I 478 mm . . I 480 mm
Location of the various identification plates, refer to the side view of the engine in the Enginesection for the locationof the enginenumber. Turning circle (kerb to kerb) .... Fuel tank capacity: .!... fSedan Station Wagon Towing capacity: Standard towbar Load equalising trailer hitch Body side bracing, trailer brakes, heavy duty towbar, equalisinghitch. *Fuel consumption: L/l 00 km (City) Automatic transmission 12.5 Manual transmission I 1.5 10.4 metres ..63 litres 68 litres . 500 kg I 200 kg . . I 590 kg L/ 100 km (Highway) 8.0 7.6
Length: Sedan,exceptCalais and GLX Calais and GLX StationWagon Wheelbase: Sedan Station Wagon Front wheel track: Except Calais and GLX Calais and GLX Rear wheel track: Except Calais and GLX Calais and GLX
*The fuel consumption information is basedon tests made according to Australian Standard 2877. The actual fuel consumption obtained will depend on many factors including prevailing conditions, driving habits, load and the vehicles equipment and condition. t85 litre fuel tank optional on some models.
GENERAL INFORMATION
1. TOOLS AhrD EQUIPMENT To successfullyperform any maintenance or repair work on a motor vehicle, suitable hand tools are essential.The use of tools for other than their intended purpose or the use of incorrectly fitting tools can causedamageto the component and/or injury to the operator. BASIC TOOL KIT The following is a suggested list of tools and equipment for the majority of the maintenance and repair proceduresdescribedin this manual. Of course, not all of the tools are required for all the jobs, so it is wise 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. Assortedpliers combination, long nose,multigrip, vice grip, snap ring (internal and external). Assorted adjustablespanners. Ball pein hammer. Cold chisels. Pin punchesand centre punch. Assorted files. Scraper. Feelergauges. Torque wrench. Hydraulic jack. Chassisstands. Car ramps. Greasegun. Oil can. Oil gun. Oil filter removal tool. Funnel. Containersfor draining oil and washing components.
A comprehensive tool kit showing a wide range of general hand tools.
General Information
Assortedtest equipment - dwell tachometer, digital multimeter, timing light and test lamp. Inspectionlamp. Test lamp. Tachometer. Timing light. Digital multimeter. Piston ring compressor. Valve spring compressor. Micrometer - inside, outside, multi range. Vernier calipers. Assorted pullers. When purchasingtools, it is sound advice to select the highest quality that can be afforded, as the working life of cheapertools is often very short. Assorted measuring devices - inside and outside micrometers,verniercalipers,wire gaugesand feeler gauges. Ensurethat the tools are suitablefor the systemof bolt and nut sizing on the vehicle. The range of vehiclescoveredby this manual use a combination of metric and A/F sizes. TOOL CARE To ensurethe longestpossiblelife for hand tools, it is important that time be spent maintaining them. At the conclusionof eachjob, all tools usedshould be washedthoroughly in keroseneor similar cleaning solvent. Ensure that all dirt and greaseis removed, particularly from tools with moving parts such as pliers and adjustablespanners.The tools should then be wiped dry with a clean cloth. Measuring devices should be given particular attention as their accuracy can be affected if not properly maintained. Feeler gaugesshould be kept clean at all times and the bladesshould be wiped with an oily cloth after use to prevent rusting.
Tension wrench, piston ring compressor and valve spnng compressor.
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Slide hammer, ball ioint puller' assorted pullers and press Plates. Views showing the correct tip profiles for a bladed screwdriver. Bladed screwdrivers should not be ground to a sharp point.
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General Information
Raising a Vehicle Alwaysjack a vehicle on firm, level ground and at the specifiedjacking points. Ensure that the wheels remaining on the ground are fully chocked. After raising the vehicle, place chassis stands underneathand allow the weight of the vehicle to rest on them. Do not usebricks, blocksof wood or similar material. NOTE: Never work under a vehiclewhich is only supported by a jack. Electrical System Always disconnect the negative battery terminal when working on any electrical components. Avoid wearing metal watches, rings and chains which may short acrosslive terminals. As battery gases are explosive,keep naked flames and sparks clear of the work area.When connecting jumper leads,use extremecaution and disconnecting to avoid sparking. Electronic lgnition Systems Electronic ignition systems produce dangerous high tension voltagesin both the primary and secondary circuits which can be fatal. Exercise extreme caution when working on or near any ignition system components.Do not disconnecthigh tension leads while the engineis running. Work Area Do not run the enginein a confined space.Ensure that the work area is adequatelyventitated. Spilt oil or water should be cleanedimmediatelv to avoid the possibility of slipping. Fuel System Always disconnect the negative battery terminal when working on any fuel components.Do not smoke. Keep naked flamesand sparksclear of the work area. Do not syphon fuel using the mouth. Use a hand pump or suitablesyphon. Do not attempt to repair a fuel tank by welding it. This is an extremely hazardousprocedureand should be entrusted to a specialist. Cooling System To avoid scalding,use caution when releasingthe radiator cap on an enginewhich is at normal operating temperature. Turn the cap anti-clockwise to the first stop and allow any pressurein the system to release. When the pressureis released,remove the cap from the radiator. Brakes As asbestos is used in some brake lining material, avoid inhaling brake dust. Do not use compressed air to remove the dust. Gentle brushing with a small brush or using a vacuum cleaner with a hose attachment are the safest methods of cleaning the brakes. The above precautions also apply to the clutch plate lining material.
If tools are to be stored for any length of time, it is good policy to wipe them with an oily cloth. Bladed screwdriversshould be checked for damageto the tip. If necessary, the tip can be returned to its original profile by careful grinding. Do not grind screwdriver tips to a sharp point. Hammer headsshould be secureon their handles and shoutd be regularly checkedfor cracking or other damage. Chisels and punchesshould be checkedfor damage or 'mushrooming' of the head. Any faults should be rectified by grinding. Hydraulic jacks should be regularly checked for fluid leaks. Chassisstands and car ramps should be checkedfor damageand cracks.Any equipment that is suspectshould not be used. STORES For routine maintenance, stores of automotive oils, greasesand additives should be kept on hand. The following is a suggested list. Engineoil. Brake fluid. Manual transmissionor automatic transmission oil - automatic transmissionoil is also used in the power steeringsystem. Rear axle oil. Cooling systemcorrosion inhibitor/antifreeze. Chassisgrease. High melting point grease, for hub bearingsetc. Penetratingoil or spray. Keroseneor similar cleaningsolvent. Methylated spirits.
Oils and greasesare availablein handy pack size for do-it-yourself lube jobs.
2. PERSONAL SAFETY
SAFETY
Safetywhen working on a motorvehicle is basically a matter of commonsense. Somesafetyprecautions to prevent personal injuries are as follows.
General Information
Lifting Equipment When using lifting equipment to lift heavy components such as the engine and/or transmission, use metal slings or chain in preference to rope. If rope must be used,ensurethat it is not placedagainstsharp edgeson the component. Automotive Lubricants and Solvents Avoid prolonged skin contact with oils, greases and solvents as some can cause skin irritations and dermatitis. Exercisecaution when using cleaning solvents as many are inflammable. Do not smoke. Keep naked flamesand sparksclear of the work area. Air Compressed Never point an air hoseat another personor allow air to blow onto your skin. High pressure compressed air forced againstthe skin can enter the bloodstream and prove fatal. Suspensionand Steering Components Damaged suspension and steering components should not be welded. Many of thesecomponentsare fabricatedfrom toughenedmetals.If welded they may lose their strength or become brittle. Damaged components should be renewed. Air Conditioning Avoid disconnecting air conditioning hoses as escapingrefrigerant can causefrostbite. The refrigerant is highly flammable and when burnt, a poisonous gasis produced VEHICLE SAFETY To prevent damageto the vehicle during servicing or repair work, note the following precautions. Brake Fluid If spilt on the vehicle paintwork, brake fluid should be immediately washedaway with clean water and allowed to dry naturally, not wiped with a cloth. Catalytic Converter The following should be observed to prevent damageto 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 engineby pouring fuel into the inlet manifold. Do not operate the vehicle if the engine is misfiring. Avoid running the vehicle out of fuel. Ensurethat the engineoil is formulated to contain low phosphoruslevels. Electronic Components The electronic components of the ignition and fuel injection systemscan be damagedby the use of incorrect testing equipment.
1l
It is essentialin all tests where voltage or resrstance is to be measuredthat a digital display multimeter with a minimum l0 megohminput impedence be used. Some types of tachometers,timing lights and ignition system analysers are not compatible with certain engine electronic systems. It is therefore recommendedthat the manufacturerof the test equipment be consultedbefore using the equipment. Jump starting, or being jump started by another vehicle can causedamage to the electronic components of the vehicle. Refer to the Roadside Trouble Shooting section for the correct jump starting procedure. 3. GENERAL REPAIR PROCEDURES
SEIZED FASTENERS Seized bolts, nuts or screws should first have a liberal amount of penetratingoil applied. The fastener should be left for a period of tirne to allow the oil to penetrate and soften the corrosion which is causing the binding. Often, a sharp hammer blow to the head of the fastenercan dislodgethe corrosion and permit it to be loosened. An impact driver, which can be fitted with a socket or screwdriver bit, can be used to loosen a seizedfastener. Another method is to heat the component in which the fastener is seized. However, extreme caution should be exercised when heating aluminium alloy componentsas the melting point is much lower than that of steel. If the above methods fail to free a seized nut, carefully hacksawthrough one side of the nut until it can be split. Care should be taken that the threads of the bolt or stud are not damaged. Should a bolt or stud break below the surface of the component, it will be necessaryto use a screw extractor to remove the remaining part. Follow the screw extractor manufacturersinstructions.
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Tap and die set and assorted screw extractors.
General Information
Damaged threads can be repaired using a die nut on studs and bolts, and a tap on nuts and threaded holes in castings.If the threads of a threaoJo t tte are damaged leyon{ repair, it will be necesrurvio AriU u larger size. Alternatively, a 31d tap the hole Helicoil insert can to be usedlo restore the hole to the original thread size. STUDS The simplestmethod for removing studsis to lock tyo lyts together on the threaded section. The stud should then be able to be removed by applyirrg "r, unscrewingaction to the lower nut. Alternatively, there are various makes of stud extracting tools available. similar levers betweenthe componentsin an attempt to lever them apart. This can causeseveredamageto the sealingsurfaces, particularly if the.o-pon.nts are made of alloy compounds. . Th9 components can be separated by tapping along tLe ioint with a soft faced hu-mer or piece of wood. Before installing a new gasket, the mating surfacesshould be cleanedof a[ Iraces of old gaskel material and sealant. check that the new gasketis correct by comparing the bolt holes and passages on the componen't face with_theopeningsin the fasket. which have been stored ^ cork and paper gask-ets tor some time may suffer from shrinkage.This can be rectified by soaking the gasketin water. BEARINGS AND BUSHES If the correct equipment is not available when removing and installing bearings and bushes, it is often possibleto improvise. Bearings can often be removed from shafts by tapping alternately on opposite sides with a hammer and drift.
Using two nuts locked together to remove a stud. OIL SEALS Oil sealscan usually be removed by levering out with a flat screwdriver or other suitabie lever. care should be taken not to damage the surface of the component which the seallip runs on. Sealscan also be removeo uy inserting a number of self tapping screwsinto rhe s"il body. ii; seatcan then be withdrawn using pliers gripping- ihe self tapping screws. . Always apply a smearofgreaseor oil to the seallip prior to installation to prorride initial tuuricaiiln. unless otherwisestated,oil sealsshould ahvaysbe installed with the lip facing inwards or towards the substance to be sealed.During installation, the seallip should be protected from dimage from .tt"rp componentssuchas shaft splinesby wrapping tape iround the sharp edges. Instal the new_ seal using a wooden block, or a socket or length of tube of rh"e"ppi"p.i"tr JilL"r.r. Ensure that the sealis installed squarity or distortion and subsequentleakagemay occ.rr. If an initaliation -iirtalled 9"pJh is- not specified, rhe seal shouto u. flush with the component surface. GASKETS . Ih"," separatingmating components(ie cylinder headand cylinder block), do not rnsertscrewdriversor
A simple bush instailingtool using a bort, nut and two washers. _ Ifu pressis unavailable,bushescan be instailed by placing the bush and component betweenthe jaws of a vice and screwing the jaws together until th6 6ush is fully inserted. A vice can alio be used to rlmove bushesby using suitably sized spacersagainst either vice jaw, one bearingonthe bush ano trrittrrei on the component. This method can also be used with a G clamp. A simple removing and installing tool can be ma$e usinq a long bolt, large and small-washers, a nut and-a tubular spacer.Refei to the illustrations-for the method and applications. Rubber bushesand bushesin blind holes can be lgmoyed- gsing . a3 expanding type masonry bolt (Rawlbolt Loxin). Instal a neat fitting -u*ry6olt to the bush. Insral and tighten the boliuntillirir,ip, tt" bush.The bolt and bush can then be remov"i.*i"g u slide hammer or levers.
General Information
l3
The pressure of the greaseon the rear of the bush should force it from the hole. ROTATING THE CRANKSHAFT There are many occasionswhen it is necessary to rotate the crankshaft to a certain position. These include timing and valve adjustment and checking valve timing. To make the engine easier to rotate, remove the spark plugs. This will relieve compressionpressure. The simplest method is to use a socket or ring spanner on the crankshaft pulley nut and turn the engine in the normal direction of rotation. On vehicleswith manual transmission,the engine can be turned by selecting top gear and rolling the vehicle forward. A variation of this method is toiaise one of the driving wheelsand, with top gear selected, rotate the driving wheel in a forward direction to turn the engine. Alternatively, the engine can be brought to the desiredposition by briefly actuatingthe starter motor.
LARGE \I/ASHER
A simple bush removingtool using a bolt, nut, suitable spacerand large and small washers. . Bushesin blind holes can also be removed using hydraulic foqce, With the hole packed with grease, insert a neat fitting drift and tap the drift into the hole.
l4
LUBRICATION AND MAINTENANCE

SPECIFICATIONS CAPACITY AND GRADE Engine: Lubricant... I5W/40SF Sump capacity Withfilter. ....4.1 litres Without filter . . 3.8 litres Cooling system capacity. . . . Approximately l0litres Manual transmission: Lubricant... .ShellXGOT5/90 Capacity ....2litres Automatrc transmission: Lubricant . . . . . . . Dexron I lD Capacity Total dry refill I I litres Servicerefill ...4.8 litres Rear axle: Lubricant... ..SAE90LS Capacity . I.7 litres Steering: Steeringgear lubricant EP Semi-fluid lithium basedtype O grease Power steeringlubricant Dexron I lD Brake fluid type. Dot 3 disc brake fluid NOTE: Lubricant capacitiesshown are approximate only. The correct lubricant level should be checked at the level plug or dipstick. The specified lubricants for the manual transmission and rear axle have been changedduring production. If uncertain 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 ramps and stop the engine. (2) Raisethe rear of the vehiclewith a jack until the vehicleis level and placechassis standsunder the rear axle assembly. (3) Using a wire brush and a cloth, clean around the engine sump drain plug and the transmission and rear axle filler plugs. (4) Place a drain tin under the engine sump, remove the engine sump drain plug with the appro-
Locationof the enginesump drain plug. priate size ring spannerand allow the enginesump to completely drain. The oil will drain more freely if the cap on the rocker cover is also removed. NOTE: It is best to drain the engine sump with the oil at operating temperature. However,if the oil is hot take care to avoid scalding. When the engine sump has completely drained, instal and firmly tighten the sump drain plug. Wipe around the drain plug after installation. NOTE: Before installing the sump drain plug check the plug sealing gasket to ensure that it is serviceable.
Removing the engine oil filter using a filter removal tool.
and Maintenance Lub ri,cati,on
15
(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 oil. specified -r When satisfied that the levels are correct instal plugs anO nrmly tighten the plugs. Wipe around the with a cloth after installation.
lnstalled view of the manual transmissiondrain and filler Plugs. (5) Remove the oil filter with a filter removal toot anOallow the residual engine oil to drain into the drain tin. Smearoil onto the sealinggasketof the new fiIt., and tighten the filter by hand as Dr the til6t.ttittg inJtructions supplied with the new filter. NOTE: Before installing the new, filte.r ensuretha{ the sealing gasketfrom the old "a.nd has not come awa! frqm the old filter filter adhered itself to thefilter sealing seat on the engine.
lnstalled view of the differential filler plug'
maintenance items. automatic transmission model' view of the engine compartment showing the various
16
Lubrication and Maintenance

NOTE: If an automatic transmission is installed to the vehicle, refer to the Automatic Transmission section for the correct procedure to check and top up the hydraulic fluid level. good policy not to pour all of the specified amount of oil into the engine in one go as sometimes the amounts specffiedare only approximate. It is best to hold back at least hal-fa litre and top up to the level mark on the dipstick after the engine has beenrunfor a few minutes. (8) Check thoroughly for oil leaks at the engine sump plug and engine oil filter. (9) Referring to the following Service Schedule, lubricate and check all other items which coincide with the oil changeintervals. (10) Lower the vehicle to the ground.
(7) Using a funnel, fill the engine with the specified amount and grade of engine oil. Start and run the engine for a few minutes. Ensure that the oil pressure warning lamp goes out. Stop the engine,wait for a few minutes and check the oil level on the dipstick. If necessary, add oil to bring the level to the full mark on the dipstick. NOTE: To prevent overfilling initially, it is
2.
SERVICE SCHEDULE Weerkly I OOOkm 5 THOUSAND KILOMETRES 1 5 2 5 35 45 5 5 65 7 5 85 9 5
JOB
ENGINE (l) Checkthe oil level on the dipstick weekly or each time the fuel tank is topped up. Top up as necessary with the correct grade of engine oil. (2) Drain and refill the crankcaseand renew the oil filter initially at 5 000 km or 3 months then every l0 000 km or 6 months. NOTE: When operating under dusty conditions, predominately short trips, inner city driving, towing or high speed heavy load conditions at high temperatures, it is recommendedthat the engineoil andfilter are changedevery5 000 km or 3 months. (3) Check the condition of the engine drive belt and the position of the belt wear indicator every l0 000 km or 6 months. (4) Check the engine compartment hoses and fittings every l0 000 km or 6 months. (5) Check the condition of the exhaust system every 10 000 km or 6 months. 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 mark on the surge tank is below the join in the tank, the coolant level has been revised to approximately 25 mm abovethe join in the tank. (2) Drain, flush and refill the cooling system wl with the recommended coolant and check the condit dition of the hosesand clamps initially at 35 000 km or or 2l months then every 40 000 km or 24 months.
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Lubrication end Maintenance

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L7
THOUSAND KILOMETRES
(3) Pressure test the cooling system and the surgetank cap every 10 000 km or 6 months. (4) Clean the outside of the radiator and if applicable,the air conditioning condenser initially at 35 000 km or 21 months then every 40 000 km or 24 months. FUEL AND ENGINE MANAGEMENT (1) Renew the air cleaner element initially at 35 000 km or 21 months then every 40 000 km or 24 months. NOTE: If the vehicle is operating in dusty conditions, renew the air cleaner element every20 000 km or I2 months. (2) Renewthe fuel filter initially at 35 000 km or 2l months then every 40 000 km or 24 months. (3) Check the oxygen sensoroperation initially at 35 000 km or 2I monthsthen every40 000 km or 24 months. (4) Check the position and security of the crankshaft sensorevery l0 000 km or 6 months. (5) Check all the vacuum hoses and fittings initially at 15 000 km or 9 months then every 20 000 km or l2 months. CLUTCH AND MANUAL TRANSMISSION ( l) Lubricate the clutch cableinitially at 25 000 km or I 5 months then every20 000 km or l2 months. (2) Checkthe transmissionfor oit leaksinitially at I 5 000 km or 9 months then every l0 000 km or 6 months. (3) Check the transmissionoil level initially at I 5 000 km or 9 months then every 20 000 km or t 2 months. NOTE: If the vehicle is usedfor caravan or trailer towing, change the manual transmission ail every40 000 km or 24 months. AUTOMATIC TRANSMISSION (1) Check the fluid level on the dipstick weekly or each time the fuel tank is topped up. (2\ Renew the automatic transmissionfluid and the filter initially at 35 000 km or 21 months then every 40 000 km or 24 months. (3) Renew the automatic transmission filter every 75 000 km or 45 months. NOTE: If the vehicle is usedfor caravan or trailer towing or inner city driving with long idling periods, the automatic transmission fluid and filter should be renewed every 20 000 km or I2 months.
18
JOB
Lubrication and Maintenance

THOUSAI\TDKILOMETRES
(3) Lubricate the transmission shift linkage initially at 25 000 km or \5 months then every40 000 km or 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 or 6 months. (2) Check the rear axle oil level initially at 15 000 km or 9 months then every 20 000 km or l2 months. (3) If the vehicle is equippedwith a limited slip differential, change the rear axle oil at 5 000 km or 3 months. NOTE: If the vehicle is usedfor towing or high speed heavy load conditions at high temperatures,change the limited slip differential oil every 20 000 km or 12 months. The limited slip dffirential can be identified by the red/brown level Plug. STEERING (1) Check the fluid level in the power steering reservoir weekly or each time the fuel tank is topped up. (2) Check the steering gear and linkage for security,damageand leaks initially at 15 000 km or 9 months then every 10 000 km or 6 months. NOTE: Check the steeringgear and linkage for security, damage and leaks every 5 000 km or 3 months if the vehicleis operatingon unsealedroads. FRONT SUSPENSION ( I ) Inspect the front suspensioncomponentsfor wear or leaksinitially at 15 000 km security,damage, or 9 months then every l0 000 km or 6 months. NOTE: Reduce the above period to every 5 0a0 km or 3 months if the vehicle is operating on unsealedroads. (2) Repack and adjust the front hub bearings initially at 25 000 km or I 5 months then every40 000 km or 24 months. BRAKES (l) Check the fluid level in the master cylinder reservoir weekly or each time the fuel tank is topped up. (2) Inspect the brake pads and discs for wear initially at I 5 000 km or 9 months then every l0 000 km or 6 months. (3) Inspect the handbrake shoe linings and drums for wear initiallv at 35 000 km or 2l months
Lubrication und Maintenance

Weerkly I OOOkr then every 40 000 km or 24 months. NOTE: Reduce the aboveperiod to 20 000 km or 12 months if the vehicleis operating on unsealedroads. (4) Drain, refill and bleed the hydraulic system initially at 35 000 km or 2l months then every 40 000 km or 24 months. (5) Inspect all the hydraulic brake lines for damageor chafing paying particular attention to the flexiblehosesinitially at l5 000 km or 9 months then every 10 000 km or 6 months. (6) Check the handbrake operation initially at I 5 000 km or 9 months then every l0 000 km or 6 months. Adjust as necessary. ELECTRICAL SYSTEM (1) Check the battery electrolytelevel initiaily at 5 000 km or 3 months then every l0 000 km or 6 months. (2) Renew the spark plugs initially ar l5 000 km or 9 months then every 20 000 km or 12 months. (3) Check the high tension lead resistance and continuity initially at 75 000 km or 45 months then every 80 000 km or 48 months. BODY (1) Lubricatethe door hinges,locks,strikersand check strapsinitially at 15 000 km or 9 months then every 20 000 km or l2 months. (2) Inspect the seatbelts and check the seatbelt operation initially at 15 000 km or 9 months then every 20 000 km or l2 months. EMISSION CONTROL (1) Checkthe operationof the PCV valve initially at 35 000 km or 2l months then every40 000 km or 24 months. (2) Check the charcoal canister for damage or leaksinitially at 45 000 km or 27 months then every 40 000 km or 24 months. (3) Check the condition and attachment of all the emission control hosesinitially at 15 000 km or 9 months then every 10 000 km or 6 months. WHEELS AND TYRES (l) Inspect the wheelsand tyres, including the spare wheel for wear and damage, and torque the wheel nuts every l0 000 km or 6 months. (2) Check the tyre pressures, when the tyres are cold, weekly. Reducethis period to dai[y if the vehicle is constantly driven on long trips or on rough roads. (3) Rotate the wheelsto equalisethe tyre wear as required.
o o
l9
JOB
THOUSAND KILOMETRES 5 1 5 25
3s 45
5 5 65 7 5 8 5 9 5
o o
20
WHEELS AND TYRES

SPECIFICATIONS *TYRE PRESSURES Up to three passengers ... 180 kPa Fully loaded . . 240 kPa *Increasethe tyre pressureby 30 kPa if the vehicle is consistentlydriven at high speed. TORQUE WRENCH SETTINGS Wheelnuts. . . 125 Nm NOTE: Always refer to the tyre placard located on the inside of the glove compartment or on the radiator support panel for tyre and wheelsizesand inflation pressures. Refer to local regulations for maximum wheel and tyre sizes if installing optional equipment. 1. HOW TO CHAI{GE A WHEEL (l) Ensure that the vehicle is level, on firm ground; clear from any passingtraffic and contains no passengers. (2) If necessary switch on the hazard flashers. (3) Place the transmission in the P (Park) position on automatic transmissionmodelsor reversegear on manual transmission models. (4) Firmly apply the handbrake. (5) On Sedan models, remove the spare wheel, jack and wheel spanneras follows: (a) Raise the luggagecompartment lid and remove any looseitems that obstruct access to the spare wheel. (b) Releasethe retaining strap buckle and pull the retaining strap away from the sparewheel. (c) Where installed, remove the spare wheel cover. (d) Lift up and remove the wheel spanner and the spare wheel from the luggagecompartment. (e) Using the wheel spanner,lower the jack and remove the jack from the storagebracket. (6) On Station Wagon models, remove the spare wheel,jack and wheel spanneras follows: (a) Open the tailgate, roll back the luggage compartment mat and fully open the spare wheel compartment cover.
Chock the front and rear of the wheel diagonally oppositethe wheel being changed. (b) [Jnscrew the spare wheel retaining nut and remove the sparewheel from the vehicle. (c) Remove the wheel spannerfrom the storage clips. (d) Using the wheel spanner,lower the jack and remove the jack from the storagebracket. (7) When changing a wheel always chock the wheel diagonally opposite to the wheel being removed. Ensure that the wheel is chocked at the front and rear. (8) Where full wheel trims are installed, remove the wheel trim by inserting the bladed section of the wheel spannerin betweenthe outer edgeof the wheel trim and the wheel. Pry the wheel trim off the wheel, using the wheel as a levering point. Repeat the above procedure at severalpoints around the wheel trim. Where centre wheel trims are installed, gently lever the centre trim off the wheel by placing the bladed end of the wheel spanner into the slot in the trim. (9) Instal the wheel spanner to a wheel nut in such a manner that the bar end of the spanner is horizontal and on the left hand side of the wheel. Apply pressureto the end of the spanner in an anticlockwisedirection and slackenthe wheel nut approximately half a turn. Carry out the above procedureon the remaining wheel nuts.
Wheelsand Tyres
2r
(16) Using the wheel spannerto operatethe jack, lower the vehicle to the ground. (17) Using the wheel spannertighten the wheel nuts in a diagonal sequence.It will be necessaryto repeat the above procedure several times until the wheel nuts are securelytightened. ( I 8) Remove the chocksffom the oppositewheel. (19) Instal the wheel,jack and wheel spannerto their original storagepositions. NOTE: Repair the flat tyre or damaged wheel as soon as possibleand checkthe tvre pressureon the wheeljust installed. View of the jack correctly positioned to the rear jacking point. (10) Instal the jack to the relevantjacking point under the body sill panel. NOTE: Thejacking points are identrfied by cutouts in the underbody sill panel. The cutout must be located in the slot of thejack head. (l l) Using the wheel sBanner,raise the vehicle slightly and check that the jack base is flat on the ground and that the jack is vertical. (12) Ensuring that the jack is correctly positioned, raise the vehicle so that the wheel and tyre clear the ground. Allow enoughclearance betweenthe tyre and the ground for the sparewheel to be installed. NOTE: Under no circumstancesget under the vehiclewhilst thejack is the only means af support. (13) Unscrew the wheel nuts and remove the wheel. (14) Instal the sparewheel to the hub and loosely instal the wheel nuts. (15) Using the wheel spannertighten the wheel nuts as much as possible.
Tighteningthe wheel nuts using the wheel spanner. 2. TYRE WEAR TROUBLE SHOOTING
ABNORMAL WEAR ON BOTH SIDES OF TREAD (1) Under inflation of the tyres: Check and inflate to the recommendedpressures. (2) Overloading: Reducethe maximum loading.
View of the jack correctly positioned jacking point.
to the front
ABNORMAL WEAR IN CENTRE OF TREAD (l) Over inflation of the tyres: Checkand reduce to the recommendedpressures.
22
Wheelsand Tyres
(3) Excessiveplay in the hub bearings: Check and adjust or renew the hub bearings. (4) Excessiveplay in the front suspensionball joints: Check and renew the ball joints. LIGHTLY WORN SPOTS AT CENTRE OF TREAD (l) Static unbalance of the wheel and tyre assembly:Check and balancethe wheel and tyre assemblv. (2) Radial run-out (eccentricity) of the wheel: Check and renew the wheel. FLAT SPOTS AT CENTRE OF TREAD (l) Repeatedse' ire brake application: Revise driving habits. (2) Lack of tyre rotation: Periodically rotate the wheel and tyre assemblies. HEEL AND TOE WEAR (SAWTOOTH EFFECT) (1) Overloading:Revisethe maximum loading. (2) High speeddriving: Avoid as far as possible. (3) Excessive braking: Revise driving habits. FEATHERED EDGE ON THE SIDE OF TREAD PATTERN Front Tyres (l) Sharpinside 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 steeringarm or tie rod and renew.
ABNORMAL WEAR ON INSIDE OF TREAD Front Tyres (1) Insufficient camber angle: Check the front end alignment. (2) Saggingfront coil springs:Check and renew the faulty springs.. (3) Looseorworn front hub bearings:Checkand adjust or renew the hub bearings. (4) Bent stub axle: Check and renew the faulty components. (5) Loose or worn suspensionarm components: Check and renew the faulty components. Align the front end.
Rear Tyres ( I ) BeRtrear axle housing:Check and straighten or renew the axle housing. (2) Bent suspension arm: Check and renew the arm. suspension 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 recommendedreplacementsprings. 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 wheel and tyre assembly:Check'and balancethe wheel and tyre assembly. (2) Lateral run-out of the wheel: Check and straightenor renew the wheel.
Rear Tyres ( 1) Worn suspension arm bushes: Check and renew the bushes. (2) Suspensionarm bent: Check and renew the arrn. suspension (3) Bent rear axle housing: Check and straighten or renew the axle housing. 3. CARE AND MAINTENANCE
STEEL WHEELS Steel wheels should be regularly cleaned of all foreign matter, suchas dirt and mud. If foreign matter is allowed to build up it will affect the balanceof the
Wheelsand Ttres
J
23
,,'-t ,;,{ ii:,H gi#i?1/e'
wheel and may causevibrations and uneventyre wear. If the paint has beenchipped or scratchedit should be touched up as soon as possibleto prevent rust. Any minor damageto the wheel rim can usually be removed using a suitable hammer after the wheel has been removed from the vehicle. However, any major rim damage or buckling of the wheel will necessitate the renewal of the wheel. It is good policy to occasionally remove the wheels from the vehicle and inspect them for damage,cracksor corrosion. ALLOY WHEELS Alloy wheels should be regularly cleaned of all foreign matter, suchasdirt and mud. If foreign matter is allowed to build up it will affect the balanceof the wheel and may causevibrations and uneventyre wear. The alloy wheelsare coatedwith a clear protective finish. Do not use abrasive cleaner, polishing compounds,steelwool etc. when cleaningthe wheels.Only mild soap and warm water are recommended.Alloy wheels are particularly susceptibleto corrosion damage particularly if exposedto salt water. Alloy.wheels being relatively soft in comparison to steel are easily scuffed,however this will not affect the serviceability of the wheel. Where major damage has been sustainedto the wheel it should be renewed. Buckling or cracking of an alloy wheel cannot be repaired. Tyres The depth of the tyre tread groovesshould never be allowed to be lessthan 1.5 mm before the tyres are renewed.The tyres should also be renewedwhen any damage,whether it be internal or external, is evident. Minor puncturesor leaksshould be properly repaired. Refer the tyre to a tyre specialistif there is any doubt about the serviceabilitv of the tvre.
When the tyre tread groove depth is less than 1.5 mm, or when the tyre is worn to the point where the tyre wear indicatorsare level with the tread surface, the tyre shouldbe renewed. The tread, tread groovesand sidewallsshould be regularly inspectedfor foreign matter, ie: nails, stones etc. Where foreign matter is detected it should be removed from the tyre and if necessary the puncture repaired. The tyre valves should always have the caps installed, be regularly cleaned of dirt or dust and be inspected for wear, leaks or damage every time the tyre pressures are checked. Regularly inspectthe tread of the tyres for signsof uneven wear, if uneven wear is apparent refer to the heading Tyre Wear Trouble Shooting in this section for possiblecauses and cures.If the uneven tyre wear is noticed early enough,the causecorrectly identified and the necessaryrepair or adjustment carried out, the life of the tyre should be extended. To preservetyre life it is good policy to periodically have the front wheels balancetl and the front end alignment checked on a reliable wheel alignment machine. The air pressurein the tyre is probably the single most important aspect of tyre care. Too little or too much pressure in the tyre can cause rapid wear or complete failure through overheating.Where possible the tyre pressuresshould be checked and adjusted when the tyres are cold. As a rule, different tyre types, tread patterns or sizesshould 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 vehicle behaving erratically under certain conditions. IJnder no circumstancesmix radial ply and conventional ply tvres.
rl
WITHOUT SPARE I
244'LDs ffi m
ffi ffi
LMLM
WITHSPARE
Tyre rotation diagram. lf desired, the wheel and tyre assemblies may be rotated in the manner shown.
24
ENGINE TUNE.UP
CAUTION: To prevent severeelectrical shock, extreme c&re must be taken wl working on or near the electronic ignitian systemas dangeroushigh tension volta. are produced in both the primary and secondarycircaits.
1. TUNE-UP SPECIFICATIONS
.... L-6-5 -4-3-2 Firing order Sp ar k plug: Type . AC R44 LTS6 1.5 mm Gap . T i g h t e n i n gt o r q u e . . . ... 30 Nm * Engine idle s pee d i n N e u t r a l. . . . .700* 100rpm * Bas e ignit ion t im i n g . . . 1 0 " B TD C Hi g h t ens ion lead re si s t anc elim it : L7 kO ....689 kPa C o m p r e s s i o np r e s s u r e( m i n i m u m ) Dri v e belt def lec t i o n S e l f a d j usti ng * N on adjus t able 2. TUNE.UP OPERATIONS
recommendedintervals of 40 000 km. This distanceis only a guide for normal operating conditions and should be reducedaccordingly if the vehicle is operating under extremely dusty conditions. NOTE: Paper air cleaner elements should not be washedin petrol or any other type of cleaning solvent. If the element has been washedin solvent or has becomeoil soaked it should be discarded and a new element installed. (1) Release the clamp securing the air intake hose to the upper air cleaner housing. (2) Disengagethe clips retaining the upper air cleanerhousing to the lower housing. (3) Raise the upper housing and remove the air cleanerelement from the air cleanerhousing. Installation is a reversalof the removal procedure with attention to the following points: (1) When renewingthe air cleanerelement,use only the manufacturersspecifiedelement. (2) Clean the air cleaner upper and lower housings thoroughly taking care not to allow any dirt to enter the air intake hose. (3) Ensurethat the air cleaner element is seated correctly before installing the top housing. TO RENEW FUEL FILTER (1) Raise the rear of the vehicle and support it on chassisstands. (2) Depressurisethe fuel system using the following procedure: (a) Remove the fuel pump fuse from the engine compartment relay housing. (b) Start the engine and allow it to idle until the engine stalls. Operate the starter motor for ten seconds to ensurethat the fuel pressure hasbeenrelieved. (3) Disconnect the negativebattery terminal. (4) Placea fuel resistantcontainer under the fuel filter. (5) Releasethe hose clamps securing the fuel hosesto the filter, disconnect the hosesand remove the filter. Installation is a reversalof the removal procedure with attention to the following points:
Special Equiprnent Required: To Test Compression - Compression gauge TO SERVICE AIR CLEANER The air cleaner is equipped with a paper type element. The element should be renewed at the
The air cleaner should be serviced at regular intervals.
Engine Tune-up
TO TEST COMPRESSION
25
(1) Start and run the engine until the normal operating temperature is obtained. (2) Switch off the engine and disconnect the high tension leads from the spark plugs ensuring that the leadsare disconnectedby pulling on the boots and not the high tension leads. (3) Ensure that the area around eachspark plug is clean to prevent foreign matter entering the cylinders and remove all the spark plugs. (4) Remove the fusible links marked ENG. INJ and ENG. COMP from the fusible link housing located adjacent to the relay housing. (5) Instal a suitable compression gauge to number one spark plug hole. Refer to the compression gaugemanufacturersinstructions if necessary.
Remove the fuel pump fuse when depressurising the fuel system.
Remove the ENG INJ and ENG COMP fusible links prior to performing a compression test.
of the Installedview of the fuel filter, located forryvard rear axle on the right hand side of the vehicle. ( I ) Instal the fuel filter with the direction arrow facing towards the engine. (2) Ensure that the fuel clamps are correctly positioned and tightened securely. (3) Instal the fuel pump fuse. (4) Test the fuel system for external leakageas described in the Fuel and Engine Management section. (5) Start the engine and increase the engine speedabove 3 000 rpm to reset the idle air control valve, thereby controlling the engine idle speed. On models equipped with a radio cassetteusing PIN security, enter the PIN code as describedunder the Radio/Cassetteheading in the Electrical System section.
Checking the compression pressure using a compresston gauge.
26
Engine Tune-up
(6) Have an assistantfully depressthe throttle pedal and operate the starter motor. Observe the compression gauge and stop the engine when the gaugehas reachedthe highest reading. (7) Record the reading and check the compression of the remaining cylinders in the samemanner. (8) Compare all the readings taken. Variation between the highest and lowest readings should not exceed 70 kPa and all readings must be above 689 kPa. (9) If a low reading is taken on one or more cylinders the trouble may be isolated as follows: (a) Inject a small amount of engine oil into the spark plug hole of the low reading cylinder ensuring that the oil is evenly distributed within the cylinder. (b) Repeat the compressiontest on the cylinder concerned. A substantial increase of compression pressure indicates faulty or worn piston rings, piston or cylinder. No increaseof compressionpressureindicates burnt, obstructed or sticking valves or a leaking or blown head gasket. TO SERVICE HIGH TENSION LEADS ( I ) Checkthe leadsfor perishingor crackingand renew as required. Never attempt to repair defective carbon impregnated core leads. The leadsmay be cleanedusing a cloth moistened with kerosene,then wiped completely dry. Using an ohmmeter, check the electrical resistance of the high tension leads as follows: (a) Disconnect one high tension lead at a time from the spark plug and the ignition coil. When disconnecting the high tension lead from the spark plug pull on the boot, not the high tension lead. (b) Connect the ohmmeter terminals to each Overhead view showing the cylinder number sequenceand the correct high tension lead routing. end of the high tension lead and measurethe resistance. If the resistanceexceedsSpecifications,renew the high tension lead. (2) Check the coil terminals for corrosion or burn marks and clean as necessary. (3) When renewing a high tension lead ensure that the lead is routed correctly and fastenedto the retainers to prevent possible chafing, burning or misfiring. (4) When connectingthe high tension lead to the spark plug ensure that the terminal is connected securelyto the spark plug and the boot has not moved on the lead. Also ensure that the metal locating tabs are completely seatedover the hexagonalrim of the spark plug. TO SERVICE SPARK PLUGS The spark plugs should be renewedat intervals of 20 000 km. Remove the high tension leads, pulling on the boot only, to prevent damageto the leads. Before removing the spark plugs, ensurethat the areaaround eachspark plug is cleanto prevent foreign matter entering the cylinder when the plug is removed. Spark plugs removed from an engine in good mechanical condition should have light powdery deposit ranging from light brown to greyish tan in colour. After considerableservice the electrodeswill show signsof wear or normal burning.
Check the high tension lead terminals for corrosion or burning.
Engi,neTune-uP
27
Black damp deposits can be caused by excessive oil consumption or incorrect plug type. Spark plugs in this condition are usually not firing.
ELECTRODES
Spark plug with burnt electrodesand white blistered possiblydue to incorrectplug type, loose appearance, plug or the enginerunningtoo hot. Due to the type of ignition system,normal spark plug wear may be indicated by the spark plugl- from bnJ Uant having worn centre electrodes while the plugs from the other bank have worn outer electrodes. ^ -Spark plugs showing a thick black oily deposit indicite arrenfine with worn piston rings or possiblya spark plug with the incorrect heat range has been installed. Spark plugs showing a white or yellowish deposit indicite sustiined high speed driving or possibly spark ptugs with a heat range that is too high have b-eeninstilled, particularly when these deposits are accompaniedby blistering of the porcelain and burning of the electrodes.
Cutaway view of a spark plug showing a crack in the insutator nose which can be caused by exerting pressure against the centre electrode when adiusting the gap. The other crack shown on the insulator is caused by tilting the Plug sPanner.
When plug electrodes are eroded to this degree the spark plug can be considered worn out and should be replaced using a plug of the recommended heat range.
28
Engine Tune-up
Checking the spark plug electrode gap with a wire gauge. Before installing the spark plugs measurethe gap between the electrodes, preferably with clean wire gauges. If wire gauges are unavailable use clean feeler gauges. Move the side electrodetowards or away from the centre electrodeto obtain the correct gap. Screwthe plugs into the cylinder head finger tight and use a torque wrench to tighten the plugs to the specified torque. TO ADJUST DRIVE BELT The drive belt tension is controlled by a tensioner assemblywhich maintains the correct tension on the drive belt and compensates for wear and stretch. The tensionerassemblyis equippedwith a tension indicator that shows when the tensioner is exerting minimum pressureon the drive belt due to excessive belt wear, necessitating renewal of the drive belt. Check the drive belt for cracks or separation between the rubber and the fibre belt by examining the portion of the belt that is positioned around the water pump pulley. Examine the drive belt for cracks or deterioration where the drive belt is positionedaround the water pump pulley. NOTE: If the drive belt is slipping and the tensionindicator is within the normal operating range, removethe drive belt and check that the pulleys operated by the drive belt including the tensioner pulley rotate smoothly without binding. If no fault can befound renew the drive belt tensioner as described in the Engine section. TO RENEW DRIVE BELT (1) Place an 18 mm ring spanneron the drive belt tensioner pulley bolt and rotate the pulley assembly anti-clockwise, raising the pulley away from the belt. (2) Hold the pulley in this position and remove
Installed view of the drive belt tensioner showing the tension indicator. Renew the drive belt when the indicator is outside the normal operating range.
Correct method of releasing the drive belt tensioner. Rotate the pulley assembly in the direction illustrated.
Engine Tune-up
29
( 1) When installing the drive belt ensurethat the groovesin the drive belt and engine pulleys align. (2) Rotate the tensionerpulley and position the drive belt onto the water pump pulley. (3) Start the engineand checkthe drive belt and tensioner operation. NOTE: It is normal for the drive belt to emit a squeak when the engine is started or stopped. TO ADJUST IDLE SPEED The engine idle speedis controlled by the idle air control (IAC) valve and is not adjustable. If the idle speedis incorrect, check the IAC valve for correct operation as described in the Fuel and Engine Management section. Schematic diagram showing installation. the drive belt TO CHECK AND ADJUST IGNITION TIMING The ignition timing is controlled by the electronic control unit, eliminating the need for adjustment to the ignition timing. NOTE: If, at the completion of the engine tune-up, there ,s reason to suspect that the engine is not performing satisfactorily, refer to the Engine and Fuel and Engine Management sections.
the drive belt from the water pump pulley. Return the pulley to its previous position. (3) Disconnect the drive belt from the engine pulleys and remove the drive belt. Installation is a reversalof the removal procedure with attention to the following points:
30
ROADSIDE TROUBLE SHOOTING

CAUTION: To prevent severeelectrical shock extreme care must he taken wl working on or near the electronic ignition systemas dangeroushigh tension volta) areproduced in hoth the pyl*ary and secondarycircuits. Seetext for precautiont notes.
This section deals with the common causesof enginefailure to start, as inevitably there will come a time when every driver will experiencethis problem and will thereforeneed to call upon his own resources to rectify the trouble. Roadside breakdowns other than engine failure can be identified by referenceto the Trouble Shooting section on the particular component affected. 1. TROUBLE SHOOTING Trouble shooting is only a processof elimination and provided the procedure is carried out correctly and systematicallyan accuratediagnosisof the trouble can be made in the minimum amount of time. For an internal combustion engine to run there are three basic requirements, these are ignition, fuel and compression.There are other factors of course but as a rule an engine's failure to start can be attributed to a fault in one of thesethree systems. Reports from field engineersof motoring organisations prove that the biggest percentageof engine breakdowns are in the order of ignition or electrical failure first, followed by fuel, with mechanical or compressionfailure the least common. Should the engine fail to start, first check that there is adequatefuel in the tank and if so, carry out the following checking procedures in the order described. SERVICE PRECAUTIONS To protect the catalytic converter, the following precautionsshould be observed: (1) Do not operatethe vehicle on leadedfuel. (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 phosphoruslevels. TO JUMP START A VEHICLE NOTE: Jump starting a vehicle can be dangerousif the procedure describedbelow
View showing the correct jumper lead connections use leads when iump starting a vehicle. lf available equippedwith a surge protectiondeviceas shown in the illustration. Jumper leads courtesy of Comproof Sales. ,s not performed coruectly. If any doubt of that the services it is recommended exists, a competentmechanicbe obtained. The range of vehicles covered by this manual is equippedwith complex electronic circuitry which can be damaged by toltage surges. These voltage surges can be generated when jump starting, or being jump started by, another vehicle. If available use jumper leads equipped with a surge protection device and follow the lead manufacturers instructions carefully, particularly regarding the connectionand disconnection of the leads. (1) Ensure that the booster battery is 12 volts and the negativeterminal is earthed. (2\ Ensurethat the vehiclesare not touching and on both vehicles that the ignition and all accessories are switched Off. (3) Ensurethat the transmissionon both vehi-
RoadsideTrouble Shooting
cles are in Park or Neutral and the handbrakes are firmly applied. (4) Remove the vent caps from the battery and check the electrolyte level. Replenish with distilled water as necessary. (5) Place the vent caps loosely over the cell apertures. (6) Connect one end of the red jumper lead to the positive (+) battery terminal of the booster battery and the other end of the red lead to the positive (+) battery terminal of the discharged battery. NOTE: The battery emits hydrogen gas which is explosive.Do not exposethe battery to nakedflames or sparks. Do not lean over the battery when connecting the jumper leads. Do not allow the ends of the jumper leadsto touch one another or any part of the engine. (7) Connectone end of the blackjumper lead to the negative (-) battery terminal of the booster battery and the other end of the black lead to a good earthing point on the engine of the vehicle with the dischargedbattery. NOTE: Do not connect the jumper lead directly to the negative(-) battery terminal of the dischargedbattery. (8) Start the engine on the vehicle with the booster battery and run the engine at a moderate speed. (9) Start the engine on the vehicle with the dischargedbattery. (10) If possible, leavethe engines of both vehicles running for l0 minutes. (11) Disconnectthe jumper leads in the reverse order of the sequence in which they were connected.
3I
Remove all dirt and corrosion from the battery' terminals. that the ignition switch is in the Offposition to prevent damage to the electroniccontrol unit. If the enginedoesnow start, increasethe speedto 3 000 rpm for l0 secondsallowing the idle air control valve to reset. On models equipped with a radio cassetteusing PIN securityn it will be necessary to enter the PIN code as describedunder the Radio/Cassette heading in the Electrical Systemsection. (b) Check that the earth lead from the battery to the engine or body frame is not broken and that the connectionsare clean and secure. (c) Check that the lead from the battery to the starter motor or starter solenoid is intact and has a clean and secureconnection. (d) Where necessary carry out repairs to (b) and (c). Again carry out the check procedure. Should the starter motor still not operate or the lamps not illuminate, one or more of the following faults may be the cause: No starter motor operation or lamps: Battery flat or defective. Lamps illuminate but no starter operation: Starter motor drive jammed in mesh with flywheel ring gear. Starter motor or solenoid defective. Ignition/starter switch faulty. On automatic transmission models, faulty neutral safety switch. Lamps dim and starter operation sluggish: Dischargedbattery or fault in starter motor. Battery flat due to broken fan belt or defective alternator. Faulty battery due to cell breakdown. If the battery and starter motor operation proves satisfactorybut the engine still fails to start, continue as follows: NOTE: Electronic ignition systemscan produce dangerously high voltagesin both the primary and secondary circuits. For this
2.
TO CHECK IGNITION AND ELECTRICAL SYSTEM
(l) Switchon the ignition and checkfor warning lamp illumination on the dashboard. (2) Operatethe starter and checkthat the srarrer rotates the engine at a steadyspeed. (3) Switch on the headlampsand check for good light intensity. Should the lamps not illuminate or the starter motor not turn the engine, carry out the following steps: (a) Disconnect the battery terminals and clean both terminals and posts. Connect the terminals and where applicable tighten firmly but not excessively. NOTE: When disconnecting or connecting the battery terminals or fusible linl<sensure
32
Securely earth the body of a test spark plug to check for spark at the high tension leads. reason, extreme care must be taken when performing thesechecks. When disconnecting the wiring from any component ensure that the ignition switch rs Off and the negativebattery terminal is disconnectedto prevent damage to the solid state circuitry. (1) Open the electrodegap of a serviceable spark plug to 6 mm. Securelyearth the spark plug using a jumper lead or by tying the plug to an earthed engine component. (2) Disconnect the high tension lead from a spark plug and connect it to the test spark ptug. (3) Have an assistantoperate the starter motor. (4) Check that a spark, if any, jumps the gap on the test spark plug.
Check that all electrical connectionsare clean and secure. (5) If the spark is sufficientbut the engineis still not operating satisfactorily, remove the spark plugs and check the condition and electrode gap as described in the Engine Tune-up section. (6) If there is no spark, check the high tension leads to ensure that they are dry and that the insulation is not crackedor perished.Check the ends of the leads for burning or corrosion. Refer to the Fuel and Engine Management section for further ignition systemchecks. (7) Ensure that all electrical connections and earth leadsare clean and secure. NOTE: On Calais models ensure that the anti-theft system has not been accidently turned on. If necessaryturn the override switch, located in the glove box, counter clockwise to turn the system off, 3. TO CHECK THE FUEL SYSTEM
Due to the complex nature of tle EFI system,it is recommendedthat should the following checksprove satisfactorybut the engine fails to start, referencebe madeto the Fuel and EngineManagement sectionofthis manual or an authorisedworkshopbe consulted. (l) Check that the fuel tank contains a reasonable amoulntof fuel. (2) Squeezethe fuel supply hose, located adjacent to the brake servo unit, between the thumb and forefinger. (3) Turn the ignition switch On. The fuel pump relay will be heard to activate and the fuel supply hose will pressurise.The pressurewill be most noticeable when the fuel pump relay deactivateswithin 2 seconds of operation.
NOTE: If the fuel pump relay fails, power will be supplied to the fuel pump via the oil pressureswitch. When starting the engine,
the fuel pump will not operateuntil the oil pressure is sufficient to extinguish the oil pressurewarning lamp. Therefore it will be necessary to operate the starter motor for a longer period than usual to start the engine.
33
(4) Check that all fuel supply connections are secure. (5) Remove the spark plugs and checkfor petrol Thoroughly cleanand dry saturation of the electrodes. the spark plugs before replacement. (6) If flooding is suspected,turn the ignition switch to the Start position while maintaining the throttle in the wide open position. (7) Check the fusible links and ensure that all wiring connectorsare clean and secure.
Squeeze the fuel supply hose to check for fuel pump operation.
Check the MAP sensor vacuum hose for splits, obstructions and a secure connection.
Check for leaks at all fuel line connections.
(8) Ensure that the MAP sensorvacuum hoseis securely connected and is not split, perished or obstructed. NOTE: If the Check Engine warning lamp on the instrument cluster is illuminated, a fault exists in the fuel and engine management system.Refer to the Fuel and Engine Management section for information on systemfaults.
4.
TO CHECK THE MECHAhIICAL SYSTEM
Ensure that the fusible links are intact and the associated wiring is securely connected.
The following check procedure assumes that the starter motor will rotate the engine.If not, on manual transmission models depress the clutch pedal to disengage the enginefrom the transmissionin casethe fault lies within the transmission. If the starter will not rotate the engine it will be necessary to remove the starter motor and attempt to
34
turn the engihe over manually. This will establish whether the fault lies with the starter motor, which could be jammed or defective, or with the engine, which could be seized or have broken internal components such as connecting rods, pistons and crankshaft etc. If the starter motor is not at fault and the engine will not rotate manually, refer to the Engine Mechanical Trouble Shooting heading in the Engine section. It should be noted that the only way that cylinder compression can be accurately tested is with a compression gauge. The method described in the following procedure is only intended to give a rough indication when checking for causesof enginebreakdown. (1) Check the coolant surge tank for loss of coolant. If coolant loss is evident, check carefully for any indication of external leakage and remove the engineoil dipstick and check for emulsification of the oil. When oil mixeswith water it will turn creamyand the oil level will also have increased. If the oil is emulsified, proceedto operation (5). (2) Remove the fusible links marked ENG.INJ and ENG.COMP from the fusible link housing located adjacent to the relay housing. (3) Remove all of the spark plugs except one. (4) Have an assistantoperatethe ignition switch to rotate the engineand listen to the sound that the engine makesas it is being turned over. Move the spark plug to a different cylinder and repeat the test. By performing the same test on all cylinders, a rough comparison of compression can be made to deterrnine if there is any loss of compressionin any cylinder. This will be apparent by the different sound the engine will make as it is being turned over. Normally, if the compression is satisfactory the cylinder with the spark plug installed will create a resistanceto the rotating engine. However, if the compressionis low in a particular cylinder, the enginewill turn over easilyand smoothly when that spark plug is in place. (5) If the above checks show a loss of coolant and this is present in the engine oil or on the spark plug, one or more of the following faults may be the cause: Blown cylinder head gasket Cracked cylinder or cylinder head Warped cylinder head and/or cylinder block faces If the compression check showed any weak or inconsistent compressions,in addition to the above faults any of the following could also be the cause:
Check the engine oil for correct level and dilution on the dipstick. Broken piston(s) Burnt or broken valve(s) Provided the previous checksdo not indicate an internal leakageof coolant, proceed with the following: (6) Remove a rocker cover and, again with an assistantoperating the ignition switch, check that all the valves open and close as the engine turns over. If the valves do not operatewith enginerotation, one of the following faults may be the cause: Broken camshaft drive chain or a shearedcrankshaft timing sprocket drive key. Refer to the Engine sectionof this manual.
Remove the ENG INJ and ENG COMP fusible links prior to performing a compression test.
Refer to supplement for more information.
35
ENGINE
SPECIFICATIONS ENGINE ASSEMBLY 6 cylinder 90" Vee with OHV and balance shaft 379lcc . . . . . Capacity ...:..96.52mm Bore 86.36mm Stroke 8.5:1 ratio Compression l-6-5-4-3-2 Firing order Type regardingenginetunNOTE: Specifications ing are listed in the Engine Tune-upsection. CYLINDER BLOCK (front to rear): Cylinder number sequence t-3-5 Left bank . 2-4-6 Right bank 96.507-96.533mm Standardbore diameter 0.010 mm Maximum ovality . 0.013 mm Maximum taper. 0.08 mm Cylinder block face machining limit CYLINDER HEAD 45" Valve seat angle. . . . Valve seatwidth: ....1.52-2.O3mm Inlet . 2.29-2.79 mm Exhaust 0.30 mm machining limit Surf,ace Minimum cylinder head face thickness . . 1.072mm VALVES AND SPRINGS Valve head diameter: mm 43.307-43.561 Inlet. . . . 3 7 . 7 1 9 - 3 7 . 9 7m 3m Exhaust Minimum valve head thickness(margin). . 0.63 mm 45" Valvefaceangle.... Valve stem diameter: ..8.641-8.666mm Inlet. ....8.648-8.666mm Exhaust. Valve stem to guide clearance: ..0.038-0.089mm Inlet mm ....0.038-0.082 Exhaust . 49.15-50. 17 mm Valve stem installedheight
0.254 mm Valve stem oversize 1.60 mm Maximum valve spring end distortion 42.93-44.45mm Valve spring installedheight PISTONS AND RINGS Piston diameter Piston to cylinder bore oil clearance Gudgeonpin diameter . Gudgeon pin to piston bore . oil clearance. Pistonoversizes Number of rings: Compression . Oil control Pistonring end gap. Piston ring side clearance: Compression. Oil control . . mm 96.477-96.497 0.010-0.056mm 22.995-23.000mm 0.010-0.020mm 0.250,0.508 mm 2 0.254-0.635mm ....0.039-0.079mm 0.028-0.206mm
CONNECTING RODS AND BEARINGS Maximum connecting . . 0.020 mm per 25.4 mm rod bend Maximum connecting . . 0.038 mm per 25.4 mm rod twist Connecting rod big end bore mm 60.294-60.313 diameter Maximum big end bore 0.008 mm taper and ovality. . Connecting rod bearing oil 0.008-0.071mm clearance 0.10-0.38 mm Connectingrod side clearance CRANKSHAFT AND MAIN BEARINGS Number of main bearings. Main bearingjournal diameter ...... 4 . 63.470' 63.495mm Maximum journal ovality and taper. . . . . 0.008 mm 0.013-0.51mm . Main bearingoil clearance. Crankshaft end float: . No. 2 main bearing Taken at ...0.08-0.28mm Range mm 57.117-57.147 Crankpinjournal diameter Maximum journal ovality and taper. . . . . 0.008 mm
36
Main bearingundersize(i'efertext) Maximum crankshaftrunout (bend) Maximum flangerunout . 0.025 mm 0.008 mm ., 0.05 mm
Engine
1. ENGINE MECHANICAL TROUBLE SHOOTING ENGINE MISFIRES AT IDLING SPEED (l) Blown head gasket: Check the cylinder compressions and renew the head gasketas necessary. (2) Burnt valves or seatsin the cylinder heads: Check the cylinder compressions and overhaul the cylinder headsas necessary. (3) Broken or worn piston rings: Check the cylinder compressionsand renew the piston rings as necessary. (4) Weak or broken valve springs: Remove the rocker covers and check the condition of the valve springs. (5) Air leak at the inlet manifold gasket:Check for air leaksby running oil aroundthe manifoldjoints. If an air leak is detected and cannot be rectified bv tightening the manifold bolts, renew the gasket.
CAMSHAFT AND BEARINGS journals. . . . Number of bearing . . . . .. 4 Bearingjournal diameter . 45.339-45.364 mm Camshaftjournal oil clearance. . . 0.013-0.089mm Camshaftlobe lift 6.909 mm Maximum timing chain movement.. . . . . 25.40 mm BALANCE SHAFT Maximum balanceshaft end float 0.203 mm Balanceshaft gearbacklash. 0.050-0.127mm Maximum front bearing radial clearance 0.028 mm Maximum rear bearingradial clearance. . 0. I 19 mm LUBRICATION Oilpumptype. .... Gerotor Maximum regulatedoil pressure 340 kpa Minimum oil pressure at I 850 rpm (normal operating temperature). 275 kpa Oil pressureswitch contact pressure . . . 4l kpa Maximum inner gear tip to outer gearclearance 0.15 mm Outer gear to timing cover clearance 0.203-0.381mm Inner and outer gear to timing cover end clearance. . . . 0.025-0.089mm Pressureregulator valve clearance 0.038-0.076mm Pressureregulator spring free length 64.8 mm TORQUE WRENCH SETTINGS Crankshaft pulley bolt . Main bearingcap bolts Connectingrod cap bolts Camshaftgearbolts.... *Cylinder head bolts: First stage Secondstage. Third stage Rocker arm pivot bolts Rocker cover bolts Hydraulic tappet retainer plate bolts Inlet manifold bolts. Exhaust manifold studs Exhaust manifold flangebolts . . . . . T i m i n gc o v e r b o l t s. . : . . . :... Oil pump pick-up pipe bolts Oil filter adaptor bolts Engine sump bolts Balanceshaft gearretaining bolt. Balanceshaft retainer bolts Flywheel/drive plate bolts
. . 325 Nm . . . 127 Nm 30 Nm + 50" ...40Nm 34 Nm + 90" 8l Nm 44 Nm I I Nm 40 Nm 12 Nm 60 Nm 27 Nm
Check the compression pressure using a compression

