Haynes Mercury Capri Owners Workshop Manual 085696655X, 9780856966552

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Mercury Capri Owners Workshoo Manual Mike Lewis/Larry Warren Models covered: All Capri, Ghia & RS models with 2.3 liter, 2.3 liter Turbo, 3.3 liter engines.

ISBN O 85696 655 X

©

Haynes Publishing Group 1981

Aacoe

All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording or by any information storage or retrieval system, without permission

in writing from the copyright holder.

Printed in England

HAYNES PUBLISHING GROUP SPARKFORD YEOVIL SOMERSET distributed in the USA by

HAYNES PUBLICATIONS 861 LAWRENCE DRIVE NEWBURY PARK CALIFORNIA 91320

USA

INC

ENGLAND

Acknowledgements We wish to thank the Ford Motor Company for the supply of technical manuals and information as well as some of the illustrations which were used in the production of this manual. Special thanks go

to the Ford Parts and Service Division’s Publications Section and the Training and Publications Department, whose employees lent invaluable help on several occasions.

Introduction to the Mercury Capri Introduced in 1979, the Capri is the first U.S.-manufactured version of a car previously built in Germany and sold here. The redesigned bodywork is available in two- or three-door models. The Capri comes with standard equipment which includes a 2.3 liter, 4cylinder engine, 4-speed manual transmission, MacPherson strut-type front suspension, coil-spring rear suspension, rack and pinion steering, halogen headlamps, and high-backed bucket seats. Options include a turbocharged, 2.3 liter, 4-cylinder engine, 3.3 liter, 6-cylinder engine, automatic transmission, various radio options, various trim options, air conditioning, power brakes, and power

steering. The V-8 engine option and its accessories are described in another Haynes manual. In addition to the two body styles, the Capri is available in three versions. The standard package is, as the name implies, the basic

Capri. The luxury version is known as the Ghia, and offers many comfort options. Performance is represented by the RS, which includes special handling and performance options. Extensive sound deadening is used so that the Capri rides as quietly as many larger cars. Economy is provided by the smaller engines and the turbocharging options. Mechanically,

the Capri is of standard

Panhard

layout, with the

engine mounted at the front of the car and the transmission mounted directly behind. A driveshaft transmits the engine power to the differential, then to the rear axles. The rear axle is of the solid type, sprung by coil springs, while the front suspension is of the MacPherson strut type. All Capri models come equipped with front disc brakes and rear drum brakes. The drums are self-adjusting.

?

About this manual Its aim

The aim of this book is to enable you to get the best value from your car. It can do so in two ways. First, it can help you decide what work must be performed, saving you the cost of diagnostic work by a mechanic, should you decide to have a dealer or garage perform the work. The routine maintenance, troubleshooting, and the text will help you pinpoint random faults and discuss their correction when they occur. It is hoped that you will use this manual for its second, fuller, purpose and perform the work yourself. This will not only provide you the satisfaction of a job well done, but will save you the time and

aggravation of arranging rides and all of the other problems which occur when dealing with a dealer or garage. On many simpler tasks, it will be actually cheaper to perform the work yourself. To reduce ever-rising labor costs, many dealerships and garages replace entire sub-assemblies, when a single component fix may be all that is needed. This book is intended to help the home mechanic determine which small part may be at fault and repair just that

components or to limit access to particular parts. Where this is the case, use of the special tool is described. If the tool cannot be borrowed or purchased, the work must be entrusted to a dealership or

garage. Using the manual

This manual

is divided

into twelve

Chapters.

Each

Chapter is

divided into numbered Sections which are headed in bold-face type and separated from the surrounding text with horizontal lines. In some Chapters, the format is broken into Parts which are identified by italic headings, but do not interrupt the serial order of the Sections. Each Section is divided into serially numbered paragraphs. There are two type of illustrations:

1) Figures — which are numbered according to Chapter then according to appearance order (eg, Fig. 1.3 means ‘‘first Chapter, third

figure’’)

special tools are recommended or used unless absolutely necessary. Most special tools are recommended to enable dealership and garage

2) Photographs — which are referenced by Section number then according to the paragraph in which the action is described (eg, 4.5 means ‘‘Section 4, fifth paragraph’’). A cross referencing is provided in the appropriate paragraph with the notation ‘(photo)’. Once a task is described in the text, it is seldom repeated. If it is necessary to refer to another Chapter, reference will be given as (for example) ‘Chapter 3’. References to another Section within the same Chapter will be given as (for example) ‘Section 16’. References to the right, left, forward and rear directions are given according to the location when seen by the driver seated in the driver's seat. Whilst every care is taken to ensure that the information in this

mechanics to perform certain tasks faster and have no bearing on the actual performance of the task other than that one thing. On a small number of occasions, a special tool is required to prevent damage to

manual is correct no liability can be accepted by the authors, or publishers for loss, damage or injury caused by any errors in, or omissions from, the information given.

problem

at lower cost.