gauge.
... .. . ... ...
12 Nm . . . . 40 Nm 12 Nm 22 Nm* 35" 40 Nm . 90 Nm
Check the inlet manifold gasket for leaks by running oil along the gasket joint.
*Tension must not exceed81 Nm during secondstage.
Engi,ne
NOTE: Use a compressiongauge to check pressurein eachcylinder as the compression described in the Engine Tune-up section. For other causesof engine misfire refer to the Fuel and Engine Management section. NOISY VALVE OPERATION (l) Faulty hydraulic tappets: Remove and dismantle the hydraulic tappets and renew as necessary. (2) Weak or broken valve springs: Remove the rocker covers and check the condition of the valve springs. (3) Worn valve guides: Overhaul the cylinder head(s). (4) Worn rocker gear:Remove the rocker gear and check the componentsfor wear. (5) Worn camshaft lobes: Renew the camshaft. (6) Low oil pressure: Refer to the Low Oit Pressureheading. BIG END BEARING NOISE (1) Low oil pressure: Refer to the Low Oil Pressureheading. (2) Excessive bearing clearance: Renew the bearing shells. Renew the crankshaft if the big end journals are oval, tapered or scored. (3) Misaligned big end bearings:Align the connecting rods and renew the big end bearing shells. NOTE: Big end bearing noise is indicated by a metallic knock which is usually loudest at approximately 60 km/h with the throttle closed. Before dismantling the engine to inspectthe big ends,check the engine oil for correct level and dilution on the dipstick. Also remove the oil pressure switch and connect an oil pressuregauge into the oil gallery to check the oil pressurereadings. MAIN BEARING NOISE (APPARENT) (1) Looseflywheel: Tighten the flywheel bolts to the specifiedtorque. (2) Low oil pressure: Refer to the Low Oil Pressureheading. (3) Excessivecrankshaft end float: Renew the main bearings. (4) Excessive bearing to journal clearance: Renew the bearing shells.Renew the crankshaft if the journals are oval, tapered or scored. NOTE: Main bearing noise is indicated by a heavy but dull knock when the engine is under load. A looseflywheel is indicated by a thud or dull click when the ignition is turned of. It is usually accompanied by vibration. Cranl<shaftend float noise is indicated by a sharp rap at idle speed.The uanlcshaft can be readily checkedfor excessiveend float by levering the cranl<shaftbackwards and forwards. Ifthe oil pressureis satisfactory,remove the main bearing capsand assess the bearing clearance using the Plastigage method as described in this section. Ovalitv and weer on the main bearingjournals can only be checked with a micrometer after the cranl<shafthas been removed.
37
EXCESSIVE OIL CONSUMPTION (1) Oil leaks: Check and renew the enginegaskets or sealsas necessary. (2) Damaged or worn valve stem oil seals:Dismantle the cylinder head and renew the damagedor worn oil seals. (3) Excessive clearance, valve stem to valve guide: Ream the valve guidesand renew the valves as necessary (4) Worn or broken piston rings: Renew the piston rings on all the pistons. (5) Rings too tight or stuck in the grooves: Renew the rings and clean out the ring grooves. (6) Excessivewear in the cylinders, pistons and rings: Recondition the cylindersand renewthe pistons and rings. (7) Coqnpression rings incorrectly installed. Oil rings cloggedor broken: Renew the piston rings. (8) Faulty PCV system operation: Check the PCV system as described in the Emission Control section. NOTE: Before checking the engine for oil leal<sthe engine should be completely degreased and cleaned. Run the engine at operating temperature for a period and visually check for oil leakage. By placing white paper on thefloor directly beneaththe engine any excessiveleak can be readily pinpointed. Damaged or worn valve stem oil seals which allow oil to be drawn down past the
Run the engine over white paper to check for engine oil leaks.
38
valve stems into the combustion chambers can be diagnosedby allowing the engine teidle for a few minutes and then openingthe throttle. If oil is being drawn down past the valvestems a heavydischargeof blue smoke will be seenat the tailpipe. Piston, ring and cylinder bore troubles are normally accompanied by a /oss of compression. Cylinder compression can only be accurately assessedby using a compressiongauge. LOW OIL PRESSURE
Engine
ENGINE WILL NOT ROTATE (l) Starter motor drive jammed: Remove the starter motor, check and renew the damaged drive and/or the flywheel ring gear. (2) Engine overheatedand seized:Remove and dismantle the engine, check and renew the damaged components.Refer to the following note. (3) Water in the cylinders due to a blown head gasketor crackedcylinder block or head: Remove the cylinder head. If the gasket is blown, check for cylinder block and head distortion, refaceif necessary. Renew the cylinder head and/or the cylinder block if they are cracked. (4) Broken crankshaft, connecting rod, piston etc. due to overheating, fatigue etc: Remove and dismantle the engine, examine and renew the components as necessary. (5) Valve head broken off due to overheating, fatigue etc: Remove the cylinder head,checkthe head, piston and cylinder for damageand repair or renew as necessary. NOTE: Frequent jamming of the starter motor drive with theflywheel ring gear can be due to a bent starter armature shaft, damaged teeth on the drive and/or ring gear. With the starter motor removed, the flywheel ring gear teeth can be examined through the starter motor mounting aperture. Renewal of the ring gear requires removal of the clutch and flywheel on manual transmission models. The checkingfor a bent armature shaft can be done by rotating the shaft by hand while the end is held in closeproximity to a fixed object. Invariably when an engine seizes, be--, cause of overheating due to lack of oil and/or water, damage is done to the bearings, pistons etc. Although there may be
( I ) Oil level low in the sump: Check and replenish the oil to the full mark on the dipstick. (2) Thin or diluted oil: Changeto the correct oil grade and rectify the source of the dilution. Ensure that 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 crankshaft journals. (7) Excessive wear of the oil pump components: Dismantle the oil pump and renew the componentsas necessary. NOTE: If the vehicleis not equippedwith an oil pressure gauge, remove the oil sender unit and connecta pressuregauge into the oil gallery. Check the oil pressure with the enginecold and hot. If the oil pump or relief valvearefaulty, low pressure will be indicated with the engine both hot and cold. However, if the bearings are at fault a fairly high oil pressure will be indicated when the engine is cold but a marked fall in pressure will be noted when the engine is hot.
Check the engine oil for correct level and dilution on the dipstick.
A blown head gasket is indicated by bubbles in the radiator coolant with the engine running.
Engine
instances where an engine will restart and run after it has cooleddown and the oil and water have beenreplenished,it will generally befound that oil consumption increases, oil pressure drops and the engine will be noisier, depending upon the degree of damage. When a cylinder head gasket blows allowing water into the cylinders, or compression /oss between cylinders, it ls essential to check the gasket faces on the cylinder block and cylinder headfor distortion. Sufficient water can enter a cylinder due to a blown gasket, cracked cylinder or head to prevent an engine from rotating. Normally this is precededby dfficult starting, misfiring, excessive steam from the exhaust and loss of water from the surge tank. By filling the surge tank with coolant until the level is halfway up the neck of the surgetank, bubblesmay be seenin the neck of the surge tank when the engine is fast idling, indicating a blown head gasket. 2. DESCRIPTION
39
,oil from one cavity to the other through orificesinside the mounting, absorbingthe shock when vibration or movement occurs. 3. ENGINE ASSEMBLY
Special Equipment Required: To Removeand Instal - Suitable lifting tackle TO REMOVE AND INSTAL (1) Depressurise the fuel systemas describedin the Fuel and Engine Management section. (2) Place suitable protection around the engine compartment to prevent damageto the vehicle body. (3) Disconnect the negativebattery terminal. (4) Disconnectthe windscreenwashertube from the T junction.
The engine installed to the range of vehicles coveredby this manual is a cast iron, water cooled V6 with pushrod operatedvalves.A featureof this engine is the inclusion of a balance shaft, located above the camshaft,to reduce engine vibration. The crankshaft is supported by four replaceable precision insert main bearings and the end float is controlled by the number two main bearing. The connecting rod journals are offset to allow the cylinders to fire at equal intervals. The connecting rod precision inserts. The manubearingsare replaceable facturer recommendsthat should the crankshaftjournals require machining, the crankshaft be renewed and standard size bearingsinstalled. Undersize bearings are not available. The camshaftis driven by a timing chain from the crankshaft.The timing chain tension is controlled by a spring tensioneddamper. Hydraulic tappetswith an integral needlebearing supported roller provide automatic adjustment of the valves by eliminating clearances in the valve train and provide a hydraulic cushion to absorb operating shock. The balance shaft is housed directly above the camshaftin the valley betweeneachbank of cylinders and is driven by a gear mounted to the camshaft behind the camshaft sprocket.It rotates at crankshaft speedbut in the opposite direction. The oil pump is integral with the timing eover and is driven by the crankshaft. The engine is supported by hydraulic engine mountings to reduce engine vibration. The engine mountings have two oil filled cavities which transfer
Righthandside view of the engineseparated from the transmission. (5) With the aid of an assistant, support the engine bonnet and remove the bolts securing the bonnet mounting brackets to the bonnet hinges. Remove the bonnet. (6) Drain the cooling systemand disconnectthe radiator hoses from the engine and the radiator. Disconnect the overflow hose from the radiator. (7) On models with automatic transmission, disconnectthe oil cooler hosesfrom the radiator. Seal the hosesand the radiator fittings to prevent the entry of dirt. (8) Disconnect the engine cooling fan wiring connector. (9) Remove the radiator retaining clips, raise and withdraw the radiator and fan assemblyfrom the vehicle. (10) Disconnectthe coolant supply,the air bleed and the heater hosesfrom the engine.
40
IN1T MANIFOLD
Engine
kick panel and manoeuvre the kick panel from the vehicle. (20) Disconnect the control unit wiring connectors and the main wiring harnessconnector. (21) Compress the lugs securing the wiring harness plug to the bulkhead and withdraw the wiring harnessfrom the passenger compartment to the engine compartment. Disconnect the wiring harness from the retaining straps located on the inner left hand side mudguard and lay the wiring harnesson the engine. (22) Disconnect the wiring connectorsfrom the throttle body, MAP sensorand the oxygensensor.On models with air conditioning, disconnect the compressorclutch wiring connector. (23) Where applicable, disconnect the coil pack earth strap from the inner left hand side mudguard. (24) Disconnect the vacuum hoses from the throttle body and the inlet manifold adaptor. (25) Suitably mark and disconnectthe fuel supply and return hoses.Sealthe hosesto prevent the entry of dirt. (26) Disconnectthe small vacuum hosesfrom the front of the throttle body. Disconnect the vacuum lines from the fuel rail clips and place the vacuum lines away from the engine. (27) On air conditioned models, remove the engine drive belt. (28) Raise the vehicle and support it on chassis stands. (29) Drain the engine oil into a container. (30) On models equipped with power steering, note the installed position of the power steeringhoses and disconnectthe hosesfrom the steeringgear.Drain the fluid into a container and seal the hosesand the steeringrack to prevent the entry of dirt. (31) Drain the transmission. Refer to the Manual or Automatic Transmission sections. (32) Mark the rear axle pinion flange and the propeller shaft flange to ensure correct alignment on installation. Remove the nuts and bolts securingthe propeller shaft to the pinion flange and remove the bolts securingthe centre bearing support to the floor pan. Withdraw the propeller shaft from the vehicle. (33) Remove the bolts securing the engine exhaust pipes to the exhaustmanifolds. (34) On models with automatic transmission, proceedas follows: (a) Remove the nut securingthe selectorlever to the transmission selector shaft and disconnect the selectorlever from the transmission. (b) Disconnect the torque converter clutch wiring connector from the side of the transmission and the vehicle speedsensorwiring connector. (c) Ensurethat all wiring is disengaged from the transmissionhousing. (35) On models with manual transmission, proceedas follows: (a) Releasethe clutch cable adjusting nut at the clutch housing.
AUTO TRANS OIL COOLER PIPES
Left hand side view of the engine separated from the transmission. (l l) Disconnect the main wiring harnessconnectors and the battery harnessconnector located to the side of the relay housing. (12) Open the cover located at the front of the fusible link housing and disconnectthe power supply wire. (13) Remove the nut securing the battery earth wire to the right hand side inner mudguard. Disconnect the wiring harnessretaining clip from the fusible link housing mounting bracket. (14) Disconnect the throttle cable from the throttle body linkage and the mounting bracket. If appticable, disconnect the cruise control cable from the throttle body linkage and remove the cruise control cable mounting bracket bolts. Place the cable to one side. (15) Releasethe clamps securingthe air intake hosesto the throttle body and the air cleanerhousing. Disconnect the wiring harnessfrom the rear of the air intake duct. Remove the air intake duct retaining nut and remove the air intake duct and the air intake hosesfrom the vehicle. (16) Open the glove compartment and prise the hinge pin from the right hand side of the glove compartment. Remove the glove compartment from the vehicle. ( I 7) Remove the fasteners retaining the lower trim panel to the undersideof the dash panel and the left hand kickpanel and remove the lower trim panel. (18) Using a small screwdriver, prise the plastic strip from the front section of the left hand side sill panel cover. Disengagethe front section of the sill panel cover from the kickpanel and the sill panel. (19) Disengage the lower front corner of the kick panel from the locating stud positioned behind the
Engine
(b) Raise the rear of the clutch cable cover and disconnect the cluth cable from the release lever. Withdraw the clutch cable towards the front of the vehicle. (c) Disconnect the wiring connectors from the reverselamp switch and the vehicle speedsensor. from the (d) Ensurethat all wiring is disengaged transmissionhousing. (36) Attach suitable lifting tackle to the engine lifting bracketsand raisethe engineslightly to take the weight offthe engine mountings. (37) Remove the nuts securing the front engine mountings to the crossmember. (38) Placea block of wood on a jack and raisethe rear of the transmission slightly. (39) Remove the bolts securingthe crossmember to the transmission mounting bracket and the underbody and remove the crossmember.Lower the transmission. (a0) On models with manual transmission, remove the bolts retaining the upper gear lever to the transmissiongear lever and raise the upper gear lever clear of the transmission. (41) On models with manual transmission, remove the nuts and bolts securingthe steeringgearto the crossmemberand pull the steeringgear from the crossmember.Angle the front wheelsfully towards the left. (a2) Raise the engine slightly and manoeuvre the engine and transmission forward slightly. On air conditioned models, remove the bolts securing the compressorto the engineand tie the compressorclear of the engine. (a3) Raise the engine and transmission assembly with the front higher than the rear and manoeuvre it
4L
through the bonnet opening. During this procedure ensurethat the assemblyis not fouling on any object. NOTE: On air conditioned models, ensure that the engine assemblydoes not contact the condenser. Installation is a reversalof the removal procedure with attention to the following points: (1) Tighten all nuts and bolts securely. (2) Fill the engine and transmission with the correct grade and quantity of oil. Fill the cooling system as described in the Cooling and Heating Systemssection. (3) On models equippedwith power steering,fill the reservoir with oil and bleed the system as described in the Steeringsection. (4) Ensure that all wiring connections are secure. (5) Check the fuel systemfor externalleakageas describedin the Fuel and EngineManagementsection before starting the engine. (6) Start the engine and increase the speed to allowing the idle air control 3 000 rpm for 10 seconds, valve to reset. Check for oil and coolant leaks and rectify as necessary. (7) On models equipped with a radio/cassette using PIN security, enter the PIN code as described under the Radio/Cassetteheading in the Electrical Systemsection.
4.
DRIVE BELT TENSIONER ASSEMBLY
TO REMOVE AND INSTAL (1) Disconnect the negativebattery terminal. (2) Drain the cooling system.Refer to the Cooling and Heating Systemssection if necessary. (3) Loosen the power steeringpump pulley retaining bolts. On models not equipped with power steering,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 pulley retaining bolts and remove the pulley. On models not equipped with power steering,remove the idler pulley retaining bolts and remove the pulley. (6) If applicable,remove the screwssecuringthe power steering pump reservoir to the drive belt tensioner mounting bracket. (7) Remove the nut securing the heater pipes and the power steeringpipe to the drive belt tensioner lower mounting stud. (S) Remove the alternator retaining bolt located at the rear of the drive belt tensioner pulley. L.oosen the alternator pivot bolt and raise the alternator. (9) Remove the bolt securing the heater inlet pipe to the front of the inlet manifold. (10) Remove the bolt securing the heater outlet
View of the engine and transmission being removed. Note the angle required to enable the engine to clear the front panel.
42
Engine
(4) Disconnect the lower radiator hose and drain the coolant into a clean container. (5) Disconnectthe coolant air bleed hose from the inlet manifold pipe. (6) Disconnectthe small vacuum hosesfrom the front of the throttle body and disconnect the hoses from the fuel rail retaining clips. (7) Slide the high tension lead retainersfrom the support brackets. (8) Disconnect the vacuum hoses from the throttle body and the inlet manifold adaptor. (9) Remove the engine vent pipe from the left hand rocker cover and the throttle body. (10) Remove the engine drive belt. Refer to the Engine Tune-up section if necessary. (11) Disconnect the wiring harness connector from the alternator. (12) Removethe alternatorretainingbolt located at the rear of the drive belt tensioner pulley. (13) Loosen the alternator pivot bolt, raise the alternator and disconnect the positive wire from the alternator. (14) Remove the alternator pivot bolt and remove the alternator. _ (15) Disconnect the water pump by-pass hose from the front of the manifold. (16) Remove the bolt securing the heater inlet pipe to the front of the manifold. ( 17) Remove the nut securing the heater inlet pipe to the drive belt tensioner lower mounting stud and remove the heater inlet pipe from the inlet manifold. ( 18) Working at the rear of the engine,release the hose clamp and disconnect the coolant outlet hose from the thermostat cover. (19) Releasethe clamps securingthe air intake
ALTERNATOR P'VOT
f,
COOLANT OUTLET iiPE
Front view of the engine showing the drive belt tensionerassembly. pipe to the coolant outlet pipe located adjacentto the lght hand rocker cover and remove the heater pipes from the timing cover and the inlet manifold. (l l) Remove the power steeringpump retaining bolts and carefutly place the pump to oni side. On models without power steering, remove the idler assemblyretaining bolts and remove the idler assembly from the engine. (12) Remove the bolts securing the drive belt tensioner to the cylinder head and remove the drive belt tensioner. Installation is a reversalof the removal procedure with attention to the following points: (l) Tighten all bolts securely. (2) Fill the cooling systemwith the recommended coolant: (3) Start the engine and increase the speed to 3 000 rpm for l0 seconds, allowing the idle aiicontrol valve to reset. check for coolant leaks and rectifv as necessary. (4) On models equipped with a radio/cassette using PIN security, enter the pIN code as described under the Radio/Cassetteheading in the Electrical Systemsection. 5. INLET MANIFOLD To Removeand Instal (l) Depressurise the fuel systemas describedin the Fuel and Engine Management section. (2) Disconnect the negative battery terminal. (3) Mark the fuel supply and return hoses to ensurecorrect installation. Disconnect the hosesfrom the fuel rail inlet pipe and the fuel pressureregulator. MANIFOLDS
AIR BLEED HOSE
Installed view of the inlet manifold.
Engine
43
View of the inlet manifoldremovedfrom the engine. hose to the throttle body and the air intake duct and remove the air intake hose. (20) Release the nuts securingthe throttle cableto the mounting bracket and disconnect the throttle cable from the throttle linkage. On models equipped with cruise control, remove the bolts securing the control cable mounting bracket to the inlet manifold adaptor and the throttle body. Disconnect the control cable from the throttle linkage. (21) On automatic transmissionmodels, disconnect the inner kickdown cable from the throttle linkage, compressthe tangs securing the outer kickdown cable to the mounting bracket and remove the kickdown cable. (22) Disconnect the wiring connectors from the throttle body, fuel injectors, MAT sensor, coolant temperaturesensorand the temperaturegaugesender
unit. Refer to the Fuel and Engine Management section if necessary. (23) Disconnectthe wiring harnessretainersfrom the inlet manifold and place the wiring harnessto one side. (24) Remove the inlet manifold retaining bolts and remove the inlet manifold from the engine. Remove and discard the sealsand gaskets. Installation is a reversalof the removal procedure with attention to the following points: (1) Thoroughly clean the mating surfacesof the inlet manifold, the cylinder heads and the cylinder block. (2) Ensurethat the inlet manifold retaining bolt and cylinder head threads are clean. (3) Apply RTV 732 sealanttp each end of the rubber valley gasketsand ensure that they are positioned firmly against the cylinder heads and the cylinder block. (4) Instal the inlet manifold gasketsto the cylinder heads,ensuring that the dowels in each gasket locate into the holes in the cylinder head. (5) Coat the inlet manifold retaining bolts with Loctite 242 and tighten the bolts to the specified torque in the sequence shown in the illustration. Repeat the tightening sequence. (6) Ensure that att wiring connections are secure. (7) Connect and adjust the throttle cable and if necessary, the cruise control cable as describedin the Fuel and Engine Management section. (8) On automatic transmission models, instal and adjust the kickdown cable as described in the Automatic Transmissionsection. (9) Instal the drive belt as described in the Engine Tune-up section. (10) Replenish the cooling system with the recommended coolant as describedin the Cooling and Heating Systemssection. (11) Checkthe fuel systemfor externalleakage as describedin the Fuel and EngineManagementseCtion before starting the engine. (12) Start the engine and increasethe speed to 3 000 rpm for l0 seconds, allowing the idle air control valve to reset. Check for coolant leaks and rectifv as necessary. (13) On models equipped with a radiolcasserte using PIN security, enter the PIN code as described under the Radio/Cassetteheading in the Electrical Systemsection. EXHAUST MANIFOLDS To Removeand Instal (l) Disconnect the negativebattery terminal. (2) Disconnect the high tension leads from the spark plugs and remove the high tension leads from the retainers. Place the high tension leads on the engine.
View of the inlet manifold showing the bolt tightening sequence.
44
Engi,ne
(4) When removing the right hand exhaustmanifold proceed as follows: (a) Remove the engine oil dipstick tube retaining nut and remove the dipstick tube from the engine. (b) Disconnect the upper radiator hose and partially drain the cooling system into a clean container. Remove the upper radiator hose. the (c) Working at the rear of the engine,release clamp securing the coolant hose to the thermostat housing. (d) Remove the bolt and nuts securing the coolant outlet pipe to the rear engine lifting bracket and the exhaustmanifold studs. (e) Remove the coolant outlet pipe from the engine. (0 Releasethe clamps and remove the coolant supply hose from the surgetank and the heater inlet pipe. (5) Raise the front of the vehicle and support it on chassisstands. (6) Remove the bolts securing the exhaust engine pipe to the relevant manifold. (7) Remove the exhaust manifold retaining studi and remove the manifold from the engine. Installation is a reversalof the removal procedure with attention to the following points: (1) If renewing the left hand manifold, remove the oxygen sensor from the manifold and instal the sensor to the new manifold, Refer to the Oxygen Sensorheading in the Fuel and Engine Management section. (2) Ensure that the cylinder head and exhaust manifold facesare clean. (3) Coat the exhaust manifold studs with a suitable anti-seizecompound. (4') Instal the manifold and tighten the retaining studs to the specifiedtorque. (5) Connect the exhaust engine pipe to the manifold and tighten the retaining bolts to the specified torque. (6) If necessary,replenish the cooling system with the recommended coolant as described in the Cooling and Heating Systemssection. (7) Connect the high tension leads to the spark plugs. (8) Start the engine and increase the speed to 3 000 rpm for 10 secondsto allow the idle air control valve to reset. Check for exhaust and coolant leaks and rectify as necessary. (9) On models equipped with a radio/cassette using PIN security, enter the PIN code as described under the Radio/Cassette heading in the Electrical Systemsection. 6. ROCKER ARMS AND PUSHRODS
lnstalledview of the left hand exhaustmanifold. (3) When removing the left hand exhaustmanifold proceed as follows: (a) Disconnectthe oxygensensorwiring connector. (b) Release the clamps securing the air inlet hosesto the throttle body and the air cleanerhousing. Remove the air inlet duct retaining nut, disconnect the wiring harness fastener from the rear of the air inlet duct and remove the air inlet duct from the vehicle.
COOLANT OUTLET PIPE:;;
TO REMOVE
Installed view of the right hand exhaust manifold.
(l)
Disconnect the negativebattery terminal.
Engine
45
(5) Inspect the pushrodsfor distortion and wear on the spherical ends. Renew as necessary.
ROOG*R o urr*r/
TO INSTAL
WY
"rr"*OO*Fl
[N
nodxenenn
Installation is a reversalof the removal procedure with attention to the following points: (1) Liberally coat the contact surfaces of the componentswith cleanengineoil prior to installation. (2\ Instal the pushrods in their original locations. Rotate the pushrod between the fingers and check for smooth movement. If the pushrod does not rotate smoothly the pushrod may not be located correctly in the hydraulic tappet.
24s*1s
+GUIDE
@
HYDRAULT. rAppEr F-l
\M
ta,
On early productionmodels, instal the guide plate as shown. (3) Instal the pushrod guide plate to the cylinder head ensuring that the words THIS SIDE UP are visible and the pushrods are correctly positioned in the guide. (4) Apply Loctite 242 to threads on the rocker arm pivot bolts and instal the rocker arms and pivots in their original location. (5) Tighten the rocker arm pivot bolts to the specifiedtorque, ensuringthat the pushrod remains in contact with the valve lifter and the rocker arm. (6) Instal the rocker covers and tighten the retaining bolts to the specifiedtorque, ensuring that the sealsare seatedin the rocker cover grooves. (7) Start the engine and check for oil leaks and Increase the valve train noise. Rectify as necessary. allowing the enginespeedto 3 000 rpm for l0 seconds idle air control valve to reset. (8) On models equipped with a radio/cassette using PIN security, enter the PIN code as described under the Radio/Cassetteheading in the Electrical Systemsection. 7. HYDRAULIC TAPPETS
Dismantledview of the valve train components. (2\ Disconnect the high tension leads from the spark plugs. (3) Releasethe lugs retaining the high tension lead cover to the left hand rocker cover and slide the cover offthe rocker cover. (4) Disconnectthe enginevent pipe from the left hand rocker cover. (5) Remove the right hand high tension leads from the retainers. (6) Remove the bolts securingeach rocker cover to the cylinder head and remove the rocker covers from the engine. (7) Remove the rocker arm pivot bolts and the rocker arrns from the cylinder head. Place the rocker arms and pivots in order of removal to ensurecorrect installation. (S) Remove the pushrod guide plate from the cylinder head. (9) Withdraw the pushrodsfrom the engineand place them in order of removal to ensure correct installation. TO CTEAN AND INSPECT (1) Wash all componentsin cleaningsolvent and air. dry with compressed (2) Clean the threads on the rocker arrn pivot bolts. (3) Inspectthe rocker arrn tip for deepscoringor damage.Renew as necessary. (4) Inspect the rocker arm pivot for scoring or cracks. Renew the rocker arm pivot and bolt as necessary.
TO REMOVE AND DISMANTLE ( 1) Remove the inlet manifold and the rocker arms and pushrods as previously described.
46
Engine
(2) Carefully place the spring and cap over the ball and pressthe cap into position using a fine bladed screwdriver. (3) Half fill the tappet body with cleanengineoil and instal the plunger spring. (4) Align the oil feed hole in the plunger with the hole in the body and instal the plunger assemblyinto the body. Fill the tappet with clean engineoil. (5) Instal the metering valve and the pushrod seat,pressthe pushrod seat down arndinstal the snap rlng. NOTE: If the snap ring cannot be installed, remove the pushrod seat and the metering valveand insert a I mm diam,eter pin intb the centre of the plunger assembly and depressthe ball. Push the plunlier asiembly down the required distance to alllowthe snap ring to be installed. (6) Ensure that the tappet body, roller and bore are clean. (7) Coat the tappet and the tappet bore with LUBRIZOL 6612 and instal the tappets to the cylinder block. (8) Instal the tappet guides, aligning the flat segmentson the tappet with the flat segments on the guide. (9) Instal the hydraulic tappet netainerplate and tighten the bolts to the specifiedtorrlue. (10) Instal the pushrods, rocker arms and the inlet manifold as previously described.
Dismantledview of a hydraulictappet. (2) Remove the bolts securing the hydrautic tappet retainer plate to the cylinder block valley and remove the retainer plate. (3) Remove the hydraulic tappet guides and place them in order to ensurecorrect installation. (4) Remove the hydraulic tappets from the cylinder block and placethem in the order of removal io ensurecorrect installation. (5) Pressthe pushrod seatand plunger down and remove the snap ring with a small screwdriver. (6) Remove the pushrod seat, metering valve, plunger assembly and the plunger spring from the tappet body. NOTE: If the plunger assemblyis dfficult to remove,turn the tappet upsidedown and tap sharply on a block of wood. If this fails to dislodge the plunger assembly, soak the tappet in cleaning solvent. (7) Using a fine bladed screwdriver,remove the cap, spring and ball from the plunger assembly. TO CLEAN AND INSPECT (1) Thoroughlywashall components in cleaning solvent. (2) Inspect the tappet body for wear or scuff marks. If wear or scuff marks are evident, renew the hydraulic tappet assembly and examine the corresponding bore in the cylinder block for scoring. (3) Renew the hydraulic tappet assemblyif the roller has any of the following faults; binding or rough operation, excessiveplay in the roller bearing, flat spots or pitting on the roller. (4) Inspect the pushrod seat for wear. If the pushrod seatis worn renew hydraulic tappet assembly and examine the corresponding pushrod for wear. Renew as necessary. NOTE: The tappet must be renewedas an assembly if any of the components are unserviceable. TO ASSEMBLE AND INSTAL NOTE: When assemblingthe hydraulic tappets it is essentialthat the componentsand the work area arefree of dirt or lint to avoid failure or unsatisfactory operation of the tappets. (1) Place the ball on the hole in the end of the plunger.
8.
CYLINDER HEADS
Special Equipment Required: To Dismantle - Valve spring cortrprSSor To Inspect - Dial gaugeand straight edge To Assemble - Valve spring compressorand vernier gauge TO REMOVE AND INSTAL (l) Remove the inlet and exhaustmanifolds and the rocker arms and pushrodsasprev'iouslydescribed. (2) When removing the left hand cylinder head, proceed as follows: (a) Release'the screw retaining the wiring harness connector to the ignition control module and disconnectthe wiring harnessconnector. (b) Remove the nuts and disconnect the earth wire terminal and the wiring harnesr; support bracket from the alternator/ignition control nnodulemounting bracket studs. (c) Remove the nut and disconnect the earth strap from the ignition control module mounting stud. (d) Remove the bolts retaining the alternator/ ignition control module mounting bracket to the cylinder head and remove the mounting bracket.
Engine
47
(l) [Jse new gasketsduring assembly. (2) Clean the cylinder headbolt and the cylinder btock threads. Renew cylinder head bolts that have damagedheadsor threads. (3) Position the head gasketsover the locating dowels on the cylinder block face, ensuring that the side of the gasketmarked TOP is facing uppermost. (4) Coat the threads of the cylinder head bolts with Loctite 242 and tighten the lboltsfinger tight. NOTE: The cylinderheadboltsare dffirent lengths. Thefour 59 mm bolts are installed in the external holes adjacent to the spark plug holes. The two 82 mnn bolts are installed at each end of the cylinder head, adjacentto the valvespringsttnd the two I l3 mm bolts are installed in the centre holes. (5) Apply an initial torque: of 34 Nm to the cylinder head bolts in the sequence shown in the illustration. (6) Set the torque wrench ta, 8l Nm and further tighten the bolts 90 degrees, Ibllowing the same sequence.Cease tightening the bolts if the torque wrench registers 81 Nm. (7) Further tighten the cylinder headbolts to 8l Nm. (8) Ensure that the earth connectionsare tightened securely. (9) Instal the pushrods, rocker arms and the inlet manifold as previously descr:ibed. (10) Fill the cooling systemwith the recommended coolant as described in the Cooling and Heating Systemssection. (l l) Start and run the enginr:and check for oi[, coolant or exhaustleaks. Rectifv iasnecessary. TO DISMANTLE (1) Clean the deposits from the combustion chamber. Do not contact the c),linder head gasket faceswith a rotary wire brush. .(2) Compress the valve spr:ingsusing a valve sprlng compressor and remove the valve retaining collets. NOTE: If dfficulty is experiencedin separating the valve spring retainer from the cbllets, apply light pressur(?to the valve spring compressorand tap the edge of the retainer with a soft faced hammer. (3) Releasethe spring compressorand remove the retainer, the valve springs anrl the valve stem oil seal. (4) Remove any burrs from the end of the valve stem to prevent damageto the valrreguide asthe valve is withdrawn. (5) Remove the valves,keepingthem in order to ensureassemblyin their original positions.
Underside view of the cylinder head showing the valve arrangement.
Cylinderhead bolt tightening sequence. (e) Remove the bolts securing the alternator mounting support bracket to the cylinder head and remove the bracket. (3) When removing the right hand cylinder head, proceedas follows: (a) Remove the power steering pump pulley retaining bolts and remove the pulley. On models not equipped with power steering, remove the idler pulley retaining bolts and remove the pulley. (b) Remove the nut securing the heater pipes and the power steeringpipe to the drive belt tensioner lower mounting stud and disconnect the pipes from the mounting stud. (c) Remove the bolts and stud and remove the drive belt tensioner bracket and the power steering pump assemblyfrom the cylinder head. On models not equipped with power steering, remove the drive belt tensioner bracket and the idler assembly. (4) Progressivelyloosen the cylinder head bolts in the reverseorder to the tightening sequence. (5) Remove the cylinder head bolts and remove the cylinder headsand gaskets. Installation is a reversalof the removal procedure with attention to the following points:
48
QdJ*ot rrs-gg f - f-RerArNERst i q # L
. =
Engine
ffi-v-qg
F-/sEots--ffi
4,.,,.,d
Dismantled view of the inlet and exhaust components. valve
II
*..='uo..u= fl ffi
vALvE ExHA,sr fi |
Measurethe cylinderheadmountingl face thicknessat the three measuringpads as showrr, using a vernier gauge. the cylinder head is distorted it must be machined. If it is necessary to machine more tha.n 0.30 mm from the cylinder head,the cylinder head must be renewed. NOTE: To determine if the q,linder head mounting face has sufficient ,thickness to allow machining, measure the depth between the cylinder head mctunting face and the three measuringpads, as shown in the illustration. From- this nreasurement subtract the distortion measurement.If the .figure ls /ess than 1.072 mm ,thecvlinder head will have to be renewed. (5) Check the cylinder block facesfor distortion using a straight edge and feeler gauges. If the distortion is within the cylinder block face machining limit, remove the engine and machine th,e cylinder block faces. If the distortion exceedsthe limit. renew the cylinder block. NOTE: Machining the cylind,er head or cylinder block faces beyond Specffications will increase the compression ratio. This .""-
TO CLEAN AND INSPECT (1) Clean the valves thoroughly and discard any burnt, warped or cracked valves. (2) Using a sharp scraper, carefully remove all tracegof gasketfrom the cylinder heads.Remove all carboR deposits from the cylinder head using a wire brush and electric drill. Do not use the wire brush on the cylinder head mounting faces. Clean the valve guides using a piece of wadded cloth or a suitable brush and cleaning solvent. (3) Thoroughly clean the cylinder heads in cleaning solvent using a soft brush. (4) Check the cylinder head mounting facesand the inlet and exhaust manifold mating surfacesfor distortion using a straight edge and feeler gauges.If
checking the cylinder head for distortion using feeler gauges and a straight edge.
Checking the cylinder block for distortion using feeler gauges and a straight erdge.
Engine
49
the ends of the valve spring coil are not parallel within Specifications,the spring is bent and must be renewed. (13) Lap the valves to the valve seats with a lapping compound. Apply a smeal of PrussianBlue to the seat to ensure the valves after lapping and checll< that a true and concentric seat has been gained. NOTE: Do not lap new valt'es as this will destroy the protective coating on the valve face. TO ASSEMBLE Assembly is a reversal of the dismantling procedure with attention to the followirngpoints: (1) To ensure correct hydraulic tappet operation, the valve stem installed height must be checked using the following procedure.
Measuring the valve stem side movement.
may cause cylinder detonation or pinging, result in lossof performanceand could afect emission levels. (6) Check the cylinder heads for cracks in the valve seats, combustion chambersand externalcracks leading to the water jackets. Check the cylinder head mounting facesfor corrosion. (7) Check for bent valve stemsusing a dial gauge and Vee blocks. (8) To check the valve stem to valve guide clearance,measurethe valve stem side movement as follows: (a) Install the valve to its original guide and secure a dial gaugeto the cylinder head so that the plunger is against the side of the valve stem approximately 8-12 mm above the top of the guide. (b) Open the valve approximately 2 mm and move the valve stem from side to side. If the dial gaugereadingexceeds 0.25 mm, remove the valve and measure the valve stem using a micrometer. If the it will be valve stem diameter is within Specifications, necessaryto ream the valve guide and install an oversize valve. (9) Check the con{ition of the valve seatsand if recut the seatswith a valve seatcutter to the necessary correct angle and width as specified. (10) Inspect the valve facesfor groovesor pitting and the valve tips for wear. If necessary,reface the valves to the specified angle and machine the valve stem tip flat on a valve refacing machine. If the valve head margin has been reduced to less than the specified thickness after refacing, the valve should be renewed. NOTE: If the valvesor seatsrequire machining it is recommended that this be carried oit by an engine reconditioning workshop. If a valveseat is cut, the correspondingvalve must be refaced. (11) Inspect the valve spring contact surf,ace on the cylinder head and the valve spring retainer for wear. Renew the faulty componentsas necessary. (12) Check the valve springs for squareness.If
Measuring the valve stem ins-ta,llled height using a vernrergauge. (a) Instal the valve to its oril;inal guide and hold it in the closedposition. (b) Measurethe height betweenthe valve spring seatand the valve stem tip using a vernier gauge.If the mar:hinethe valve stem height exceeds Specifications, fip to achievethe correct dimensiron. (2) Measure the valve spring installed height using the following procedure: (a) Instal thd valve to its original guide and instal the valve spring retainer and the retaining collets. (b) Place a finger under the retainer and raise the valve againstits seat.Ensurethat the retainer and the collets are fully seated. (c) Measure the height betw,eenthe valve spring
50
Engine
(4) On models with an automertictransmission, remove the torque converter inspection cover and, using a suitableimplement, lock the drive plate or ring gear to prevent the engineturning. l'he manufacturer recommends removing the startermotor and.placinga lever between the engine block and the drive plite teeth. (5) On modelswith a manual transmission,fully engagethe handbrake, select top gear and chock the rear wheels. (6) Remove the crankshaft pultey retaining bolt and remove the crankshaftpulley from the crankshaft. (7) Drain the cooling systemand disconnectthe radiator hoses and the air bleed hose from the radiator. (8) On modelswith an automatic transmission, disconnectthe oil cooler hosesfrom the radiator. seai the hosesand the radiator fittings to preventthe entry of dirt. (9) Disconnect the engine cortling fan wiring connector,remove the radiator retairringclips and lift the radiator and fan assemblyfrom rthevehicle. (10) Release the water pump by-pass hoseclamp and disconnectthe hose from the water pump. (l l) Releasethe lower radiator hose clamp and disconnectthe hose from the timing cover. . (I2) Remove the nut securing the heater supply pipes to the drive belt tensionermounting brackefand disconnect the heater pipes and ii' applicable, the power steeringhose from the mounting stud. . (13) Remove the bolt securingthe heatersupply pipe to the coolant outlet pipe located adjacentto itrb right hand side rocker cover and remove the heater supply pipe from the timing cover. (14) Disconnect the wiring contlectors from the crankshaft sensorand the oil pressureswitch. (15) Disconnect the crankshaftsr3nsor wiring harnessfrom the clamp located at the side of the timing cover. Remove the clamp retaining nut and remove
Measuring the valve spring installed height using a verniergauge. seat and the valve spring contact face on the retainer using a vernier gauge.If the height exceedsSpecifications, instal valve spring seat shims to achieve the correct dimension. (3) Thoroughly clean all the components and dry with compressed air. (4) Lubricate the valve stems and valve guides with clean engine oil and instal the valves intd their guides. (5) Instal the valve stem oil seals to the valve guides ensuring that the oil sealsare installed to the correct valve guide as the sealsfor the inlet and the exhaustguidesare different. (6) Instal the valve springs and the retainer. Compressthe valve springs and instal the retaining collets, ensuring that the collets are correctly seated before releasingthe valve spring compressor. (7) Lightly tap the top of the valve stem with a soft faced hammer to settle the collets in the retainer. (8) Instal the cylinder heads as previously described. ,. TIMING COVER
TO REMOVE AND INSTAL (l) Disconnect the negativebattery terminal. (2) Releasethe engine drive belt tensioner and disconnectthe drive belt. Refer to the EngineTune-up section if necessary. (3) Raise the front of the vehicle and support it -Tvres on chassis stands. Refer to the Wheels and section if necessarv.
CRANKSHAFT PULLEY
View of the timing cover and associated components removed from the eng,ine.
Engine
the clamp and the wiring harness earth connection terminal. ( 16) Remove the crankshaft sensor retaining bolts and remove the crankshaft sensor from the timing cover. Refer to the Fuel and Engine Management section if necessary. ( I 7) Remove the sump plug and drain the engine oil into a container. (18) Remove the bolts securingthe enginesump to the timing cover. Loosenthe remaining sump bolts and allow the sump to separate from the cylinder block and the timing cover. (19) Removethe timing cover retainingbolts and carefully remove the timing cover from the engine.It may be necessaryto remove the water pump pulley retaining bolts and the pulley from the water pump. (20) If necessary, to dismantle the oil pump assembly,refer to the Oil Pump heading. (21) If necessary, to remove and instal the water puffip, refer to the Cooling and Heating Systems section. Installation is a reversalof the removal procedure with attention to the following points: (l) Remove the crankshaft oil seal from the timing cover using a hammer and a suitable drift. Instal a new oil sealto the timing cover, ensuringthat the lip of the sealfacesthe inside of the timing cover. (2) Ensure that the timing cover and the cylinder block surfacesand the timing cover retaining bolt threads are clean. (3) Ensure that the camshaft thrust bearing and spring are correctly installed in the front of the camshaft. (4) Instal a new timing cover gasket to the cylinder block. (5) Instal the timing cover, ensuringthat the flat segmentson the crankshaft sprocket align with those on the oil pump inner gear. Ensure that the sump gasket is located correctly between the timing cover and the sump. (6) Coat the threads of the timing cover retaining bolts with Loctite 242 and instal the bolts finger tight. (7) Instal the engine sump to the timing cover securingbolts and tighten to the specifiedtorque. (8) Tighten the timing cover retaining bolts to the specifiedtorque. (9) Tighten the remaining sump bolts to the specifiedtorque. (10) Instal and if necessary, adjust the crankshaft sensoras described in the Fuel and Engine Management section. (11) Instal the crankshaft pulley and tighten the retaining bolt to the specifiedtorque. (12) Instal a new O ring sealto the heater supply pipe and connect the pipe to the timing cover. (13) Ensure that all coolant hose clamps are securelytightened. (14) Fill the engine with the correct grade and amount of engine oil.
5l
(15) Fill the cooling systemwith the recommended coolant as described in the Cooling and Heating Systemssection. ( l6) Ensurethat all wiring connectorsare securely fastened. (17) Start the engine and increasethe speed to 3 000 rpm for l0 secondsallowing the idle air control valve to reset. Check for oil and coolant leaks and rectify as necessary. (18) On models equipped with a radio/cassette using PIN security, enter the PIN code as described under the Radio/Cassetteheading in the Electrical Systemsection.
10. TIMING CHAIN, SPROCKETS AI\D BALANCE SHAFT GEARS TO REMOVE AND INSTAL (l) Removethe timing cover from the engineas previously described. (2) With the timing cover removed, hold the timing chain damper away from the timing chain and move the chain in and out between the camshaft and crankshaftsprockets.If the movement exceeds Specifications, renew the timing chain and closely inspect the sprocketsfor wear when removed. (3) Measure the balance shaft gear backlash using the following procedure: (a) Mount a dial guageto the cylinder block and position the plunger againstthe face of a balanceshaft gear tooth. (b) Partially rotate the balance shaft gear until all clearanceis removed and zero the dial gauge. (c) Rotate the balanceshaft gear in the opposite direction and note the dial gaugereading.
Hold the damper away from the timing chain and measure the movement in the chain between the crankshaft and camshaft sprockets. The movement must not exceed 25.40 mm.
52
Engine
Repeat the above procedure at four points, turnbetweeneach point. ing the balanceshaft 90 degrees (d) If the backlashexceedsSpecificationsat any point, renew the camshaft and balance shaft gears. (4) Withdraw the camshaft thrust bearing and spring from the front of the camshaft. (5) Rotate the crankshaftuntil the timing marks on the camshaftand crankshaft sprocketsare aligned. (6) Remove the camshaft sprocket retaining bolts, hold the timing chain damper away from the timing chain and remove the camshaft sprocket and timing chain from the engine. NOTE: After removing the timing chain do or camnot attempt to turn the cranl<shaft shaft as damage to the pistons or valvesmay result. (7) Slide the crankshaftsprocketfrom the crankto remove the shaft. A puller should not be necessary crankshaft sprocket, however, if the sprocket is difficult to remove, carefully lever against the sprocket with a large screwdriver.
*\
oo"tT
ee#
View of the timing chain, sprockets and damper removed from the engine. (12) Inspectthe timing chain roller links for wear or stretch. Renew the timing chain as necessary. Installation is a reversalof the removal procedure with attention to the following points: (1) If removed, instal the balance shaft and camshaft gears, ensuring that the timing marks are aligned. Tighten the balance shaft gear retaining bolt to the specifiedtorque. (2) Instal the crankshaft sprocketand temporarily instal the camshaft sprocket to ensure that the timing marks are in alignment. If the marks are not in alignment, carefully rotate the crankshaftor camshaft. (3) Remove the camshaftsprocketand instal the damper and tensioning spring, ensuring that the end of the spring is located in the hole adjacent to the damper retaining bolt. Tighten the damper retaining bolt securely. (4) Instal the camshaft sprocket and the timing chain, holding the damper away from the chain. When installed, release the damper and check that the timing marks are aligned. (5) Tighten the camshaft sprocket retaining bolts to the specifiedtorque.
'PRTNG /
View of the camshaft timing marks correctly aligned. (8) Remove the damper tensioning spring from the damper retaining bolt. Remove the bolt and the damper from the engine. If necessaryremove the balance shaft gears as follows: (a) Instal two bolts, approximately 35 mm long, into the camshaft gear and place a lever between the bolts to prevent the gear turning. (b) Remove the balance shaft gear retaining bolt and remove the gear. (9) Remove the bolts from the camshaft gear and remove the gear from the camshaft. (10) Clean all components in cleaning solvent air. and dry with compressed (11) Inspect the sprocketsand gearsfor worn or damaged teeth. Renew the sprockets or gears as necessary.
View of the balance shaft timing aligned.
marks correctly
Engine
(6) Instal the camshaft thrust bearing into the front of the camshaft. (7) Instal the timing cover as previously described. 11. CAMSHAFT AND BALANCE SHAFT
53
TO MEASURE CAMSHAFT LOBE LIFT (1) Remove the rocker arms from the cylinder headsas previously described. (2) Mount a dial gaugeto the cylinder head and position the plunger on the end of the pushrod. (3) Rotate the crankshaft until the pushrod is at its lowest point and zero the dial gauge. (4) Rotate the crankshaft and note the maximum reading on the dial gauge. Repeatthe procedureon the remaining pushrods. If th maximum reading on any pushrod is below Specifications, a worn camshaft lobe is indicated. Renew the camshaft as describedunder the following heading. If the reading is as specified, instal the rocker arms as previously described. TO REMOYE (l) Removethe inlet manifold, rocker arms and pushrods, hydraulic tappets, timing cover, timing chain and camshaftsprocketand the camshaftgearas previously described. (2) Measurethe balanceshaft end float using the following procedure: (a) Mount a dial gaugeto the cylinder block and position the plunger against the end of the balance shaft gear retaining bolt. (b) Move the balance shaft fully towards the front of the engine and zero the dial gauge. (c) Push the balanceshaft fully towards the rear
Measuring the balance shaft bearing radial clearance using 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 balance shaft and front bearing assembly. (3) Measure the balance shaft radial clearance using the following procedure: (a) Mount a dial gauge to the cylinder block and position the plunger against the top of the front counter weight on the balance shaft. (b) Zero the dial gauge and raise the balance shaft noting the dial gauge reading.
View of the camshaft components removedfrom the engrne. Specifications, a worn front If the reading exceeds balanceshaft bearing is indicated. Renew the balance shaft and front bearing assembly. (c) Repeat the previous operations on the rear counterweightand note the dial gaugereading. If the reading exceedsSpecifications, a worn rear balance shaft bearing is indicated. Renew the rear bearing as described under the heading To Renew Balance Shaft Rear Bearing. (4) Temporarily instal the camshaft gear to the camshaft using two bolts approximately 35 mm long and place a lever between the bolts to prevent the camshaftgear turning. Loosen the balance shaft gear retaining bolt. (5) Remove the bolts from the camshaft gear and remove the gear. (6) Carefully withdraw the camshaft from the engine, ensuring that the camshaft lobes do not damagethe camshaftbearingsasthe camshaftis being removed.
Measuring the balance shaft end float using a dial gauge.
54
Engine
TO INSTAL (l) Lubricate the balanceshaft front bearingand the rear bearing sleevewith clean engine oil. (2) Instal the balance shaft and lightly tap the front of the balance shaft until the front bearing is fully installed in the cylinder block. Ensure that the balanceshaft rotates freely. (3) Instal the balance shaft retainer and tighten the retaining bolts to the specifiedtorque. (4) Lubricate the camshaftbearingjournals with clean engineoil and the camshaft lobes with LUBRIZOL 6612lubricant. (5) Smear Molybdenum Disulphide grease around the camshaft front bearing bore. (6) Carefully instal the camshaft, ensuring that the lubricant on the lobes is not removed when passing through the camshaft bearings. Ensure that the camshaftrotates freely. (7) Instal the balance shaft and camshaft gears, the camshaft sprocket and timing chain, the timing cover, 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 as previously described and separate the transmission from the engine. (2) Remove the balanceshaft from the engineas previously described. (3) Remove the flywheel or drive plate as described later in this section under the Flywheel/Drive plate heading. (4) Using a suitable socket and bar, knock the rear bearingand the welch plug from the rear of the cylinder block.
BLOCK CYLINDER
(7) Remove the balanceshaft retainer bolts and remove the retainer from the engine. (S) Position two screwdrivers behind the shoulderon the rear of the balanceshaft gearand lever the balance shaft and front bearing from the engine. Do not lever againstthe gear teeth.
BALANCE SHAFT
m
BEARING
,ao*,"/
View of the batanceshaft components removed from the engine. NOTE: If the balance shaft cannot be removed using two screwdrivers,remove the balance shaft gear, instal a suitable slide hammer to the balanceshaft and withdraw the balanceshaft andfront bearingfrom the engine. TO INSPECT (1) Check the camshaft bearing journals and lobes for wear, damage and discolouration, which is an indication of overheating. (2) Using suitable micrometers, measure the camshaft bearing journals and the camshaft bearing bores and calculate the oil clearance using these Renew the camshaft and/or the cammeasurements. shaft bearingsas necessary. NOTE: If the camshaft bearings are slightly scoredremoveany burrs with emery paper and lightly polish the bearings with steel wool. Polish the camshaft bearing journals if necessary. If the camshaft bearings require to removethe engine renewalit is necessary and have the bearings removed and installed by an engine reconditioning workshop. (3) Support the camshaft between two vee blocks placed under each end journal and mount a dial gaugeso that the plunger is resting on the back of the camshaft lobe. Zero the dial gauge. Rotate the camshaft and note the maximum reading on the dial gauge.Repeatthis procedure on the remaining lobesIf a camshaft lobe lift does not meet Specifications, renew the camshaft. (4) Inspect the balanceshaft rear bearing sleeve for wear or pitting. If the sleeve is worn or pitted renew the balance shaft and front bearing assembly and renew the balanceshaft rear bearing as described under the appropriate heading.
zaslto:e until A: 22-18 shaft rearbearing Instalthebalance 22-6A mm from the rear of the cylinderblock.
Engine
Installation is a reversalof the removal procedure with attention to the following points: (l) Liberally coat the rear bearing with clean engine oil prior to installation. (2) Using a suitablesocketor tubular drift, instal the bearing into the bearing bore from the rear of the cylinder block ensuring that the side of the bearing with the flat face is towards the rear. The rear bearing is correctly locatedin the bearing bore when the distance between the rear face of the bearing and the rear face of the cylinder block is 22.18-22.68mm. (3) Coat the sealingedgeof the new welch plug with Loctite 620 and instal the welch plug into the rear of the cylinder block. (4) Instal the flywheelor drive plate asdescribed under the Flywheel/Drive plate heading. (5) Instal the balance shaft as previously described. (6) Instal the engine as previously described.
9C
(6) Remove the oil pump gearsfrom the timing cover. (7) Remove and discard the timing cover gasket and the crankshaft oil seal. TO INSPECT (1) Washall components in cleaningsolventand dry with compressedair. (2) Inspect the timing cover and the oil pump scoring or damage. cover plate for cracks,excessive (3) Inspect the pressureregulatorvalve for scoring. Instal the valve in the timing cover and check for free movement. Check the pressure regulator valve bore in the timing cover for burrs. (4\ Measure the pressure regulator spring free length. If the length is not as specifiedor the condition of the spring is suspect,renew the spring. (5) Check the oil pump gearsfor excessive wear, scoring or damage. (6) Instal the oil pump gears into the timing cover and carry out the following checks:
r$.j)Y"
12. OIL PUMP TO REMOVE AND DISMANTLE (l) Place a container under the oil filter and remove the oil filter. (2) Remove the timing cover as previously described. (3) Remove the bolts securing the oil filter adaptor to the timing cover and remove the oil filter adaptor. Remove and discard the gasket. (4) Remove the pressure regulator valve and spring from the timing cover. (5) Using a Torx T30 bit, remove the oil pump cover plate retaining screws and remove the cover plate.
Measuring the inner gear tip to outer gear clearance.

TIMING COVER
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OIL PRESSI.'RE I
! SPRING I
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OUTER GEAR
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INNER GEAR
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Dismantled view of the oil pump assembly. Measuring the outer gear to housing clearance.
56
Engine
pressurewarning 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 negativebattery terminal. (2) Raise the vehicle and support it on chassis standsplaced under the side frame members. (3) Remove the sump plug and drain the engine oil into a container. (4) Remove the front suspensioncrossmember as describedin the Front Suspensionsection. (5) Place chassisstands under the front engine mountings to securethe engine.
Measuringthe inner and outer gear to timing cover end clearance. (a) Measure the clearance between the inner gear tip and the outer gear. (b) Measure the clearance between the outer gear and the timing cover. (c) Measurethe end clearance betweenthe inner and outer gearsand the timing cover. (d) Using suitable micrometers, measure the pressureregulator valve and the corresponding bore in the timing cover. Subtract the valve measurement from the bore measurementto calculatethe pressure regulator valve clearance. If any component is excessively worn or unfit for service, or if any clearance exceedsSpecifications, renew the timing cover and oil pump assembly. TO ASSEMBLE AND INSTAL (l) Using a tubular drift, instal a new crankshaft oil seal into the timing cover. (2) Thoroughly coat the oil pump gears with Petroleum Jelly and instal the gears into the timing cover. The inner gear must be installed with'the chamfered inner edge facing away from the timing cover. (3) Completely fill the oil pump cavities with Petroleum Jelly. Failure to do this will result in delayed lubrication of the engine when the engine is started. (4) Instal the cover plate and tighten the retaining screwssecurely. (5) Lubricate the pressureregulator valve with clean engine oil and instal the spring and valve into the timing cover. (6) Using a new gasket, instal the oil filter adaptor and tighten the retaining bolts to the specified torque. (7) Instal the timing cover to the engine, ensuring a new gasketis installed as previously described. Instal a new oil filter as necessary. (S) Start the engine and check that the oil
View of the engine with the sump removed showing the oil pump pick-uppipe. (6) Remove the bolts securing the wiring harnessclamps to the front of the sump. (7) On automatic transmission models, remove the screwssecuringthe oil cooler pipes to the sump. (8) Remove the sump retaining bolts and lower the sump from the engine. Remove and discard the sump gasket. (9) Remove the bolts securing the oil pump pick-up pipe to the cylinder block and remove and discard the gasket. TO CLEAN AND INSPECT ( I ) Clean the cylinder block and sump mating surfaces. (2) Wash the inside of the sump to remove carbon and sludge deposits. Check for any metal deposits which will indicate an imminent bearing failure. (3) Inspectthe sump for dents,cracksor damage
Engi,ne
to the mounting surface. Inspect the threads on the sump plug and sump for damageor wear. Repair or renew as necessary. (4) Thoroughly clean the oil pump pick-up pipe screenwith cleaning solvent and a brush. (5) Inspect the oil pump pick-up pipe for cracks or dents. Renew as necessary. TO INSTAL Installation is a reversalof the removal procedure with attention to the following points: ( 1) Using a new gasket,instal the oil pump pickup pipe and tighten the retaining bolts to the specified torque. (2) Place the new sump gasket onto the sump, aligning the recessesin the gasket with the corresponding dimples on the sump mounting surface. (3) Instal the sump to the cylinder block and tighten the retaining bolts to the specifiedtorque. (4) Instal and tighten the sump plug to the specifiedtorque. (5) Securethe wiring harnessand, if necessary, the oil cooler pipes to the sump and tighten the retaining bolts securely. (6) Instal the front suspensioncrossmemberas describedin the Front Suspensionsection. (7) Fill the sump with the correct grade and quantity of oil. (8) Start the engine and check for oil leaks. Rectify as necessary. Increase the engine speed to 3 000 rpm for 10 seconds,allowing the idle air control valve to reset. (9) On models equipped with a radio/cassette using PIN security, enter the PIN code as described under the Radio/Cassetteheading in the Electrical Systemsection. 14. CRAhIKSHAFT OIL SEALS FRONT CRANKSHAFT OIL SEAL To Removeand Instal (1) Disconnect the negativebattery terminal. (2) Releasethe engine drive belt tensioner and disconnectthe drive belt. Refer to the EngineTune-up section if necessary. (3) Raise the front of the vehicle and support it on chassis stands. Refer to the Wheels and Tyres section if necessary. (4) On models with an automatic transmission, remove the torque converter inspection cover and, using a suitableimplement, lock the drive plate or ring gear to prevent the engineturning. The manufacturer recommendsremoving the starter motor and placing a lever between the engine block and the drive plate teeth. (5) On modelswith a manual transmission,fully engagethe handbrake, select top gear and chock the rear wheels.
5l
CRANKSHAFT PULLEY
View of the timing cover and associatedcomponents removedfrom the erngine. (6) Remove the crankshaft pulley retaining bolt and remove the crankshaftpulley from the crankshaft. (7) Drain the cooling systemand disconnectthe radiator hoses and the air bleed hose from the radiator. (8) On models with an automatic transmission, disconnectthe oil cooler hosesfrom the radiator. Seal the hosesand the radiator fittings to prevent the entry of dirt. (9) Disconnect the engine cooling fan wiring connector,remove the radiator retaining clips and lift the radiator and fan assemblyfrom the vehicle. (10) Using a punch, tap a small hole in the front face 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 reversalof 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 faces the inside of the timing cover. Check the sealcontact area on the crankshaft pulley for groovesor damage and renew the crankshaft pulley as necessary. (2) Instal the crankshaft pulley and tighten the retaining bolt to the specifiedtorque. (3) Instal the radiator and fan assembly and connect the engine cooling fan wiring connector. (4) Ensure that all hose clamps are securely tightened. (5) Fill the cooling systemwith the recommended coolant as described in the Cooling and Heating Systemssection. (6) On models with an automatic transmission, check the transmission fluid levefias describedin the Automatic Transmission section. (7) Start the engine and increasethe speed to 3 000 rpm for 10 secondsallowing the idle air control valve to reset. Check for oil and coolant leaks and rectify as necessary.
58
Engine
(8) Instal the appropriate lengthsof sealinto the oil seal grooves in the cylinder block and compact them until the ends are flush with the cylinder block. If necessary,soften the rope seal with oil to aid installation. Trim the ends to ensurethat no fibres or REAR CRANKSHAFT OIL SEAL strands are protruding in the joint face. (9) Remove the rear main bearing shell and , To Removeand Instal apply an adhesivesuch as l.octite 401 to the inside of To renew the rear crankshaft oil seal it is necesthe oil seal groove. sary to remove the engine from the vehicle and (10) Placea new sealinto the oil sealgrooveand remove the crankshaft. This procedure is described press firmly into place.Use a hammer handle or other under the heading Crankshaft and Bearings. round smooth object in a rolling motion to ensurethat It is possibleto repair a leaking rear crankshaftoil the sealis tightly packed in the groove. sealwithout removing the engine as describedunder (l l) Use a razor blade or similar and trim the the following heading. excessseal flush with the bearing cap mating face. To RepackOil Seal Firmly hold the oil seal in place when trimming the (l) Disconnectthe negativebattery terminal. sealends. (2) Remove the sump from the engine as pre( 12) Apply a light film of Loctite 5 I 5 Gasket viously described. Eliminator to the main bearing cap mating face,instal (3) Remove the rear main bearing cap bolts and the bearing shell and lubricate the bearing shelt and tap the cap with a soft faced hammer to break the the crankshaftjournal with clean engine oil. sealing compound. Instal a slide hammer into the (13) Instal the rear main bearingcap and tighten sump bolt holes and remove the main bearing cap. the bolts finger tight. Tap the bearing cap into position (4) Using a suitable tool gently drive the oil seal using a soft faced hammer and tighten the bolts to the rope into the groove in the cylinder block until it is specifiedtorque. tightly packed.The amount the sealcan be compacted (la) Inject RTV 732 sealantinto the rear maln will vary between 6-9 mm. Repeat this operation on bearing cap side channelsuntil the sealantbegins to the other end of the seal. extrude from the joint gaps. (5) Remove the oil seal from the rear main (15) Instal the sump to the engine as previously bearing cap. Thoroughly clean and dry the oil seal described. groove and remove all traces of sealant from the channelson each side of the bearing cap. (6) Measurethe depth that each side of the seal 15. PISTONS, CONNECTING RODS AND hasbeencompacted in operation(4) and add 2.0 mm. CYLINDER BORES (7) Cut two lengths of seal to the dimensions calculatedin operation (6), from the old sealremoved SpecialEquipmentRequired: from the main bearing cap. To Remove- Ridge removingtool To Measure Piston and Bore - Micrometer, cylinder measuring gauge To DeglazeBores - Cytinder bore hone To Instal - Piston ring compressor TO REMOVE AND DISMANTLE (l) Drain the engineoil and coolant and remove the cylinder heads,sump and oil pump pick-up pipe as previously described. (2) If a ridge is present at the top of the cylinder bores, remove the ridge with a ridge removing tool. Ensurethat the piston is at the bottom of the cylinder and is covered with a cloth to collect anv metal shavings. (3) Using a centre punch, carefully number the connectingrods and connectingrod capsin relation to the cylinders from which they are removed. (4) Using feeler gauges,measurethe side clearance of each connecting rod. If the side clearanceis not within Specifications,renew the connectingrod. (5) With the pisron at the bottom of the cy-
(8) On models equipped with a radio/cassette using PIN security, enter the PIN code as described under the Radio/Cassetteheading in the Electrical Systemsection.
View of the rear main bearing cap removed showing the crankshaft oil seal installed.
Engine
59
Measuring the connecting rod side clearance using feeler gauges.
ffi _ U P PE R LowER-+ cottlPREssloN ffi e*"*-*-*"-""**'s
linder, remove the connecting rod cap bolts and remove the cap and the lower bearing shell. Wipe the bearing shell and the exposedpart of the journal with a piece of clean lint free cloth, insert a piece of Plastigageacross the journal and instal the connecting rod cap and lower bearing shell. Tighten the bolts to the specifiedtorque. Remove the bolts and cap and measurethe spread width of the Plastigage to determine the bearing clearance. Compare the measurementto Specificationsand if the clearance exceedsthe limit, use new bearing shellson installation. Repeat the procedure on the remaining bearings and note each individual bearing clearancefor installation purposes. (6) Remove each connecting rod cap in turn keeping them in order and, using a wooden hammer handle, carefully push each piston assemblyfrom the cylinder block. Instal the cap and bearing shell to the correct connecting rod after removal. (7) Remove and discardthe piston rings. TO INSPECT PISTONS AND RODS CONNECTING
coMPREssloN RING
OIL RINGS
PISTON-
(1) Inspect the pistons for scuffmarks, scoring, cracksor burning. Renew the piston(s) as necessary. (2) Clean all carbon deposits from the piston crowns and using a piece of broken ring, clean out the ring grooves. (3) Remove any deposits from the piston skirts using a suitable cleaning solvent. (4) Inspect the ring grooves of the pistons for excessive wear. Use a new piston ring and check the
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BEARING SHELI-S CONNECTING ROD CAP
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Dismantled view of the piston and connecting rod components.
Measuring the piston ring side clearance using feeler 9auges.
60
Engine
(9
Ie
Measuringthe piston diameter using a micrometer. side clearanceof the ring in the ring groove.If the side clearanceexceedsSpecifications,renew the piston. (5) Measure each piston at the top and bottom of the piston skirt, at right anglesto the gudgeonpin axis. Renew the piston if the diameter is not within Specifications. (6) Inspect each pair of bearing shellsfor wear. If one or both of the bearing shells are worn on the outer edgeit is likely that the connectingrod is bent. If necessary, have the connectingrod alignment checked at an engine reconditioning workshop. (7) If the bearing clearanceexceededSpecifications when previously checkedwith Plastigage, measure each crankpin journal diameter with a micrometer. If the journal is worn beyond Specificationsit will be necessary to remove the engine and renew the crankshaft. (8) Before renewing a piston, inspect the cylinder block to seeif it requiresmachining or renewal. Cylinders that require boring will have to have new pistons installed. (9) If it is necessaryto renew a piston and/or connectingrod, take the assemblyto an enginereconditioning workshop (10) Check the connectingrod cap bolts for wear and stretch by comparison with a new bolt. TO INSPECT CYLINDER BLOCK AND BORES With the pistons removed as previously described,carry out the following checksand measuring procedures: (l) Check the cylinder bores for cracks, scores and scuffs. (2) Using an accurate cylinder gauge,measure each cylinder bore for wear, ovality and taper. Take the measurementsat the upper, middle and lower sectionsof the bore in two directions, along and across the block.
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qf
Check for cylinder bore wear. Difference between A and B measurement at top of piston travel is out of round dimension. Difference between A at top and at bottom of piston travel is cylinder taper.
Checkingthe cylinderblock for distortion using feeler gaugesand a straight edge. If either the diameter, ovality or taper exceeds Specifications, it will be necessaryto rebore those cylinders and instal oversizepistons. NOTE: It ,s not necessary to rebore all cylinders if correction is required to one or two cylinders only, as oversizepistons are manufactured to the same weight as standard pistons. (3) Check the top facesof the cylinder block for distortion using a straight edge and feeler gauges.If distortion is present and is within the machining limit, remove the engine and machine the cylinder block top faces.If the distortion exceeds the machining limit, the manufacturer recommendsrenewingthe cylinder block. NOTE: Machining the cylinder block faces beyond Specifications will increase the compressionratio. This may ceusecylinder detonation or pinging, result in /oss of
Engi,ne
performance and could afect Australian Design Rules emission requirements. (4) Thoroughly clean the cylinder block with a suitable cleaning solvent and compressedair. TO CHECK PISTON CLEARANCE (1) Using an accuratecylinder measuringgauge, measure and note the diameter of each bore as previously described. (2) Measure each piston skirt as previously described. (3) Subtract the piston skirt diameter from the cylinder bore diameter to calculate the piston clearance. (4) Cylinders that have been rebored and honed for oversize pistons should also have the clearance checkedin the manner described. TO DEGLAZF. CYLINDER BORES Cylinder bores that are fit for further service with original pistons but require re-ringing should be deglazedwith a hone. ( 1) Use a surfacing hone with 32A-400 gdt stonesfor deglazing. NOTE: When deglazing cylinder bores with the cranl<shaftinstalled, plenty of clean rag should be placed over the uanl<shaft to prevent abrasive materials entering the oil ways. (2) Move the hone up and down the cylinder walls fast enough to achievea crosshatch pattern. The cross hatch pattern most satisfactory for correct seating of the piston rings is when the ltone marks intersect at 30-45 degrees. ' NOTE: When deglazing, the cylinder should be honed only sufficiently to eliminate the glazed condition. Excessivehoning will increase bore size and thus increase piston clearance. (3) Lubricate the bore with honing oil during honing. Do not use engine oil, transmission oil, mineral spirits or kerosene. (4) When honing is completed ensure that the cylinder bore, crankcasearea and oil ways are thoroughly cleaned using a scrubbing brush with warm water and detergent.Do not use solvents. (5) After the cylinder block has been cleaned and dried, wipe the bores with a lint free cloth and coat them with engine oil to prevent rusting. TO FIT NEW PISTON RINGS AND INSTAL PISTONS Once the correct piston and bore relationship has been determined and the pistons cleanedor renewed as necessary,proceed as follows:
z*ltnaltos
6l
Measuring the piston ring end gaP. (1) Selecta set of rings to suit the bore, standard or oversize,whichever is necessary. (2) Place a compression ring into number one cylinder bore and using an inverted piston, push the ring down the bore approximately 50 mm. (3) Withdraw the piston and measurethe gap in the ring with feeler gauges.If the end gap does not either substitutewith another ring meet Specifications or file the ring to the specifiedgap. (4) Repeat the previous procedures on the remaining cylinders. (5) Treat each ring and cylinder bore individually and ensure that the rings are assembledto the respectivepiston from the cylinder bore in which the rings were originally checked for end gap clearance. (6) Prior to installing the rings to the piston, roll the outer circumference of each compression ring around its respectivering groove to ensurethat it is free. If the ring binds due to a high spot in the ring groove, carefully file the ring groove until the piston ring is free' FRoNT
Diagram showing the installed position of the piston ring gaps. [ : Upper compression ring, B = Oil ring rail gaps, C : Lower compression ring, D : Oil ring expander within this arc.
62
Engi,ne
RING LOWERCOMPRESSION
AF
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View of the piston rings showing the identification markings. If a ring has insufficient side clearance,place a sheetof emery paper on a piece of flat glassand rub the piston ring on the emery paper until the specified clearanceis obtained. (7) Instal the oil ring expander into the lower ring groove,ensuringthat the endsof the expanderare butting together. Position the tang on the oil ring expanderin the hole or slot in the ring groove within the arc shown in the illustration. (8) Instal one oil ring rail from the top of the piston down into the oil ring groove. (9) Instal the other oil ring rail from the bottom of the piston into the oil ring groove. Check that the ends of the oil ring expanderhave not overlapped. (10) Using a piston ring expander, instal the lower and then the upper compression rings. The
Instal the piston to the cylinder block using a ring compressor and a hammerhandle. upper and lower compressionrings are identified by markings on the ring adjacentto the gap.One marking identifies the upper compression ring, two identical markings identify the lower compressionring. Instal the rings to the piston with the markings facing towards the top of the piston and position the gapsas shown in the illustration. (11) Using the sameprocedure,instal the piston rings to the remaining pistons. (12) Remove the connectingrod cap bolts from number one piston and connectingrod assemblyand remove the connecting rod cap. ( 13) Rotate the crankshaft until the number one journal is at the bottom of its stroke. (14) Ensure that the bearing shell is correctly installed in the connecting rod and liberally coat the piston assemblyand the bearing shell with engineoil. (15) Instal the piston and connectingrod assembly into the cylinder bore with the arrow on the top of the piston facing the front. Instal a piston ring compressor over the piston and compressthe rings into their grooves. NOTE: Connectingrod and piston assemblies must be replaced in the cylindersfrom which they were removed. (16) Carefully push the piston assemblydown the
Installed view of the pistons showing the direction arrows.
Engine
cylinder bore and align the connecting rod on the crankpin journal, ensuringthat the bearing shell is not dislodged. ( l7) Instal the connectingrod cap and tightenthe bolts. Loosen the bolts one turn and tighten to the specifiedtorque. ( l8) If new bearing shellswere installed,recheck the bearing clearanceusing Plastigageas previously described. (19) Instal the remaining pistons in the same manner. (20) Prior to installing the oil pump pick-up pipe and sump, retighten the connecting rod cap bolts. (21) Instal the various components,referring to the appropriate headings.
63
16.
CRANKSHAFT AND BEARINGS
View of the No. 2 main bearingcap removedshowing the bearingshell. NOTE: Ensure that the bearing caps and connectingrods are numberedin relation to each other to facilitate correct assembly. (7) Prise the crankshaft forward and using feeler gauges, measurethe crankshaft end float betweenthe front of the No. 2 main bearing thrust face and the crankshaft. If the end float exceeds Specifications, renewthe No. 2 main bearing shells. (8) Check the main bearing oil clearanceusing Plastigage as follows: (a) Remove the bearing cap and with a piece of lint free cloth, wipe the journal and bearing clean. (b) Position a piece of Plastigagethe approximate length of the bearing width onto the main bearing journal, parallel to the centreline of the crankshaft. Ensure that the Plastigageis not over the oil hole. (c) Instal the bearingcap and tighten the bolts to the specifiedtorque. NOTE: Do not rotate the crankshaft while the Plastigage is in position. (d) Remove the bearing cap bolts and carefutly remove the cap and the lower bearing shetl. (e) With the Plastigage scale,measurethe compressed Plastigage strip to determine the oil clearance. (0 The widest point of the strip will indicate the minimum clearance and the narrowest point the maximum clearance. (g) The remaining bearings can be checked in turn using the sameprocedure. (9) On manual transmissionmodels,remove the clutch assembly and the flywheel. On automatic transmissionmodels, remove the drive plate. Refer to the following heading if necessary. (10) Remove the bearing cap bolts and remove the bearing caps. To remove the rear bearing cap, remove the bolts and tap the cap with a soft faced hammer to break the sealingcompound. Instal a slide hammer into the sump bolt holesand remove the cap.
Special Equipment Required: To Measure Journals - Micrometer To Check Oil Clearance- Plastigage TO REMOVE (1) Removethe engineand transmissionassembly 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 for the correct procedure. (5) Remove the spark plugs. (6) Remove the connectingrod cap bolts and the connecting rod caps. Carefully push each connecting rod and piston assembly up the cylinder without exceedingthe normal travel of the piston.
To measure the crankshaft end float, lever the crankshaft forward and measure the clearance between the front of the No. 2 main bearing and the crankshaft.
64
Engine
excessseal flush with the bearing cap and cylinder block mating faces. - Firmly hold the oil seal in place when trimming the sealendsand pack any loose strandsor fibres intS the rope sealgrooves. (5) Thoroughly clean the crankshaft journals and oilways, the bearing caps and the cylindLr block bearing bores. (6) Ensure that the bearing shellsare clean and dry ang install them to their respectivepositions ensuring that the oil feed holes in the upper shells align with the holes in the cylinder block. NOTE: The bearing shells are not inter_ changeable and must be installed in the coruect location. To determine the correct location, compare the part number stamped on the rear of the shells with the identifica_ tion chart. The grooved main bearing shells must be installed in the cylinder btock. _ (7) Lubricate the No. Z main bearing thrust faces with Molybdenum Disulphide greaseand the main bearing shellswith clean engine oit. (8) carefully lay the crankshlft into the cylinder block, guiding the connecting rod journals into their respectiveconnecting rod. (9) Instal the main bearing caps to their correct position in the cylinder block. instil the bearing cap bolts loosely_ and tap the bearing cap into position using a soft faced hammer. when the bearing cap is securelyseatedtighten the retaining bolts finger tight. Prior to installing the rear main bearing capl apply a light film of Loctite 515 Gasket Elimittuto. to itre mounting face of the bearing cap. NOTE: The -dimples on the main bearing caps must,fq.ce towards the front of thb engineand the number of ribs on the side of the main bearing caps indicate its numbir or position.
(l l) Carefully lift the crankshaft from the cylinder block, taking care not to dislodgeor damagetlie upper halves of the main bearing shels if they are to be used again. If new bearings are to be installed, remove the upper halves of the bearing shells from the cylinder block. (12) Remove the rope crankshaft sealsfrom the rear main bearing cap and the cylinder block. (13) Remove all tracesof sealantfrom the cvlinder block and the rear main bearing cap. TO CHECK AND INSPECT (l) Thorouehly washthe crankshaft in a suitable cleaning solvent and blow out the oilways with compressedair. Dry completely with compressedair. . (2) Inspect the bearingjournals for cracks,scoring, roughness or discolouration. The crankshafi must be renewed if cracks, scoring or discolouration are present.Slight roughness of a journal may be removed with a fine emery cloth soakedin engine oil. Remove burrs with a fine oil stone. (:l Measure the main bearing and connecting rod journals for wear, taper and ovility. If any of th6 measurements exceed Specifications, renew the crankshaft. (4) Support the crankshaft at each end in Vee blocks and, using a dial gauge,check the crankshaft for bend at No. 2 and No. j main bearing journals. Renew the crankshaft if the bend exceedJSpecifications. (5) With the crankshaft still supported in Vee blocks,position a dial gaugeagainstth-hywheel/drive qlate mo-untingflangeand measurethe fl-ange runout. Ensurethat the crankshaft is prevented froir moving towards or away from the dial gaugewhile performin[ this check. _ (6) Check the No. 2 main bearing thrust faces for w_ear or pitting. If wear or pitting is evident, renew the No. 2 main bearing shells. (7) Check the bearing shells for uneven wear, scores, flaking and generaldeterioration of the bearing surface.Renew the bearing shellsas necessary. TO INSTAL Installation is a reversalof the removal procedure with attention to the following points: (l) Thoroughly clean and dry the rear oil seal grooves in the main bearing cap and the cylinder block. (2) Apply an adhesivesuch as Loctite 401 to the inside of the oil seal grooves. (3) Place the rope seals in their respective grooves and press them firmly into place using a hammer handle or other ro,md r-ooth object in a rolling motion to ensure that the seals urb tightty packed into the grooves. (4) Use a razor blade or similar and trim the
lnstalled view of the crankshaft showing the maird bearing caps installed with the dimplesfaJing forward and the ribs on the side of the tap indiciting the correct location.
Engi,ne
65
MAIN
t r'
I
| 988/90
MODEL YEAR
24500076 MAGENTA
BiEAF,,NG
UPPER COLOUR NO1
that the main bearing caps and connecting rod caps are installed to their original positions. Check the crankshaft end float as previously described. (16) Instal the remaining components as described under the relevant headings and instal the engine in the vehicle as previously described. TO RENEW MAIN BEARINGS Crankshaft Installed (l) Disconnect the negativebattery 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 crankshaftweb and raise the jack until it is just taking the weight of the engine. (c) Wipe the main bearing shell and the crankshaft journal with a piece of clean, lint free cloth. (d) Placea pieceof Plastigage acrossthe bearing shell and instal the main bearing cap to the cylinder block. Tighten the bolts to the specifiedtorque. (e) Remove the bearing cap and measure the spread width of the Plastigage to determine the bearing oil clearance. Compare the measurementto Specificationsand renew the bearing shellsas necessary. Repeat the procedure on the remaining bearings and note each individual bearing oil clearance. (4) Remove the hydraulic jack and remove the bearing cap in which the shells are to be renewed. Remove the lower bearing shell(5) Instal a suitable rivet into the crankshaft oil hole and slowly rotate the crankshaft counter-clockwise when viewed from the front. As the crankshaft turns the upper bearing shell will roll out of the cylinder block bearing bore. (6) Remove the upper bearing shell and the rivet. Thoroughly clean the crankshaft journal, the cylinder block bearing bore and the bearing cap. (7\ Lubricate the upper bearing shell with engine oil. The upper bearing shellsare identified by the groove in the centre of the shell. (8) Insert the flat end of the bearing shell over the journal and partially slide the shell into the bearingbore from the side which hasthe locating tang. (9) Instal the rivet into the crankshaft oil hole and rotate the crankshaft until the bearing shell is in position. Remove the rivet from the crankshaft. (10) Lubricate the lower bearing shell and instal the bearing cap. Tap the bearing cap into position and tighten the bolts to the specifiedtorque. ( I I ) Renew the remaining bearings using the same procedure, with attention to the following points. (12) To remove the rear main bearing cap, remove the bolts and tap the cap with a soft faced
LOWER COLOUR UPPER COLOUR LOWER COLOUR

UPPER COLOUR
24500077 MAGENTA
N/A N/A 18001490 L I M EG R E E N 18001492 L I M EG R E E N 24500076 MAGENTA 2450AO78 N/A
NO2
NO3
LOWER COLOUR UPPER COLOUR LOWER COLOUR
NO4
Main bearing identification chart. (10) Recheckthe bearing oil clearance using Plastigage as previously described. If the clearance is not within Specifications, remove the bearing shell from the bearing cap and examine the rear of the shell. An undersizebearing is identified by the size stamped on the rear of the bearing shell. If the bearing shell is not undersize, instal an undersize bearing shell to the main bearing cap and recheckthe clearance. If the clearance is not as specified, renew the crankshaft. NOTE: The cranl<shafthas rolledfillet journals and the manufacturer states that the cranl<shaft cannot be machinedbut must be renewed if the specifiedclearancescannot be obtained. ( I I ) To align the No. 2 main bearing thrust faces, loosen the main bearing cap retaining bolts and lever the crankshaft backwards and forwards several times with the final movement being forward. ( 12) Tighten the main bearing cap bolts to the specifiedtorque. (13) Inject RTV 732 sealantinto the rear main bearing cap side channels until the sealant begins to extrude from the joint gaps. ( I a) Pull the connectingrods onto the crankshaft journal and instal the connecting rod cap and bolts. Tighten the connecting rod bolts, loosen them one turn and tighten to the specifiedtorque. (15) Rotate the crankshaftto checkfor free operation. If the crankshaft does not rotate freely, check
66
Engine
hammerto breakthe sealing compound. hammer ro the sump boli holes ;il Instara slide ;;;ove the bearing cap.
the No. 2 rna)n bearing ghgllg, coattheth.u.i ib."., *i,t Motybdenum phidegrease prior ro instailution.-iigr,l;;;. Disulborts (13) When installing
finger tight and lever the crankshaft backwards and forwards severaltimes with the nttai -;;;;;"t being forward. This procedure will arign the thrust !.r s\ faces. Tighten the bolts to the specified?..;; NOTE: The ^dimples on the main bearing caps must face towards the front ij tne engine. (14) Prise the crankshaftforward and using feeler gauges'measurethe crankshaft end float between the front of the No. 2 main uea.i"g trr-ri-r"ie and the crankshaft.If the end float is not-witrri" sp."ifications ,repeat t!. previous operation to align tt. main bearing thrust faces. (15) Prior to installingthe rear main bearing remove all tracesof sealantfrom the ctrann;6;" cap, side of the cap. Applv a light nrm of-ioctite each st GasketEliminato. to the morinting ru.. ortil"L""rrrrg s cap. Instal themain bearing cap aid tightenihe bolts to the specifiedtorque. (16) Recheckthe bearingcrearance previously as described. If the clearancels not withinTpecifications, remove the bearingshell from trttu*-ring cap and examine the rear of ttre shell. a,, ""a.rsize bearingis identifi94 bv the size stampedon the rear of the bearingshell..Ifthe bearingsheliis noi.rrrdrrrire, instal an undersize bearing sf,eil to the-u.arirrg ,ap and recheckthe clearance. If the clearance is not as specified, renew the crankshaft. - ( I 7) with the main bearing cap borts tightened to the specifiedtorque, rotate ttre crinkshaft ind check for free operation without binding ut u"V poirrt. If the crankshaft binds check that tie bea.ing shells and cap are installed correctly and check -the crankshaft end float as previously descriUeO. (.18) Instal tl.reoil pump pick_uppipe and sump as previously described. 17. TO REMOVE (l) Remove the transmissionfrom the vehicle as describedin the Manual or Automati. i;;;ission sections,whichever is applicable. (2) On manual transmissionmodels,remove the clutch pressure plate and driven prate is described under the clutch Unit and Release Mechanism -pi.rrur. heading in the Clutch section. Ensure that the plate and flywheel are marked to r"rui.-.Lrr..t installation. (3) On automatic transmissionmodels,mount a FLYWHEEL/DRIVE PLATE
Installedview of the drive plate assembly. dial gauge in a position where the plunger will rest against the driveTlate adjacent to the Iorqu. converter bolt holes. check the runout at eachof the bolt holes. If the runout exceeds0.20 --, li^ may be possible to correct using a mallet. If thi;'f;ir, renew the drive.plate. (4) Remove the flywheel or drive plate retaining bolts and remove the flywheel or drive irr"iilrom ttre crankshaft. TO CHECK AND INSPECT . (l) Inspect the flywheel face for cracksor excesslve scorrng. (2) Inspect the ring gearfor damaged,cracked or worn teeth- If ne,cessary, the ring gear on the flywheel pay be renewed separately as described under the following heading, lio*"rrer, if the ,i6;;in ttre drive plate requires renewal, the drive piut. urr.mbly must be renewed. . (3) Inspect the drive plate bolt holes for elonga_ tion, causedby loose retaining bolts. (4) Inspect the drive plate for cracks. NOTE: The flywheel and drive plate are (es.ignedand .manufactured rc 5, iri- of balance 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 the ring gear. NOTE: Do not drill right throush the rins gear as this will damage the flinge on th"e flywheel. (2) Secure the flywheel, with the drilled hole uppennost, in a vice_ equipped with soft jaw guards. (3) Placea cold chisel above the hoie in",h. ring gear 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 be installedto the flywheelwith the teeth leading edges in the same direction. (5) Remove the ring gear, clean the mounting face on the flywheel and remove any burrs. (6) Polish a few spots of the new ring gear with emery cloth and heat the ring gear evenly until the polished spots turn blue. NOTE: Do not heat the ring gear past the point requiredto achieve a blue colour or the tempering of the gear teeth will be impaired. (7) With the flywheel suitably supported, pick the ring gear up using pliers and place it evenly onto the flywheel. NOTE: Allow the ring to cool slowly. Do not quench in water. TO INSTAL Installation is a reversalof the removal procedure with attention to the following points: (1) As the flywheel or driveplate retaining bolt holes are offset, the flywheel or driveplate can be installed in one position only. (2) Tighten the retaining bolts to the specified torque. (3) On manual transmission models, instal the clutch and pressureplate assemblyas describedin the Clutch section. (4) Instal the transmission to the vehicle as describedin the Manual or Automatic Transmission sections. 18. ENGINE MOUNTINGS FRONT MOUNTINGS To Removeand Instal (1) Disconnect the negativebattery terminal. (2) Release the clamp securingthe air inlet hose to the throttle body and disconnectthe hose. (3) Raise the front of the vehicle and support it on chassisstands. (4) Remove the nuts securingthe enginemounting to the crossmemberand 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 mounting proceedas follows: (a) On automatic transmission models, remove the bolt securingthe front of the starter motor to the enginebracket. (b) On air conditioned models, remove the air conditioner compressorretaining bolts and securethe compressoraway from the engine. (7) Remove the engine bracket retaining bolts, raise the engine slightly and remove the engine bracket and engine mounting.
67
esf
Dismantled view of the right hand engine mounting components.
Dismantled view of the left hand engine mbunting components.Air conditionedmodel shown. Installation is a reversalof the removal procedure with attention to the following points: (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 aircontrol valve to reset.
68
Engine
(2) When installing the crossmember to the mounting bracket ensure that the insulating washers are correctly positioned at each end of the insulating bushesand tighten the nuts and bolts finger tight. (3) Instal the crossmemberto the vehicle underbodv and tighten the bolts securely. (4) Remove the jack and tighten the crossmember to mounting bracket nuts and bolts securely.
(3) On models equipped with a radio/cassette using PIN security, enter the PIN code as described under the Radio/Cassetteheading in the Electrical Systemsection. REAR MOUNTING To Removeand Instal ( I ) Raise the front of the vehicle and support it on chassis stands placed under the front jacking points. with a (2) Positiona jack underthe transmission suitable piece of timber placed between the head of the jack and the bottom of the transmission and raise the transmissionslightly to relieve the weight from the rear mounting. (3) Remove the bolts retaining the transmission crossmemberto the vehicle underbody and the nuts and bolts retaining the crossmemberto the mounting bracket.
CROSSUEMBER Hur+@
19.
EXHAUST SYSTEM
TO REMOVE AND INSTAL (1) Raise the vehicle and support it on chassis stands. (2) Remove the clamp securingthe rear muffler and tailpipe assemblyto the intermediate muffler. (3) Remove the bolts securing the rear muffler remove support bracket to the tailpipe. If necessary the support bracket and rings. (4) Separate the rear muffler and tailpipe assembly from the intermediate muffler. NOTE: Should dfficulty be experienced when separating the exhaust pipesfrom the or mufrler, they may be cut with a hacl<saw pipecutter when a replacementsystem is to "frozen" joints be installed. When heating to loosenthem, take extreme cere nearfloor panels, fuel and brake lines and electrical wiring. (5) Support the engine pipes in front of the catalytic converter. (6) Remove the bolts retaining the intermediate pipe to the catalytic converter. (7) Remove the support insulator from the body bracket and manoe-uvrethe intermediate pipe and muffler from the underbody. (8) Remove the bolts securing the left hand exhaustenginepipe to the left hand exhaustmanifold flange. (9) Remove the clamp securing the right hand exhaust engine pipe to the left hand exhaust engine pipe junction. (10) Separatethe left hand exhaust engine pipe and. catalytic converter from the right hand exhaust engine pipe and remove the catalytic converter and engine pipe assembly. (l l) Remove the bolts securing the right hand exhaust engine pipe to the right hand exhaust manifold flange and remove the right hand engine pipe from the vehicle. ( 12) If necessary, remove the bolts securing the catalytic converter to the left hand exhaust engine pipe and separatethe pipe from the converter. Discard the gasket, NOTE: Do not drop or hit the catalytic
t\"o t 4
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Dismantled view of the rear engine mounting assembly. (4) Withdraw the transmission crossmember from the vehicle. (5) Working through the holes provided in the rear mounting bracket, remove the bolts retaining the mounting to the extension housing and withdraw the mounting. (6) If necessary, remove the nuts retaining the mounting bracket to the mounting and separatethe two components. Installation is a reversalof the removal procedure with attention to the following points: (l) If the rear mounting and mounting bracket instal the mounting bracket to the rear wereseparated, mounting ensuring that the arrow on the top of the mounting bracket is facing to the left side of the vehicle when installed.
Engine
converteror damage to the ceramic core will result. Installation is a reversalof the removal procedure with attention to the following points: (l) [Jsenew gaskets when installing the catalytic converter. (2) Instal all componentsof the exhaustsystem to the underbody but do not tighten any nut or bolt.
69
(3) Check the system for correct positioning. Ensure that all components clear the underbody sufficiently. (4) Progressively tighten the exhaust system, starting from the exhaust manifold flangesand working towards the tailpipe. (5) Start the engineand check for exhaustleaks. Rectify as necessary.
lnstalled view of the exhaust system.
70
COOLING AND HEATING SYSTEMS
SPECIFICATIONS Coolant capacity Coolant Approximately 10 litres . . 50% ethylene glycol corrosion inhibitor and 5070clean water
Thermostat: Opening temperature . 89 - 93 deg C Valve lift at 106 deg C . . . . . . More than 9 mm Fan cut in temperature Above 102 deg C Fan cut out temperature Below 99 deg C Surgetank pressurecap opening pressure . . . . l2O I 50 kPa TORQUE WRENCH SETTINGS Engine drain plugs Water pump bolts: Long bolts Short bolts Thermostat cover bolt . Water pump pulley bolts Fan to motor shaft nut. Fan shroud to radiator bolts
54 Nm 40 Nm l4 Nm 34 Nm l6 Nm 2.5 Nm 4.5Nm Checkthe radiatorhosesfor cracksor deterioration. NOTE: Check the cooling systemfor external leakageby running the engine to operating temperature over a dry floor and checkingfor the sourceof a leak. Also check the vehicleinterior below the heater unit for moisture. If a welch plug is found to be rusted, it is recommendedthat all the welch plugs be renewed. COOLANT LEAKAGE INTERNAL
1. COOLING SYSTEM TROUBLE SHOOTING COOLANT LEAKAGE EXTERNAL
(l) Loose hose clip or faulty hose: Tighten the hoseclip or renew the faulty hose. (2) Leaking radiator core or tanks: Repair or renew the radiator. (3) Worn or damaged water pump seal assembly: Renew the water pump assembly. (4) Worn or damaged water pump bearing assembly: 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 cylinder head:Repair or renew any faulty components. (7) Leaks at the thermostat cover or water pump: Renew the gasketsor O rings as required. (8) Leaking heater core or valve: Repair or renew any faulty components. (9) Loose or rusted welch plugs: Renew the welch plugs.
(l) Cylinder head gasket leak due to warped cylinder head or cylinder block gasket faces: Reface cylinder head(s)or cylinder block and renew cylinder head gasket(s). (2) Crack in the cylinder head or cylinder block: Repair or renew the faulty components. NOTE: Check the engine for internal leakage by withdrawing the dipstick and inspectinsfor emulsffiedoil. Run the engine and checkfor excessive steam at the exhaust pipe which would indicate water leakage into the combustion chamber. Check the compression as described in the Engine Tune-upsection to locate a leaking cylinder head gasket.
Cooling and Heating Systems

ENGINE OVERHEATING (1) Surgetank pressurecap defective:Renewthe pressurecap. (2) Insufficient coolant: Replenish the coolant, check the cooling system for leakage and repair as necessary. (3) Obstructed air passage through the radiator core: Blow out the obstruction by applying air or water pressurefrom the rear to the front of the radiator core. (4) Faulty coolant temperature sensor, electric cooling fan or wiring: Check and renew the coolant temperaturesensoror electric cooling fan or repair the wrrrng. (5) Leaking cylinder head gasket: Check and rectify as described under Coolant Leakage Internal.
7r
A blown head gasket is indicated by bubbles in the radiatorcoolantwith the enginerunning. (6) Faulty thermostat: Check and renew the thermostat. (7) Faulty water pump: Renewthe 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 Management section and rectify as necessary. (12) Low engine oil level: Stop the engine immediately and replenish the oil in the sump to the correct level. (13) Incorrectly adjusted or dragging brakes: Check and rectify by adjustment or renewal of componentsas describedin the Brakessection. (14) Slipping clutch: Repair the clutch as necessary. NOTE: Engine overheating is usually accompanied by steam emitting from the engine compartment. A leaking cylinder head gaiket ls sometimes indicated by bubbles in the coolant when the engine is running. COOLANT CIRCULATION FAULTY
Check the condition of the valves and the seal on the surge tank cap.
Ensure that the wiring connections to the cooling fan are clean and secure.
(1) Insufficientcoolant in the system:Replenish the coolant and check for leaks. (2) Partial blockage of the radiator core tubes: Reverseflush or renew the radiator. (3) Sludgedepositsin the enginewater passages: Clean and reverseflush the engine cylinder block. (4) Faulty thermostat: Check and renew the thermostat. (5) Collapsingradiatorhose: Check and renew the radiator hose. (6) Faulty water pump: Renew the water pump.
72
Cooling and Heati,ng Systems

NOTE: This condition is best checked by removing the surge tank cap and running the engine until it reaches the normal operating temperature. Check for water turbulence in the tank. A normal system should show turbulence at part throttle. As most adverse conditions can be caused by more than one fault, diagnosis can only be made after checking the items by process of elimination in the order shown. If blocked radiator core tubes are detected, it li recommended that the radiator be taken to a reliable specialistfor repair. 2. HEATER AITD AIR CONDITIONING TROUBLE SHOOTING heater hoseswill remain cold. With the aid of an assistant, and with the enginerunning, check that the valve operates when the control inside the vehicle is movedfrom the cold position. If the heater core is blocked, the hoseon one side will be hot while the other will be cold. NO COOLED AIR INSIDE VEHICLE (l) Engine drive belt slipping: Check and renew the drive belt as described in the Engine Tune-up section. (2) Insufficient refrigerant: Check the systemfor leaks and top up as necessary. Refer to the Air Conditioning heading in this section for information on checkingthe refrigerant level. (3) Compressorinoperative: Check for power to the compressorbefore removing the cornpressorfor repair by a specialist. (4) Heater systemallowing warm air to mix with cooled air: Check the operation of the heater system. NOTE: The above trouble shooting procedures are basic checlcsonly. If the air conditioning system li suspect, it l's recommendedthat the vehicle be taken to an authorised dealerfor testing and repair. It is normal for water to be seendraining under the vehicle from the evaporator after the vehicle has been operated with the air conditioning on. 3. DESCRIPTION
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) Blockedheatercore:Clean or renew the core. (5) Heater controls inoperative: Check the vacuum hosesfor leaks. (6) Lack of coolant in engine: Check the surge tank coolant level. NOTE: Ensure that the engine is reaching normal operating temperature. If in doubt check the operation of the thermostat as describedunder the Thermostat heading in this section. When the engine is at normal operating temperatureand the heater valveis open,all the heaterhoses shouldfeel warm/hot. If the valveis not allowing the coolant to flow, the
ENGINE COOLING SYSTEM The cooling systemusesthe thermo-siphon principle with a water pump and an electric cooling fan providing assistance.The system is pressurised in order to raise the boiling point of the coolant and so increasethe efficiencyof the engine. A lightweight aluminium crossflow radiator is used with plastic radiator tanks. On automatic transmission modelsthe left hand side radiator tank houses the transmission oil cooler. Provision for pressureand vacuum relief of the systemis incorporated in the surgetank pressurecap. The surgetank has three hoseconnections,an air bleed port from the inlet mainfold, a coolant overflow from the top of the radiator and a coolant supply port. Temperature within the cooling system is controlled by a thermostat located at the rear of the inlet manifold. The function of the thermostat is to prevent the circulation of the coolant through the radiator until the engine has reached operating temperature. This restricted circulation allows the engine to warm up more quickly improving driveability and fuel economv.
View of the heater shut off valve. The valve should close when the heater control is moved to the full cold jrcsition. Adjust the heater control rod if necessary.
Coolinga,ndHeati'ngSystems
The water pump is driven by the automatically adjusted engine drive belt. The body of the water pump is made from aluminium alloy to assist in gnging lyeight roduction, It is equipped with a double to* bull bearing and a spring loaded seal assembly. The water pump is a disposableunit and thus cannot be repaired. The electric cooling fan is mounted on the rear of the radiator and its operation is regulated by the coolant temperature sensor and the engine control unit. Power is supplied by a relay and fuse which are locatedin the enginecompartment relay housing.The control unit also operates the fan when the att conditioning is switchedon and vehicle speedis below 55 km/h, or if the coolant temperaturesensoris faulty. To avoid accidental scalding, exercise caution when releasing the surge tank pressure cap on an engine that is at normal operating temperature. 4. RADIATOR
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(1) Slowly fill the surge tank with the specified coolant until the coolant begins to flow from the bypassand radiator overflow hose connections.Connect the hosessecurely. (8) Continue filling the surgetank until coolant flows from the hosewhere the screwdriveris installed. Remove the screwdriver and tighten the clamp securely. (9) Fill the surge tank with the specified coolant as previously described and install three cooling system pellets, available from the vehicle manufacturer, into the surge tank. NOTE: The pellets are required to prevent depositsforming on the water pump seal which may cause coolant leakage. (10) Start and run the engine for 20 minutes to dissolve the pellets and purge any air that may be trapped in the cylinder heads.Check the coolant level as previously described. TO REMOVE (l) Disconnectthe negativebattery 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.
TO CHECK COOLANT LEVEL NOTE: On models where the COLD mark on the surge tank is below the join in the tank, the coolant level has been revised to approximately 25 mm above the join in the tank. (l) With the enginecold, check the level of the coolant in the surge tank. The level should be at the cold mark on the surgetank. (2') If the level is below the cold mark. remove the surgetank pressurecap and add the recommended coolant coolantand cleanwater mixed in a ratio of 50Vo to 5006water until the level is correct. (3) Run the engine and check for coolant leaks. pressuretest the surgetank cap to check If necessary, for serviceabilitv if coolant loss occurs and leaks are not apparent. TO DRAIN AND REFILL (l) Set the heatercontrols to the hot position. (2) Position a suitable container under the cylinder block drain plugs and remove the surgetank cap. The drain plugs are located on each side of the cylinder block. (3) Remove the cylinder block drain plugs, disconnectthe lower radiator hoseand drain the coolant into the container. (4) When the coolant has drained clean the cylinder block drain plugs, apply Loctite 242 or equivalent to the threads and tighten the drain plugs to Specifications. Connect the lower radiator hose. (5) Disconnect the water pump bypass hose from the front of the inlet manifold, and the overflow hose from the radiator. (6) Loosen the clamp retaining the thermostat cover outlet hose to the pipe at the rear of the engine and insert a blunt nose screwdriverbetweenthe hose and pipe using care not damage the hoss.
View of the radiator and associated components removed from the vehicle.
74
(5) Disconnect the upper and lower radiator hoses. (6) On automatic transmission models, loosen the hose clamps and disconnect the oil cooler hoses from the left hand side radiator tank. Plug the hoses and the fittings to prevent the loss of fluid and the entry of dirt. (7) Using a pair of pliers, squeeze the radiator retaining clips and remove them from the radiator support panel. (8) Lift the radiator upwards and out of the engine compartment. Plug the radiator inlet and outlet hose fittings and fill the radiator with coolant. NOTE: When a radiator that has been in use for some time ,J removed from the vehicleto enablerepairs to be carried out to the engine,it should not be allowed to stand empty for any length of time. The radiator should be kept full. Failure to observethis precaution may result in overheatingwhen the engine is put back into service.This is caused by internal deposits in the radiator drying and flaking and so obstructing the circulation of the coolant in the system. TO FLUSH AND CLEAN (1) With the radiator removed as previously described, block off the overflow passageand place the radiator on its side. (2) Insert a hose in the radiator outlet fitting, sealthe gap around the hosewith suitable waste cloth and reverseflush the radiator until the water flowing from the inlet fitting is clean. NOTE: If excessive back pressure or diminished flow indicates severely blocked radiator coretubes,which cannot be cleaned by reverse flushing, it is recommendedthat the radiator be repaired by a radiator specialist. (3) Apply a stream of water or compressed air to the radiator core from the rear to the front.
Cleaningthe radiatorcore using a gardenhose. To avoid damageto the radiator core maintain a distance of 40 - 50 cm between the cleaning nozzLe and the radiator core. Continue the cleaningprocedureuntil all dirt and foreign matter is removed from the radiator core. TO REPAIR The aluminium core of the radiator can be repaired using an Aluminised Silicon material available from an authorised dealer. If the plastic side tanks develop a leak, the tanks must be renewed. When renewing side tanks always use a new seal. If a leak is apparent in the join betweenthe side tanks and the core assembly,tighten the clinch tabs evenly using vice grip type pliers. If the leak is still present remove the side tanks for inspection. To prevent damage to the engine the following precautions should be observed: Do not remove more than 25 mm of the total fin area of the radiator. Do not block off more than two tubes of the radiator. Replace the radiator core if there are more than three clinch tabs broken on one side of the header or more than two adjacent tabs broken. When the side tanks are removed for any reason always use new sealsduring 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 the repair will fail when the radiator is put into service. (2) If necessary cut away approximately 6 mm of the fin material beyond the area to be repaired to exposethe damagedarea.
Reverse flushing the radiator using a garden hose.

(3) Clean the damagedareawith a small amount of petrol to remove any tracesof oil. (4) Thoroughly stir the contents of the repair agent. (5) Apply the repair agent sparingly using a wooden spatula or similar to drip the agent onto the radiator core. (6) Allow the radiator to stand cleanand dry in a well ventilated areafor a minimum of three hours. Do not apply heat to promote drying. (7) Instal the radiator as describedlater in this section. 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 core repair 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 suitabletool or screwdriver. Lift the tabs only enough to allow removal of the side tanks. (3) Lift the side tank from the core using light taps of the palm of the hand to release sealadhesionif necessary. (4) Remove and discard the seal. Clean the sealingsurfacesof the core and tank. (5) Check the header area of the core for burrs and other damageand repair the area as necessary. (6) If the oil cooler is to be removed from the left hand tank and installed in a new one proceed as follows: (a) Remove the oil cooler nuts and washersfrom the oil cooler fittings. (b) Remove the oil cooler from the radiator tank. (c) Instal new sealsto the new radiator tank and slide the oil cooler through the seals. (d) Instal the nuts and washersthen torque the nuts to 20 Nm. (7) Instal the tank and the seal to the core and securelyclamp it in position using adjustablebuilders clamps ensuringa 30o/o compressionof the seal. (8) Clamp the clinch tabs to the tank using vice grip type pliers. Start at the centre of the radiator and work outwards in a circular sequence. (9) Instal the radiator as described later in this section. To Renew Oil Cooler Seals It is not necessary to remove the side tank from the radiator if the oil cooler sealsare being renewed. (1) Remove the radiator from the vehicle and flush it out thoroughly. (2) Remove the oil cooler nuts and washersand push the oil cooler into the side tank. NOTE: Lay the radiator down so that the oil cooler doesnot slide to one end.
t5
(3) Remove the sealsusing 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,dry the tank and coolersealareasusinga hot air gun or hair dryer. (5) Using long nosepliers in conjunction with a strongwire hook pull the oil cooler through the rubber seals. IJse care to ensure that thre rubber does not becomedislodgedduring this operration. (6) Instal the oil cooler nuts and washers and tighten the nuts to 20 Nm. (7) Instal the radiator as des,cribed later in this section. TO INSTAL Installation is a reversalof the removal procedure with attention to the following points: (l) Instal the shroud and fernassemblyto the radiator. (2) Carefully instal the radiator, ensuring that the pegs on the bottom of the radiator are fully inserted in the lower mountings. (3) Instal the radiator retaining clips and connect the fan wiring connector. (4) Instal all radiator hosesand hoseclamps. (5) On automatic transmissionmodels connect the oil cooler hoses. (6) Refill the cooling syst,sm as previously describedand check for leaks. (7) Connect the negative battery terminal. Start the engine and increasethe speedto 3 000 rpm for 10 secondsallowing the id,leair control valve to reset. On models equipped with a radio cassetteusing PIN security,it will be necessary to enter the PIN code as describedunder the Radio/Cassiette headingin the ElectricalSystemsection. (8) Road test the vehicle and check for correct operation. (9) On automatic transmissrionmodels check and if necessary top up the transnnission fluid to the correct level. Refer to the Autonratic Transmission section for the correct procedure. 5. COOLING FAI{ AI{D COOLI\NT TEMPERATURE SEI\ISOR
TO TEST COOLING FAN AND SYSTEM (l) With the cooling systemcold, switch on the ignition and confirm that the coolinLg fan is stationary. (2) If the cooling fan rotates, proceedas follows: (a) Remove the cooling fan relay from the engine compartment relay housing. (b) Check for continuity betrveenthe relay terminals 30 and 87 using an ohmmeter. If continuity is displayed,renew the relay.
76

A 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 temperature sensor as described in the Fuel and Engine ManagementSection,code 14. (c) On air conditioned modelsa further checkon the fan is possible.Remove the jumper lead from the ALDL, start the engineand allow it to idle. Switch the air conditioning on and ensure that the cooling fan runs. If the fan does not run, check the f,an relay as describedin the Fuel and Engine Managementsection under the EFI and Fuel Pump Relays heading.
COLOUR CODE B -Black L -Blue Y - Yellow W -W h i te O - Orange K -Pi n k
theterminals (a) Connect ajumperleadbetween
KEY l : FuseS / - Fuse23 $ : Cooling fan relay

Q,'
TO REMOVE AND INSTAL COOLING FAN ( I ) Disconnect the negativebattery terminal. (2\ Separatethe cooling fan wiring harnessconnector adjacent to the top radiator hose. (3) Remove the bolts retaining the fan shroud assemblyto the radiator and manoeuvrethe assembly from the vehicle.
$ $ J $
= : _ :
Coolingf an Coolant temperature sensor Cont r olunit To throttle position switch Gonnector
Schematic layout of the cooling fan and coolant temperature sensor showing the cooling fan relay terminal numbers. If continuity is not displayed,proceedas follows: (c) Switch the ignition Off and disconnect the engine control unit wiring connector. If necessary, refer to the Fuel and Engine Managementsection. (d) Using an ohmmeter, check for continuity betweenthe relay connector terminal 85 and earth. If continuity is displayed,rectify the short to earth in the wiring harness between the relay connector terminal 85 and the control unit connector terminal If continuity is not displayed, renew the control unit. (3) In step (1) if the cooling fan is stationary proceedas follows:
cl.
Dismantled view of the cooling fan assembly. (4) If necessary, the fan and motor assemblycan from the shroud assemblyby removing be separated. the fan nut and the motor retaining screws. NOTE: If thefan will not come offthe motor shaft, place the fan nut back on the motor shaft and lightly tap thefan shaft with a soft faced hammer while holding thefan blades. Installation is a reversalof the removal procedure with attention to the following points: (l) Ensure that the fan does not contact the shroud when rotating. (2) Tighten all screwsand bolts securely. (3) Connectthe negativebattery terminal. Start the engine and increasethe speedto 3 000
Location of the diagnostic link connector. lnset shows the terminal identification. The connector may be concealed behind the kick panel.

rpm for l0 secondsallowing the idle air control valve to reset. On models equipped with a radio cassetteusing to enter the PIN code PIN security,it will be necessary as describedunder the Radio/Cassetteheading in the Electrical Systemsection. (4) Road test the vehicle and check for correct operating temperature. TO TEST COOLANT TEMPERATURE SENSOR Testing and renewal of the coolant temperature sensoris coveredin the Fuel and Engine Management section. 6. THERMOSTAT
77
(1) Ensure that the mating surfacesof the thermostat cover and inlet manifold are clean and free from corrosion. Use a new O ring during installation. (2) Instal the throttle body and the inlet manifold adaptor as described in the Fuel and Engine Managementsection. (3) Fill the cooling system as previously described,run the engine and check for coolant leaks. TO CHECK (1) Check that the thermostat is fully closed when cold.
Special Equipment Required: To Check Thermostat - Thermometer TO REMOVE AND INSTAL (l) Drain the cooling systemto a level below the thermostat as describedunder the Radiator heading. (2) Remove the throttle body and the inlet manifold adaptor as describedin the Fuel and Engine Managementsection. (3) Loosen the hose clamps and disconnect the coolant hose from the thermostat cover. (4) Remove the thermostat cover retaining bolt and pull the cover from the inlet manifold. Discard the O ring. Installation is a reversalof the re,movalprocedure with attention to the following Foints:
THERII,PMETER
THERMOSTA
WATER FILLED CONTA I N E R HEAT SOURCE
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O*rO**
249/515
Linedrawing showingthe correct method usedto test a thermostat. (2) Suspend and immerse the thermostat together with a reliable thermometer, in a vessel of 50/50 glycol/water,ensuringthat neither the thermostat nor the thermometer are touching the sides or bottom of the vessel. (3) Progressivelyheat the coolant mixture noting the temperature reading on the thermometer as the thermostat valve commencesto open. SeeSpecifications for the correct opening temperature.Heat the coolant to 106 degrees C and check that the thermostat valve opens more than 9 mm. A thermostatwhich doesnot perform asdescribed above should be renewed. 7. WATER PUMP
THEnuosrar+
TO REMOVE AND INSTAL (1) Disconnect the negativebattery terminal. (2) Drain the cooling system as described previouslv in this section.
View of the thermostat and associated components.
78
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6ry
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il
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rpm for 10 secondsallowing the idle air control valve to reset. On models equipped with a radio cassetteusing PIN security,it will be necessary to enter the pIN code as describedunder the Radio/cassetteheading in the Electrical Systemsection. 8. WELCH PLUGS
To facilitate the casting of the cylinder block and cylinder head, a number of openingshad to be made at manufacture. These openings are plugged with welch plugs. The plugs may have to be renewedwhen engine water jackets or when the plugs -cleaningth_e become defective due to corrosion. Dismantledview of the water pump components. (3) Before removing the drive belt loosen the water pump pulley retaining bolts. (4) Using an 18 mm ring spanner,loosen the drive belt tensioner and remove the drive belt. (5) Remove the water pump pulley bolts and withdraw the pulley from the pump. (6) Remove the water pump retaining bolts and using a soft faced hammer lightly tap the oiate, pump to remove it. (7) If necessary remove the water pump spacer plate and discard the gasket. (8) Inspect the water pump for cracks and damageto the gasketsurfaces.Check the water pump bearing for roughnessor noisy operation. Inspect the wafer pump drain hole for signsof coolant leakage.If defects are found, renew the water pump as an assembly. Installation is a reversalof the removal procedure with attention to the following points: (t) Ensure that all mating faces are clean and free.from old gasketmaterial. Always use new gaskets during installation. (2) Clean the threads of the water pump retain_ ingbolts and apply Loctite sealant 242 or equivalent to the threads. NOTE: Do not apply sealant to thefirst I - 2 threads of the bolts. (3) Instal the bolts and tighten progressively. The shorter water pump retaining bolts have a muih smaller torque than the longer bolts, refer to Specifications. (4) Instal the water pump pulley and tighten the retaining bolts securelybut not exceisively. (5) Instal the drive belt as descriLed in the Engine Tune-up section. (6) With the drive belt installed checkthe torque of the water pump pulley bolts. (7) Fill the cooling system as previously described, run the engine and check for ioolant leaks. (8) Connect the negativebattery terminal. Start the engine and increasethe speedto 3 000 TO RENEW NOTE: If one welch plug is found to be defective it is good policy to ienew all the welch plugs. (1) Drain the radiator and cylinder block as previously described. (2) Remove the necessary enginecomponentsor accessories to gain ample working spacearound the plug. (3) Using a suitablepunch and hammer,tap the welch plug on its outer circumferenceinto its opening. (4) Grasp the edgeof the welch plug with a piir of multigrip pliers and using the shoulder of the multigrip pliers, lever the plug out of its opening. (5) Thoroughly clean and dry the welch plug opening. (6) Lightly smearthe edgeof the new welch plug and its openingwith o'Stag" jointing compound. (7) Place the welch plug into the opening and using a suitable tube or socket fitting the rim of tne plug, drive the plug squarely into the opening. NOTE: The plug must be driven into the opening sqparely or leaks may occur.
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lnstalled view of the engine welch plugs.
Cooling and Heating SYstems

(8) Instal the components which were removed gain access to the Plug. to -(9) Fill the cooling system as previousty d9s"riUed. With the surge tank pressure cap installed, mn the engine until it reaches normal operating temperature and check for coolant leaks. 9. HEATER UNIT AI{D BLOWER MOTOR
79
TO REMOVE AND INSTAL NOTE: On air conditionedmodels,removal of the heaterunit requiresthe disconnection of tne air conditioner evaporatorlines. This the evacuation and rechargwill necessitate ing of the system by an authorised dealer. nifer to the Air Conditioning heading. (l) Remove the dashboard from the vehicle as describedin the Body section. (2) Drain the cooling system as previously described. (3) Disconnect the water hosesfrom the heater pipei in the engine compartment adjacent to the bulkhead. (4) Disconnectthe vacuum hosefrom the heater water valve in the engine compartment. (5) Remove the screws retaining the vent and demisting ducts to the heater unit. Disconnect the ducts from the heater unit.
(6) Working in the enginecompartment, remove the heater unit retaining screws. (7) Working inside the vehicle, remove the scre*s retaining ihe heater unit to the bulkhead. (8) CarefJlly withdraw the heater unit from the vehitle, using care not to drip coolant on the interior of the vehicle. (9) If necessary,the blower motor can be remorredfrom the heaier unit by removing the retaining screwsand unplugging the motor cooling hose. Installation is a reversalof the removal procedure with attention to the following points: (1) Moisten the heater hose fittings with water prior to installation through the bulkhead grommets. (2) Tighten all screwssecurelY (l) Eniure that the heater hosesare pushedfully onto the fittings prior to installing the clips. (4) Fill the cooling system as previously described in this section. (5) Bring the engine to operating temperature and check the operation of the heater unit. 10. HEATER AND AIR CONDITIONING CONTROLS DESCRIPTION The heater controls use three adjustments to direct air through the vehicle at the most comfortable temperature.
View of the heater unit with the dashboard removed and the vent and demisting ducts removed.
80
Cooling and Heati,ng Systems

through the vehicle. Vacuum is suppliedby the engine and stored in a vacuum tank located under the front left hand side of the vehicle. For proper operation of the heater and air conditioner controls it is important that all vacuum hoses,the vacuum tank and all connections remain in good condition. Air conditioned models use identical controls with the addition of an air conditioner On/Offbutton. The fan must be set on I or above before the air conditioning will operate. TO REMOVE, INSTAL AND ADJUST (1) Disconnect the negativebattery terminal. (2) Prise up the rear of the centre consolecover panel and pull the panel rearwards slightly to allow to the radio/cassette access surround screws. (3) Remove the screwsfrom the lowerpart of the radio/cassettesurround and pull the surround rearwards carefully until the locating lugs at the top releasefrom the dashboard.
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o
Installed view of the heater and air conditioning controls. The air flow control directs air to the vehicle floor, windscreen or dashboard outlets as required. This control also has a biJevel position and a recirculate position. On bi-level, the air from the dashboard outlets is cooler than the air from the floor outlet. On the recirculate position, the air from within the vehicle is recirculated.This position is for usein dusty conditions or to allow rapid heating or cooling of the vehicle. The temperaturecontrol opensor shutsthe heater water valve as it moves offthe full cold position then operatesa flap within the heater unit to regulatethe temperature. A vacuum switching shut off valve is used to control the heater water valve. The fan speedcontrol switchesthe fan on and off and is used to selectthe desired fan speed. The air flow and temperature controls use vacuum servos to adjust and direct the air flow
Disconnecting the vacuum block from the heater controls. (4) Disconnect the electrical connectors from the radio/cassettesurround panel noting their positions as an aid to assembly. (5) Working in the drivers footwell, disconnect the heater control rod from the control lever at the right hand side of the heater unit. (6) Rernove the screw retaining the heater controls to the dashboard and pull the heater control rearwards. (7\ Disconnectthe vacuum block and the electrical connector from the heater controls and withdraw the heater controls from the vehicle. Installation is a reversalof the removal procedure with attention to the following points: (l) Ensure that the heater vacuum hosesare in good condition and that they are not pinched or kinked when installing the heater controls. (2) Turn the temperaturecontrol to the full cold position and ensurethe heater control lever is also in
o e
lf the heater controls are not working, check all vacuum hoses and connections for damage, kinking or leaks starting at the vacuum tank under the front of the vehicle.
Cooling a,nd Heati,ng SYstems
81
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View of the heater unit showing the position of the heater shut off vatve and lever when the heater controls at the full cold position.
the full cold position before installing the snap-in rod. Operate the temperature control severaltimes. (3) Turn the temperaturecontrol knob to the full cold position again and ensurethat the heater control lever 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 to operate the shut of valve properly, remove the shut of valve and elongate the holes slightly using a small round file. The valve can then be positioned closer to the lever. (4) Connect the negativebattery terminal. Start the engine and increasethe speedto 3 000 rpm for l0 secondsallowing the idle air control valve to reset. On models equipped with a radio cassetteusing to enter the PIN code PIN security,it will be necessary as describedunder the RadiolCassetteheading in the Electrical Systemsection. (5) With the engine running and with the aid of an assistantoperatingthe temperaturecontrol, ensure that the heater water valve is shut when the temperature control is in the fully closedposition. Adjust the rod and the shut off valve again if necessary. 11. AIR CONDITIONING DESCRIPTION The air conditioning systern removes heat and moisture from the air within the vehicle-
The system may be operated alone during warm weatheror in conjunction with the heater during cold weather. When used in conjunction with the heater, the system will provide warm, dry air which will rapidty demist the interior glassof the vehicle. The basic components of the air conditioning system are an evaporator, condenser, compressor, accumulator, expansion valve and pipes and hoses carrying the refrigerant through the system.Various subsidiary controls and sensorsare used to monitor high and low pressure within the system, and to prevent the engine stalling at idle. The refrigerant will boil at a very low temperature (-33"C), thereforeit must be containedunder pressure. Escapingrefrigerant can causefrostbite and eye damage,and will produce a poisonousgaswhen burnt.
View of the air conditioning condenser and the high pressure switch.
82

MAINTENANCE The air conditioning system reqruires little maintenance other than the following. Where applicable, refer to the Lubrication and Maintenance section for the recommendedservice intervals. (1) Inspect the air conditioner pipes arid hoses Evidenceof oil for leaks,deterioration and alignmenrt. leakage is an indication of leakage of refrigerant. Repair or renew as necessary. (2) Inspect the evaporator drain tube and the condensercooling fins for blockage. Clean as necessary. (3) Checkthe drive belt for deterioration and for correct tension. Refer to the Engine Tune-up section for the correct procedure. (4) Operate the system at least once every two weeks for approximately 10 minurtes to keep the compressorsealslubricated.
Installedview of the air conditioningaccumulatorand the low pressureswitch. If the system suffers a rapid loss of refrigerant, oil from the compressorwill be lost with the refrigerant. It is recommendedthat any work requiring disconnection of the refrigerant lines be referred to an authorised dealer or an air conditioning specialist.
83
FUEL AND ENGINE MANAGEMENT

CAUTION: To prevent severeelectrical shock, extreme care must be taken n l working on or neer the electronic ignition systemas dangeroushigh tension volta) are produced in both the primary and secondarycircuits. Seetext for precautionr notes.
SPECIFICATIONS FUEL INJECTION Type FUEL PUMP High pressure: Type Electric, roller vane Fuel pressure with ignition On . . . 280-320 kpa Fue[ pressureat idle 240-260 kpa *Low pressure: Type Electric Centrifugal Fuel pressure 20-25 kpa FUEL FILTER Type AIR FILTER Type IGNITION SYSTEM Type . . . Direct Fire Ignition (DFI) Firing order l-6-5-4-3-2 Coil primary resistance ... 0.3-1.5 ohms resistance Coil secondary . . . . . 10 000-14 000 ohms High tension lead resistancelimit 17 000 ohms *Long range fuel tank only. TORQUE WRENCH SETTINGS Air cleaner housing retaining nuts . . . . . 7 Nm Throttle body retaining nuts . . . . 20 Nm Throttle body adaptor retaining nuts . . 20 Nm Fuel rail retaining bolts . . . 30 Nm Throttle cable mounting bracket bolts . 34 Nm Ignition control module retaining nuts. 1l Nm Crankshaft sensoradjusting bolt. . 5 Nm Crankshaft sensorretaining bolts 40 Nm Crankshaft pulley retaining bolt . . . . . 325 Nm Coolanttemperaturesensor.... .12Nm Oxygen sensor . 46 Nm ... Disposablepaperelement ... Disposablepaperelement . . Electronic controlled multi-point Manifold air temperature (MAT) sensor. Detonationsensor.... Hand tighten plus one turn ....22Nm
1. FUEL AI{D ENGINE MANAGEMENT TROUBLE SHOOTING NOTE: The fottowing Trouble Shooting procedures are basic checks onlv. If these proceduresfail to locate the fauit, iompr"hensive fault diagnosis procedures are describedunder the SystemDiagnosis heading. Faults in the Fuel and Engine Management system can be divided into three categories: fuel supply, electrical connections and electrical componentfailure. Electrical componentfailure accountsfor less than ten percent offaults. Prior to performing any of thefollowing operations, refer to the Service Precautions and Proceduresheading. ENGINE WILL NOT START OR HARD TO START (l) Fault in the fuel supply system: Check the fuel pump fuse and relay. Check the fuel filter for blockage. Check the fuel pressure. Check the ftel pump connections.Check for water in the fuel. Check the fuel injector circuit. (2) Fault in the power supply: Checkthe battery, fusible links and fuses.Check for clean secureconnections, particularly the earth connections. Check the EFI relay. (3) Fault in the ignition system:Check that the high tension leadsare clean,dry and securelyconnectqd to the coil pack terminals and the spark plugs. Check that the spark plugs are not faulty, fouled br incorrectly gapped.Check the ignition control module and the coil pack. (4) Faulty engine managementcomponent wiring connections: Check that all component wiring connections are clean and secure.
84
Fuel and Engine Managernent

water in the fuel. Check the fuel pressure.Check the injectors for faulty operation. (2) Faulty, fouled or incorrectly gapped spark plugs: Renew or clean and adjust the spark plugs. (3) Vacuum leak at the inlet manifold: Check all joints and hosesfor vacuum leaks. (4) Faulty engine managementcomponent wiring connections: Check that all component wiring are cleanand secure. connections (5) MAP sensorvacuum hoseblocked or disconnected: Clear or connect the vacuum hose. (6) Faulty MAP sensor operation: Check the MAP sensorcircuit. (7) Faulty idle air control (IAC) valve operation: Check the IAC valve circuit. Check the alternator voltage output. (8) Faulty throttle position sensor operation: Check the throttle position sensorcircuit. (9) Loose or corroded battery terminals and earth straps: Clean and tighten the battery terminals and earth straps. ENGINE MISFIRES (1) Faulty, fouled or incorrectly gapped spark plugs: Renew or clean and adjust the spark plugs. (2) Weak or inconsistent spark: Check the high tension leads for moisture, dust, cracks and burns. Check the resistanceof each lead. (3) Weak ignition coil output: Check the ignition systemcircuit. (4) Faulty fuel injector operation: Checkthe fuel injection circuit. (5) Faulty crankshaft sensor: Check the crankshaft sensor and the crankshaft pulley blades for damage,Renew as necessary. (6) Fault in the fuel supply system: Check the fuel supply system for a blocked fuel filter, incorrect fuel pressureor water in the fuel.
Check that all electrical connections are clean and secure.
Check the MAP sensor vacuum hose for splits, obstructionand a secureconnection. (5) MAP sensorvacuum hoseblocked or disconnected: Clear or connect the vacuum hose. (6) Engine flooded: Fulty depress the throttle pedal until the engine starts. Check the coolant temperature sensor circuit. Check the injectors for leakage. NOTE: If the fuel pump relay fails, power will be supplied to the fuel pump via the oil pressureswitch. When starting the engine, the fuel pump will not operateuntil the oil pressure is sufficient to extinguish the oil pressurewarning lamp. Therefore it will be necessary to operate the starter motor for a longerperiod than usual to start the engine. ENGINE STARTS THEN STALLS (1) Fault in the fuel supply system:Cheek for

(7) Vacuum leak: Check for vacuum leaksat the vacuum hoses,the throttle body and the inlet manifold. NOTE: To check if a fuet injector is functioning, hold the blade of a long screwdriver againit the body of the fuel injector while the engine is idling. Listen to the opposite end of the screwdriverfor a clicking sound, indicating that thefuel iniector is functioning. ENGINE LACKS POWER (l) Fault in the fuel supply system: Check the fuel supply system for a blocked fuel filter, water in the fuel or incorrect fuel pressure.
85
for leakage. Checkall fuel lines and connections (5) Faulty manifold absolute pressure (MAP) sensoroperation: Check the MAP sensorcircuit. (6) Faulty fuel injector operation: Checkthe fuel injection circuit. (7) Vacuum leaks: Check for vacuum leaks at the vacuum hoses, the throttle body and the inlet manifold. (8) Faulty thermostat operation: Refer to the Cooting and Heating Systemssection. (9) Faulty enginecooling fan operation. Refer to the Cooling and Heating Systemssection. 2. DESCRIPTION
The air cleaner should be seruiced at regular intervals-
(2) Blocked air cleaner: Check the element and clean or renew as necessary. (3) Faulty, fouled or incorrectly gapped spark plugs: Renew or clean and adjust the spark plugs. (4) Excessivehigh tension lead resistance:Test eachlead and renew as necessary. (5) Incorrect alternator voltage output: Check the alternator operation. (6) Loosecontrol unit earth connections:Ensure that all connectionsare secureand clean. (7) Incorrectly adjusted throttle cable: Check and adjust the throttle cable as necessary. EXCESSIVE FUEL CONSUMPTION (1) Incorrect fuel pressure:Check the fuel pressure with a pressuregauge. (2) Leaks in the fuel system:Check the connections and componentsfor leakage. (3) Faulty coolant temperaturesensoroperation: Check the coolant temperature circuit. (4) Faulty manifold air temperature(MAT) sensor operation: Check the MAT sensorcircuit.
The engine management system on the range of vehiclescoveredby this manual controlsthe operation of the following systems; Fuel injection, Ignition, Engine cooling fan and if equipped, the Automatic transmission torque converter clutch and the Air conditioning compressorclutch. The central component ofthe enginemanagement system is the control unit. The control unit is a microcomputer which controls the ignition timing and the amount of fuel injected according to signals are detectAs changes receivedfrom various sensors. ed in engineload and speed,coolant temperature,air temperature, barometric pressure, throttle position, vehicle speedand exhaustoxygencontent, the control unit altersthe ignition timing and the fuel injection to achieveoptimum engineefficiencyunder those conditions. The control unit also incorporatesa self diagnosis mode which stores and displays codes relating to certain systemmalfunctions. Whenever power is supplied to the control unit, the control unit performs a seriesof tests on various components in the system and records the results. If a fault is discovered, the
86
Fuel a,nd Engine Ma,nagernent

(HTDDEN) cooLANT TEMPERATUBE SENSOR
View of the engine showing the engine management components.
Check Engine warning lamp will illuminate on the instrument cluster while the engine is running. When the self diagnosismode is activated, the Check Engine warning lamp will flash coded signals indicating the area in which the fault has occurred. This function is very useful in locating system faults, particularly intermittent problems. However, the self diagnosismode does not provide comprehensive testing of the engine management system, and therefore should always be used in conjunction with the test proceduresdescribed later in this section in order to accuratelylocate systemfaults. When a fault is discovered,the control unit will by-passthe fault and substitute a signal calculatedby the control unit, allowing near normal operation of the systemuntil the fault is rectified. The direct fire ignition (DFI) systemconsistsof a control module, coil pack assemblycontaining three ignition coils, crankshaft sensor and crankshaft pulley. The feature of this system is the absenceof a distributor. The control module controls the primary circuit to the coils and the ignition timing when a fault is discoveredin the Engine Managementsystem. Each coil fires two spark plugs simultaneously, however, the firing sequenceensuresthat one spark plug fires on the compression stroke and the other spark plug fires on the exhauststroke. The spark plug
firing on the compressionstroke receivesmost of the available voltage as the spark plug firing on the exhauststroke requires little voltage to spark. The crankshaft sensor is made up of three segments. The centre segment is a magnet and the segments on either side are sensors. A magneticfield is created between the sensorsand the magnet. When the interrupter blades on the rear of the crankshaft pulley passthrough the channelsbetweenthe magnet and the sensors the magneticfield is broken and pulse signalsare produced. The signalsare supplied to the control module to determine the position of the piston. The control module then supplies signals to the control unit which calculates engine speed and controls ignition timing. If detonation is detectedby the detonation sensor, the control unit retards the ignition timing up to 8' and slowly reverts to the appropriate ignition timing when detonation has ceased. The electronic fuel injection system uses multipoint injection, where a metered amount of fuel is injected into the air stream at the inlet ports of the cylinder head. The airlfuel mixture then enters the combustion chamber via the inlet valves. The fuel is supplied under pressure by a high pressureelectric fuel pump which is mounted to the fuel gaugesenderunit inside the fuel tank. The fuel is maintained at a constant pressure,relevant to var-
87
Schematic diagram of the engine management system.
1. 2. 3. 4. 5. 6.
F uel l i n e Vacuum line Electrical circuit Air cleaner element Throttle body Manifold absolute pressure (MAP) sensor 7. High pressure fuel pump (Standard fuel tank) 7. Low pressure fuel pump (Long range fuel tank)
8. High pressure fuel pump (Long range fuel tank) 9. Fuel damper (Long range fuel tank) 10. Fuel filter 1 1. Pressure regulator 12. Fuel injector 13. Oxygen sensor 14. Detonation sensor 1 5. Goolant temperature sensor
16. Manifold air temperature (MAT) sensor 17. ldle air control (lAC) valve 18. Throttle position sensor 19. Control unit 20. lgnition control module 21. Crankshaft sensor 22. Spark plug 23. Fuel tank 24. Yehicle speed sensor 25. Neutral safety switch
88

from the vehicle before attempting any welding operations. Do not direct a steam cleaning or pressurewashrng nozzle at engine management components when cleaningthe engine. Handle all engine management component with care, particularly the control unit and oxygen sensor. At the completion of a self diagnosis test procedure or the repair or renewalof a component,clearthe fault codes,run the engine for 2 minutes and test for fault codesto ensurethat the fault has been rectified. Do not attempt to dismantle the control unit or air flow meter. If faulty, these components must be renewedas complete assemblies. Do not directly apply battery voltage to the injectors. NOTE: If the power supply to the control unit has been interrupted by disconnecting the negativebattery terminal or the ENG. COMP fusible link, it will be necessaryto run the engine at 3 000 rpm for l0 seconds to allow the idle air control valveto reset. If the battery has been disconnectedon modelsequippedwith a radio/cassetteusing PIN security, enter the PIN code as described under the Radio/Cassette heading in the Electrical System section. TO CONNECT ELECTRICAL TEST EQUIPMENT NOTE: Some typesof tachometersand ignition system analysers ere not compatible with this engine managementsystem.It is thereforerecommendedthat the manufacture of the test equipment be consulted beforeproceedingto use the test equipment. Multimeter It is essential that in all tests where voltage or resistanceis to be measured a digital display multimeter with a minimum l0 megohmsimpedancebe used. All meter readings are to be performed with the component wiring connectors installed unless otherwise instructed. This can be done by inserting the meter test probes from the wiring harnessside of the connector,or back probing. If the test probes are not thin, they should be modified by attachinga thin piece of wire to the end of the probe, giving a fine point that will not damagethe connector.Ensurethat the wire is making good contact with the probe. To facilitate testing of the control unit wiring connectors,disconnect the connectorsfrom the control unit, remove the plastic retaining clips from both sidesof the connectorsand instal the connectors to the control unit. Ensure that the retaining clips are installed to the connectors at the completion of the test procedure.'
iances ln manifold pressure, by the fuel pressure regulator. Excessfuel is returned to the fuel tank via the fuel return line. Models equipped with a long rangefuel tank have the high pressure pump mounted externally and an additional low pressurepump is mounted to the fuel gaugesenderunit inside the fuel tank. A fuel damper is installed between the external high pressure fuel pump and the fuel filter to suppressfuel pulsations createdwhen the two fuel pumps are in operation. The amount of fuel injected is relevant to the time the injectors remain open. The basictime the injectors remain open is controlled by the control unit, which uses information from the various sensors to give optimum engine efficiency for the relevant conditions. The idle air control (IAC) valve controls the idle speedduring enginewarm up and maintains the basic idle speed at a set value by compensatingfor loads such as air conditioning or the selection of Drive on automatic transmission models. The throttle body is mounted to the rear of the inlet manifold and controls the amount of air entering the engine by the action of the throttle pedal. Efficient operation of the EFI systemdependson accuratesignalsbeing receivedby the control unit and controlled air flow beyond the throttle valve. Therefore it is essential that all air, fuel and electrical connectionsare clean and secure. 3. SERVICE PRECAUTIONS AND PROCEDURES
Electronic ignition systemscan produce dangerously high voltagesin both the primary and secondary circuits. For this reason,extreme care must be taken when working on or near the ignition system. Do not start the engineif the battery terminals are not clean and tight Do not use the fast chargeor boost settings on a battery chargerto start the engine. Do not disconnectthe battery terminals while the engineis running. Disconnect the battery terminals before charging the battery. Disconnect the negative battery terminal before working on the engine managementsystem. Do not subject the control unit to temperatures above 80 deg C. Ensure that all wiring connectors are clean and tight. Ensure that the ignition is Off before disconnecting any engine managementcomponent. Depressurise the fuel systembefore removing any fuel supply components.The fuel systemmaintains a high residual pressureat all times. Disconnect the battery terminals and the control unit wiring connector and remove the control unit
89
Tachometer To measure engine rpm an inductive pick-up tachometermust be usedand set on 2 cycleoperation. If the tachometer does not have cycle adjustment, halve the indicated rpm. Connect the tachometer to the engine following the instrument manufacturersinstructions.
4.
SYSTEM DIAGNOSIS
The correct method of backprobing the wiring harness connections. The meter test probe should be modified with a piece of thin wire as shown.
NOTE: Due to the useof complex electronic components in the enginemanagementsystem, the diagnosis and testing procedures described in this section should not be carried out by persons lacking an understanding of electronicsand the precautions associated with the servicing of electronic components.It is recommendedthat should a Jirult arise in the system, the vehicle be taken to an authoriseddealerfor rectifrcation. The control unit can be damaged by componentfaults not indicated by the self diagnosis codes and the renewal of the control unit without locating the cause of foilure will result in the failure of the replacement unit. It is for this reason that the practice of substituting componentsto isolatefaults is not recommended. Prior to performing any of thefollowing operations, refer to the ServicePrecautions and Proceduresheading. PRELIMINARY CHECKS Prior to performing the Self DiagnosisTest Procedure, catry out the following preliminary checksand rectify as necessary. (1) Check for fuel in the fuel tank. (2) Check the wiring connectors and eafth points of all engine management components for clean, secureconnections.To prevent damageto the control unit, disconnectthe negativebattery terminal before disconnectingany engine managementwiring connectors. (3) Check the condition of the battery. Refer to the Electrical System section in this manual for checking procedures.Rectify any faults as necessary. (4) Check the air cleanerelementfor restriction. (5) Check for air leaks at the throttle body, inlet manifold and all related hoses. (6) Ensurethai the control unit wiring harnessis routed away from all other wiring harnesses. (7) Check the fuel pump pressureas descdbed later in this section. (8) Ensure that the engine is in satisfactory mechanical condition and is in tune. Refer to the Engine and Engine Tune-up sectionsas necessary.
Remove the retainingclips from the controlunit wiring connectorsto facilitate backprobetesting. If sealing plugs or boots are removed from the wiring connectors to facilitate backprobing, ensure that they are correctly installed at the conclusion of the test procedure. To identify wiring connector terminals, refer to the fuel and engine managementwiring diagram and note the wiring colour codes to the various components. Test lamp When a test lamp is specified,it is essentialthat the test lamp doesnot draw a current of more than 0.3 amp to avoid damageto the electronic components. To check the current draw of the test lamp, connect an accurateammeter, such as the multimeter describedpreviously, in serieswith the test lamp. Test the assemblyacrossthe vehicle battery. If the ammeterreadslessthan 0.3 A or 300 ma the test lamp is suitable. If the test lamp is not suitable, fabricate an LED (light emitting diode) test lamp as described in the Electrical Systemsection.
90
ENG. COMP FUSIBLELINK 30 A
FueI and Engine Management
MAIN FUSIBLE LINK 60 A
FUSE No.9 5 A
Anti-Thetl Circuit
ALARM
OVERRIDE
FUSE No. 21 15A To Oil Pressure Lamp
EFI RELAY
D7
"_j
811 DETONATION Dl0 A9 A5 A7 A't2 D6 o3 D1
GW ZB
CA UO
c5
A10 c't2 All c11 c14 c13 02 c10
+
COLOUR CODE B.BLACK L.BLUE G-GREEN R.RED Y . YELLOW W. WHITE N-BROWN O-ORANGE K-PINK S . GREY 249t452MD144
Cooling Fan Relay
c1 810
MAP SENSOR
+
< Tachometer N
Neutral Safety Switch (4,/T)
COOLANT TEMP SENSOR
6d
a
-
A,iC Relay Starter Circuit
,, 82 A2
{#
TriD Comouler
Auto Trans 4th Gear/femp Switch
B5
B R- B R
B3 D4 D5
DB-DB
The first letter ot the code representsthe main wire colou( the other letters represenl the trace colours. V.VIOLET P-PURPLE X-LIGHTGREEN Z-LIGHTBLUE M. DARK GREEN T - DARK BLUE A-LIGHTBBOWN E.SLATE D.TAN
-.1
INJECTORS ELECTRONIC CONTROLUNIT
Fuel and engine management system circuit diagram.

SELF DIAGNOSIS This function is very useful in locating system faults, particularly intermittent problems. However, the self diagnosismode does not provide comprehensive testing of the engine management system, and therefore should always be used in conjunction with the other test procedures described later in this section in order to accuratelylocate systemfaults. To Interpret Self Diagnosis Codes Once the self diagnosismode is activated, various fault codeswill be displayed as a seriesof flashesby the Check Engine warning lamp on the instrument cluster. To identify the codenumber, count the number of times the Check Engine warning lamp flashes.Each fault code comprisestwo groups of flashesseparated by a 1.2 secondpause.The first group representstens and the second group represents single units. For example I flash followed by a 1.2 second pause followed by 4 flashes would be code number 14. Similarly, 4 flashesfollowed by a 1.2 second pause followed by 2 flasheswould be code number 42. The code will be displayed three times. If more than one fault code is present, the self diagnosis systemwill indicate eachone in numerical order, with a3.2 secondpausebetweeneachcodeand then repeat the sequence. The fault codescan be identified as follows: CODE NUMBER FAULT AREA Satisfactoryoperation Oxygen sensorcircuit Coolant temperature sensor circuit Throttle position sensorcircuit MAT sensorcircuit Vehicle speedsensorcircuit MAP sensorcircuit No crankshaft input signals (enginewill not start) Electronic spark timing (EST) circuit Detonation sensorcircuit Mem-Cal unit Control unit input circuits
9l
heading,perform the circuit test procedureand rectify the causeof the code before proceeding. If the Check Engine warning lamp flashescodes other than code 55, check the wiring harnessbetween the diagnostic link connector terminal - and the control unit wiring connector terminal A.9 for shorts. Repair or renew the wiring harnessas necessary. If no fault can be found, renew the control unit. If the Check Engine warning lamp does not illuminate, proceedas follows: (a) With the ignition switched On, check that the instrument cluster warning lamps light. If they do not light check that the instrument cluster wiring connectorsare securelyinstalled. Also check the instrument cluster printed circuit for damageor open circuits. (b) Check the condition of fuses 9 and 11 and the fusible links. Renew the componentsas necessary. (c) Check the wiring harnessconnectorsto the instrument cluster. Ensure'that the wiring harness connector terminals are secureand clean. (d) Check the Check Engine warning lamp bulb. Renew as necessary. (3) Connect a jumper lead acrossterminals A and B on the diagnosticlink connector.
r2
13,44,45 14,15 21,22 23,25 24 33,34 4l 42 43 5l 55
Test Procedure (l) Perform the following checks: (a) Ensure that the battery voltage is above I I volts. (b) Ensurethat 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 Enginewarning lamp on the instrument cluster is illuminated but not flashing. If code 55 is displayed, refer to the Control Unit
Locationof the diagnosticlink connector.Inset shows the terminal identification.The connectormay be concealed behindthe kick panel. (4) Note the codes indicated by the flashing Check Engine warning lamp. If code 12 is displayed, the system is operating correctly. If codesother than code t2 aredisplayed,refer to the component or circuit test procedure under the appropriate headingas indicated by the codenumber. If more than one code is being displayed,test each indicated fault working in the order of display of the code numbers. (5) After completing the self diagnosistest procedure, remove the jumper lead fiom the diagnostic link connector. (6) After repairing or renewing the necessary
92

(3) Check the fuel systemfor leaksat all connections from the fuel tank to the injectors. (4) If renewalof any component is required, the fuerl system must be depressurised as previously described. NOTE: Useonly hosesand clamps as specified by the manufacturer. (5) Turn the ignition Offand removethejumper lead from the diagnostic link connector. TO TEST FOR INTERNAL LEAKS (l) Depressurisethe fuel system as previously described. (2) Disconnect the negativebattery terminal. (3) Disconnect the fuel supply hose from the fuel supply pipe located under the throttle cable mounting bracket.
components, erase the self diagnosis memory as describedlater in this section. (7) Repeat the self diagnosistest procedure and ensurethat code 12 is displayed. To Erase Memory (l) With the ignition Off, remove the ENG. COMP fusible link, located adjacent to the relay housing,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 control valve to reset. 5. FUEL SUPPLY COMPONENTS
Special Equipment Required: To Check Fuel Pressure- 600 kPa pressure gauge,suitable T piece fitting NOTE: Before proceeding with any of the operations in this section, refer to the Service Precautions and Proceduresheadings. TO DEPRESSURISE FUEL SYSTEM ( 1) Remove the fuel pump fuse from the engine compartment relay housing. (2) Start the engineand allow it to idle until the engine stalls. (3) Operate the starter motor for 10 secondsto ensurethat the fuel pressurehas been relieved. (4) Replacethe fuse.
Testing the fuel system for correct pressure and internalleakage. (4) Using a suitable T piece, a short length of fuel hoseand hoseclips, instal the T pieceand the fuel hose to the fuel supply hose and the fuel supply pipe. (5) Instal a suitable pressure gauge to the T piece, ensuring that all connections and test equipment are capableof withstanding pressures up to 600 kPa. (6) Instal the fuel pump fuse and connect the negative battery terminal. Check the fuel system for external leaks as previously described. Removethe fuel pump fuse when depressurising the fuel system. TO TEST FOR EXTERNAL LEAKS (l) Ensure that the fuel tank has a sufficient amount of fuel. (2) Connect a jumper lead betweenterminals C and D in the diagnostic link connector which is located at the top of the pasbenger side kick panel and turn the ignition On. NOTE: To prevent misleading pressure gauge readings, ensure that the ignition is Onfor 15 seconds to purge thefuel systemof air. (7) Remove the jumper lead from the diagnostic link connector and turn the ignition Off for l0 seconds. (8) Turn the ignition On and note the reading on the pressuregauge.

If the pressure does not decrease,no internal leakageis indicated. NOTE: There may be a small initial decrease in pressure when the fuel pump switchesoff. This is acceptableand doesnot indicate a fault in the system. (9) If the pressure decreases,clamp the fuel supply hosebetweenthe T piece and the fuel rail and note the reading on the pressuregauge.If the pressure stops decreasingthe high pressurefuel pump may be consideredfaulty and should be renewedas described later in this section. NOTE: If the fuel pressure has decreaseda large amount, turn the ignition On for approximately I0 secondsto pressurise the system. This should be done be:hre the fuel hose is clamped. Pressurise the system as necessary during the testing procedure. (10) If the pressure continuesto decrease, release the clamp from the fuel supply hose and clamp the fuel return hose from the pressureregulator. Pressurise the fuel systemif necessary. gauge. ( I I ) Note the readingon the pressure If the pressurestops decreasing, the pressureregulator may be considered faulty and should be renewed as delater in this section. sc.ribed (12) If the pressurecontinues to decrease, release the clamp from the fuel return hose. (13) Remove the fuel rail and injector assembly from the inlet manifold as described later in this section.Connectthe fuel pipe and hosesto the fuel rail ensuringthat the joints are securedfirmly. (14) Pressurise the fuel systemand observewhich injectors are leaking, Renew the faulty injector(s) as necessary. (15) Pressurise the fuel systemand check for any pressuredecrease. (16) Depressurise the fuel system as previously describedand remove the pressuregaugeand fittings. (17) Instal all components and connect all fuel hosesand clamps securely. (18) Test the system lbr external leaks as previously described. (19) Start the engineand increasethe speedto allowing the idle air control 3 000 rpm for 10 seconds, valve to reset. (20) On models equipped with a radio/cassette using PIN security, it will be necessaryto enter the PIN code as described under the Radio/Cassette heading in the Electrical Systemsection. TO TEST FUEL PRESSURE High PressureFuel Pump (1) Depressurisethe fuel system as previously described. (2\ Disconnect the negativebattery terminal. (3) Disconnect the fuel supply hose from the
93
fuel supply pipe located under the throttle cable mounting bracket. Disconnect the pressureregulator vacuum hose. (4) Using a suitable T piece, short length of fuel hose and hose clips, instal the T piece and the fuel hoseto the fuel supply hose and the fuel supply pipe. (5) Instal a suitable pressure gauge to the T piece, ensuring that all connections and test equipup to 600 ment are capableof withstanding pressures kPa. (6) Instal the fuel pump fuse and connect the negative battery terminal. Check the fuel system for external leaks as previously described. (7) With the jumper lead remaining connected to the diagnostic link connector, turn the ignition On for one minute until the fuel pressurereading stabilises.The pressuregaugeshould read 280-320 kPa. (8) If the fuel pressure is as specified,test the pressureregulator as follows: (a) Connect a hand vacuum pump to the pressure regulator vacuum connection. (b) Switch the ignition On and note the fuel pressure. Apply 50 kPa vacuum to the pressure 15 kPa or regulator.The fuel pressureshould decrease more. If the pressure did not decrease, renew the pressureregulator. (9) If the fuel pressure is below the specified readings,carry out the following procedure: (a) Check the fuel lines for blockages and kinks. Also check for a blocked fuel filter or fuel pump pickup strainer. (b) If no fault can be found in the previous checks clamp the fuel return hose from the pressure regulator. (c) Turn the ignition On and note the pressure gaugereading. If the pressureis lessthan 320 kPa the fup! Fump may be considered faulty. If the pressureis greater than 320 kPa the pressure regulator may be considered faulty. (10) If the fuel pressure is above the specified reading as described in operation (7), carry out the following procedure: (a) Disconnect the fuel return hose from the :pressure regulator. (b) Connect a suitable length of fuel hoseto the ,pressure regulator and place the opposite end of the ihoseinto a petroleum resistant container. (c) Turn the ignition On and note the pressure gaugereading. If the pressureis within 280-320 kPa locate and remove the restriction in the fuel return pipe. If the pressureis greaterthan 320 kPa the pressureregulator may be consideredfaulty. (11) Remove the pressure gauge and fittings, connect all fuel hosesand tighten the clampssecurely. (12) Test the system for external leaks as previously described.
94
Fuel end Engine Managernent

engine compartment relay housing. Renew the fuse if necessary. (2) Switchthe ignition On. If the fuel pump fuse blows, refer to the headingEFI and Fuel Pump Relays and carry out the test procedures. (3) Switch the ignition Off. Connect a test lamp between the diagnostic link connector terminals D and B. (4) After ten secondsswitch the ignition On and note the test lamp. It should illuminate for 2 seconds. If the test lamp illuminates as specified,proceedto the following operation. If the test lamp does not illuminate, a fault in the fuel pump relay or the fuel pump relay circuit is indicated. Refer to that heading and carry out the test procedures. If the test lamp remains illuminated after 2 seconds, disconnect the oil pressure switch wiring connector. If the test lamp goes out, renew the oil pressureswitch. If the test lamp remains illuminated, a fault in the fuel pump relay or the fuel pump relay circuit is indicated. Refer to that heading and carry out the test procedures.
(13) Start the engine and increasethe speedto 3 000 rpm for l0 seconds allowing the idle air control valve to reset. (14) On models equipped with a radio/cassette using PIN security, it will be necessary to enter the PIN code as described under the Radio/Cassette heading in the Electrical Systemsection. Low PressureFuel Pump: LonB RangeFuel Tanlt (l) Depressurisethe fuel system as previously described. (2) Disconnect the negativebattery terminal. (3) Raise the rear of the vehicle and support it on chassisstands. (4) Using a hand pump or suitablesiphon, drain sufficient fuel from the fuel tank to reduce the fuel level to below the fuel gauge sender unit. Do not siphon fuel using the mouth. (5) Disconnect the fuel supply hose from the fuel gaugesenderunit. (6) Disconnectthe fuel return hosefrom the fuel tank. (7) Using a suitable T piece, two lengths of fuel hose and hose clips, instal the T piece and the fuel hosesbetweenthe fuel gaugesenderunit and the fuel return hosetank connections. (8) Instal the pressuregaugeto the T piece and ensurethat there is sufficient fuel in the tank to cover the fuel pick-up. (9) Disconnect the external fuel pump wiring connections. (10) Connect the negativebattery terminal. (11) Connect a jumper lead acrossterminals C and D on the diagnosticlink connector,located at the top of the passenger side kick panel. (12) Turn the ignition On and note the readingon gauge. The pressureshouldbe2}-25 kPa. the pressure If the fuel pressure is less than the specified pressure, remove the low pressure fuel pump as described later in this section and check the strainer for blockage. If the- strainer is not blocked the low pressurefuel pump should be renewed. (13) Remove the pressuregaugeand connect the fuel supply and return hoses. (14) Start the engine and increasethe speedto 3 000 rpm for l0 seconds, allowing the idle air control valve to reset. (15) On models equipped with a radio/cassette using PIN security, it will be necessary to enter the PIN code as described under the Radio/Cassette heading in the Electrical Systemsection. TO RENEW FUEL FILTER The procedureto renew the fuel filter is described in the Engine Tune-up section. FUEL PUMP To Test Operation (1) Check the fuel pump fuse located in the
Squeezethe fuel supply hose to check for fuel pump operation. (5) Remove the test lamp from the diagnostic link connector. (6) Connect a jumper lead betweenterminals C and D on the diagnosticlink connector and switch the ignition On. (7) Squeeze the fuel supply hose adjacent to the brake seryounit and feel for pulsationswhich indicate fuel pump operation. It should alsobe possibleto hear the fuel pump operating in the fuel tank. If the fuel pump is operating, the fuel pump circuit is serviceable. If the fuel pump is not operating, disconnect the round wiring connector at the fuel pump/tank sender unit and connect a test lamp betweenthe two terminals in the wiring connector. If the test lamp illuminates,renew the fuel pump.

If the test lamp does not illuminate, check the wiring harnessbetweenthe fuel pump wiring connector, the diagnostic link connector terminal D and the earth connection for continuity. Repair or renew the wiring harnessas necessary. Ifno fault can be found, checkthe fuel pump relay circuit as describedunder the heading EFI and Fuel Pump Relays. To Removeand Instal High Pressure Fuel Pump Standard Fuel Tank (l) Depressurisethe fuel system as previously described. (2) Disconnect the negativebattery terminal. (3) Raise the rear of the vehicle and support it on chassisstands. (4) Using a hand pump or suitable siphon, drain sufficient fuel from the fuel tank to reduce the fuel level to below the fuel gauge sender unit. Do not siphon fuel using the mouth. (5) Disconnect the wiring connectors from the fuel gaugesenderunit. (6) Loosen the hose clamp and remove the fuel hosefrom the fuel gaugesenderunit. (7) Remove the screwsretaining the fuel gauge sender unit and manoeuvre the sender unit and the fuel pump assemblyfrom the fuel tank, being careful not to damagethe strainer. (8) Disconnect the wiring connector from the fuel pump. (9) Remove the strainer from the fuel pump inlet.
95
Installedview of the fuel gaugesenderunit. (10) Slide the pulsator along the pick-up tube until it is clear of the fuel pump outlet. ( I I ) Manoeuvre the fuel pump from the mounting bracket. Installation is a reversalof the removal procedure with attention to the following points: (1) Ensurethat the fuel pump wiring is wound around the fuel pump outlet pipe to prevent it fouling the fuel gaugefloat arm. (2) Ensurethat the strainer is installed securely. (3) Use only hoses and clamps as specified by the manufacturer and ensure that all fuel clamps are properly seatedand tight. (4) Test the fuel system for external leakageas previously described. (5) Start the engine and increasethe speedto 3 000 rpm for l0 seconds allowing the idle air control valve to reset. (6) On models equipped with a radio/cassette using PIN security, enter the PIN code as described under the Radio/Cassetteheading in the Electrical Systemsection. To Removeand Instal High PressureFuel Pump Long Range Fuel Tank (1) Depressurisethe fuel system as previously described. (2) Disconnect the negativebattery terminal. (3) Raise the rear of the vehicle and support it on chassis stands. (4) Using a hand pump or suitablesiphon, drain sufficient fuel from the fuel tank to reduce the fuel level to below the fuel gauge sender unit. Do not siphon fuel using the mouth. (5) Note the installed positions of the wiring connectors. Disconnect the wiring connectors from the fuel pump. (6) Place a suitable drain tray below the fuel pump. (7) Remove the fuel pump clamp retaining bolt and remove the clamp.
Viewof the high pressurefuel pump removed from the fuel tank. Standard fuel tank.
96
BoLr+PA
t38/51s
g ffi .6 _
FueI and Engine Management

connectoralong the pick-up tube until clearof the fuel pump. Manoeuvre the fuel pump from the mounting bracket.
E -
cLAMp *I
wF$ffiffi
l.l -wAsHER cLAllPs
ffi
ffi/ont"t"
HosE
:-
F'UEL DAMPER To Removeand Instal (1) Depressurisethe fuel system as previously described.
@_
*r,
High pressure fuel pump and damper removed from the vehicle. (8) Loosen the hose clamps and disconnect the fuel hosesfrom the fuel pump. Remove the fuel pump from the vehicle. Installation is a reversalof the removal procedure with attention to the following points: (1) Use only hoses and clamps as specified by the manufacturer and ensurethat itt fuel tlamps ate properly seatedand tight. @ Test the fuel systemsfor external leakageas previously described. (3) Start the engine and increase the speed to 3 000 rpm for l0 seconds,allowing the idle speed control valve to reset. (4) On models equipped with a radio/casserre using PIN security, enter the pIN code as described under the Radiolcassette heading in the Electrical Systemsection. To Removeand Instal Low PressureFuel pump Iong Range Fuel Tank The procedurefor the removal and installation of the low pressurefuel pump is the same as the high pressurefuel pump installed to the standard fuel tank with attention to the following points: ( I ) When removing the fuel pump from the tank sender unit note the installed position of the fuel pump wires to ensurecorrect installation. Remove the nuts retaining the fuel pump wires to the terminals and remove the wires. (2) Remove the clip retaining the rubber connector to the pick-up tube and slide the rubber
Installed view of high pressure fuel pump,damperand fuel gaugesenderunit. (2) Disconnect the negativebattery terminal. (3) Raise the rear of the vehicle and support it on chassis stands. (4) Place a suitable drain rray beneath the fuel damper. (5) Loosen the hose clamps retaining the fuet hosesto the fuel damper and disconnectthe hoses. (6) Remove the nut and washer retaining the fuel damper to the mounting bracket and removi the fuel damper from the vehicle. Installation is a reversalof the removal procedure with attention to the following points: (1) Use only hosesand clamps as specifiedby the manufacturer and ensure that all fuel clamps are properly seatedand tight. (2) Test the fuel system for external leakageas previously described. (3) Start the engine and increase the speed to 3 000 rpm for l0 secondsallowing the idle air control valve to reset. (4) On models equipped with a radio/cassette using PIN security, enter the PIN code as described under the Radio/Cassetteheading in the Electrical Systemsection.
%
Dismantled view
H-e
of low pressure components. fuel pump
r/
FUEL PRESSURE REGULATOR To Removeand Instal (1) Depressurisethe fuel system as previously described.
Fuel end Engine Managernent
e7
Installed view of the fuel pressureregulator. (2) Disconnect the negativebattery terminal. (3) Disconnect the fuel return hose and the vacuum hose from the pressure regulator. Plug the fuel return hoseto prevent the entry of dirt. (4) Remove the bolts retaining the pressure regulator to the fuel rail and remove the pressure regulator. (5) Seal the opening in the fuel rail to prevent the entry of dirt. Installation is a reversalof the removal procedure with attention to the following points: (l) Instal the regulator to the fuel rail ensuring that a new O ring is installed and lubricated with engineoil. (2) Connect the fuel return hose to the pressure regulator and tighten the clamp securely.Connect the vacuum hoseto the pressureregulator. (3) Test the system for external leakageas previously described. (4) Start the engine and increase the speed to 3 000 rpm for 10 secondsallowing the idle air control valve to reset. (5) On models equipped with a radio/cassette to enterthe PIN using PIN securityit will be necessary code as describedunder the Radio/Cassetteheading in the Electrical Systemsection. FUEL RAIL AND INJECTORS To Test Iniector Circuit and Injectors (l) Disconnect the wiring connectors from the injectors. (2\ Connecta test lamp betweenthe terminals of one injector wiring connector ensuring that the test lamp probes do not make contact with each other. (3) Switch the ignition On and note the test Iamp. It should not light. If the test lamp lights, check the wiring harness for shorts to earth between the injector wiring connectorsand the control unit wiring connectorterminals Dl5 and Dl6. Repair or renew the wiring harnessas necessary. (4) With the aid of an assistant, operate the startermotor and observethe test lamp. The test lamp should flash.
If the test lamp does not light, proceed to operation (6). ti the test lamp lights but fails to flash, connect an ohmmeter betweenthe terminals of eachinjector. The should be 15-17 ohms. resistance If the resistance of each injector is as specified renew the control unit. of an injector is not as specified, If the resistance renew the injector and repeat the test procedure. (5) Repeat operation (2) to (4) on the remaining injector wiring connectors. If the test lamp flashes *h.n connectedto each injector wiring connectorthe circuit can be consideredserviceable. If the test lamp doesnot flash when connectedto a particular injector wiring connector, check the wiring harness for continuity between the injector wiring connector, the EFI relay and the control unit wiring terminalsD15 and D16. connector
Checkingthe resistanceof a fuel injector. (6) Switch the ignition On 4nd probe each terrninal of an injector wiring connectorwith a test lamp to earth. If the test lamp lights when the probe contactsthe light blue wire terminal, check the wiring harnessfor shorts to voltage between the injector wiring connectors and the control unit wiring connector terminals D l 5 a n dD 1 6 . If the test lamp does not light when the probe contactsthe orange and red wire terminal, a fault in the EFI relay or circuit is indicated. Refer to that heading in this section and carry out the test procedures. If the test lamp lights when the probe contactsthe orangeand red wire terminal proceed as follows: (7) Switch the ignition Off and connect the injector wiring connectors. (8) Switch the ignition On and backprobe the control unit wiring connectorterminalsD15 and Dl6 with a test lamp to earth. The test lamp should light when the probe contacts each terminal. If the test larnp does not light as described check
98
Fuel and Engine Management correctly seated,

(3) (4) Tighten Connect
the wiring harnessfor continuitybetween the injector wiring connectors and the control unit wiring connec- , tor teminals Dl5 and D16. Repair or rinew the wiring harnessas necessary. To Remove and Instal (1) Depressurisethe fuel system as previously described. (2) Disconnect the negativebattery terminal. (3) Disconnect the fuel return hose and the vacuum hose from the pressure regulator. plug the hosesto prevent the entry of dirt. (4) Disconnect the vacuum hosesfrom the front of the throttle body and the fuel rail. (5) ' Disconnectthe fuel supply pipe from the fuel -entry rail. Plug the fuel pipe to prevent the of dirt. I{OTE: When disconnectingthe fuel supply pipe 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 the support brackets. (7) Disconnect the wiring connectors from the fuel injectors. (q) Ensure that the area around each injector is free from dirt. (9) Remove the bolts securingthe fuel rail to the inlet manifold and carefully remove the fuel rail and the injectors from the engine.Sealthe openingsin the inlet manifold to prevent the entry of foreign material. (10) If necessary,remove the injector retaining clips and withdraw the injectors from the fuel rail. Discard the O ring seals. Installation is a reversalof the removal procedure with attention to the foltowing points: (1) When installing the injectors, lubricate the new O ring sealswith clean engine oil.
BOLTS
(2) Ensure that the injector retaining clips are

th.e fuel rail retaining bolts to the
specifiedtorque.
andtighten the flare nut secuiely.Ensurethat the fuei rail flangeis supportedwith the correct sizespannerto prevent damageto the fuel rait. (5) Connect the fuel return hoseand the vacuum hoseto the pressureregulator. Tighten the fuel return hose clamp securely. (6) Test the system for external leaks as pre_ viously described. O Start the engine and increase the speed to 3 000 rpm for l0 seconds, allowing the idle aiicontrol valveto reset. (8) On models equipped with a radio/cassette using PIN security, enter the pIN code as described under the Radio/cassette heading in the Electrical Systemsection. FUEL TANK To Removeand Instal (1) Depressurise the fuel system as previously described. (2) Disconnect the negativebattery 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 fuet using the mouth. (5) Loosen the hose clamp and disconnectthe fuel hose from the fuel gaugesenderunit. (6) Loosen the hose clamp and disconnect the fuel return hose from the fuel tank. (7) Disconnect the wiring connectorsfrom the fuel gaugesenderunit. (8) Remove the screwsretaining the stoneguard and remove the stoneguardfrom under the right hand side rear wheel arch. (9) Disconnect the fuel vapour hose from the metal pipe which connectsto the charcoalcanister.
the fuel supply p)pe to the fuet ra;l
B/
"g
@::'.-""EREGuLAroR
&+ORING
View of the fuel rail partially dismantled.
Installed view of the fuel tank. Station Wagon model.
Fuel a,nd Engi,neManagernent
99
Installation is a reversalof the removal procedure with attention to the following points: (1) When renewingthe air cleanerelement,use only the manufacturersspecifieditem. (2) Clean the air cleaner housings thoroughly, taking care not to allow dirt to enter the air intake hose. (3) Ensurethat the air cleanerelementis seated correctly before installing the upper housing. To Removeand Instal Air Cleaner Housing (1) Disconnectthe negativebattery terminal. (2) Releasethe clamp securing the air intake hoseto the air cleanerupper housing.
View of the fuel tank removed from the vehicle. Station Wagon model shown. (10) Support the fuel tank and remove the bolts and nut retaining the support straps. NOTE: If a jack is used to support the fuel tank, place a block of wood betweenthejack and thefuel tank to preventpossible damage to thefuel tank. ( I I ) On Sedanmodels,lower the tank slightly and disconnectthe vapour hosesfrom the top of the fuel tank and carefully passthe hosesthrough the vehicle chassis. (12) Lower the fuel tank and filler neck assembly from the vehicle. Installation is a reversalof the removal procedure with attention to the following points: (l) Apply petroleumjelly to the upper end of the filler tube as an aid to installation. (2) Ensure that all fuel clamps are properly seatedand tight. (3) Test the fuel system for external leakageas previously described. (4) Start the engine and increase the speed to 3 000 rpm for l0 secondsallowing the idle air control valve to reset. (5) On models equipped with a radio/cassette using PIN security, enter the PIN code as described under the Radio/Cassetteheading in the Electrical Systemsection. 6. AIR FLOW COMPONENTS
INTAKEDUCT ,/
Dismantledview of the air cleaner. (3) Disengagethe clips retaining the air cleaner upper housingto the lower housing. (4) Raisethe upper housingand disconnectthe air intake hose.Remove the air cleanerelement. (5) Remove the nuts securing the air cleaner lower housing to the mounting insulators. Installation is a reversalof the removal procedure with attention to the following points: (l) Tighten the air cleanerlower housingretaining nuts to the specifiedtorque. (2\ Ensurethat the air cleanerelementis seated correctly before installing the upper housing. (3) Tighten the air intake hose clamp securely.
NOTE: Before proceeding with any of the operations in this section, refer to the Service Precautions and Procedures headingAIR CLEANER To Removeand Instal Element (l) Releasethe clamp securing the air intake hoseto the air cleanerupper housing. (2) Disengagethe clips retaining the air cleaner upper housingto the lower housing. (3) Raisethe upper housingand remove the air cleanerelement from the air cleanerlower housing.
r00

(8) On models equipped with cruise control, remove the bolts retaining the cruise control cable mounting bracket to the throttle body and the inlet manifold adaptor. Place the cruise control cable and mounting bracket to one side. (9) Remove the nuts retaining the throttle body to the inlet manifold adaptor and remove the throttle body. (10) If necessary remove the inlet manifold adaptor using the following procedure: (a) Remove the bolts retaining the throttle cable mounting bracket to the inlet manifold adaptor. (b) Remove the nuts retaining the inlet manifold adaptor to the inlet manifold and remove the inlet manifold adaptor. Installation is a reversalof the removal procedure with attention to the following points: (1) Ensurethat all gasketfacesare cleanand new gasketsare installed. (2) Tighten all nuts and bolts to the specified torque. (3) Ensure that the wiring connectors are fastened securelyto the throttle body. (4\ If removed, instal the throttle cable mounting bracket and connect the throttle cable and if equipped, the kickdown cable and the cruise control cable. (5) Check and if necessary,adjust the throttle cable and if equipped, the cruise control cable as describedin this section. On models with automatic transmission,checkthe kickdown cableadjustment as describedin the Automatic Transmission section. (6) Connect the air intake hose to the throttle body and tighten the retaining clamp securely. (7) Start the engine and increase the speed to 3 000 rpm for 10 secondsallowing the idle air control valve to reset. (8) On models equipped with a radio/cassette using PIN security, enter the PIN code as described under the Radio/Cassetteheading in the Electrical Systemsection. To Adjust Base ldle Speed NOTE: The idle speed is controlled by the idle air control (IAC) valve and li not adjustable. The throttle stop screw controls the base idle speed and is factory set. The following baseidle speedadjustment should only be performed if the throttle body has beenrenewed,or if comprehensive testing of related components indicates that adjustment is required. (l) Start the engineand allow it to reachnormal operating temperature. Perform the following checks: (a) Check that the air cleanerelement is serviceable. (b) Check the air intake systemfor leaks.
(4) Start the engine and increase the speed to 3 000 rpm for l0 secondsallowing the idle air control valve to reset. (5) On models equipped with a radio/cassette using PIN security, enter the PIN code as described under the Radio/Cassetteheading in the Electrical Systemsection. AIR INTAKE DUCT To Removeand Instal (l) Releasethe clamps retaining the air intake hosesto the throttle body and the air cleaner upper housing. (2) Remove the nut securingthe air intake duct to the mounting bracket. (3) Remove the wiring clamp securedto the rear of the air intake duct. (4) Remove the air intake duct and the air intake hosesfrom the vehicle. Installation is a reversal of the removal procedure ensuringthat the air intake hose retaining clamps are tightened securely. THROTTLE BODY To Removeand Instal ( I ) Disconnectthe negativebattery terminal. (2) Releasethe clamps securing the air intake hose to the throttle body and the air intake duct and remove the air intake hose. (3) Disconnect the engine vent hose from the throttle body. (4) Disconnect the vacuum hosesfrom the front of the throttle body. (5) Disconnect the MAP sensor vacuum hose from the rear of the throttle body. (6) Disconnect the wiring connectors from the throttle body. (7) Disconnect the throttle cable from the throttle body linkage. If applicable, disconnect the cruise control cableand the kickdown cablefrom the throttle body linkage.
THROTTLE BODY
lAC VALVE
View of the throttle body and inlet manifold adaptor removed from the engine.

rDLE ArR CONTROL (rAC) VALVE
101
View of the throttle body showing the throttle stop screw, IAC valve and the throttle position sensor. lnsert shows the IAC valve terminalidentification. NOTE: Vacuum leal<swill make the engine idle faster than it should. (c) Ensure that all accessories are switched off. (d) Checkthat all wiring connectorsand vacuum hosesare securelyconnected. (e) Ensure that the transmission is in Park or Neutral with the handbrake engaged and the rear wheelschocked. (2) Stop the engine, switch the ignition On and connect a jumper lead betweenterminals A and B on the diagnostic link connector. (3) After 30 seconds disconnect the idle air control valve wiring connector. (4) Ensure that the throttle valve moves freely and returns to the fully closed position when slowly released. (5) Connect an inductive tachometer to a spark plug lead and start the engine. If the engine will not start, open the throttle slightly. Allow the throttle to slowly return to the fully closedposition after starting. (6) Allow the engineto idle for 2 minutes, ensure that the cooling fan is stationary and note the idle speed.The idle speedshould be 500-600 rpm. (7) If adjustment is necessary,remove the cap from the throttle stop screwand turn the throttle stop screwuntil an idle speedof 500-550 rpm is obtained. NOTE: If the engine has completed less than 3 000 km, do not alter the throttle stop screw if the idle speedis 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 erasethe memory codesas previously described. (l l) Start the engine and increase the speed to 3 000 rpm for 10 secondsallowing the idle air control valve to reset.
To Test (1) With the engine idling in Park or Neutral at normal operating temperature, and if applicable, the air conditioner switched off, note the engine idle speedwith a suitable inductive pick-up tachometer. (2) Switch the engineOffand disconnectthe idle air control valve wiring connector. (3) Start the engineand note the enginespeed,it should be over I 500 rpm. If the engine speedhas not increasedproceed to operation (4). If the engine speed has increased switch the engine Off, connect the idle air control valve wiring connector and start the engine. If the engine speed doesnot return to the idle speednoted in operation (1) proceedto operation (4). If the enginespeedreturns to the idle speednoted in operation (1) the idle air control valve can be consideredserviceable. If the idle speedis not 650-750 {pm or is erratic, check the following possiblecauses: (a) Vacuum leaks at the inlet manifold or the throttle body. (b) Sticking or binding throttle cableor linkages. (c) Loose or dirty bittery terminals & earttt connections. (d) Worn or incorrectly gappedspark plugs. (e) Incorrect alternator output voltage. (0 Foreign material inside the throttle body causingthe idle air control valve to stick. (g) Incorrectly adjusted throttle stop screw. (h) Faulty neutral safetyswitch operation (Automatic models). (i) Coolant temperature sensorresistance. 0) Faulty throttle position sensoroperation. (k) Incorrect fuel pressureor leaking injectors. 0) Faulty air conditioner relay or circuit. (4) Stop the engine, switch the ignition On and connect a jumper lead betweenterminals A and B on the diagnostic link connector. (5) Disconnect the idle air control valve wiring connector and connecl a suitable test lamp between each connector terminal and earth for 5 seconds. If the test lamp flasheswhen connected to each connectorterminal checkfor looseor broken terminals in the idle air control valve. If the terminals are satisfactoryrenew the idle air control valve. If the test lamp does not light when connectedto the connector terminals proceedto operation (6). If the test lamp lights and does not flash when connected to the connector terminals, proceed as follows: (a) Switch the ignition Off and disconnect the control unit wiring connectors. (b) Switch the ignition On. (c) Connect the test lamp betweeneachterminal on the idle air control valve connector and earth. (d) If the test lamp lights when connectedto a
102
Fuel and Engine Management

greaterthan 28 mm, push the pintle towards the valve body while moving it slightly side to side until it retracts to a distancelessthan 28 mm. (3) Lubricate the O ring with clean engine oil. (4) Tighten the Torx screwssecurely. (5) Instal the throttle body as previously described. (6) Connect the negativebattery terminal. (7) Remove the ENG. COMP. fusible link from the fusible link housing for l0 seconds and replacethe fusible link. (8) Start the engine and increase the engine speedto 3 000 rpm for 10 seconds,allowing the idle air control valve to reset. (9) On models equipped with a radio/cassette using PIN security, enter the PIN code as described under the Radio/Cassetteheading in the Electrical Systemsection. MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR To Test - Codes33 and 34 NOTE: The following test procedure assumes that fault codes33 or 34 have been displayed during the self diagnosis test procedure.If no codeshave been displayed but the operation of the MAP sensor is suspect begin the testprocedureat operation (15). (1) Erase the self diagnosis code memory as previously described. (2) Start and run the engine at idle speed for 60 secondsor until the Check Engine warning lamp illuminates. (3) Stop the engine,switch the ignition On and connecta jumper lead betweenterminals B and A on the diagnostic link connector. Note any fault codes displayed. If code 33 is displayed,remove the jumper lead from the diagnostic link connector, erase the self diagnosiscodesand proceed to operation (4). If code 34 is displayed,remove the jumper lead from the diagnostic link connector, erase the self diagnosiscodesand proceedto operation (7).
terminal checkthe wiring harnessfor shortsto voltage between the idle air control valve connector and the control unit wiring connector. Repair or renew the wiring harnessas necessary and repeat the test procedure. (e) If the test lamp does not light when connected to the terminals check for loose or broken terminals in the idle air control valve. If the terminals are satisfactoryrenew the idle air control valve. (6) Disconnect the control unit wiring connectors and check the wiring harnessfor shorts and continuity betweenthe control unit wiring connector terminals C4, C3, C5 and C6 and the idle air control valve connectorterminals A, B, C and D. Repair or renew the wiring harnessas necessary and repeat the test procedures. If no fault is found with the wiring harness proceedas follows: (7) Connect an ohmmeter between terminals A and B, and C and D on the idle air control valve and measure the resistance.If the reading is not 40-80 ohms, renew the idle air control valve. (8) Checkthat there is no continuity betweenthe idle air control valve terminals A and D. (9) Check for loose or broken terminals in the idle air control valve and the control unit. If the terminals are satisfactory,renew the control unit. To Removeand Instal (l) Disconnectthe negativebattery 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 the throttle body and remove the valve. Instailation is a reversalof the removal procedure with attention to the following points: (l) Ensure that the area in the throttle body wherethe idle air control valve seatsis clean to ensure a full seal of the O ring. (2) Prior to installing the valve to the throttle body, measure the distance between the tip of the pintle and the flangemounting face. If the distance is
When installing the idle air control valve, ensure that distance A is less than 28 mm.
lnstalled view of the MAP sensor.
Fuel and Engi,neManagement
103
Check the MAP sensor vacuum hose for splits, obstructionsand a secureconnection. If no codesare now displayed,but codes33 or 34 were displayed when the self diagnosistest procedure was originally performed, an intermittent fault is indicated. Proceedas follows: (a) Check for faulty wiring connections. Check that all wiring connectorsare 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 speedfor 60 seconds or until the Check Engine warning lamp illuminates. (6) Stop the engine, switch the ignition On and connect a jumper lead betweenterminals A and B on the diagnostic link connector. Note any fault codes displayed. If code 33 is displayed,connecta voltmeter across terminal B on the MAP sensorwiring connector and earth. If the voltmeter reads lower than I volt the electronic control unit can be consideredfaulty. If the voltmeter readshigher than I volt, checkthe wiring harness and wiring connectors for shorts wiring connecbetween terminal B on the MAP sensor tor and terminal Cll on the control unit wiring connector. Repair or renew the wiring harness as necessary. If code 34 is displayed,proceedas follows: (a) Check for a restricted or leaking MAP sensor vacuum hose. (b) Check the wiring harnessfor continuity and shorts betweenterminal A on the MAP sensorwiring connectorand terminal Al I on the control unit wiring connector. Repair or renew the wiring harness as necessary. If no faults can be found proceed to operation
(1s).
(7) Disconnect the wiring connector from the MAP sensor and connect a jumper lead between terminals B and C on the wiring connector. (8) Start and run the engine at idle speedfor 60
seconds or until the Check Engine warning lamp illuminates. (9) Stop the engine, switch the ignition On and connecta jumper lead betweenterminalsB and A on the diagnostic link connector. Note any fawlt codes displayed. If code 33 is displayed,proceedto operation( I 5). If code 34 is displayed, proceedas follows: (10) Remove the jumper lead from the MAP sensor wiring connector and measure the voltage acrossterminals A and C on the MAP sensorwiring connector. If the voltage is below 4 volts, proceedto operation (12). If the voltage is 4 - 6 volts proceedas follows. ( I 1) With the ignition Off disconnectthe wiring from the control unit and checkthe wiring connectors harnessfor continuity and shorts between the MAP sensorwiring connector terminal B and control unit wiring connector terminal Cll. Check the wiring connectorsfor faults also. Repair or renew the wiring harnessas necessary. If no fault is found, renew the control unit and retest for fault codes. (I2) Disconnect the wiring connectorfrom the throttle position sensor. (13) Measurethe voltageacross terminalsA and C on the MAP sensorwiring connector. If the voltage is 4 - 6 volts, renew the throttle position sensoras describedlater in this section. If the voltage is below 4 volts, proceedas follows: ( 14) With the ignition Off, disconnectthe wiring connectorsfrom the control unit and checkthe wiring harnessfor continuity and shorts between the MAP sensorwiring connector terminal C and control unit wiring connector terminal Cl4. Check the wiring connectors. Repair or renew the wiring harness as necessary. If no fault is found. renew the control unit and retestfor diagnosiscodes. (15) Test the MAP sensor as follows: (a) With the ignition On and the MAP sensor wiring connector connected, measure the voltage acrossterminals A and B by back probing the MAP sensor wiring connector. The voltage should be as follows: VOLTAGE ALTITUDE 3.8 - 5.5 volts Below 305 m m 3 . 6- 5 . 3v o l t s 6 1 0 305 3 . 5- 5 . 1v o l t s 6 1 0- 9 1 4m 914 - l2l9 m 3.3 - 5.0 volts I2l9 1524m 3.2 - 4.8 volts 3.0 - 4.6 volts 1524- 1829m 1829- 2133m 2.9 - 4.5 volts 2.8 - 4.3 volts 2133- 2433m 2.6 - 4.2 volts 2438- 2743 m 2.5 - 4.0 volts 2743- 3048m If the voltage is not as specified,renew the MAP sensor.
104
Fuel and Engi'neManagernent
(b) If the voltage is as specified,apply a 34 kPa vacuum to the MAP sensor using a vacuum pump. The voltage should be 1.2-2.3 volts lower than that measuredin operation (a). If the voltage is not as specified,renew the MAP sensor. If no fault is found, checkthe vacuum supply hose for restriction or leakage. To Removeand Instal (1) Disconnect the negativebattery terminal. (2) Disconnect the MAP sensorwiring connector and the vacuum supply hose. (3) Remove the retaining screwsand remove the MAP sensorfrom the vehicle. Installation is a reversalof the removal procedure with attention to the following points: (1) Ensure that the vacuum hose is connected securelyto the MAP sensor. (2) Start the engine and increase the speed to allowing the idle air control 3 000 rpm for 10 seconds, valve to reset. (3) On models equipped with a radio/cassette to enter the using PIN security, it will be necessary PIN code as described under the Radio/Cassette heading in the Electrical Systemsection. THROTTLE CABLE To Removeand Instal (l) Loosenthe adjusting nuts and disconnectthe 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 dashboard panel and remove the trim panel from the vehicle. (4) Remove the retainer from the top of the throttle pedal and disengagethe throttle cable from the pedal. (5) Withdraw the throttle cable from the engine compartment. Installation is a reversalof the removal procedure. Adjust the throttle cable as described under the following heading. To Adjust (1) Remove the clips retaining the drivers side lower trim panel to the underside of the dash panel and remove the trim panel from the vehicle. (2\ Have an assistantdepressthe throttle pedal fully. (3) Working in the engine compartment, adjust the throttle cable adjusting nuts so that the throttle valve is in the fully open position. Tighten the adjusting nuts securely. (4) Release the throttle pedal and ensurethat the throttle valve is in the fully closed position, that the throttle lever is touching the throttle stop screw and the pedal is contacting the pedal stop.
lnstalledview of the throttle cableshowingthe adiusting nuts. (5) Check that there is a minimum of pedal free play and approximately 10-15 mm deflection of the inner cable between the outer cable end and the throttle body linkage. (6) Instal the lower trim panel to the vehicle.
ELECTRONICCOMPONENTS NOTE: Before proceeding with any of the operations in this section, refer to the Service Precautions and Proceduresheading. 6. IGNITION SYSTEM To Test - Code 41 (1) Attempt to start the engine. If the enginestartsan intermittent fault is indicated. Proceedas follows: (a) Check for faulty wiring connections.Check that all wiring connectionsare clean and secure. (b) Check that all earth wires are secure. If the engine does not start proceedas 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 securethe high tension lead to a non-metallic object. (4) Connect one end of a jumper lead to earth and connect the other end of the jumper lead to the non-metallic object leaving a gap of 8 mm from the exposedend of the conductor to the end of the jumper lead. (5) Operate the starter motor and check for a strong spark between the conductor and the jumper lead. Repeat the operation on the remaining high tension leads. If there is no spark when connectedto any lead proceedto operation(10). If there is spark at one or two of the leadsproceed to operation (20). If there is spark when connected to each lead proceed as follows:
105
To test for sufficient coil output, insert a conductor into the high tension lead and place a jumper lead connected to earth 8 mm from the conductor. Crank the engineand check for spark. (6) Switch the ignition Off and disconnect the wiring connectorsfrom the control unit. (7) Backprobethe control unit wiring connector terminal 85 with a voltmeter to earth. (8) Switch the ignition On and note the voltage. It should be lessthan 1 volt or approximately 5 volts. If the voltage is not as specified,check the wiring harnessfor continuity or shorts between the control unit wiring connector terminal 85 and the ignition control module wiring connector terminal D. Repair or replacethe wiring harnessas necessary. If no fault can be found, renewthe ignition control module. (9) Observe the voltmeter and operate the starter motor. The voltage should read between 2 and 3 volts. If the voltage is not as specified, replace the ignition control module. If the voltage is as specified,checkthe control unit terminal B5 and the correspondingwiring connector terminal 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 connectorterminal P and earth and switch the ignition On. The test lamp should lieht. If the test lamp does not light, check the number 1l fuse and the wiring harness for continuity and shorts between the ignition switch and the ignition control module wiring connector terminal P. Repair or replacethe wiring harnessas necessary. (12) Switch the ignition Otr and connect a
jumper lead between the ignition control module wiring connector terminals N and P. Connect a jumper lead between the ignition control module wiring connector terminal M and earth. Ensure that the jumper leads do not contact each other. (13) Connect a test lamp between the ignition control module wiring connector terminal H and the positive battery terminal and switch the ignition On. (14) Using a socket and bar, slowing rotate the crankshaft pulley one revolution and observethe test lamp. The test lamp should go on and off 3 times during one revolution. If the test lamp does not light as described,check the wiring harnessfor shorts and continuity between the crankshaftsensorterminals B, A, C and D and the ignition control module terminals G, H, M and N. Repair or renew the wiring harnessas necessary. If no fault can be found renew the crankshaft sensor. (15) Switch the ignition Offand removethe test lamp probe from terminal H and connectit to terminal G. (16) Switch the ignition On and slowly rotate the crankshaft pulley one revolution and observethe test lamp. The test lamp should go on and off l8 times during one revolution. If the test lamp does not light as described,check the wiring harnessfor shorts and continuity between the crankshaftsensorterminals B, A, C and D and the ignition control module terminalS G, H, M and N. Repair or renew the wiring harnessas necessary. (17) Switch the ignition Off and closely inspect the crankshaftsensorfor damage.Renewasnecessary. (18) Slowly rotate the crankshaft pulley and closely examine the blades on the rear of the crankshaft pulley as they pass through the channelsof the crankshaft sensor.
Rear view of the crankshaft pulley showing the interrupter blades.
106

ELECTRONIC SPARK TIMING (EST) To Check Operation (l) Start the engine and maintain the engine speedat 1600-1 800 rpm. Do not adjust the throttle stop screw. (2) Connect a jumper lead betweenterminals A and B on the diagnostic link connector and note the in the engine speed. decrease If the engine speeddoes not decrease, a fault in the EST circuit is indicated. If necessary,carry out the following test procedure. To Test Code 42
If any of the bladesare bent, renew the crankshaft pulley. If any of the blades contact the crankshaft sensor renewthe crankshaftpulley and the crankshaftsensor. (19) Disconnect the test lamp and the jumper leads from the ignition control module wiring connector and instal the connector to the ignition control module. (20) Disconnect the high tension leads from the coil pack assembly and remove the Torx screws to the ignition control retaining the coil pack assembly module. (21) Raise the coil pack assembly and disconnect the three wires with black stripes from the coil pack assembly.Do not disconnectthe blue wires. (22) Connecta test lamp betweenone of the blue wire connectorsand the disconnectedblue and black striped wire connector.Operatethe starter motor and observethe test lamp. The test lamp should blink.
view of the coil pack assemblyshowingthe Underside wiring connections. (23) Repeat the previous operation on the disconnectedgreen and black and the yellow and black striped wires. If the test lamp does not blink in the above operations,renew the ignition control module. (24) Switch the ignition Off and connect a digital ohmmeter betweenthe blue and black striped wire connector and the blue wire connector and measure the resistance.The resistanceshould be 0.3 - 1.5 ohms. (25) Repeat the previous operation betweenthe greenand black and the yellow and black striped wires and its opposite blue wire connector. If the resistance is not as specified,renew the coil pack assembly. (26) Connect an ohmmeter between the coil packhigh tensionterminals 1 and4,2 and5 and 6 and should be l0 - 14 k/ohms. 3. The resistance If the resistanceis not as specified,renew the coil pack assembly.
(1) Erase the self diagnosis code memory as previously described. (2) Start and run the engine at idle speedfor 60 seconds or until the Check Engine warning lamp illuminates. (3) Stop the engine,switch the ignition On and connecta jumper lead betweenterminals A and B on the diagnostic link connector. Note any fault codes displayed. If code 42 is displayed,proceedto operation (4). If code 42 is not displayed, but was displayed when the self diagnosistest procedure was originally performed, an intermittent fault is indicated. Proceed as follows: (a) Check for faulty wiring connections. Check that all wiring connectorsare clean and secure. (b) Check that all earth wires are secure. (4) With the ignition Off, disconnectthe control unit wiring connectors. (5) With the ignition On, measure the resistance between control unit wiring connector terminal D4 and a good earth point. The resistanceshould be less than 500 ohms. If the resistance is more than 500 ohms, checkthe wiring harnessbetween the ignition control module wiring connector terminal A and the control unit wiring connector terminal D4 for continuity and ensurethat terminal A has a secureconnection to the ignition control module. If no fault can be found, renew the ignition control module. If the resistance is as specified,proceedasfollows: (6) With the lead of a test lamp connectedto the positive battery terminal, probe the control unit wiring connectorterminal D5. If the test lamp does not light, proceed to operation (7). If the test lamp lights, disconnect the ignition control module wiring connector. If the test lamp remains illuminated, check the wiring harness betweenthe ignition control module wiring connector terminal B and the control unit wiring connector terminal D5 for shorts to earth. Repair or renew the wiring harnessas necessary.