This manual has drawings and descriptions to show the function and operation of the various components so that their layout can be understood. The repair tasks are described with the novice home mechanic in mind and every attempt has been made to simplify complicated functions and tasks.

In describing the various tasks, it is assumed that the home mechanic has a normal set of tools available to him (or her), and no

Contents Page

Acknowledgements

2

Introduction to the Mercury Capri

2

About this manual

2

General dimensions, weights and capacities

6

Buying spare parts and vehicle identification numbers

7

Tools and working facilities

8

Bolts, nuts and fasteners

10

Recommended

12

lubricants and fluids

Safety First!

16

Routine maintenance

17

Troubleshooting

21

Chapter 1 Part A 4-cylinder engine

28

Chapter 1 Part B 6-cylinder engine

56

Chapter 2 Cooling system

78

Chapter 3 Fuel, exhaust and emissions systems

86

Chapter 4 Ignition system

110

Chapter 5 Turbocharger

AZ

Chapter 6 Clutch

127

Chapter 7 Transmission

133

Chapter 8 Drive shaft, rear axle and differential

153

Chapter 9 Braking system

158

‘

Chapter 10 Suspension and steering Chapter

11

177

Electrical system

191

a Chapter 12

Index

Bodywork

a

a 242

265

1979 Mercury Capri RS

1980 Mercury Capri 3-door

General dimensions, weights and capacities Dimensions Overall laren ccresresrt-svsuitsssvssscscactesantyavertesccecesnosanvesepnartceesscessospeonvannesunts sunioasest

179.1

Overall wichtniesccis; sutesaatosvaraconcacsecensnugnansrscumes uareoraieeseerec eitsavanwarcttexaetseenseuect cate

67.4 in

in

Overall halghtiscscicescccdactvastvapineter fannanetuce¥ancs case otravesigtexsnaneruaate oremnaeeaatedeel

51.4 in

Wheel bea ce chats ees scesascitacs soospneete pees ew nian vasesapa srcutwan onesaveceeceainmoneriaceneetenes

100.4 in

2-GOOM ..ssssanvessusaendasngsnseuatsapnason'a csuhinetestvshuseabievecua aphectuaeeeteRemers eBaatoxtaentnnenexeee SB—CHOOM. ..ssedpussivadia cade nxpteitaaptnnaasvvsactlgareas ciceeanetiuiatn osotaiendia taupeUae aint eeneae

2530 Ib 2560 Ib

Capacities Fuel tank

1 D7

OS, BOs, scsdgeesurncdvecacstvenebaaemnaadabanens aatiueaeeteatons abccsebicelanet reetonalotetat

11.5 U.S. gal

Coolant*

2.3L, WITHOUT AIK, COMGILIONING smsresejecnsrenniceasscnre ttatevianrrinertanseetenexts 2.3L, WIthtalr conditioning cs sscsahearisneterecsstestassianey teesanenonere 2.3L Tarboxpll windels 2: Sscnoceet iad cs ca ean 3.3L, all models * figures are actual, but may vary + 15% due to system variations Engine oil

2.38, without: filter charige RSTITDENCTES CCITAITIQLON Meer atetes Mececsscnecssntenatenvatensaxvdccsecsccesacsateadssabtastactieesttectesss

Ring groove width SOTTIEIFGSSIOUIA COPD) Meeeeresrer tr cwccer sntactitsncsratestocsscaecsaesetensssesvessctcrosseoteess REVIT SSSION (OO ULONINI) esteeceectaiascancvousscsceronascicedevsresnaascka Messen chesagticesats Re)[ee ee ee ere ey oicecveneccresncsdedccckorecest@ionssstterstdesenss

at the piston pin bore, centerline — 90° to the pin

Non-Turbo 3.7780 to 3.7786 in Turbo 3.7760 to 3.7766 in Non-Turbo 3.7792 to 3.7798 in Turbo 3.7772 to 3.7778 in Non-Turbo 3.7804 to 3.7810 in