If the test lamp does extinguish, renew the ignition control module. (7) Connect an ohmmeter between the control unit wiring connector terminal D4 and a good earth point. (8) With the lead of a test lamp connectedto the positive battery terminal, backprobe the control unit wiring connector terminal D5. As the test lamp probe touches the terminal, the ohmmeter reading should changefrom lessthan 500 ohms to over 5 000 ohms. If the reading is as specified,switch the ignition Off, instal the control unit wiring connectorsand run the engine for I minute or until the Check Engine warning lamp illuminates. Stop the engine,turn the ignition On and check for fault codes as previously described. If code 42 is displayed, check for faulty connections. If no fault can be found, renew the control unit. If the reading is not as specified proceed as follows: (9) Disconnect the ignition control module wiring connector. (10) Check for continuity between the control unit wiring connector terminal D4 and earth. There should be no continuity. If continuity exists, check the wiring harness betweenthe ignition control module wiring connector terminal A and the control unit wiring connector terminal D4 for shorts to earth. Repair or renew the wiring harnessas necessary. If there is no continuity, check the wiring harness betweenthe ignition control module wiring connector terminal B and the control unit wiring connector terminal D5 for continuity and ensurethat terminal B is a secureconnection to the ignition control module. If no fault can be found renew the ignition control module. IGNITION CONTROL PACK ASSEMBLY MODULE AND COIL
TO$( SCREWS
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Dismantled view of the ignitioncontrolmoduleandthe coil pack assembly. Installation is a reversalof the removal procedure with attention to the following points: (1) Where applicable,instal the earth lead to the control module mounting stud, between the alternator mounting bracket and the retaining nut. (2) When installing a new coil pack bend the wiring connectorterminals inwards 90'. (3) Instal the original gasket between the coil pack and the ignition control module. (4) Connect the ignition control module wiring terminals to the coil pack, using the referencemarks made at removal to ensurecorrect connection. (5) Connect the negative battery terminal and start the engine. Increase the engine speed to 3 000 rpm for l0 secondsallowing the idle air control valve to reset. (6) On models equipped with a radio/cassette using PIN security, enter the PIN code as described under the Radio/Cassetteheading in the Electrical Systemsection. CRANKSHAFT SENSOR To Removeand Instal (1) Disconneit the negativebattery terminal. (2) Place an l8 mm ring spanneron the drive belt tensionerpulley bolt and rotate the pulley assembly anti-clockwise, raising the pulley away from the drive belt. (3) While maintaining the pulley in this position remove the drive belt from the water pump pulley. Return the pulley to its previous position and remove the drive belt from the engine. (4) Using a 28 mm socketand bar, slowly rotate the crankshaft pulley while closely inspecting each of the outer interrupter blades,locatedbehind the crankshaft pulley, as they pass through the crankshaft
To Removeand Instal (l) Disconnectthe negativebattery terminal. (2) LJnscrew the ignition control module wiring connector retaining screw and remove the wiring connector from the ignition control module. (3) Disconnect the high tension leads from the coil pack assembly. (4) Remove the Torx screws retaining the coil pack assemblyto the ignition control module. (5) Tilt the coil pack assemblyto one side and mark the wiring connectorsto ensurecorrect connection at installation. (6) Disconnect the wiring connectors from the coil pack assemblyand remove the coil pack assembly from the ignition control module. (7) Remove the nuts securingthe ignition control module to the alternator mounting bracket and remove the ignition control module.
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(8) While maintaining a light pressureon the sensor,pushing it against the feeler gaugeand the outer blade, tighten the clamp bolt to the specified torque. If the clamp bolt is not tightened to the specifiedtorque the crankshaft sensorcould move or the crankshaft sensorbracket could be distorted. (9) Remove the feeler gauge and check the clearance as described in operation (7) in three positions around the crankshaft pulley, approximately l20 apart. If any of the blades contact the outer segmenton the crankshaft sensor during rotation of the crankshaft pulley, loosen the crankshaft sensorclamp bolt and repeat the previous three operations.
sensorchannel.Renew the crankshaftpulley if a blade is bent. (5) Remove the bolt retaining the crankshaft pulley to the crankshaft and slide the pulley off the crankshaft. (6) Disconnectthe crankshaftsensorwiring connector. (7) Remove the crankshaft sensor retarnrng bolts and remove the crankshaft sensor from the engine.
Installed view of the crankshaft sensor. Crankshaft pulley removed for clarity. Instatlation is a reversalof the removal procedure with attention to the following points: (1) [Jnscrew the crankshaft sensor clamp bolt sufficiently to allow the sensorto move freely. (2) Instal the crankshaft sensor to the engine, ensuring that the dowel pin locates in the crankshaft sensorbracket and tighten the retaining bolts to the specifiedtorque. (3) Instal the crankshaft pulley onto the crankshaft while positioning the crankshaft sensorto locate the blades of the crankshaft pulley between the channelson the crankshaft sensor. (4) Carefully rotate the crankshaft pulley until the keyway aligns with the crankshaft key and push the crankshaft pulley against the stop. (5) Instal the crankshaft pulley retaining bolt and tighten to the specifiedtorque. NOTE: When tightening the crankshaft pulley retaining bolt, block the flywheel to preventthe crankshaftturning. If the crankshaft turns, damage to the cranlcshaftsensor could result. (6) Slowly rotate the crankshaft pulley until one of the outer blades is positioned in the outer channel of the crankshaft sensor. (7) Insert a 0.5mm feeler gauge between the outer face of the blade and the outer segmenton the crankshaft sensor.
Measure the interrupter blade to crankshaft sensor clearanceusing feeler gauges. If the clearanceis still unsatisfactory,renew the crankshaft pulley. (10) Connect the crankshaft sensorwiring connector. (l l) Instal the drive belt. Refer to the Engine Tune-up section if necessary. (12) Connect the negative battery terminal and start the engine.Increasethe speedto 3 000 rpm for l0 secondsallowing the idle air control valve to reset. (13) On models equipped with a radio/cassette using PIN security, enter the PIN code as described under the Radio/Cassetteheading in the Electrical Systemsection. EFI AND FUEL PUMP RELAYS To Removeand Instal (1) Disconnect the negativebattery terminal. (2) Remove the cover from the relay housing which is located in the engine compartment forward of the coolant surgetank.
r09
86 and Continuity shouldexistbetweentermilnals 87. and 30 terminat! 85 but should not exist between (3) Using suitablejumper leads,apfly 12 volts to terminal 86 and connectterminal 85 to {he negative battery - '(4i terminal Using an ohmmeter, check for continuity 30 and 87. terminals between If continuity exists, the relay can be considered satisfactory. If continuity does not exist renew the relay. To Test Relay Circuits (l) Remove the relay from ttre 't eficle as previously described. Connect the negative battery terminal. (2) Connect a test lamp between thp relay connector terminal A and earth. The test lhmp should light. If the test lamp does not light when (hecking the EFI relay circuit, check the fusible link fo{ continuity. Renew the fusible link if necessary. If the fusible link blows, check the wiling harness between the relay connector terminal A and the fusible link for shorts to earth. Repair dr renew the wiring harnessas necessary. If the test lamp does not light when gheckingthe fuel pump relay circuit, check the fuel pqmp fuse for continuity. Renew the fuse if necessary. If the fuse blows, check the wiring harness between the relay connector terniinal A, the oil pressureswitch and the fuel pump fuse for shorts to earth. Repair or renew the wiring harndssas necessary(3) Switch the ignitioq On and cohnect a test lamp between the relay connector terr4inal B and earth. The test lamp should light. When dheckingthe fuel pump relay circuit the test lamp should extinguish 2 secondsafter the ignition has been swi If the test lamp does not light when oheckingthe
fuel pump relay circuit, check the wi{ing harness
View of the relay housing showing the location of the EFi and fuel PumPrelaYs. (3) Remove the relevant relay from the connection block. Installation is a reversalof the removal procedure with attention to the following points: (l) Connect the negativebattery terminal and start the engine.Increasethe speedto 3 000 rpm for l0 seconds,allowing the idle air control valve to reset. (2) On models equipped with a radio/cassette using PIN security, enter the PIN code as described under the Radio/Cassetteheading in the Electrical Systemsection. To Test Relays (l) Remove the relay from the vehicle as previously described. (2) Using an ohmmeter, check for continuity betweenterminals 86 and 85, and terminals30 and 87 on the relay.
between the control unit wiring connecfor terminal Al and the fuel pump relay connector tefminal B for continuity. Repair or renew the wirin$ harness as necessary.
fn
T'
le
FUEL PUMP
zasltos Testing a relay using a multimeter. lllustration showing the terminal i EFI and fuel pump relay connectprs.
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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 continuity. Renew the fuse if necessary. If the fuse blows, check the wiring harness betweenthe fuse panel, the diagnostic link connector terminal C and the EFI relay for shorts to earth. Repair or renew the wiring harnessas necessary. (4) Switch the ignition Off and connect the lead of a test lamp to the positive battery terminal and probe the relay connector terminal C. The test lamp should light. If the test lamp does not light, check the wiring harnessbetween the relay connector terminal C and earth for continuity. Check that all earth connections are clean and secure. Repair the wiring harness as necessary. (5) When checkingthe EFI relay circuit proceed as follows: (a) Disconnect the wiring connectors from the fuel injectors. (b) Connect a jumper lead between the positive battery terminal and the relay connector terminal D. (c) With the lead of a test lamp connected to earth, probe the red wire terminal of an injector wiring connector. The test lamp should light. If the test lamp does not light, check the wiring harnessbetween the relay connector terminal D and the injector wiring connectorsfor continuity. Repair or renew the wiring harnessas necessary. (6) When checking the fuel pump relay circuit, proceedas follows: (a) Disconnect the round wiring connector at the fuel pump/tank sender unit and connect a test lamp betweenthe two terminals in the wiring connector. (b) Connect a jumper lead betweenthe positive battery terminal and the relay connector terminal D. The test lamp should light. If the test lamp does not light, check the wiring harnessbetween the relay connector terminal D, the diagnosticlink connector terminal D, the oil pressure switch and the fuel pump wiring connector for continuity and shorts. Repair or renew the wiring harnessas 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 warning lamp is illuminated and not flashing proceed to operation (4). If the Check Engine warning lamp is displaying code 55 proceedas follows: (2) Switch the ignition Off and disconnect the wiring connectorsfrom the control unit. (3) Switch the ignition On and check the following control unit wiring connector terminals for volt a g eA , 9 , 8 1 1 , C l 0 , C l l , C 1 2 a n dC l 3 .
lnstalled view of the control unit located behind the passenger side kick panel. If there is no voltageat any of the terminals renew the control unit. If there is voltage at any terminal, a short to voltage in the particular wiring circuit is present. Repair or renew the wiring harnessas necessary. (4) Connect a jumper lead between terminals A and B on the diagnosticlink connector.Note any fault codesdisplayed. If code 55 is displayed proceed as follows: (5) Remove the jumper lead from the diagnostic link connector and erase the self diagnosis code memory as previously described. (6) Start and run the engine for 2 minutes and repeat 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, backprobe the control unit wiring connector terminals Bl and 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 the fuse is serviceable, an open circuit betweenthe fusible link and the wiring connectorterminalsBl and C16 is present. Repair or renew the wiring harnessas necessary. (2) Disconnect the control unit wiring connectors and measure the resistance between terminals A^l2,Dl, D3, D6 and Dl0 and earth. The resistance should be O ohms at each terminal. If the resistanceis not as specified,check that the earth connections located at the coil pack mounting bracket retaining bolt and the timing cover bolt, directly below, are clean and secure.If no fault can be found, an open circuit between the wiring connector terminal(s) is present. Repair or renew the wiring harnessas necessary. To Removeand Instal (1) Disconnect the negativebattery terminal. (2) Remove the fastener securing the lower dashboardtrim panel to the left hand side kick panel. (3) Using a small screwdriver, prise the plastic
Fuel and Engi'neManagernent
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(3) When installing a new control unit transfer the identification and bar code label to the new control unit. (4) Ensure that the control unit wiring connectors are securelyinstalled to the control unit. codes.If code 51 (5) Activate the self-diagnosis is displayed or the Check Engine warning lamp is constantly iltuminated, the Mem-Cal unit is not fully installed. If the Mem-Cal unit is installed correctly a fault in the Mem-Cal unit is indicated. Renew the Mem-Cal unit as previously described. (6) Start the engine and increase the speed to allowing the idle air control 3 000 rpm for l0 seconds, valve to reset. (7) On models equipped with a radio/cassette using PIN security, enter the PIN code as described under the Radio/Cassetteheading in the Electrical Systemsection.
View of the control unit with the Mem-Cal removed.
strip from the front section of the left hand side sill panel cover. (4) Disengagethe front section of the sill panel cover from the kick panel and the sill panel. (5) Remove the lower front corner sectionof the door sealingrubber. (6) Disengagethe lower front corner of the kick panel from the locating stud positioned behind the kick panel and manoeuvre the kick panel from the vehicle. (7) Disconnect the wiring connectors from the control unit. (8) Lever the plastic tongues away from the control unit and withdraw the control unit from the mounting brackets. (9) Remove the screws retaining the Mem-Cal cover to the control unit. (10) Releasethe Mem-Cal unit retaining clips, grasp the Mem-Cal unit at each end and remove it from the control unit. Installation is a reversalof the removal procedure with attention to the following points: ( I ) When installing the Mem-Cal unit, align the notchesin the Mem-Cal unit with those in the control unit and push on each end of the Mem-Cal unit. Do not 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.
MEM.CAL UNIT To Test - Code 5l Should fault code 5l be displayed during the self diagnosistest procedure,proceedas 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,renewthe MemCal. (d) Erase the fault code memory and retest for fault codes. (e) If code 5l is still displayed,renewthe control unit. To Removeand Instal The Mem-Cal unit is incorporated within the control unit. Refer to the previous heading for the removal and installation procedure. THROTTLE POSITION SENSOR To Test - Codes2l tnd,22 NOTE: The following test procedure assumes that fault codes2I or 22 have been displayed during the self diagnosis test procedure.If no codeshave been displayed but the operation of the throttle position sensor is suspect,begin the testprocedureat operation (23). (1) Erase the self diagnosis code memory as previously described. (2) Start and run the engine at idle speedfor 60 seconds or until the Check Engine warning lamp illuminates. If the engine will not start proceed to operation (4). (3) Stop the engine, switch the ignition On and connect a jumper lead betweenterminals B and A on
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( 10) With the ignitionOff,disconnect the control unit wiring connectors.
(11) With the ignition On, measure the voltageat the control unit wiring connectorterminal C13. If the voltage is less than I volt, check the wiring harnessfor shortsbetweenthe throttle position sensor and the control unit. If no fault is found, renew the control unit. (12) Start and run the engineat idle speed. (13) With the engine idling, connect a jumper lead acrossterminals A and C on the throttle position sensorwiring connector and idle the engine for l0 seconds. ( l4) Stop the engine,switch the ignition On and connecta jumper lead betweenterminalsi A and B on the diagnostic link connector. Note any' fault codes displayed. If codes 2l and 22 are displayed, proceed to operation (23). If code 22 only is displayed, proceed as follows: (15) Remove the jumper lead from the throttle position sensorwiring connector. ( l6) Measurethe voltage acrossthe throttle position sensorwiring connectorterminalsA and B. If the voltage is below 4 volts, proceedto operation (19). If the voltage is 4-6 volts, proceedas follows: (17) With the ignition Off, disconnect the control unit wiring connectors. (18) Check the wiring harnessbetweenthe control unit wiring connector terminal Cl3 and the throttle position sensorwiring connector terminal C for continuity and shorts. Repair or renew the wiring harness as necbssary.Check the control unit wiring connectorterminals. If no fault is found, renew the control unit and retest for fault codes. (19) Disconnect the wiring connector from the MAP sensor. (20) Measurethe voltage acrossthe throttle position sensorwiring connectorterminalsA and B. If the voltageis 4-6 volts, renewthe MAP sensor. If the voltage is below 4 volts, proceedas follows: (21) With the ignition Off, disconnect the control unit wiring connectors. (22) Check the wiring harnessbetween the control unit wiring connector terminal Cl4 and the throttle position sensorwiring connector terminal A for continuity and shorts. Repair or renew the wiring harnessas necessary. Check the control unit terminals and the control unit wiring connector terminals for damageor poor connections. If no fault is found, renew the control unit and retest for fault codes. (23) If removed, instal the wiring connector to the throttle position sensor. (24) With the ignition On, measurethe voltage at the control unit terminal Cl3 by backprobing the wiring connector. The voltageshouldbe 0.2-1.2 volts.
the diagnostic link connector. Note any fault codes displayed. If codes 2l or 22 are displayed, proceed to operation (4). If codes 21 or 22 are not displayed, but were displayed when the self diagnosistest procedure was originally performed, an intermittent fault is indicated. Proceedas follows: (a) Check for faulty wiring connections. Check that all wiring connectorsare clean and secure. (b) Check that all earth wires are secure.
Installedview of the throttle body showing the throttle position sensor. Enginevent pipe removed for clarity. (4) Remove the jumper lead from the diagnostic link connector. (5) Erasethe self diagnosis codes as previously described (6) Disconnect the wiring connector from the throttle position sensor. If code 22was displayedin operation (3), proceed to operation (12). If code21 was displayedin operation(3), proceed as follows: (7) Start and run the engine at idle speed for 2 minutes or until the Check Engine warning lamp illuminates. If the engine will not start, proceed to operation(10). (8) Stop the engine, switch the ignition On and connect a jumper lead betweenterminals B and A on the diagnostic link connector. Note any fault codes displayed. If code 2 1 is displayed,proceedto 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 into terminal B on the throttle position sensor wiring connector. If the test lamp lights, proceedto operation (23). If the test lamp does not light, check the wiring harnessbetween throttle position sensorwiring connector terminal B and control unit wiring connector terminal D2 for continuity. Repair or renew the wiring harnessas necessary and retest for fault codes.
Fuel and Engi,neManagernent

If the voltage is as specifiedproceedto operation
IDLEArRcoNTRoL vALvE o RING
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(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 sensorand repeat operation (24). (26) It the voltage is higher than I volt check the wiring harnessbetween the control unit wiring connector terminal C13 and the throttle position sensor wiring connector terminal C for a short to voltage. Repair or renew the wiring harnessas necessary. (27) lf the voltage is lower than 1 volt, check the wiring harnessbetween the control unit wiring connector terminal D2 and the throttle position sensor wiring connector terminal B for continuity. Repair or renew the wiring harnessas necessary. If no fault is found, renew the throttle position sensor. (28) Check the base idle speed as previously described.Adjust if necessary. (29) Repeat operation (24). If the voltageis not as specified,renewthe throttle position sensor. If the voltage is as specified,proceedas follows: (30) With the voltmeter connected as described in operation (24), slowly open the throttle. The voltage should increase steadily as the throttle progresses to the wide open position. With the throttle wide open, the voltmeter should read over 4 volts. NOTE: Ensure that there are no floor mats or carpet under the throttle pedal, prevent' ing the throttle from openingfully. If the voltageis not as specified,renewthe throttle position sensor. To Removeand Instal (1) Disconnect the negative battery terminal. (2) Remove thg throttle body as previously described. (3) Remove the throttle position sensor retaining screwsusing a number 20 Torx bit and remove the throttle position sensorfrom the throttle body. Installation is a reversal of the removal procedure with attention to the following points: (1) With the throttle valve in the fully closed position, instal the throttle position sensor onto the throttle shaft at a position 30 degreesclockwise past the throttle position sensor retaining screw holes in the throttle body. (2) Align the holesin the throttle position sensor with those in the throttle body, instal the retaining screwsand tighten securely. (3) Instal the throttle body as previously described. (4) Start the engine and increase the speed to allowing the idle air control 3 000 rpm for l0 seconds, valve to reset.
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View of the throttle position sensor and the idle air control valve removed from the throttle body. (5) On models equipped with a radio/cassette using PIN security, it will be necessaryto enter the PIN code as described under the Radio/Cassette heading in the Electrical Systemsection. COOLANT TEMPERATURE SENSOR To Test - Codes14 and 15 (1) Erase the self diagnosis code memory as previously described. (2) Start and run the engine at idle speedfor 60 seconds or until the Check Engine warning lamp illuminates. NOTE: If the engine is warm and will not start, hold the throttle in the wide open position until the enginestarts. (3) Stop the engine, switch the ignition On and connect a jumper lead between terminals A and B on the diagnostic link connector. Note any fault codes displayed. If codes 14 or 15 are displayed, proceed to operation(4). If codes-14 or 15 are not displayed, but were displayed when the self diagnosistest procedure was originally performed, an intermittent fault is indicated. Proceedas follows: (a) Check for a faulty wiring connection. Check that all wiring connectorsdre 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 wiring connector. The voltage should be above 4 volts. If the voltage is below 4 volts, proceed to operation (9). If the voltage is as specified,proceedas follows: (6) Remove the coolant temperature sensor from the vehicle. (7) Connectan ohmmeter to the coolant temperature sensorterminals. (8) Immerse the metal end of the coolant temperature sensorin a 50/50 mixture of glycol and iced
rt4
TO OHMMETER

If no fault is found. renewthe control unit and retestfor fault codes.
To Remove and Instal
(1) Disconnect the negativebattery terminal. (2) Disconnect the wiring connector from the coolant temperature sensor. (3) Drain the cooling systemto a level below the coolant temperature sensor.
THERMOM E rER
(4) Unscrewthe coolanttemperature sensor
/
TEMPERATURE COOLANT --+ SENSOR
249t237tLD14
from the rear of the inlet manifold. Installation is a reversalof 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 Systems section if necessary. (3) Start the engine and increase the speed to 3 000 rpm for l0 seconds, allowing the idle air control valve to reset. (4) On models equipped with a radio/cassette using PIN security, it will be necessary to enter the PIN code as described under the Radio/Cassette heading in the Electrical Systemsection.
,/COOLANTFILLEDCONTAINEB
A
A +HEAr souRcE
TEMPERATUREGAUGE SENDER
Schematic drawing showing the correct method used to test the coolant temperature sensor. water at a temperature of 0 deg C. The resistance should be 6 000 ohms. Slowly heat the mixture and measure the resistance of the coolant temperature sensorat the following temperatures. Compare the results with the specifiedvalues: 0degC... approx 6000 ohms 20degC... a p p r o x2 5 0 0 o h m s 30degC... a p p r o x1 8 0 0 o h m s 4Odegc... a p p r o xl 2 0 O o h m s 70degC... 450ohms ... approx 90degC... ... approx250 ohms 100degC. . . . . . approx 190 ohms I l0 deg C. . . . . . approx 110 ohms If the resistancesobtained are not the specified value at any of the given temperatures, renew the coolant temperature sensorand retest for fault codes. (9) Disconnect the control unit wiring connectors. (10) Check the wiring harnessbetweenthe coolant temperature sensorwiring connector terminal A and control unit wiring connectorterminal ClO for shorts. Repair or renew the wiring harnessas necessary.
MAT SENSOR
lnstalled view of the coolant temperature sensor, MAT sensorand the temperaturegaugesender. MANIFOLD AIR TEMPERATURE (MAT) SENSOR To Test - Codes23 nd 25 (l) Erase the self diagnosis code memory as previously described. (2) Start and run the engine at idle speedfor 60 seconds or until the Check Engine warning lamp illuminates. (3) Stop the engine, switch the ignition On and connect a jumper lead betweenterminals A and B on the diagnostic link connector. Note any fault codes displayed. If codes23 or 25 are displayed proceedto operation (4). If codes 23 or 25 are not displayed, but were

displayed when the self diagnosistest procedure was originally performed, an intermittent fault is indicated. Proceedas follows: (a) Check for faulty wiring connections.Check that all wiring connectorsare clean and secure. (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 wiring connector. The voltage should be 4-6 volts. If the voltageis below 4 volts proceedto operation (10). If the voltage is over 6 volts check the wiring harness between the MAT sensor wiring connector terminal A and the control unit wiring connector terminal Cl2 for shorts to voltage. Repair or renew the wiring harnessas necessary. If the voltage is 4-6 volts proceedas 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 sensorin a 50/50 mixture of glycol and iced water at a temperatureof 4 deg C. The resistance should be 7 500 ohms. Slowly heat the mixture and measure the resistance of the MAT sensor at the following temperatures. Compare the results with the specifiedvalues. 4degc... 20degc... 38degc... 7Odegc... l00degc... .:.7500ohms ...3400ohms l800ohms 450ohms l85ohms
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(a) Check the wiring harnessbetween the MAT sensorwiring connector terrninal A and the control unit wiring connector terminal C12 for continuity. Repair or renew the wiring harnessas necessary. (b) Ensure that the terminals are making firm contact when connectedto the control unit. (c) If no fault can be found, renew the control unit and retest for fault codes. To Removeand Instal (1) Disconnectthe negativebattery 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 reversalof the removal procedure with attention to the following points: ( 1) Coat the threads of the MAT sensor with Loctite 242 sealantprior to installation. (2) Connect the negativebattery terminal. (3) Start the engine and increase the speed to 3 000 rpm for 10 secondsallowing the idle air co?rtrol valve to reset. (4) On models equipped with a radio/cassette using a PIN security, enter the PIN code as described under the Radio/Cassette heading in the Electrical Systemsection. OXYGEN SENSOR To Test - Codes13, 44 and 45 (l) Run the engine until the normal operating temperature is obtained. (2) With the engine running connect a jumper lead betweenterminals B and A on the diagnosticlink connector. (3) Increasethe engine speed to I 600-1 800 rpm for 2 minutes and note the flashing sequenceof the Check Engine warning lamp. If the Check Engine warning lamp flasheson and offat equal intervals of approximately I per secondor slower, the oxygen sensor is functioning correctly. If code 44 or 45 are being testedan intermittant fault is indicated. Proceedto operation (4). If code 13 is being testedproceedas follows: (a) Remove the jumper lead from the diagnostic link connector. (b) With the engine running increasethe speed above 2 000 rpm for 2 minutes and note the Check Engine warning lamp. If the Check Engine warning lamp lights, switch the engine Off and check for fault codes. Perform the relevant code test procedure. If the Check Engine warning lamp doesnot 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 connectorsare clean and secure. (b) Check that all earth wires are secure.
If the resistancesobtained are not the specified value at any of the given temperatures, renew the MAT sensorand retest for fault codes. (9) Checkfor looseterminals in the MAT sensor wiring connector and ensure that the terminals are making firm contact when connected to the MAT sensor. If no fault is found, renew the control unit and retest for fault codes. (10) Connect a voltmeter between the MAT sensor wiring connector terminal A and earth and measure the voltage. The voltage should be 4-6 volts. If the voltage is as specified,proceed as follows: (a) Check the wiring harnessbetween the MAT sensor wiring connector terminal B and the control unit wiring connector terminal Al1 for continuity. Repair or renew the wiring harnessas necessary. (b) Ensure that the terminals are making firm contact when connectedto the control unit. (c) If no fault can be found, renew the control unit and retest for fault codes. (11) If the voltage is not as specified,proceedas follows:
I l6

engineblock is clean and secure.Repair or renew the wiring harnessas necessary. If no fault can be found, a faulty oxygen sensor connector or oxygen sensoris indicated. NOTE: A faulty oxygen sensor can be caused by contamination to the oxygen sensor through the use of leaded fuel or unsuitableRTV silicone sealantson engine components and may be identfied by a white, powdery substancecovering the tip of the oxygen sensor. A contaminated oxygen sensorshould be renewedand the causeof the contamination rectffied. (10) If code 45 was originally displayed,checkthe following possiblecauses: (a) High fuel pressure. (b) Leakinginjector(s). (c) Charcoal canister saturatedwith fuel. (d) Faulty coolant temperature sensorcircuit. (e) Faulty MAT sensorcircuit. (0 Faulty MAP sensorcircuit. 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 sensorwiring connector. . (12) Start the engine and maintain the speed at I 600-1 800 rpm for at least 30 secondsand note the Check Engine warning lamp. If the warning lamp failed to light for 30 seconds, switch the ignition Off and check the wiring harness between the oxygen sensorwiring connector and the control unit wiring connector terminal D7 for a short to earth. Repair or renew the wiring harnessas necessary. If no fault can be found, renew the control unit and retest for fault codes. If the warning lamp flasheson and offat 2 flashes per secondcheck the following possiblecauses: (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 sensorvent. (0 Restriction in fuel injector(s). If no fault can be found renew the oxygen sensor and retest for codes. To Removeand Instal (l) Disconnect the negative battery terminal. (2) Disconnectthe oxygensensorwiring connector. (3) Remove the oxygen sensorfrom the exhaust manifold. If accessto the oxygen sensor cannot be gained, remove the exhaust manifold as describedin the Engine section.
Installedview of the orygen sensor. If, in operation (3) the Check Engine warning lamp flashes on and off at 2 flashes per second oi proceed as follows: flashesan unequal sequence (5) If code 44 was originally displayed proceed to operation(11). (6) Switch the ignition Off and disconnect the oxygen sensorwiring connector. (7) Connect a jumper lead between the oxygen sensorwiring connector and eafth. (8) Start the engine and maintain the speed at I 600- I 800 rpm and note the Check Engine warning lamp. If the warning lamp failed to light for approximately 30 secondsproceedto operation (9) if code l3 was originally displayed or operation (10) if code 45 was originally displayed. If the Check Engine warning lamp remained illuminated, or flashes,proceed as follows: (a) Check the wiring harnessbetweenthe engine earth connection and the control unit wiring connector terminal D6 for continuity. Ensure that the earth connection at the engine block is clean and secure. Repair or renew the wiring harnessas necessary. (b) Check the wiring harnessbetween the oxygen sensor wiring connector and the control unit wiring connector terminal D7 for shorts and continuity. Repair or renew the wiring harnessas neiessary. (c) If no fault can be found, renew the control unit and retest for fault codes. (9) If code l3 was originally displayedcheckthe wiring harnessbetween the engine earth connection and the control unit wiring connector terminal D6 for continuity. Ensure that the earth connection at the
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(2) Using a small hammer, quickly and repeatedly tap the engine block, cylinder head or inlet manifold. The enginespeedshould drop when tapping the engine and slowly increaseto the original speed when the tapping has ceased. carry out If the engine speed does not decrease, the 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 betweenterminals B and A on the diagnostic link connector. Note any fault codes displayed. If code 43 is displayed proceedto operation (4). If code 43 is not displayedbut was displayedwhen the self diagnosis test procedure was originally performed, an intermittent fault is indicated. Carry out the following checks. (a) Check for faulty wiring connections. Check that all wiring connectorsare clean and secure. (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. The resistance should be 3 000-5 000 ohms. If the resistance is not as specified, renew the detonation sensor. (6) Using a voltmeter, measurethe voltageat the detonation sensorwiring connector terminal. If the voltage is less than 4 volts or more than 6 volts, check the wiring harnessbetween the detonation sensor and the control unit wiring connector terminal Bl l for shorts to earth or voltage. Repair or renew the wiring harnessas necessary. If the voltage is between 4-6 volts check that the sensorwire is not bare and ensurethat the wire hasnot been chafing due to normal engine movement. If no fault can be found, renew the control unit and retest for fault codes. To Removeand Instal (l) Disconnect the negativebattery terminal. (2) Squeeze the wide sidesof the wiring connector together and remove the connector from the detonation sensor. (3) IJnscrew the detonation sensor from the cylinder block. Installation is a reversalof the removal procedure with attention to the following points: (l) Ensure that the threads of the detonation sensorand the cylinder block are clean. (2) If the original sensoris being installed, apply Loctite 242 to the threads on the sensor. (3) Tighten the detonation sensior to the specified torque.
View of the o)rygensensor removed from the exhaust manifold. NOTE: It may be necessary to heat the exhaust manifuld if the oxygen sensor is dfficult to remove. Failure to heat the manifuld may result in damage to the threads in the exhaust manifold. Installation is a reversalof the removal procedure with attention to the following points: (l) When installing an oxygen sensor that has previously been removed, ensurethat the threads are coated with an anti-seizecompound. (2) Tighten the oxygen sensor to the specified torque. (3) Connect the negative battery terminal and start the engine.Increasethe speedto 3 000 rpm for 10 seconds,allowing the idle air control valve to reset. (4) On models equipped with a radio/cassette using PIN security, enter the PIN code as described under the Radio/Cassetteheading in the Electrical Systemsection. DETONATION SENSOR To Check Operation (1) Start the engine and increase the engine speed to I 600-1 800 rpm and set the throttle to maintain that engine speed.
lnstalled view of the detonation sensor.
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with the throttle closed, allow the vehicle to coast in gear until the enginespeedis lessthan I 500 rpm. (4) Check fuses9 and 12.lf either of the fuses are blown, checkthe wiring harnessfor shortsto earth betweenthe fuse panel, the instrument clusterand the vehicle speedsensor.Refer to the wiring diagramsin the Electrical System section. Repair or renew the wiring harnessas necessary. If the fusesare serviceable,retest for fault codes. If code 24 is displayed proceed as follows: (5) Checkthe operationof the speedometer and the instrument cluster warning lamps. If the speedometer is functioning, proceed to operation (12). If the speedometerand the instrument cluster warning lamps are not operating, a fault in the instrument cluster wiring harnessis indicated. Refer the fault to an authorised dealer. If the speedometer only is not operating,proceed as follows: (6) Remove the vehicle speed sensor as described under the following heading. (7) Remove the instrument cluster as described in the Electrical Systemsection. (8) Connect the vehicle speed sensor wiring connector. (9) Connect the negativebattery terminal. (10) Connect a 4.7 Vohm 0.5 watt resistor betweenthe blue instrument cluster wiring connector terminals 7 and 11 and connect a digital voltmeter betweenterminal 7 and earth. ( I I ) Slowly rotate the vehicle speedsensorshaft and note the voltmeter reading. It should pulse betweenzero and battery voltage. If the voltmeter does not read as specified,check the wiring harnessfor continuity betweenthe vehicle speed sensor, the blue instrument cluster wiring connector terminal7 and the earth connection. If no fault can be found, renew the vehicle speed sensor. (12) On modelswithout a trip computer,raisethe rear of the vehicle, support it on chassisstands and
(4) Connect the negative battery terminal and start the engine. Increasethe speedto 3 000 rpm for 10 seconds, allowing the idle air control valve to reset. (5) On models equipped with a radiolcassette using PIN security, enter the PIN code as described under the Radio/Cassetteheading in the Electrical System section. VEHICLE SPEED SENSOR To Test - Code24 NOTE: If code 24 has not been displayed, but the operation of the vehiclespeedsensor perform operations(6) to (11). is suspect, (l) Checkfuses9 and 12. Renewif necessary. If the fusesare serviceableproceedto operation (5). (2) Erase the self diagnosis codes as previously described. (3) Start and run the engine for 5 minutes and drive the vehicle at a speedof at least 100 km/h and,
Installed view of the vehicle speed sensor. Automatic transmission model.
Installed view of the vehicle speed sensor. Manual transmission model.
View showing the location and terminal numbers of the instrument cluster wiring connectors.
Fuel and Engine Mana,gement

shift the transmissionto neutral. Proceedto opeiation
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(le).
On models with a trip computer, proceed as follows: (13) With the ignition switch Off, depress and hold the trip computer RESET button. Switch the ignition On and releasethe RESET button. If the trip computer displays FAIL, a fault in the trip computer circuitry is indicated. Refer the fault to an authorised dealer. (1a) Switch the ignition Off. (15) Raise the rear of the vehicle and support it on chassisstands. (16) Depress the trip computer RESET button and start the engine. Release the button when the engineis running..' ( 17) Placethe transmissionin first gearand allow the rear wheelsto slowly spin. ( l8) Observethe trip computer display. It should act as a digital speedometer,indicating the speedof the 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 secondsand then switch the ignition On. (20) With the aid of assistants,slowly spin both the rear wheelsby hand while backprobing the control unit wiring connector terminal Al0 with a digital voltmeter to earth. The voltage should alternate from under I volt to over 10 volts. If the voltmeter reads as specified, the vehicle speedsensoris operating satisfactorily, indicating an intermittent fault was the cause of the fault code. Proceedas follows: (a) Check for faulty wiring connections. Check that all wiring connectorsare clean and secure. (b) Check that all earth connectionsare secure. If the voltmeter continually reads over 10 volts, proceedto operation (25). If the voltmeter continually reads under 1 volt, proceedas 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 connector terminal A10 and a jumper lead connectedto the positive battery terminal. (23) Connect a voltmeter between the control unit wiring connectorA10 and earth. (24) Slowly spin the rear wheels and note the voltmeter. If the voltmeter-reads over 10 volts, renew the control unit. If the voltmeter reads under 1 volt, check the wiring harnessfor a short to earth between the control unit wiring connector Al0 and the orangeinstrument cluster wiring connector terminal 4. Repair or renew the wiring harnessas necessary.
If no fault can be found in the wiring harness, check the flexible printed circuit on the rear of the instrument cluster for damage.On models with a trip computer, ensure that the trip computer wiring connector is secure when installed to the instrument cluster. If no fautt can be found, renew the trip computer. On models without a trip computer, renew the speedometer. (25) Switch the ignition Off and disconnect the control unit wiring connectors. (26) Switclr the ignition On and measure the voltage at the control unit wiring connector terminal Al0. If the voltage is over 10 volts, check the wiring harnessfor a short to voltagebetweenthe control unit wiring connectorterminal Al0 and the orangeinstrument cluster wiring connector terminal 4. Repair or renew the wiring harnessas necessary. If the voltage is under I volt, proceedas follows. (27) Switch the ignition Off. (28) Remove the instrument cluster as described in the Electrical Systemsection. (29) With an ohmmeter, check for continuity between the control unit wiring connector terminal Al0 and the orangeinstrument clusterwiring connector terminal 4. If there is no continuity, repair or renew the wiring harnessas necessary. If continuity exists, check the printed circuit on the rear of the instrument cluster for damage. On models with a trip computer ensure that the trip computer wiring connector is securewhen installed to the instrument cluster. If no fault can be found, renew the trip computer. On models without a trip computer, renew the speedometer. To Removeand Instal (l) Disconnect the negativebattery terminal. (2) Raise the vehicle and support it on chassis stands. (3) Disconnect the vehicle speedsensorwiring connector. (4) (Jnscrew the vehicle speed sensorfrom the drive adaptor. speedometer Installation is a reversalof the removal procedure with attention to the following points:
'@0#&wh.m
'EAL sENsoR
o::Y'o"
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I
Dismantled view of the vehicle speed sensor.
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(7) Backprobe the neutral safety switch wiring connectorterminal B with a test lamp connectedto12 volts. The test lamp should light. If the test lamp does not light, check the wiring harness between the neutral safety switch wiring connector terminal A and the wiring harnessearth connection for continuity. Ensure that the earth connection is clean and secure.Repair or renew the wiring harnessas necessary. (8) Engagethe parking brake and move the gear selectorinto D (Drive) position. The test lamp should go out. If the test lamp remains illuminated, renew the neutral safety switch as described in the Automatic Transmission sectionunder the Neutral SafetvSwitch heading. 7. DESCRIPTION The electronic cruise control system enablesthe vehicle to maintain a preset speedwithout the driver operating the throttle pedal. Cruise control is not available on models with manual transmission. The system consistsof an electronic control module and a control switch assembly. The electronic control module receives a signal from the speedometer and activates an electric motor inside the electronic control module. The motor adjusts the throttle position via the control cable to maintain the pre-setspeed. The systemis deactivatedwhen the brake pedal or the control switch is depressed.Two switches are installed on the brake pedal support bracket. The lower switch is a combination stop lamp/cruise cancel switch and the upper switch is a failsafe cruise cancel switch, should the lowepswitch fail. The cruisecontrol system will not activate until the vehicle speed is above 40 km/h. The cruise systemincorporates complex electronic circuitry, thereforeit is recommendedthat the vehicle be taken to an authorised dealer for testing and CRUISE CONTROL
( I ) Connect the negative battery terminal and start the engine.Increasethe speedto 3 000 rpm for 10 secondsallowing the idle air control valve to reset. (2) On models equipped with a radio/cassette using PIN security, enter the PIN code as described under the Radio/Cassetteheading in the Electrical Systemsection. NEUTRAL SAFETY SWITCH To Test Circuit (l) Remove the centre consoleselectorcover by carefully raising the rear section of the cover to disengage the retaining clips. Disconnectthe electrical connectors,rotate the cover 90" and remove the cover from the console. (2) Disconnect the neutral safety switch wiring connector. (3) Switch the ignition On and connect a digital voltr,neter between the neutral safety switch wiring connectorterminal B and earth. The voltmeter should read battery voltage. If the voltmeter readsbattery voltage, proceedto operation (5). If the voltmeter does not read battery voltage, proceedas follows: (4) Backprobethe control unit wiring connector terminal B10 with a digital voltmeter connected to earth. 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, check the wiring harnessfor shorts and continuity between the control unit wiring connector terminal Bl0 and the neutral safety switch wiring connectorterminal B. Repair or renew the wiring harnessas necessary. (5) Switch the ignition Off and connect the neutral safety switch wiring connector. (6) Placethe gearselectorin Park or Neutral and switch the ignition On.
Installed view of the neutral safety switch showing the location of the wiring connector and the wiring connector terminal identification.
Installed view of the cruise control module.

repair should the operation of the systembe in doubt and the following proceduresfail to rectify the problem. CONTROL CABLE To Removeand Instal (l) Remove the retaining clip securingthe inner control cableto the throttle linkage and disconnectthe inner control cable. (2) Depressthe edgesof the outer control cable retaining clip and withdraw the control cable assembly from the mounting bracket. (3) Remove the control cable retaining strap from the left hand side inner mudguard. (4) Depressboth sidesof the outer control cable retaining clip and withdraw the control cable assembly from the control module. Disengage the inner control cable from the connecting strap and remove the control cable from the vehicle. Installation is a reversalof the removal procedure with attention to the following points: (1) Instal the inner cable to the connectingstrap and pull the opposite end of the cable until tight. If necessaryrotate the connecting strap to remove any twists. (2) While holding the inner cable taut, instal the outer cable to the control module, ensuring that the the control module. retaining clip engages (3) Instal the control cable to the mounting bracket, ensuring that the retaining clip locks the outer control cable mounting flange in position.
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(4) Raise the cable lock plate, located in the outer control cable mounting flange,and connect the inner control cable to the throttle linkage. Instal the retaining clip. (5) Pressthe 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) Raisethe cablelock plate locatedin the outer control cable mounting flange. (3) Slowly pull the outer control cable until the throttle linkage begins to move and slowly return the outer control cable until the throttle linkage is just touching the throttle stop. (4) While holding the cable in this position, press the cable lock plate down firmly. CRUISE CANCEL SWITCHES To Removeand Instal The procedurefor the removal and installation of the combination stop lamp/cruise cancel switch and the failsafe cruise cancel switch are identical. Proceed as follows: (1) With the ignition switchedOff, 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 the module to one side. (3) Disconnect the electrical connectors from the relevant switch. (4) Pull the switch assemblyfrom its bracket to remove. Installation is a reversalof the removal procedure with attention to the following adjustment. To Adjust posi(1) Hold the brake pedal in its depressed tion and instal the switchesinto the tubular clips until they stop. Audible clicks will be heard as the switch slides through the clips. (2) Pull the brake pedal back against its stop until the audible clicking sounds can no longer be heard. (3) Apply and release the brake pedal several times to ensurethat the adjustment is correct. (4) If the combination stop lamp/cruise cancel switch has been adjusted, ensurethat the stop lamps operate correctly.
View of the cruise eontrol cable connected to the throttle linkage.
122
Referto supplement
for more information.
EMISSION CONTROL
INTRODUCTION To reduce the output level of the three primary automotive emissions,carbon monoxide (CO), hydrocarbons(HC) and oxides of nitrogen (NOx), and thus comply with legislation on the maintenance of clean air, severaldifferent typesof emissioncontrol systems are usedin the Commodore rangeof vehiclescovered by this manual. The systemswill be discussed under the headings (l) Positive Crankcase Ventilation (PCV) System,(2) Evaporative Control Systemand (3) Exhaust Control System. 1. POSITIVE CRAI{KCASE VENTILATION (PCV) SYSTEM DESCRIPTION To prevent the emission of crankcasevapours to the atmosphere,a closedPCV system is used. vapours are drawn into the inlet maniCrankcase fold from the enginevia the PCV valve and hose,and are then consumed in the combustion process.Clean air is drawn from the throttle body and entersthe left hand side rocker cover via the engine vent pipe.
If the engineis being operatedunder hard acceleration or heavy load conditions, and the generated blow-by vapours exceed the capacity of the PCV valve, the excess vapours flow back through the engine vent pipe to the throttle body and are drawn into the inlet manifold. If the engineis excessively worn and blow-by is at a high level, a small amount of crankcase vapour will flow back through the rocker cover and into the throttle body, irrespective of throttle position. The engineoil dipstick and filler cap are sealedto the atmosphere.These sealsmust be effective for the PCV systemto operatecorrectly. TO CHECK OPERATION OF PCV VALVE ( 1) With the engine running at idle, disconnect the PCV valve and hose from the base of the inlet manifold. (2) Place a finger over the PCV valve inlet. A strong vacuum should be felt immediately as the finger is placed over the valve inlet. (3) Stop the engine, disconnect the PCV valve from the hoseand shakeit. A rattling noise should be heard. Renewthe PCV valve if it is found to be defective.
Installed view of the PCV system components.
Checking the PCV valve operation.
Emission Control
TO SERVICE THE SYSTEM The system should be regularly serviced with particular attention given to the following points: (1) Check the condition of the rubber hoses, ensuring that they are not blocked, collapsed or deteriorated.Renew the hosesif necessary. (2) Check the sealson the engine oil filler cap, the dipstick and the PCV hose connections. Renew the sealsif damagedor if the sealingquality is suspect. (3) Check the operation of the PCV valve as previously described. 2. EVAPORATIVE CONTROL SYSTEM
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TO SERVICETHE SYSTEM
The evaporative control system should be serviced initially at 1 500 km or I month, and then every 40 000 km or 24 months with attention to the following points: (1) Visually inspectall hosesand pipesensuring that they are not damagedor restricted and check all connectionsfor tightness. (2) Check the fuel tank filler cap sealfor damage and check the operation of the vacuum relief valve. (3) Remove the charcoalcanisterfrom the vehicle. Inspect the charcoal canister for damage as follows: (a) Shakethe canister.There shouldbe no sound from within the canister. (b) Using a vacuum pump, apply 20-35 kPa of vacuum to the vacuum control port on the canister.It should be possible to blow low pressureair through the purge port, which is located directly under the vacuum control port. (c) Releasethe vacuum to the control port. It should not be possible to blow low pressure air through the purge port.
DESCRIPTION The evaporative control system reduces the amount of hydrocarbons emitted to the atmosphere through fuel evaporation.
Installedview of the charcoalcanister. The Commodore rangeof vehiclesusethe absorption regenerationsystem to reduce vapour loss. The systemutilises a canister of activated charcoal to trap and hold the fuel vapours until they can be fed into the induction system for burning in the combustion chambers. The basic componentsof the evaporative control systemare: (a) Fuel tank with integral expansion tank and sealedfiller cap. (b) Charcoal canister with integral purge valve. When the engine is at rest, vapour through evaporation gradually fills the air spacein the fuel tank expansion chamber. As the fuel tank is fitted with a sealedfiller cap, pressurebuilds up within the system forcing the fuel vapour to flow into the charcoal canister. When the engine is started and run at medium to high speed,fuel vapour stored in the charcoalcanister is drawn into the engine via the purge hose. This is controlled by a vacuum signal from the throttle body. Checkthe conditionof the seal on the fuel filler cap. (d) Apply compressed air at a pressureof 20-35 kPa to the fuel tank port. Air should flow freely from the other ports. (e) If air flow through the drain port on the bottom of the canisteris restricted,cleanthe charcoal canister filter by blowing compressedair at a pressure of 300 kPa into the purge port and suitably blocking the fuel tank port. If air flow through the drain poft is still restricted, the canister should be renewed. (0 Apply compressedair at a pressureof 20-35 kPa to one of the ports and suitably block the others.If any leaksare evident, the canistershould be renewed. 3. EXHAUST CONTROL SYSTEM
The exhaust system is the greatest source of pollutant emissions from the internal combustion engine.
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ErnissionControl
The catalytic converter does not require periodic maintenance or replacement under normal circumstances.However, it can be damagedor poisoned by excessively high exhaust gas temperatures, raw fuel and the use of leaded fuel. To prevent the use of leaded fuels a small diameter fuel filler neck with a spring loaded trap door is used. To prevent damageto the catalytic converter,the following precautions should be observed. Do not operatethe vehicle on leadedfuel. 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 the catalyst. Do not operatethe vehicle for long periods if the engine is misfiring. Do not instal used converter flangegaskets. Avoid running the vehicle out of fuel. Ensure that the engine oil and oil additives are formulated to contain low phosphoruslevels. If it is necessary to weld the converterhousing,use only MIG or TIG with stainlesssteelwire. Do not use oxy/acetylenewelders. To Inspect Catalytic Converter (l) Inspect the converter for dents and damage. If the converter is excessivelydamaged,it should be renewed. (2) Inspect the converter heat shield for damage and ensurethat it is positioned correctly. Renew the converter heat shield if necessarv. To Removeand Instal To remove the catalytic converter refer to the Exhaust Systemheading in the Engine section.
On the range of vehicles covered by this manual, the exhaust control system is largely controlled by the engine management system. The control unit of the engine management system constantly monitors the exhaust gasesvia an oxygen sensorlocated in the exhaust manifold. Fuel injection is then adjusted accordingly to give the minimum amount of exhaustemission. For more comprehensive service procedures, refer to the Fuel and Engine Managementsection. CATALYTIC CONVERTER Description A catalytic converter, which is located in the exhaust system, converts harmful hydrocarbons, oxides of nitrogen and carbon monoxide present in into carbon dioxide, nitrogen, water the exhaustgases heat. and
Installcd view of the catalytic converter.
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CLUTCH
SPECIFICATIONS ..... Type Operation... Pressureplate type . Release bearing type. Driven plate: Hub type. Outsidediameter Inside diameter ... Thickness Singledryplate ... Cable Diaphragm spring . Prelubricated ball
Spring cushion ...252.7 mm 165.lmm 7.85-8.35mm compressed by 740 kg load *Clutch pedal height 168.0 + 2.0 mm 102.0mm Release lever pivot ball height. . . . *With pad removed from clutch pedal. Check the clutch driven plate for wear. (3) Worn or scored flywheel face: Machine or renew the flywheel. (4) Worn or scored Bressureplate face: Renew the pressureplate assembly. (5) Worn driven plate facings:Renewthe driven plate. (6) Oil on the driven plate facings: Renew the driven plate and rectify the oil leak. NOTE: In most casesclutch slippage is first evident by a marked increasein engine revs, for no apparent reason, when pulling up a steep hill. The clutch condition can be positively diagnosed as follows: With the handbrake firmly applied and the wheels chocked,place the transmission in top gear and increase the engine speed to approxi' mately I 500rprn. Slowly releasethe clutch pedal. Clutch slippage ,s evident if the engine does not stall. Make the test as quickly as possible to prevent any further clutch damage. CLUTCH SHUDDER (1) Oil on the driven plate facings: Renew the driven plate and rectify the oil leak. (2) Loose or broken engine mountings: Check and tighten or renew the engine mountings as necessary.
TORQUE WRENCH SETTINGS Pressureplate to flywheel bolts Releaselever pivot ball locknut Clutch housing to engine bolts Clutch pedal pivot bolt 1. CLUTCH TROUBLE SHOOTING CLUTCH SLIPPING (l) Incorrectly adjusted clutch cable:Check and adjust the clutch cable. (2) Weak or broken pressure plate diaphragm spring: Check and renew the pressureplate assembly. 25 Nm 34 Nm 90 Nm 16 Nm
Check the clutch pressure plate for scoring.
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Clutch
(3) Worn driven plate hub or transmissioninput shaft splines:Renew parts as necessary. (4) Loosediiven plate facings:Renewthe driven plate. NOTE: Clutch shudder is usually most evident when reversing up an incline. As loose or damaged engine mountings a.re a cause of clutch shudder, thoroughly check the enginemounting rubbersand mounting hardwarefor damage and looseness before removing the clutch for inspection. plate diaphragm Checkthe clutch pressure fingersfor scoringor other damage. bearing noise.If the releasebearing isfaulty and has to be renewed alwavs check,the other clutch components. 2. DESCRIPTION
Checkthe engine mountingsfor deterioration. INSUFFICIENT CLUTCH RELEASE (l) Incorrect cltrtch pedal height: Check and adjust the clutch pedal height. (2) Incorrect release lever pivot ball height: Cleck and adjust the releaselever pivot ball height. (3) Worn or damaged clutch release components: Check and renew parts as necessary. (4) Worn pressure plate diaphragm fingers: Renew the pressureplate assembly. (5) Driven plate hub binding on the transmission input shaft splines:Remove the clutch assembly and free up or renew parts as necessary. NOTE: With the engine idling, disengage the clutch,.wait at least nine seconds and select reverse gear. Gear clash indicates insufrcient clutch release. RELEASE BEARING NOISE ( I ) Dry or worn release bearing: Check and renew the releasebearing. (2', Damaged pressureplate diaphragm spring: Check and renew the pressureplate assembly. NOTE: Lightly depress the clutch pedal with the engine running to check for release
The clutch consists of a single dry driven plate, splined to slide on the transmission input shaft. A diaphragm spring type pressure plate assembly is bolted to the engine flywheel. The driven plate is sandwiched between the pressure plate and the flywheel and transmits the drive from the engine to the transmission. Damper springs are interposed between the driven plate hub and the driven plate facingsin order to cushion the drive. The releasemechanism is activated by the clutch pedal through the clutch cable. The releasemechanism consistsof the releaselever, releasebearing and the diaphragm spring in the pressureplate assembly. On some models, a steel mass damper is welded to the releaselever to suppressvibrations. Operation of the clutch pedal moves the release bearing and the diaphragm spring centre towards the flywheel. When the outer edge of the diaphragm deflects,the clutch is causedto disengage. 3. CLUTCH UNIT AND RELEASE MECHANISM
Special Equipment Required: To Renew Spigot Bush - Suitable extraction tool To Instal - Clutch aligning tool TO REMOVE (l) Remove the transmissionfrom the vehicle as describedin the Manual Transmission section. (2) Disconnectthe left hand side engineexhaust pipe from the left hand side exhaustmanifold flange. (3) Disconnect the engine pipe flange at the front of the catalytic converter. (4) Loosen the clamp and disconnect the right hand side engineexhaustpipe from the left hand side
Clutch
engineexhaustpipe. Remove the left hand side engine exhaustpipe from the vehicle. (5) Loosen the right hand side engine exhaust pipe flange at the right hand side exhaust manifold and allow the right hand side enginepipe to hangclear of the clutch housing. (6) Loosen the adjusting nut on the outer clutch cable at the lower end of the cable abutting the clutch housing. (7) Lift the rear of the clutch cable cover at the clutch housing and move the cover forward clear of the clutch housing. (8) Disconnect the inner clutch cable from the end of the release lever and pull the clutch cable forward out of the clutch housing. (9) Securethe clutch cable to one side clear of the work area. (10) Remove the retaining bolts and remove the lower front coyer from the clutch housing. (11) Remove the retaining bolts and remove the clutch housing from the rear of the engine. (12) Mark the installed position of the pressure plate cover to the flywheel to aid installation and progressivelyloosenthe pressureplate retaining bolts acrossthe assembly. using a diagonal sequence (13) Remove the pressureplate assemblyand the driven plate assembly from the vehicle noting the installed position of the driven plate hub. (la) Working on the clutch housing, pull the release lever off the pivot ball and withdraw the release lever and bearing assembly from the clutch housing. (15) Clean the pressureplate and flywheel faces using a soft cloth moistened with cleaning solvent. NOTE: Do not usepetroleum basedsolvent to clean the abovefaces. (16) By gentlebrushrng,removethe accumulated dust from the inside of the pressureplate being careful not to inhale any of the dust which may contain asbestos.
PRESSURE PLATE ASSEIIBLY DRIVEN PI.ATE
r27
( 17) Wash the releaselever and the inside of the clutch housing using a suitable solvent. bearing NOTE: Do not immerse the release in cleaning solvent as the factory installed lubricant will be destroyed. TO CHECK AND INSPECT (1) Check the driven plate facings for wear, glazing or oil contamination. Checkthe hub for weak or broken cushion springs and wear in the centre spline. Renew the driven plate if wear or damage is found. (2) Check the pressureplate assemblyfor wear on the diaphragm spring fingers, cracked diaphragm spring and a cracked or distorted cover. Check that the pressureplate face is not badly scored.
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Checkthe clutch drivenplate hub cushionspringsfor wear or breakage. (3) Check the flywheel face for heat cracks,burn marks or scoring. Should the flywheel have scoresor damagewhich cannot be correctedwith emery paper, the flywheel can be removed and a light cut taken acrossthe face in a lathe. (4) Check that the transmission input shaft spigot bush in the end of the crankshaft is serviceable. If necessary renew the bush using the following procedure: (a) Withdraw the bush using a suitable extraction tool. (b) Clean the bore for the bush and carefully instal a new bush using a close fitting mandrel and a hammer. (c) Apply a few drops of SAE90 gear oil to the new bush. (5) Check the releaselever for cracks,distortion and wear. Check the pivot ball for wear and measure the installed height using the following procedure: (a) Place a straight edgeacrossthe front face of the clutch housing. (b) Measure from the top edge of the pivot ball to the straight edge.
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View of the clutch pressure Plate assemblY, plate and flywheel.
128
Clutch
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lllustrationshowing clutch aligningtool. The tool can be readily fabricated from a length of round section wood or metal. Dimension A : diameter of transmission input shaft spigot. Dimension B : inside diameterof driven plate hub. progressivelyin a diagonal sequenceto the specified torque. Withdraw the clutch aligning tool. (6) Sparingly lubricate the recessin the release bearing carrier, the pivot ball groove in the release lever and the carrier contact surfacesof the release lever with high melting point molybdenum disulphide grease. (7) Instal the release bearing to the release lever and the releaselever to the pivot ball. (8) Ensure that the mating faces of the clutch housing and the rear of the engine are clean and free from burrs and instal the clutch housingto the engine. Tighten the retaining bolts to the specifiedtorque. (9) Connect the clutch cable to the clutch housing and the releaselever and adjust the clutch pedal height as describedlater in this section. (10) Instal the left hand side engine exhaustpipe to the vehicle. (11) Instal the transmission to the vehicle as describedin the Manual Transmission section. ( 12) Road test the vehicle and check for correct clutch operation. (13) Check and if necessaryadjust the clutch pedal height as describedlater in this section.
lllustration of the release lever pivot ball height point. Dimension measuring A - 1O2.O mm. (c) If necessary, loosen the locknut and raise or lower the pivot ball to obtain the specifiedheight. (d) Tighten the locknut to the specified torque and check that the height is still correct. (6) Check the releasebearing for noise, wear or roughness. If the bearing is to be renewed, support the bearingon its outer edgeand tap the carrier out of the bearing. Instal a new bearing so that the thrust face of the bearing is facing away from the lever end of the catTrer. TO INSTAL Installation is a reversal of the removal procedure with attention to the following points: (l) Sparingly lubricate the splines of the transmission input shaft with high melting point molybdenum disulphide grease.Slide the driven plate onto the input shaft, withdraw the driven plate and remove greasefrom the hub and the input shaft. any excess (2) Position the clutch driven plate onto the flywheel with the cushion spring section towards the pressureplate and the long end of the splined hub towards the flywheel, as noted on removal. (3) Instal a clutch aligning tool through the driven plate and into the spigot bush to hold the driven plate in position. (4) Instal the pressure plate to the flywheel, aligning the marks made on dismantling. Instal the retaining bolts finger tight. NOTE: If installing a new pressure plate assembly, align the white paint marlcs on the pressure plate with the white paint marl<s on the flywheel as close as possible. (5) Tighten the pressure plate retaining bolts
4.
CLUTCH CABLE
TO REMOVE AND INSTAL (l) Disconnect the negativebattery terminal. (2) Raise the front of the vehicle and support it on chassisstands. (3) Loosen the adjusting nut on the outer clutch cable at the lower end of the cable abutting the clutch housing. (4) Lift the rear of the clutch cable cover at the clutch housing and move the cover forward clear of the clutch housing. (5) Disconnect the inner clutch cable from the releaselever and pull the clutch cable forward out of the clutch housing. (6) Working inside the vehicle, remove the trim cover from the lower right hand corner of the dashboard.
Clutch
r29
allowing the idle air control 3 000 rpm for l0 seconds, valve to reset. (6) On models equipped with a radio/cassette using FIN security, enter the PIN code as described under the Radio/Cassetteheading in the Electrical Systemsection. 5. CLUTCH PEDAL
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Viewof the innerclutchcableconnectedtothe release lever. Clutch cable cover removed prior to disconnec' tion of the cable. (7) On vehicles with power windows, remove the mounting screwsfrom the power window electrical module, disconnect the wiring and remove the module from the vehicle. (8) Disconnect the wiring from the stop lamp switch. (9) Remove the mounting screwsfrom the fuse and electrical module panel and move the panel away from the steeringcolumn. (10) Lift the clutch pedal and disconnect the inner clutch cable from the hook on the top of the clutch pedal. ( 1I ) Working in the engine compartment, disconnect the coil spring from the outer clutch cable and pull the clutch cable out of the bulkhead. Note the installed positions of the componentson the bulkhead end 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) Ensurethat the componentson the bulkhead end of the outer cable are positioned correctly as noted on removal. (2) Lubricate the clevises at both ends of the clutch cable with molybdenum disulphide grease. (3) Ensure that adequate clearance exists between the cable and any exhaust system components. (4) Adjust the clutch pedal height as described later in this section. NOTE: Do not fully depressthe clutch pedal prior to adjusting the clutch pedal height as damage could occur to the pressure plate assembly. (5) Start the engine and increase the speed to
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 dashboard. (3) On vehicles with power windows, remove the mounting screwsfrom the power window electrical module, disconnect the wiring and remove the module from the vehicle. (4) Remove the screw retaining the right hand side floor air duct to the heater assemblyand remove the air duct from the vehicle. (5) Disconnect the wiring from the stop lamp switch. (6) Remove the mounting screwsfrom the fuse and electrical module panel and move the panel away from the steeringcolumn. (7) Remove the clutch pedal pivot bolt, lower the pedal slightly and disconnect the inner clutch cable from the hook on the top of the pedal. (8) Disconnectthe upper end of the clutch pedal return spring from the pedal mounting bracket and withdraw the clutch pedal from the vehicle.
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Dismantled view of the clutch pedal.
130
(9)
clutch Bedal. - (to) Examine the bushes and spacer for -the wear and
Clutch
Remove the bushes and spacer from the
damage. Examine the clutch pedil and leturn spring for wear,bends,cracksand damage. Renew partsasnecessary. Installation is a reversal of the removalprocedure
with attention to the following points: (1) Lubricate the spacer,bushesand pedal bore with molybdenum disulphide grease. (2) Ensurethat the clutch pedal return spring is correctly positioned on the pedal and the mounting bracket. (3) Tighten the pivot bolt to the specified torque. (4) Adjust the clutch pedal height as described in the following text. (5) Start the engine and increasethe speed to 3 000 rpm for l0 seconds, allowing the idle air control valve to reset. (6) On models equipped with a radio/cassette using PIN security, enter the PIN code as described under the Radio/Cassetteheading in the Electrical Systemsection.
lllustration of the clutch pedal height measuring point. Note that the pad is removed from the pedal. Dimens i o n A - 1 6 8 . 0 + 2 . Om m . the centre of the metal pad on the bottom of the clutch pedal 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 until the specified height is obtained. (6) With the engine idling, operate the clutch
TO ADJUST CLUTCH PEDAL HEIGHT ( 1) Remove the rubber pad from the bottom of the clutch pedal. (2) Roll back the floor covering to expose the floor panel in the drivers footwell. (3) Lightly depress the clutch pedal by hand until resistancefrom the pressureplate assemblyis felt. Hold the pedal in this position. (4) Measurethe distancefrom the floor panel to
and checkfor correctgearselection.
131
MANUAL TRANSMISSION
SPECIFICATIONS Type . . . . 5 speed,synchromesh on all forward gears Model Borg Warner T5 Gear ratios: First 3.25:l Second. 1.99:1 Third. 1.29:l Fourth. 1.00: l Fifth . 0.72:l Reverse 3.15: I Gear end float: First. ...0.18-0.33mm Second . 0.18 - 0.76 mm Third. ..0.18-0.69mm Fifth. ...0.04-0.98mm Laygear . . . . 0 . 0 1 3- 0 . 1 0 2m m Synchro ring to gear clearance: First and secondgears. Third and fourth gears.. . . . 0.95 - 1.5 mm Fifth gear . 0.7 - 2.0 mm Mainshaft preload: Ideal ....0.05mm Acceptablerange . . 0.025 - 0. 13 mm TORQUE WRENCH SETTINGS Transmission to clutch housing bolts . . 84 Nm Top cover bolts 15 Nm Filler and drain plugs 40 Nm Extension housing to transmission casebolts... ..60Nm Crossmembermounting bolts . . . 50 Nm Fifth/reversepivotpin ....68Nm Reverselamp switch . 27 Nm I-aygearretainer Tom bolts 20 Nm Input shaft bearing retainer bolts 25 Nm Rear propeller shaft flange coupling bolts . . . 65 Nm Centre bearing mounting bolts . . 25 Nm Selectorcover bolts . 20 Nm 1. TRANSMISSION TROUBLE SHOOTING DIFFICULT GEAR CHANGE (1) Worn selectormechanism: Checkand renew the faulty componentsin the selectormechanism. (2) Faulty gear synchronisermechanism: Overhaul the transmission assembly. (3) Faulty clutch or clutch releasemechanism: Check and overhaul the clutch and/or adjust the releasemechanism. (4) Excessive end float in the transmission mainshaft: Renew the worn or damagedcomponents in the transmission. NOTE: First check the clutch fo, correct operation. If reverse gear can be selected without any sign of gear 'clash' this is a fairly good indication that the clutch ls functioning normally. Check that the coruecttype and viscosity oil is used in the transmiiiion as this can also causedifficult gear changing. GEAR CLASH ON CHANGING DOWN (l) Faulty clutch or clutch releasemechanism: Overhaul the clutch and/or adjust the release mechanism. (2) Faulty synchro rings and cones: Check and overhaul the transmission.
Check the friction surfaces of the synchro rings and cones for wear and damage.
r32
Manual Transrncsseon
(3) Engine idle speed too high: Check the idle speed. (4) Broken or incorrect positioning of the synchro shift plate retaining springs:Check and overhaul the transmission. (5) Lubricating oil too heavy: Drain the transmission and refill with the correct quantity and grade of oil. NOTE: Check the clutch for correct operation aspreviously describedbeforeremoving the transmissionfor dismantling and inspection.Also check that the correct type of lubricating oil is being used. SLIPPING OUT OF GEAR (l) Weak or broken detent springs or components: Check and overhaul the transmission. (2) Worn synchroniserassembly,worn synchro ring or teeth: Check and overhaul the transmission.
Checkthe extensionhousingoil seal as a likelysource of leakageif the lubricantis low. (3) Excessive laygear end float: Check and renew the laygearbearings. (4) Insufficient lubricant: Fill the transmission with the correct quantity and grade of oil. NOTE: First checkthe lubricant level in the transmission. Transmission front bearing or layshaft bearing noise can be isolated by depressingthe clutch and placing the transmission in any gear. NOISE (FORWARD TRANSMISSION ENGAGED, VEHICLE MOVING) GEARS
Check the synchronising teeth on all gears and synchro rings for damage or wear. (3) Excessive laygear end float: Check and renew the laygear bearings. (4) Worn input shaft or mainshaft bearings: Check and renew any faulty componentsas necessary. (5) Worn shift forks or selector mechanism: Check and renew any faulty componentsas necessary. NOTE: In most cases, slipping out of gear is causedby wear or damage to internal components. However, prior to dismantling the transmission, check that the gear selector mechanism is nat excessivelvworn and is operating correctly. TRANSMISSION NOISE (IN NEUTRAT)
(l) Worn transmission bearings: Overhaul the transmission and renew the bearings. (2) Chipped or pitted gears:Overhaul the transmission. (3) Lack of lubricant: Fill the transmissionwith the correct quantity and grade of lubricant. NOTE: Check the oil level in the transmission before dismantling.
2.
PROPELLER SHAFT TROUBLE SHOOTING
(l) Worn transmission front bearing: Overhaul the transmission and renew the bearing. (2\ Chipped or pitted constant mesh gears(laygear, front drive gear or lst, 2nd, 3rd or 5th speed mainshaft gears):Overhaul the transmission.
SHAFT VIBRATION (l) Bent propeller shaft: Renew the propeller shaft as an assembly. (2) Excessivewear in the universal joint trunnion and bearings: Renew the complete universal joint (trunnion and bearings). (3) Propeller shaft out of balance: Balance or renew the complete propeller shaft. (4) Excessive in the wear of the front joint sleeve rear extension housing: Renew the transmission extension housing bush and sleeve. (5) Rear universal joint to pinion flange bolts loose: Renew and tighten the loose flangebolts.
Manual Transrnrss?on
133
shaft. End float preload is adjustable by means of a shim at the front of the input shaft. The input shaft is supported on a tapered roller bearing located at the front of the transmission and a bearing installed in the rear of the crankshaft. Gear lever movement is transferred to the selector forks via the gear lever and a single selector rail. All gears,forward and reverse,with the exception of the fifth gear are located inside the transmission case.The fifth gear assemblyis located in the extension housing. The first, second and third gears, when not engagedare free to rotate on the mainshaft. 4. Checkingthe rear universalioint for wear by manual manipulation. NOTE: First check that all coupling bolts and nuts are tight. Check the universal joints for wear by manual manipulation. It will be necessary to use a dial gauge or pointer if propeller shaft run out is suspected. Check that the propeller shaft is still carrying its balance weights. EXCESSIYE BACKLASH ( I ) Worn universaljoint trunnion and bearings: Renew the joint trunnion and bearings as an assemblv. (2) Worn mainshaft and universal joint sleeve: Renew the worn components. NOTE: Check the universaljoints and universaljoint splined sleeve for wear by manual manipulation. The test should be made with the transmission in neutral and the rear of the vehicle clear of the floor so that the rear road wheelsare free to turn. 3. DESCRIPTION TRANSMISSION ASSEMBLY
Special Equipment Required To Dismantle - Suitable Torx sockets and adaptors, suitable laygear bearing puller, press and press plates To Assemble- Dial indicator gauge,micrometer, suitable Torx sockets and adaptors TO REMOVE AND INSTAL (1) Disconnect the negativebattery terminal. (2) Raise the front and rear of the vehicle and support it on chassisstands. (3) Drain the transmissionoil into a cleandrain tin. Check the oil for foreign particles to assist in locating worn componentsif the transmissionis to be dismantled and overhauled. (4) Place mating marks on the propeller shaft rear flangeand the differential drive pinion flange to ensurereplacementto the original position (5) Remove the coupling bolts from the propeller shaft rear flange. (6) Remove the propeller shaft centre bearing mounting bolts. (7) Lower the centre bearing and separatethe propeller shaft rear flange from the differential drive pinion flange. (S) Slide the propeller shaft out of the rear of the transmissionand remove the propeller shaft from the vehicle. (9) Disconnectthe wiring from the vehicle speed sensor located on the extension housing and the reverselamp switch located on the side of the transmission. Secure the wiring to one side clear of the transmission. (10) Remove the bolts retaining the stiffener to the vehicle underbodv and remove the stiffener from the vehicle. (l l) Disconnectthe engineexhaustpipe from the front of the catalytic converter. (12) Support the transmissionon a jack with a block of wood interposedbetweenthe headof the jack and the bottom of the transmission.
The five speedBorg Warner transmission,model T5, has five forward gearsand one reversegear. Full synchromesh is available in all forward gears. All forward gears are helical cut and in constant mesh with the laygear to provide smooth and quiet operation. The reverse idler gear is of the sliding gear type and on engaging, slides into mesh with its mating gearson the mainshaft and laygear. The laygear nrns on two sets of tapered roller bearings and end float is adjustable by means of a shim at the front of the transmission. The mainshaft assemblyis supportedby a tapered roller bearing located at the rear of the transmission, and a needleroller bearing inside the rear of the input
r34
Manual Transrnosseon
(3) Ensure that the weight of the transmission does not hang on the clutch driven plate at any time during installation. (4) Tighten all bolts to the specifiedtorque. (5) If the transmissionhas been overhauledand new paper lined synchro rings were installed, add 150 mls of Lubrizol 7906 to the oil when filling the transmission. (6) When-1 the engine is started, increase the allowing the idle speedto 3 000'rpm for 10 seconds, air control valve to reset. (7\ On models equipped with a radio/cassette using PIN security, enter the PIN code as described under the Radio/Cassetteheading in the Electrical Systemsection. TO DISMANTLE (1) Remove the transmissionfrom the vehicle as previously describedand thoroughly cleanthe outside of the transmission. (2) Remove the retaining bolt and clamp plate and remove the vehicle speedsensorfrom the transmission extension housing. (3) Remove the retaining bolts and remove the selectorcover from the extensionhousing. (4) Using a suitable pin punch, remove the roll pin retaining the linking joint to the shift rail. NOTE: Do not attempt to removethe linking joint from the extension housing. A detent lug on the linking joint prevents its removal. (5) Remove the bolts retaining the extension housing to the transmission case. (6) Separatethe extension housing and linking joint assemblyfrom the transmission case. NOTE: Careful taps with a soft faced hammer may be necessary to separatethe mating faces. (7) Remove the linking joint, roll pin, detent ball and spring from the extensionhousing. (8) Remove the top cover retaining bolts. Note the location of the two dowel bolts. (9) Carefully lever the top cover away from the transmission casemating face. (10) Lift the top cover slightly and slide the cover towards the filler plug side of the transmissioncaseto allow the shift mechanism to clear the groove in the fifth/reverse shift lever. Remove the top cover from the transmissioncase. (l l) Depress the clip retaining the speedodrive and slide the speedo drive rearwards off the mainshaft. Remove the clip from the mainshaft. (12) Carefully prise the plastic oil guide from the rear of the laygear. (13) Remove the snap ring and the fifth gear synchro shift plate retainer from the rear of the laygear.
lnstalledview of the manualtransmission. ( l3) Working in the enginecompartment,disconnect the air flow duct from the throttle body. (14) Remove the mounting bolts from the transmission rear crossmember. (15) Removethe nuts retainingthe rear transmission mounting to the crossmemberand remove the crossmemberfrom the vehicle. (16) Carefully lower the jack and remove the bolts retaining the upper gear lever to the transmission gear lever. Raise the upper gearlever clear of the transmission. (17) Removethe bolts retainingthe transmission to the clutch housing. (18) Slide the transmission rearwards clear of the clutch housing. Lower and remove the transmission from under the vehicle. NOTE: Do not allow the weight of the transmission to hang on the clutch driven plate at any time during the removalprocedure as damage may occur. Installation is a reversalof the removal procedure with attention to the following points: (l) Ensure that the mating faces of the clutch housing and the transrnissionare clean and free from burrs. (2) Sparingly lubricate the input shaft spigot with SAE90 gearoil and the splineswith high melting point greaseprior to installation.
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Right hand side view of the manual transmission removed from the vehicle.
Manual Transmission
(1a) Support the rear of the shift rail and remove pin from the fifth gear shift fork. roll the (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/reverseshift lever to the lever pivot pin. ^ (17) Remove the reverse lamp switch from the transmission case. (18) Using a suitable Torx socket and adaptor, remove the fifih/reverse pivot pin from the transmission case. (19) Disengagethe fifth/reverse shift lever from the fifth/reverse shift mechanism and remove the shift lever from the transmission case. (20) Remove the retaining bolts and remove the input shaft bearing retainer from the front of the trinsmission case.Note the position of the word TOP stamped on the bearing retainer. (21) Remove the bearingcup, preload shims and the seal from the bearing retainer. Note the number and thicknessof the shims to aid assembly. (22) Rotate the input shaft until the cut away section aligns with the laygear and remove the input shaft and fourth gear synchro ring from the transmission case.Do not drop the thrust bearing or the roller bearing located in the rear of the input shaft. (23) Pull the mainshaft rearward and remove the mainshaft rear bearing cup from the transmission to use the mainshaft to jar case.It may be necessary the cup loose if difficulty is encountered. (2a) Raise the front of the mainshaft and lift the mainshaft assemblyout of the transmission case. (25) Unhook the reverse inhibitor spring from the anchor inside the transmission case. (26) Pull the fifth/reverse shift rail out of the transmission case. (27) Remove the reverse shift fork and the reverse inhibitor spring from the transmission case.
FORK sTHSHIFT
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135
sTH/REV SHIFTRAIL
INHIBITOR
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View of the fifth/reverse shift components.
(28) Remove the roll pin from the front of the reverseidler shaft using a suitable pin punch. (29) Straightenthe tabs on the laygearrear bearing retainer and remove the retaining bolts using a suitable Torx socketand adaptor. (30) Remove the laygear rear bearing retainer and shim from the transmission case. (31) Remove the laygear rear bearing cup from to use the the transmission case.It may be necessary laygearto jar the cup looseif difficulty is encountered. (32) Removethe reverseidler shaft out the rear of the transmission case.Remove the O ring, gear and roll pin from the transmission case.
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GEAR SYNCHRO SLEEVE
lllustration of the transmission components removed from the transmission housing. Note that the reverse i gear and shaft are not shown.
136
Manual Transmiss'ion
gear, press the mainshaft out of the third/fourth synchroniserassembly.Remove the third gear,needle roller bearing and spacerfrom the mainshaft. (37) Remoye the snap ring retaining the'fifth gear to the mainshaft. (38) Using suitable press plates to support first gear,pressthe mainshaft out of the fifth gear, the rear bearing and first gear. (39) Remove the first gear needle roller bearing and sleevefrom the mainshaft. (40) Remove the first gear bearing sleevelocating pin from the mainshaft. (41) Remove the first gearsynchroring assembly. (42) Remove the snap ring retaining secondgear to the mainshaft. Remove the thrust washer, second gear, needle roller bearing and spacerfrom the mainshaft. (a3) Using a small screwdriver,remove the spiral snap ring retaining the first/second synchroniser assembly to the mainshaft. Remove the thrust washer.
(33) Using a suitable puller, remove and discard the laygear rear bearing from the laygear. (34) Move the laygear rearward, lift the front of the laygear and withdraw the laygear from the transmission case. measurethe end float of (35) Using feeler gauges, the first, second and third mainshaft gears. To measure the third gear end float use the following procedure: (a) Ensure that the secoirdgear is held against the first/second synchroniser and push the third gear toward the second gear. (b) Holding the gears in the above position, measure the distance between the second and third gears. (c) Pull the third gear away from the second gear and measurethe distancebetweenthe two gears. (d) The difference between the two measuremgnts is the third gear end float. (36) Using suitable press plates to support third
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lllustration of the mainshaft and laygear components dismantled.
Manual Tronsmission
r37
IST/2ND SHIFT FORK
points for the first/secondsynchro ring to gear clearance. (5) Check each synchro assemblyfor wear and damagepaying particular attention to the shift plates and springs.Renew worn componentsas necessary. (6) Check all the roller bearings and cups for pitting and wear. Renew worn bearingsas necessary. NOTE: Do not spin the bearings with compressed air as damage to the bearings and/or injury to the operator could result.
INTERLOCK PLATE ARM SELECTOR
249tatt17
Dismantledview of the top cover. (44) Suitably mark the sleeve in relation to the hub and remove the first/secondsynchroniserassembly from the mainshaft being careful not to lose the detent ball and spring, where applicable. NOTE: The Jtrst/second synchroniser hub cannot be separatedfrom the mainshaft. (45) Suitably mark the sleevesin relation to the hubs and dismantle the third/fourth and fifth gear synchroniser assemblies.Keep the components of each synchroniser assemblyseparatefrom the other assemblies. (a6) Working on the top cover assembly, mark the position of the shift mechanismcomponentsas an aid to assembly. (47) Position the interlock mechanism in neutral and rotate the shift rail counter clockwise. When the selectorarm disengages from the shift plates pull the shift rail rearwards as far as possible. (48) Using a hammer and punch, remove the now accessible shift rail roll pin and withdraw the shift iail from the top cover. (49) Removethe shift forks, shifl plates,interlock plate and selector arm from the top cover. (50) Remove the O ring from the rear of the top cover. TO CLEAN AND INSPECT (l) Wash all the transmission componentsthoroughly in suitable cleaning solvent. (2) Check all the gears for tooth damage and wear and renew if necessary. (3) Check all the shafts for wear and damage. Renew worn or suspectshafts. (4) Check each synchro ring for wear on the contact face and teeth. Push the synchro ring onto its respective gear cone and measure the ring to gear clearance.Renew the synchro rings as necessary. Refer to the illustration for the correct measuring
(7) Check all the needle roller bearings for distortion pitting or wear. Check the running surfaces of the mainshaft and renew parts as necessary. (8) Check the shift forks and rail for bend, wear and damage. Renew parts as necessary.Check the shift forks for excessive clearance in the synchro sleeves.Renew parts as necessaryif excessiveclearance exists.
24elLDls
lllustration showing the correct measuring points for the first/second synchro ring to gear clearance. X cfearance shouldbe 1 .1 -2.1 mm. Y clearance should be 2.4 - 3.2 mm. (9) Where applicable, check the detent spring and ball for damage,wear and breakageand renew as necessary.These components can be deleted without affecting transmission operation. (10) Check the reverseidler componentsfor wear and damage.Renew parts as necessary. (l l) Check the transmissionbreatherlocated in the extension housing for blockage. Clean as necessary. (12) Renew all the oil sealsand O rings. TO ASSEMBLE (l) Lubricate all the transmission components with the recommended grade of lubricant prior to assembly. (2) If new paper lined synchro rings are being installed, soak the rings in transmissionlubricant for at least ten minutes prior to installation. (3) Working on the top cover, carefully instal a new O ring to the rear of the cover and assembleusing the following procedure: (a) Instal the shift platesand nylon insertsto the shift forks. NOTE: The shift plates are interchangeable.
138
Ma,nual Transmission
damage could occur to the inner surface of the third gear. (1 l) Instal the first gear bearing sleeve locating
(b) Instal the selectorarln and interlock plate to the top cover ensuring that the interlock plate is positioned in the top cover slot with the selector arm roll pin hole towards the rear of the cover. (c) Position the shift forks in the top cover. The first/second shift fork is the larger and the offset of both forks must face the rear of the cover. The third/fourth shift plate must be positioned underneath the first/secondshift plate. (d) Instal the shift rail ensuring that the flat is facing upwards, away from the cover. Align the roll pin hole and instal the roll pin until it is flush with the end of the hole. (4) Assemble the third/fourth and fifth gear synchronisercomponentsto the positions marked on dismantling. Ensurethat the tangson the endsof each shift plate spring locatein the sameshift plate and that the springs rotate away from the shift plate in opposite directions.
pin to the mainshaft.

(12) Instal the three piece first gear synchro ring
z+s|rra
lllustration showing the correct positioning of the synchroniser shift plate springs. (5) Where applicable, instal the detent ball and spring to the first/secondsynchro hub. Instal the shift platesand the synchrosleeveto the marked positions. (6) Instal the shift plate springs to the first/ secondsynchro shift plates ensuringthat the tangs on the ends of each shift plate spring locate in the same shift plate and that the springs rotate away from the shift plate in opposite directions. (7) Instal the three piece second gear synchro ring assemblyto the mainshaft ensuringthat the outer ring slots engagethe shift plates and the inner ring splinesengagethe mainshaft splines. (8) Instal the thrust washer and the spiral snap ring to the mainshaft. (9) Instal the spacer,needle roller bearing and secondgear to the mainshaft. Ensure that the slots in the gear align with the tab on the synchro ring. (10) Instal the thrust washerand a new snap ring to the mainshaft. NOTE: Do not stretch the snap ring as
assemblyto the mainshaft ensuringthat the outer ring slots engage the shift plates and the inner ring splines engage the mainshaft splines. (13) Instal the first gear bearing sleeveensuring that the slot in the sleeveengages the locating pin. (14) Instal the needleroller bearing and first gear to the mainshaft ensuring that the slots in the gear align with the tab on the synchro ring. (15) Instal the rear mainshaft bearing ensuring that the bearing taper facesthe rear of the mainshaft. (16) Lubricate the splines of fifth gear and the mainshaft with transmission lubricant and instal the gear to the mainshaft using a press. Ensure that the first gear and rear bearing are held in position while pressing and that the squared edge of the fifth gear teeth 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 synchroniserassemblyensuring that the slots in the ring engage the shift plates. (20) Pressthe third/fourth synchroassemblyonto the mainshaft ensuringthat the hub offsetand the side of the sleevewith the machined groove or the wide chamfer is facing the front of the mainshaft and that the third gear synchro ring remains in position. (21) If necessary to renew the front laygearbearing, use the following procedure: (a) Remove the bearing cone from the front of the laygearusing a suitable puller. (b) Support the transmission case around the location of the bearing cup using a suitable pipe and pressthe cup from the transmission case. (c) Instal a new O ring to the new bearing cup and coat the cup with Loctite 620 or equivalent. (d) Support the front face of the transmission case on press plates and press the cup into the
/\
z4st226lLD25
lllustration of the input shaft components dismantled.
Manual Transrnessoon
transrnission caseusing a suitable mandrel. Instal the cup so that the flangeis level with the end of the bore. (e) Using a suitable tube, press a. new bearing cone 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 input shaft using a suitable puller. (b) Support the end of the input shaft on press plates and pressthe new bearing cone onto the input shaft using a suitable tube. (23) Instal a new oil sealto the input shaft bearing retainer ensuring that the lip of the seal faces the transmission case.Lubricate the seal lip with'transmission lubricant. (24) Prise the oil sealfrom the extensionhousing and instal a new oil sealensuringthat the lip of the seal facesthe transmissioncase.Lubricate the seallip with transmissionlubricant. (25) Manoeuvre the laygearinto the transmission caseand place the transmission caseupright with the front face supported on flat, clean pressplates. (26) Position two spacers,7 mm thick, 15 mm wide and 100 mm long between the front of the laygear and the transmission case and press a new bearing cone onto the rear of the laygear.Remove the assemblyfrom the pressand remove the spacers. (27) Instal the reverseidler gear to the transmission casewith the selectorgroovetowards the rear and instal the reverseidler shaft through the gear. (28) Instal a new O ring to the front of the reverse idler shaft and push the shaft fully into the front support aligning the roll pin hole. (29) Instal the laygear rear bearing cup to the transmissioncase. (30) Instal the shim and the laygear rear bearing retainer, tighten the retaining bolts to the specified torque. (31) Using a dial gaugewith the plunger contacting the end of the laygear, measure the laygear end float. If necessary, adjust the end float by changingthe shims under the laygear rear bearing retainer. NOTE: Shims are availablefrom 2.55 mm to 3.85 mm in increments of 0.007 and 0.008mm. (32) When the laygear end float is correct, bend the lock tabs over the retainer bolts. (33) Instal the reverseidler shaft roll pin so that the pin protrudes equally from each end of the hole. (34) Connectthe long end of the reverseinhibitor spring to the reverseshift fork tang and position the reverse shift fork onto the reverse idler gear. (35) Manoeuvre the mainshaft assemblyinto the transmissioncase. (36) Apply multi-purpose grease to the input shaft bore and instal the roller bearing and the thrust bearing to the input shaft. (37) Instal the fourth gear synchro ring to the
139
third/fourth synchroniser assembly ensuring that the slots in the ring are aligned with the shift plates. (38) Instal the input shaft to the transmission casealigning the cut away section with the laygear. (39) Instal the input shaft bearing cone to the bearing retainer without the preload shim. (40) Temporarily instal the input shaft bearing retainer to the position noted on removal and tighten the retaining bolts to the specifiedtorque. (41) Instal the mainshaft rear bearing cup to the transmissioncase. (42) Instal the fifth driving gear to the end of the laygear.
IIFT FORK INHIBTTORSPRING
249ln6lLDttA
lllustration of the transmission case showing the layout of variouscomponents. (43) Slide the fifth/reverse shift rail through the rear of the transmissioncase,through the reverseshift fork and inhibitor spring and into the front of the transmissioncase. (aa) Using a pair of long nosedpliers connectthe front of the reverse inhibitor spring to the anchor inside the transmission case. (45) Instal the synchro ring and the shift fork to the fifth gear synchroniser assembly and instal the assemblyto the rear of the laygear ensuring that the hub offset and the side of the sleevewith the wide chamfer is facing towards the rear of the laygear. (46) Align the holes in the fifth gear shift fork and while supporting the end of the shift rail, instal the roll pin. (47) Instal the shift plate retainer and new snap ring to the rear of the laygear. (48) Carefully tap the plastic oil guide into the rear of the laygear. (49) Instal the speedodrive retaining clip to the mainshaft and instal the speedodrive ensuringthat it is securelyheld in position by the clip. (50) Instal the fifth/reverse shift lever to the transmission case ensuring that the lever correctly engages the fifth/reverse shift mechanism.
140
Manual Transmission
(56) Apply a 3 mm bead of RTV Silastic l0E0 or equivalent to the extensionhousing mating face. (57) Instal the extension housing over the mainshaft and shift rail until the shift rail just enters the selectorhousing on the rear of the extensionhousing. (58) Coat the detent ball and the detent spring with multipurpose geaseand instal the ball to the detent plate. (59) Instal the detent spring to the linking joint and push the linking joint into position on the shift rail while pushing the extensionhousing into position againstthe transmission case. (60) Apply RTV Silastic 1080or equivalentto the threads of the two upper extension housing retaining bolts. Instal and tighten all the retaining bolts to the specifiedtorque. (61) Instal the linking joint roll pin using a suitable pin punch. (62) Position the transmission caseupright with the front face resting on the open jaws of a vice. (63) Mount a dial gaugeto the extensionhousing so that the plunger is contacting the rear of the mainshaft. (64) Push the mainshaft downwards and zero the dial gauge. (65) Push the input shaft upwards and measure the mainshaft end float. (66) Add 0.05 mm to the end float measurement obtained to ascertain the shim thickness required behind the input shaft bearing cup. (67) Remove the input shaft bearing retainer and remove the input shaft bearing cup. (68) Instal the required shim behind the input shaft bearing cup and instal the cup to the bearing retainer. (69) Apply a 3 mm bead of RTV Silastic 1080or equivalent to the input shaft bearing retainer mating facesand instal the bearing retainer to the transmission case. NOTE: Ensure that the sealant does not cover the oil return slots in the bearing retainer.
(51) Apply Loctite 620 or equivalent to the threadsof the fifth/reversepivot pin and instal the pin to the transmission case. Tighten the pin to the specified torque using a suitable Torx socket and adaptor. (52) Apply sealant to the threads of the reverse lamp switch and instal the switch to the transmission case.Tighten the switch to the specifiedtorque. (53) Instal the C clip to the fifth/reverse pivot pin.
(i(-cur
SEI..ECTOR COVER
ttn\..6
S;"""
Dismantled view of the extension housing. (5a) Apply a 3 mm bead of RTV Silastic 1080or equivalent to the top cover mating face and instal the top cover from the filler plug side of the transmission case until the shift forks and the fifth/reverse shift lever are correctly engaged. NOTE: Ensure that all the synchronisers and shift forl<s are in neutral to facilitate installation of the top cover. (55) Instal and tighten the top cover retaining bolts to the specified torque. Ensure that the dowel bolts are installed to the positions noted on removal.
(70) Instal and tighten the bearing retainer bolts to the specifiedtorque. (71) Apply a 3 mm bead of RTV Silastic 1080to the selectorcover mating face and instal the cover to the extension housing ensuring that the end of the lower gear lever engages the linking joint. (72) Instal and tighten the selectorcover retaining bolts to the specifiedtorque. (73) Instal the speed sensor and clamp plate to the extensionhousing.Instal and tighten the retaining bolts securely. (74) Selecteach gear in turn and ensurethat the transmission rotates freely in each gear. Investigate and rectify any malfunctions. (75) Instal the transmission as previously described.
Manual Transrncssoon
5. PROPELLER SHAFT ASSEMBLY Do not dismantle a universaljoint un' lessthe componentsare to be renewed.Do not hold the sleeveof the front universal joint in the unprotected jaws of a vice, otherwisedamage will result.
t4r
Special Equipment Required: To Removeand Instal Constant Velocity Joint Press and press Plates To Renew Centre Bearing - Press and press plates TO REMOVE AND INSTAL ( I ) Raisethe vehicle to a suitableworking height and support it on chassisstands. (2) Suitably mark the rear propeller shaft flange and the differential drive pinion flange to ensure replacement to the original location, remove the coupling bolts and nuts from the flangesand separate the propeller shaft flange from the differential flange. to lightty tap the NOTE: It may be necessary end of the shaft with a soft hammer to free the shaft assembly from the drive pinion flange. (3) Remove the bolts retaining the centre bearing support bracket to the vehicle underbody, slide the front propeller shaft out of the transmissionextension housing and remove the propeller shaft from the vehicle. NOTE: Take care when removing the propeller shaft from the transmission not to mark or damage thefront sleeveas this can lead to rear transmission oil sealfailure on assembly. (4) Plug the end of the transmission extension housing to prevent the loss of lubricant and the entry of dirt. NOTE: A used propeller shaft yoke sleeve can be usedfor this purpose or a length of plastic or metal pipe sealedat one end and with a diameter the same as the yoke sleeve of the propeller shaft. Rag should not be jammed in the end of the transmission extension housing as this could distort the seal lip causingfailure. Installation is a reversalof the removal procedure with attention to the following points: (l) Apply Loctite 242 to the centre bearing retaining bolt threads and tighten to the specified torque. (2) Check and if necessary top up the transmission with the specified lubricant. UNIVERSAL JOINTS To Renew NOTE: Each universaljoint is servicedas a kit which includes trunnion, seals, snap rings and the needle roller bearings and cups.
( I ) Remove the propeller shaft assembly from the vehicle as previously described. (2) Remove the snap rings securing the needle roller bearingsof the front universal joint. (3) Support the propeller shaft on a partially opened vice and using a metal drift, tap one of the bearing cups in to drive the other bearing cup out of the yoke.
BEARING CUPS
SNAPRINGS
BEARINGCUPS
Dismantledview of universaljoint. (4) Again using the drift, tap the trunnion of the bearingjust removed to drive the other cup back into and then out of the yoke. NOTE: The prapeller shaft is balanced to fine tolerancesand must not be dented or otherwise damaged. (5) Manoeuvre the front yoke and trunnion out of the propeller shaft. (6) Treat the other two bearings of the front universal joint and the bearingsof the rear universal joint in a similar manner to completely dismantle the universaljoints. Installation is a reversalof the dismantling procedure. CONSTANT VELOCITY JOINT To Removeand Instal (1) Remove the propeller shaft frorn the vehicle as previously described. (2) Mark the front and rear shafts and the
r42
Manual Transrm,sscon
(4) Apply sealant to clean, greasefree mating areas on the constant velocity joint and dust boot retainer. (5) Apply sealantto the rear shaft flangeand the threads of the sockethead screws. (6) Tighten the sockethead screwssecurely. CENTRE BEARING ASSEMBLY To Renew NOTE: The centre bearing should not be removed unless it is faulty. If the centre bearing is removeda new bearing and rear dust slinger must be installed. (l) Remove the constant velocity joint as previously described. (2) Remove the bolts and nuts from the cup guidesand remove the bracket. Straightenthe tabs on the lower cup guide and separatethe guidesfrom the rubber mounting cup. (3) Using a suitable punch tap off the bearing rear dust slinger. (4) Remove the bearing retainer snap ring. (5) Using suitableadaptor platesto fit as Close to the centre line of the shaft as possible, press off the centre bearing and mounting cup assembly. (6) Using a hammer and punch, remove the rubber dust slinger from the front shaft. NOTE: During the above operations take care not to damage the metal dust slinger which is fixed to the shaft. Installation is a reversalof the removal procedure with attention to the following points: (1) Instal the rubber dust slinger to the front shaft using a hammer and tube. (2) Keep the bearing and shaft clean and free from dirt.
constant velocity joint to ensurecorrect relocation on assembly. (3) Remove the six sockethead screwssecuring the rear shaft to the constant velocity joint. NOTE: If it is necessary to clamp the assembly in a vice use soft protective vice jaws. Clamp the shaft only on the extremities outward of the weld beadsand useonly sufficient pressureto provide a stable working unit. Support the protruding section of the shaft. Do not tighten the vice up to preventthe overhanging weight of the shaft from rotating the unit in the vicejaws. If pressureof the vice is used to do this, distortion of the shaft will occur. (4) IJse a soft punch and tap the rear propeller shaft flangeoff the constant velocity joint. (5) Remove the rear snap ring from behind the constantvelocity joint.
SHAFT
,'reil?t M#l"'il
"'/ RfNc DUsr Boor nJrntpen -A'fr @.*\
srANr vElocrrY JotNr I w-.,,';* sNApRTNG \
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{
scREws
il
scREws
Dismantledview of constant velocity joint components. (6) Tap the dust boot retainer away from the constant velocity joint and remove the gasket. (7) Using suitable adaptor plates to provide contact with the inner sectionof the constantvelocity joint, pressthe constant velocity joint from the front shaft. (8) Remove the thrust washer and remaining snap ring. (9) If the dust boot is split or damagedrelease the holding clamps and remove the dust boot. Installation of the constant velocity joint is a reversal of the removal procedure with attention to the following points: ( I ) Ensurethat the parts are clean and free from dust and foreign matter. NOTE: It is essential that extreme cleanlinessis usedat assemblyof the unit if a full servicelife is to be obtained. If the dust boot is split or perished it must be renewed. (2) Pack the assemblywith 80 g of molybdenum disulphide grease, working it well into the joint. (3) Align and instal the parts as marked during disassemblv.
BOL
1241il5 FRONT SHAFT TET BEARING
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Dismantled view of centre bearing components.
nBFW
Manual Transrnesscon
(3) Press the centre bearing and mounting cup assemblyonto the shaft by applying pressureto the inner race only. (4) Instal the retaining snap ring and instal a new rear dust slinger. Use care not to push the rear dust slinger too far onto the shaft. It is important that a small amount of clearance
r43
be maintained between the mounting cup and the slinger. to the (5) Instal the upper and lowercup guides mounting cup. Bend the tabsover on the lower cuP guide. (6) Instal the constant velocity joint as previously described.
144
AUTOMATIC TRANSMISSION
SPECIFICATIONS Model Type Turbo Hydra-Matic 700 R4 Four forward gearswith overdrive, reversegear and lock up torque converter 3.06:I 1.63: I 1.00: I 0.7:l 2.29:l NO DRIVE IN ANY RANGE (1) Low fluid level in the transmission: Check the fluid level in the transmission and top up if necessary (2) Incorrectly adjusted selector linkage: Check and adjust the selectorlinkage. (3) Incorrect or contaminated transmission fluid: Drain and refill the transmission with the recommendedgrade of fluid.
StJI*i,:s:
First Second Third Overdrive Reverse
Automatic, hydraulic
_. TORQUE WRENCH SETTINGS Converter to drive plate Converter housing to engine Selectorrod trunnion lock bolt . Oil pan bolts Converterhousingcover Crossmembermounting bolts Mounting to crossmember Kickdown cable retaining bolt . I.
: .. .
75 Nm . 24 Nm il Nm ....... l0Nm 5l Nm 40 Nm . . l0 Nm
AUTOMATIC TRANSMISSION TROUBLE SHOOTING NOTE: The following transmission faults can be caused by conditions that may be rectified within the scopeof the infurmation given in this section. Checkthe extension housingoil seal as a likely source of leakage. NO TRANSMISSION KICKDOWN
(l) Incorrectly adjusted throttle cable: Check and adjust the cable as described in the Fuel and Engine Managementsection. (2) Incorrectly adjusted kickdown cable: Check and adjust the cable as describedin this section. (3) Broken kickdown cable:Renewthe cableand adjust as described. NOTE: Check the throttle cable and kickdown cable for fraying: Adjust the throttle cable before adjusting the kickdown cable. SLIPPING OR ROUGH IN UPSHIFT
Check the oil cooler hose connections fur leaks.
(l)
Incorrectly adjusted throttle cable: Check
Automatic Tr ansmis sion

and adjust the cable as described in the Fuel and repair proposition for the averageperson. However, if the transmission must be removed for overhaul by a specialist or replacementby an exchange unit, the removal procedure and installation is described at the end of this section. 3. TRANSMISSION FLUID
r45
section. Management Engine
(2) Incorrectly adjusted kickdown cable: Check and adjust the cable. (3) Kickdown cable sticking: Disconnect the kickdown cable and check for smooth movement. STARTER MOTOR WILL NOT OPERATE IN P oR N POSITIONS, OR WILL OPERATE IN ANy POSITION
(l) Incorrectly adjusted or worn selectorlinkage and bushes: Adjust the selector rod or renew the linkage and bushes. (2) Neutral safety switch faulty: Check and renew as necessary. NOTE: Check possible causesin the order given. 2. DESCRIPTION
Only the recommended automatic transmission fluid should be used when topping up or changingthe transmission fluid. Refer to the Specificationsin the Lubrication and Maintenance section of this manual for the recommendedfluid. TO CHECK AND TOP UP (l) Bring the transmissionto the normal operating temperature, by idling the engine for 15 minutes or driving the vehicle on the road until the engine temperature gaugeregistersthe normal temperature. (2) Park the vehicle on a level surface.With the engineidling and the handbrakefirmly applied, move the selector lever through all the gear positions and
The Turbo Hydra-Matic 700 R4 automatic transmission consists of a lock up type torque converter and a hydraulically controlled epicyclic gear system which provides four forward and one reverse gear. The hydraulic system consists of a pump and a valve body. The hydraulic fluid is circulated through an oil cooler located in the radiator. The oil cooler is connectedto the transmission by pipes. The fluid level is checked by a dipstick located in the filler tube. The floor mounted selector lever has a lock mechanismto prevent accidental selectionof Park or Reverse when the vehicle is moving forward. The overdrive position gives the best vehicle performance for normal travelling. However, D (drive) position improvesthe perfornance when overtaking or negotiating hilly terrain. 2 (second) or I (first) can be selectedwhen increasedengine braking is required. It is necessaryto select P (park) or N (neutral) when starting the engine. When tuning or testing the engine,the handbrake must be firmly applied and the transmission must be in P (park) or N (neutral) otherwise the vehicle may move when the engine speedis increased. The vehicle may be towed in N (neutral) for distances under 55 km at speeds not exceeding 55 km/h. If the vehicle has transmission damage,the propeller shaft must be disconnected from the differential and secured to the underbody, leaving the transmission sealedagainstdirt and contamination. The transmission can be removed from the vehicle as an assemblywithout removing the engine. NOTE: As extensive knowledge and equipment is required to overhaul the automatic transmission, it is not considered a viable
Location of the automatic transmission dipstick.
Checking the automatic transmission fluid level on the dipstick.
146
sion Automatic Tr a,nsmis
select P (Park). Allow the engine to idle in this range througlrout the checking procedure. (3) Clean around the filler tube and the top of the dipstick to ensure that dirt cannot enter the transmission when the dipstick is withdrawn. (4) Withdraw the dipstick and wipe it clean on a piece of lint free cloth. Replacethe dipstick fully into the filler tube. (5) Withdraw the dipstick and check the level which must be at the Full Hot mark on the dipstick. Check the fluid for contamination. discolouration or burnt smell. NOTE: Dfficulty can be encounteredwhen judging the actualfluid level on the dipstick. Repeat operations (4) and (5) above and checkboth sidesof the dipstick until the true fluid level is ascertained. Fluid which ,s contaminated, discoloured or smells burnt usually indicates a mechanical problem within the transmissionrequiring specialist attention. (6) If necessary, add a sufficient quantity of the recommendedfluid through the filler tube to bring the level to the Full Hot mark on the dipstick. Allow a period of time for the fluid to drain out of reasonable the filler tube to avoid a false reading when the level is checked. NOTE: Do not overfill the transmission or foaming and unsatisfactoryoperation of the transmission may result. If it has been necessaryto add a substantial quantiiy of Jluid to the transmission the cause of the fluid loss should be immediately investigatedand rectified. It is difrcult to gain an accuratefluid level check if the vehicle has been operated in ambient temperain city tures above 32 degC, at sustainedhigh speeds, traffic in hot weather, or as a towing vehicle. In any of the above circumstances, allow the transmission to cool for approximately 30 minutes before checkingthe fluid level. TO DRAIN AND REFILL I
View of the transmission with the oil pan removed.
Removing the filter from the transmission. separatethe oil pan from the transmission housing and tilt the oil pan to allow the fluid to drain. (6) Remove the remaining front bolts from the oil pan and remove the oil pan from the transmission. Drain the remaining fluid into the drain tin. Check the fluid and the bottom of the oil pan for abnormal metal and friction material particles which would' indicate an internal mechanical problem. (7) Clean the inside of the oil pan and the oil pan and transmission housing mating faces. (8) If necesSsry,remove the filter from the transmission. (9) Instal the new filter and O ring, ensurethat the filter is correctly located. (10) Instal the oil pan, using a new gasket, instal and tighten the retaining bolts to the specifiedtorque in a diagonal sequence.
(l) Ensurethat the transmissionis cold, raisethe vehicle and support it on chassis standsplacedclear of the work area. (2) Clean the outside of the transmissionoil pan and the area of the transmission housing around the oil pan mating face. (3) Position a suitable drain tin under the transmission oil pan, prefqrably the drain tin should be larger in area than the oil pan to avoid fluid spills. (4) Remove the oil pan retaining bolts in a diagonal sequenceleaving the front bolts loosely in position. (5) Carefully tap the corner of the oil pan to
slon Automatib Tr ansrnis
147
(4) Remove the kickdown cable retaining bolt from the transmission housing. (5) Lift the kickdown cable out of the transmission and disconnectthe inner cablefrom the transmission link. (6) Remove the kickdown cable from the vehicle. Installation is a reversalof the removal procedure with attention to the following points: (1) Renewthe sealat the transmissionend of the cable prior to installation of the cable. (2) Tighten the retaining bolt to the specified torque. (3) Adjust the cableas describedin the following text. TO ADJUST (1) Ensure that the throttle cable is correctly adjusted as describedin the Fuel and EngineManagement section. (2) Depress the metal tab and pull the outer cable away from the throttle linkage until the end of the cable contacts the adjuster fitting. Release the metal tab.
View of the transmission with the filter removed. (l l) Lower the vehicle to the ground and refill the transmission with new fluid approximately the sameamount asdrained. Refer to the Lubrication and Maintenance section. Carry out the procedure described previously under the heading To Check and Top Up. 4. KICKDOWN CABLE
TO REMOVE AND INSTAL (1) Disconnect the inner cable from the throttle linkage. (2) Disconnect the outer cable from the mounting bracket on the throttle body. (3) Raise the front of the vehicle and support it on chassisstands.
Installed view of the kickdown cable showing the location of the metal tab. (3) Fully open the throttle valve. The cable will move through the adjuster fitting and automatically stop at the correct position when the throttle valve is opened fully. 5. TO ADJUST (1) Raise the front of the vehicle and support it on chassisstands. Securelyapply the handbrake. (2) Loosen the bolt retaining the trunnion to the transmissionselectorlever. (3) Working inside the vehicle, place the vehicle selectorlever in P (park). (4) Working Uineaftr the vehicle, place the transmission selectorlever in P (park). SELECTOR LINKAGE
Disconnecting the inner kickdown transmission link.
cable from the
148
ston Automatic Tr ansrnts

assemblyto the centre console, disconnect the quadrant lamp connector and remove the support assembly from the vehicle. (5) Disconnect the wiring connector from the neutral safety switch. (6) Remove the neutral safety switch retaining screwsand manoeuvre the switch from the vehicle. Installation is a reversalof the removal procedure with attention to the following points: (l) Ensurethat the switch operatescorrectly and that the reverse lamps operate when reverse gear is selected. NOTE: The neutral safety switch is not adjustable.Adjustment is automatic when the prevtously desuibed selector linkage adjustment is performed.
View of the selector linkage adjustment point. (5) Tighten the trunnion retaining bolt to the torque. specified (6) Remove the chassis stands and carefully lower the vehicle to the ground. (7) Road test the vehicle and check for correct transmission operation. (8) Check that the neutral safety switch is operating correctly. 6. NEUTRAL SAFETY SWITCH
(2) Start the engine and increase the speed to allowing the idle air control 3 000 rpm for l0 seconds, valve to reset. (3) On models equipped with a radio/cassette using PIN security, enter the PIN code as described under the Radio/Cassetteheading in the Electrical Systemsection. 7. TRANSMISSION ASSEMBLY
TO REMOVE AND INSTAL (1) Disconnect the negativebattery terminal. (2) Carefully prise the rear of the consolecover from the centre console. Disconnect the wiring connectors, turn the cover 90 degreesand manoeuvre it over the selectorlever handle. (3) Remove the gearposition scaleand trim, the slide indicator and the indicator support. (4) Remove the screws retaining the support
Special EquipmentRequired: To Remove and Instal - Suitable trolley jack to which the transmission can be secured. TO REMOVE AND INSTAL (1) Disconnect the negativebattery terminal. (2) Raise the front and rear of the vehicle and support it on chassisstands. (3) Drain the transmission fluid as previously described. (4) Remove the bolt retaining the filler tube to the converterhousingand pull the filler tube out of the transmission.Remove the filler tube from the vehicle. Plug the hole in the transmission to prevent the entry of dirt. (5) Remove the propeller shaft from the vehicle as describedin the Manual Transmission section. (6) Remove the engine exhaust pipes from the vehicle as describedin the Engine section. (7) Remove the retaining bolt and disconnect the kickdown cable from the transmission.Securethe cable to one side clear of the transmission. (8) Remove the bolt retaining the trunnion to the selectorlever. (9) Disconnect the wiring from the speedsensor on the transmission extension housing. (10) If applicable, disconnect the speed sensor wiring from any clips on the transmission and secure the wiring to one side clear of the transmission. (l 1) Remove the retaining bolts and remove the cover from the bottom of the converter housing.
Installed view of the neutral safety switch.
Automati,cTr ansmis sion
149
Right hand side view of the automatic transmission removed from the vehicle.
KICKDOWN CABLE ADJUSTER
Attach a strap to the torque converter housing to retainthe converterduring removaland installationof the transmission. (20) Remove the bolts retaining the converter housing to the rear of the engine. (21) Instal a metal strap to the converterhousing to retain the converter in position. (22) Carefully manoeuvrethe transmissionrearwards until the torque converter is clear of the drive plate, lower the transmission and withdraw the transmission from under the vehicle.
ELECTRICAL CONNECTOR
Left hand side view of the automatic transmission removed from the vehicle. (12) Mark the torque converter in relation to the drive plate and remove the bolts retaining the torque converter to the drive plate. NOTE: Rotate the engine by means of the cranl<shaft pulley to gain access to the converterbolts. (13) Disconnect the wiring from the electrical connector on the left hand side of the transmission. (14) Remove the stiffener retaining bolts and remove the stiffener from the underbody. (15) Removethe bolts retainingthe rear mounting to the transmission. (16) Support the transmissionon a trolley jack with a piece of timber interposedbetweenthe head of the jack and the oil pan. Securethe transmissionto the jack. (17) Remove the crossmembermounting bolts and remove the crossmemberfrom the vehicle. ( l8) Lower the trolley jack and support the rear of the engine using a chassis stand and timber contacting the sump mounting rail. (19) Disconnect the oil cooler pipes from the transmission. Plug the ends of the pipes and the transmission fittings to prevent the entry of dirt.
NOTE: The transmission and converter must be removedfrom the engine as an assembly. Installation is a reversalof the removal procedure with attention to the following points: ( 1) Ensurethat the converterhousingand engine mating facesare clean and free from burrs. (2) Ensure that the torque converter is installed to the marked position on the drive plate. (3) To prevent damageto the sealson assembly, instal the new kickdown cableand filter tube sealsinto the transmission. (4) Tighten all bolts to the specifiedtorque.
lnstalled view of the driveplate.
150
Aut oma tic T r ansrnls sr,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 described under the Radio/Cassetteheading in the Electrical System section. (8) Road test the vehicle. Check that the level is on the Full Hot mark on the dipstick with the transmission at the normal operating temperature. Refer to the heading To Check and Top Up for the correct procedure.
(5) Adjust the kickdown cable and selectorlinkage as previously described. (6) If the transmissionhas been overhauledor if unit is being installed, pour approximatean exchange ly I I litres oftransmissionfluid into the transmission. Refer to the Lubrication and Maintenance section. With the engine cold (running in Park) the level should be 16 mm below the Full Hot mark on the dipstick. Increase the engine speed to 3 000 rpm for l0
l5l
REAR AXLE
SPECIFICATIONS Type . . Salisburytype, semi-floatingaxle shafts with hyPoid final drive Borg Warner 78 series Model preload Pinion bearing Collapsiblespacer adjustment... Pinion and carrier bearing types . . . . Tapered roller Pinion preload: Old bearingswithout pinion seal . . 0.8-1.4 Nm New bearingswithout pinion seal . 1.6-2.8 Nm . . Shims Carrier bearing preload adjustment . . Carrier preload: Old bearingswithout axles . 0.5-1.4 Nm or pinion installed New bearingswithout axles . 1.1-2.8 Nm or pinion installed . . . Tapered roller Axle shaft bearing type Axle shaft end float: . . . Maximum 0.76 mm Old bearings . . 0.40-0.48 mm New bearings 0.10-0.18 mm Crownwheelto pinion backlash . . 3.08:1 Ratio Fluid: Type . . . Hypoid gear oil LS 90 GL5 Capacity TORQUE WRENCH SETTINGS *Crownwheelbolts... . . . 60 Nm Bearing cap bolts . . 3l Nm Differential carrier cover bolts. Axle shaft retaining plate nuts. . 45 Nm Limited slip differential casebolts . . . Upper suspensionarrn to axle housing ....75Nm bolts Lower suspensionann to axle housing ...110Nm bolts . . . 29 Nm Lower shock absorbermountings . . . 70 Nm Panhard rod to axle housing nut . . . 10 Nm Stabiliser lower mounting nut 18 Nm Stabiliserbar to axle housingnut *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 renew the faulty components. (2) Defective brake components: Overhaul the brakes as describedin the Brakes section. (3) Defective axle shaft bearing: Remove the axle shaft and instal a new bearing. (4) Bent axle housing or shaft: Renew the axle housing or shaft.
With the axle shaft removed,turn the bearingby hand to check for roughness. (5) Wheel bent or out of balance: Renew the wheel or balancethe wheel and tyre assembly. NOTE: Check the wheel nuts for tightness. Raise and supportthe rear of the vehicleand spin the wheels to check for run out. Axle shaft bearing noise can be diagnosed by spinning one wheel at a time and listening for a rumble. When carrying out the bearing test place the transmission in neutral and stop the other side wheelfrom turning. If the of being bent remove axle shaJtis suspected the axle shaft and checkfor run out between centres. FINAL DRIVE GEAR NOISE (1) Lack of lubricant: Rectify the leak and top up with the correct grade of lubricant. (2) Loose bearing cap bolts: Torque the bolts to Specifications. (3) Loose pinion nut: Tighten the pinion nut. Check the pinion preload.
r52
Rear Axle
NOTE: Withdraw the axle shafts and check for breakage.Remove the dffirential cover and check the crownwheel bolts. It ls imperative that all foreign metal particles are removed from the rear axle before refilling with oil. LOSS OF LUBRICANT (l) Leaking drive pinion oil seal:Renewthe oil seal and inspect the flange. (2) Leaking axle shaft oil seal: Renew as necessary.
Final drive gear noise can also be caused by internal damageor wear. NOTE: Check possible causesin the order given. Final drive gear noise can also be caused by internal damage or wear, in which casethe rear axle assemblywill have to be removedfor overhaul. In most casesif the dffirential assembly is damaged it is best to instal an exchangeunit. 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 coruectly and overloadingis not the causecheck the rear axle housingfor bend. PINION SHAFT WILL ROTATE BUT NOT DRIVE VEHICLE (l) Broken axle shaft: Check and renew the axle shaft. (2) Sheared crownwheel bolts: Renew the crownwheel bolts. Check the rear axle breatherfor blockageas internal pressurecan force lubricantout of the seals. (3) Leaking cover plate gasket: Renew the gasket. Repair (4) Porous or crackedrear axle assembly: or renew as necessary. NOTE: Check the breather for clogging before thoroughly washing down the rear axle assemblyand checkingfor leaks. If oil leakageis not apparent when the rear axle is cold, run the vehicle on the road until the rear axle reaches ,operating temperature.
Check the drive pinion oil seal as a likely source of oil

leakage.
Check the crownwheel and bearing caP bolts for tightness.
Rear Axle
Check thoroughly for small craclcs in the do rear axle housing.Normally small craclcs not open up and leak oil until the rear axle reachesoperating temqerature. LIMITED NOISE SLIP DIFFERENTIAL OPERATING 3. AruE SHAFT AND BEARING
153
Special Equipment Required: To RemoveAxle Shaft - Slide hammer To Renew Bearing - Vertical press and press plates TO REMOVE AND INSTAL (1) Raise the rear of the vehicle, support it on chassisstandsand remove the relevant wheel. (2) Remove the caliper anchor plate retaining bolts and lift the caliper off the brake disc. (3) Place a spacerapproximately as thick as the brake disc between the brake pads and support or suspendthe caliper out of the way without stretching the 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 gaugewith the plunger positioned against the axle flange and move the axle shaft in and out. If the end float exceedsthe maximum end float Specification the axle bearing must be renewed. hole in the axle (6) Working through the access flange,remove the nuts from the axle shaft retainer. (7) Using a slide hammer secured to the axle shaft, remove the axle shaft. NOTE: If a puller is not available, reverse the brake disc and loosely instal it on the axle flange bolts with the wheel nuts. Use the disc assembly as a slide hammer type puller. Under no circumstancesmay the disc be hammered. (S) If necessary, carefully remove the bearing cup from the axle housing using a slide hammer and a suitable adaptor. Installation is a reversalof the removal procedure taking care to engage the axle shaft with the differential side gears. NOTE: On vehiclesequippedwith a limited slip differential, ensurethat the axle shaft is not rotated until the opposite rtxle shaft is installed or misalignment of the cone and side gears will result. TO RENEW BEARING AND OIL SEAL (l) Remove the axle shaft as previously described. (2) Drill a 6 mm hole into the bearingretainer at right angles to the axle shaft ensuring not to drill completely through the retainer as damageto the axle shaft will result. (3) Restingthe bearing retainer on an anvil, split the retainer with a cold chisel across the hole previously drilled. (4) Using a press and press plates, support the
(1) Whirring sound:This noise doesnot indicate failure of the differential, it is usually caused by severelyunbalanceddrive conditions. (2) Groaning or chattering noise: Possiblelubrication failure. Drain and refill the differential using the correct lubrication. Road test, if the noise remains remove the differential and inspect. NOTE: If a limited slip dffirential rs installed ensure that both rear tyres are exactly the same size.
2.
DESCRIPTION
The Borg Warner 78 series Salisbury type rear axle is of the semi-floating type with hypoid final drive gears. The crownwheel and differential assemblyis carried on tapered roller bearings. Axial adjustment of the assembly controlling the bearing preload and crownwheelto pinion backlashis obtained by the use of spacer shims installed between the bearing outer cups and the differential housing abutments. Shims are also used to obtain pinion height position. Pinion bearing preload is controlled by a collapsible spacerinstalled between the inner cones of the front and rear pinion bearings. Axle shaft and bearing assembliesand axle shaft and pinion oil seals can be removed and installed without removing the axle housing from the vehicle. Removal and installation of the axle assemblyis recommended to facilitate the dismantling, assembling and adjusting proceduresof the differential. The tapered roller type axle shaft bearings are installed from the splined end of the shaft to abut a locating shoulder on the shaft, and are retained by a collar which is an interference fit on the shaft and which bearsagainstthe bearing inner race. The axle shaft oil sealsare located outboard of the on the axle shafts,therefore if axle bearing assemblies the oil seal is faulty the bearing must be removed to gain access to the oil seal.It is recommendedthat once the axle bearing assemblyhas been pressedfrom the axle shaft it should be discarded and a new bearing installed in its place. The oil seals have a sleeve built into the outer circumference which contacts the retaining plate and the bearing rib ring to retain the bearing cup into position in the axle tube flange.
t54
Rear Axle
(9) Apply grease to the cavity between the sealing lips of the new oil seal and instal it to the axle shaft with the lips facing away from the axle flange.
(10) Positionthe new bearingon the axleshaft

ensuringthat the machined groove on the outer raceis towards the axle flange. (l l) Check that the bearing is squarely positioned on the axle shaft and instal the new bearing retainer. (12) Press the bearing and retainer on the axle shaft simultaneouslyusing the pressand pressplates. (13) Lubricate the bearing with the specified lubricant. (14) Instal the axle shaft as previously described in this section. 4. TO RENEW (1) Raise the rear of the vehicle and support it on chassis stands. (2) Mark the relationship betweenthe propeller shaft and the pinion flange,remove the retaining bolts and nuts and disconnectthe propeller shaft from the pinion flange.
223t735
. .i_"]t*{+iisn+*_
BEARING
DRIVE PINION OIL SEAL
Removing the rear axle bearing retaining collar.
bearing inner cone and pressthe axle shaft from the bearing. Discard the bearing. (5) Remove the oil sealand retaining plate from the axle and discard the oil seal. (6) Check the retaining plate for wear or distortion, renew if necessary. (7) Clean the axle shaft and inspect the bearing seatsurfaceand oil sealsurfaceto ensurethat there is no damage. NOTE: Use of a suitable press and press plates are essentialwhen renewingthe bearing. If these are not available the shaft assembly should be taken to a reliable worlcshop for bearing installation. (8) Instal the retaining plate to the axle shaft with the flat side facing away from the axle flange.
COLLAPSIBLESPACER
!il*ffi J;" "l c(
Dismantled view of the drive pinion.
",!*,ffi
(3) Mark the pinion nut, the pinion flange and the pinion shaft to ensurecorrect assembly. (4) With the aid of an assistant applying the brakes, remove the pinion nut and washer. (5) Place a container beneath the pinion flange and remove the pinion flange and dust cover. NOTE: If difficulty is encountered in removing the pinion flange, a suitable puller will be required. (6) Prise the oil seal from the rear axle housing and discard. (7) Allow the lubricant to drain then clean the seal surfaceand inspect for damage. (8) Lubricate the lip of the new sealwith grease. Lightly coat the outer surface of the new seal with a non-hardening sealantand tap the seal squarelyinto the axle housing. (9) Coat the pinion flange splines and seal surface with greaseand instal the pinion flange to the pinion shaft ensuringthat the marks made on removal are aligned.
RETAINING
BEARING
Dismantled
view of axle shaft.
Rear Axle
(10) Instal the pinion nut and washer and tighten the nut until the marks made on removal ate aligned then tighten to a position not more than five past the alignment setting. degrees (11) Instal the propeller shaft to the pinion flange aligning the marks made on removal. Instal the retaining bolts and tighten to 65 Nm. NOTE: It is imperative that all marked components are assembled in the same posilion as they wereprior to dismantling. If -the pinion flange nut is tightened excessively then the collapsible spacer may col' lapsb, causing excessive preload on the pinion bearings. top up the rear axle (12) Check and if necessary with the correct grade of lubricant. (13) Remove the chassisstands and lower the vehicle to the ground. (14) Road test the vehicle and check that there are no oil leaks at the oil seal. NOTE: If renewal of the oil seal fails to recttfu the oil leakage, thoroughly clean the rear axle housing in the vicinity of the oil seal and checkfor a porous axle housing. 5. COVER PI.ATE GASKET
155
Underbodyview showing the rear axle assembly. (5) Remove the cover plate bolts and manoeuvre the cover plate from the vehicle. (6) Clean all traces of gasket from the axle housingand cover plate ensuringthat no piecesof the gasketfall inside the axle housing. (7) Coat both sides of the new gasket with a suitable sealer and place the gasket on the axle housing. (8) Instal the cover plate and retaining bolts and tighten the bolts to the specifiedtorque. (9) Instal the brake union to the bracket and clip the brake pipe to the cover. (10) Instal the Panhard rod nut and washer,do not tighten at this stage. (1 l) Fill the rear axle with the correct grade and quantity of lubricant. Remove the container from beneaththe vehicle. (12) Lower the vehicle to the ground and tighten the Panhard rod retaining nut. 6. DIFFERENTIAL AI{D FINAL DRIVE ASSEMBLY
TO RENEW (1) Raise the rear of the vehicle and support it on chassisstands. (2) Remove the Panhard rod lower mounting nut and washer.Disconnectthe Panhard rod from the rear axle housing and push the rod out of the way. (3) Remove the securing bolt from the brake union bracket and unclip the brake pipe from the cover plate. (4) Placea container beneaththe cover plate and loosen the retaining bolts sufficiently to allow the oil to drain.
Extensive knowledge and specialisedequipment is required to carry out internal repairs to the differential and final drive assembly. As the cost of the equipment required normally exceeds repair costs by a specialist or a factory exchangeunit, it is not a worthwhile proposition for the owner/driver or the person of limited knowledge and equipment to attempt the overhaul procedure.
156
Rear Axle
OR|lJE
'.r/ CENTRE ilARKING
Ol|tRDRIUt
ToEoF ToorH
CENTRE TOE
Crownwheel Tooth Marking for Correctly Adiusted Crownwheel and Pinion. Marking will be slightly Closer to of Tooth on Overdrive or Concave Side. Changes in Thickness of Pinion PositioningShimswill Afrect Tooth Mar on 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.)
80/P83
TOELOIV
HEEL LOIV
Low Profile Marlcing on Both Sides of Tooth. Rectify by Reducing Thickness of Pinion PositioningShims and R (A l l model s.) B ackl ash
/ ,
1HEEL HIGH
\
TOE HIGH
Markins Hieh Pro{ile on BothSides of Crown"!:"J*lfftti[T:[t?I
In"'".sinsof Pinion Posiiionins Shims andR
TOE OF TOOTH
CENTRE. TOE
TOE SLIGHTLY LOW
Toe Marking on Drive Side and Low Profile Marking on Overdrive Side of Crownwheel Toofh. To Reciify, Incr -may within Spec of Pinion PosiiioningShimsto Maintain Backlash Backlash.lt be Necessaryfo IncreaseThickness Limitr (All models.)
HEELCENTRE
HEELSLIGHTLY HIGH
Heel Marking on Drive Side and High Profile Marking on Overdrive Side of Crownwheel Tooth. To Rectify, Re< within'Speci if Pinion PositioningShimsto Maintain Backlash Backlash. lt fiay be Necessaryto DJcreaseThickness Limik (All models.)
Rear Axle
Specifications, illustrations and a tooth marking chart are included in the section for those who may feel competentand sufficiently equipped to undertake the operation. 7. REAR A)(LE ASSEDIBLY
r57
Installation is a reversal of the removal procedure with attention to the following points: NOTE: If an exchangeor secondhandrear axle assemblyis being installed, ensurethat the correct assemblyis obtained. arm bolt towards (1) Instal the upper suspension the centre of the vehicle but do not tighten. (2) Ensurethat the propeller shaft is installed to the mark made on removal. (3) Bleed the brakes as describedin the Brakes section. (4) Tighten all the bolts and nuts to the specified torque with the weight of the vehicle on the suspension. (5) Fill the rear axle with the specifiedgradeand quantity of lubricant. 8. LIMITED SLIP DIFFERENTTAL
TO REMOVE AND INSTAL (l) Raise the rear of the vehicle and support it on 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 cablesfrom the actuating levers. Refer to the Brakes section for further information. (5) Disconnect the hose from the underbody brake pipe union and plug the pipe and hose to prevent fluid loss and the entry of dirt. (6) Remove the brake hose retaining clip and disconnectthe hose from the bracket. (7) Raise the rear axle slightly using a trolley jack, disconnect the shock absorber lower mounting bolts and push the shock absorberup to clear the axle housing. (8) Remove the nuts, washer and the rubber bushesfrom the lower ends of the stabiliser bar links and pull the stabiliser bar clear of the links. Remove the nut and washer from the Panhard rod lower mounting and push the rod up out of the way. (9) Lower the jack and axle assemblysufficiently to remove the coil springs. Remove the coil springs and insulators from the vehicle. (10) Removethe botts and nuts securingthe rear axle assembly to the upper and lower suspension arrns. (l l) Ensure that the rear axle is securely supported by the trolley jack. Disconnect the upper suspensionanns from the axle housing, slightly raise and move the assembly rearwards to clear the lower control arms. l,ower the jack and remove the assembly from the vehicle.
Special Equipment Required: To Test - Axle shaft adaptor DESCRIPTION The limited slip differential unit is almost identical with that of the conventional unit regardinggear and preload settingsand generalmaintenanceaspects, but testing, operating proceduresand precautionsare slightly different. The differential case, in addition to the normal conventional components, houses two cone type clutches splined to the axle shaft and positioned behind the side gears and these correspond with matching facesmachined into the differential case. Three preload springsenclosedin the centreof the pinion cross shaft and interposed between the two side gears,preload the gearsand conesand force the taperedface of the conesinto contact with the mating facesin the case. The cone arrangement directs the major driving force to the rear wheel with greater traction, but it does not interfere with either the differential action or steeringcharacteristics. The partial locking action resulting from the spring load on the cones is increasedby the inherent separatingforces between the side gearsand pinions which progressively increase the resistance as the torque is increased. Where there are extremely unbalancedtraction conditions betweenthe wheels,such as one wheel on hard or dry surfaceand the other on slippery or soft material, a conventional differential will tend to transmit the bulk ofthe power to the wheel offering the least resistance if over acceleration is attempted, resulting in wheel spin and loss of vehicle motion. With the limited slip differential unit however, when there is any tendency for wheel spin to occur the increased friction generated by the cones transfers the bulk of the driving force to the non-
ROD
Rear suspension and axle assembly removed from the vehicle.
158
Rear Axle
(3) Remove the rear brake disc as describedin the Brakes section. (4) Instal the specialtool (which is an adaptor to enable a standard torque wrench to be attached) on the 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 a minimum of 68 Nm. (6) In the event of the torque not being as specified,it will be necessary dismantlethe differential for further examination. (7) Carry out the same test on the opposite side rear wheel. NOTE: Never run the engine with the transmission in gear and one wheel raised. The driving force transmitted by the cone arrangement may causethe vehicle to move.
spinning wheel providing continued traction and vehiclemotion. TO TEST (PRIOR TO DISMANTLING) Any chatter emanating from the differential side cones may be due to lack of lubricant between the cone friction surfaces.To ensure lubrication of the friction surfacesproceed as follows: ( t ) Drive the vehicle at approximately ten kilometres per hour and executefive left and right hand turns on full steeringlock. (2) If the chatter is still noticeable, it may be nec.essary to changethe lubricant. (3) Should the chatter still persist,after carrying out operations (1) and (2) it will be necessaryto dismantle the differential for further examination. To check the differential for correct operation carry out the following test: (l) Raiseone side of the vehicle at the rear and support it on a chassisstand. Remove the wheel. (2) With the transmission in neutral, chock the front wheels and releasethe handbrake.
#p1 'er#
cr@; {@ d:*ffi#
lpwsryr
b @
O@ Dismantled view of the limited slip differential.
159
STEERING
PART I. STEERING TROUBLE SHOOTING
FAULTS, CAUSES AND REMEDIES EXCESSIVE PLAY OR LOOSENESS IN STEERING (1) Tie rod end looseor worn: Tighten or renew the worn tie rod end. (2) Steering gear assembly loose on crossmember: Inspect for damageand tighten the steering gear mounting bolts. (3) Steering gear worn: Overhaul the steering gear.
Checkfor fluid leaks at the pipe fittings. tyres and inflate to the recommendedpressure. (2) Low fluid level in the power steering reservoir: Checkfor leakage, repair and/or renew the faulty components,top up the fluid level. (3) Suspension worn or out of alignment: Check the front suspensionfor wear, renew the worn components and realign. (4) Misalignment betweenthe steeringgear and column mountings: Check and align the steeringgear and column mountings. (5) Binding in the intermediate shaft joints: Check the joints and renew the intermediate shaft coupling assemblyif necessary. (6) Insufficient power steering pump pressure: Check the pump drive belt tension and the reservoir fluid level, if necessary renew the pump assembly. NOTE: Ensure that both front tyres have ample depth of tread and are inflated to the correctpressure.Check thefront suspension componentsfor wear before having the steering geometry checked. See the Front Suspension sectionfor componentchecking procedure. STEERING PULLS TO ONE SIDE (1) IJneven tyre wear or pressure: Check the condition of the tyres and inflate to the recommended pressures.
Check the tie rod end rubber boot for deterioration and the tie rod end ball joint for wear.
(4) Worn or loose intermediate shaft coupling assembly: Tighten or renew the worn coupling assembly. NOTE: Loosenessin the steering linkage is with the weight of the vehicle best assessed on the front wheels. Have an assistant turn the steering wheelfrom left to right while the inspection is found for wear is being made. If looseness to be in the steering gear, then it will be necessaryto overhaul the steering gear o,ssembly. HEAVY STEERING (l) Low or uneven type pressures:Check the
160
Steering- Part I
(2) Incorrect front wheel alignment: Check and align the front end. (3) Dragging brakes: Check each wheel for dragging brakes.Overhaul the brakes as necessary. (4) Damaged suspension or crossmember: Inspectand renew the damagedcomponents. (5) Faulty hydraulic valve in the power steering: Check and renew the pinion valve assembly. NOTE: If the tyre condition and wheel alignment are satisfactory, raise thefront of the vehicle and spin both front wheels to checkfor brake drag. FRONT WHEEL WOBBLE OR SHIMMY (l) IJneven tyre wear or incorrect tyre pressures: Check the condition of the tyres and inflate to the recommended pressures. (2) Tyre or wheel unbalance: Check and balance as necessary. (3) Worn of badly adjusted hub bearings:Check the condition and adjust the front hub bearings. (4) Faulty or worn suspensionunits. Check and overhaul or renew as a pair. NOTE: Check the steering linkage as previously desuibed. Raise the front of the vehicleand check the adjustment of the hub bearings by working the road wheel in and out at the top and bottom. No perceptible movement in the bearings should be felt. Check the suspension uiits as outlined in the Front suspensionsection STEERING ERRATIC OR WANDERING (l) Incorrect or uneven wheel alignment setting: Check and adjust the steeringgeometry. (2) Smooth front tyres: Check and renew the tyres as necessary. (3) Steering gear assembly loose on crossmember: Inspect for damageand tighten the steering gear mounting bolts. (4) Wear in the tie rod assembly: Renew the worn tie rod assembly. (5) Wear in the rack and pinion: Overhaul the rack 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 indicated by uneven wear of the tyres. The vehicle will have to be set up on a reliable wheel alignment machine and the error corrected. Loss of lubricant due to deteriorated rubber boots will causepremature wear to the tie rod ball joints. FAILURE OF POWER ASSISTANCE ( I ) Looseor broken enginedrive belt: Renewthe engine drive belt as describedin the Engine Tune-up section. (2) Low fluid level in the power steeringreservoir. Check for leakage, repair or renew the fuulty components.Top up the fluid level. (3) Insufficient power steering pump pressure: Check the engine drive belt tension indicator and the reservoir fluid level, if necessaryrenew the pump assembly. (4) Faulty power steering gear assembly: Remove and overhaul the power steeringgear assembly. NOTE: When a power assistancefailurehas occurred, the vehicle should only be driven repairs the minimum distancenecessaryfor to be carried out.
l6l
PART 2. POWER STEERING

SPECIFICATIONS Steeringgear type Steeringcolumn type . Linkage tie rods and steeringarms 2.68 Turns lock to lock. Ratio 17.2:l Rack centre 11.8:1 R a c ke n d s , Steeringpump: Saginaw Make Droop flow vane impeller Type . 9 300 - l0 000 kPa Pressure at idle speed Pulley Drive. Belttension. ... Selfadjusting Fluid: ... Dexronll Type Approximately 650 mls Capacity Tighten to 12 Nm Rack pad adjustment then loosen25 - 30 deg TORQUE WRENCH SETTINGS 54 Nm Pump mounting bolts ..2.5Nm Reservoirmountingscrews... . . . 20 Nm Pump pulley bolts ....56Nm Steeringgearmountingnut. . 100 Nm Tie rod assemblyto rack . . . . 7l Nm Tie rod end castellatednut. . . . 65 Nm Rack pad locknut . . . . . 60 Nm Rack bearing retaining screw . 45 Nm Pinion bearing nut . 60 Nrn Pinion bearing screw. 6 Nrn Pinion valve housing screws 30 Nm Intermediate shaft upper bolt and nut . 22 Nm Intermediate shaft lower bolt and nut . 16 Nm Steeringcolumn mounting nut . 22 Nm Steeringwheel nut. . 1. DESCRIPTION The power steering gear is a variable ratio rack ,and pinion type incorporating a torsion bar and rotary control valve and spool to control and direct'the hydraulic pressure to the appropriate side of the power piston which operates in a cylinder incorporated in the rack housing. Hydraulic pressureis supplied to the power steering gear by a pump which is belt driven from the engine crankshaft pulley. A fluid reservoir is mounted to the top of the pump assembly. No lubrication of the steering gear is required in service and in the event of a loss of power assistance . . . Variable ratio rack and pinion with integral power cylinder Collapsible energy absorbing the steering will continue to operate but with greatly increased effort. However, as the steering gear and pump are lubricated by the power steering fluid, the cause of the fluid ,loss must be determined and repaired promptly to prevent damage to the power steeringpump and, to a lesserextent,the steeringgear. The steeringgearis connectedto the steeringarms by tie rods which have non-repairable ball joints attachedto the rack and sealednon-repairabletie rod ends attachedto the steeringarms. The assembly is protected against the entry of water and dust by a seal on the pinion shaft and by comrgated rubber boots which are clamped at one end to the steeringgearhousing and at the other end to the tie rod. The boots expand and contract with the movement of the rack. The steering column shaft is connected to the steeringgear by a flexible intermediate shaft and the steering column assembly is a collapsible type designedto absorbsecondaryimpact in the event of a severefront end collision. 2. PRELIMINARY INSPECTION AND TESTING
If the power steeringsystembecomespartially or fully inoperative it is most important that the following preliminary inspection and testing procedure be performed prior to undertaking any trouble shooting or repair operations. ENGINE DRIVE BELT Inspection, adjustment and renewalof the engine drive belt is fully covered in the Engine Tune-up section. TO CHECK FLUID LEVEL The fluid level is checked at the fluid reservoir when the fluid is at operating temperature.The fluid level must be at or slightly below the H indicator marked on the reservoir dipstick. (l) Ensure that the vehicle is level. Inspect the level indicated on the reservoir dipstick. (2) If the fluid level is low top up with the specifiedfluid. Do not overfill. (3) If the reservoir is dry, the system must be bled as described under In Car Adjustments and Minor Repairs in this section. TO CHECK FOR FLUID LEAKS (1) Using a suitable solvent clean around all power steering assemblies and hose fittings where fluid leakagemay occur and then start the engine. (2) Turn the steering wheel from lock to lock several times, contacting the lock stops lightly and stop the engine.
r62
Steering- Part 2
(4) Start the engine.With the engine at idle speed,turn the steeringwheel from lock to lock
severaltimes, contacting the lock stops lightly. (5) When no air bubbles appear in the fluid reservoir and the fluid level remains constant, the systemcan be consideredbled. (6) Turn the wheels to the straight ahead position, stop the engine and lower the vehicle to the ground. TO REMOVE AND INSTAL POWER STEERING LINES (l) Raise the front of the vehicle and support it on chassisstands. (2) Position a container under the steeringgear. (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 pressureline from the pump. Plug the pump and steering gear to prevent entry of dirt. (6) Manoeuvre the lines from the vehicle. (7) Remove and discard the O rings from the power steeringlines. Installation is a reversalof the removal procedure with attention to the following points: (l) Ensure that new O rings are installed to the power steeringlines. (2) Tighten the unions and hoseclamp securely. (3) Ensurethat the lines are routed correctly. (4) Refill and bleed the power steering system and check for leaks as previously described in this section.
Checking the power steering fluid level. The fluid must be at or slightly below the indicator at operating temperature.
Checkfor fluid leaks at the pipe fittings. is found at Where leakage (3) Checkfor leakage. is the pipe fittings, tighten and recheck.Where leakage found at the steering pump specialist attention is Where leakageis found around the top of necessary. the reservoir, remove the cap and check the cap breather holes for blockage. IN CAR ADJUSTMENTS AI{D MINOR REPAIRS 4. STEERING WHEEL Steering wheel
Special Equipment Required: To Remove Steering Wheel puller. TO REMOVE AND INSTAL
3.
TO BLEED SYSTEM (1) Check the fluid level and top up if necessary as previously described. (2) Raisethe front of the vehicle so that the front wheels are clear of the ground and support it on chassisstands. (3) With the engine stopped, turn the steering wheel from lock to lock severaltimes. Top up the fluid as necessary.Repeat until the fluid level remains constant.
(l) Disconnect the negative battery terminal. (2) Remove the horn pad by pulling the pad from the steeringwheel. (3) Remove the steeringwheel retaining nut and mark the relationship of the steering wheel to the steering shaft to aid in the correct positioning on installation. (4) Using a suitable puller, remove the steering wheel from the steeringshaft. Remove the spring. NOTE: Do not strike the end of the puller or the steering shaft as sharp blows can cause irreparable damage to the collapsible steering shaft.
- Part 2 Steeri,ng
5. STEERING COLUMN
163
Special Equipment Required: To Remove Steering Wheel puller. TO REMOVE
Steering wheel
Installedview of a steeringwheel puller. Installation is a reversalof the removal procedure with attention to the following points: (1) Lubricate the horn contact with a suitable greaseprior to installation. (2) Ensure that the mark on the steering wheel and steering shaft are aligned. (3) Apply Loctite 242 to the threads of the retaining nut and tighten to the specifiedtorque.
(1) Disconnect the negativebattery terminal. (2) Remove the steering wheel as previously described. (3) Open the fusecover 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 securingthe lower trim panel and screwsand fasteners remove the panel.
HORN PAD
Installed view of the power window module.
View of the steering wheel and componentsremoved from the vehicle. (4) Connect the negative battery terminal and check the operation of the horn. Ensure that the turn signal switch self cancels. Start the engine and increasethe speed to 3 000 rpm for 10 secondsallowing the idle air control valve to reset. On models equipped with a radio cassetteusing to enter the PIN code PIN security,it will be necessary as describedunder the Radio/Cassetteheading in the Electrical Systemsection.
Mark the relationship of the intermediate shaft to the clamp prior to removal.
t64
Steering- Part 2
BRACKETS MOUNTING INTERMEDIATE SHAFT
,/
SWITCH IGNITION
Steering column removed from the vehicle.
(6) On vehicles equipped with power windows, remove the mounting screwsfrom the power window module. Lower the module and disconnectthe wiring harness.Remove the module from the vehicle. (7) Remove the screwsretaining the upper and lower covers to the steering column, maneouvre the coversfrom the vehicle. (8) Disconnect the wiring harness connectors from the ignition switch, combination switch and horn contact. Releasethe wiring harness from the steeringcolumn and move it to one side. (9) Raise the front of the vehicle and support it on chassisstands. (10) From under the vehicle mark the relationship of the intermediate shaft to the lower clamp. ( I I ) Remove the upper bolt and nut on the lower clamp. (12) Removethe steeringcolumn mounting nuts and manoeuvrethe steeringcolumn from the vehicle. TO DISMANTLE, INSPECT .A,NDASSEMBLE
housing anti-clockwise and withdraw it from the column. (5) Turn the ignition switch to the On position and withdraw the steeringshaft from the column. NOTE: Do not strike or apply load to the steering column or shaft as this may cause irreparable damage to the collapsible components. (6) If the steeringcolumn lower bearing is to be renewedproceedas follows: (a) Securely hold the lower end of the steering column tube in a vice equipped with soft jaws. (b) Using a drift, drive the bearing and seal assemblyfrom the lower end of the steeringcolumn tube and discard. (c) Instal the new bearingassemblyensuringthat the sealing lips are facing away from the steering column. The bearing is correctly installed when the outer edge is 9-11 mm from the lower end of the steeringcolumn tube. (d) Instal a new seal assembly to the lower steering column tube. The seal assemblyis correctly installed when the metal cap is flush with the end of the steeringcolumn tube. (7) Inspect the steeringcolumn tube for collapse by measuringfrom the end of the lower column tube to the top of the upper bracket. Dimension should be 356.5-359 ffirn, if not within Specificationsthe column tube must be renewed.
INTERMEDIATE SHAFT
(l) Remove the boot from the lower end of the steeringcolumn. (2) Remove the intermediate shaft upper clamp bolt and nut and slide the intermediate shaft from the steering shaft. (3) Remove the retaining snap ring and washer where applicable, and withdraw the spring and washer from the upper end of the steeringshaft. (4) Remove the locking plugs retaining the upper bearing housing to the steeringcolumn, turn the
STEERING SHAFT
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Dismantled view of the s-teering column components. The asterisk indicates late model components
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STEERING COLUMNLQryVER BEARING
Steering- Part 2
165
356.5to359mm
Check the steering column and steering shaft for collapse. (8) Inspectthe steeringcolumn shaft for collapse by measuringfrom end to end. Dimension should be 662 ffiD, if not within Specifications the steering column shaft must be renewed. (9) Inspectthe intermediate shaft universaljoint for wear, damage or binding and renew as necessary. (10) Inspect the rubber boot for cracks or deterioration and renew as necessary. (l 1) Check that the steeringlock operatesfreely. (12) Inspect the steering column upper bearing renew as describedin this section. and if necessary Assembly is a reversal of the dismantling procedure with attention to the following points: (1) Ensure that the steeringcolumn lower bearing assembly is not disturbed when installing the steering shaft. (2) Instal new locking plugsto the upper bearing housing. (3) Instal the intermediate shaft ensuring that the bolt hole aligns with the groove in the steering shaft. (4) Tighten the bolts to the specified torque settings. (5) Ensure that the steering column boot is correctly installed. (6) Instal the steeringcolumn asdescribedunder the following heading. TO INSTAL Installation is a reversal of the removal procedure with attention to the following points: (l) Instal the steeringcolumn and intermediate shaft ensuring that the marks made on removal are aligned. (2) Ensure that the steering column boot is correctly installed to the floor panel. (3) Tighten the steeringcolumn mounting bolts to the specifiedtorque settings. (4) Connect the negativebattery terminal. Start the engine and increasethe speedto 3 000 rpm for l0 secondsallowing the idle air control valve to reset. On models equipped with a radio cassetteusing PIN security,it will be necessary to enter the PIN code as describedunder the Radio/Cassetteheading in the Electrical Systemsection. TO RENEW STEERING COLUMN UPPER BEARING (l) Remove the steering wheel as previously describedin this section. (2) Remove the screwsretaining the upper and lower covers to the steering column, manoeuvre the coYersfrom the vehicle. (3) Depress the retaining clips on the combination switch and remove it from the bearing housing. (4) Remove the wiring from the horn contact. (5) Remove the retaining snap ring and washer where applicable, and withdraw the spring and washer from the upper end of the steering shaft. (6) Remove the locking plugs retaining the upper bearing housing to the steering column, turn the housing anti-clockwise and withdraw it from the column. (7) Mount the housing in a soft jawed vice. (8) Prisethe locking tangsaway from the bearing using a fine bladed screwdriver. (9) While applying pressureto the bearing, dis-
Dismantled view of the steering column upper bearing housing.
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Steering- Part 2
7. POWER STEERING GEAR ASSEMBLY
Special Equipment Required: To RemoveTie Rod Assembly - Suitable spanner or large Stillsons To Instal Tie Rod Assembly - Suitable torque wrench adaptor As extensive knowledge and specialised equipment is required to overhaul the power steering gear, it is not a worthwhile repair proposition for the averageperson. However, if the power steering gear is to be removed for overhaul by a specialist or if it is to be replaced by an exchangeunit, the removal and installation proceduresare describedin this section. The procedures to renew the corrugated rubber are boots, the tie rod ends and the tie rod assemblies describedlater in this section. TO REMOVE AND INSTAL (l) Raise the front of the vehicle and support it on chassisstands.Remove the front wheels. (2) On manual transmission models disconnect the clutch cable as follows: (a) Back offthe adjusting nut on the clutch cable at the clutch housing. (b) Lift the rear of the clutch cable cover and to the clutch cable. move it to one side to allow access (c) Disengagethe cable from the clutch release lever. (d) Remove the clutch cable by pulling towards the front of the vehicle. Remove the cover. (3) Place a container under the power steering gear. (4) Disconnect the power steeringlines from the steering gear and allow the fluid to drain into the container. Plug the lines and steeringgear to prevent the entry of dirt. (5) Mark the relationship of the intermediate shaft lower clamp to the steering gear pinion and remove the lower clamp lower bolt and nut. (6) Remove the split pins and castellatednuts from the tie rod ends. (7) Place a hammer or dolly againstone side of the steering arm and strike the other side with a hammer. Disconnect the tie rod end from the steering arm. Ensure that the nylon spacerson the tie rod end studs are in good condition and secure.If necessary renew the nylon spacers. (8) Remove the bolts, nuts and washersretaining the steeringgear assemblyto the front suspension crossmember. (9) Manoeuvre the steeringgear away from the suspensioncrossmemberand slide the steering gear pinion from the lower clamp. Installation is a reversalof the removal procedure with attention to the following points:
Cross sectional view of the steering column upper bearing housing showing the location of the locking tangs and locatinglugs. engagethe locating lug from behind the bearing and drive the bearing from the housing. (10) Instal the new bearing ensuring that the locating lugs are correctly seatedbehind the bearing. ( I 1) Using a pin punch and hammer, locateboth locking tangs to the groove in the upper bearing. (12) Instal the upper bearing housing and instal new locking plugs. (13) Instal the turn signalswitch and horn wire. (14) Instal the upper and lower covers. (15) Instal the spring and steeringwheel. (16) Tighten the steeringwheel retaining nut to the specifiedtorque setting. 6. INTERMEDIATE SHAFT ASSEMBLY
TO REMOVE AND INSTAL (1) Remove the steering column as previously describedin this section. (2) Remove the boot from the lower end of the steeringcolumn. (3) Remove the intermediate shaft upper clamp bolt and nut and slide the intermediate shaft from the i steeringshaft. Installation is a reversalof the removal procedure ensuring that the bolt hole in the intermediate shaft aligns with the groove in the steeringshaft.
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lntermediate shaft removed from the vehicle.
- Part 2 Steering
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lnstalled view of the power steering gear.
(l) Ensurethat the power steeringgearis centralised, this is achievedby rotating the pinion from lock to lock and halving the rotations. The white lines on the pinion and the steeringhousing should align. (2) Ensurethat the steeringwheel is centralised. (3) Ensure that new O rings are installed to the power steeringlines. (4) Tighten all bolts, nuts and lines to the specifiedtorque setting where applicable. (5) Instal new split pins to the tie rod end castellatednut. (6) On vehicles equipped with manual transmission, connect and adjust the clutch cable. (7) Refill and bleed the power steering system and check for leaks as previously described in this section. (8) Check and if necessary adjust the toe in as describedin the Front Suspensionsection. TO RENEW TIE ROD END (1) Raise the front of the vehicle and support it on chassisstands.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 a hammer. Remove the tie rod end from the steering arm. Ensurethat the nylon spaceron the tie rod end is renew the in good condition and secure.If necessary, nylon spacer. (5) Mark the installed position of the tie rod end on the tie rod and remove the tie rod end. Installation is a reversalof the removal procedure with attention to the following points: (1) Ensurethat the new tie rod end is positioned to align with the marks made on removal. (2) Tighten the tie rod end castellatednut to the specifiedtorque setting. (3) Instal a new split pin to the castellatednut. (4) Check and if necessaryadjust the toe in as describedin the Front Suspensionsection. TO RENEW CORRUGATED RUBBER BOOT (1) Remove the tie rod end as previously described. (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 sidewaysto the locking teeth. disengage (4) Remove the clip retaining the rubber boot to the steeringgearby pushing out the centrepin using a thin pin punch. (5) Slide the rubber boot along the tie rod and remove the rubber boot from the vehicle.
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Tie rod dismantled showing components.
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r68
Steering- Part 2
(6) Turn the steeringgearto full lock and check that the rack lubricant is not contaminated or gritty, indicating the presenceof dirt. (7) If necessary,clean the rack and coat the sliding surfaces and the teeth with EP Semi fluid lithium'based type O grease. Apply the greaseto the corrugations in the rubber boot and instal the rubber boot to the steeringgearby reversing the removal procedure. Ensure that the rubber boot retaining clips are installed correctly and secure. NOTE: Position the front wheels straight ahead before installing the outer endsof the rubber boot in the machined groove in the tie rod and tightening the outer retaining clips. (8) Instal the tie rod end as previously described. TO RENEW TIE ROD ASSEMBLY (1) On some models it may be necessaryto remove the steering gear as previously described. If this is not necessary,remove the tie rod end as previously described. (2) Remove the comrgated boot as previously described. (3) To remove the right hand tie rod turn the steering to full left hand lock. (4) Straighten the tabs of the lockwasher on the right hand tie rod. (5) Using a suitable spanner grip the exposed section of the steering rack. (6) Using a suitable spanner or large Stillsons, loosen and remove the right hand tie rod from the rack and discard the lock washer. (7) To remove the left hand tie rod rotate the steeringuntil 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 the rack. Installation is a reversal of the removal procedure with attention to the following points: (1) Instal the new lock washersto the steering rack ensuringthat the tangsare located in the slots of the rack ends. (2) Using a suitable adaptor, tighten the tie rod assemblyto the specifiedtorque setting. (3) Bend the tabs of the lock washer against the flats of the tie rod to secure. (4) Instal the rubber boots and tie rod ends as previously described. 8. POWER STEERING PUMP
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PUMPASSEMBLY
PUMP PULLEY BOLTS
Dismantled view of the power steering pump and components. removed for overhaul by a specialist or it is to be replacedby an exchange unit, the removal and installation proceduresare describedas follows. TO REMOVE AND INSTAL (1) Loosen the power steering pump pulley retaining bolts.
As extensive knowledge and equipment is required to overhaul the power steeringpuhp, it is not a worthwhile repair proposition for the averageperson. However, if the power steering pump is to be
Installed view of the power steering pump.
- Part 2 Steering
(2) Using a ring spanner, rotate the tensioner anti-clockwise and remove the engine drive belt from the vehicle, releasethe tensioner. (3) Remove the power steering pump pulley retaining bolts and remove the pulley. (4) Placea container beneaththe power steering pump assembly. (5) Loosen the low pressure hose clamp and disconnectthe hose from the reservoir. (6) Loosen the high pressure line union and disconnectit from the power steeringpump. Discard the O ring. (7) Plug the hosesand pump to prevent the entry of dirt.
r69
(8) Remove the reservoir mounting screwsand disconnectthe reservoir from the pump assembly. (9) Remove and discard the reservoir O ring. ( l0) Remove the power steering pump mounting bolts and remove the pump from the vehicle. Installation is a reversalof the removal procedure with attention to the following points: (l) Ensure that a new O ring is installed to the reservoir and high pressureline. (2) Tighten all mounting screwsand bolts to the specifiedtorque settings. (3) Refill and bleed the power steering system and check for leaks as previously described in this section.
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Dismantled view of the power steering pump.
170
PART 3. MANUAL STEERING

SPECIFICATIONS . . . Variable ratio rack and pinion Linkage . . . . Direct from rack ends to tie rod and steeringarms Turns lock to lock. 4.48 Ratio: Rack centre 19.7:l Rack ends. . 23.3:l Rack pad adjustment Tighten to 12 Nm then loosen25 - 30 degrees TORQUE WRENCH SETTINGS Steeringgear mounting nut . Rack pad locknut . Pinionretainingscrew Steering gear type
(5) Placea hammeror dolly against one sideof the steeringarm and strike the other side with a
hammer to disconnect the tie rod ends from the on the tie steeringarms. Ensurethat the nylon spacers rod end studs are in good condition and secure. If renew the nylon spacers. necessary, (6) Remove the bolts, nuts and washersretaining the steeringgear assemblyto the front suspension crossmember. (7) Manoeuvre the steering gear away from the suspensioncrossmemberand slide the steering gear pinion from the intermediate shaft lower clamp. Installation is a reversalof the removal procedure with attention to the following points: (1) Ensure that the steering gear is centralised. This is achievedby rotating the pinion shaft until it is midway betweenits lock to lock rotations. The white lines on the pinion and steeringhousing should align. (2) Ensurethat the steeringwheel is centralised. (3) Tighten all bolts and nuts to the specified torque settings. (4) Instal new split pins to the tie rod end castellatednuts. (5) On manual transmission models, connect and adjust the clutch cable. (6) Check and if necessaryadjust the toe in as describedin the Front Suspensionsection.
. . 65 Nm ....60Nm
1. STEERING GEAR ASSEMBLY Special Equipment Required: To Removeand Instal Pinion Retaining Screw Suitable tanged socket To Measure Pinion Rotating Torque - Suitable torque gauge To Instal Tie Rod Ball Joint - Suitable torque wrench adaptor TO REMOVE AND INSTAL (l) Raise the front of the vehicle and support it on chassisstands.Remove the front wheels. (2) On manual transmission models, disconnect the clutch cable as follows: (a) Back offthe adjusting nut on the clutch cable at the clutch housing. (b) Lift offthe rear of the clutch cable cover and move it to one side to allow access to the clutch cable. (c) Disengagethe clutch cable from the clutch releaselever. (d) Remove the clutch cableby pulling the cable toward the front of the vehicle. Remove the cover. (3) Mark the relationship of the inrermediate shaft lower clamp to the steering gear pinion and remove the clamp lower bolt and nut. (4) Remove the split pins and castellated nuts from the tie rod ends.
TO DISNIANTLE (l) Remove the steeringgear assemblyfrom the vehicle as previously describedand clean the outside of the assemblyusing a suitable solvent. (2) Mount the steering gear assemblyin a vice equipped with soft jaws, gripping the left hand side mounting boss. (3) Remove the corrugatedrubber boots as previously describedin the Power Steeringsection. (4) Rotate the pinion fully anti-clockwise and grip the exposedsection of the rack ensuringthat the vice is equipped with soft jaw guards. (5) Straighten the lock washer on the tie rod joint and disconnect the joint from the rack using a suitable spanner.Remove the right hand side tie rod and joint assembly.
TlE ROD
238/693
View of the manual steering gear removed from the vehicle.
Steering- Part 3
(6) Rotate the pinion clockwise, grip the left hand end of the rack in the vice and repeatoperations (4) and (5). Remove the left hand sidetie rod andjoint assembly. (7) Grip the left hand side mounting boss in the vice and loosen the rack pad adjusting screwlocknut, remove the locknut and remove the rack pad adjusting screw. Discard the O ring from the rack pad adjusting screw. (8) Remove the spring, nylon washer and rack pad from the steeringgear housing. (9) Using a suitable tanged socket, remove the pinion retaining screwfrom the steeringgearhousing. ( l0) Remove the pinion and bearing assembly position from the steeringgear housing. If necessary, the jaws of a l3 mm open end spannerin the pinion groove and tap on the spanner with a soft faced hammer to remove the pinion. NOTE: Thepinion and bearingare serviced as an assemblyand no attempt should be made to separate the bearing from the pinion. (l 1) Partially slide the rack out of the right hand side of the steeringgear housing until the rack end is free of the bush in the left hand end of the steeringgear housing. (12) Position the steering gear housing upright resting on one end of the rack and the other end of the rack positioned against the bush in the left hand end of the steeringgear housing. (13) Using suitablesnap ring pliers in the holes
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provided in the rackbush, compressthe rackbush and use the rack to push the bush out of the steeringgear housing. Discard the O rings from the bush. (14) Remove the rack from the steering gear housing. (15) Removethe oil sealfrom the pinion retaining screw. TO CHECK AND INSPECT gear of the steering (1) Cleanall the components air, with compressed dry blow and solvent in suitable if available. (2) Inspect the pinion bearing for wear and roughnesswhile turning the bearing by hand. Do not spin the bearing with compressed air. Renew the pinion and bearing assemblyif the bearing is worn or damaged. (3) Inspect the pinion teeth for wear and damage. for (4) Inspectthe rack teeth and sliding surfaces wear and damage.Do not mistake the normal lightly polished surfaceson the rack for wear. (5) Inspect the lower pinion bearing in the steering gear housing for wear and damage. The bearing cannot be removed from the steering gear housing.Renew the steeringgear housing assemblyif the bearing is unserviceable. (6) Inspect the steeringgear housing for cracks, wear and damage.Renew the steeringgear housing if cracks,wear or damageare detected. (7\ Inspect the rack pad, the nylon washer and
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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 discarded and instal a new oil sealto the pinion retaining screw using a suitable punch. Renew all components found to be unserviceablein the above inspections. TO ASSEMBLE (l) Mount the steering gear housing in a vice equipped with soft jaws, gripping the left hand side mounting boss. (2) Lubricate the rack bush and O rings with the specified lubricant. Refer to the Lubrication and Maintenance section. (3) Using suitable snap ring pliers in the holes provided in the rack bush, compress and instal the bush into the end of the steeringgear housing. -(4) Liberally coat the rack teeth and sliding surfaceswith the specifiedlubricant. _ (5) Slide the rack into the steeringgear housing from the right hand end aligning the rack teeth with the position occupiedby the pinion and centralisethe rack in the housing by measuring from the end of the rack to the machined shoulder inside each end of the steeringgear housing. The measurements at each end will be equal when the rack is centralised. (6) Pack fifty grams of the specified lubricant into the steering gear housing through the pinion aperture ensuring that the lower pinion bearing is lubricated. (7) Lubricate the upper pinion bearing with the specified lubricant and instal the pinion into the steering gear housing ensuring that the flat on the pinion is parallel with the rack teeth and away from the rack pad aperture. (8) Lubricate the pinion oil seal with the specified lubricant, instal and tighten the pinion retaining screw to the specifiedtorque. Stake the steering gear
Using a torque wrench and adaptor to tighten the rack pad adjusting screwSpecial seruice tools courtesy of Kent-Moore Australia.
Using a torque wrench and adaptor to tighten the rack pad adjusting screw locknut.
'speciat service
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Using a torque wrench and tanged socket to tighten the pinion retaining screw. Speciat seruice tools courtesy of Kent-Moore Australia.
housinginto the retaining screwat two positions using a suitable punch. - - (gl Lubricate the rack pad with the specified lubricant, instal the rack pad, the nylon waslrer and the spring to the steeringgear housing. ( 10) Instal the rack pad adjusting screwand with the rack centralised as previously deicribed, tighten the screwto 12 Nm loosen the sciew 25 - 30 degrees, instal and tighten the rack pad adjusting screwtoitcnui to the specified torque while holding the adjusting screwin the adjusted position. (l l) Attach a suitabletorque gaugeto the pinion and measurethe pinion rotating torque. The iorque should not exceed2.5 Nm over-the full travel of itre rack. If necessary,repeat the rack pad adjustment described in operation (10) and rent* parts as required if rack pad adjustment is not the cause of variations in the pinion rotating torque.
Steering- Part 3
173
( 17) Instal the comrgatedrubber boots to the gearaspreviouslydescribed. steering

(18) Instal the locknuts and tie rod ends to the marked positions. Do not tighten the locknuts. (19) Instal the steering gear assembly to the vehicle aspreviously describedand adjust the toe in as described in the Front Suspension section. Ensure that the nylon spacersare in position on the tie rod end stud. Renew the nylon spacers if they are worn or damaged. TO RENEW TIE ROD END The procedures for renewing a tie rod end are fully covered in the Power Steering section under the Power SteeringGear assemblyheading. TO RENEW CORRUGATED RUBBER BOOTS The proceduresfor renewing the comrgated rubber boots are fully covered in the Power Steering section under the Power Steering Gear assembly heading. TO RBNEW TIE ROD ASSEMBLY The procedures for renewing a tie rod assembly are fully covered in the Power Steering section under the Power SteeringGear assemblyheading. 2. STEERINb WNEET
Using a torque wrench and adaptor to tighten the tie rod joint. of Kent'Moore spociat service ,T;"r::;:"* (12) Instal new lock washersto the tie rod joints ensuring that the presseddimples on the centre of the lockwasher are facing the rack. (13) Rotate the pinion fully anti-clockwise and grip the exposed section of the rack ensuring that the vice is equipped with soft jaws. (14) Instal the right hand side tie rod and joint to the end of the rack, tighten the joint to the assembly specified torque using the illustrated adaptor or equivalent ensuring that the pressed dimples on the lock washer are positioned in the slots in the end of the rack and bend the lock washer over both flats on the joint. (15) Rotate the pinion clockwise to exposethe left hand end of the rack, change the assembly in the vice and grip the exposedend of the rack. (15) Instal the left hand side tie rod and joint assemblyto the end of the rack, tighten the joint to the specified torque using the illustrated adaptor or equivalent ensuring that the pressed dimples on the lockwasher are positioned in the slots in the end of the rack and bend the lock washer over both flats on the joint.
The procedures for removing and installing the steering wheel are fully covered in the Power Steering section under the SteeringWheel heading. 3. STEERING COTUMN
The procedures for removing, dismantling, assembling and installing the steeringcolumn are fully covered in the Power Steering section under the SteeringColumn heading. INTERMEDIATE SHAFT ASSEMBLY The procedures for removing and installing the intermediate shaft assemblyare covered in the Power Steeringsection under the Intermediate Shaft Assembly heading. 4.
174
Refer to supplement
for more information.
FRONT SUSPENSION
SPECIFICATIONS Independent MacPhersonstrut type with coil springs and lower control arm Coil spring free length: Standard models 360 mm 363 mm Models with V5W option with FE2 option . . Sedans 315 mm Shock absorber: Wet strut Type 350 ml Fluid capacity Fluid type. . . HMC 1588 *Wheel alignment: Caster angle Modelswith FE2 option.. . 2 deg t I deg Models without FE2 option. . . . . . I deg 30 min t ldeg Camber angle Models with FE2 option minus 30 min + 30 min Models without FE2 option minus I deg + 30 min Toein ...4mm+2mm * Measurements should be taken with the vehicle unladen and the fuel tank full. TORQUE WRENCH SETTINGS Pibton rod nut 85 Nm Gfand packing nut. . 1 2 0N m Tib rod end castellatednut. . 71Nm Su]spension unit to upper body nuts . l6 Nm I-qwer control arm pivot bolt nut . 1 1 0N m Stabiliserbar bracket bolts. 25 Nm Stabiliserbar link nuts . l0 Nm Rddius rod nuts: Front 1 5 5N m Rear ll0Nm Bdll joint to suspensionunit nut: *Self lockingnut ....110Nm Castellatednut . . 95 Nm iper mounting bolts 90 Nm * 50 deg pension crossmembermounting nuts . . . . 80 Nm *New nut must be installed. Type
I.
FRONT SUSPENSION TROUBLE SHOOTING
FRONT END NOISE (1) Loose upper suspension unit mounting or piston rod: Tighten the mounting or piston rod nuts. (2\ Loose or worn suspension unit lower ball joint: Tighten or renew the lower ball joint. (3) Noise in the suspensionunits: Overhaul the suspension units.
Check the ball joints for wear and deterioration.
Checking the lower control arm inner pivot bolt for tightness.
Front Suspension
the front hub bearings and lower control arm inner pivot bushes.The suspensionball joint is spring loaded in its socket to compensatefor normal wear, therefore if any movement can be detected then the ball joint should be renewed.As a further check on the inner pivot bushesand to check the have the radius rod front mounting bushes, assistantpush the wheels firmly towards the rear and then the front of the vehicle. Stabiliser bar mounting rubbers can be visually checkedfor damage or deterioration.
175
Checkthe stabiliserbar mounting for deterioration. (4) Worn or loose steering gear: Overhaul the steeringgear assembly. (5) Incorrectly adjusted front hub bearings:Adjust the hub bearings. (6) Loose or defective stabiliser bar or radius rod mountings: Check,tighten or renew the mounting rubbers. NOTE: To check thefront suspension .componentsfor wear,first raise the front of the vehicle, support it on chassis stands and allow both front wheels to hang free. With an assistantpushing and pulling the front road wheels in and out at the top and then at the bottom, checkfor excessive looseness at
POOR OR ERRATIC ROAD HOLDING ABILITY (1) L,ow or uneven tyre pressures:Inflate the tyres to the recommendedpressures. (2) Defective suspensionunit: Check, overhaul or renew the faulty unit, preferably in pairs. (3) Incorrect front end alignment: Check and adjust the alignment as necessary. (4) Loose or defective stabiliser bar mounting rubbers or link nuts: Check and tighten or renew the mounting rubbers. (5) Weak or uneven front coil springs: Check and renew front coil springs as a matching pair. (6) Broken or weak rear spring: Renewboth rear springsas a matching pair. NOTE: As a quick guide to suspension unit condition, bouncethefront of the vehicleup and down (one side at a time), the vehiale should come to rest in a single movement. If it bounces two or three times before stopping, the suspension unit shouldbe removed and overhauled.If the front of the vehicleis laying down further on one side than the other, remove the coil spring and check its free length against a new spring. If the spring is found to be unserviceable it is good practice tofit two new springsas a matching pair. This also applies to the springs on the rear of the vehicle. 2. DESCRIPTION
Using a lever to check the lower control arm pivot bushes for wear.
Each front suspensionunit comprises a vertical tubular strut and shock absorberunit, surrounded at the upper end by a coil spring on the top of which is the upper mounting attached to the underside of the front wheel housing. The piston rod of the shock absorber is in turn attached to the upper centre of the spring upper mounting by a rubber mounted thrust bearing assemblv. The lower end of the suspensionunit is mounted to the outer end of the lower control arm by a swivel ball joint. The lower control arm pivots at its inner
176
Fron'tSuspension
move the caliper. Suspendthe caliper from a convenient point by tying it with a piece of wire. This will ensure that no damage is done to the flexible brake hose. (3) Remove the dust cap, split pin and castellated nut from the hub assembly. (4) Withdraw the hub assembly from the stub axle, taking care not to drop the bearings and damage them. Remove the washer and outer bearing from the hub. (5) Remove the inner bearingand the grease seal from the stub axle. (6) Where necessary, using a suitabledrift, drive the two bearing cups from the hub. The inner bearing cup is driven towards the inside of the hub and the outer bearing cup towards the outside of the hub.
Installed view of the right hand side front suspension components. end on a bolt and rubber bush in the channel section of the front crossmember. A stabiliserbar, attachedto the body sub-frame forward of the suspension and connectedto each suspensionunit by a link bolt and rubber bushes contributes considerably to the handling quality of the vehicle. In order to maintain the lower control arm in the correct relationship with the other suspensioncomponents in service,a radius rod is mounted between the lower control arrn and the front suspension crossmember. Casterand camber may be adjustedmarginally by rotating the upper mounting. Rotation toward the front will increase the camber and decreasecaster, rotation toward the rear will increasethe camber and caster. 3. FRONT HUB
TO CLEAN AND INSPECT (l) Remove all the old grease and wash all parts in a suitable solvent. (2) Inspect the bearings and cups for scoring, chips and pitting. If damaged,renew the bearingsas complete assemblies comprising cup and cone. (3) Inspect the brake disc for distortion, chipping or cracking. (4) Check the inner surface of the hub which rotates on the greaseseal. Remove small scoresand burrs with emery paper. (5) Renew the greaseseal. TO ASSEMBLE AND INSTAL ( I ) Where removed, t&D the two hub bearing cups into position in the hub so that their tapers are opposedto each other. (2) Apply wheel bearing grease(suitable for disc brake application) to the rollers of the inner bearing cone assembly. Smear the cup with greaseand slide the cone into position in the hub. (3) Place a new greaseretafiing seal onto the stub axle. The sealshould be firmlv seatedon the stub axle. NOTE: The new grease retaining seal lip should be lightly coated with grease before installing the hub. Do not pack the spacein the hub between the two bearings with grease. (4) Apply greaseto the cone and rollers of the outer hub bearing. Smear the cup with grease,place the hub assemblyon the stub axle, and position the outer cone and roller assemblyin the outer end of the hub. (5) Instal the flat washer and castellatednut on the stub axle and, while rotating the hub, tighten the nut to 18 Nm. (6) Slacken off the nut until there is slight end float, then tighten the nut to 13 Nm. (7) Slackenthe nut one to one and a half slots and instal a new split pin. Replacethe dust cap.
TO REMOVE AND DISMANTLE (1) Raise the front of the vehicle and support it on chassisstands.Remove the front wheel. (2) Remove the caliper retaining bolts and reHUA AND DIS ASSY
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Dismantled view of front hub components.
Front Suspenseon
177
(7) Using a suitablelever, prise the lower control arm and the ball joint bolt from the suspensionunit. (S) Support the suspensionunit on a iack, raise the enginebonnet and working in the engine compartment, remove the retaining nuts securingthe suspension unit to the upper support member. NOTE: Observe the position of the upper suspensionmounting in the upper srypport member. It wiil be seen that between the inner two studs there is a mark on the suspension mounting and the uppersupport member. This is a factory setting for caster and camber: Ensure the suspensionunit is returned to the same position or the wheel alignment will be altered. (9) Lower the jack and remove the suspension unit from the vehicle. Pack the hub bearingsby thoroughlyworking grease between the rollersand the inner race and rollercage. (8) Instal the caliper, tighten the bolts to Specifications and pump the brake pedal two or three times. (9) Instal the front wheel and lower the vehicle to the ground. 4. SUSPENSION UNIT
TO DISMANTLE (l) Prior to dismantling the suspensionunit, clean it thoroughly and ensure that a clean working area is available. Clamp the assembly upright in a vice. NOTE: Clamp the suspension unit by the steering knuckle only. (2) Instal a coil spring compressorto the suspension unit. Compressthe spring, remove the dust seal and the piston rod nut. (3) Remove the upper support bearing assembly, washer,spring seat and insulator.
Special Equipment Required: To Remove- Ball joint removing tool To Dismantle - Spring compressor,gland packing nut wrench or Stillson To Assemble- Spring compressor,gland packing nut wrench or Stillson TO REMOVE (l) Raise the front of the vehicle 4nd support it on chassisstands. Do not support the vehiclb under the lower control arms. (2) Remove the front wheel. (3) Remove the brake caliper and hub assembly as previously describedunder the headingFront Hub. NOTE: Turn the sleeveon the brake hose bracket and disengage the hose from the suspensionunit. (4) Remove the upper nut, washer and bush from the stabiliser bar link bolt. (5) Take out the split pins and remove the nuts from the steering tie rod end and the lower control arm ball joint. (6) Disconnect the tie rod end ball joint stud by placing a suitabledolly or hammer againstone side of the steering ann eye and striking the opposite side with a hammer. Insert the ball joint removing tool and disconnect the lower control arm ball joint.
SPRING COMPRESSOR
Suspension unit with spring compressor installed.
178
+ sp',rf eeEAr
GLANO NUT
Front Suspenseon partswhere (6) Renewall worn or damaged necessary.

TO ASSEMBLE (1) Prior to assembly,ensure that all parts are clean. Do not use cotton waste for wiping down as particles could lodge in the cylinder and result in faulty operation. (2) Place half the quantity of the specifiedfluid in the suspensionunit body. (3) Instal the kit from the sealedpackage but do not tighten the gland nut. (4) Operate the unit up and down until an even resistanceis felt. (5) Raisethe unit slightly and add the remainder of the fluid. (6) Instal the unit with the new O ring and gland nut and using the gland nut wrench or Stillson,tighten the gland nut to the specifiedtorque. (7\ Instal the dust cover, bump rubber and filter to the suspension unit. Position the dust cover so that the bottom of the filter assemblyis approximately 2025 mm abovethe lowestpart of the spring seatthen instal and tighten a new tie. (8) Operate the suspension unit fully several times and ensurethat the dust cover doesnot move on the suspensionunit body. (9) Replace the compressed spring on the suspensionunit, instal the insulator and the spring seat and instal the washer and upper support bearing assembly. NOTE: Ensure that the notch on the spring seatflange faces the stub axle and that the edgeof the washerfaces upward. (10) Instal and tighten the piston rod nut to the correct torque, ensurethat the spring is aligned with the spring seat and releasethe spring compressor. TO INSTAL Installation is a reversalof the removal procedure with attention to the following points: ( I ) Working below the front mudguard, place the suspensionunit in the same position as it was removed, see note in removal section. Instal the washersand nuts but do not tighten the nuts at this stage. NOTE: Ensure that the underside of the wheelhousing is clean beforeofering up the suspension unit. (2) Engagethe control arm ball joint bolt in the bottom of the suspensionunit, instal and tighten the nut to the specifiedtorque and, if applicable,instal a new split pin. If a locking nut is installed to the ball joint bolt, it must be renewedeachtime it is removed. (3) Fully tighten the three nuts securing the suspensionunit to the upper support member.
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PISTON ASSEMBLY
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Dismantledview of suspensionunit.
(4) Remove the spring compressorand the coil spring. Remove the rubber bump stop and dust cover from the suspensionunit. NOTE: The dust cover is retained at the bottom by a plastic tie. This tie will have to be cut. (5) Push the piston rod down until it bottoms, clean the gland nut and surrounding area and using the special gland packing nut wrench or a Stillson, remove the gland packing nut. (6) Pull the piston rod slowly upwards, remove the O ring from the top of the piston guide and withdraw the piston rod and cylinder assembly. NOTE: Do not remove the piston rod and guide from the cylinder as they are serviced as an assembly. TO CLEAN AND INSPECT (l) Drain all oil from the suspension unit body. air. Non Wash componentsand dry with compressed metallic parts should be cleanedby air only. (2) Renew the gland packing nut, O ring and tie. Inspect and clean the filter and dust cover. Renew the filter and dust cover if necessary. (3) Check the suspensionunit body for distortion and cracks. Inspect the stub axle for distortion. Check the base and threaded section for fatigue and damage. (4) Test the coil spring for sag and fatigue and check the rubber components. and (5) Checkthe support bearing for roughness general wear.
Front Suspension
(4) Instal the stabiliser link bush, washer and nut. (5) Engagethe steeringtie rod end stud into the steeringarm, instal and tighten the nut to the specified torque and instal a new split pin. (6) Instal the hub and brake caliper assemblies as previously described. (7) Instal the front wheel and lower the vehicle to the ground. 5. LOWER CONTROL ARM
179
Special Equipment Required: To Remove- Ball joint removing tool TO REMOVE AND INSTAL (l) Raise the front of the vehicle and support it on chassisstands. Do not support the vehicle under the lower control arms. (2) Remove the front wheel. (3) Remove the radius rod nut and washerat the control arm. (4) Remove the split pin, where applicable,and remove the nut from the ball joint. Using a ball joint remover, disconnectthe ball joint from the suspension unit. (5) Remove the nut and washerfrom the control arm pivot bolt. (6) Withdraw the pivot bolt and remove the control arm from the vehicle. (7) Clean the control arm and inspect for distortion and fatigue. Check the pivot bush, the ball joint and radius rod bush for damageor wear. Renew parts as necessary. NOTE: Special equipment is required to renew the pivot bush and the radius rod
S--nut *rr,rr,"
bush. If these special tools are not used in the removal and replacement of these bushes,serious distortion of the lower control arm may occur. For this reason, if replacement of these bushesis necessary the complete lower control arm should be taken to an authorised dealerfor renewal of the bushes. Installation is a reversalof the removal procedure with attention to the following points: (l) Instal the radius rod onto the lower control arm with the convex side of the front washer toward the bush, instal but do not tighten the nut at this stage. (2) Instal the lower control arm into the crossmember 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 bushes then tighten the control arm nut and the radius rod nut to the specifiedtorque. 6. BALL JOINT
TO REMOVE AND INSTAL (l) Removethe lower control arm as previously described. NOTE: The ball joint is an interferencefit in the lower control arm and any attempt to remove or replace it without the use of special tools will seriously distort the lower control arm. It is therefore recommended that should replacementof this part become necessary,the complete lower control arm be taken to an authorised workshop for renewalof the ball joint. Installation is a reversalof the removal procedure. 7. RADIUS ROD
BALL JOINT BOLT
TO REMOVE AND INSTAL (l) Removethe lower control arm as previously described. (2) Remove the nut and washer at the crossmember mounting bracket and withdraw the radius rod from the vehicle. Check the radius rod for distortion and renew the rubber bushesand washers where necessary.
12413f,.2
BALL JOINT
NOTE: When removing the radius rod note that the longer shoulderedend is installed to the crossmember and the shorter end to the lower control arm. Installation is a reversalof the removal procedure with attention to the following points: (l) It is important that on installation of the radius rod the concave side of the front washer is
View of lower control arm and associated components. Model with castellated nut and split pin.
r80
^
Front Suspensron
(4) Mark the stabiliserbar on one side so that it can be replaced in its original position, lift it off the ' links and remove it from the vehicle. NOTE: Usea daub of paint to mark the bar. Do not make a file mark or cut of qny description as this would set up fatigae dnd lead to failure of the stabiliser bar. Installation is a reversalof the removal prpcedure with attention to the following points: (1) Ensure that the rubber busheson lhe connecting links are in good condition and tighten the link nuts to the specifiedtorque. (2) Ensure that the front mounting rubbers are in a serviceable condition and a good frl in the mounting brackets, The open ends of the mounting rubbers must face the front of the vehicle. (3) Instal the stabiliser bar so that the paint mark made on removal is in the sameposition.
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ROD
Dismantledview of radius rod components. placedtoward the bush. And that on installation of the lower control arm the convex side of the front washer is toward the bush. (2) Before final tensioning of the radius rod nuts the vehicle should be lowered to the ground and bounced at the front to settle the bushes. NOTE: If the radius rod bushes in the crossmember need to be renewed special tools are needed.For this reason the vehicle should be taken to an authorised dealerfor renewal of the bushes. 8. STABILISER BAR
9. Special Equipment Required: To Remove- Overhead engine lifting gear TO REMOVE AND INSTAL (l) Disconnect the negative battery tprminal. Remove the engine bonnet as describedin the Body section of this manual. (2) Raise the front of the vehicle and sdpport it on chassis stands located under the front jacking points. If necessary,refer to the Wheels and Tyres section for the location of the front jacking foints. (3) If applicable,remove the retaining bolts and remove the engine sump guard from the vehicle. (4) Remove the inner pivot bolts and nuts from both lower control arms. (5) Remove the radius rods from both sides of the vehicle as previously described and sep4ratethe lower control arms from the crossmember. (6) Remove the steering gear mounting bolts from the crossmember. (7) Raise the engine slightly using qverhead lifting gear and remove the bolts retaining the engine mountings to the crossmember. Loosen the bolts retaining the enginemounting bracketsto the cylinder block. (8) Support the crossmemberon a trofley jack to the and remove the nuts retaining the crossmember vehicle subframe. (9) Lower the jack and remove the crossmember from the vehicle. Installation is a reversalof the removal pfocedure with attention to the following points: (l) Refer to the lower control arm installation procedure prior to tightening the inner pivotlbolts.
TO REMOVE AND INSTAL (1) Raise the front of the vehicle and support it on chassisstands. Do not support the vehicle under the lower control arms. (2) Remove the lower nuts, washersand bushes from the stabiliser bar links. (3) Take out the retaining bolts from the front of each stabiliser bar mounting bracket and loosen the bolts at the rear of each bracket.
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BOLTS .
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Dismantted view of one end of the stabiliser bar showing the mounting components.
Front Suspenston
181
lnstalled view of the front suspension crossmember.
(2) Ensurethat the weight of the engineis resting on the mountings prior to tightening the retaining bolts. (3) Tighten all bolts to the specifiedtorque. (4) Start the engine and increase the speed to 3 000 rpm for l0 seconds allowing the idle air control valve to reset. (5) On models equipped with a radio/cassette using PIN security, enter the PIN code as described under the Radio/Cassetteheading in the Electrical Systemsection.
10.
SUSPENSION AND STEERING AhIGLES
linkage, front hub bearing adjustments, suspension joints and rods, springs and suspensionunit recoil action. Renew or repair componentswhere necessary. The tread of the front tyres should be examined for excessive or uneven wear as certain conditions of tyre wear are indicative of damagedor worn components in the suspension,steeringlinkage or the wheels and bearings. Refer to Tyre Wear Trouble Shooting in the Wheels and Tyres section. If tyres are found to be defective renew with serviceabletyres. The vehicle should be unladen except for a full tank of fuel, with the tyres inflated to the normal pressures. TO CHECK AND ADJUST TOE IN (1) With the vehicle on a level floor, raise the front of the vehicle and support it on chassisstands. (2) Spin each front wheel in turn and using a piece of chalk, mark a thin line around the periphery of each tyre as near to the centre as possible. (3) Lower the front of the vehicle to the floor andbounce the vehicle up and down severaltimes and let it find its own level. Set the front wheels in the straight aheadposition. (4) Mark the centre line on both tyres in front of the suspensionat the height of the wheel centres.
NOTE: Extensive knowledge and specialised equipment is required to measureand correct the suspensionand steering angles except the front wheel toe in. It is therefore not a worthwhile propositions for the layman to do a complete wheel alignment and the vehicle should be taken to a wheel alignment specialist. Prior to carrying out a wheel alignment the front suspension should be completely checkedto ascertain that it is in a serviceablecondition. Carry out a thorough inspection of the steering
182
Front Suspenseon
(6) Maintain the wheels in the straight ahead position, roll the vehicle forward until the marks are the same distance above the floor, but to the rear of the front suspension. (7) Again, use the telescopic gauge, or rule to measureand record the distance between the marks on the tyres. The distancemeasuredat the front of the taken at the wheelsmust be lessthan the measurement for correct toe in rear of the wheels.SeeSpecifications setting. (8) If adjustment of the toe in is required proceed as follows: (a) Remove the outer clips from the rack boots and loosen the tie rod end locknuts. (b) Adjust the tie rods as required until the correct toe in is reached. NOTE: It is important to make equal adjustments to each tie rod to maintain the central position of the steering gear. (c) Tighten the tie rod end locknuts and instal the outer clips to the rack boots. (d) Check the position of the steeringwheelwith the front wheels in the straight ahead position. If remove and reposition the steeringwheel. necessary Refer to the Steering section for the correct steering wheel removal and installation procedure.
REAR WHEELS LD/12
WHEELS
Diagram indicating front wheel toe in. Distance A should be less than distance B. See Specifications. (5) Using a telescopic gauge or rule, measure and record the distance between the two marks on the tyre centres.
Referto supplement
183
formore information.
REAR SUSPENSION
(2) Loose or defective suspensionarm bushes: Check, tighten or renew as necessary. (3) Worn coil spring insulator: Renew the insulator. (4) Worn stabiliser or link rubbers: Renew the rubber 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 absorber condition, bounce the vehicle up and down (oneside at a time) and observeif the vehicle comes to rest in a single movement.If the vehicle bounces two or three times before coming to rest the shock absorberis suspect. If suspect, remove the shock absorber and test and check as described under the appropriate heading. To check the suspension arm bushes and pins, insert a lever betweenthe suspect unit and its mounting and lever the unit back and forth checkingfor excessive movement. Checkthe rear spring coils visuallyfor brealcs. Also checkthe insulatorsfor damage or distortion. If a coil spring is found to be unserviceable it is goodpractice to instal two new springs as a matching pair. REAR WHEELS NOT IN ALIGNMENT WITH FRONT WHEELS (1) Springbadly sagging on one side:Renewthe defective coil spring. (2) Sprung or bent axle housing: Renew the axle housing. (3) Distortion of body and subframe:Check and rectify the body alignment. (4) Upper or lower suspensionarm bolt broken or missing: Renew the suspensionarm bolt. (5) Panhard rod mounting bolt missing or broken: Renew the bolt. NOTE: To check this condition measure from the centre of the front wheels to the centre of the rear wheels on both sides. Compare the measurements which must be
SPECIFICATIONS Live axle with locating arms, coil springs,telescopicshock absorbers, stabiliser bar and Panhard rod Shockabsorbertype. .... Doubleacting Coil spring type Progressiverate Stabilisertype. ..Decoupled Type TORQUE WRE,NCH SETTINGS *Lower suspensionarm mounting bolt nuts I l0 Nm *Upper suspensionarm mounting bolt nuts . 75 Nm *Shock absorberupper nut. . 16 Nm *Shock absorberlower bolt nut . . 29 Nm *Panhard rod: Axle housing attaching nut. . 70 Nm Body attachingnut . I 10 Nm Stabiliserbar: Bracketto axle housingbolts l8 Nm Stabiliserlink nuts l0 Nm Wheelnuts. . . 125Nm *Torque these nuts to Specificationsonly when the vehicle 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 wear and deterioration.
184
Rear Suspenston
Rubber bump stops are fitted to tions of the underbody to limit the travel of t housing during compressionof the springs. A stabiliser bar attached to the axle housi through links and rubber insulators, connect underbody is installed. It reducesroll and i handling. A Panhard rod is installed to control movement of the axle housing.Abell shapedr installed to the Panhard rod retaining nut at housing point. This is to prevent damageto tank in the caseof a rear end collision.
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fuel
A worn suspension arm bush will readily show up by levering between the suspension arm and the axle housing bracket.
3. TO REMOVE
SHOCK ABSORBERS
equal. Before measuring ensure that the front wheels are in the straight ahead position. 2. DESCRIPTION
The rear axle is locatedby four trailing arms and a Panhard rod and is sprung by progressiverate coil springs. Shock absorbers are installed between the outer suspensionarm rear brackets and the vehicle underbody. The suspensionarms hold the axle square to the vehicle and share in controlling axle reactions to drive, braking and accelerationforces. The upper arms carry rubber bushesat both ends. The lower arrns incorporate bushesat their front end. The lower arrn rear bushesare located in brackets on the axle housing.The forward ends of all arms mount to bracketson the vehicle underbody. The axle housinghasmountingbrackets welded to it to provide mounting points for the rear ends of the upper and lower suspensionarms. The springs are insulated from the underbody and suspension arm seatsby meansof rubber insulators.
Sedan (1) Raise the rear of the vehicle and su rt lt standsplacedbeneaththe rear axle ousrng on chassis as closeas practicableto the road wheels. ment (2) Working inside the luggage com nting remove the protective cap from the upper to the and remove the nut securingthe shock abso body. Remove the washer and rubber insula press (3) Working underneath the vehicle, the the shock absorberclear of the body and lower retaining bolt and nut. (4) Withdraw the shock absorber fi the mounting bracket. NOTE: Gasfilled rear shock absorbers As this type be installed on some vehicles.
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View of the rear suspension components and axle assembly removed from the vehicle. View of the shock absorber and mounting removed from the vehicle.
Rear Suspension
it will is difrcuh to compress, absorber shock mounttop the removing after be necessary ing nut, rubber insulator and washer,to the lowerretainingbolt and nut and remove manoeuvrethe shock absorberfrom the
vehicle. Station Wagon (1) Raise the rear of the vehicle and support it standsplacedbeneaththe rear axle housing on chassis as close as practicable to the road wheels. (2\ Working inside the load area lift back the floor covering to expose the shock absorber upper mounting covers. (3) Remove the retaining screwsand remove the cover. Remove the nut securingthe shock absorberto the body and remove the washerand rubber insulator. (4) Working underneath the vehicle, compress the shock absorberclear of the body and remove the lower mounting retaining nut and washer. (5) Withdraw the shock absorber from the mounting.
185
method, the shock absorberis evidently defectiveand should be renewed. NOTE: If gas filled shock absorbers are installed to the vehicle, inspect visually for leal<s which will indicate a faulty shock absorber.Excessivenoise will also indicate a faulty unit. If either of thesefaults are evident the shock absorber should be renewed. Do not puncture or incinerategasfilled shock absorbers TO INSTAL Installation is a reversalof the removal procedure with attention to the following points: (1) Ensure that the rubbers and bushesare in a serviceablecondition. (2) Bleed the shock absorbersprior to installation and keep the shock absorber in an upright position during installation. (3) The weight of the vehicle must be taken by the wheels prior to torquing the shock absorber mountings to Specifications. SUPERLIFT SHOCK ABSORBERS with built in pressurised Optional shockabsorbers air bags assisting the springs can be fitted to all models. The air bags in both shock absorbersare inflated from a common tee valve, the pressuredependingon the load of the vehicle. The valve assemblyis situated at the rear of the vehicle. NOTE: Pressure in the vehicle air bags should not exceedI 034 lcPaand should not be below 103 kPa. Do not operate the vehicle in a lightly laden condition with the air bags inflated to I 034 kPa. To Remove ( 1) Loosenthe air pipe at the shockabsorberand let the air escape. (2) Remove the fitting and the air pipe from the shock absorberand remove the shock absorber from the vehicle as previously describedfor standard type shock absorbers. To Test and Bleed Superlift shock absorbersare tested in the same manner as conventional shock absorbers. When the shock absorber is extended and compressed,air will flow through the pipe connector as a result of the movement in the air bag. To Instal (l) Instal the shock absorber as previously described for standard type shock absorbers.
View of Station Wagon rear shock absorber upper mounting.
TO TEST AND BLEED

The extent to which a shock absorber can be tested without special equipment is limited to the following: (1) Check the body of the shock absorber for dents or damage and for fluid leaks. The shock absorbercannot be repaired and should be renewedif defective. (2) Check the rubber bushesand grommets for wear and deterioration. Renew as necessary. (3) Mount the shock absorber upright in a vice by the lower mounting eye. (4') Grasp the upper half of the shock absorber, pull up to the fully extendedposition and then slowly push down until the shock absorber is fully compressed. (5) Repeat operation (4) six to eight times to remove any slack spotscausedby air in the system.If slack spots exist and cannot be removed by this
186
Rear Suspension
INSULATORS
(4) Slowly lower the jack and remove the spring and insulators from the vehicle. NOTE: If a spring is found to be unserviceable it is good practice to instal two new springs as a matching pair.
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Dismantled view of Superlift rear shock absorber components. (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, connectionsand shock absorbersfor air leaks. This can be done with soapy water brushed onto the components. 4. COIL SPRINGS
Installation is a reversalof the removal procedure with attention to the following points: (1) Placethe jack beneaththe lower suspension arm. (2) Instal the lower insulator and spring to the suspension arm. (3) Placethe upper insulatoronto the springand raise the jack and spring into the upper spring seat. ITIOTE: The coil spring is tapered and is installed with the taper at the top. (4) Continue to lift the suspension arm until the rear retaining bolt can be install-ed. (5) Lower the vehicle onto car ramps and torque the rear retaining bolt to the specifiedtorque. 5. UPPER SUSPENSION ARMS
TO REMOYE AND INSTAL (1) Raise the rear of the vehicle and support it on chassis standsplacedunder the jacking points. (2) Remove the rear wheel. (3) With the jack placed beneath the lower suspension arm directly under the spring, lift the arm enough to remove the rear lower suspension arm retaining bolt.
TO REMOVE AND INSTAL (l) Raise the rear of the vehicle and support it on chassisstandsplaced under the jacking points. (2) Raise the rear axle assembtywith a jack to take the spring load off the upper suspensionarm. (3) Remove the front and rear attaching bolts and withdraw the arm from the vehicle. NOTE: Check the condition of the bushes. Special tools are required to renew the bushesin the arm. For this reason should the bushesrequire renewal the units should be taken to an authorised dealer or the proper tools obtained. To remove both upper suspensionarms
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Rear suspension coil spring components.
Upper suspension arm removed from vehicle.
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to place at the sametime it will be necessary a jack directly under each coil spring to minimise the movement of the axle housing. Installation is a reversalof the removal procedure with attention to the following points: (1) The upper suspensionarms are to be installedwith the lips facing outwards and the attaching bolts must be installed with the heads facing the outsideof the vehicle. (2) The weight of the vehicle must be taken by the rear springs before torquing the arm mounting bolts as specified. 6. LOWER SUSPENSION ARMS
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TO REMOVE AND INSTAL (1) Raise the rear of the vehicle and support it on chassisstandsplaced under the jacking points. (2) Remove the rear wheel.
renewal the units should be taken t0 an authorised dealer or the proper tools ob' tained. Installation is a reversalof the removal procedure with attention to the following points: (1) Place the front of the lower suspensionarm in the body mounting bracket and instal the bolt but do not tighten. (2) Placethe jack beneaththe lower suspension arm. (3) Instal the lower insulator and spring to the arm. suspension (4) Placethe upper insulator onto the spring, raise the jack and guide the spring into the upper spring seat. NOTE: The coil spring is tapered and is fitted with the taper at the top. (5) Continue to lift the suspension arm until the rear retaining bolt can be installed. (6) Lower the vehicle onto car ramps and torque the retaining bolts to the specifiedtorque. 7. STABILISER BAR
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TO REMOVE AND INSTAL (1) Raise the rear of the vehicle and support it on chassis stands placed beneath the rear axle housing. (2) Hold each link and remove the lower nut. Remove the washersand rubber insulators. (3) Swing the stabiliser bar downwards and remove the remaining bottom insulators and washers from the links.
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Lowersuspension arm removedfrom the vehicle. (3) With the jack placed beneath the lower suspensionarm directly under the spring, lift the arm enough to remove the rear lower suspension arm retaining bolt. (4) Slowly lower the jack and remove the spring and insulators from the vehicle. (5) Remove the front retaining bolt and remove the suspensionarm. NOTE: The front bush will remain in the suspensionarm whilst the rear bush will remain in the bracket on the rear axle housing. Check the condition of the bushes. Special tools are required to renew the bushesin the arm or the axle housing.For this reason should the bushes require
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188
Rear Suspension
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(4) Remove the bracket attachingbolts and nuts on the rear axle housing, remove the biackets and the stabiliser bar. open and remove the split mounting bracket rubbers. (Sl To renew the link or upper link insularors, hold the link and remove the top nut at the upper mounting bracket. (6) Withdraw the link, washersand insulators. Installation is a reversalof the removal procedure with attention to the following points: (l) Ensurethat all rubber mountings and insula_ tors are in a serviceablecondition. - - (2) Tighten the link nuts and bracket attaching bolts to Specifications.
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TO REMOVE AND INSTAL (U Raise the rear of the vehicle and support it on chassis stands placed beneath the r"ui axle housing. \Zl Remove the nut and fuel tank protective washer securingthe Panhard rod to the axle housing. (3) Remove the upper body mounting nut and bolt and remove the Panhard rod. Installation is a reversal of the removal procedure with attention to the following points: (l) The eye with the sleevemust be installed to the body bracket. (2) Ensurethat the fuel tank protective washeris installed.
Dismantled view of Panhard rod mounting components.Body bracket side. TO RENEW BUSHES (l) Remove the panhard rod as previously describedand clamp it securelyin a vice. (2) Remove the sleeve from the bush using a suitable punch and hammer. (3) Remove the bushes, if necessarycut the busheswith a sharp knife or hacksawblade. (4) Clean the eyes of the panhard rod and lubricate the new bushes and the eyes with soapy water. (5) Pressthe new bushesinto the eyesby hand and then instal the sleeve. (6) Instal the Panhard rod to the vehicle.
189
BRAKES
SPECIFICATIONS Type front . Solid disc with single piston TyBe rear . caliper incorporating drum type handbrake Mechanical on rear wheels Handbrake . . Master cylinder bore diameter: ...23.81 mm Standardbrakes . . 25.4 mm Heavy duty brakes Front disc: Diameter (nominal) ....270.8-271 mm Standardbrakes . . 288.8-289 mm Heavy duty brakes Thickness(minimum). ....21.0 mm Runout limit . . 0.10 mm Front caliper bore diameter 54.0 mm Rear disc: Diameter (nominal) . . 278.8 - 279 mm Thickness(minimum). 9.5 mm Runout limit . . 0.13 mm 160 mm Handbrakediameter. . Handbrakemaximum out of square. . . 0.05 mm Handbrake maximum out of round . . . 0.08 mm Rear caliper bore diameter 38 mm TORQUE WRENCH SETTINGS Front caliper to steering knuckle bolts Rear caliper to brake support plate bolts. Guide pin self locking bolt . Master cylinder end plug 1. 90 Nm * 50 deg . . 70 Nm . . . . 34 Nm NOTE: To check this condition, raise the vehicle and support it an chassisstands. Spin the wheels one at a time to checkfor binding. If the wheelsare not binding, have an assistant apply the brakes and qelease them. Check if the brakes releaseimmediately. A clogged master cylinder Bort will causebinding on the two wheels fed bv that particular circuit from the master cylinder. Open the bleeder valve on one of the otfftnding wheelsto check if pressurebuild up is the cause of the blinding. A frozen handbrake cable will usually cause binding on a rear wheel. To check this condition disconnect the handbrake cableat the supportplate and check if the wheel will then turn freely. (4) Frozen caliper pistons: Check and overhaul the calipers. (5) Vacuum servo system inoperative: Check the servo systemand rectify. NOTE: The vacuum servo system can be checked as follows: With the engine switched off, pump the brake pedal s,everal times to deplete any vacuum in the sltstem. With the engine still switched ofr press downfirmly on the brake pedal and hold it rethere, noting the position and presst4re quired. Holding down on the Qrakepedal, start the engine.Ifthe servounit is apd,rating correctly, the brake pedal will sink slightly and the pressure required to hold it may even reduce. If the pedal does not sink slightly when the engine is started, the,brake servo unit can be consideredinoperalive. BRAKE DRAG (l) Clogged master cylinder ports: Check and clean the master cylinder and the fluid reservoir. (2) Frozen caliper pistons: Check and overhaul the calipers. (3) Frozen handbrake linkage: Free up or renew the linkage. (4) Frozen handbrake cables:Renew the cables.
BRAKES TROUBLE SHOOTING
BRAKE PEDAL HARD (1) Incorrect brake pads installed: Check and replacewith the recommendedtype. (2, Frozen pedal pivot: Rectify or renew the pivot pin and bushes. (3) Restricted brake line from the master cylinder: Check the brake lines and remove the restriction, or renew the line.
190
Brakes
brake specialist who will also be ahle to determineif a new disc needsto be installed. BRAKE FADE (1) Brake pads saturated with hydraulic fluid: Renew, as a complete set, all the brake pads and rectify the leak. (2) Incorrect pads installed: Check and instal pads in sets. new recommended
LOW SPONGYBRAKE PEDAL (l) Lack of sufficient Check fluid in the system:
for leaks, replenish the fluid and bleed the system. (2) Air in the brake hydraulic system:Bleed the hydraulic system. NOTE: A spongy brake pedal in most cases is causedby air in the hydraulic system.For air to enter the system one or more of the sealing rubbers or pipes must be sucking in air. Always recttfu the cause of the trouble before bleeding the brake system. Faulty components usually show up as fluid leakage.
Check the brake pads for serviceabilitythrough the inspectionhole in the caliper. NOTE: In most ca,ses brake fade is caused by overuseof the footbrake, which in turn causes a build up of heat at the friction material and discs.Oncethis excessive build up of heat is allowed to dissipate the brakes should again function normally. BRAKES OVERHEATING (l) Faulty handbrake cables or adjustment: Check the cables,renew or adjust. (2) Frozen caliper pistons: Check and overhaul the calipers. (3) Obstructed or damaged hydraulic hose or line: Remove the obstruction or renew the hydraulic hoseor line. (4) Obstructed master cylinder compensating port: Clear the compensatingport. (5) Blocked vent in the mastercylinder reservoir cap: Check and remove the obstruction in the vent. (6) Broken rear suspension arm: Check and renew faulty components. (7) Overuseof footbrake: Revisedriving habits. NOTE: To checkfor brake binding, raise the vehicleand spin each wheel in turn by hand. If it is found that one caliper piston l's sticking then it is advisable to overhaul all the calipers and the master cylinder.
Check the disc for scoring and wear.
BRAKES LOCK ON APPLICATION ( I ) Gummy brake pads due to oil or fluid contamination: Renew the brake pads. (2) Distorted brake disc: Check and renew any faulty disc. (3) Incorrect brake pads installed: Check and renew the pads as a set, with the recommendedtype. NOTE: If this condition arises,first remove all the wheelsand check the condition of the friction materialfor both oil contamination and excessivewear. A distorted brake disc will be indicated by pulsating on the brake pedal when the brakes are lightly applied. BRAKE PEDAL PULSATES (1) Distorted brake disc: Check and renew the brake disc as required. (2) Looseor worn hub bearings:Adjust or renew the bearings. NOTE: Adjust or renew the hub bearingsas outlined in the relevant suspensionsection. Brake discsthat prove to bb distorted must be machined. This job is best entrusted to a
Bra,kes
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Faulty master cylinder: Remove and overLoss of brakc fluid due to a leaking caliper:
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Overhaul or renew the caliper assemblyand bleed the hydraulic system.
BRAKE NOISE (1) Brakes squeal on application: Glazed friction material. Remove and inspect the brake pads and deglazethe friction material with emery paBgr. (2) Grinding noise on application: Friction material worn away. Inspect the friction material on the brake pads and renew the brake pads as necessary. Machine or renew the brake disc if it is scored. NOTE: Brake squealin most casesis caused by the friction material on the brake pads becomingglazed. Unsuitablefriction material or the omissionof anti-rattle springsmay also causebrake noise. If the brake pads are worn, always renew the pads as a complete set. 2. DESCRIPTION
Check the brake system for leaks. (3) Loss of brake fluid due to a fractured hose, pipe or faulty union: Renew the faulty componentsas necessary and bleed the hydraulic system. (4) Air in the hydraulic system:Locatethe source of 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 sourceof a brakefluid leak, refill the master cylinder and reservoir pump with brakefluid and havean assistant the brake pedal. Checkfor obvious signs of external leakage,prior to dismantling and overhauling the braking system.
The front and rear disc brakes are applied by independent circuits, by means of the dual circuit master cylinder. The two front outlets are connected to the left and right hand front calipers. The rear outlet is connectedto the rear brakes. Should a malfunction occur in one circuit, the remaining circuit is capable of stopping the vehicle safely. The disc calipers are of the floating type and are self adjusting. The single piston hydraulic brake for brake pad wear caliper automatically compensates by the sliding caliper feature. The caliper slides on guide pin sleeveslocated on the anchor plate. When the brakesare in the offposition, a constantclearance is maintained betweenthe pads on the disc. Elastic deformation of the piston seal on the piston takes place when the brakes are applied and returns the piston to its normal off position when the brakesare released. Some models are equipped with heavy duty brakeswhich are identified by cooling fins on the front brake caliper body. Should the master cylinder be renewed,the new cylinder must have the same proportioning valve number stamped on the front of the cylinder. The handbrake is operated by a lever located in the centre console which is connected to the rear handbrake drums via flexible cables.The small diameter drums are incorporated within the rear disc assembly. 3. MASTER CYLINDER
TO REMOVE AND INSTAL (1) Working in the engine compartment, instal covers to the mudguards to prevent damage to the vehicle paintwork. (2) Disconnect the wiring from the pressure differential switch.
Check the brake hoses for deterioration.
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Brakes
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(3) Disconnect the brake fluid pipes from the outlet ports on the master cylinder. Plug the pipes to prevent the entry of dirt. (4) Remove the support bracket to master cylinder retaining bolt. (5) Removethe retaining nuts holding the master cylinder support bracket to the body side member and remove the bracket. (6) Remove the nuts and lock washerssecuring the master cylinder to the brake servo unit and withdraw the master cylinder. NOTE: Care should be exercised when removing or installing the master cylinder assemblyto ensure that brake fluid is not permitted to drop onto the surrounding paintwork of the vehicle. Do not apply the brake pedal when the master cylinder is removedor the servo unit may be damaged. Installation is a reversalof the removal procedure with attention to the following points: (l) If the master cylinder has been renewed ensure that it has the same proportioning valve number stamped on the end of the cylinder as the cylinder removed.
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Dismantledview of the brake master cylinder.pn some modelsthe washer markedwith an asteriskis]replaced by an O ring. ] (3) Remove the reservoir retaining nut and washer. (4) Separate the reservoir from the rcylinder body and remove the two reservoir sealinggfommets from the cylinder body. (5) Remove the snap ring from the rear of the cylinder bore. (6) Withdraw the primary piston together with the return spring from the cylinder bore. l (7) Using a suitableblunt rod, pressthe secondary piston into the cylinder bore and at the same time remove the retaining stud and coppe{ washer from the cylinder body. (8) Tap the cylinder gently on a block of wood and allow the secondarypiston and return spring to be dislodged from the cylinder bore. (9) Remove the pressuredifferential sqitch and contact spring from the cylinder body. l ( l0) Carefully remove the end plug froml the rear of the cylinder body. NOTE: When the end plug has been |oosenedunscrewby hand to prevent the iniernal componentsfrom springing out. l ( I I ) Withdraw the bore plug and the aluminium sealblock. If the assemblycannot be readily removed by hand, lightly tap the cylinder body on a block of wood. (12) Withdraw the large spring and thel pressed steelpoppet valve retainer. ( I 3) Withdraw the plastic poppet valve and spool assembly using long nose pliers, gripping tde outer edge of the poppet valve. Should the valve lseparate from the spool, remove the spool by gripping the poppet valve retaining extension on the end of the spool using long nose pliers. (14) Removethe return springsfrom thetprimary the rubber O ring . and secondarypiston assemblies, from the bore plug and the sealfrom the reser{'oircap.
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Installed view of the master cylinder showing the location of the proportioningvalve number. (2) Pour a small amount of new brake fluid into the reservoirsand pump the piston assemblies with a suitable blunt rod until fluid begins to emerge from the outlets. (3) Loosely instal the master cylinder to the brake servo unit. (4) Loosely instal the brake fluid pipes and tighten the master cylinder retaining nuts. (5) Instal and tighten the support bracket. (6) Tighten the brake pipe union nuts and connect the wires to the pressuredifferential switch. (7) Bleed the brakes as described under the headingHydraulic System. TO DISMANTLE (l) Remove the master cylinder as previously described. (2) Remove the reservoir cap and sealand drain the fluid from the reservoir.
Brakes
(l 5) If the pistons are to be reused,cut the plastic cup retainerswith a sharpknife and remove the piston crrpsusing a blunt instrument. Ensure that the pistons are not damaged during this operation. TO CLEAN AND INSPECT ( I ) Wash all componentsthoroughly in methylated spirits. Do not use petrol, kerosene or other cleaning solvents. (2) Check the master cylinder bores for wear, corrosion or pitting. NOTE: Do not hone the master cylinder bore. If the bore is pitted or worn renew the master cylinder as an assembly. (3) Ensurethat all inlet and compensatingports between the reservoirs and the cylinder bore are free of any obstruction. (4) Discard all rubber parts. TO ASSEMBLE NOTE: Always use a genuine major repair kit which contains preassembled rubber sealsand pistons. The useof a major kit will ensurea thorough overhaul and long service from the unit. Assembly is a reversal of the dismantling procedure with attention to the following points: (l) Liberally lubricate the cylinder bores and all internal parts with clean brake fluid. NOTE: Instal all the parts supplied with the repair kit. The aluminium seal block and bore plug supplied in the sealed plastic bag must not be washed.They are prelubricated and no further lubrication on assembly is necessary. (2) Hold the cylinder body vertical with the open end to the top and carefully instal the plastic poppet valve and spool assembly with the poppet valve uppermost into the cylinder bore. (3) Lower the pressed steelpoppet valve retainer open end first into the cylinder bore. Ensure that the valve retainer is positioned correctly over the poppet valve. (4) Pushdown on the poppet valve retaineruntil the spool is correctly positioned in the bore. The measurement, from the top of the bore to the top of the small end of the poppet valve retainer, should be 44.5 mm when positioned correctly. (5) Instal the large spring over the poppet valve retainer. (6) Carefully instal the seal block, washersend first, into the bore and onto the large spring. (7) Instal a new O ring onto the bore plug and position the bore plug ensuring the slotted end abuts the sealblock. .{
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193
(8) With the end plug installed onto a thin the bore plug carefullydepress Phillips screwdriver, into the cylinderbore.
(9) Using finger tension only, instal the end plug and tighten until the head of the plug is below the cylinder mounting flange. Using the correct size spannertighten the end plug to the specifiedtorque. (10) Place the switch contact spring onto the pressure differential switch plunger, small end first. Ensurethat the spring stayson the plunger by inverting the switch, if not close the small end. (11) Instal the pressuredifferential switch to the side of the cylinder body. (12) Instal the new O ring seal onto the middle groove of the secondarypiston. (13) Instal one of the three identical cup seals onto the groove adjacent to the O ring seal ensuring that the lip of the cup seal facesaway from the O ring seal. (14) Instal the second of the three identical cup sealsonto the groove at the return spring side of the secondary piston, ensuring that the seal lip facesaway from the O ring seal installed previously. (15) Instal the last of the three identical cup seals onto the groove at the return spring side of the primary piston. Ensure that the lip of the seal faces away frorn the piston pushrod end. (16) Instal the secondaryseal into the groove at the pushrod end of the primary piston. Ensurethat the lip of the sealfacesaway from the piston pushrod end. (17) Instal a plastic cup retainer to the front end of the primary and the secondarypistons. Engagethe retainer to the retainer groove and using a small blunt instrument, push the retainer completely into the groove. Take care not to damagethe cup sealson the piston. (18) Slide the secondary return spring into the end of the secondarypiston and carefully instal the piston assembly,spring first, into the master cylinder bore. (19) Using a suitable blunt rod, push the secondary piston down to its full travel and instal the secondarypiston stud with a new copper washeror O ring. Screwthe piston stop down by hand and tighten the piston stop securely.Instal a new O ring to the stud. (20) Instal the primary piston return spring to the front end of the primary piston and carefully instal the piston assembly,spring first into the master cylinder bore. (21) Push the piston assemblies into the cylinder bore and instal the snapring into the groovein the end of the cylinder bore. (22) Placethe reservoir sealinggrommets into the recess on top of the master cylinder body. (23) Place the reservoir into the sealing grommets. Instal the reservoir retaining nut and washer. (24) Instal a new seal assemblyto the reservoir cap.
194
Brakes
(25) Instal the mastercylinderto the vehicleas previously described.

4. FRONT DISC BRAKES
TO RENEW BRAKE PADS Brake pads should be examined regularly and worn. renewedif the pad linings are excessively (1) Raise the front of the vehicle, support it on chassisstandsand remove the front wheels.
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Dismantledview of the front brake caliper. (6) Ensurethat the guide pins move freely in the anchor plate and that the dust covers are in good condition. NOTE: Never lubricate the guide pins wiith mineral oil or grease. Use only a silicqne type grease. (7) Clean any dirt from the piston face contact area and the caliper to pad contact area. (8) Push the piston squarely by hand ,into the caliper bore and check for fluid leaks. Installedview of the front brake caliper. (2) Drain approximately two thirds of the brake fluid from the master cylinder reservoir. This can be doneby looseningthe brake line at the mastercylinder and draining the fluid into a container. Do not reuse this fluid. NOTE: Do not completely remove the brake line or drain off all the fluid from the reservoir otherwise it will be necessaryto bleed the hydraulic system. The fluid is drained from the reservoir to prevent overflow when the caliper piston is pushed back into its bore to facilitate pad renewal. Complete work on one caliper at a time and replace brake pads as sets of four. (3) While holding the guide pin hexagonwith a suitable spanner,remove the self locking bolts retaining the caliper housing to the guide pins. NOTE: Renew the self locking bolts retaining the caliper housing to the anchor plate gaide pins. They must be renewed as they are designedto be used once only. (4) Remove the caliper housing and suspendor support the caliper housing in such a manner that the caliper weight is not taken on the brake hose. (5) Note the position of the brake pads and the anti-rattle springs. Lift the pads from the anchor plate. NOTE: Overhaul the caliper if lealcs qre evident or the dust seals are deteriorated (9) On models without heavy duty brakes, apply brake pad adhesiveto the back of the brake pads and the corresponding caliper and piston contact surfaces. (10) Place the new brake pads onto the anchor plate, with the anti-rattle springs parallel with the pads and their open ends facing outwards. If the brake pads are marked Inner, Outer or Piston Side, ensure installation to the correct side of the anchor plate. (11) Instal the caliper housing to the anchor plate and instal and tighten the new retaining bolts. (12) Top up the brake master cylinder reservoir with the recommended brake fluid and pump the brake pedal to bring the pads to their normal position alongsidethe disc. (13) Instal the front wheels. TO OVERHAUL CALIPER (1) Raise the front of the vehicle, support it on chassisstandsand remove the front wheels. (2) Disconnect the brake hose from the brake caliper by removing the banjo bolt holding the hoseto the caliper. Plug the brake hoseto prevent the loss of fluid and entry of dirt. (3) Remove the bolts retaining the caliper housing to the anchor plate guide pins and withdraw the caliper. Discard the retaining bolts.
(4) Placea pieceof soft clothin front of the
Brakes
piston and using a low air pressure applied to the hydraulic brake hose aperture, gently force the piston from the caliper bore. NOTE: If dfficulty is experiencedin removing the caliper piston, remove the brake hose,instal it to the caliper and apply the air through the brake hose. (5) Disengagethe dust seal from the locating groove in the end of the caliper bore and remove it from the caliper. (6) Using a thin blunt probe, perferably made from wood or plastic, lift and remove the piston seal from its groove in the caliper bore. (7) Pull the guide pins and their dust covers from the anchor plate. (8) Clean all parts except the brake pads in methylated spirits and examine carefully for wear and corrosion. Renew any corroded, worn or doubtful parts. Discard the piston seal and the dust seal. Assembly and installation is a reversal of the dismantling and removal procedurewith attention to the following points: (l) Check the brake pads on the anchor plate for wear and renew where necessary. (2) Instal the dust covers to the guide pins ensuringthat they are correctly seatedin the guide pin groove. (3) Lubricate the guide pins with a silicone type greaseand push the guide pins into the anchor plate. Seat the dust covers in the grooves on the anchor plate. NOTE: Do not use mineral oil or greaseto lubricate the gaide pins. (4) Dip the new piston seal in clean brake fluid and instal the sealinto the groove in the caliper bore. Ensure that the seal is not twisted and is correctly seatedin the groove. (5) Smearthe caliper bore with cleanbrake fluid and instal the new dust seal to the outer groove of the bore. Ensure that the dust seal is squarely and firmly seatedin its groove. (6) Smear the outside of the piston with clean brake fluid. Guide the lip of the dust seal over the piston and push the piston into the bore. Push the piston by hand completely into the bore and instal the outer lip of the dust seal squarely into the piston groove. (7) Instal the caliper over the brake pads and disc and instal and tighten the new retaining bolts. (8) Instal new copper washersto the brake hose banjo bolt and securethe brake hose to the caliper. (9) Bleedthe hydraulic systemas outlined under the heading Hydraulic System. (10) Start the engine to activate the brake servo unit and press the brake pedal hard. Check for fluid leaks. TO REMOVE AND INSTAL BRAKE DISC
195
(1) Raise the front of the vehicle, support it on chassisstandsand remove the front wheel. (2) Remove the caliper anchor plate to stub axle flangeretaining bolts and lift the caliper assemblyoff the disc. (3) Place a spacerapproximately as thick as the brake disc between the brake pads and support or suspendthe caliper out of the way without stretching the brake hose. (4) Remove the grease cap from the hub and the split pin from the stub axle.
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Dismantled view of the front hub components. (5) LInscrewthe adjusting nut on the end of the stub axle, remove the thrust washer and the outer bearing cone and roller assembly. (6) Withdraw the hub and disc assernblyfrom the stub axle. (7) Clean the disc with solvent and examine for wear, damageor scoring. (8) If necessary the hub bearingsand sealcan be servicedas describedin the Front Suspension section. Installation is a reversalof the removal procedure with attention to the following points: (1) Adjust the front hub bearingsas describedin the Front Suspensionsection.
Checking the brake disc for runout using a dial gauge.
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(2) Instal the brake caliper and tighten the mounting bolts to Specifications. (3) Pump the brake pedal to relocate the brake pads after installation. TO CHECK BRAKE DISC (l) Raise the front of the vehicle, support it on chassisstandsand remove the front wheel. (2) Remove the greasecap from the front hub. Remove the split pin and tighten the front hub bearing nut until the front hub bearingsare preloaded. (3) Rotate the front hub and measurethe runout of the brake disc machined surface. (4) Machine or renew the brake disc if the runout exceedsSpecifications. 5. REAR DISC BRAKE ASSEMBLY
Brakes
NOTE: Renew the self locking bolts retaining the caliper housing to the anchor plate gaide pins. They must be renewed as they are designedto be used once only. (5) Remove the caliper housing and suspendor support the caliper housing in such a manner that the caliper weight is not taken on the brake hose. (6) Note the position of the brake pads and the anti-rattle springs.Lift the padsfrom the anchor plate. (7) Ensurethat the guide pins move freely in the anchor plate and that the dust covers and sealsare in good condition. NOTE: Never lubricate the gvide pins with mineral oil or grease. Use onllt a silicone type grease. (8) Push the piston squarely by hand into the caliper bore and check for fluid leaks. NOTE: Overhaul the caliper if fluid lealcs are evident or the dust seals are deteriorated. (9) Place the new brake pads onto the anchor plate. The anti-rattle springs should be parallel with the pads, their open ends facing outwards. (10) Instal the caliper housing to the anchor plate and instal and tighten the attaching bolts. (l l) Top up the brake master cylinder reservoir with the recommended brake fluid and pump the brake pedal to bring the pads to their normal position alongsidethe disc. ( l2) Instal the rear wheelsand lower the vehicle to the ground. TO OYERHAUL CALIPER (l) Raise the rear of the vehicle, support it on chassisstandsand remove the rear wheels. (2) Disconnect the brake hose from the brake caliper by removing the banjo bolt holding the hoseto the caliper. Plug the brake hoseto prevent the loss of fluid and entry of dirt. (3) Remove the bolts retaining the caliper to the anchor plate guide pins and withdraw the caliper. NOTE: Renew the self locking caliper retaining bolts. (4) Place a piece of soft cloth in front of the piston and using a low air pressure applied at the hydraulic brake hose aperture, gently force the piston from the caliper bore. (5) Disengage the dust seal from its locating groove in the end of the caliper bore and remove it from the caliper. (6) Using a thin blunt probe, perferably made from wood or plastic, lift and remove the piston seal from its groove in the caliper bore. (7) Pull the guide pins and their dust covers from the anchor plate.
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 on chassisstandsand remove the rear wheels. (2) Look through the square hole in the caliper housingand note the thicknessof the friction material remaining on the pad. (3) Drain approximately two thirds of the brake fluid from the master cylinder reservoir. This can be doneby looseningthebrake line at the mastercylinder and draining the fluid into a container. Do not reuse this fluid. NOTE: Do not completely remove the brake line or drain off all the fluid from the reservoir otherwise it will be necessaryto bleed the hydraulic system. The fluid is drained from the reservoir to prevent over-, flow when the caliper piston is pushed back into its bore to facilitate pad renewal. (4) Remove the bolts retaining the caliper housing to the anchor plate guide pins.
Installed view of the rear brake caliper.
Brakes
BLEEDERVALVE
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(10) Start the engine to activate the brake servo unit and press the brake pedal hard. Check for fluid leaks. TO REMOVE AND INSTAL BRAKE DISC (1) Raise the rear of the vehicle, support it on chassisstandsand remove the rear wheels. (2) Remove the caliper and anchor plate to brake support plate retaining bolts and tift the caliper off the disc. (3) Place a spacerapproximately as thick as the brake disc between the brake pads and support or suspendthe caliper out of the wiy without sfritching the brake hose. (4) Withdraw the disc assembly from the axle shaft. NOTE: If difficulty is experienced in removing the brake disc, ensure that the handbrake ,s in the released position and disconnect the handbrake cable from the handbrake relay rod. (5) Clean the disc with solvent and examine for wear, damageor scoring. Installation is a reversalof the removal procedure with attention to the following points: (l) Instal the brake caliper and tighten the mounting bolts to Specifications. (2) Pump the brake pedal to relocate the brake pads after installation. TO CHECK AND OVERHAUL HANDBRAKE ASSEMBLY (1) Raise the rear of the vehicle, support it on chassisstandsand remove the rear wheels. (2) Remove the brake caliper and disc assembly as describedunder To Remove and Instal Brake Disc. NOTE: Checkthe liningsfor excessive wear, oil saturation or gumminess and renew as pairs with the correspondinglining and shoe assembly on the other wheel. If the linings are to be renewedproceedwith thefollowing steps. (3) Disconnectthe lower return spring from both brake shoes. (4) Disconnect the upper return spring from both brake shoesand remove the brake adjuster. (5) Remove both brake shoeretaining springsby compressing the spring and rotating the pin 90'. Rotate the axle flange as required. (6) Remove the handbrake shoes from the vehicle. (7\ If necessary, remove the reaction plate and pin from the vehicle. (8) If necessary, disconnectthe return spring and handbrake cable and remove the actuating lever from the vehicle.
%
&M*ffi &
I I
Dismantledview of the rearcaliperand anchor plate. (8) Clean all parts except the brake pads in methylated spirits and examine carefully for wear and corrosion. Renew any corroded, worn or doubtful parts. Discard the piston seal and the dust seal. Assembly and installation is a reversal of the dismantling and removal procedurewith attention to the following points: (1) Check the brake pads on the anchor plate for wear and renew where necessary. (2) Lubricate the guide pins with a silicone type grease and push the dust coversinto the groovesin the guide pins. NOTE: Do not use mineral oil or greaseto lubricate the guide pins. (3) Push the guide pins into the anchor plate. Ensurethat the dust coversare seatedcorrectly in the grooveson the anchor plate. (4) Dip the new piston seal in clean brake fluid and instal the seal into the groove in the caliper bore. Ensure that the seal is not twisted and is correctly seatedin the groove. (5) Smearthe caliper bore with cleanbrake fluid and instal the new dust sealto the outer groove of the bore. Ensure that the dust seal is squarely and firmly seatedin its groove. (6) Smear the outside of the piston with clean brake fluid. Guide the lip of the dust seal over the piston and push the piston into the bore. Push the piston by hand completely into the bore and instal the outer lip of the dust seal squarely into the piston groove. (7) Instal the caliper over the brake pads and disc and instal and tighten the new retaining bolts. (8) Instal new copper washersto the brake hose banjo bolt and securethe brake hoseto the caliper. (9) Bleedthe hydraulic systemas outlined under the heading Hydraulic System.
198
Brakes
r
(9) Check the inside of the brake disc assembly for cracks,scoring or ovality and renew or regrind as necessary. (10) Ensure that there are no burrs on the brake support plate where the shoesslide. (11) Check the tension of the brake shoe return springsby comparison with new springsand renew as necessary. for wear. (12) Checkthe actuatinglever assembly (13) Check that the adjusterthread is not burred or damagedand turns freely by hand. (1a) Check the operationof the handbrakecabie. (15) Checkthe retainingspringsand pins for wear or damage. Installation is a reversalof the removal procedure with attention to the following points: (1) Install the brake shoeswith the longeststep betweenthe friction material and the end of the brake shoeat the bottom. (2) Lubricate all metal to metal contact surfaces with a light smear of zinc oxide grease. (3) Sparinglylubricate the adjusterassemblyand the reaction plate pin with Molybdenum disulphide glease.
ffiffi# 'm
/ \
ASSEMBLY ADJUSTER
@-",,1".-
z-
PaN
Dismantled view of the handbrake assembly
t'* &249t261t3,j,9
(8) Set the adjuster length to obtain minimum clearancebetween the brake shoesand the disc with no drag when the disc is rotated. (9) Install the caliper assemblyand tighten the anchor plate bolts to the specifiedtorque. Install the rear wheel. If applicable, connect the shock absorber lower mounting. (10) Check the handbrake operation and if necessary,adjust the handbrake cable as described under the Brake Adjustments heading. 6. HANDBRAKE LEVER AI{D CABLE
TO REMOVE AND INSTAL HANDBRAKE LEVER Installedview of the handbrakeassembly. (4) Position the brake shoeson the support plate and install the retaining springsand pins. Ensure that the pins are correctly locked. (5) Install the brake adjuster and the upper and lower return springs to the brake shoes. (6) Loosen the handbrake cable adjusting nuts until there is no tension in the handbrake cable and the actuating levers are fully retracted. (7) Extend the brake adjuster until the brake Ensurethat the disc slidesneatly over the brake shoes. brake shoes are centralised by firmly operating the handbrake severaltimes. (l) Raise the rear of the vehicle and support it on chassisstands. (2) Remove the handbrakecable adjusting nuts, cable and equaliserfrom the handbrake relay rod.
LEVER ASSY
+BOLT
Dismantled view of the handbrake lever and associated components.
Brakes
(3) Remove the retaining clip and the rubber boot assemblyfrom the handbrake relay rod. (4) Remove the centre console as described in the Body section. (5) Remove the handbrake lever securingbolts. To gain accessto the securingbolts lift and support the carpet so that it does not interfere with further operations. (6) Manoeuvre the lever assemblyup far enough to permit the removal of the handbrake warning lamp switch. (7) Remove the handbrake lever assemblyfrom the vehicle. Where necessary remove the damper and washer from the relay rod. Installation is a reversalof the removal procedure with attention to the following points: (l) Lubricate all working points of the handbrake mechanismwhen assembling. (2) Ensurethat the rubber boot sealingthe relay rod is correctly installed. (3) Adjust the handbrake as described under Brake Adjustments. TO REMOVE AND INSTAL HANDBRAKE CABLE (l) Raise the rear of the vehicle and support it on chassisstands. (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 vehicle and disconnectit from the retaining clips on the body floor. (4) Remove each handbrake cable return spring from its actuating lever and disconnectthe hand6rake cable from the levers. (5) Pull the cabletoward the front of the vehicle and slide out of the retainers. Installation is a reversalof the removal procedure with attention to the following points: (1) Lubricate all working points of the handbrake mechanism when assembling. (2) Adjust the handbrake as outlined under the appropriate heading. 7. BRAKE ADJUSTMENTS
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View showing the handbrakecable adjustingpoint. NOTE: If a pair of calipers is not available adjust the brake shoes until the disc is a neat, slidingfit on the brake shoesand turns with no drag. (6) Instal the disc, rear brake caliper and rear wheel as previously described. (7) Operatethe handbrakelever severaltimes to set the brake shoes. (8) From the fully released position pull the handbrakelever up six notches. (9) Check that there is a moderate drag at the rear wheels,approximately 20 - 40 Nm. (10) Releasethe handbrake and check that the rear wheelsrotate freely. (11) If necessary, repeat steps (5) to (10) and lower the vehicle to the ground. 8. TO BLEED Bleeding the hydraulic system is necessary when some portion of the systemhas been disconnectedor air has been allowed to enter the svstem. The brake fluid in the hydraulic systemshould be changed at regular intervals, refer to the Lubrication and Maintenancesection.The procedurefor changing the brake fluid and bleeding the hydraulic system are similar with attention to the notes in the text. There are four points in the systemwhere bleeder valves are installed; one on each brake caliper. (l) Fill the fluid reservoir on the mastercylinder with clean hydraulic brake fluid and maintain at least half full throughout the entire bleeding operation. (2) Attach a rubber bleeder tube to the left rear bleedervalve and immerse the other end of the tube in a small amount of brake fluid contained in a clean glassjar. HYDRAULIC SYSTEM
TO ADJUST HANDBRAKE (1) Raise the rear of the vehicle and support it on chassisstands. (2) Remove any slack from the handbrakecable by adjusting the relay rod nuts. (3) Mark the positions of the rear wheels in relation to the rear hubs and remove the rear wheels. (4) Remove the rear brake disc as previously described. (5) Adjust the handbrake shoes to 159.5 mm outside diameter using the adjuster and measuring with a pair of calipers.
200
Brakes
of a vacuum failure act as a single pushrod without assistance. The servo unit is connectedby a hoseto the inlet manifold. On models with heavy duty brakes, a tandem brake servo unit is installed. TO CHECK OPERATION ( I ) With the engine switched off, apply the footbrake several times to exhaust all vacuum from the system. (2) Again apply the footbrake, but this time hold the brake pedal fully depressed. (3) Start the engine.If the servo unit is functioning satisfactorily a distinct downward movement of the brake pedal should be noticed. Should the pedal fail to fall away when the engine has been started, the vacuum system can be considered inoperative.
Method of bleeding air from the brake hydraulic system. (3) Pump the brake pedal severaltimes and with the brake pedal depressed,open the bleeder valve. Closethe bleedervalve whilst air, or fluid and air is escaping from the bleeder valve. Allow the brake pedal to return slowly and repeat this step until air bubbles cease to flow from the bleeder tube. NOTE: If changingthe brakefluid, continue bleeding the system until clean new fluid flows from the bleeder tube. (4) Carry out the bleeding operations, in the samemanner, on the remaining bleeder valves in the system. Always work from the longest line in the systemdown to the shortest. NOTE: Do not allow the fluid in the reservoir to fall below the haA full level at any time during the bleeding operation or air may enter the system and a fresh start will haveto be made.Always usenewfluid when topping up the reservoir. (5) After bleeding the system the brake pedal should be firm when depressedwith no evidence of Ensurethat all the bleedervalvesare tight. sponginess. NOTE: If sponginessis evident in the brake pedal after the bleeding operationsare completed it may be necessary to pressurebleed the system to expel all tracesof air from the lines. This is bestleft to an authorised dealer or brake specialist. (6) Top up the master cylinder reservoir with clean brake fluid. 9. DESCRIPTION The brake servo unit is installed between the brake pedal and the brake master cylinder. The valve and rod assemblyof the servo unit and the pedal pushrod are on the sameaxis and in the case BRAKE SERVO UNIT
Checking for vacuum at the servo unit vacuum hose connection. NOTE: If the pedal continues to fall away there is a fault in the hydraulic system. (4) Ensure that the brake pedal is fully off, start the engine and run it at medium speed. Stop the engine. Let the vehicle stand for 1-2 minutes, then press the brake pedal two or three times and check its operation. If there is no vacuum assistance,the vacuum system has developed a leak or the one way check valve is defective. NOTE: Before removing the servounitfrom the vehicle for inspection, disconnect the vacuum supply hose at the unit, start the engine and check that manifold vacuum is in fact reaching the servo unit. Also check the one way check valve as describedbelow. TO TEST ONE WAY CHECK VALYE (1) Release the hoseclip and disconnectthe hose from the check valve. Carefully lever the check valve from the servo unit.
Brakes
(2) Check the valve for sticking- Suction-on the manif'otd side should allow air to flow freely. Air blown into the valve from the manifold side should not be able to flow through the valve. (3) Check the rubber seal for deterioration and renew if necessary. (4) Instal the valve and check the operation of the servo unit as previously described. NOTE: Check that there are no air lealcsat and that the hoseclips the hoseconnections are tight. Also check that the hose is nol bulged or collapseddue to deterioration. TO REMOVE AND INSTAL SERVO UNIT (l) Remove the brake master cylinder as previously described (2) Disconnect the vacuum hosefrom the check valve. (3) Working inside the vehicle, remove the retaining clip and washer from the brake pedal clevis pin and slide the pushrod from the clevis pin. (4) Remove the nuts securingthe servo unit to the bulkhead and manoeuvre the servo unit with the bracket from the engine compartment. Installation is a reversal of the removal procedure to bleed the hydraulic system. it but will be necessary
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 prise out the left hand side hinge pin and 90 degrees, withdraw the fuse cover from the vehicle. (3) Remove the nuts retaining the throttle pedal assemblyto the bulkhead and place the assemblyto one side. (4) Remove the retaining clip and washer from the brake pushrod clevis Pin. (5) Slide the pushrod from the clevis pin and collect the remaining washers. (6) Remove the nut securing the brake pedal shaft to the pedal support.
Installedview of the brake Pedal. (7) Tap the shaft through the brake and'if applicable, the clutch pedal components noting the location of all springs,washersand spacers. (8) Manoeuvre the throttle pedal assemblyclear to allow the pedal shaft to be withdrawn sufficiently to allow pedal removal. (9) Withdraw the pedal and return spring assemblv. (10) Inspect the componentsfor wear, bending or cracks.Check the tension of the return spring. Installation is a reversalof the removal procedure with attention to the following points: (l) Apply a coating of multi-purpose greaseto the outer facesof the pedal shaft. (2) Manoeuvre the pedal and spring into position and instal the pedal shaft. (3) Instal the nut and washer to the pedal shaft and tighten securely.If the shaft turns it can be held using a suitable spanneron the flats provided. (4) If necessary adjust the brake pedal switch or switchesas describedin the Electrical Systemsection.
Brake seruo unit removed from the vehicle.
10. BRAKE PEDAL TO REMOVE AND INSTAL (l) Working inside the vehicle, remove the
202
for norc intomation,
Refer to supplement
ELECTRICAL SYSTEM
SPECIFICATIONS BATTERY Type Polaritv gravity: Specific ^ Fu[f charged Fullydischarged... ALTERNATOR Make Maximum output Voltage Brush length: Standard Minimum STARTER MOTOR Manual Transmission Make Delco Remy Type Four pole, four brush solenoid operated pinion with reduction gear and overrunning clutch Commutator: Maximum out of round 0.05 mm Minimum diameter 27.0 mm Minimum depth of undercut 0.2 mm Brushes: Minimum length 9 mm Springtension 15-17 N Automatic Transmission Make Bosch Type Four pole, four brush solenoid operatedpinion with overrunning clutch Commutator: Maximum out of round 0.05 mm Minimum diameter 33.5 mm M i n i m u m d e p t ho f u n d e r c u t . : . . . . . . 0 . 7m m IGNITION SYSTEM .The ignition system is an integral part of the engrnemanagementsystem. The specifications,testing and overhaul proceduresare fully covered in the Fuel and Engine Management section. 85 amps 14.25- 14.55volts 9.3 mm 4.0 mm 12 volt lead acid Negative earth Above 1.250- 1.270 Belowl.l30
TORQUE WRENCH SETTINGS Startermotor retaining bolts Startermotor bracebolt. Alternator pulley retaining nut . Alternator mounting bolts Wiperpivotbolts
. . . . 50 Nm . . 35 Nm . 68 Nm . 34 Nm ....2Nm
1. BATTERY AND CHARGING SYSTEM TROUBLE SHOOTING BATTERY UNDERCHARGED (l) Loose or slipping engine drive belt: Renew the engine drive belt and check the adjuster. (2) Faulty alternator voltage regulator: Renew the regulator. (3) Faulty battery: Instal a new battery of the recommendedtype and capacity. (4) Faulty alternator: Overhaul or renew the alternator. (5) Fault in the charging circuit wiring: Check and repair or renew the wiring harness.
Examine the drive belt for cracks or deterioration where the drive belt is positioned around the water pump pulley.
Electrical S,tstem NOTE: Checkt;hestate of charge(specrfic gravity)of thebatteryasdescribed underthe Battery headingin this section.If the batcheck the possible tery rs undercharged, causes in the ordergiven. BATTERY OVERCHARGED (l) Faulty alternatorvoltageregulator:Renew
the regulator. (2) Faulty battery: Renew the battery. (3) Faulty alternator: Overhaul or renew the alternator. (4) Faulty charging circuit wiring or connections: Check and renew or repair any faulty components. NOTE: An overchargedbattery is indicated by continual lossof water through boiling. This l's usually accompanied by discolouration of the electrolyte. CHARGE INDICATOR LAMP REMAINS ON (l) Broken engine drive belt: Renew the engine drive belt. (2) Faulty regulator: Check and renew the regulator. (3) Faulty alternator: Check and overhaul the alternator. (4\ B* lead from alternator broken: Repair or renew the B* lead. (5) S lead from alternator broken: Repair or renew the S lead. (6) Short to earth in the lamp circuit: Check and repair the circuit. (7) Battery overcharged:Refer to the previous heading. CHARGE INDICATOR LAMP DOES NOT OPERATE ( I ) Charge indicator lamp bulb blown: Check and 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 rectify the open circuit. (4) Open circuit in the rotor windings: Check and 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 the bearings. (3) Loose alternator pulley: Tighten the pulley retaining nut. (4) Faulty alternator: Overhaul or renew the alternator.
203
Spin the alternator pulley by hand to check the bearings for roughness.
NOTE: To check if the noise is in the alternator or drive belt, remove the drive belt. If the noise is gone when the engine is runfor a short time, checkthe serviceability of the belt and alternator components. 2. BATTERY AND STARTING SYSTEM TROUBLE SHOOTING
STARTER LACKS POWER TO CRANK ENGINE (l) Battery undercharged: Check the charging systemand rectify as necessary. (2) Battery will not hold charge: Check and renew the battery. (3) Battery terminals loose or corroded: Clean and tighten the terminals. (4) Faulty starter motor: Check and overhaul the starter motor. (5) Faulty starter or dirty solenoid switch or contacts:Check and renew the solenoid as necessarv.
Remove all din and corrosion from the battery terminals.
204
Electrical System
NOTE: Check the state of charge of the battery and check all terminals for cleanliness and security. If necessary, test and overhaul the starter motor as described in this section. STARTER WILL NOT ATTEMPT TO CRANK ENGINE (l) Open circuit in the starting system: Check for dirty or loose terminals, dirty commutator, faulty solenoid or faulty switch. (2) Discharged battery: Check for a fault or a short circuit in the system. (3) Battery fully charged but will not crank engine: Check for a locked drive and ring gear, internal starter fault or a seizedengine. (4) Automatic neutral safety switch faulty: Check the switch and renew if necessary. (5) Faulty starter or dirty solenoid switch or contacts:Check and renew the solenoid as necessary. NOTE: Turn the engine over by hand to ensure that the starter drive is not locked with the flywheel ring gear and that the engine is not seized.Ensure that the ignition is switched Off before turning the engine. 3. LIGHTING SYSTEM TROUBLE SHOOTING
Usinga test lamp to check for power at the headlamp wiring connector. (4) Fuse or fusible link blown: Rectify the fault and renew as necessary. (5) Headlamp relay or relay fuse faulty: Check and renew as necessary. (6) Tail lamp fuse blown: Renew the fuse. NOTE: Switch on the headlamps and using a test lamp, check that the lamp circuits are operating. This is best done by starting at the lamp wiring connector and working back to the power source. LAMP OR LAMPS INCORRECTLY ILTUMINATED (1) Lamp or lamps incorrectly earthed: Check the lamp earth for looseness or poor contact, either at the lamp body or the wire and repair as necessary. (2) Incorrect bulbs installed: Check the bulb wattageand voltage and renew with the correct type if necessary. (3) Dirty or damaged lamp reflector: Clean or renew the lamp reflector. (4) Faulty bulbs: Check with a known serviceable unit and renew if necessary. (5) Dirty lamp lens: Clean or renew the lamp lens. NOTE: The most common causefor this condition is incorrect lamp earthing. Check the lamps at their earthing points. LAMPS FLARE WITH ENGINE SPEED INCREASE ( 1) Faulty battery: Check and renew the battery. (2) Battery in a low stateof charge:Recharge the battery and check the charging system. (3) High resistance or faulty connections between the battery and the alternator: Checkthe circuit and rectify the condition. (4) Poor earth connection between the battery
LAMP OR LAMPS FAIL TO LIGHT (l) Faulty bulb: Check and renew the faulty bulb. (2) Open circuit in the wiring or connections: Check and rectify the fault. (3) Faulty lamp switch: Check and renew the switch.
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 - revised to 3O amp, 4 : low beam headlamp relay fuse - 15 amp, 5 : High beam headlamp relay fuse - 25 amp.
Electrical System
and the engine: Check the battery earth lead and the earth between the engine and the body. (5) Faulty alternator voltage regulator: Renew the regulator. (6) Alternator faulty: Check and repair or renew as necessary. NOTE: The most common causefor this condition is dirty terminals on the earth leads. Checkall earth leadsat their earthing points. 4. TURN SIGNAL LAMP TROUBLE SHOOTING
205
(2) Front or rear bulb blown on the turn side: Check and renew the bulb. NOTE: If the flasher unit is to be renewed always try to obtain a genuine replacement part. HAZARD WARNING LAMPS DO NOT OPERATE (1) Fuse blown: Rectify the fault and renew as necessary. (2) Flasher unit faulty: Renew the flasherunit. (3) }{azard warning switch faulty: Renew the switch. (4) Fault in the wiring circuit: Check and repair the fault. 5. TEST EQUIPMENT AND SOME APPLICATIONS Soldering
TURN SIGNAL LAMP DOES NOT LIGHT AND NO AUDIBLE NOISE FROM FLASHER UNIT (1) Fuse blown: Rectify the fault and renew the fuse. (2) Flasher unit faulty: Renew the flasherunit. (3) Turn signal switch faulty: Renew the switch. (4) Fault in the wiring circuit: Check and repair the fault. TURN SIGNAL WARNING LAMP DOES NOT FLASH BUT AUDIBLE CLICKING FROM FLASHER UNIT ( I ) Warning lamp bulb blown: Check and renew the bulb.
Special Equipment Required: To Make Test Lamp or Jumper Lead iron
When working on the electrical system, a test lamp and jumper leads can be very useful to check circuits. TO MAKE A JUMPER LEAD The minimum materials required to make a jumper lead are one length of 4 mm wire and two small alligator clips. (l) Bare both ends of a suitable length of 4 millimetre wire. (2) Connect a small alligator clip to each end of the wire. Solder and tape the connections. (3) Test the jumper lead for continuity by removing one battery cable and connecting the lead betweenthe cable and the battery terminal. Turn the
Turn the retaining clips 9O degreesand open the fuse cover to gain accessto the flasher unit. (2) Fault in the warning lamp wiring: Check and repair the fault. NOTE: When renewing bulbs ensurethat a new bulb of the coruectwattage is used. TURN SIGNAL LAMPS FLASH WEAKLY AND AT GREATER THAN NORMAL SPEED (1) Faulty flasher unit: Check and renew the flasher unit.
Assembldd view of the various sized jumper leads.
206
Electrical System
(5) Mount the probe in the case.If using a pen case,push the probe through the lower end of the pen after removing the refill. (6) Push the lead attachedto the K lead of the LED through the hole made in the side of the caseand solderthe alligator clip to the lead. (7) Mount the LED to the case.If using a pen case,the LED may be mounted in the plug at the top of the pen after drilting the plug to acceptthe LED. (8) Suitably attach the probe to the caseusing adhesiveor tape. TO TEST SWITCHES (l) Disconnectthe wires from the switch. (2) Using a testlamp, test eachwire to locatethe power wire. It may be necessary to turn the ignition switch On as the switch may be wired throrfih the ignition circuit. (3) Disconnect the test lamp and connect a jumper lead between the power wire and the wire from the other side of the switch. If the circuit functions, the switch can be consi_ dered faulty and should be renewed. Refer to the headingSwitchesand Controls. TO TEST BULBS ( I ) Remove the bulb from the bulb holder. (2) Connect a jumper lead betweenthe positive terminal of a battery and the baseof the bulb. (3) Connect another jumper lead between the negativebattery terminal and the contact on the base of the bulb. The bulb should illuminate. If the bulb has two filaments, connect the jumper lead to the secondcontact on the baseof the bulb. The secondfilament should illuminate. If the bulb fails to light. It should be renewedwith a 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,reconnecithe corrr"cior and continue checking towards the motor or bulb end of the circuit. If power is not available, continue checking towards the battery or switch end of the circuit. 6. BATTERY
ignition key to On, the dashboard warning lamps shouldoperateindicatinga completed circuit through thejumper lead. (4) Removethejumper leadfrom the circuit and reconnectthe battery. NOTE: Make a few jumper leads of various lengths using dffirent sizes and types of alligator and battery clips. TO MAKE A TEST LAMP Due to the extensive useof electroniccomponents in the electricalsystem,an LED (light emitting diode) test lamp is recommended. A simple LED test lamp can be made from a suitablelength of 3 mm wire, an alligator clip, an LED, a t/qwafi 560 ohm resistor,a suitablecasesuch as an old ball point pen caseand a lengthof rod or wire sharpened to form a probe. ( I ) Solderthe length of wire to the K (cathode) lead of the LED, The K lead is the shorterof the two leadsand is adjacentto the flat on the LED. (2) Solderthe 560 ohm resisror to the A (anode) leadof the LED. (3) Soldera short lengthof wire to the other lead of the resistorand to the probe. (4) Drill a hole in the side of the caseto accept the wire attachedto the K lead of the LED.
PEN CASE
y'wtRE
451/LDs
Special Equipment Required: To Test - Hydrometer To Charge - Battery charger

Schematic of an LED test lamp. Ensure that the connections to the K (cathode) lead and A (anode) lead of the LED are as illustrated.
TO REMOVE AND INSTAL NOTE: Prior to disconnecting the battery determine if the vehicle radioTcassette unit
Electrical System
is equipryd with a PIN number security code.If the radio/cassetteis equippedwith a to ltave tlte PIN number it will be necessary number and instruction sheetsuppliedwith methe vehicleso that the radio/cassette mory and security code can be reset.If the number has been lost it may be obtained by contacting an authorised dealer and providing proof of ownership. After connecting the battery, start and r4n the engine at 3 000 rpm for l0 seconds to reset the idle air control valve. (l) Disconnect the negativeand positive battery terminals. (2) Remove the battery holding clamp and lift the battery from the vehicle. Installation is a reversalof the removal procedure with attention to the following points: (l) Ensure that the terminals and posts are clean. (2) When connecting the leads to the battery, ensure that the polarity is correct. Connect the positive lead first. (3) Do not overtighten the terminal clamp nuts. (4) Apply petroleum jelly to the battery terminals to prevent corrosion. MAINTENANCE Battery maintenance should be performed at the scheduledservices. NOTE: Keep naked flame away from the battery as the battery gases are hishly explosive. (l) Keep the battery and the surrounding area clean and dry. In particular, ensurethat the top of the battery is free from dirt and moisture to prevent voltage flow betweenthe terminals. clean the battery caseas follows: If necessary,
207
(a) Remove the battery from the vehicle as previously described. (b) Pour hotwater over thebattery beingcareful not io-allow any water to enter the battery through the filler cap vent holes. (c) Wipe the battery caseclean. (2) Clean the battery terminals and postsusing a battery post cleaner, wire brush or emery cloth. Remove all dirt and corrosion. (3) Remove the filler caps and check that the vent holes are clear. (4) Check the electrolyte level and replenish The correct level is with distilled water as necessary. just above the top of the plates. Do not overfill the battery. Do not transfer electrolyte from one cell to another. (5) If the battery electrolyte requires frequent replenishing,check the battery casefor cracks. If the caseis damaged,renew the battery. Check for overchargingby measuringthe output of the alternator as describedlater in this section. (6) Apply petroleum jelly to the battery terminals to prevent corrosion. (7) If the electrolyte has overflowed and contaminated the battery carrier and surrounding body panels,proceedas follows: (a) With the battery removed from the vehicle sprinkle bicarbonateof soda over the corroded areas. (b) Pour hot water over the bicarbonateof soda. The bicarbonate of soda will react with the water and begin to foam. (c) When the bicarbonate of soda has stopped foaming, rinse the area with clean water and allow to dry. (d) Remove any blistered paint from the contaminated areas. (e) Paint the contaminated areas with a corrosion inhibiting paint. TO TEST AND CHARGE (l) Using a hydrometer, test the specify gravity of the battery electrolyte.Refer to the following chart which shows charge conditions for various specific gravity readings: Fullydischarged 1.110-1.130 Nearly discharged 1. 140- 1.I 60 1.170- I . 190 Approximately one quarter charged
r.200-r.220
1.230-1.250 Approximately three quarter charged 1.260-1.280 Fully charged Thesereadingsare for electrolyteat atemperature of 20 deg C. For every l0 deg above 20 deg C, add 0.007. For every l0 deg below 20 deg C, substract 0.007.
Remove all dirt and corrosion from terminals. the battery
NOTE: An accurate specificgravity reading cannot be obtained if distilled water has recently beenadded to the electrolyte.If the
208
Electrical System
internal integrated circuit regulator. The voltage regulator is not adjustable. An electrical cut out unit is not necessaryas the diodes prevent a reverse current flow through ttre alternator. SERVICE PRECAUTIONS (1) Ensurethat the battery is connectedwith the negativeterminal to earth. (2) Do not short circuit or ground any terminals common to the charging circuit. (3) Always disconnect the battery before connecting a battery charger. (4) If a boosterbattery is used,alwaysconnectit in a parallel circuit i.e. positive to positive (+ to *) and negativeto negative(- to -) to maintain a 12 volt supply. (5) Never disconnectthe battery or terminals in the charging circuit while the engine is running. (6) Regularly check the drive belt tension. (7) Keep the battery terminals clean and all electrical connectionstight. (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 has been started and run at approximately I 000 rpm or the charge rate is suspected of being outside the specified range, indicated by a discharged or overchargedbattery, carry out the following tests. (l) Stop the engine,do not open circuit any parts of the chargingcircuit whilst the engine is running. (2) Check the condition and adjustment of the drive belt. (3) Clean the battery terminals, tighten all the electrical connections, checking the wiring for short circuits to earth and/or bridged circuits, ensure that the battery is fully charged.If the battery is in a low state of charge,either rechargeit or replace it with a fully charged battery. (4) Start the engine and allow it to run until normal operating temperature is reached, then stop the engine. NOTE: Whilst performing thefollowing test an the alternator, do not attach leads with alligator clips. All cannections should be made with clamp or bolted type connectors. This will prevent leads becoming detachedduring the testand opencircuiting the alternator which would result in failure of the diodes. (5) Disconnect the negative terminal from the battery. Refer to the note under the Battery heading in this section. Remove the nut and washer from the alternator output terminal (B+) and disconnect the alternator output lead.
electrolyte level is below the battery plates, replenishwith distilledwater and chargethe battery beforetesting the specificgravity. (2) If a low state of chargeis indicated, or if the specific gravity readings vary more than 0.030 between cells, the battery should be charged using a commercially available battery chargerwith attention to the following points: (a) Disconnect the negativeand positive battery terminals. (b) Check the battery electrolyte level and replenish as necessary. (c) Remove the filler caps from the battery. (d) Follow the battery charger manufacturers instructions. (3) Should the battery fail to operate satisfactorily after charging, it is recommended that it be taken to an authorised dealer with necessaryequipment to perform a load test. Load testing, when performed in conjunction with the specific gravity tests described above, will give an accurate indication of the serviceability of the battery. 7. ALTERNATOR
Special Equipment Required: To Test - 100-0-100 Ammeter, voltmeter, a I 000 watt (min) lamp bank with switching, tachometer,ohmmeter To Dismantle Soldering iron, press, press plates, bearing puller To Assemble- Soldering iron, press,pressplates DESCRIPTION The Bosch alternator installed in the range of vehicles covered by this manual has an internal voltage regulator which is battery voltage sensitive, this ensuresthat the alternator charying rate is directly determined by the condition of the battery. The alternator consistsof a fixed coil winding or stator, a shaft wound coil or rotor, a rectifier or diode pack and an internal voltage regulator. A magnetic field is produced in the rotor by electrical current fed into the rotor windings by brushes bearing on slip rings mounted on the rotor shaft. Three phase alternating current (AC) is produced in the star wound stator by the rotation of the magnetic field. As it is not possible to charge a storage battery with alternating current (AC), it is necessary to rectify the output of the stator windings to direct current (DC). This is done by using a bank of diodes or diode pack, mounted within the alternator slip ring end bracket. The current output of the alternator is governed by the inbuilt characteristicsof the alternator. The voltage output of the alternator is governed by the
Electrical System
(6) Connect one lead of a 100-0-100 ammeter to the output terminal (B+) and the other lead of the ammeter to the lead removed from the output terminal. (7) Connect the negative battery terminal and the I 000 watt lamp bank to the battery. (8) If necessary,connect an inductive tachometer to one of the high tension leads following the manufacturers instructions. NOTE: Ensure that the tachometer to be usedis of the inductive pickup type and that the scale is setfor 2 cycle operation. If no 2 cycle position is available the tachometer reading will have to be halved. (9) Start the engine and increase the engine speedto 1 480 rpm. (10) Adjust the lamp bank and engine speed until the voltmeter is showing 14 volts and engine speedis I 480 rpm. (l l) The ammeter should now indicate 85 amps C. at 2Odegrees NOTE: If the temperature is more than 20 deg C engine rpm will have to be increased slightly to a maximum of 2 200 rpm at 60 deg C. (12) Overhaul or renewthe alternator if a fault is indicated. (13) Return the engine to idle speed prior to switching off the lamp bank. TO REMOYE AND INSTAL (l) Disconnect the negativebattery terminal. NOTE: Refer to the note under the Battery heading in this section prior to disconnecting the battery. (2) Disconnect{he terminal blogk from the alternator by pulfing on the terlninal block, not the wires
.-.:i -.f4ffi, OUTPUT TERIIB{AL B}
.r !.!E
209
and remove the terminal nut and lockwasher to remove the wiring from the B * terminal. (3) Using an 18 mm ring spanner rotate the drive belt tensionerpulley anti-clockwiseand remove the drive belt from the alternator pulley. (4) Remove the alternator mounting bolts, lift the alternator upward and remove the nut and lockwasherretaining the B* terminal wiring. Disconnect the wiring from the alternator and withdraw the alternator from the engine. Installation is a reversal of the removal procedure with attention to the following points: (1) Instal the B* terminal wire to the alternator and tighten the retaining nut securely. (2) Instal the alternator to the support brackets and tighten the retaining bolts to the specifiedtorque. (3) Connect the terminal block and place the drive belt around the alternator pulley while holding pressrireon the belt tensioner. Refer to the Engine Tune-up section for further information regarding the drive belt adjustment. TO DISMANTLE (1) Remove the alternator from the vehicle as previously described. (2) Scribe a mark across the drive end bracket, stator and slip ring end bracket to facilitate correct alignment during assembly. (3) Remove the screwsand washerssecuringthe regulator and brush holder assembly. Withdraw the regulator and brush holder assembly from the alternator. (4) Remove the long screwssecuring the drive end bracket to the slip ring end bracket and withdraw the drive end bracket, rotor and pulley assembly. NOTE: Ensure that the sealing O ring behind the rotor shaft rear bearing in thb slip ring end bracket is not mislaid. (5) Holding the rotor in a suitable soft jawed vice to protect the rotor, unscrew and remove the drive pulley retaining nut and the spring washer from the rotor shaft. (6) Remove the drive pulley, spacer, plate washer and fan from the rotor shaft. (7) Using a suitable press and press plates, support the drive end bracket with the pulley end of the rotor shaft uppermost and carefully pressthe rotor shaft from the Spacer, bearing and the drive end bracket. (8) Remove the spacerand the bearing retainer plate screwsfrom the drive end bracket. (9) Remove the bearing retainer plate and the bearing from the drive end bracket. (10) If necessary, using suitable pullers, remove the rear bearing from the rotor shaft.
END BRAGKET
SENS,SIG TERMINAL S
WARNB{G LAMP TERIIhIAL
ffis
z4Bh+st2ra
View of the ahernator removed from the vehicle.
210
Electrical System
NOTE: The diode pack rs supplied es an integral ,unit and in the event'6f o ,oiponent {ailure, the diode pack *"il i" renewedas a complete unit. (13) Jag and mark all wiring connectionsprior to removal to avoid incorrect connections during assembly. ( 14) Where necessary, using a very hot soldering iron and a pair of rongtror.d pliers, unsolder the stator leads from rhe connector terminais i;;;;;;ir" ,t. diode pack.
View of the stator assembly and the slip ring end bracket. NOTE: When removing the rotor bearinss. note the position of theleating shields o;;; aid to assembly. (J tl Remove the nut, spring washerand output terminal gomponentsfrom tire (i+) t.;i;; ln the outside of the slip ring end bracket.' (12) Working inside the slip ring end bracker, remove the screws securing the diodi pack to the bracket and withdraw the stitor and diod-epult ur un assembly.Remove the insulating spacerand washer from the (B*) terminal.
PLATE WASHER I FAN /
NOTE: Do not apply undue heat rc the connections as damage may result to the terminal insulator and/o, diodes. TO CLEAN PARTS - (l) Do not immerse units of the alternator in cleaning solvents as damage to the windinls will result. @ Thoroughly clean and dry the end bracketsin a suitable solvent.after. they have been .o-pr"t"rv dismantled from the unit. - (3) Check the rear bearing sealing O ring for damageand deterioration and renew as necessary. (4) compressedair can be carefully ur.o io blow
ww ,.^",.* ffi"
ROTOR BEARING
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SLIP RING END BRACKET
DIODEPACK
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Dismantled view of the alternator.
Electrical System
out the dust from the stator windings and the field winding on the rotor. (5) Slip ringsthat are burned or scoredshouldbe polished using very fine glasspaper. (6) Clean the brushes and the brush holders using a petrol damp rag, check and remove any burrs from the holder. (7) Check the rotor shaft bearingsfor wear and roughness and renew as necessary. TO CHECK AND TEST COMPONENT PARTS All partsbeingelectricallytestedshouldbe resting on a non-conductivepad. Field Windings and Rotor Assembly ( I ) The insulation to earth test is done with an ohmmeter.Connectone of the test prods to one of the field wires or slip rings and the other test prod to one pole piece of the rotor. &;i,
S L I PR I N G S
2rr
use anon'lT:l,l'? internat :;:1"':J,jJ#:xl:n!r

(4) If there is any variation in resistancebetween phasesit will be necessary to renew the stator assembly. (5) Connect a jumper lead from the negative terminal of a charged 12 volt battery to the stator winding frame. Connectone end of a test lamp to the battery positive terminal, the other end of the test lamp to the stator lead, one at a time. (6) Should the test lamp lighr or burn dimly a short circuit is indicatedand the statorassemblv must be renewed. Diodes The diodes may be tested after their disconnectestingcan be done by usinga l2 volt battery and lio_n, 1.5 watt bulb in serieswith a jumper lead. (l) Connect a jumper lead from the negative terminal of a charged battery to the carrier/biacket holding the diode to be tested. (2) Connectone end of a test lamp to the battery positive terminal and the other end of the lamp to th6 diode lead.Note whetherthe lamp is illuminated and then reversethe connectionson the battery. (3) If the lamp was illuminated in both directions or was not illuminated at all the diode is faultv and the diode pack/heatsink must be renewed. Brush Spring and Brushes (l) Unsolder and remove the brushesfrom the holders. (2) Check the brush springsfor overheating and distortion, check for binding in the brush holders. (3) Check the brush length and renew as necessary. Refer to the Specifications. TO ASSEMBLE The assemblingprocedure is a reversal of the dismantling operationwith attention to the following points:
Checkingrotor windings for shon to earth. (2) If the ohmmeter shows a reading and no visual earthing can be seenand rectified, a new rotor assembly will have to be installed. (3) To check for bridged or internal shorringof therotor windings,checkthe resistance betweentheslip rings.The resistance shouldbe2.47-2.l3ohms. A low reading indicates a bridged circuit internally, a high readingindicatesan open circuit or high resistanceln the windings. In both casesa new rotor assembly will haveto be installed. Stator Windings The stator test is carried out using an ohmmeter. (l) The stator leadsmust be detachedfrom the diode pack. (2) Connect one test prod of the ohmmeter to one stator lead and the other test prod to another stator lead. Note the ohmmeter reading. - (3) Repeatthe operationon the remaining leads alternatelyto checkeachphase.
212
Electrical System
pinion with the flywheel ring gear and at the $ame time closes the switch supplying power from the positive lead of the battery to the starter motor field coils and the armature to operate the motor. As the engine fires, the ovemrnning clutch of the drive pinion assemblyprevents higl speedrotation of, and possible damage to, the starter armature if the solenoid windings are not immediately de-energised by releasingthe ignition key. The starter solenoid switch windings are energised by the key operated combination ignition and starter switch. TO TEST ON VEHICLE Shouldthe starterfail to operatewhen the ignition switch is moved to the Start position, check the following points: (1) Check the battery condition and state of charge.Refer to the Battery heading. (2) Cleanthe battery terminals, taking particular care to remove the scale from the positive (+) terminal post and terminal. NOTE: Refer to the note under the Battery heading in this section prior to disconnecting the battery. (3) Check the earth connections for tightness and cleanliness. (4) Switch on the headlamps and turn the ignition switch to Start. If the lamps dim but the starter is not heard to operate, it could indicate that a short circuit has developed in the starting system which could be either external or internal. Also check that the engineis not seizedor locked up as this condition would give the sameindication as above. (5) If the lamps do not dim and the starter does not operate,this would indicate dirty or contaminated starter solenoid contacts in which case the solenoid should be renewedor an open circuit such as a broken or disconnectedwire, or a switch not operating. Turn the ignition switch to Start and move the transmission selectorlever through all the gear selection ranges.If the starter operatesin any position other than N or P, the neutral safety switch is faulty. (6) Check all the external wiring to ensure that the fault is not external. If the external circuit proves satisfactory, indicating that the problem is in the the unit will have to be removed and starter assembly, overhauled. TO REMOVE AND INSTAL (1) Disconnect the negativebattery terminal. NOTE: Refer tu the note under the Battery heading in this section prior to disconnecting the battery. (2) Raise the front of the vehicle and support it on chassisstands.
(l) If previously disconnected, using a hot soldering iron and a long nosed pair of pliers as a heat sink, solder the stator leads to their respective terminals on the diode pack. (2) Instal the insulating washerand spacerto the (B+) terminal post and position the diode pack and stator assemblyonto the slip ring end bracket. Instal the diode pack retaining screws and tighten them securely. (3) Working on the exterior of the slip ring end bracket, instal the output terminal componentsto the (B+) terminal and securewith the retaining nut. (4) Position the bearing retainer, bearing and spaceron the rotor shaft. (5) Using a suitable press and press plates, support the rotor shaft on the front face of the spacer and carefully press the rotor shaft fully into the bearing and spacer. (6) Position the rotor shaft assembly into the rear of the drive end bracket and instal and tighten the bearing retainer plate screws. (7) Instal the fan, plate, spacerand drive pulley to the rotor shaft and securethem with the retaining washer and nut. (8) If necessary, using a suitable pressand press plates, support the rotor shaft rear bearing and carefully press the rotor shaft fully into the bearing. NOTE: Ensure that pressureis applied only to the inner race of the bearing. (9) Ensure that the rotor shaft bearing O ring is securelylocated in the slip ring end bracket and insert the rotor in the stator and slip ring end bracket assembly. ( 10) Align the marks made on dismantling and instal and tighten the through screws. (11) Position the regulator and brush holder assemblyto the slip ring end bracket and instal and tighten the retaining screws. (I2) Instal the alternator to the vehicle and test the operation as previously described. 8. STARTER MOTOR - AUTOMATIC TRANSMISSTONMODELS
Special Equipment Required: To Renew Brushes - Soldering iron DESCRIPTION The Bosch starter motor fitted to automatic transmission models is the induced pole type with four brushesand four pole shoeswith field coils. A solenoid switch is attached to the starter drive end bracket. The solenoid plunger is connectedto the overrunning clutch and drive pinion assembly through a link, lever and pivot bolt arrangement. When the solenoid windings are energised,the plungeracting on the lever and pivot engages the drive
Electrical System
(3) On vehicles equipped with air conditioning, remove the left hand exhaust manifold. Refer to the Engine section if necessary. NOTE: Removal of the exhaust manifold enablesaccess to the solenoid terminals and the starter motor support bracket. (4) Remove the nut and washer retaining the battery lead to the starter motor. Pull the switch wire from the solenoid by pulling on the connector not the wiring. (5) Remove the bolts, nuts and washersretaining the steering gear assembly to the front crossmember and allow the steeringgear assemblyto hang freely. (6) Removethe starter motor retaining bolts and the support bracket bolt, lower the starter motor and allow it to rest on the front suspensioncrossmember. (7) Remove the torque converter housing cover retaining bolts and withdraw the cover from the torque converter. (8) Withdraw the starter motor rearwards. Installation is a reversalof 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 the starter motor terminals before installing the exhaust manifold. (2) Torque all nuts and bolts to Specifications as describedin the relevant sections. (3) After reconnectingthe negative battery terminal, start the engine and increasespeed to 3 000
DRIVE END BRACKET
HEAT SHIELD
2r3
View of the starter motor removedfrom the vehicle. rpm for l0 secondsto allow the idle air control valve to reset. (4) On models equipped with a security coded radio enter the PIN code as described under the Radio/Cassetteheading in this section. TO DISMANTLE ( 1) Remove the startermotor from the vehicle as previously describedand mount the startermotor in a soft jawed vice. (2) Disconnect the field connector strap from the lower terminal on the solenoid switch. (3) Rernovethe heat shield retaining screwfrom the drive end bracket and remove the heat shield.
scREws
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Frhrf,
SOLENOID
BRACKET WASHERS
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6
FORK
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STOPCOLLAR PINIONAND CLUTCHASSIY
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BRUSH HOLDER
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Dismantled view of the Bosch starter motor.
214
Electrical System
(3) Check the brush springs, and cornpare with new springs. (4) Check that the commutator ig free from pitting and burning. Clean the commutator with a petrol moistened cloth and polish with a strip of fine glasspaper. A badly worn commutator may be cleaned by mounting in a lathe, spinning at high speed, and taking a light cut with a very sharp tool. After turning, undercut the insulation between the segments to Specifications. (5) Check the armature for short circuit, using an ohmmeter. Place one of the test prods on the armature shaft or core and move the other prod around the circumferenceof the commutator. If the ohmmeter showsa reading at any point the armature is faulty and should be renewed. (6) Test the field coils for continuity by connecting the test prods in serieswith the field windings. Failure of the ohmmeter to show a reading indicatesan open circuit in the wiring of the field coils. (7) Check the field coil for ground by placing one test prod on the field coil lead and the other prod on the yoke. If the ohmmeter showsa reading the field coils and yoke assemblyare faulty and will have to be renewed. (8) Check the drive clutch assemblypinion teeth for wear, scoring or chipping. A clutch in good condition should take up the drive in one direction only. It should rotate easily and smoothly in the nondrive direction and the assembly should move smoothly along the armature helical splines. (9) Check the armature shaft bushes for wear and renew as necessary.The old bushes must be removed and the new ones pressed into the end brackets using a polished mandr6l of the exact diameter of the armature shaft. NOTE: The new bushes must not be reamed to size, as reaming will impair the porosity of the bushesand cause early failure. New bushes should be allowed to stand immersed in clean light engine oil for one hour before installation. TO ASSEMBLE
(4) Remove the solenoid retairting screws and withdraw the solenoid leaving the solenoid plunger and spring on the drive end bracket. (5) Disconnect the solenoid plunger from the pinion fork and remove the plunger and spring from the bracket. (6) Remove the end cover cap retaining screws and remove the cap and seal from the commutator end cover. (7) Remove the C clip and thrust washersfrom the rear of the armature shaft, noting the number of washersinstalled. (8) Remove the through bolts and remove the bolts and the support bracket from the starter end cover. (9) Separate'the commutator end cover from the starter yoke. (10) Withdraw the yoke and brush holder assembly from the armature and drive end brackets. (11) Remove the sealingblock from the drive end bracket and withdraw the armature and pinion fork from the drive end bracket. (12) Carefully spread the pinion fork arms and disconnectthe pinion fork arms from the drive pinion dowels. Remove the pinion fork. (13) Support the armature in a vertical position with the drive pinion uppermost:. (14) Using a suitable drift, tap the stop collar towards the drive pinion and clutch assembly and remove the snap ring from the armature shaft. (15) Remove any burrs from the shaft and withdraw the stop collar and the drive pinion and clutch assemblyfrom the armature shaft. ( 16) Clean all parts thoroughly but do not immerse the yoke, armature or drive clutch in cleaning solvent. (17) Ifthe field coils are to be removed,markthe location of eachindividual pole shoebefore removing the mounting screws. NOTE: Do not remove the field coils unless they are suspectedof being unserviceable. Thepole shoesmust be replacedin the same position from which they were removed to avoid the possibility of the armature poling when the starter motor is assembled. TO CHECK AND INSPECT (l) With the starter motor dismantled, checkthe brush holder insulation using an ohmmeter. Connectone test prod to the brush holder positive side and the other prod to the negative side. If the ohmmeter reading is other than infinity, repair or renew the brush holder. (2) Check the brushes for adequate length. Brushesshould be renewedwhen their length is below Specifications. They should be a free sliding fit in the brush holders.
Assembly is a reversal of the dismantling procedure with attention to the following points: (l) Sparingly lubricate the armature helix and pinion clutch assembly interior with Molybdenum Disulphide lithium basedgrease. (2) Instal the stop collar to the armature shaft and position the snap ring in the locating groove on the armature shaft. (3) Rotate the drive pinion to push the stop collar over the snap ring until the collar is locked on the snap ring.
Electrical System
(4) Sparingly lubricate the armature shaft busheswith engine oil. (5) Position the armature and the pinion fork into the drive end bracket. (6) Engagethe solenoid plunger on the pinion fork. Instal the plunger spring, sealing block and solenoid to the drive end bracket. Securethe solenoid with the retaining screws. (7) Instal the yoke over the armature. (8) Instal the brush holder with brushes installed. It is necessary to push the brushesagainstthe spring tension into the holder and then slide the assemblyonto the commutator. (9) Instal the commutator end cover, the support bracket and the through bolts. Ensure that the field connector strap and insulators are seated correctly. (10) Instal the thrust washersto the end of the armature shaft and secure them with the C clip. Adjust the armature end float to 0.05-0.30 mm by adding or subtracting thrust washers. (l l) Placethe end cover cap and gasketover the armature shaft and instal the retaining screws. (12\ Instal the heat shield to the starter motor and instal the starter motor to the vehicle as previously described. 9. STARTER MOTOR - MANUAL TRANSMISSION MODELS
215
(1) Check the battery condition and state of charge.Refer to the Battery heading. (2) Clean the battery terminals taking particular care to remove the scale from the positive (+) terminal post and terminal. NOTE: Refer to the note under the Battery heading in this section prior to disconnecting the battery. (3) Check the earth connections for tightness and cleanliness. (a) Switch on the headlamps and turn the ignition switch to Start. If the lamps dim but the starter is not heard to operate, it could indicate that a short circuit has developed in the starting system which could be either external or internal. Also check that the engine is not seizedor locked up as this condition wodld indicate an open circuit such as a broken or disconnectedwire or a switch not operating. (6) Check all the external wiring to ensure that the fault is not external. If the external circuit proves satisfactory, indicating that the problem is in the starter assembly, the unit will have to be removed and
overhauled.
TO REMOVE AND INSTAL (l) Disconnectthe negativebattery terminal. NOTE: Refer to the note under the Battery heading in this section prior to disconnecting the battery. (2) Raise the front of the vehicle and support it on chassisstands. (3) Remove the nut and washer retaining the battery lead to the starter motor, putl the switclr-wire from the solenoid by pulling on the connector not the wiring. (4) On vehicles equipped with air conditioning, remove the bolts, nuts and washers retaining the and steeringgear assemblyto the front crossmember allow the steeringgear assemblyto hang freely. NOTE: On modelswithout air condit,ioning there is sufficient spaceto remove the ptarter motor by sliding it towards the front of the engine and out between the stabiliser bar and thefront engine mount. (5) Removethe starter motor retaining bolts and if applicablethe starter motor meshadjusting shim(s). (6) Withdraw the starter motor from the engine. Installation is a reversalof the removal procedure with attention to the following points: (l) Ensurethat the starter motor meshadjusting shim(s) are in position if removed. (2) Torque all nuts and bolts to Specifications as describedin the relevant sections. (3) If the original starter motor is replacedby a new or exchange unit or if the starter motor operation
DESCRIPTION The Delco Remy reduction gear starter motor fitted to manual transmission models is the induced pole type with four brushesand four pole shoeswith field coils A solenoid switch is attached to the starter drive end bracket. The solenoid plunger is connectedto the ovemrnning clutch and drive pinion assembly through a link and lever assembly. When the solenoid windings are energised,the plunger acting on the lever and pivot engages thp drive pinion with the flywheel ring gear and at the same time closes the switch supplying power from the positive lead of the battery to the starter motor field coils and the armature to operate the motor. As the engine fires, the ovemrnning clutch of the drive pinion assemblypreventshigh speedrotation of, and possible damage to, the starter armature if the solenoid windings are not immediately de-energised by releasingthe ignition key. The starter solenoid switch windings are energised by the key operated combination ignition and starter switch. TO TEST ON VEHICLE Shouldthe starterfail to operatewhen the ignition switch is moved to the Start position check the following points:
216
Electrical System
ming the starter motor away from tho flywheel is required, refer to step (9). (8) If the clearanceis more than 1.5 mm, shimming the starter motor towards the flyvheel is required, refer to step (9). (9) If shimming is required loosen the inboard starter mounting bolt and remove the outboard mounting bolt. Shims can be added and srbtracted as necessary to achievethe desired clearance. If it is necessary to move the starter motor closer to the flywheel, a 0.4 mm shim inserted at the outboard mounting bolt location will decrease pinion clearanceapproximately 0.3 mm. TO DISMANTLE ( I ) Remove the startenmotor from the vehicle as previously describedand mount the startermotor in a soft jawed vice. (2) Disconnect the field connector strap from the lower terminal on the solenoid switch. (3) Remove the solenoid retaining screws and unhook the solenoid from the pivot lever. Note any shims that may be between the solenoid and the end bracket and place the shims to one side. (4) Remove the starter motor brush cover retaining bolts and the small screwsretaining the brush holder. (5) Remove the brush covef from the field coil yoke. (6) Remove the armature and field coil yoke as an assemblyfrom the centre housing. (7) Using a fine bladed screwdriver prise back each brush spring in turn so that each brush can be pulled away from the armature approximately 8 mm. Use the spring pressureon the side of the brush to hold the brush in the releasedposition.
is noisy, check and adjust the pinion mesh as described under the following side heading. (4) After reconnectingthe negative battery terminal start the engineand increasethe speedto 3 000 rpm for 10 secondsto allow the idle air control valve to reset. (5) On models equipped with a security coded radio enter the PIN code as described under the Radio/Cassetteheading in this section. TO CHECK AND ADJUST PINION MESH Incorrect starter pinion mesh is usually indicated by a high pitched whine during cranking which indicatesthat there is too much clearance betweenthe starter pinion and the ring gear or a high pitched whine after starting which indicates that there is too little clearancebetweenthe starter pinion and the ring gear. Two starter motor shim sizes are available; 1.0 mm and 2.0 mm. Washerscan be usedbut total shim thicknessmust not exceed3.0 mm. (l) Remove the transmissionfrom the vehicle as describedin the Manual Transmission section. (2) Remove the clutch housing from the vehicle as describedin the Clutch section. (3) Using a dial indicator or a suitable pointer rotate the flywheeland mark the high point of the ring gear runout. (4) Rotate the flywheel until the high point is positioned adjacent to the starter motor. (5) Pull the pinion gear into mesh with the flywheel using a suitable lever and hold. (6) Using wire gauges measure the clearance betweenthe top of the pinion teeth and the ring gear. (7) If the clearanceis less than 0.5 mm. shim-
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Dismantled view of the Delco Remy starter motor.
Electrical System
(8) Rbmove the armature from the yoke and field coil assembly. (9) Remove the cover retaining screws and remove the cover from the centre housing. (10) Remove the C clip and the shim from the centre housing. (11) Removethe bolt retaining the centrehousing to the end bracket. (12) Remove the centre housing from the end bracket. Note the shims installed on the pinion shaft as an aid to assembly. These shims control pinion shaft end float. (13) Remove the reduction gear, the rubber spring holder and the two springs from the end bracket. (14) Using a suitablediameter mandrel or a 16 mm socket installed over the end of the pinion shaft and a hammer, releasethe stop collar from the clip. (15) Using a pair of snapring pliers, remove the clip from the end of the pinion shaft. ( 16) Using a small file, remove any burrs from the end of the pinion shaft. (17) Remove the stop collar, spring and pinion from the pinion shaft. (18) Remove the pinion shaft and pivot lever assemblyfrom the end bracket. (19) If necessary, the pivot lever can be removed from the pinion shaft after noting the installed direction of the lever. (20) Clean all parts thoroughly but do not immerse the yoke, armature, drive clutch or bearings in cleaning solvent. If the field coils are to be removed mark the location of eachindividual pole shoebefore removing the mounting screws. NOTE: Do not remove the field coils unless they are suspectedof being unserviceable. Thepole shoesmust be replacedin the same position from which they were removed to avoid the possibility of the armature poling when the starter motor is assembled. TO CHECK AND INSPECT (l) With the starter motor dismantled, checkthe brush holder insulation using an ohmmeter. Connectone test prod to the brush holder positive side and the other prod to the negative side. If the ohmmeter reading is other than infinity, repair or renew the brush holder. (2) Check the brushes for adequate length. Brushesshould be renewedwhen their length is below Specifications.They should be free sliding fit in the brush holders. NOTE: The vehiclemanufacturer statesthat brushes are not available separately. The positive brushesare incorporated as part of
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the yoke assemblyand the negativebrushes are incorporated as part of the brush holder assembly.However, brushes may be available from automotive electrical suppliers. (3) Check the brush springs and compare with new springs. (4) Check that the commutator is free from pitting and burning. Clean the commutator with a petrol moistened cloth and polish with a strip of fine glasspaper. A badly worn commutator may be cleaned by mounting in a lathe, spinning at high speedand taking a light cut with a very sharp tool. After turning, undercut the insulation between the segments to Specifications. (5) Check the armature for short circuit, using an ohmmeter. Place one of the test prods on the armature shaft or core and move the other prod around the circumferenceof the commutator. If the ohmmeter shows a reading at any point the armature is faulty and should be renewed. (6) Test the field coils for continuity by connecting the test prods in serieswith the field windings. Failure of the ohmmeter to show a reading indicatesan open circuit in the wiring of the field coils. (7) Check the field coil for ground by placing one test prod on the field coil lead and the other prod on the yoke. If the ohmmeter showsa readingthe field coils and yoke assemblyare faulty and will have to be renewed. (8) Check the drive clutch assembly pinion teeth for wear, scoring or chipping. A clutch in good condition should take up the drive in one direction only. It should rotate easily and smoothly in the nondrive direction and the assembly should move smoothly along the helical splines. (9) Check the reduction gearfor wear and renew if necessary. (10) Check the armature and pinion shaft bearings for wear and renew if the bearings are rough or noisy. TO ASSEMBLE Assembly is a reversal of the dismantling procedure with attention to the following points: (l) Lubricate the pinion shaft splines with Molybdenum'Disulphide greaseand instal the pinion shaft, spring, pinion and stop collar. (2) Instal the stop collar clip and using a small puller on the pinion, slide the stop collar over the clip to lock the clip in position. It may be necessary to lightly tap the stop collar clip inwards with a punch to assistin installation. (3) Lubricate the pivot lever fingerswith Molybdenum Disulphide greaseand instal it to the pinion shaft with the lug towards the end bracket. (4) Instal the gear, shims, pivot lever, springs
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Electrical System
11. IGNITION SYSTEM The ignition system is fully covered in the Fuel and Engine Management section. 12. SWITCHES AND CONTROLS IGNITTON SWITCH AND LOCK CYLINDER To Rernoveand Instal (l) Disconnect the negativebattery terminal. NOTE: Refe, to the note under the Battery heading in this section prior to disconnecting the battery. (2) Twist the fuse panel cover retaining clips 90 degrees and allow the cover the swing down. (3) Loosen the lower steering column cover retaining screws and rernove the lower steering column cover from the vehicle. (4) Insert the ignition key into the lock cylinder and turn the key to the On position.
I.OCK CYLINDER
and the spring rubber and instal the centre housing and the retaining bolt. (5) Instal the shim and the C clip to the end of the pinion shaft and check the pinion shaft end float as follows: (a) Push the pinion shaft towards the centre housing and using feeler gauges under the C clip measurethe end float. (b) If end float is not 0.5 mm, instal shims which are availablein two thickness, 0.25 and 0.5 mm, until the end float is correct. (6) Half fill the cover with Molybdenum Disulphide grease and instal the cover to the centrehousing and retain with the retaining screws. (7) Instal the armature to the centre housing ensuring that the'splines engage properly. (8) Instal the yoke assemblyto the centre housing. The field coil lead must be positioned in the centre housing locating tabs. (9) Instal the brush holder ensuring that the brushesare a free sliding fit in the brush holder and that the brush holder screw holes will align with the brush cover when the brush cover is installed. (10) Instal the brush cover/brush holder screws ensuringthat the drain tube is at the bottom when the starter motor is mounted on the vehicle. Tighten the through bolts securely. (l l) Instal the solenoid and if applicable,the shims. Tighten the solenoid attachingscrewssecurely. (12) Check the pinion position using the following procedure: (a) Connect the positive lead from a 12 volt battery to the switch terminal of the starter solenoid. (b) Momentarily touch the negative lead from the battery to the starter motor to bring the pinion into the mesh position. (c) Push the pinion back and forth by hand and measure the amount of pinion shaft movement, 0.5-2.0 mm is acceptable.Disconnect the negative battery terminal. NOTE: Do not have the battery connected at a time. for more than 30 seconds (d) If necess?ry, add shims to decrease the pinion clearance or remove shims to increase the clearance. The shims are locatedbetweenthe solenoid and the centre housing. (13) Instal the starter motor to the vehicle as previously described. 10. STEERING WHEEL AND HORN PAD TO REMOVE AND INSTAL The removal and installation proceduresfor the steeringwheel and horn pad are fully covered in the Steeringsection.
COLUMN
View of the ignition switch and lock cylinder. (5) Insert a 3 mm wire into the locking pin hole and depress the locking latch. Withdraw the lock cylinder from the steeringcolumn. NOTE: It is not necessary to removethe lock cylinder if only the ignition switch is to be renewed. (6) Disconnect the wiring harness connector from the ignition switch. (7) Using a small bladed screwdriverremove the ignition switch retaining screws.Withdraw the switch from the steeringcolumn. Installation is a reversalof the removal procedure with attention to the following points: (l) When installing the lock cylinder ensurethat the ignition key is in the On position, marked II on the switch. (2) When installing the ignition switch ensure that the slot in the switch aligns with the steppedend of the lock cylinder shaft.
Electrical System
COMBINATION SWITCH
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To Removeand Instal (1) Disconnect the negativebattery terminal. NOTE: Refer to the note under the Battery heading in this section prior to disconnecting the battery. (2) Remove the steering wheel as described in the Steeringsection. (3) Remove the lower steering column cover retaining screws and withdraw the lower steering column cover from the vehicle. (4) Manoeuvre the upper steeringcolumn cover from the vehicle. (5) Depress the lock tangs and withdraw the switch assemblyslightly. Disconnect the wiring connector from the switch assembly and withdraw the assemblyfrom the vehicle. Installation is a reversalof the removal procedure with attention to the following points: (l) Ensure that the switch assemblywiring connector is properly connected. (2) Check the operation of the switch assembly before installing the column covers.
To Removeand Instal (1) Refer to the note under the Battery heading in this section and disconnect the negative battery terminal. (2) Remove the screwssecuringthe instrument cluster surround to the instrument cluster. (3) Withdraw the surround slightly and disconnectthe wiring connectorsat the rear. Mark or tag each connector as an aid to assembly. (4) Remove the nut and bracket securing the switch bank to the rear of the instrument cluster. Installati"",:::::Jersal of the removal procedure.
Rearview of the instrumentcluster surroundshowing the satellite switch banks. REAR WIPEWWASHE& AIR CONDITIONING AND FOG LAMP SWITCHES To Removeand Instal (1) Refer to the note under the Battery heading in this section and disconnect the negative battery terminal. (2) Prise up the rear of the centre consolecover panel and pull the panel rearwards slightly to allow surround screws. to the radio/cassette access (3) Remove the screwsfrom the lower part of the radio/cassettesurround and pull the surround rear-
Removingthe combinationswitch from the steering column. SATELLITE SWITCH BANKS The satellite switch banks are mounted to the left hand and right hand sides of the instrument cluster surround. The switch bank on the right hand side operates the headlamps and hazard warning lamps and on some models the power aerial and the cruise control. The switch bank on the left hand side operatesthe wipers and washers, the rear demister, instrument lamp dimmer, interior lamp and on some models the trip computer. The individual switchesare not available separately, if a switch is faulty the entire switch bank must be renewed.
Removing the connectors from the rear wiper/washer, air conditioning and fog lamp switches when removing the radio/cassette surround. Not all switches are installed to all models.
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Electrical System
minals of the reverselamp switch wiring conilector. (5) Switch on the ignition and check the reverse lamps. If the reverselamps now operate, the reverse lamp switch can be considered faulty and should be renewed. NOTE: If the reverse lamps still fail to operatewith the switch connectorteryminals jumped, check the condition of the lamps and thefuses. To Removeand Instal (l) Raise the front of the vehicle and support it on chassisstands.
wards carefully until the locating lugs at the top releasefrom the dashboard. (4) Disconnect the electrical connectors from the switches noting their positions as an aid to assembly. (5) To removp the switches depressthe switch retaining tangs and slide the switchesout of the front of the panel. Installation is a reversalof the removal procedure. COURTESY LAMP DOOR SWITCH To Removeand Instal (l) With the door fully open, remove the retaining 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 reversalof the removal procedure.
View of the manualtransmissionshowingthe reverse lamp switch. (2) Disconnectthe wiring from the reverselamp switch on the side of the transmission. (3) Remove the reverse lamp switch from the transmissionhousing. Installation is a reversalof the removal procedure with attention to the following points: (l) Instal teflon tape to the threadsof the reverse lamp switch. (2) Tighten the switch to a torque of 27 Nm. STOP LAMP SWITCH To Test (l) With the ignition switched on, depressthe brake pedal and have an assistant check if the stop lamps operate. (2) If the stop lamps do not operate, switch off the ignition open the fuse cover and working through the fuse cover aperture, disconnect the stop lamp switch wiring connectors. NOTE: On models with power windows it will be necessaryto remove the power window module retaining bolts and move the module to one side to allow accessto the stop lamp switch wiring connector. (3) Connect a jumper lead betweenthe wiring connectorterminalsand switch on the ignition. If the
View of the courtesy lamp door switch removed from the doorpillar. RE\rERSE LAMP SWITCH On vehicles equipped with an automatic transmission, a combined neutral safetyswitch and reverse lamp switch is installed on the side of the selector lever. The renewal procedure is described in the Automatic Transmission section. On vehicles equipped with a manual transmission, use the following procedures. To Test (l) Switch on the ignition and select reverse gear.The reverselamps should operate. (2) If the reverselamps do not operate,raise the front of the vehicle and support it on chassisstands. (3) Disconnect the wiring from the reverselamp switch on the side of the transmission. (4) Connect a jumper lead between the ter-
Electrical System
SOp hfip*,operat the switch is incorrectly adjusted or 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 the module to one side. (3) Disconnect the electrical connectors from the stop lamp switch. On models with cruise control the stop lamp switch is combined with an electrical releaseswitch and it has four terminals. HANDBRAKE WARNING LAMP SWITCH
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To Renew (1) Remove the handbrake lever assembly as describedin the Brakes section. (2) Disconnectthe Switchwiring and remove the switch. (3) Instal the new s{"itch to the handbrakelever and instal the lever assembly to the vehicle as describedin the Brakes section. (4) Adjust the handbrake as necessary.
Dismantled view of the handbrakelever showing the warning lamp switch location. 13. INSTRUMENT CLUSTER
TO REMOVE AND INSTAL (l) Disconnect the negativebattery terminal. NOTE: Refer to the note under the Battery heading in this section prior to disconnect' ing the battery. (2) Remove the steeringwheel from the steering column as describedin the Steeringsection. (3) Remove the screwsretaining the instrument cluster surround, slide the instrument cluster sur' round rearwardsslightly and disconnectthe electrical connectors. (4) Withdraw the instrument cluiter surround from the instrument cluster. (5) On Calais models open the fuse cover and reach up on the right hand side of the instrument cluster and disconnect the connector that passes through the hole in the dashboard assembly.
VOLTAGEREGULATOR
View of the stop lamp switch with the fuse cover

removed.
(4) Pull the switch assembly from its bracket to remove. Installation is a reversalof the removal procedure with 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 operating eorrectly. To Adjust - Models With Cruise Control (l) Hold the brake pedal in its depressedposition and instal the switchesinto the tubular clips until they stop. Audible clicks will be heard as the switch slidesthrough the clips. (2) Pull the brake pedal back against its stop until the audible clicking sounds can no longer be heard. (3) Apply and release the brake pedal several times and ensure that the stop lamps are operating correctly.
Rear view of the instrument cluster.
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Electrical System
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INSTRU ENT CLUSTER
Removing the connectors from the rear wiper/washer, air conditioning and fog lamp switches when removing the radio/cassette surround. Not all switches are installed to all models.
View of the instrument cluster with the lens and speedometerremoved. (6) Remove the screwsretaining the instrument clusterto the dashboardand withdraw the instrument cluster. Installation is a reversalof the removal proced're with attention to the following points: (l) Run the engineat 3 000 rpm for l0 seconds to allow the idle air control valve to reset. (2) On radio/cassettes incorporating a security PIN number enter the security code ai described under the Radio/Cassetteheading in this section. 14. RADIO/CASSETTE Disconnectingthe vacuum block from the heater controls. (7) Disconnect the electrical connectorsand the vacuum block from the heater controls and remove the heater controls from the dashboard. (8) Reach in beside the right hand side of the radio and using a short Phillips head screwdriver, loosen the anti-theft screw a few turns. (9) Drill out the pop rivets or shear-offscrews retaining the radio/cassette to the instrument panel. (10) Slide the radio/cassette unit rearwards slightly. If necessary,loosen the anti-theft screw to gain access to the electrical connectorsat the rear of the radio/cassette. (l l) Disconnect the aerial connector and the electricalconnectorfrom the rear of the radio/cassette unit. Remove the unit from the dashboard. Installation is a reversalof the removal procedure with attention to the following points: (l) (Jse new pop rivets or shear-off screws on installation.
TO REMOVE AND INSTAL (1) Disconnectthe negativebattery terminal. NOTE: Refer to the note under the Batterv heading in this section prior to disconneciing the battery. (2) Prise up the rear of the centreconsolecover panel and pull the panel rearwards slightly to allow access to the radio/cassette surround screws. (3) Remove the screwsfrom the lowerpart of the radio/cassettesurround and pull the surround rearwards carefully until the locating lugs at the top releasefrom the dashboard. (4) Disconnect the electrical connectors from the radio/cassettesurround panel noting their positions as an aid to assembly. (5) Working in the drivers footwell, disconnect the heater control rod from the control lever at the right hand side of the heater unit. (6) Remove the screw retaining the heater controls to the dashboard and pull the heater control, rearwards.
Electrical System
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DUST COVER
View of the headlamp assembly rtrtrovd from the vehicle. (5) Withdraw the headlamp and turn signal lamp assemblyfrom the body ensuring that the turn signal lens is not scratchedby the mudguard peak. Installation is a reversalof the rem<>val procedure with attention to the following points: (l) Hold the headlamp in position and tighten all nuts and bolts securely. (2) Check and if necessary adjust the headlamp aim as describedlater in this section. To Adjust Headlamp Aim (l) Ensure that the tyres are irrflated to the correct pressureand that the vehicle is positioned on level ground. (2) Ensure that the vehicle is unlarden. (3) When using headlamp aiming equipment refer to the manufacturers instrucrions for the appropriate instructions for that equipment. (4) When using an aiming board position the vehicle 7.6 metres from and squareto the board. (5) Mark a referenceline on the board to correspond with the horizontal centre line of the headlamps.
Disconnecting the radio aerial connector from the radio/cassette unit. (2) Ensure that the heater control rod is positioned correctly. Refer to the Cooling and Heating Systemssection if necessary. (3) Connect the negative battery terminal and where applicable, enter the radio security code using the procedure described under the following side heading. (4) Start the engine and run at 3 000 rpm for 10 secondsto allow the idle air control valve to reset. TO ENTER SECURITY CODE On some models a radio/cassettesecurity code must be entered whenever the power supply is interrupted, such as when the vehicle battery is disconnected. The codeis given to the original owner on delivery of the vehicle. If necessary, the code can be obtained from an authorised dealer on production of proof of vehicle ownership.The code comeswith the information necessary to enter it into the radio. 15. LAMP UNITS
COMBINATION HEADLAMP, PARK LAMP AND TURN SIGNAL LAMP ASSEMBLY To Removeand Instal (l) Disconnect the negativebattery terminal. NOTE: Refer to the note under the Battetry heading in this section prior to disconnecting the battery. (2) Remove the screwsretaining the upper part of the radiator grille to the radiator support panel. Lift the grille out from the body and place to one side. (3) Disconnect the wiring from the headlamp and the front turn signal lamp. (4) Remove the retaining nuts from the lower edgeof the headlamp and the bolts from the radiator support panel.
CORRECT LIGHT PATTERNS
Diagram showing the method of adjusting headlamp aim using an aiming board. Dimenslon R to be 7.6 metres.
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Electrical System
and slide the turn signal lamp unit fornlards and off the headlamp assembly. I (3) Remove the dust cap from th4 rear of the headlamp assembly,disconnectthe wiriqg connector, disengagethe bulb retaining clips andiremove the I bulb. (4) Remove the dust cover froni above the driving lamp. Remove the bulb partially and disconnect the electrical connector from the bulb. (5) Carefully prise the retaining spring clips from the headlamp body and separate the lens and seal from the headlamp. (6) If necessarythe headlamp adjusting screws can be loosened sufficiently and the reflector can be removed as an assembly. Assembly is a reversal of the dismantling procedure with attention to the following points: (l) Ensure that the reflector and lens are securely located prior to installing the lens retaining clips. (2) Ensure that the lens retaining clips are installed by entering them first on the headlamp lens and then onto the body otherwise damageto the lens may occur. (3) Instal the headlamp as previously described. To Renew Headlamp Bulb ( I ) Working inside the engine compartment, unscrewthe dust cover from the rear of the headlamp assembly. (2) Remove the wiring connector from the rear of the bulb. (3) Unclip the spring retainer from the bulb and withdraw the bulb. NOTE: Care must be taken not to handle the glassportion of the bulb as this will shorten the life of the butb. Accidental fingerprints can be removed by applying methylated spirits to the bulb ani drying with a clean tissueor cloth. (4) Carefully instal the bulb and the retaining clips to the headlamp body. (5) Instal the wiring connector to the bulb and the dust cover to the headlamp body. (6) Check the operation of the headlamp and adjust the aim if necessary as describedin this section. To Renew Driving Lamp Bulb (1) Removethe retaining screwsand removethe dust cap from abovethe bulb. (2) Disconnect the spring clip from the bulb, lift the bulb upwards with the wiring attached and disconnect the wiring connectors. (3) Withdraw the bulb. NOTE: Care must be taken not to handle the glassportion of the bulb as this will
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Rear view of the headlamp showing the adjusting screws. (6) Mark two reference lines on the board to correspond with the vertical centre lines of the headlamps. (7) Switch on the headlamps and select low ,beam. (8) Adjust the headlampsby turning the adjusting screwsat the rear of the headlamp assemblies. (9) Adjust the headlamps to comply with local regulations. As a guide, adjust the lamps so that the low beam pattern strikes the aiming board with the horizontal cut off point 105 mm below the horizontal centre line and the point where the beam raisesfrom horizontal is on or to the left of the vertical centreline. To Dismantle and Assemble Headlamp ( I ) Remove the headlamp assembly as previously described.Rotate and remove the turn signal bulb sopketfrom the turn signal lamp assembly. (2) Remove the turn signallamp retaining screw
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Dismantled view of the headlamp assembly.
Electrical System
shorten the life of the bulb. Accidental ftngerprints can be removed by applying methylated spirits to the bulb and drying with a clean tissue or clath. (4) Connect the wiring connectors to the bulb before installing the bulb retaining clip. (5) Ensure that the bulb operates correctly and that the dust cap is located securely. To R.enewPark 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 the holder from the lamp assembly.
225
Removing the bulb from the Sedancombinationlamp. rotate the appropriate bulb holder and remove the bulb holder. NOTE: The spare wheel must be removedto gain access to the left side bulb holders. Where installed, rotate the holder retaining lever in an anti-clockwise direction and remove the bulb holdersfrom the lamp. (2) Depress and rotate the bulb in an anticlockwise direction and remove the bulb from the holder. (3) Installation is a reversal of the removal procedure ensuring that the bulb holder is free from corrosion. 'NOTE: When installing new bulbs, ensure that they are of the correct voltage and wattage. REAR COMBINATION WAGON LAMP STATION
Renewingthe front turn signal lamp bulb. (2) Rotate the bulb and remove it from the holder. (3) Instal the bulb in the holder and instal the holder into the turn signal lamp. To Removeand Instal Turn Signal Lamp (1) Remove the headlamp assembly as previously 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 signal lamp forwards and remove it from the headlamp. Installation is a r.eversal of the removal procedure. REAR COMBINATION LAMP SEDAN
To RenewBulb (l) Open the tailgate and remove the screws retaining the lamp to the vehicle body.
To Renew Bulb ( I ) Working inside the luggage compartment
Renewing a bulb in the Station Wagon rear combination lamp.
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Electrical System
(2) Depress the small lever and turn the bulb holder in the direction of the arrow to remove. (3) Depress and rotate the bulb in an anticlockwise direction and remove it from the bulb holder. (4) Instal the bulb in the reverse manner to removal ensuring that the bulb holder is free from corrosion and that the bulb has the correct pin configuration. (5) Instal the combination lamp to the rear of the 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 assemblyand remove it from the lamp assembly. (3) Pull the bulb from the bulb holder. (4) Instal the bulb in a reverse manner to removal ensuring that the bulb holder is free from corrosion. NUMBER PLATE LAMP STATION WAGON
Removingthe courtesylamp lens. (2) Carefully remove the festoon bulb ensuring that the terminals have sufficient tension to provide a good electrical contact. GLOVE COMPARTMENT LAMP
To RenewBulb (1) Using a suitable screwdriver, remove the number plate lamp lens retaining screwsand remove the lens and bulb.
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 ensuringthat the terminals are free from corrosion and that the terminals have sufficient tension to ensuregood electrical 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 good electrical contact. Removing the bulb from the Station Wagon number plate lamp. (2) Remove the bulb from the lens assembly. (3) Instal a new bulb to the lensensuringthat the bulb holder is free from corrosion and that the terminals have sufficient tension to ensure a good electrical contact with the bulb. (4) Instal the lens to the tailgate and tighten the retaining screwssecurely. COURTESY LAMPS To Renew Bulb (l) Carefully prise the lamp lens from the lamp cover. 16. WIPER MOTORS AITD ARMS
WINDSCREEN WIPER ARM To Removeand Instal (1) Raise the engine bonnet and support it with the bonnet stay. (2) Raise the cover on the wiper arm to gain access to the retaining nut. (3) Lift the blade away from the windscreen until the retainer pin hole aligns with the hole in the wiper head. (4) Insert a suitable piece of wire or a nail through this hole to hold the blade offthe windscreen.
Electrical System
(5) Remove the nut retaining the arm to the pivot shaft. (6) Carefully prise the wiper arm from the pivot shaft taking care not to damagethe vehicle paintwork. Installation is a reversal of the removal procedure with attention to the following point: When the wiper is in the park position the right hand wiper blade should be 45-55 mm from the windscreen surround'and the left hand wiper blade should be 25 mm from the windscreensurround.
227
WIPER MOTOR AND LINKAGE To Removeand 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 screwretaining the wiper motor eafth lead to the body. (6) Disconnect the wiper motor wiring connector. (7) Remove the bolts retaining the wiper motor and linkage assemblyto the plenum chamber.
Removing the windscreen wiper arm from the pivot shaft. WINDSCREEN WIPER BLADE To Removeand Instal ( I ) Remove the wiper ann as previously described. (2) Depressthe retaining.clip at the end of the . wiper arrn and slide the wiper blade from the U-shapedend of the wiper ann. Installation is a reversalof the removal procedure ensuringthat 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 assembly from the wiper blade. NOTE: It is advisableto instal a new rubber and spine as an assembly to ensure correct contact between the rubber and the windscreen. (3) Slide the new rubber and spine into the wiper blade ensuringthat the spine entersall the lugs on the blade and that the retaining clip locks into the wiper blade. (4) Instal the wiper blade to the wiper ann. View of the wiper motor and linkage assembly with the plenum chamber water deflector removed. (gl Manoeuvre the wiper assemblyand linkage out from the plenum chamber. (9) The wiper motor may now be removed from the linkage and servicedas necessary. Installation is a reversalof the removal procedure with attention to the following points: (l) Tighten the wiper pivor assemblybolts to the specifiedtorque. (2) Ensure that the wiper arms are installed to the correct dimension as previously described. TAILGATE WIPER MOTOR AND ARM To Removeand Instal Wiper Btade and Rubber The removal and installation procedure for the tailgate wiper blade and rubber is very similar to the windscreen wiper blade and rubber except that the blade is located to the arm with a snap in shaft. To Removeand 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 damagethe paintwork. Installation is a reversalof the removal procedure
228
Electrical System
18. FUSES, FUSIBLE TINKS AI{D BEIAYS
ensuringthat the wiper blade is approximately 22 mm from the glassweatherstrip in the park position. To Removeand Instal Wiper Motor ( I ) Remove the wiper arm as previously described. (2) Remove the cap hexagon nut, washer and spacerfrom 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 the panelsto gain access to the hidden triJn retainers. (5) Remove the retainers and carefully peel the edges of the trim away from the tailgate.The edges are retained with glue. (6) Remove the tailgate trim completely and place to one side ensuring that dirt etc is not allowed to contact the glue,
TO CHECK AND RENEW A FUSE NOTE: If a fuse is found to be faulty or burnt out, use a replacement fuse of the specified amperage only. The spectfied amperageis marked on thefuse. The use of a higher amperagefuse than that specified could cause damage to the vehicle wiring harness.
Turn the retaining clips 9O degrees and open the fuse cover to gain access to the interior fuses, relays and the flasher unit.
Installedview of the rear wiper motor. (7) Disconnect the wiring connector from the wiper motor. (8) Remove the bolts retaining the wiper motor to the tailgate and withdraw the wiper motor, washer and spacerrubber. Installation is a reversalof the removal procedure with attention to the following points: (l) Ensure that the wiper motor earth lead terminal is lobated under one of the retaining bolts. (2) Test the oBerationof the wiper motor before installing the tailgate trirn.
17.
HEATER BLOWER MOTOR
TO REMOVE AND INSTAL The removal and installation proceduresfor the heater blower motor is described in the Cooling and Heating Systemssection.
View of the fuse cover label. The letters and number correspond to those marked on the fuses and relays.
Electri,cal System
The fuses are mounted in a fuse box located below and slightly to the right of the steringeolumn and under the bonnet in the engine compartment. (l) Turn the fuse cover retainers 90 degrees, open the fusecover and using the information marked on the cover, locate the fuse protecting the circuit at fault. (2) Pull the fuseout of the fusebox and inspectit for serviceability. (3) Should the fuse appearto be in a serviceable condition, test its iontinuity with an ohmmeter or test lamp. (4) Should the fuse appear to be faulty or burnt out, 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 automotive electrician or an authorised dealer. TO CHECK AND RENEW FUSIBLE LINKS NOTE: If a fusible link is found to befaulty or burnt out, use a genuine replacement fusible link of the specifiedamperage only. The use of a higher amperagefusible link than that specifiedcould cause damage to the vehicle wiring harness. A new fusible link should not be installed until the fault which cqused the original link to fail has been repaired. (l) Release the retaining clips and open the fusible link cover. (2) Inspect the condition of the fusible link through the window in the top. (3) To disconnect all fusible links except the main one pull the fusible links out of the holder.
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(4) To renew the main fusible link proceed as follows: (a) Disconnect the negativebattery terminal. (b) Remove the screwsretaining the fusible link assembly and raise the assembly upwards to gain to the fusible link terminal bolts. access (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 the removal procedure. (5) Should the fusible link appar to be in a serviceable condition, test its continuity using an ohmmeter or a powered test lamp. (6) If the fusible link is faulty, instal a new fusible link and checkthe circuit for correct operation. RELAY LOCATIONS The various relaysernployedin the vehicle electrical system are located adjacent to the battery in the enginecompartment and in the fuse box below and to the right of the steeringcolumn. The engine compartment relays power the electronic control unit (ECU), air conditioning compressor, horn, fuel put'np, engine fan, starting, low beam,high beam,warning checklamp, anti-theft horn and fog lamp circuits. The interior fuse box relays power the ignition system,heated rear window, blower fan and the turn signal circuits. Not all vehicles are equipped with all relays becauseof different equipment levels. To renew a relay, pull the relay out of its socket. When installing a relay, ensure that the relay terminals are making good electrical contact. 19. TRAILER WIRING There are several brands of trailer wiring connectorswith a variety of pin configurations.The most common is the sevenpin type which provides for two auxiliary circuits, usually used for reverselamps and electric trailer brakes.
FOR CONNECTING UTILUX SOCKET TO BRYLITE PLUG
FOR CONNECTTNGFIVE PIN UTILUX SOCKET TO SIX PIN UTILUX PLUG
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 - revised to 3O amp, 4 : Low beam headlamp relay fuse - 15 amp, 5 : High beam headlamp relay fuse - 25 amp.
Useful connections which can be used if the trailer to be towed is equipped with a different type plug to the towing vehicle socket.
230
Electrical S^tstem
When installing a trailer socket,it may be necessary to replacethe original vehicle flasherunit with a heavy duty unit to maintain the flash rate in accordance with local regulations. Local regulations may also require the installation of a dashboardmounted repeaterlamp. Should the trailer socketand plug not be matched, adaptors can be made or obtained to facilitate connection.
TO INSTAL'TRAILER SOCKET The minimum material required are a trailer socket, mounting bracket, seven core flex, insulated wiring connectorsand a rubber grommet. (l) Disconnect the negativebattery terminal. NOTE: Refer to the note under the Battery heading in this section prior to disconnecting the battery.. (2) Locatethe wiring harnessfor the lamps at the rear of the vehicle. (3) Identify the wires for the right turn signal lamp, left turn signal lamp, tail lamp, stop lamp, reverselamp and earth. Use the vehicle wiring diagram in this section to determine the wire colour for each lamp circuit. (4) Connect the seven core flex to the various lamp wires using insulated connectors. For sevenpin socketsand plugs, usethe following standard trailer wiring code: Terminal No. I 2 3 4 5 6 7 Circuit Left turn signal lamp Reversinglamp Earth Right turn signal lamp Electric brakes Stop lamp Tail lamp Colour Yellow Black White Green Blue Red Brown Minimum material needed for installing a trailer socket and plug. Utilux trailer socketand plug shown. (5) Drill a suitablesizedhole through the vehicle floor and instal a rubber grommet to the hole. NOTE: Before drilting the hole, check whether there is an existing hole whic'hmay be used. Ensure th;at a rubber grommet is installed to prevent chafing of the wires. (6) Passthe seven core flex through the rubber grommet. (7) Cut the sevencore flex to the reqruired length and slide the dust cover onto the flex. (8) Remove approximately l5 mm o,finsulation from each wire in the flex. (9) Connect the wires of the seven core flex to the terminals of the socket,using the standardwiring code and following the socket manufacturersconnection procedure. (10) Assemble the socket and instal the dust cover to the rear of the socket. (11) Instal the mounting bracket ,as close as possible to the tow bar ball and high enough to maintain vehicle ground clearance. (12) Instal the socketto the mounting bracket. (13) Connect a trailer plug to the socketand test for correct lamp operation. TO INSTAL TRAILER PLUG The minimum materials required are a trailer plug, sevencore flex and insulated wiring connectors. The installation procedure for the trailer plug is
For six pin socketsand plugs, use the following standard trailer wiring code: Terminal No. Circuit I Tail lamp 2 Left turn signal lamp Right turn signal lamp 3 4 Stop lamp Auxiliary circuit 5 Earth 6 For five pin socketsand plugs, use the standard trailer wiring code: Terminal No. Colour Brown Yellow Green Red Blue White following Colour Yellow White Green Red Brown
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Circuit Left turn signal lamp Earth Right turn signal lamp Stop lamp Tail lamp
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The Brylite seven pin trailer plug and socket.
Electrical S'tstem
simllar to that for ttre socket with attention to the following pqints: ( 1) Connect the trailer wiring to the plug according to the standard wiring colour code and the plug manufacturers instructions. Use a suitable length of seven core flex and insulated connectors should the trailer wiring not be long enough. (2) trf the trailer wiring does not conform to the standard colour code, identify eachcircuit as follows: (a) Locate the trailer earth wire. 20.
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terminal of a 12 volt battery to the earth wire. (c) Connect a jumper lead to the positive terminal of a 12 volt battery and connect each of the trailer lamp wires in turn to the positive battery terminal jumper lead, noting the colour of the wire and the lamp circuit operated. (3) After installation, connect the trailer plug to the socket on the vehicle and check for correct lamp operation.
(b) Connecta lumper tead ftom the negative
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harness 7 pin socket - Bosch, Hella, Utilux 7 pin plug - Bosch, Hella, Utilux TrailerRHtumsignal lamp Trailer tail lamp
6 . Trailer stop lamp 7 . Trailer reverse lamp 8. T r a i l e r L H t u r n s i g n a l lamp 9 . 6 pin socket - Utilux 1 0 . 5 pin socket - Bosch, Hella 11. 7 pin socket - Brylite 12. Trailer electric brakes
232
Electrical System
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Wiring diagram for the starting, charging, engine cooling, air conditioning, heating, crube contrr and radio cassette. Wire colours in brackets indicate models from October 1989.
COLOURCODE The first letter of the code represents the main wire colour, the other letters represent the trace colours. B - BLACK L - BLUE G - GREEN R . R E D Y - YELLOW W - WHITE N - BROWN O - ORANGE K - PINK S - GREY V - VIOLET P - PURPLE X - LIGHTGREEN Z - LIGHT BLUE M - DARKGREEN T - DARKBLUE A - LIGHTBROWN E - SLATE D- TAN KEY 1. Fusible link - main 60 AMP 2. Fusible link - alternator 30 AMP 3. Battery 4. To flasher relay 5. To radio/cassette 6. Radio suppressor 7. Ahernator g. To ahernator warning lamp 9. Starter motor 10. Starter relay 11. lgnition switch 12. lgnition relay 13. To brake fail warning switch 14. Warning lamp check relay 15. Neutral safety switch (automatic transmissionl 16. To EFI control unit 17. To cigarette lighter 18. To rear demister switch 19. Fuse No 23 - engine cooling fan relay 30 AMP 20. Engine cooling fan relay 21.To EFI control unit 22. Auxiliary cooling fan (V8 with air conditioningl 23. Engine cooling fan (V6l 24. Air conditioner compressor clutch 25. Air conditioner compressor relay 26. To EFIcontrol unit 27. To EFIcontrol unit 28. Air conditioner high pressure switch 29. Air conditioner low pressure switch 30. Air conditioner evaporator switch 31. Air conditioner switch 32. Fuse No 8 - blower fan, air conditioner, rear demister relay 25 AMP 33. Heater blower motor switch 34. Heater blower motor resistorc 35. Heater blower motor 36. Heater blower motor relay 37. To anti-theft module 38. Fusible link - heater blower motor 30 AMP 39. To fuse No 10 40. Gruise control module 41. To cruise control sngage indicator lamp 412.To trip computer tlil. Cruise control brake switch tl4. Cruise control brake switch 45. Cruise control switch 46. To fuse No 7 47. Fuse No 13 - radio, power antenna module 5 AMP (pre Oetober 19891 10 AMP (Oetober 1989 onl tl8. To fuse No 1 49. To earth 50. Radio/casset.te 5l.LHfrontspeaker 52.RHfrontspeaker 53.LHrearspeaker 54.RHrearspeaker 55. To fuse No 3 56. Power antenna module 57. Fuse - powcr antenna motor 6 AIIP {some modelsl 58. Power antenna motor 59. Power antenna switch dl. Main wiring harness earth 61. Gruise control and rear wiper switch illumination lamps 62. Circuit applicable to models from November 1989 without a power antenna module
Electri,cal System
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Wiring diagram for the engine management system. Pre Ostober 1989 models.
COLOURCODE The first letter of the mde represents the main wire colour, the other letters represent the trace colourc. B - BI.ACK L - BLUE G - GREEN RRED Y - YELLOW W - WHITE N - BROWN O - ORANGE K - PINK S - GREY V . VIOLET P - PURPLE X - LIGHTGREEN Z - LIGHT BLUE M - DARKGREEN T - DARKBLUE A - LIGHTBROWN E - SLATE D - T A N KEY 1. To fuse No 12 2. Overdrive switch (automatic transmission) 3. Oil temperature svvitch {automatic transmissionl 4. Transmission lock-up solenoid {automatic transmissionl 5. Fuel pump - internal 6. Fuel pump - external llong range fuel tankl 7. MAT sensol 8. MAP sgnsor 9. EFI control unit 10. To check engine waming lamp 11. To EFI control unit refer No 38 12. Diagnostic link conneetor 13. Fuse No 21 -fuel pump relay 15 AMP ltl. Oil pressure switch 15. Fuel pump relay 16. EFI relay 17. Fusible link - ENG.INJ 30 AMP 18. To engine cooling fan relay 19. Fuel iniector No 1 20. Fuel iniector No 2 21. Fuel injector l\&o3 22.Fuel iniestor No 4 23. Fuel injector ilo 5 24. Fueliniector No 6 25. Fuel injector l{o 7 lV8 only} 26. Fuel injector No 8lV8 onlyl 27. Throttle position sensor 28. Coolant tomperature sensor 29. Detonation gensor (VGonlyl 30. Oxygen sensor 31. To starter relay 32. To air conditioner compressor clutch relay 33. To air conditioner compressor clutch relay 34. To brake fail warning lamp 35. To trip computer 36. To trip computer 37. ldle air controlvalve 38. To diagnostic link connector - refer No 11 39. To anti-theft module 40. Anti-theft override switch 41. To anti-theft module tP. Tachometer signal wire rti}. Fusible link ENG.COMP 30 AMP 44. Fuse No 11 - ignition system lOAMP 45. To tachometer t[6. Crankshaft sensor 47. lgnition control module 48. EFI control unit 49. lgnition control module 50. To tachometer 51. Hall Effect device 52. Radio suppressor 53. lgnition coil 54. Distributor 55. Tachomcter signal wire 56. Main wiring harneas earth
234
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COLOURCODE The first letter of the code represents the main wire colour, the other letterc represelil the trace colours. B L G RY W N O. K S . V P _ X Z M T A E DBLACK BLUE GREEN RED YELLOW WHITE BROWN ORANGE PINK GREY VIOLET PURPLE LIGHTGREEN LIGHT BLUE DARKGREEN DARKBLUE LIGHTBROWN SLATE TAN KEY 1. To fuse No 12 2. Overdrive switch (automatactransmissionl 3. Oil temperature switch (automatic transmission I 4. Transmission lockup solenoid {automatic transmission) 5. Fuel pump - internal 6. Fuel pump - external 7. MAT sensor 8. MAP sensor 9. EFI control unit 10. To check engine warning lamp 11. To EFIcontrol unit refer No 38 12. Diagnostic link connector 13. Fuse No 21 - fuel pump relay 15 AMP 14. Oil pressure switch 15. Fuel pump relay 16. EFIrelay 17. Fusiblelink - ENGINE 30 AMP 18. To engine cooling fan relay 19. Fuelinjector No 1 20. Fuelinjector No 2 21. Fuelinjector No 3 22. Fuel injector No 4 23. Fuel injector No 5 24. Fuel iniector No 6 25. Fuel injector No 7 (VB only) 26. Fuelinjector No 8 (V8 onlyl 27. Throttle position sensor'... 28. Coolant temperature sensol 29. Detonation sensor (VGonlyl 30. Oxygen sensor 31. To starter relay 32. To air conditioner compre*sor clutch relay 33. To air conditioner compressor clutch relay 34. To brake fail warning lamp 35. To trip computer 36. To trip computer 37. ldle air control valve 38. To diagnostic link connector ,- refer No 11 39. To anti-theft module 40. Anta-theft override switch 41. To anti-theft module 42. Tachometer signal wire t|i|. To instrument cluster (trip computer) 44. Fuse No 9 - ignition system, instruments 7.5 AMP 45. To tachometer 46. Crankshaftsensor 47. lgnition control module 48. EFlcontrol unit t[9. lgnition control module 50. To tachometer 51. Hall Effect device 52. Radio suppressor 53. lgnition coil 54. Distributor 55. Tachometer signal wire 56. Main wiring harness earth 57. To anti-theft module 58. To fuel pump relay and fuse 21 59. To instrunrent cluster
Electrical System
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Wiring diagram for the interior lamp+ parking lamps, stop and tail lamps, headlamps,reverselaml and turn signal lamps. Wire colours in brackets indicate models from October 1989.
KEY 1. Luggage compartment lamp (Sedanl 2. Luggage compartment lamp switch (Sedanl 3. Luggage compartment lamp switch (Station Wagonl 4. Luggage compartment lamp (Station Wagon) 5. Fuse No t[ - interior, luggage compartment and stop lamps 20 AMP {pre Oetober 1989} interior and luggage compartment lamPs 10 AMP {October 1989 onl 6. L H rear courtesy lamp 7. L H rear courtesy lamp switch 8. R H rear courtesy lamp 9. R H rear courtesy lamp switch 10. L H map lamp switch ll.LHmaplamp 12. R H map lamp switch 13.RHmaplamp Itl. Courtesy lamp 15. To courtesy lamp switch 16. R H Gourtesylamp door switches 17. L H courtesy lamp door switches 18. To power window module 19. Glove c-ompartment lamp switch 20. Glove compartment lamp 21.To lights on warning lamp, instrument and switch illumination lamps 22. Automatic transmission indicator lamp 23.f o cigarette lighter lamp 24.To cruise control and power antenna switch lamps 25. Fog lamp switch lamp 26. Rear washer switch lamp 27. Rear wiper switch lamp 28. Fuse No 7 - instrument illumination lamps 5 AMP 29. Air conditioner switch lamp 30. Heater control illumination lamp 31. L H front parking lamp 32. R H front parking lamp 33. High mounted stop lamp 34. To fuel gauge sender unit and rear washer motor 35. Fuse No 1 -parking and instrument, illumination lamps, trip Gomputer, radio 15 AMP 36. To radio/cassette, trip computer and high beam indicator lamp 37. Headlamp switch 38. Stop lamp switch 39. Stop and tail lamp (Sedan onlyl tl{).Stop and tail lamp 41. Number plate lamp (Station Wagon and Utilityl 42.To rear wiper motor 4il. Number plate lamp (Sedanl 44. High beam switch 45. To fog lamp indicator lamp tl6. Fog lamp switch 47. Fog lamp relay 48. Headlamp relay 49. Fusible link - headlamps 30 AMP (Pre October 19891 t10AMP (October 1989 on) 50. Fuse No 18 - headlamp relay 1 5A M P 51. Fuse No 19 - high beam relay 25 AMP 52. High beam relay 53. To high beam indicator lamp 54. Fog lamp 55. Fog lamp 55. To parking lamps 57. L H headlamp 58. L H high beam lamp 59. R H high beam lamp 60. R H headlamp 6l.LHreverselamp 62.RHrevercelamp Gf. To reverse indicator lamp 64. Reverse lamp switch (automatic transmission ) 65. Reverce lamp switch (manual transmissionl 66. To transmission lockup solenoid (automatic transmissionl 67. To vehicle speed sensor 68. Fuse No 12 - automatic transmission, reverse lamps, vehicle speed sensor 10 AMP 69. Fuse No 2.- hazard lamps, turn signal lamps, anti-theft system 20 AMP 70. To anti-theft module, antitheft horn relay and luggage compartment lock switch 71. Fuse No 14 - wipers, turn signal lamps, hazard lamps 15 AMP 72.To wiper switch and motor 73. Hazard lamp switch 74. Flasherrelay 75. To anti-theft module and L H turn signal indicator 76. To earth 77. Turn signal switch 78. L H front turn signal lamp 79. Vacant connector 80. L H rear turn signal lamp 81. R H rear turn signal lamp 82.To anti-theft module and R H turn signal indicator 83. R H front turn signal lamp 84. Main wiring harness earth 85. To anti-theft module 86. lgnition lock illumination lamp 87. To anti-theft module 88. Fuse No 16 - stop lamps 15 AMP {October 1989 onl
236
Electrical System
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Wiring diagram for the rear demister, front and rear wipers, instruments, instrument illumination r trip computer. Wire colours in brackets indicate models from Oetober 1989.
KEY 1. Fuse No 3 - rear demister, power antenna 25 AMP 2. To power antenna module 3. To fuse No 9 4. Rear demister relay 5. To rear demister nrarning lamp 6. Rear demister 7. Neutral safety switch (automatic transmissionl 8. To automatic transmission indicator lamp 9. Cigarette lighter 10. Gigarette lighter lamp 11. To fuse No 7 12. Fuse No 15 - cigarette lighter, rear wiper and washer 20 AMP 13. Rear wiper switch 14. Rear wiper motor 15. Rear washer motor 16. To earth 17. Rear washer switch 18. To Gourtsylamp door switch 19. Warning lamp check relay 20. Rear demister switeh 21. Gourtesy lamp switch 22. Dimmerswitch 23. Ingtrument illumination resistor 24. Windscreen washer switch 25. Windscreen wiper switch 26. Trip computer switch 27.Tsig computer switch lamp 28. Rear demister and power ' antenna switch lamp 29. Electronic module 30. To fuse No 14 31. Windshield wiper motor/rear wiper motol 32. Windshield washer motor 33. To earth 34. To fuse l\l,o 12 35. Vehicle speed sensor 36. To earth 37. To earth 38. Fuel gauge sender unit 39. To cruise control module 40. To fuge No 1 41. To EFI control unit 42. lnstrument cluster (3. Trip computer 44. Trip computer display lamp 45. Fuel gauge t16.Speedometer 47. Tachometer tl8. Temperature gauge 49. Instrument cluster lamps 50. High beam indicator lamp 51. Gruise control engage indicator lamp 52. Rear demister indicator lamp 53. Fog lamp indicator lamp 54. Lights On indicator lamp 55. Ahernator warning lamp 56. Reverce indicator lamp (Pre October 1989); Engine disabled warning lamp (Ostober 198!l onl 57. L H turn signal indicator lamp 58. R H turn signal indicator lamp 59. Brake failure warning lamp 60. Check Engine warning lamp 61. Oil pressure warning lamp 62. Park brake warning lamp 6il. Coolant temperature warning lamp 64. Overcpeed warning lamp 65. To fuse l\lo 7 66. To high beam relay 67. To cruise control module 68. To rear demister relay 69. To fog lamp switch 70. To alternator 71. To revGrse lamp switch (Pre october 19891; To anti-theft module and trip computer (Ostober 19&l onl 72.To turn signal switch 73. To warning lamp check relay 74. Brake fail warning switch 75. To EFI control unit 76. Oil pressure switch 77. Park brake warning lamp switch 78. To EFIcontrol unit 79. To earth 80. Temperature gauge sender 81. To ignition control module 82. To EFI control unit IXl. To rear demister relay and EFI relay 8t[. Fuse No f - inst]ument warning lamps 5 AMP (Pre october 198917.5AMP (October 1989on| 85. Main wiring harness earth 86- To engine disabled warning lamp {anti-theft systeml 87. Lowfuel warning lamp 88. Vohage rogulator
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Electrical System
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KEY 1. To electric door lock switch LHfront 2. L H front power window switch 3. L H front power window motor 4. L H rear power window motor 5. L H rear power window switch 6. R H front power window switch 7. R H rear power window switch 8. R H rear power window motor 9. Circuit breaker 10. Powerwindow module 11. To courtesy lamp door switch 12. R H front power window motol 13. Luggage @mpartment lock solenoid 14. Luggage compaftment lock solenoidswitch 15. To fuse ilo 2 16. Fuse ib 10 - cruisa control, electrh mirrors, power windows, eleqtric door locks 10 AMP 17. To eruise control ngage switch 18. Eleetric mirror switah 19. L H electric miror horizontal motor 20. L H electric mirror * vertical motor 21. R H electric mirror horizontal motor 22. RH electrh mirror vertical motol 23.To powgr window switch 24. Elecrie door lock switch L H front 25. Door lock anti-theft switch 26. Fuse lUo 6 - electric door locks 15 AMP 27. Eleqtricdoor lock module 28. L H front door lock switch 29. L H front electric door lock 30. R H front door loc* switch 31. R H front electric door lock 32. L H rear electrie door lock 33. R H rear electric door lock 34. Anti-theft override switch 35. Anti-theft bonnet switch 36. To R H turn signal lamPs 37. To L H turn signal lamps 38. To fusible link - heater blower motol 39. To anti-theft override switch 40. To fuse No 2 41. Fuse t[o 22 - hom 15 AMP t12.Anti-theft horn relay rlil. Horn relay 44. Anta-theft horn diode 45. Horn contact 46. Anti-theft hom tl7. Horn 48. Horn . Main wirlng hamess earth 50. Anti-theft module
Wiring diagram for the po{rer windows and elestric mirrors on all models and t{re electric door loc Wire coldurs in brackets ind-rcatr anti:thedsJstem and homs on all models prior to kober 1!189. models from October l$f.
COLOUR CODE The first letter of the eode represents the main wire colour, the other letters reprsgnt the trace colourS. B . L G RY W. N O K . S BLACK BLUE GREEN RED YELLO]'I' WHITE BROWN ORANGE PINK GREY PURPLE LIGHTGREEN LIGHT BLUE DARKGREEN DARKBLUE LIGHTBROWN SLATE TAN
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Wring diagram for the anti-theft system, elestric door locks and horns. Models from October lgg:f
COLOURCODE The first letter of the code represents the main wire colour, the other letterc represent the trace colours. B - BLAGK L . BLUE G - GREEN RRED Y - YELLOW W WHITE N - BROWN O ORANGE K - PINK S - GREY V - VIOLET P - PURPLE X - LIGHTGREEN Z - LIGHT BLUE M - DARKGREEN T - DARKBLUE A - LIGHTBROWN E . SLATE D. TAN KEY 1. Fuse No 6 - electric door locks 15 AMP 2. To rear companment lock solenoid switch 3. To anti-theft ultrasonics connector - main wiring harness 4. To anti-theft ultrasonics connector - main wiring harness 5. To anti-theft ultrasonics connegtor - main wiring harness 6. To fuse No 14 7. To anti-theft override switch 8. To anti-theft override switch 9. To front courtesy lamp switch 10. To fuse No 2 11. To rear compartment lamp switch 12.To front courtesy lamp switch 13. To EFI control unit 14. To trip computer module 15. To engine disabled warning lamp 16. Fuse No22- horn 15 AMP 17. To turn signal switch 18. Anti-theft LED indicator 19. Anti-theft module 20. Door lock module 21. L H front electric door lock key switch 22. RH front electric door lock key switch 23. L H front elestric door lock motor 24. R H front electric door lock motol 25. L H rear electric door lock motor 26. R H rear electric door lock motor 27. Anti-theft bonnet switch 28. Anta-theft override switch 29. Anti-theft horn relay 30. Horn relay 31. Horn contact 32. Anti-theft horn 33. Horn, low note 34. Horn, high note 35. To fuse No 21 36. Anti-theft horn diode 37. Main wiring harness earth 38. To fuse No 10
Electri,cal System
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Wiring diagram for the electronic climate oontrol system.

COLOURCODE The first letter of the code represents the main wire colour, the other letters represent the trace colours. B - BLACK L - BLUE G . GREEN R - R E D Y - YELLOW W - WHITE N - BROWN O. ORANGE K - PINK S GREY KEY 1. Fuse No 23 - engine cooling fan 30 AMP 2. Engine cooling fan relay 3. A/C auxiliary fan 4. AIC low pressure sritch 5. A/C high pressure switch 6. A/C relay 7. AlCcompreslxrl 8. Fuse No 8 - air conditioning 10 AMP 9. Fusible link - heater blower motor 30 AMP 10. Heater blower motor 11. Heater blower motor relay 12. Heater blower motor switch 13. Fuse No 17 - climate control 5 AMP 14. Vacuum solenoid pack 15. Climate control module 16. Air mix motor 17. Thermosensor 18. Air temperature sensor 19. A/C evaporator inlet control switch 20. lntake air temperature sensor 21. Ambient air temperature sensor 22. Solar sensor 23. To radio amplifier 24.To fuse No 7 25. To fuse No 1 26. To EFlcontrol unit 27.To ignition relay 28. Main wiring harness earth
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P X Z M T A E D
PURPLE LIGHTGREEN LIGHT BLUE DARKGREEN DARKBLUE LIGHTBROWN SI.ATE A N
240
BODY
I.
WINDSCREEN AI{D REAR GI.ASS
The renewal or replacement of the windscreen and the rear glassfollows the same basic procedure. The successfulfitting and sealing of the windscreenor rear glasswill dependto a largeextent on the technical knowledge and experience of the operator and it is not recommended that rear glass or windscreen replacement be attempted by anyone lacking previous experience. 2. FROhIT DOORS Removal tool
Special Equipment Required: To RemoveSnipper Button -
INTERIOR HANDLES AND TRIM PANEL To Removeand Instal (1) On vehicles equipped with power windows or electric mirrors disconnect the negative battery terminal. (2) On vehicles not equipped with power windows, lever back the regulator handle and using a suitable wire hook, withdraw the handle retaining clip, then remove the handle and washer. Alternatively, slide a piece of sturdy cloth under the handle and pull on each corner to release the retaining clip. (3) Prise the cover from the armrest handle and remove the securing screws.
(4) Remove the handle from the door trim and where applicable, disconnect the electric exterior mirror wiring. (5) On vehicles equipped with manual exterior . mirrors, remove the plug from the control knob. Open the tabs on the control knob and carefully pull the knob offthe shaft. (6) Remove the screw from the mirror inner cover. Carefully pull the cover away from the door and move it rearward to remove the cover from the vehicle. (7) Fabricate a special tool to the dimensions shown in the illustration. Insert the tool down the left hand side of the snipper button and locate it behind the orangeinsert. Pull the tool sharply to disengagethe insert from the snipper button. Slide the snipper button up off the control rod. (8) Remove the screw retaining the snipper button escutcheonand remove the escutcheon. (9) Using a flat bladed screwdriver, carefully disengage the trim panel retaining clips from the door. Starting at the lower rear corner, work acrossthen up
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3mm WIRE
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Line drawing of the snipper button removing tool.
Snipper button removed from the vehicle showing the insert disengaged.
Body
both sides alternately. Remove the trim panel from the door. (10) Carefully peel the plastic sealingpanel away from the door while cutting the sealantusing a sharp knife. Remove the plastic sealing panel from the vehicle. Installation is a reversalof the removal procedure with attention to the following points: (l) Use a suitable sealant to adhere the plastic sealingpanel to the door. (2) Instal the trim panel to the door, carefully locating the trim panel clips in the door.
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(5) Raise the rear upper corner of the window glassand remove the window glassthrough the glass openingat the top of the door. Installation is a reversalof the removal procedure with attention to the following points: (1) Ensurethat the window glassis locatedin the run channels and correctly aligned. Adjust the position of the pivot plate retaining bolts in the slotted holes to align the window assembly in a parallel attitude. (2) Instal the trim panel as previously described. WINDOW REGULATOR To Removeand Instal ( I ) Remove the trim panel and plastic sealing panel as previously described. (2) Remove the window glassas previously described and on power operated window models, disconnectthe regulator wiring connector. (3) Using an electric drill remove the rivets retaining the regulator to the door. Disengagethe regulator from the pivot plate and remove the regulator through the lower aperture in the door. Installation is a reversalof the removal procedure with attention to the following points: NOTE: If installing new nylon sliders to the support and regulator arms, ensurethat the sliders are soaked in hot water for a minimum of two minutes prior to installation. ( I ) Lubricate the regulator friction surfacesand associatedparts with lithium grease. (2) Instal the regulator to the door and attach using suitable screws.
View of the front door with the trim panel and plastic sealing panel removed. (3) Instal the window regulator handle escutcheon, handle and cllp to tfrg door ensuring that the handle apd gl4ssare'posilioped as o$ the opposite door. NOTE: The regulator handle retaining clips should be placed on the handle before installing the handle to the regulator. WINDOW GLASS To Removeand 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 bladed screwdriver,carefully prise the inner window moulding from the door, working from the rear end of the moulding. (3) Support the window glass and remove the pivot plate retaining bolts. (4) Manoeuvre the window glass to disengage the window lift channelsfrom the regulator arms.
Front
door window
regulator and window components.
glass
242
Body
panel as previously described. (2) On vehiclesequipped with electrically operated door locks, remove the actuator retaining screws and disconnectthe control rod from the lock. (3) Remove the lock security shield retaining screw and by pushing the shield upwards, remove it from the door cavity. (4) Disconnectthe lock cylinder control rod, the snipper button control rod and the remote control rod by releasingthe retaining clips. (5) Remove the lock retaining screwsfrom the door and remove the lock through the door aperture. (6) If necessary, remove the remote control by disengaging the control rod from the guide and lifting the rear section from the door. Slide the remote control assemblyrearwardS:and remove the assembly
(3) On power operated window models, instal the regulator wiring connector. (4) Instal the window glass as previously described. EXTERIOR DOOR HANDLE To Removeand Instal (l) Remove the trim panel and plastic sealing panel as previously described. (2) Remove the lock security shield retaining screw and by pushing the shield upwards, remove it from the door cavity. (3) Disconnect the lock cylinder control rod from the door lock by releasingthe retainer clip. (4) Withdraw the slide clip from the rear of the exterior door handle. (5) Manoeuvre the handle section from the escutcheon from inside the door, then remove the escutcheon and seal from the door. Installation is a reversalof the removal procedure with attention to the following points: (l) Tilt the top of the escutcheonaway from the door to assistwith installation of the handle section. (2) Ensure that the escutcheon and seal are correctly installed prior to installing the slide clip. REMOTE CONTROL AND DOOR LOCK To Removeand Instal (l) Remove the trim panel and plastic sealing
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with attention to the following points: (1) Ensure that the control rods are correctly installed. (2) If equipped, instal and connectthe door lock actuator. (3) Ensure that the door lock controls and the exterior handle operatecorrectly prior to installing the trim panel. NOTE: Tighten the lock retaining screwsto 3-5 Nm. Do not exceed this torque setting or damage to the door loclcswill result. /
,, ur.r,.rsal procedure of theremoval
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Dismantled view of the front door lock and remote control components. tt is important not to overtighten the t lock retaining screws or damage to the door locks will resutt.
Body
LO,CXCYLINDER To Removeand Instal ( I ) Remove the trim panel and plastic sealing panel as previously described. (2) Remove the exterior door handle as previously described. (3) Withdraw the retaining clip from the escutcheon and remove the lock cylinder. Installation is a reversalof the removal procedure with attention to the following point: Powdered graphite is the only lubricant recommendedfor 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 pillar according to the pencil marks made on removal. (4) Close the door and observe the alignment with the rear door. If incorrect, loosenthe striker plate retaining screwsand move the striker plate in or out to achievea flush fit. If the door lifts or drops when the lock engages the striker plate, loosen the screwsand move the striker plate up or down to eliminate the problem. NOTE: After each adjustment tighten the striker plate screws and check the adjustment. Readjust as necessary. EXTERIOR MIRROR
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To Removeand Instal ( I ) On vehicles equipped with manual exterior mirrors, remove the plug from the control knob. Open the tabs on the control knob and carefully pull the knob off the shaft. (2) On vehicles equipped with electric exterior mirrors, remove the trim panel and plastic sealing panel. Disconnect the negative battery terminal and the mirror door wiring. (3) Remove the screw from the mirror inner cover. Carefully pull the cover away from the door and move it rearwards. Remove the cover from the vehicle. (4) Remove the screws retaining the mirror to the door and remove the mirror from the vehicle. Installation is a reversalof the removal procedure with attention to the following point: If applicable, connect the negative battery terminal and start the engine,increasethe speedto 3 000 rpm for 10 secondsto allow the idle air control valve to reset. On vehicles equipped with a radio/cassette using PIN security, enter the PIN code as described under the radio/cassette heading in the Electrical Svstemsection.
Dismantled view of a manual exterior mirror and associatedcomponents. 3. REAR DOORS Removal tool
Special Equipment Required: To RemoveSnipper Buffon -
INTERIOR HANDLES AND TRIM PANEL To Removeand Instal ( I ) On vehicles equipped with power windows, disconnectthe negativebattery terminal. (2) On vehicles not equipped with Bower windows, lever back the regulator handle and using a suitable wire hook, withdraw the handle retaining clip, then remove the handle and washer. Alternatively, slide a piece of sturdy cloth under the handle and pull on each corner to release the retaining clip. (3) Prise the cover from the armrest handle and remove the securingscrews.Remove the handle from the vehicle.
lnstalled view of the front door lock striker.
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security, enter the PIN code as dessribed under the radio/cassette heading in the Electrical System section. WINDOW GLASS AND FIXED GLASS To Removeand Instal ( 1) 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 bladed screwdriver, carefully prise the inner and outer window mouldings from the door, working from the rear end of the mouldings. (3) Remove the rear section of the run channel rubber and remove the screwsretaining the rear run channel to the door. (4) Remove the rear run channel from the fixed window rubber. (5) Carefully move the window glassrearwards to disengagethe window glass frorn the regulator. Remove the window glassthrough the opening at the top of the door. by pris. (6) ,If necesssry,remove the fixed gnass ing the fixed glassrubber from the uppei door-frbme and sliding forwards.
View of the rear door with the trim panel and plastic sealing panel removed. (4) Fabricate a special tool to the dimensions shown in the illustration under the Front Doors heading. Insert the tool down the left hand side of the snipper button and locate it behind the orangeinsert. Pull the tool sharply to disengage the insert hom the snipper button. Slide the snipper button up off the control rod. (5) Remove the screw retaining the snipper button escutcheon and remove the escutcheon. (6) Using a flat bladed screwdriver, carefully disengage the trim panel retaining clips from the dooi. Starting at the lower rear corner, work acrossthen up loth sides alternately. Remove the trim pangl from the door. (7) Carefully peel the plastic sealingpanel away from the door while cutting the sealantusing a sharp knife. Remove the plastic sealingpanel from itre dooi. Installation is a reversalof the removal procedure with attention to the following points: (tl Use a suitable sealant to adhere the plastic sealingpanel to the door. (2) Instal the trim panel to the door, carefully locating the trim panel clips in the door. (3) Instal the window regulator handle escutcheon, handle and clip to the door, ensuring thpt the handle and glass are positioned as on ttre=oppoqite door. NOTE: The regulator handle retaining clip should be placed on the handle befoie iistalling the handle to the regulator.(4) Connect the negative battery terminal and start the engine, increasethe speedto 3 000 rpm for l0 secondsto allow the idle air control valve to reset. On vehiclesequipped with a radio/cassette using pIN
II'INDOW GLASS
Rear door window
regulator and window components.
glass
Body
Installation is a reversal of the removal procedure with attention to the following points: (l) Ensure that the fixed glass and rubber are correctly installed to the door frame. (2) Ensure that the inner and outer window mouldings are coffectly located prior to tapping them into place. (3) Check the window glass operation prior to installation of the plastic sealingpanel and trim panel. WINDOW REGULATOR To Removeand Instal ( I ) Remove the trim panel and plastic sealing panel as previously described. (2) Remove the window glass as previously described and on power operated window models, disconnectthe regulator wiring connector. (3) Using an electric drill, remove the rivets retaining the regulator to the door. Remove the regulator through the lower aperture in the door. Installation is a reversalof the removal procedure with attention to the following points: ( I ) Lubricate the friction surfaces and associatedparts with lithium grease. (2) Instal the regulator to the door using suitable screws. (3) On power operated window modelsi instal the regulator wiring connector. EXTERIOR DOOR HANDLE To Removeand 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 escutcheon from inside the door, then remove the escutcheonand seal from the door. Installation is a reversalof the removal procedure with attention to the foflowing point: Ensure that the escUtcheon and sealare correctly installed prior to installflngthe slide clip.
REMOTE CONTROL AND DOOR LOCK To Removeand Instal (1) Remove the trim panel and plastic sealing panel as previously desoribed. (2) On vehicles equipped with electrically operated door locks, remove the actuator retaining screws and disconnectthe control rod from the lock. (3) Disconnect thg remote control rod and the snipper button control rod by releasingthe retaining clips. (4) Remove the lock retaining screwsfrom the door and remove the lobk assemblythrough the door aperture. (5) If necessary, rpmove the remote control by disengaging the control fod from the guide and lifting the rear section from the door. Slide the remote control rearwardsand remove it from the door. Installation is a reversalof the removal procedure with attention to the following points: (l) Ensure that the control rods are correctly installed. (2) If equipped,instal and connectthe door lock actuator. (3) Ensure that the door lock controls and the exterior handle operatecorrectly prior to installing the trim panel.
SEAL
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ROD-_ CONTROL NUT ADJUSTING CONTROL REMOTE
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Dismantled view of the rear door lock and remo-te control components. lt is important not to overtighten the t lock retaining screws or damage to the door locks will result.
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Body
(3) With the aid of an assistant,remove the bolts securingthe bonnet mounting bracketsto the boanet hinges.Carefully remove the bonnet from the vehicle. Installation is a reyersal of the remova.lprocedure. TO ALIGN (1) To align the bonnet fore and afr, loosen the bonnet hinge mounting bolts sufficiently to allow the bonnet to be moved.
(4) Tighten the lock retaining screwsto 3-5 Nm. Do not exceedthis torque setting or damage to the door 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 pillar accordingto the pencil marks made on removal.
Installed view of the bonnet hinge showing the location of the securing bolt.
Installedview of the rear door lock striker. (4) Close the door and observe the alignment with the body. If incorrect, loosen the striker plate retaining screwsand move the striker plate in or out to achievea flush fit. If the door lifts or drops when the lock engages the striker plate, loosen the screwsand move the striker plate up or down to eliminate the problem. NOTE: After each adjustment tighte.n the striker plate suews and check the adjustment. Readjust as necessary. 4. ENGINE BONNET To align the front of the bonnet loosenor tighten the lock bolt. (2) To align the height of the rear of rhe bonner, loosenthe bonnet bracket mounting bolts sufficiently to 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 nominal length is 52 mm from the bonnet to the lock bolt shoulder. NOTE: Correctalignment is achievedwhen the spacing and height of the bonnet and adjacentcomponentsare even. 5. LUGGAGE COMPARTMENT LID
TO REMOVE AND INSTAL ( 1) Raise the bonnet and support it with the bonnet stay. (2) Disconnectthe windscreenwashertube from the T piece.
TO REMOVE AND INSTAL (1) Raisethe luggage compartment lid and mark the installed position of the hinges using a soft lead
Body
247
Mark the installed position of the luggage compartment lid hinge prior to removal. pencil. If applicable, disconnect the solenoid wiring connector. (2) With the aid of an assistant, remove the hinge mounting bolts and remove the luggagecompartment lid from the vehicle. Installation is a reversalof the removal procedure ensuring that the hinges are relocated to the pencil markings made on removal. TO ALIGN ( I ) To align the luggagecompartment lid fore and aft loosenthe hinge mounting bolts sufficiently to allow the lid to be moved. (2) To align the height of the front of the luggage compartment lid, shims must be added or removed. (3) To align the height of the rear of the luggage compartment lid the lock striker must be raised or lowered. LUGGAGE COMPARTMENT LOCK To Removeand Instal ( I ) Raise the luggagecompartment lid and disconnect the lock cylinder control rod. On vehicles equippedwith remote release, disconnectthe solenoid wiring and the control rod. (2) Remove the screwsretaining the lock to the luggagecompartment lid and remove the lock from the vehicle. (3) If necessary,on vehicles equipped with a remote releasesolenoid, remove the screwsretaining the solenoid to the luggage compartment lid and remove the solenoid from the vehicle. Installation is a reversalof the removal procedure. LOCK CYLINDER To Removeand Instal ( I ) Raise the luggagecompartment lid and disconnect the lock cylinder control rod from the lock. (2) Compressthe lock cylinder retaining tangsor remove the retaining clip and remove the lock cylinder from the luggagecompartment lid. Installation is a reversalof the removal procedure. lnstalledview of the luggagecompartmentlock, lock cylinderand striker with the lid closed. LOCK STRIKER To Removeand Instal ( 1) Raisethe luggage compartment lid and mark the installed position of the lock striker using a soft lead pencil. (2) Remove the lock striker attaching bolt and remove the lock striker. Installation is a reversalof the removal procedure ensuring that the tock striker is located to the pencil markings made on removal.
lnstalled view of the luggage compartment lock striker. To Adjust (1) Loosen the lock striker attaching bolt sufficiently to allow movement. (2) Close the luggage compartment lid and observe the height in relationship to the rear mudguards. (3) Lower or raisethe striker plate so that a flush fit is achieved.Tighten the lock striker attachingbolt.
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6. TAILGATE
Body
TO REMOYE AND INSTAL (1) Disconnect the negativebattery terminal. (2) Raise the tailgate, remove the trim clips retaining the trim panel to the tailgate and remove the trim panel. (3) Disconnect the electrical connectors from within the tailgate and tie a piece of string to the connectors.Separate the rubber tubing from the top of the tailgate. NOTE: The string is usedto draw the wiring through the tailgate on installation. If the wiring is pulledfrom the tailgate without the string attached, installation will be dfficult. (4) Pull the wiring from the tailgate leaving the ends of the string exposed.Untie the string from the wiring.
Installedview of the tailgate lock striker. (3) Connect the negative battery terminal and start the engine, increasethe speedto 3 000 rpm for l0 secondsto allow the idle air control valve to reset. On vehiclesequipped with aradio/cassetteusing pIN security, enter the PIN code as described under the radio/cassette heading in the Electrical System section. TAILGATE LOCK To Removeand Instal (1) Raise the tailgate, remove the trim clips retaining the trim panel to the tailgate and remove the trim panel. (2) Remove the screwsretaining the lailgate lock to the tailgate. (3) Swing the lock up inside the tailgate and manoeuvrethe control rod from the lock. Remove the lock from the tailgate. Installation is a reversalof the removal procedure.
Installed view of the tailgate showing a hinge and support. (5) Carefully prise out the window washer nozzle from the outer tailgate panel and disconnect the washer hose. Tie a piece of string to the washer hose and remove it from the tailgate, as previously describedfor the wiring. (6) With the aid of an assistantsupporting the tailgate, using a thin bladed screwdriver, remove the retaining clips from the lower end of the tailgate supports and disconnect the supports from the pivot ball. (7) With the assistant supporting the tailgate, remove the hinge pin retaining clips and remove the hinge pins. Remove the tailgate from the vehicle. Installation is a reversalof the removal procedure with attention to the following points: (l) Ensure that all electrical connectors are installed prior to installing the tailgate trim. (2) Ensure that the tailgate lock engagesthe tailgate lock striker correctly. If necessary, loosen the lock striker retaining screwsand adjust to altow the tailgate lock to engagefreely.
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+CONTROL
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Dismantled view of the tailgate lock, handle and components.
Body
I{rcKCYLINDER AND HANDLE ASSEMBLY
249
To Remore rnd Instal (1) Remove the tailgate lock as previously described. (2) Remove the nuts retaining the handle to the tailgateand disconnectthe wiring. Remove the handle from the vehicle. (3) Remove the lock cYlinder from the handle and disconnectthe control rod. Installation is a reversalof the removal procedure. 7. RADIATOR GRILLE
CONSOLE
TO REMOYE AND INSTAL (1) Raise the engine bonnet and support it with the stay. (2) Remove the retaining screwsfrom the top of the grille. (3) Lift the grille up to disengagethe locating lugs from the bumper bar, remove the grille assembly. (4) If necessary,remove the grille retainer plugs from the bumper bar. Installation is a reversalof the removal procedure.
View of the automatic transmission centre console and 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 on power operated window models, disconnect the wiring connectors. (6) Loosen the adjusting screwsat the front of the console to lower the console. Disengage the locating lugsand remove the consolefrom the vehicle. Installation is a reversal of the removal procedure with attention to the following point: Connect the negative battery terminal and start the engine, increase the speed to 3 000 rpm for l0 secondsto allow the idle air valve to reset. On vehicles equipped with a radio/cassetteusing PIN security, enter the PIN code as described under the radio/cassette heading in the Electrical System section. 9. FRONT SEATS SEATS
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View of the radiator grille removed from the vehicle. 8. CENTRE CONSOLE
TO REMOVE AND INSTAL (1) Disconnect the negativebattery terminal. (2) On manual transmissionmodels,remove the gear knob from the gear lever, carefully prise the rear of the console cover from the centre console. Disconnect the wiring connectorsand remove the cover from the vehicle. (3) On automatic transmission models, proceed as follows: (a) Carefully prise the rear of the consolecover from the centre console. Disconnect the wiring connectors, turn the cover 90 degreesand manoeuvre it over the selectorlever handle. (b) Remove the gearposition scaleand trim, the slide indicator and the indicator support. (c) Remove the screws retaining the support assembly to the centre console, disconnect the quadrant lamp connector and remove the support assemblyfrom the vehicle.
To Removeand Instal (l) Adjust the seatto the fully rearwardposition and remove the front securingbolts. (2) Adjust the seat to the fully forward position and remove the rear securingbolts. (3) Lift the seatfrom the vehicle and place it on a clean dry surface.
location of the front seat ]ear securing bolts.
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Body
(3) Lift the seat cushion from the vehicle and place it on a clean dry surface. Installation is a reversal of the remotal procedure with attention to the following points: (1) Ensure that ther seat belts are positioned through the elastic loops rprior to installing the seat cushion. (2) Ensure that the retaining clips are properly engaged to the floor panel bracketi.
Locationof the front seat front securing bolts. Installation is a reversalof the removal procedure with attention to the following points: (l) Lubricate the seat slides with multi-purpose greaseprior to installation of the seat. (2) Apply Loctite 242 to the securingbolts prior to installation and torque the bolts to 35 Nm. SEDAN To Removeand Instal (l) Firmly bump the front of the seat cushion rearwardsto releasethe retaining clips from the floor panel brackets. (2) With the retaining clips released, lift the seat cushion from the vehicle and place it on a clean dry surface. Installation is a reversalof the removal procedure with attention to the following points: (1) Fnsure that the seat belts are correctly positioned prior to installing the seat cushion. (2) Ensure that the retaining clips are properly engaged to the floor panel brackets. REAR SEAT CUSHION STATION WAGON REAR SE.ATCUSHION Locationof 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 SEDAN
To Removeand Instal (l) Remove the rear seat cushion as previously described. (2) Remove the bolts,retaining the seatbackrest frame to the floor panel. (3) Lift the seat backrest from the retaining brackets. (4) Remove the seat backrest from the vehicle and place it on a clean dry surface. Installation is a reversalof the removal procedure. STATION WAGON To Removeand Instal (l) Remove the rear seat cushion as previously described. (2) Remove the lower seat belt mounting bolts and withdraw the seatbelts from the elastic loops. (3) Releasethe rear seat backrest lock button, then remove the bolts retaining the seat backrest bracket to the vehicle body. (4) Remove the seat backrest from the vehicle and place it on a clean dry surface. Installation is a reversalof the removal procedure. REAR SEAT BACKREST -
To Removeand Instal (l) Firmly bump the front of the seat cushion rearwardsto releasethe retaining clips from the floor panel brackets. (2) With the retaining clips released, lift the front of the seat cushion and remove the seat belts from the elastic loops on the rear of the seat cushion.
Body
10. SEAT BELTS ,:
25r
The front and outer rear seatsare equipped with ; lap/sashinertia reel seat belts, which are designedto i lock with any sudden changein vehicle motion. The centre rear seat is equipped with a manually i adjustable lap seatbelt. ,, The seat belts should be periodically inspectedas d 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 .l loadings in a collision, should be renewed as a complete assembly : Only mild soapand water should be usedto clean ', polish, with oil, bleaches the webbing.Contamination be avoided. should chemicals other and
Check the seat belt webbing for fraying, cuts, burns, or other damage. (c) Drive the vehicle at walking pace and attempt to withdraw the belt slowly while braking sharply. The reel should lock. If the retractor mechanism does not function correctly, renew the seat belt assembll'.
11. Installed view of the front seat belt showing the mounting bolt locations. TO INSPECT ( I ) Check the seatbelt webbing for fraying, cuts, burns or other damage. On inertia reel seat belts, slowly pull the belt from the reel to allow the entire length to be examined. If the webbing is damagedor worn, 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 If the buckles are damagedor do secureengagement. not function correctly, renew the seatbelt assembly. (5) On inertia reel seatbelts, check the retractor mechanism as follows: (a) Pull the belt slowly from the reel and check for a smooth operation. Releasethe belt and ensure that it retracts fully. (b) Pull the belt rapidly from the reel. The reel should lock.
DASHBOARD
TO REMOVE AND INSTAL (1) Disconnectthe negativebattery terminal. (2) Remove the centre console as previously describedin this section. (3) Remove the steeringcolumn as describedin the Steeringsection. (4) Remove the radio as describedin the Electrical Systemsection (5) Remove the instrument cluster as described in the Electrical Systemsection. (6) Open the glove companment and using a flat bladed screwdriver,prise out the hinge pin at the right hand side and remove the compartment. (7) From under the dashboarcl, remove the screwsand fasteners securingthe lower trim panel and remove the panel. (8) Using a small screwdriver,prise the plastic strip from the front section of the left hand side sill panel cover. (9) Disengagethe front section of the sill panel cover from the kick panel and the sill.
252
Body
(10) Disengage the lower front corner of the kick panel from the locating stud. Remove the kick panel from the vehicle. (11) D i sconnect the dashboardw i ri ng. (12) Remove the screw retaining the ientre fascia panel to the dashboard and remove the panel from the vehicle. (13),Remove the screws retaining the dashboard end coversr?trd remove the end covers. (14) Remove the retaining screws from the side vent housings and remove the side vent housings. (15) Remove the retaining screws from the speaker covers and remove the speaker covers. (16) Remove the demister grille retaining screws and remove the demister grille. (17) Remove the speaker retaining screws and withdraw the speakers sufficiently to disconnect the wiring. Remove the speakers.
One of the dashboard end cover retaining screws is accessed from behind the lower trim panel. On the passenger side, this end cover screw is accessedwith the glove compartment removed.
Dashboard end cover removed showing the location of the side vent housing retaining screws.
side venthousing retaining screws removed showing the location of the speaker cover retaining screw.
A I t
V iew of t he da s h b o a rd re mo v e d fro m th e vehi cl e w i th arrow s show i ng the l ocati on of the mount ing ' screws and bolts. Bolts marked A are deleted from models iftet February f SgS.
253
Rear v iew o f th e d a s h b o a rd p a rti a l l y removed show i ng the w i ri ng routi ng dnd retai ner l ocation. (18) Disconnect the heater ducts from the apertures in the outer ends of the dashboard. (19) Remove the dashboard mounting bolts from the outer ends of the dashboard. (20) Remove the retaining screw and bolt from the lower centre dashboard at the heater assembly. (21) Fully recline both front seats. (22) With the aid of an assistant, remove the remaining mounting screws adjacent to the windscreen demister ducting. (23) Carefully swing the passenger side of the dashboard away from the bulkhead and support it on the drivers seat, as illustrated. (24) Separate the wiring from the dashboard noting the installed position of the connectors and the wiring retainers. (25) Remove the dashboard from the vehicle and place it on a clean dry suqface. Installation is a rever$al of the removal procedure with attention to the following points: (1) Ensure that the lviring is correctly routed as noted during removal. (2) Adjust the heatqr control cable as described in the Cooling and Heating Systems section. (3) Ti ghten al l the retai ni ng nuts, bolt s and screws securely. (4) Check the operation of all the components disturbed during removal; NOTE: When instdlling the dashboard, be careful not to trqp any wiring between the dashboard and the bulkhead.
254
SUPPLEMENT
This supplement provides additional information pertaining to all models manufactured from 1990 and is presented in two parts. Part 1 is applicable to all models manufactured from 1990 including the Commodore VG series Utility which was introduced in August 1990. The Utility is available in Ute (basemodel) and S variants with a five speedmanual transmission as standard equipment and a four speed automatic transmission available as an option. A column shift is optional with an automatic transmission and a split bench seat is available on all models except those with a floor shift automatic transmission. A limited slip differential is standardon S models. Part 2 covers further changes applicable to models manufactured in l99L All changescovered in Part 1 also apply io tggl models unlessrevised rnPart2. As some of the production changeswere introduced prior to the model commencement dates and are therefore applicable to earlier models, it is recommended that the supplement be thoroughly read in conjunction with the main part of the manual and compared to the particular vehicle being serviced. Specifications and procedures not listed in this supplement remain as described in the main manual.
PART I. T99OMODELS
\TEHICLE IDENTIFICATION, GENERAL SPECIFICATIONS, LUBRIC.ATION AIND MAINTENAI\CEO WHEELS AI\D TYRESO ENGINE TUNE.UR ROADSIDE TROLIBLE SHOOTING AI\D FIJELAI{D ENGINE MANAGEMENT
1. VEHICLE IDENTIFICATION AND GENERAL SPECIFICAf,IONS GENERAL VEHICLE SPECIFICATIONS Utility Models Length Width Wheelbase Wheeltrack: Front Rear
Fuel tank capacity Towing capacity: Fully loaded *Front tRear
2I0 kPa . 27O kPa
.4997 mm ..'1,794mm ...2822mm . . . . 1 4 5 1m m | 478mm 63 litres
*Increase the tyre pressureby 29 kPa if the vehicle is driven constantly at high speed. tlncrease the tyre pressureby 39 kPa if the vehicle is driven constantly at high speed. HOW TO CHANGE A WHEEL Utility Models The procedure remains as described in the main manual with attention to the following point. (1) Remove the spare wheel as follows: (a) Remove the jack and handle, wheel spannerand the sparewheel winch handle from behind the drivers seat. (b) Instal the winch handle through the aperture adjacent to the rear number plate and engage the spare wheel winch shaft. (c) Rotate the winch handle anticlockwise to lower the spare wheel. Remove the winch cable plate from the spare wheel and withdraw the wheel from beneath the vehicle. Installation is a reversal of the removal procedure.
Load equalisingtrailer hitch Trailer brakes,heavy duty towbar, equalisinghitch, autotransoil cooler
1 200kg 1 590kg
2. LUBRICATIONAND MAINTENANCE
SPECIFICATIONS Rearaxle lubricant: Utilitv models .
. . . . Mobilube SHC 80W140 ID or CastrolSAF-XA 80W140 hypoid gearoil synthetic
NOTE: Use of incorrect lubricant may result in damageto the dffirential gears. SERVICE SCHEDULE On all models manufacturedfrom 1990, it is not to checkthe operationof the oxygensensoras necessary heading undertheFuelandEngineManagement described of the main manual. in the serviceschedule 3. WHEEI-S AITD TYRES SPECIFICATIONS Tyre Pressures: Up to threepassengers *Front *Rear
4. ENGINETUNE-UR ROADSIDE TROLJBLE SHOOTING AITD FI.JELAT{D ENGINE MANAGEMENT in the main remainas described All procedures to thefollowingpoints. manual with attention
(1) On models manufacturedfrom mid October havebeenmadeto the wiring 1989,a numberof changes the ENG COMP andENG harness. Due to thesechanges, by one30 andreplaced INJ fusiblelinks havebeendeleted amp fusible link markedENGINE. is made in the main manualto the Where reference fusible links markedENG COMP and/orENG INJ, this shouldbe readasthe fusiblelink markedENGINE. (2) Powerto the ignition controlmoduleis supplied throughthe EFI relay circuit. (3) On Utility models,the fuel tank is installedin
200 kPa .200 kPa
256
- Part l. 1990 Models Supplement
MAIN FUSIBLE LINK 60 A
EFI RELAY
v{
r-,
pnesslne f LUS! IswricHI PUMP l--l

T\_-/-
EN-gl_{E LAMP
g-l^E,ct{
.'D'..FROM N O V1 .990....a.......8.......
DETONATION
DIAGNOSTIC CONNECTOR
GW 'zB
tl
MAP SENSOF __ Inp Computer

a
I
or fuC Switch <ts-N A/C Relay a B8 ," 82 A2 , Aulo Trans 4th Gear/femD Switch
SR COLOUR CODE The first lener of the cod reprsents the main wire colou( the other bners reDresent the trace @lours. B.BLACK L . BLUE G. GREEN B-RED Y. YELLOW W. WHITE N . BROWN O-ORANGE K - PINK S - GREY V-VIOLET P. PURPLE X . L I G H TG R E E N Z - LIGHT BLUE M- DARKGREEN T - DARK BLUE A. LIGHT BROWN E-SLATE D' TAN
-DA
INJECTORS ELECTRG.IIC CONTROL UNIT
a U
N
249t452/WD12A
Fuel and engine management system circuit diagram. All models from October lggg.
t E
- Part 1. 1990 Models Supplement
257
FILLER HOSE
Fuel tank removed from the vehicle. Utility model. (7) Loosen the clamp and disconnect the vapour separatorfrom the filler neck hose. (8) Loosen the clamp and disconnect the hose from the filler neck. (9) Remove the fuel tank retaining bolts and partially withdraw the tank from the vehicle until accesscan be gained to the front of the fuel tank. (10) Suitably mark and disconnect the fuel supply and retum hoses from the fuel tank. (l 1) Disconnect the wiring from the front of the fuel tank and withdraw the tank from the vehicle. (I2) Remove the retaining screws and withdraw the fuel pump and fuel gauge sender unit from the fuel tank using care not damage the strainer. (13) If necessary,dismantle the fuel pump as follows: (a) Disconnect the fuel pump wiring, noting the installed 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 the mounting bracket.
Locationof the ENGINEfusible link. the load compartment under the front floor panel and the fuel pump is mounted inside the tank. If removing the fuel pump, it is necessary to remove the fuel tank from the vehicle 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 ensure that the fuel pressurehas been relieved. Instal the fuel pump 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 load compartment. (6) Suitably mark and disconnect the vent hoses from the top of the fuel tank.
t\r
\
r1"
\l
CONNECTOR WIRING
,'1\
\
FUELPUMP
Location of the fuel tank with the floor panel removed. Utility model.
High pressure,internal fuel pump. Utility model.
258
Supplement- Part I. 1990 Models

marks made previously. Ensure that all bose cl,amps are correctly seatedand secure. (4) When installing the fuel rank, apply perroleum jelly to the filler hose to aid installation.
Installation is areversal of theremoval procedure with attentionto the following points: (l) Ensurethat the wiring is woundaroundthe fuel pumpoutletpipeto preventit fouling thefuel gaugesender unit float arm. (2) Ensurethat the strainer is installedsecurely. (3) Use only hosesand clampsas suppliedby rhe manufacturerand connect the hoses according to the
(!) Tightenthe fuel tank retainingboltssecurely. (6) Test the fuel sys(em for external leakage as describedin the main part of the manualbeforeinstilling the front floor panel.
- Part 1. 1990Models Supplement
259
ENGINE
SPECIFICATIONS TORQUE WRENCH SETTINGS Rocker arm pivot bolts Support brace to converter housing bolts Support brace to clutch housing bolts Support brace to sump retaining stud nuts I. DESCRIPTION A larger timing chain damper is installed on models manufactured from July 1989 to reduce engine noise and can be installed to previous models. The following production changesto the engine apply to vehicles manufactured from mid October 1989: (a) Moulded plastic rocker covers are installed with revised sealsand retainers which can be installed to earlier models. (b) The double valve springs installed to earlier model engines are replaced by a single valve spring and the shapeof the retainer is modified to suit the single valve spring. The single valve spring can be installed to earlier models providing that the colresponding retainer is also installed. (c) The steel pushrod guide plate is replaced by three alloy retainers which support revised rocker arm pivots. The revised pivots can be installed to earlier models providing the alloy retainers are also installed. (d) The camshaft has decreased lobe lift, increased valve timing duration and has a thrust washer installed between the flange and the front of the cylinder block. The camshafts can be identified by measuring the distance between the rear face of the front flange and the end of the camshaft. On early model camshafu the distance is 374.5 mm and on late model camshaftsthe distance is375.2 mm. The late rnodel camshaft and thrust wastrer can be installed to the early mo&l engirre providing tlre correqponding Mem-Cal unit is insalled to the engine control unit (e) On automatic transmission models, a retaining plate is installed to the drive plate and a support brace is installed between the engine and the front of the transmission. On models with a manual transmission, the support brace is installed to models manufactured from April 1990. (0 The gasket installed between the oil pump pickup pipe and the cylinder block on previous models is replaced by an O ring and the direction arrow on the top of the pistons is deleted. During 1990, high flow hydraulic tappets were introduced which can be installed to previous models. The improved tappets are identified by the yellow snap ring above the pushrod seat. . .65 Nm . .60 Nm 35 Nm . 12 Nm NOTE: If the cooling systemisdrained,ensure that it isfilled as described later in this supplement to prevent engine overheating. 2. ROCKER ARMS AND PUSHRODS
All procedures remain as described in the main manual with attention to the following points. (1) Operation (3) of the installation procedure should read as follows: Instal the rocker ann pivot retainers ensuring that the arrows on the top of the retainers face towards the centre of the engine and the base of the pivots seat correctly in the retainers.
g:)g
ROCKER ARMS
?A*261ffi
W,@
\
Rockerarm componentsremovedfrom the engine. (2) In Operation(4) of the installationprocedure,it is not necessary to apply Loctite 242 to the rocker arrn pivot bolts. Ensure that the pivot bolts are tightened to 65 Nm. 3. TIMING COVER The procedure to removeand instalthe timing cover remainsasdescribedin the main manualwith attentionto the following points.
260
- Part l. 1990Models Supplement

(2) Prior to installing the camshaft, apply Molybdenum Disulphide greaseto both sidesof the thrust washer and instal the washer to the camshaft. 5. SUMP AND OIL PUMP PICK.I.JP PIPE All procedures remain as described in the main manual with attention to the following points. (1) Where applicable, remove the support brace as described later in this supplement. (2) The O ring located between the pick-up pipe and cylinder block must be renewed. (3) Prior to installing the sump, apply a 2-3 mm bead of Dow Corning RTV 732 or equivalent sedlantover the timing cover and rear main bearing cap joints. Apply a thin bead of the sealant to the sump mating face directly below the timing cover joints. (4) If applicable, instal the support brace as described later in this supplement. 6. CRANKSHAFT OIL SEAI-S
(1) Where applicable, remove the support brace as described later in this supplement. (2) If the sump gasket has separated from the cylinder block, remove the remaining sump retaining bolts and apply a 2-3 mm bead of Dow Corning RTV 732 or equivalent sealant over the timing cover and rear main bearing cap joints. (3) Apply a thin bead of the specified sealantto the sump mating face directly below the timing cover joints. (4) If applicable, instal the support brace as described later in this supplement.
4. CAMSHAFT
AND BAIANCE
SHAFT
All procedures remain as described in the main manual with attention to the following points. (1) When the camshaft is withdrawn from the cylinder block, remove the thrust washer.
TO REMOVE AND INSTAL FRONT CRANKSHAFT OIL SEAL The procedure remains as described in the main manual with attention to the following point. (1) On automatic transmission models, operation (a) of the removal procedure requires that the drive plate be locked prior to removing the crankshaft pulley retaining bolt. This will necessitatethe removal of the support brace as described later in this supplement.
7. SUPPORT BRACE TO REMOVE AND INSTAL (1) On automatic models,removethe transmission motor asdescribed later in this supplement. starter
Sealant application points on the rear main bearing cap and the timing cover joints.
Sealant application points on the sump mating face.
lnstalled view of the support brace. Automatic transmission model.
- Part 1. 1990Models Supplernent

(2) Remove the retaining bolts and withdraw the exhaust engine pipes from the vehicle. (3) On manual transmission models, disconnect the clutch cable from the releaselever as previously described in the main manual. (4) Remove the bolts and nuts and partially withdraw the steering gear from the front suspension crossmember. (5) Remove the retaining nuts and bolts and manoeuvre the support brace from the vehicle. Installation is a reversal of the removal procedure with attention to the following points: (l) If the sump retaining studs have been disturbed, check that the support brace mounting faces on the studs are 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 studs are tightened to 8-12 Nm. (2) Retain the support brace in position by loosely installing the sump stud retaining nuts. (3) Hold the support brace flush against the clutch or converter housing and tighten the support brace to sump stud retaining nuts to the specified torque. Tighten the rear nuts first. (4) Check that the gap between the support brace and the clutch or converter housing is not more than 0.2 mm. If the gap is excessive,loosen the nuts and repeat the previous operation. If the correct gap cannot be achieved, renew the support brace. (5) Instal the support brace to clutch or converter housing retaining bolts and tighten to the specified torque. NOTE: If the retaining bolts cqnnot be installed, remove the support brace and enlarge the bolts holes to 13 mm. If the bolts still cannot be installed, renew the support brace. (6) Where applicable, instal and adjust the clutch cable as described in the main manual. (7) Instal the engine pipes ensuring that a new gasket is installed at the catalytic converter joint. (8) Where applicable, instal the starter motor as described in the main manual.
26r
8. PISTONS, CONNECTINGRODS AND CYUNDER BORES

All procedures remain as described in the main manual with attention to the following point. (1) The direction arrow on the top of the pistons has been deleted. When installing the pistons into the cylinder bores, ensure that the letters and numbers stamped on the top of the piston are facing towards the front of the engine.
9. FLYWHEEL/DRM PIATE
All procedures remain as described in the main manual with attention to the following point. (1) On automatic transmission models, a retainer plate is installed between the drive plate and the retaining bolts. When the retainer plate is installed, ensure that the dimple is facing away from the drive plate.
Ensure that the drive plate retainer is installed with the dimple facing outwards.
262
COOLING AI\D HEATING SYSTEMS

1. DESCRIPTION
During April lgg},the following changes were made to the cooling system. An overflow cap is installed over the surge tank pressure cap and is sealed to the surge tank with in O ririg. A coolant reserve tank is installed to the left hand inner mudguard and an overflow hose is installed between the reserve tank and the overflow cap. NOTE: If the reserve and surge tanks require frequent topping up, check the cooling system for leakage. The surge tank should be completelyfull of coolant at all times. If the surge tank requires topping up but the reserve tank does not, check that the surge tank overflow cap and O ring are sealing fully and that the overflow cap and hose are not blocked or damaged. (a) Disconnect the overflow hose and unscrew the cap from the surge tank. Fill the surge tank with the specified coolant. (b) Remove the O ring from the surge tank and check for signs of wear and damage. Renew the O ring as necessary.
OVERFLOW CAP
Installed view of the surge tank and reservetank. As the coolant volume expands due to a rise in temperature, the pressurevalve in the surge tank pressure cap opens and allows the excess coolant to flow into the reserye tank via the overflow hose. When the coolant temperaturefalls, the vacuum valve in the surge tank pressurecap opens, allowing the coolant to siphon back into the surge tank. The design of the thermostat has been revised to improve reliability, however the operating characteristics are 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 Maximum marks. (2) If the level is below the Minimum mark, remove the cap and add the specified coolant to the reserve tank until the level is correct. (3) Check that the surge rank is completely full of coolant. If the surge tank requires topping up, proceed as follows.
PRESSURE CAP
Surge tank overflow and pressure caps separated. (c) Lubricate the O ring with soapy water and instal it to the surge tank. (d) Instal the cap to the surge tank and tighten securely. When the cap is installed, the overflow hose connection must be facing towards the front right hand side of the vehicle at an angle of approximately 45". _ If the angle is incorrect, lever the overflow cap from the.pressure cap using two screwdrivers and correctly position the overflow cap ensuring that the slots in the cap align with the lugs on the pressure cap. Unscrew the pressure cap sufficiently to allow the overflow cap to be

minal, refer to the note under the Battery heading in the main manual.
263
panel (2) Removethe radio/cassette surround and Pull the top of thepaneloutwards screws. retaining
raise the panel to disengagethe retaining lug. (3) Disconnect the wiring connectors from the switches noting their installed positions as an aid to assembly and withdraw the surround panel. (4) Rotate the retaining pins 90 degrees and open the fuse cover on the right hand side of the steering column. Remove the hinge pin and remove the cover from the dashboard. (5) Open the glove compartment, remove the hinge pin and remove the glove compartment from the dashboard. (6) Remove the centre fascia panel retaining screws and remove the centre fascia panel from the vehicle.
lnstalled view of the surge tank cap correctly installed with the overflow hose connection at approximately 45". installed and firmly push the overflow cap onto the pressure cap. (e) Connect the overflow hose to the cap ensuring that the hose is not kinked or restricted. TO DRAIN AND REFILL The procedure to drain and refill the cooling system is described in the main manual. Check the coolant level as previously described in this supplement.
3. HEATER AND AIR COI\DITIONTNG CONTROI-S TO REMOVE AND INSTAL Split BenchSeatModels (1) Disconnect batteryterminal. the negative the batteryterNOTE: Prior to disconnecting
Radio/cassette and heater controls with the centre fascia panel removed. Split bench seat models. (7) Remove the heatercontrol cable retaining screw located behind the heater controls assembly. (8) Working in the drivers footwell, disconnect the heater control cable from the control lever at the right hand side of the heater unit. (9) Remove the retaining screw and partially withdraw the heater controls. Disconnect the wiring and the vacuum block and remove the heater controls from the vehicle. Installation is a reversal of the removal procedure with attention to the following points: (1) Ensure that the heater vacuum hosesare in good condition and that they are not pinched or kinked when installing 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 in the full cold position before installing the snap in cable end. Operate the temperature control several times.
I' i.ll} r*l{I,}i;.rrrl'
Location of the radio/cassette surround panel retaining screws. Split bench seat models.
264

heaterwater valve is shut when the temperature control is valveagainif necessary.
(4) Turn the temperature control knob to the full cold position again and ensure that the heater control lever is pushing in on the vacuum shut off valve. Adjust the heater control snap in cable end if necessary. NOTE: If the rod cannot be adjusted to operate the shut offvalve properly, remove the shut off valve and elongate the holes slightly using a small roundfile. The valve can then be positioned closer to the lever. (5) Connect the negative battery terminal. Start the engine and increase the speed to 3 000 rpm for 10 secondsallowing 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 as described under the Radio/Cassetteheading in the Electrical System section. (6) With the engine running and with the aid of an assistantoperating the temperaturecontrol, ensurethat the
in thefully closed position. Adjust therodardtheshut off

4. AIR CONDMONING
DESCRIPTION - Some models are equipped with Elecrronic Climate Control, an automatic, ele^cironically controlled system that maintains the interior of the vehicle at a preset ternpera-ture by activating the heater and air conditioner as necessary. Jhe system is controlled by an electronic control unit which receives signals from various sensorsthat monitor the temperature and intensity of light inside the vehicle. Due to the complexity of the system, it is recommended that the vehicle be referred to an authorised dealer if the operation of the system is suspect.
- Part l. 1990Models Supplement
265
MTJTC.H AI\D AUTOI\,IATI C TRAD{SMISSION

I. CLUTCH
All procedures rernain as described in the main manual with attention to the following points which relate to models from April 1990. (1) When removing the clutch'unit and release mechanism, remove the bolts retaining the clutch housing to the support brace prior to removing the lower front cover from the clutch housing. (2) When installing the support brace, follow the procedure described in the Engine section of this supplement.
2. AUTOMATIC TRANSMTSSION
The following changes have been made to the automatic transmission. (l) The transmission identification has changed from Turbo Hydra-Matic 700 R4 to Hydra-Matic 4L60 and improvements have been made to some of the internal components. (2) When removing and installing the transmission it is necessary to remove and instal the support brace as previously described in this supplement. (3) On sornemodels, a column shift transmission is available as an option. All procedures remain as described in the main manual except for those under the following headings which apply to models with a column shift transmission. SELECTOR LINKAGE To Adjust The adjustment procedure for the selector linkage , fitted to column shift models follows the same basic procedure described forthe floor shift models described in the main part of the manual with attention to the following point. (1) If necessary, adjust the selector indicator as described later in this supplement. To Remove and Instal (l) Raise the front of the vehicle and support on chassis stands. Apply the handbrake and place the transmission 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 of the column selector shaft and separate the lever from the shaft. (4) Remove the spring clip, washer and dished washer and withdraw the bellcrank from the shaft. COLUMN SHIFT View of the selector linkage adjustment point. (5) Working under the vehicle, remove the nut retaining the selector lever from transmission shaft. (6) Remove the selector lever from the transmission and manoeuvre the linkage from the vehicle using care to avoid damage to the wiring and hoses. (7) Dismantle the selector linkage noting the installed position of the components. (8) Check the rods and the bellcrank for bends and
*% TRUNNTON eusx {dl
SLEEVE ( d FLATwASHER /
Selector linkage components.
266
elongated holes. Check the pins and the bellcrank shaft for wear. Renew the worn components as necessary. (9) Check the rubber bush in the transmission selector lever for wear and deterioration. Renew the bush as necessary. Installation is areversal of the removal procedure with attention to the following points: (1) Apply multipurpose greaseto the contact points at the joints. (2) Ensure that the linkage is assembled with the dished side of the washers facing towards the rods and that the number on the bellcrank is facing towards the front of the vehicle. (3) Ensure that the sleeve is installed in the rubber bush. (4) Renew the nut retaining the lever to the column selector shaft and tighten to a torque of 35 Nm. (5) Adjust the selector linkage as previously described in this supplement. (6) Road test the vehicle and check for correct transmission operation. SELECTOR SHAFT To Remove and Instal (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 selector shaft. Discard the nut. (4) Remove the steering wheel using a puller. If necessary,refer to the Steering section in the main manual. (5) Rotate the retaining pins 90 degrees and open the fuse cover on the right hand side of the steering column. Remove the hinge pin and remove the cover from the dashboard. (6) Remove the steering column lower cover retaining screws, disconnect the illumination lamp and withdraw the lower cover. (7) Remove the accesscover and the selector lever boot 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. COLUMN SHIFT
Installed view of the selector shaft and lever assembly with the lower cover removed.
Removing the column shift selector shaft assembly. (10) While supporting the selector shaft, remove the bolts retaining the selector shaft mounting bracket to the steering column and lower the selector shaft sufficiently to
ROLL PINS
z6IlLD3
SELECToR
LEVER
Sefector shaft measuring points. Dimension A = 23F.241mm. Dimension B = 344.5-347.5mm. Dimension B shoul, measured between the centre of the universal joint and the centre of the roll pin.

clear,the upper covr.:It rnay be necessary to disconnect the wiring from the ignition switch. (11) If necessary, remove the retaining screws and remove the neutral safety switch from the mounting bracket. (12) Carefully withdraw the selector shaft from the vehicle ensuring that it is supported at each end. (13) Check the selector shaft for damage, distortion and worn or binding universal joints. Renew as necessary. (14) Measure the selector shaft as shown in the illustration. If the dimensions are not correct. renew the selector shaft. Installation is a reversal of the removal procedure with attention to the following points: (1) Ensure that the pin protruding from the selector lever housing engagesthe neutral safety switch. (2) Tighten the selector shaft mounting bracket bolts to a torque of 3 Nm. (3) Renew the nut retaining the lever to the column selector shaft and tighten to a torque of 35 Nm. (4) Adjust the selector indicator as described later in this supplement. (5) Instal the steering wheel as described in the main manual. SELECTOR INDICATOR To Remove and Instal (1) Place the transmission in Park. (2) Remove the accesscover located at the side of the steering column. Remove the indicator cable retaining screw. COLUMN SHIFT Installed view of the steering column covers.
267
(1) Adjust the selector cable using the procedure thatfollows. To Adjust (l) Apply thehandbrake andplacethetransmission in Neutral. (2) Removethe access cover locatedat the side of the steering column.
(3) Loosen the indicator cable retaining screw and adjust the indicator cable until the indicator needle is 'N' position. centrally aligned over the Tighten the cable retaining screw. NOTE: The indicator cable is spring tensioned towards the Park position. If the indicator is fixed in a position and cannot be adjusted, it is likely that the spring is broken. (4) Instal the accesscover.
Removing the selector indicator assembly. (3) Using a small flat bladed screwdriver, lever the cover from the selector indicator. (4) Remove the indicator retaining screws and withdraw the illumination lamp socket from the indicator. Remove the indicator from the vehicle. Installation is a reversal of the removal procedure with attention to the following point:
Location of the indicator cable retaining screw.
268
NEUTRAT SAFETY SWITCH -

COLUMN SHIFT switch is previously described under the headinl RemoveandInstalselectorshaft' (3), However,operations \-" (12), \'-" (13), \+r' and (14) should be disregarded.
To Remove and Instar The procedure to removeandinstalthe neutralsafety
269
REAR A>(LE, STEERING AI{D FRONT SUSPENSION

1. REAR A}(LE All proceduresremain as described in the main manualwith attentionto the following point, (1) On Utility models, ensure that Mobilube 80W140 ID or Castrol SAF-XA 80W140 synthetic hypoid gearoil is usedin the rear axle. NOTE: The use of incorrect lubricant may causedamageto the differentialgears.
Disconnect the wiring from the ignition switch, combination switch and the horn contact. (13) While supporting the selector shaft, remove the bolts retaining the selector shaft mounting bracket to the steering column and lower the selector shaft. (14) Remove the steering column mounting nuts and pull the column rearwards to disengage the brake pedal bracket support stud. (15) Remove the intermediate shaft upper clamp bolt and remove the steering column from the vehicle. Installation is a reversal of the removal procedure with attention to the following points:
2. STEERING TO REMOVE AND INSTAL STEERING COLUMN Column Shift Models (1) Disconnect batterytenninal. the negative refer (2) Removettre steeringwheel.If necessary, to the Steeringsectionin the main manual. (3) Rotate the retaining pins 90 degreesand open the fuse cover on the right hand side of the steering column.Removethe hingepin andremovethe coverfrom the dashboard. (4) On vehicles equippedwith power windows, lower removethepowerwindowmoduleretainingscrews, the wiring. Removethe module the moduleanddisconnect from the vehicle. (5) Disconnect the wiring from the stop lamp switch. (6) Remove the screws retaining the fuse panel panel and posimounting bracketto the lower dashboard tion the mountingbracketto one sideclear of the steering column. (7) Pull back the rubberboot from the lower end of the steeringcolumn and remove the nut from the intermediateshaft upper clamp bolt. Open the clamp slightly using a screwdriverleaving the clamp bolt in position. Mark the steering shaft in relation to the intermediate shaft. (8) Release thewiring harness thecabletie securing column. to the steering (9) Remove the steering columnlower coverretainthe illuminationlamp andremove ing screws, disconnect cover. the lower coverandthe access (10) Removethe indicatorcableretainingscrew. (11) Removethe cover from the selectorindicator and withdraw the illumination lamp socket from the indicator. clampanddiscon(12) Straighten the wiring harness nect the neutralsafetyswitch wiring connector.
Installed view of the steering column with the lower cover removed. (l) Instal the steering column and intermediate shaft ensuring that the marks made on removal are aligned. (2) Ensure that the steering column boot is colrectly installed to the floor panel. (3) Tighten all the bolts and nuts and ensurethat all electrical connections are secure. (4) Adjust the selector indicator cable as previously described under the Automatic Transmission heading in this supplement. (5) Instal the steering wheel ensuring that the marks are aligned and that Loctite 242 is applied to the threads on the retaining nut.
3. FRONT SUSPENSION SPECIFICATIONS Coil springfree length: Utilitymodels
....363mm
270

Toein 2mm*2mm
Wheelalignment: Caster angleUtility models . . . I deg 30 min * I deg Sedan andStationWagon models . . . . 2 d e g 3 0 m i n * I deg CamberangleUtility models . . .Minus I deg+ 30 mm Sedan andStationWagon modelswith FE2 option . . . Minus 42 min + 30 min Sedan andStationWagon modelswithout FE2 option . . .Minus I deg + 30 min
DESCRIPTION On models manufactured from mid June 1989. the wheel alignment specificationson Sedan and Station Wagon models were changeddue to the installationof revisedsuspension unit upper mounting and bearingassemblies. The revisedmountings areidentifiedby the L (left) or R (right) markingon the upperfaceof eachassembly and mustnot be installedto the oppositesuspension unit.
27r
REAR SUSPENSIONAI{D BRAKES

1. REAR SUSPENSION TORQUE WRENCH SETTINGS Utility Models Assist spring mounting bolts Shock absorberlower mounting nut DESCRIPTION The rear suspensionon Utility models is the same as Sedan and Station Wagon models except that the rubber bump stops are replaced by rubber assist springs which contact pads on the rear axle housing when the vehicle is loaded. All procedures remain as described in the main manual except for those under the following headings which apply only to Utility models. TO REMOVE AND INSTAL ASSIST SPRING (1) Raise the rear of the vehicle and support it on chassis stands.Remove the rear wheel. (2) Remove the bolts retaining the assist spring mounting bracket to the vehicle underbody and remove the assist spring from the vehicle. (3) Separate the mounting bracket from the assist spring outer sleeve and remove the inner sleeve from the assist spring outer sleeve noting the installed direction. (4) Examine the assist spring components for damage, deterioration and wear. Renew unserviceable components as necessary. lnstallation is a reversal of the removal procedure with attention to the following points: (l) Do not apply any type of lubricant to the assist spring components. (2) Instal the inner sleeve to the direction noted on removal. (3) Tighten the mounting bolts to the specified torque. . .35 Nm .35 Nm DESCRIPTION On models manufactured from mid November 1989, brake shields are installed behind the front brake discs to reduce water entry to the discs in wet conditions. On Utility models, the brake master cylinder proportioning valve is deleted and replaced by a load sensing valve which is attachedto the rear suspensionpanhard rod. The load sensing valve controls the amount of hydraulic pressure applied to the rear brakes depending on the vehicle load. Onmodels with a splitbench seat,the handbrake lever is located at the right hand side of the drivers seat. All procedures remain as described in the main manual except for those under the following headings which apply only to Utility models. MASTER CYLINDER W hen di smantl i ng and assembl i ng t he m ast er cylinder on Utility models, note that the proportioning valve sealblock, spring, retainer and poppet valve assembly has been replaced by a spacer with sleeve and O rings, and a spool with an O ring and a return spring. 2. BRAKES
Brakemastercylindercomponents. ,
m t
4p/mffi rc"
-
l*
LOAD SENSING VALVE To Remove and Instal (1) Raisethe rear of the vehicle and supportit on chassis stands. (2) Disconnect the brakepipesfrom the load sensing valve.Plug the endsof the pipesto preventthe lossof fluid and the entry of din. (3) Hold the load sensing valve operating arm towardsthepanhardrod anddisconnect the anchorbracket from the panhardrod. Slowly releasethe arm.
Ub=-?
Assist spring components.
272

TO REMOVEAND INSTAL HANDBR,A.KE LEVERAND CABLE
Split Bench Seat Models (1) Raise the front and rear of the vehicle and support it on chassis stands.Releasethe handbrake. (2) Remove the screws and withdraw the cover from the handbrake lever. (3) Squeeze together the tabs on the end of the handbrake warning lamp switch plunger and remove the wiring terminal. (4) Working under the vehicle, loosen the handbrake cable adjusting nuts at the equaliser until the rear handbrake cables are slack. Disconnect the return spring from the relay lever. (5) Move the relay lever towards the front of the vehicle and disconnect the front cable from the relay lever. (6) Pull the front cable towards the front of the vehicle until the cable can be withdrawn through the opening in the retaining bracket. (7) Remove the nut and bolt retaining the front cable support clamp to the vehicle. Remove the screws retaining the handbrake outer cable retaining plate to the floor panel.
Load sensing valve. (4) Remove the retaining bolts and remove the load sensing valve from the vehicle. Installation is a reversal of the removal procedure with attention to the following points: (1) Tighten the load sensingvalve retaining bolts to a torque of 30 Nm. (2) Bleed the brake hydraulic system as described in the main manual. (3) Adjust the valve anchor bracket as described in the following text. To Adjust (1) Locate the anchor bracket U bolt 483 mm ro rhe left of the panhard rod mounting bolt on the rear axle housing.
Front handbrake cable and associatedcomponents.
Load sensing valve adjustment. Dimension A = 1 1 5 .5 -1 1 6 .5 mm. (2) Adjust the anchor bolt until a distance of I 15.5116.5 mm exists between the upper face of the anchor bracket and the top edge of the operating arm where the chain is connected. NOTE: If the operation of the load sensing valve is suspectedof being faulty, it is recommended that the vehicle be taken to an authorised dealerfor the necessaryrepairs.
(8) Operate and release the handbrake lever to draw the inner cable towards the handbrake lever and disconnect the inner cable from the handbrake lever. (9) Remove the snap ring from the outer cable and withdraw the cable through the floor panel. (10) Remove the retaining bolts and remove the handbrake 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 with attention to the following points: (1) Lubricate the lever, pivots and cable ends with multipurpose grease. Ensure that the relay lever operates freely. (2) Adjust the handbrake as described in the main manual.
- Part 1. 1990Models S;upplement
273
ELECTRIC.ALSYSTEM
1. STARTER MOTOR TO REMOVE AND INSTAL (6) Remove the indicator cable retaining screw. (7) While supporting the selector shaft, remove the bolts retaining the selector shaft mounting bracket to the steering column and lower the selector shaft. (8) Using a small flat bladed screwdriver, lever the cover from the selector indicator. (9) Remove the steering column retaining bolts and lower the steering column sufficiently to allow the upper cover to be removed. Support the steering column in this position.
The removal and installation procedure has been revised and is applicable to all models. (1) Disconnect the negative battery terminal. (2) Raise the front of the vehicle and support it on chassisstands. (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) O n mo d e l s w i th a u to ma ti c tra n smi ssi on, 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 compartment. Where applicable, do not misplace the adjusting shims on models with manual transmission. NOTE: On some models with manual transmission, it may be necessary to remove the support brace to allow the starter motor to be withdrawn. Installation is a reversal of the removal procedure with attention to the following points: (1) Ensure that all starter motor retaining bolts are tightened securely. Ensure that the wiring is clean and secure. (2) On manual transmission models, if a new or exchange starter motor is installed or the starter motor operation is noisy, check and if necessaryadjust the pinion mesh as described in the Electrical System section in the main manual.
lnstalled view of the combination switch witfi the lower cover removed. (10) Depress the tangs at the side of switch and withdraw the switch assembly from the steering column bearing housing. Disconnect the wiring and remove the switch from the vehicle. Installation is a reversal of the removal procedure with attention to the following points: (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 supplement.
2. COMBINATION SWITCH TO REMOVE AND INSTAL

Column Shift Models batteryterminal. (1) Disconnect the negative (2) Removethe steeringwheel using a puller. refer to the Steeringsectionin the main If necessary, manual (3) Remove columnlowercoverretainthe steering ing screws,withdraw the illumination lamp and remove cover. the lower cover and the access (4) Disconnectthe wiring connectorfrom the ignition switch. (5) Open the fuse cover by turning the retainers90 priseout the left degrees. Using a flat bladedscrewdriver, handsidehingepin andremovethe cover.
3. HANDBRAIG WARNING I.AMP SWITCH TO REMOVEAND INSTAL

Split Bench Seat Models (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
The arrows indicate the centre fascia panel screw locations. radio/cassette surround and pull the surround carefully towards the rear until the locating lugs at the top release from the dashboard. (4) Disconnect the electrical connectors from the radio/cassettesurround panel, noting their installed positions as an aid to assembly. Remove the surround panel. (5) Working in the drivers footwell, disconnect the heater control rod from the control lever at the right hand side of the heater unit. NOTE: The heater control rod is not installed to models equipped with electronic: climate control. (6) Remove the screw retaining the heater controls or the electronic climate control panel to the dashboard and partially withdraw the controls from the dashboard. (7) D i sconnect the el ectri cal connect or s, t he vacuum block and, on models with electronic climate control, the aspirator tube and remove the heater control/electronic climate control panel from the vehicle. (8) On automatic transmission models, proceed as follows:
Installed view of the handbrake warning lamp switch. handbrake warning lamp switch plunger and remove the wiring terminal. (4) Remove the warning lamp switch from the mounting bracket. Installation is a reversal of the removal procedure. 4. RADTO/CASSETTE TO REMOVE AND INSTAL Bucket Seat Models The following procedure applies to models manufactured from mid September 1989, when the radio/cassette mounting brackets were revised to provide increased security. (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 access to the radio/cassettesurround screws. (3) Remove the screws from the lower part of the
Centre console front height adjusting screw locations.
Radio/cassette mounting locations.
- Pa,rt1. 1990Models Supplement

(a) Diseonnect the centre console cover wiring connector, turn the cover 90 degrees and manoeuvre it over the selector lever handle. (b) Rernove the gear position scale and trim, the slide indicator and the indicator support. (c) Remove the screws retaining the support assembly to the centre console, disconnect the quadrant lamp connector and remove the support assembly from the vehicle. (9) Loosen the centre console front height adjusting screws and lower the front of the centre console sufficiently to disengagethe locating lugs at the bottom of the centre fascia panel. (10) Rotate the retaining pins 90 degrees and open the fuse cover on the right of the steering column, remove the hinge pin and remove the cover from the dashboard. (11) Open the glove compartment, remove the hinge pin and remove the glove compartment from the dashboard. (I2) Remove the centre fasciapanel retaining screws and remove the centre fascia panel from the vehicle. (13) Remove the retaining screws and withdraw the ventilation ducts from the heater unit. (14) Remove the radio/cassette retaining bolts located behind the side brackets. (15) Remove the radio/cassette front mounting screws and partially withdraw the radio/cassettefrom the dashboard. (16) Disconnect the wiring and the aerial from the radio/cassette and remove the radio/cassette from the vehicle. Installation is a reversal of the removal procedure with attention to the following points: (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. Split Bench Seat Models (1) Disconnect the negative battery terminal.
275
Location of the radio/cassette surround panel retaining screws. Split bench seat models. (6) Remove the centre fascia panel retaining screws and remove the centre fascia panel from the vehicle. (1) W orki ng from the l eft hand side of t he radio/cassette,remove the wing nut and earth lead from the radio/cassetterear mounting stud. NOTE: It may be necessary to use a long screwdriver to loosen the wing nut. (8) Remove the radio/cassette front mouhting screws and partially withdraw the radio/cassettefrom the dashboard. (9) Disconnect the wiring and the aerial from the radio/cassetteand manoeuvre the radio/cassettefrom the vehicle. Installation is a reversal of the removal procedure with attention to the following points: (1) Ensure that all the wiring is securely connected.
NOTE: Prior to disconnecting the battery terminal, refer to the note under the Battery heading in the main manual. (2) Remove the radio/cassette surround panel retaining screws. Pull the top of the panel outwards and raise the panel to disengage the retaining lug from the centre panel. (3) Disconnect the wiring connectors from the switches, noting their installed positions as an aid to assembly, and withdraw the surround panel. (4) Rotate the retaining pins 90 degrees and open the fuse cover on the right of the steering column. Remove the hinge pin and remove the cover from the dashboard. (5) Open the glove compartment, remove the hinge pin and remove the glove compartment from the dashboard.
Radio/cassette with the centre fascia panel removed. Split bench seat models.
276
- Part 1. 1990Msdels Supplement

(1) Disregard operarion(2) of the removal procedure. (2) The wiper arrnsaremarkedD (driversside) and P (passengers side) adjacentto the retaining hole and are not interchangeable. (3) Insial the wiper arm to rhepivot shaftso rhatthe distancebetweenthe left hand end of the wiper blade and the windscreen surroundis 61-71 mm on tire right hand blade and 31-41 mm on the left hand blade in the park position. 7. I.AMP UMTS REAR COMBINATION LAMP - UTILITY To RenewBulbs The rear combinationlamp on Utility modelsis the sameas StationWagonmodels.To renewthe bulbs,refer to the procedure in the main manual. HIGH MOUNTED STOP LAMP To RenewBulb (l) Remove the retaining screw and remove the coverfrom the lamp base. (2) Rotate the bulb holder anticlockwise and withdraw it from the lamp.
(2) Ensurethat the wingnut stud entersthe hole in the bracketandtightenthe wingnutsecurely. (3) Tightenall the retainingscrewssecurely. (4) Run the engineat 3 000 rpm for 10 seconds to resetthe idle air controlvalve. (5) Whereapplicable, enterthe securityPIN code. 5. TO CHECK AND RENEW FUSES AI{D FUSIBLE UNKS The procedure to check and renew the fuses and fusiblelinks remains asdescribed in themainmanualwith attention to the following point. (l) On models manufacturedfrom mid October 1989,a numberof changes havebeenmadeto the wiring hamess. Due to thesechanges, the ENG COMP andENG INJ fusible links have been deletedand replacedby one 30 amp fusible link marked ENGINE and the raring of the fusiblelink markedHEADLAMP is increased to 40 amp. The fusesin the interiorfusebox havebeenrevisedas follows: Fuse No I 2 3 4 5 6 7 8 9 Circuit Parkinglamps,trip computer,radio/ powerantenna cassette, Hazardlamps,luggagecompartment lock Rearwindow demister Interior lamps Powerwindows Electric door locks Instrument andswitchilluminationlamps Enginecooling fan relay and air conditioning Instruments, rearwindow demister relay, fuel injectionandignition system Powerwindows,electricmirrors and door locks andcruisecontrol Vacant Automatictransmission, reverse lamps and speedsensor Radio/cassette and power antenna Windscreenwiper motor and turn signal lamps Cigarettelighter andrear wiper motor Stoplamps Vacant Fuse Rating AMP
15 20 25 l0 20 15 5 25 7.5 10 l0 10 l5 20 15
10 tl 12 13 t4
15 l6 t7
Renewing the high mounted stop lamp bulb. Station Wagon 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 the lens from the number plate larnp.
6. UNDSCREEN
WTPER ARMS
The removal and installation procedureremains as described in the main manualwith attention to the following points.
- Part I. 1990Models Swpplcment
277
(2) Removethe bulb from the lamp base. (3) Instala new bulb andensuring thattheterminals are clean and have sufficient tensionto retain the bulb If necessary, securely andprovidegoodelectricalcontact. removethe bulb andbendthe terminalstowardsthe centre of the lamp. (4) Checkthat the lens sealis not split or perished andinstalthe lensto the lamp assembly. (5) Instal the lamp to the vehicle and tighten the retainingscrewssecurely.
8. WIRING DI.AGRAMS
Renewing the bulb in the Utility number plate lamp. The wiring diagrams covering all models are displayed in the main manual.
278
Supplement - Part 1. 1990 Models

.. i': .,':.,".
. o : ' "4r
BODY
1. FRONT AND REAR DOORS REMOTE CONTROL AND DOOR LOCKS O n m odels ma n u fa c tu re d fro m O c to b e r 1989. redesigned power door locks were introduced with the actuator integral with the lock assembly. With the introduction of the new type power door locks, the nylon sleeved door lock strikers were deleted. The proceduie to remove and instal the front and rear door remote control and door lock is basically the same as described in the main manual allowing for minor variation. NOTE: Damage could result if nylon sleeved door lock strikers are installed to vehicles originally equipped with plain door lock strikers.
2. TAILGATE UTILITY MODELS

To Remove and Instal (1) Operate the releasehandle and open the tailgate. (2) Support the tailgate on padded srands anddisconnect 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 securely tightened. 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 disconnect the limit cables from each end of the tailgate. (3) Remove the release handle retaining screw and remove the releasehandle from the lock shaft.
Location of the tailgate hinge retaining bolts. (4) Remove the retaining screws and remove the cover surrounding the lock shaft from the tailgate. (5) Disconnect the retaining clips from the operating rods and lift the rods out of the lock lever. (6) Remove the retaining screws from the limit cable brackets and remove the brackets and operating rods from the tailgate. (7) Hold the lock shaft to avoid dropping the lock mechanism inside the tailgate, remove lhe retaining screws and manoeuvre the lock mechanism out of the tailgate. Installation is a reversal of the removal procedure with attention to the following points: (1) Priorto installation,lubricateall thr:moving and sliding surfacesusing lithium based grease. (2) Ensure that the operating rods enter:from the top of the lock lever and lock the retaining clips securely. (3) Tighten all the retaining screws ser:urely.
279
NART2. 199I MODELS

ENGINE
SPECIFICATIONS CYLINDER HEAD Minimum cylinderheadfacethickness. . . . . PISTONSAND RINGS Pistonring endgap: ring Uppercompression ring Lower compression
Connecting rod bearing oil clearance .
1.12 mm
CAMSHAFT AND BEARINGS Bearingjournal diameter journaloil clearance Camshaft lobelift: Camshaft Inlet Exhaust endfloat Camshaft
45.33445.369mm mm . .0.021-O.107 . 6.43mm ...6.48mm . . . .0.164.27 mm
....0.305-{.559mm ....0.25m.635mm
CONNECTINGRODSAND BEARINGS mm .0.A234.053
CRANKSHAFT AND MAIN BEARINGS mm .0.023-0.53 Main bearing oil clearance . . .
LUBRICATION Maximum regulated ....Approximately4I4kPa oilpressure... Minimumoil pressure at 1 850 rpm (normal ....375kPa operatingtemperature).. . 66.3 mm regulatorspringfree length . . . Pressure
@
t'"';
,::...,.,-::::&,':r::,..:::t::.:...:..,.., i AIR INTAKE DUCT
&",,
HOSE OVERFLOW
View of the engine compartment.
280
TORQUE WRENCH SETTINGS Main bearingcapbolts Camshaft sprocket bolt Rockerarm pivot bolts Timing chaindamperretainingbolt Oil filter adaptor bolts Flywheel/drive platebolts Camshaft thrustwasherscrews
. . 39 Nm + 48" 200 Nm . . 65 Nm . 26 Nm . .35 Nm . . . .22 Nm + 75" 18 Nm
1. DESCRIPTION The following production changes to theengineapply to modelsmanufactured from mid November1990. A redesigned inlet manifoldis installedwhich cannot be installedto previousmodels.To improve air distribution, a hllmouth is installedbetweenthe inlet manifold and the throttle body adaptor.To reducenoise and vibration, cast iron exhaustmanifoldsare installedwhich are connected to redesigned enginepipes.The oxygensensor is installedto the left handenginepipe. The cylinderheads haverevisedcoolantpassages and a 20 mm hole is drilled in the inlet manifold face for the positivecrankcase ventilationsystem. The cylinder head gasketsare coatedwith an adhesiveon one side and are markedwith anzurowwhich mustfacerearwards whenthe gaskets areinstalled. Due to the revisedcoolantpassages, the cylinder headsand gaskets must not be installedon
FOWER STEERilG RESERVOIR fL ALTERI{ATOR , /THROTTLEBODY
INLET MANIFOLD
rHRorrLE"""t-nQ@
Inlet manifold bellmouth, adaptor and throttle body. earlier models. Improved valve stem oil sealsare installed which are identified by the course sealing ribs and the letters IPC on the top the seals.These sealscan be installed to earlier models. The cylinder block, which is not compatible with
DRIVEBELTTEN$OHER
I
&
WATERPUMPPULLEY
CRANKSHAFT'PULLEY
EXHAUSTIIAMFOLD STARTER TSOTOR
ilOUilNNG WIRINGHARNESS
Engine and transmission assembly.

E

earlier,itifdfi, ;hi'ffmdsiSxr aleradons and is iden-
281
tified by the EV6 mark which is cast in each side of the
cylinder block. Stainless steel welch plugs are installed to the cylirder block and cylinder heads. 'ihe pistons are redesigned with an oval shapedztop ring land to provide improved piston clearance during thermal expansion and are identified by the arrow on the piston crown that is formed by a number of dots. The pistons can be installed to previous models. The oil pump is unchanged except for the installation of a longer pressure regulator spring to increase oil pressure. The camshaft sprocket and gear are secured to the camshaft using a key and a single retaining bolt. The timing chain cannot be used on early models as it is incompatible with the tooth profile on the camshaft and crankshaft sprockets. The camshaft thrust bearing and spring installed to earlier models is deleted and the camshaft is retained by a
to thefrontof thecylinder whichis secured thrustwasher

block with three screws. The valve timing and lobe lift is the same as 1990 models but the front of the camshaft is redesigned to suit the installation of the thrust washer and the revised camshaft sprocket and gear. The timing cover has redesigned coolant passagesto improve coolant circulation and cannot be installed on earlier models. A shield is installed to the timing cover to prevent foreign objects contacting the crankshaft sensor and the intemrpter blades at the rear of the crankshaft pulley. To ensure security, the crankshaft pulley is now a press fit on the crankshaft and is identified by three elongated holes in the front face of the hub. The pulley can be installed to previous models if the corresponding retaining bolt and washer are installed. Unlike previous models, the crankshaft is the samefor automatic and manual transmission models. On manual transmission models, a redesigned spigot bearing is installed which cannot be installed to earlier models. The crankshaft cannot be installed on earlier models due to the additional flywheel/drive plate retaining bolt holes and the redesigned rear flange which is machined to suit a one piece neoprene rear crankshaft oil seal. Unless otherwise stated, all procedures remain as described in the main manual and Part I of this supplement. However, due to a number of changesin the cooiing system, allowance should be made for variations when reference is made to the coolant and heater hoses and pipes. NOTE: If the cooling system is drained, ensltre that it isfilled as described loter in this supplement to prevent engine overheating.
Drive belt tensioner and associated components. Power steering pump removed. (1) Prior to installing the heater pipe, check the condition of the O ring and renew as necessary. Apply petroleum jelly to the O ring and instal the heaterpipe fully into the timing cover. 3. IhILET IVIAMFOLD The procedure to remove and instal the inlet manifold remains as described in the main manual with attention to the following points. (1) Disregard operations (5) and (9) of the removal procedure. (2) Operation (17) of the removal procedure should read as follows:
2. DRIVE BEI.JT TENSIOhIER

The procedure to remove and instal the drive belt tensionerremains as describedin the main manual with attention to the following point.
Inlet manifold gaskets and seals correctly installed.
282
- Part 2. 1991 Supplement Models

5. ROCHER ARIftSAstD,PUSlnil)S
tescribedr in the main manual and Part I of this supplement with dtentisr ts the following points. (l) Disregard operation (a) of the removal procedure in the main manual.
View of the inlet manifold showing the tightening sequence of the retaining bolts. Release the clamp and disconnect the heater hose from the rear of the inlet manifold. (3) Operation (18) of the removal procedureshould read as follows: Release the clamp and disconnect the upper radiator hose from the thermostat cover. (4) When installing the inlet manifold, ensure that the cut out portions of the rubber valley seals are sitting over the cylinder block protrusions.
Ensure that retainers are installed with the arrows facing towards the inlet manifold. (2) When removing the left hand rocker cover, remove the lock nuts and withdraw the left hand engine lifting bracket from the exhaust manifold retaining studs. (3) Prior to installation, liberally coat thelcontact surfaces of the rocker arrns and pivots with a mixture of molybdenum disulphide greaseand clean engine oil.
4. D(HAUST MAMFOLDS
The procedure to remove and instal the exhaust manifolds remains as described in the main manual with attention to the following points. (l) Where applicable, remove the lock nuts and lock plates prior to removing the manifold retaining studs. (2) When removing the left hand exhaust manifold, disregard operation (3) (a). (3) When removing the right hand exhausr manifold, disregard operations (a) (b) ro (4) (0.
6. CYLINDER HEADS
All procedures remain as described in the main manual with attention to the following points.
Installed view of the right hand side exhaust manifold and the engine pipes.
The cylinder head gaskets must be installed with the arrow facing towards the rear of the engine, Tighten the cylinder head bolts in numerical -equenIe.
Suf'plm,nt- Part 2. 1991 Models

(1) Whenchecking mountingface thecylinderhead thickness, referto Specifications in this supplement. (2) When installingthe cylir&r headgaskets, use ciEg&,Walscr*ftiag &e swf&es which are coated with an adhbsiveand ensurethat the arrow on the top of the gaskets is facingtowardsthe rearof the engine. 7. TIMING COVER The procedureto remove and instal the timing cover remainsasdescribed in the main manualandPart I of this supplement with attentionto the following points. (l) It is necessary to usea suitablethreejaw puller to removethe crankshaftpulley. (2) To remove the shield from the timing cover, insert a screwdriver behind the shield adjacent to the retaining studs and gradually lever the shield from the studs.
283
Method of preventing the balance shaft turning when removing the retaining boh. If necessary,remove the balance shaft gears, as follows: (a) Slide the balance shaft drive gear from the camshaft and remove the key from the end of the camshaft. (b) Using a T30 Torx socket, remove one of the screws retaining the camshaft thrust washerto the cylinder block. (c) Instal the balance shaft drive gear to the camshaft so that one of the holes in the face of the gear is aligned with the vacant thrust washer retaining screw hole and instal a5/rc UNC x 30 mm bolt finger tight. (d) Instal al2mmthick spacerwith an inside diameter 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 bolt and withdraw the gear from the balance shaft. (0 Remove the lock bolt and the retaining bolt and withdraw the gear from the camshaft. (4) Remove all sealant from the threads on the camshaft sprocket and the balance shaft gear retaining bolts. (5) Apply Loctite 242 or equivalent sealant ro the
"1"
@l
/
ffiebre
CRANKSHAFT SENSOR
Grankshaft pulley, timing cover and associated components. (3) Where applicable, bend rhe lock tabs over the rear sump bolts. (4) Check the condition of the heater pipe O ring and renew as necessary. Apply petroleum jelly to the O ring and instal the heater pipe fully into the timing cover. (5) Check the adlbstment of the crankshaft sensor as described later in this supplement. (6) Prior to installing the crankshaft pulley, apply RTV 732 sealantto the keyway slot. 8. TIMING CHAIN, SPROCKETS AITD
BAIANCE SHAFT GEARS

The procedure to remove and instal the timing chain, sprockets and balance shaft gears remains as described in the main manual with attention to the following points. (1) Disregard operation (a) of the removal procedure in the main manual. (2) Operation (8) of the removal procedure should read as follows: Remove the retaining bolt and withdraw the damper assernbly from the engine, noting the installed position of the spring.
Balanceshaft timing marks correctly aligned.
284

scREws
-:T' $,.Em n' rE.#ff.
i0
o/
"r *{u*
}'o*
THRUSTWASHER
Gamshaft and associated components.
Gamshaft timing marks correctly aligned. threads on the balance shaft gear and the camshaft sprocket retaining bolts and to the thrust washer retaining screws. (6) Ensure that the key is installed to the camshaft and that the balance shaft and camshaft timing marks are aligned. (7) Instal the damper assembly ensuring that the end of the spring is located in the hole adjacent to the retaining bolt. Tighten the bolt to the torque specified in this supplement. (8) Disregard operation (6) of the installation procedure.
Camshaft thrust washers correctly installcd. The word TOP must be uppermost and facing outwards. previously described in this supplement under the Timing Chain, Sprockets and Balance Shaft Gears heading. (3) Operation (5) of the removal procedure should read as follows: Remove the remaining Torx screws and withdraw the camshaft thrust washer. (4) Remove all traces of sealantfrom the threads of the thrust washer retaining screws and the cylinder block. (5) Apply clean engine oil to the camshaft and thrust washer contact surfacesand instal the thrust washer ensuring that the word TOP is uppermost and is facing outwards. (6) Apply Loctite 242 or equivalent sealant to the thrust washer retaining screws and tighten to the torque specified in this supplement.
10. OL PUMP
Ensure that the end of the damper spring is located in the retaining hole. All procedures remain as described in the main manual with attention to the following point. (1) When checking the oil pressure or the pressure regulator spring free length, refer to Specifications in this supplement.
9. CAI}TSHAFTAI\ID BAI.ANCE SHAFT

All procedures remain the same as the main manual with attention to the following points. (1) When checking the camshaft lobe lift, journal diameter and oil clearance, refer to Specifications in this supplement. (2) In operation (4) of the removal procedure loosen but do not remove the balance shaft gear retaining bolt as
11. SUMP AND OIL PI.JMP PICK.UP PIPE

All procedures remain as described in the main manual and Part I of this supplement with attention to the following points.
- Part 2. 199I Models Suppternent

i'Pfidf torernQvfig fte fear sump bolts, straighten (f ::: :': : r'r'r' krck pfate. the tabs'ontlie ' (2)" EnSurethatttwtWo'yelbw bolts are installed to the centre troles at the rearof the sump and bend the lock plate tabs over the bcilts. 12. CRANKSHAFT TO REMOVE AND INSTAL Front Crankshaft Oil Seal The procedure remains as described in the main manual with attention to the following points. (l) On automatic transmission models, operation (4) of the removal procedure in the main manual requires that the drive plate be locked prior to removing the crankshaft pulley retaining bolt. This will necessitatethe removal of the support brace as described previously in Part 1 of this supplement. (2) It is necessaryto use a suitable three jaw puller to remove the crankshaft pulley. (3) Prior to installing the crankshaft pulley, apply RTV 732 sealantto the keyway slot. R,earCrankshaft Oil Seal (1) Remove the transmission as described in the relevant transmission section in the main manual. (2) Remove the flywheel or drive plate as described in the Engine section in the main manual. (3) Using a screwdriver, lever the seal from the engine ensuring that a thin piece of shim brass or steel is positioned between the screwdriver and the crankshaft to protect the crankshaft surface. (4) Check the seal recessfor burrs and damage and rectify as necessary. (5) Check the seal contact surface on the crankshaft for burrs and repair or renew the crankshaft as necessary. (6) Apply clean engine oil to the inner and outer sealing surfaceson the new seal. (7) Ensure that the seal lip is facing towards the front of the engine and, using a mandrel, instal the seal OIL SEAIS
285
squarely into the recessuntil the distance the between the rear face of the seal and the rear face of the crankshaft flange is 4.24.7 mm. NOTE: The rear main bearing cap oil return hole will be blocked if the seal is installed further than 4.7 mm into the seal recessand will result in oil leakage. (8) Instal the flywheel or drive plate ensuring that the bolts are tightened to the torque specified in this supplement. On automatic transmission models, ensure that the retainer plate is installed with the dimple facing away from the drive plate as shown in Part I of this supplement. (9) Instal the transmission as described in the relevant transmission section in the main manual. 13. PISTONS, CONNECTING RODS AND
CYUNDER BORES
All procedures remain as described in the main manual with attention to the following points. (1) Ensure that the connecting rod bearing oil clearance is within Specifications in this supplement. (2) The piston diameter must be measuredat a point 44 mm below the top of the piston at a right angle to the gudgeonpin axis. (3) The direction arrow on the top of the pistons must face towards the front of the engine as originally described in the main manual. (4) Ensure that the piston ring end gap is within Specifications in this supplement.
14. CRANKSHAFTAND BEARINGS

All procedures remain as described in the main manual with attention to the following points.
Method of removing the rear crankshaft oil seal.
The main bearing caps must be installed in numerical order and with the ribs facing towards the starter motor.
286
MAIN BEARING
- Part 2. 1991Madel,s Supplement

STANDARD UNDERSIZE 24500039 24500640
18017978 18017974 18017975 18017976 numerical order and with the ribs on the side of the caps facing towardsthe startermotor sideof the iylinder block. (6) Undersizemdn pearingsheUs can be identified usingthe identificationchartaspreviouslydescribed. (7) Tighten the main bearing cap bolts using rhe following procedure: (a) Tightenthe bolts to a rorqueof 3l*39 Nm. (b) Using an angle gauge, tighten the bolts and additional45". (8) Instal a new rear crankshaftoil seal as previously described in this supplement. (9) Whenever therearmainbearing capis removed, the rear crankshaftoil sealmust be renewedaspreviously described.
UPPER
NO1
24500740 24500741
18017982 18017983 18017979 18017980 24500740
LOWER
UPPER
NO2 LOWER UPPER

NO3
LOWER UPPER
NO4 LOWER
24500639
24500641
15. EXHAUST SYSTEM

The procedure to remove and instal the exhaust system remains as described in the main manual with attention to the following points. (1) The oxygen sensor is installed to the left hand engine pipe. If the engine pipe reqqires renewal, the oxygen sensor must be removed. The removal and installation procedure for the oxygen sensoris described in Fuel and Engine Management section in the main manual. (2) The engine pipes are secured to the exhaust manifolds using studs and nuts. (3) The rear muffler assembly is connected to the intermediate muffler using a flange type joint, gasket and bolts. (4) On Sedan and Station Wagon models, a flexible joint is installed to the rear muffler inlet pipe to reduce resonancein the exhaust svstem.
24500742
Main bearing identification chart. (l) The two piece rope crankshaft oil seal installed to previous models is replaced with a one piece neoprene oil seal. (2) Disregard operations ( 1) to (4) of the installarion procedure in the main manual. (3) Ensure that the main bearing shells are installed in the correct location. Compare the part number on the bearing shells with the identification chart. (4) Lubricate all bearing surfaces including the No 2 main bearing thrust faces with clean engine oil. (5) The main bearing caps must be installed in
ent - Part 2. 1991 Models
287
,COOLING
AI\D HEATING SYSTEMS

2. RADIATOR TO CHECK COOLANT LEVEL (l) With the engine cold, the coolant level in the reserve tank should be between the Minimum and Maximum marks. (2) If the level is below the Minimum mark. remove the cap and add the specified coolant to the reserve tank until the level is correct. NOTE: Do not top up the reserve tank with coolant containing a dtfferent type of corrosion inhibitor. If necessary,drain and refill the cooling system using coolant containing the correct type of inhibitor in the specified ratio. If the reserve tank requires frequent topping up, check the cooling systemfor leakage. (3) If the reserve tank is completely empty, remove the radiator cap and check the coolant level. If coolant cannot be seen in the filler neck, fill the radiator as described under the following heading. NOTE: The coolant level in the radiator should be checked periodically when the engine is cold. If the radiator requires topping up and the reserve tank is not empty, check for a faulty seal on the radiator cap or a loose or blocked overflow hose. TO DRAIN AND REFILL This engine is equipped with an air bleeder valve. The valve is used when refilling coolant using the manufacturers special tool AU425. It is not necessaryto open the valve when refilling the coolant 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, and remove the drain plugs. (4) When the coolant has drained, clean the cylinder block drain plugs, apply Loctite 242 or equivalent sealant to the threads and tighten the drain plugs securely. Connect the lower radiator hose. (5) Mix approximately 12 litres of coolant, consisting of 6 litres of the specified corrosion inhibitor and 6 litres of clean water.
SPECIFICAf,IONS
Coolant: T y pe . . . : . ...S } Vo e th y l e n e g l y c o l corrosi on
capacity
Radiator cap: Pressurerating Operating pressure
lil':li:'1"0]*::i:11Y,?f:
....135kPa . . l20 kPa-150 kPa
r. DESCRIPTION The following changesto the cooling system apply to models equipped with the revised engine described previously. The radiator has a conventional filler neck and a radiator cap and the surge tank installed to earlier models has been replaced with a reserve tank. An overflow hose is connected between the radiator filler neck and the reserve tank. As the coolant volume expands due to a rise in temperature,the pressurevalve in the radiator cap opens and allows the excesscoolant to flow into the reservetank via the overflow hose. When the coolant temperaturefalls, the vacuum valve in the radiator cap opens, allowing the coolant to siphon back into the radiator. Due to the redesign of the inlet manifold, the thermostat, coolant temperaturesensorand the temperaturegauge sender are located towards the front of the inlet manifold. The water pump spacerplate has been deleted and the coolant passages revised to suit the redesigned timing cover. The water pump pulley is narrower than previous models and neither the water pump or the pulley are interchangeablewith earlier models.
lnstalled view of the thermostat tank.
cover and the reserve
288
Supplement- Part 2. 1991 Moidels

3. THERMOSTAT The procedure: [o naneve, instal and check the thermostat remainsas debcribed in the main manualwith attentionto the following points. (1) The thermostat is locatedat rhefront of the inlet manifold. (2) Disregardoperation(2) of the removaland installation procedure. (3) The thermostatcover is retainedto the inlet manifoldusingtwo boltsanda gasket. The gasket mustbe renewed.
THERIIOSTAT I
(6) Disconnect the upper radiator hose from the thermostat cover and hold the hose verticaily, ensuring that the end of the hose is higher than the thermostat cover. (7) Fill the cooling system with coolant through the open end of the upper radiator hose until coolant flo*s from the radiator filler neck. Instal the radiator cap. (8) Continue to pour coolant into the op"n end of the upper radiator hose until coolant flows from the thermostat cover. (9) If the _cooling system has been completely place three cooling sysrem pellets (pirt No $1ai_ne$, M40124) into the upper radiator hose. (10) Quickly connect the upper radiator hose to the thermostat cover to prevent excesiive coolant loss ensuring that the pellets are not displaced. Tighten the hose clamp securely. (ll) Fill the reserve tank to approximately 25 mm above the Maximum mark and instal the cap. (I2) Start and run the engine for 20 minutes to dis_ solve the pellets and_purgeany air that may be trapped in the cylinder heads. check the coolant levei as previously described.
dffin
'wEry
!.sI:-
A
IN
tV
261861 oL**
Thermostat and associated components.
- Part 2. 1991Models Suppl,ement
289
AI{D ENGINE MAI.{AGEMENT AIND EMISSION CONTROL FI.TEL

I. FI.JELAND ENGilNE MANAGEMEIYT SPECIFICATIONS Injectorresistance resistance Coil secondary limit: High tensionleadresistance No 1, 3 and5 leads No 2, 4 and 6 leads Crankshaftsensorair gap TORQUE WRENCH SETTINGS Fuel rail retainingbolts Oxygensensor Crankshaftsensorretaining studs clampbolt sensor Crankshaft
FUEL RAIL AND INJECTORS The procedure to remove and instal the fuel rail and injectors remains as described in the main manual with attention to the following Point. Operation (5) of the removal procedure should read as follows: Releasethe clamp and disconnect the fuel supply hose from the fuel rail.
REGULATOR PRESSURE ETAINER
...15-17C, . . . 5-7 kO . 17kC) ' 25 kg' Refer to text . 11 Nm . . .60 Nm . . . 30 Nm . .5 Nm
#\
BOLT
O RING
DESCRIPTION to the fuel andenginemanageThe following changes ment systemapply to modelsequippedwith the revised previously. enginedescribed The fuel rail is redesignedand the flow rate of the A specialfuel hoseis installed injectorshasbeenaltered. betweenthe fuel supplypipe andthe fuel rail to reducefuel pulsations.The revised fuel rail and injectors are not with earliermodels. interchangeable The Coil pack installedon previousmodelshasbeen by threeindividualignition coils andthe igniliol replaced control module has been revised to suit the individual coils. is installedin the left handengine The oxygensensor thattheoxygen to ensure pipeandanearthwire is installed sensoris earthedsecurely.To prevent foreign objects andthe interrupterblades contactingthe crankshaftsensor pulley, a shieldis installedto at the rearof the crankshaft the enginetiming cover.
l ,w I
/ RETAINER
i \BoLr
0.p
components. and associated Fuelrail,iniectors IGNITION SYSTEM To Test- Code41 The procedureremains as describedin the main to the following points. manualwith attention (1l)' (1) If the testlampdoesnot light in operation in described as circuits associated checkthe EFI relay and the main manual. (2) Disregardoperations(20) to (26) in the main asfollows: manualandproceed
lnstalled view of the fuel rail and the fuel pressure regulator.
Installed view of the ignition control module and the ignition coils.
290
- Part 2. lgg l AMels Supplement

lefer to the.cylinder numbers stamped on the rear upper face of the ignition control module adjacent to each coil wlren csnnecting.the.h[h,gT!ry1l@s". i. . . ; i, CRANKSHAFT SENSOR Special Bquipment Required: To Instal and Adjust Crankshaft Sensor * tool4U423 (refer to text)
(a) Disconnectthe remaining high tension leads ftgT the ignition coils, removethJscrJws retainingthe coils to the ignition controlmoduleandpull eachcoil from the moduleusingcarenot to damage th-e terminals. (b) Connect a test lamp between a pair of the primary terminalsprotrudingfrom the top of ihe ignition controlmoduleandcheckthat the testlamp flashei when the starter motoris operated. Repeat thetesiontheremaining moduleterminals. If the test lamp doesnot flash at eachof the primary terminals, renewthe ignition controlmodule.
Speciat
Gheckingthe ignition coil secondary resistance. (c) Switch the ignition Off and using an ohmmerer, check the resistancebetween the primary te-rminals of each coil. Renew any coil which does not hive a resistance of 0.3-1.5 ohms. (d) Connect an ohmmeter between the high tension terminals of each coil. Renew any coil which doer not have a secondary resistanceof 5-7'k/ohms. IGNITION CONTROL MODULE AND IGNITION COILS The procedure to rernove and instal the ignition control module and ignition coils remains as desJribed in the main manual with attention to the following points. (l) To remove the ignition coils, remove the screws retaining_theignition coils to the ignition module and pull each coil from the module using care not damage the terminals (2) When installing the ignition control module, ensure that the retaining studs are correctly seated in the module. Align the mounting lugs on the base of the module with the corresponding holes in the mounting bracket and tighten the nuts securely. (3) Ensure that the seals are installed to the module terminals. If the sealsare damaged,they must be renewed. (4) Instal the ignition coils using care not to bend the terminals and tighten the screws. (5) If an ignition coil has been renewed, it will not have the cylinder identification numbers. If necessary,
To Remove and Instal (1) Disconnect the negative battery terminal. (2) Remove the engine cooling fan as described in the cooling and Heating Systems iection in the main manual. (3) Using an 18 mm ring spanner, rotate the ten_ . s.i9ne1 pulley bolt clockwise to raiie the pulley from the drive belt and remove the belt from the engine.(4) On manual transmission models, apply the handbrake fully, select top gear and chock the reai*heels to prevent the crankshaft turning. (5) On automatic transmission models, remove the support brace as previously described in part I of this supplement and place a lever between the cylinder block and 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 the crankshaft sensor. (8) Insert a screwdriver behind the shield adjacent to the retaining studs and gradually lever the shield from the studs. (9) Remove the retaining studs and withdraw the crankshaft sensor. (10) Check the interrupter blades at the rear of the crankshaft pulley for damage and signs of contact with the crankshaft sensor. Renew the crankshaft pulley as necessary. Installation is areversal of the removal procedure with attention to the following points: (1) Apply Loctite 242 or equivalenr sealant ro the retaining studs, instal the crankshart sensor to the engine ensuring that the dowel pin locates in the crankshaft sensor bracket and tighten the retaining studs finger tight.
t'Ttt 24st1261t2ffiA
I @,fl
/
BOLT
ffi@ =ilr-H?
@W /ru sxtelo
CRANKSHAFT SENSOR
ffiffi@
Grankshaftpulley, timing cover and associated components.
- Part 2. 199I Models Swfrlement

(2).. ,Unserew tharankshsftrsrsor elampbolt sufficiently to sllow,the senror.tcrnmrefreely. (3) Inssal the speial tool over the end of the crankshaftso that the one of the ymes is located in the crankshaftsnsorouter clpnnel and tighten the retaining studsto the specified torque. NOTE: The special tool, Part No AU423, is availablefrom Kent-MooreAustralia Pty Ltd (NSW). (4) Rotatethe specialtool severaltimes and adjust the position of the sensoruntil the vanes pass evenly throughthe sensorchannel. (5) Tightenthe clamp bolt to 3-5 Nm and confirm that the sensor is correctlyadjusted. NOTE: Overtightening theclampbolt will distort the mounting bracket and may cause damageto the sensorthrough contactwith the interrupter blades. (6) Ensure thatthe terminals arecleanandinstalthe wirias connectorto the crankshaftsensor. to the crankshaftpulley t?, Apply RTV 732 sealant keyway and instal the crankshaftpulley. (8) Rotatethe crankshaft slowly andcheckthat the intemrpter bladesdo not contact the crankshaftsenor.If necessary, remove the crankshaftpulley and check the crankshaft sensor adjustment usingthe specialtool. If the adjustment is correct,renewthe crankshaft pulley. (9) Tighten the crankshaft pulley rerainingbolt to the specifiedtorque. (10) Instalthe enginecoolingfan. .r,,.'. (11) Raisethe tensioner and instatthe drive belt. If riecessary, refer to the illustrationin the EngineTune-up sectionin the main manual. COOLANT TEMPERATURE SENSOR All proceduresremain as describedin the main manualwith attentionto the following point. (l) To gain access to the coolanttemperature sen-
29r
sor, it is necessaryto remove the engine drive belt, remove the alternator retaining bolt and, ensuring that the negative battery terminal has been disconnected, pivot the alternator upwards. OXYGEN SENSOR To Test Code 13
(l) With the engine at operating temperature, run the engine at 1 600-1 800 rpm for two minutes. (2) Using the backprobing method, connect the positive lead of a voltmeter to the control unit wiring connector terminal D7 and the negative lead to terminal D6. If the voltage is not 325475 millivolts, an intermittent fault is indicated. Check that all wiring and earth connections are clean and secure. (3) With the voltmeter remaining connected to the control unit wiring connector, disconnect the oxygen sensor wiring connector and, using a jumper lead, connect the harness connector violet wire terminal to a good earth point. If the voltage is less than 200 millivolts with the engine running, check the oxygen sensor and the harness connector for loose or dirty terminals. If no fault can be found, renew the oxygen sensor. NOTE: A faulty orygen sensor can be caused by contamination to the orygen sensor through the use of leaded fuel or unsuitable silicone sealants on engine components and may be identffied by o white, powdery substance covering the tip of the oxygen sensor. A contaminated orygen sensor should be renewed and the cause of the contamination rectified. (4) Stop the engine, disconnect the jumper lead from the harness connector terminal and connect a voltmeter 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 oxygen sensor for continuity and secure connections. If no fault can be found, renew the control unit. If the voltage is above 600 millivolts, check the circuits and connections between the oxygen sensor, the control unit terminal D6 and the engine earth terminals for continuity. If no fault can be found, renew the control unit. To Test Code 44
Location of the coolant temperature sensor.
(1) With the engine at operating temperature, run the engine at I 600-1 8fi) rpm for two minutes. (2) Using the backprobing method, connect the positive lead of a voltmeterto the control unit wiring connector terminal D7 and the negative lead to terminal D6. If the voltage does not remain constant below 300
2e2
- Part 2. Igg l Models Supplement

the xse of leded.fwl or unnitablesillcone sealants on engirte avmponefis.andvtWy tn identified by a white, pawdery subs&nce covering the tip of tlre orygen sensor., A contaminatedorygn sensor should be renewedand the causerectified. 2. EMISSION CONTROL DESCRIPTION The emissioncontrol systemremainsas described in the main manualexceptfor the foltowing changes to the positivecrankcase ventilation(PCV) systemwhich apply to models equippedwith the revised engine described previously. Cleanair is drawn from the throttlebody into the left hand side cylinder head via a vent hoseand an internal passage at the rear of the inlet manifold and the cylinder head. The PCV valve is installedinsidethe front of the inlet manifoldin a passage thatrunsbetween the inlet manifold plenumchamber andthe right handsidecylinderhead.
millivolts, an intermittent fault is indicated. check thatall wiring connections arecleanandsecure. (3) With the voltmeterremainingconnected to the controlunit wiring connector, disconnect the oxygensensorwiring connector andcheckthevoltagewith theengine idling. If the voltage is not 300-550 millivolts, check the circuit between the control unit terminal D7 and the oxygensensor connector for a shortto earth.If no fault can be found,renewthe controlunit. If the voltageis 300-550millivolts, checkthe circuits and connections betweenthe oxygen sensor, the control unit terminal D5 and the engine eirth terminals for continuity. If no fault can be found, check the following possible causes: Low fuel pressure Blockedinjectors Contaminated fuel Exhaustleaksahead of the oxygensensor MAP sensor Blockedoxygensensor vent to atmosphere (4) If the above componentsand conditions are satisfactory, renewthe oxygensensor. To Test- Code45 (l) With the engineat operatingtemperature, run the engineat I 600-1 800 rpm for two minuies. method,connect the posi. \Zl Using the backprobing tiveleadof a voltmeterto thecontrolunit wiring connector terminalD7 andthe negative leadto terminalD6. If the voltage does not remain constantabove 750 millivolts, an intermittent fault is indicated. check that all wiring connections arecleanandsecure. (3) With the voltmeterremainingconnected to the controlunit wiring connector, disconnect the oxygensensorwiring connector and,usingajumper lead,connect the harnessconnectorviolet wire terminal to a good earth point. If the voltageis above350 millivolts with the engine running,check the circuits and connections betweenthe oxygensensor, thecontrolunit terminalD6 andtheengine earth terminalsfor continuity. If no fault can be found, renewthe control unit. If the voltageis below 350 millivolts, checkthe following possible causes : High fuel pressure Leakinginjector(s) Ignition controlmoduleearthcircuit (ignition controlmoduleto controlunit terminal83) Charcoalcanistersaturated with fuel Coolanttemperature sensor MAT sensor MAP sensor Throttlepositionsensor (4) If the above components and conditions are satisfactory, renewthe oxygen sensor. NOTE: Afaulty orygensensorcan be caused by contaminationto theorygensensor through
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.
O RING I
AI II
tl
261/355
WM,W
pcvvAlve cAP
PGV valve and associated components.
- Part 2. 1991 Models
293
UAL TRAI{SMISSION, AUTOMATIC

TRANShfiIS$ON AI{D ELECTRICAL SYSTEM
1. CLUTCH AND IIANUAI TRANSMISSION
STARTER MOTOR On automatic transmission models manufactured from August 1991, the Bosch starter motor is replaced by a Delco Remy starter motor. The Delco Remy starter motor is similar to the type installed to manual transmission models as described in the main manual and is identified by the NO SHIM imprint on the end bracket.
DESCR,IPTION The clutch and manual transmission is the sameas previous models except that the design and operating characteristics of the clutch unit has ben revised to achievesmootheroperation.The front bearingretaineron the transmission is 9 mm shorterto suit the revisedclutch unit. The revised clutch unit can be installed to earlier models provided that the transmissionfront bearing retaineris shortened by 9 mm. If the transmission is to be installedto an earlier model, the longer type front bearing retainer mustbe installedto the transmission if the revised clutch unit is not alsobeinginstalled. All proceduresremain as describedin the main manual. 2. AUTOMATIC TRANSMISSION DESCRIPTION The automatictransmission is the same as 1990 modelsexcept thatthe shiftpointshavebeenaltered to suit the revisedengine. 3' H PgaBICAL SYSTEM ALTERNATOR The alternator is sameasthe oneinstalted to previous modelsexceptthat the installedposition of the slip ring endbracket,statorandassociated components are rotated 90" in relationto the drive end brackefto improve access to the altemator wiring and to accommodate the revised inlet manifold. All servicingprocedures remain as described in the main manual.
View of the Delco Remy starter motor removed from the vehicle.
For all servicingprocedures referto the main manual. However,it shouldbe notedthat on all modelsmanufactured from August 1991includingthosewith a manual transmission wherethe startermotor end brackethas the NO SHIM imprint, the pinion meshmustnot be adjusred. The Delco Remy and Bosch starter motors are not interchangeable. WIRING DIAGRAMS The wiring diagramscovering all models are displayedin the main manual.
294
CONVERSION TABLES
Quantity
Imperial Unit
inch (in) foot (fr) yard (yd) furlong (fur) mile (for navigation)
Metric Unit millimetre (mm) or eentimetre (em) eentimetre or metre (m) metre (m) metre (m) or kilometr.e (km) kilometre (km)
internationallautieal (n mile) gl'am (c) Cram (g) kilogram tonne (t) square square square square square heetare hectare square eubic cubie cubie eubie mile
c onue rsion Fac tors re piiffi

-Htpfri ' ' MetricAnits
LENGTH
i*iiiliu""u,
I cm : 0.894 in lm : 3.28 ft l m : 1 . 0 9y d l k m : 4.97fur l k m + 0,62l.mile 1 8 5 2m 0 . 0 3 5 3o z : 2.20Ib kg= : 0.157 stone kg= + 0.984 ton
cm2 : 0.lb5 inz
I ih-='S5.{ ffi
f ft : 30.b em r yd : 0.914m lfur:201 m I mile t.6t km lnmile:
MASS
ounce (oz) pound (lb) stone ton square inch (inz; square foot (ftz) square yar.d (yd2) perch (p) rood (rd) acre (ae) square mile
(ks) ;;lilosram
AREA
VOLUME
eentimetr.e (emz) eentimetre (cmz) or metre (mz) metre (mz) metre (mz) (ha) (ha) kilometre (kme)
oz : 28.8 g lb:454g stone : 6.85 kg ton : 1.02 t 1 inz : 6.4b cmz I fbz : 929 emz
I I I I
cubie inch (ina) eubic foot (fts) cubic yard (yda) bushel (bus)
I ydz : 0.886 mz lp : 25.3 mz I rd : 0.101 ha I ae : 0.405 ha 1 square mile : 2.bg kmz l i n s : 16.4 em3 1 f t 3 : 0.0283 m3 l y d a : 0.765mg l b u s : 0 . 0 3 6 4m g l f l o z : 28.4 ml r p t : 568 ml I gal : 4.55 litre I acre foot : l2B0 m3 : r.2B Ml : r lbf 4.45 N 1 tonf : 9.96 kN I psi : 6.89 kpa I atm : l0l kpa 15.4 Mpa
eentimetre (cms) metre (mr) metre (rpe) metre (ma)
m 2 : 10.8 ftr m 2 : 7.2Oydz m 2 : 0 . 0 3 9 5p h a : 9.88 rd h a : 2.47 ae k m z : 0.386 squaremile
VOLUME (fluids)
fluid ounee (fl oz) pint (pt) gallon (gat) acre foot
pound-foree (lbf) ton-foree (tonfl pound per square inch (psi) atmosphere (atm) ton per square inch (ton/in2) psi
millilitre (mt) millilitre (mt) or litre (l) litre (/) or cubic metre im) cubic metr.e (m3) or megalitre (Mt)
newton (N) kilonewbon (kN) kilopascal (kpa) kilopascal (kpa) or megapaseal (Mpa) megapaseal (Mpa)
I em3 - 0.0610 ins lm3 - 35.8 ftg 1 m 3 : 1 . 3 1y d s 1 m 3 : 27.5 bus I ml : O.OB52 ft oz I litre : l.?6 pt I ms : Z2O gil I Ml : 0.811 acre foot
FORCE PRESSURE
N : 0.225 lbf kN : 0.10O tonf I kPa: I MPa : I MPa : 0 . 1 4 5p s i

i
I ton/in2 : I psi :
9.8? atm 0.0G47 ton/in2 1 4 . 2 2p s i 0.621 mph
kg/emz
VEI,OCITY
mile per hour (mph) (for navigation) temperature ("F)
0.070 kg/cmz
Il3f&.;;
hour (km/h) Per

("C)
I kg/cmz: I km/h :
I mph : l.6t km/h I kn : 1.85 km/h
TEMPERATURE DENSITY
temperature
"c:+("F-sz)
1 lb/in3 : 27.7 t/mg
9X"C r. :_1+ 82 1t/mr : 0 . 0 3 6 1l b / i n 3
pound per cubic inch (lblina)
ton per cubic yard
ENERGY
gram per cubie centimetre (g/cmB) : tonne per cubic metre (t/ms) tonne per.cubic metre (t/m3) kilojoule (kJ) megajoule (MJ) kilowatt hour (kWh)
1 ton/yda
British thermal unit (Btu) therm (for eleetrical energ-y)

horsepower (hp)
l.BB t,/mg
I t/mz :
0.752 ton/yda
POWER TIME
kilowatt (kW)
seeond (s) minute (min) hour (h)
I Btu : 1.06 kJ I therm : 106 MJ r kwh : I hp : 0.246kW
l k J : 0.948 Btu l M J :9.48 X l0stherm 3.60 MJ
I kW : r.B4hp
FREQUENCY ANGUI.AR VELOCITY TORQUE
I min': 60 s th:3600s lels:1Hz LHz:lc/s
cyele per second (c/s) revolution per minute (rpm)
hertz
(Hz)
radian per seeond (radls) revolution per minute (rpm) Nm
1 rpm :
0.10b rad/s
I radls :
9.55 rpm
lb-ft
inches of mercury (in Hg)
VACUUM
r lb-ft : 1.85582 Nm
I in Hg : 3.386 kpa
I Nm : o.iARz ru_ft
I kPa : 0.295 in Hg
kilopaseal (kpa)
Conaersion Tables
295
rxcHES
fnchor I
iilLLltlETiES m.mr.
Flttltt'lETRES 70 INCHES Inchcr rn.rnt. I
FAHRENHEIT
& CELSIUS
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157
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VN VP Commodore Calais Workshop Manual

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VN VP Commodore Calais Workshop Manual

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Commodore Executive Station Wagon

Lexcen Station Wagon

Not for distribution outside of AllCarManuals.com

Description mechanism Clutch unit and release

LUBRICATION AND MAINTENANCE

WHEELS AND TYRES

ROADSIDE TROUBLE SHOOTING

Hydraulic tappets Cvlinder heads

Description Preliminary inspectionand testing

COOLING AND HEATING SYSTEMS

FUEL AND ENGINE MANAGEMENT

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2ffi 260 2ffi

CLUTCII AND AUTOMATIC TRANSMISSION

Rear axle IteerinS Front suspension

REAR AXLE, STEERING AND FRONT SUSPENSION.

ST]PPLEMENT . PART 1. l99OMODELS

Camshaft and balance shaft

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Referto supplement for more information.

VEHICLE IDENTIFICATION AND GENERAL SPECIFICATIONS

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

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Tension wrench, piston ring compressor and valve spnng compressor.

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Not for distribution outside of AllCarManuals.com

Tap and die set and assorted screw extractors.

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Not for distribution outside of AllCarManuals.com

Not for distribution outside of AllCarManuals.com

Referto supplement for more information.

LUBRICATION AND MAINTENANCE

Removing the engine oil filter using a filter removal tool.

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and Maintenance Lub ri,cati,on

lnstalled view of the differential filler plug'

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Lubrication and Maintenance

SERVICE SCHEDULE Weerkly I OOOkm 5 THOUSAND KILOMETRES 1 5 2 5 35 45 5 5 65 7 5 85 9 5

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Lubrication end Maintenance

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Lubrication and Maintenance

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Lubrication und Maintenance

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Referto supplement for more information.

WHEELS AND TYRES

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View of the jack correctly positioned jacking point.

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Not for distribution outside of AllCarManuals.com

Not for distribution outside of AllCarManuals.com

Referto supplement for more information.

The air cleaner should be serviced at regular intervals.

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Checking the compression pressure using a compresston gauge.

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Check the high tension lead terminals for corrosion or burning.

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ffi _ U P PE R LowER-+ cottlPREssloN ffi e"--"-""**'s