Turbo 3.7784 to 3.7790 in Non-Turbo 0.0014 to 0.0022 in Turbo 0.0034 to 0.0042 in Non-Turbo 0.9123 to 0.9126 in Turbo 0.9124 to 0.9127 in

0.080 to 0.081 in 0.080 to 0.081 in 0.188 to 0.189 in

Piston pin MUINORENVesaerecreranestysceetvstessrtceveebeccesesi seoteseacscorcosasasctucriaticervescensstseaeesvivarccs¥erss Diameter PS EATICIAALErte atte etcetera caee recta aces soabractvcdescaitetaisascsssatvisadercoeiaeans OVEN SIZ ORrer eete tiercree. va tedcscvasucucshsasnadtssasaduyssdcvepanisdsatvsisaecbersteese VC rt secon aus auitasabesunsduesadavcncxaunsenaccuatvonerausdecstave Ry ANG a 2 eR PIStOM=tO=pin CLEA EMCO irerceveseatendier viaessasvestastiacasedscceceucsctsactonsivstcverannesseoe RN RIA EOC CI SEMEIAGE: terete reacaessuavueheulusdsvivs dcbéscsaensiesccncnsssnecscancetervosssanenes

3.010 to 3.040 in 0.9119 to .9124 in 0.9130 to .9133 in 0.9140 to 0.9143 in 0.0002 to 0.0004 in Interference fit

Piston rings Ring width Compression (tOp) crs......cscecssssecsesscesssssssssceroceecssssesensesseecenenensesarscseeos Compression (DOttOM) ..........scsscsessseseereesseresesesseesserenssssseneneneesenesees Side clearance Compression: (tOp) ........:.--ceccscscssssesssssssssssnenesenseeenenenesenssssensersssesenens Compression (bOttOM) .........sscesssssrsseseesesesseessneeeenenentensnsesesensseesenens

Ojltrivig css.hs PR SVC ONT TATE Ieee

PR ave iacesescncasssencevesecudtniosncnshsstesketnestaaeenss rea bea kahnscaguedtbaaeileneDaveventdeietedieeveseceanataswcvsees

Ring gap COMPFesSiON (TOP) .......sessescsessesceessesteneseseenensnsesnsnsensncnsnsenessasenenensanens Compression (DOttOM) ......cccscescccsesseseseseseseseetenenseseeesessnenseseseraeaeeese aibswedvics ceo es ce shd faces acendtes oceantsscvasvevevenvonvses Rio PUD ateses ea)ayeaUa

0.077 to 0.078 in 0.077 to 0.078 in

0.002 0.002 Snug 0.006

to 0.004 in to 0.004 in fit in max.

0.010 to 0.020 in 0.010 to 0.020 in 0.015 to 0.055 in

Chapter 1 Part A 4-cylinder engine

32 (a

Lubrication system

Oil pump Relief valve spring tension (Ibs spec. leMgth) ........eseceeeeeeseeeeeesees

Driveshaft-to-housing bearing Clearance ........ccscsccsseeeeersstereeeteeseneess

Relief valve-to-bore Clearance .ncicciscesescacsesssstedssinedenatiacenasentsatepbavenevetsens Rotor assembly end clearance (aSSeMbled) ..........cccsceseeseeeecssteeeeseees Outer race-to-housing Clearance 0.0.0... ccccsesteeesesteestenteesssneerecessoneaeess lbsanacity (qtarts, US) vaccccevsastiecsrnesvesiussriavecateesesn cnasevennensscnnvttoreGucroniate

15.2 to 17.2 at 1.20 in

0.0015 to 0.0030 in 0.0015 to 0.0030 in 0.004 in max. 0.001 to 0.013 in 4 — add one pint with filter change

Fuel pump Stave pressure

nee eee eee (pal): wicca

RA THATTARA TY VO LUITI Gn CLO Vitis ivecceyranete ooracne oeerotnnnaie

PECOMNITIC LOtAINNTCE 3

coc cae a ee Ree

eee

Torque specifications SNTanit teary SENATE CEE IONE creecoece cxexatns cessagcvounepenaesay cenatess shremepetr rasanereneanemn roar

Auxiliary shatt Balt tensioner Belt tensioner Garishiaht, Geat

thrust plate: bolt ....;-seeysest-aetencsvicensts neesnareeretaaramesesareterscs (timing. pivot DOIt) cccccic,.sssccastpuselteocersa\ervanceateees -vaaeeeiaheant otencts (timing). adjusting DOM i .s.cccccc.sssccdeovsedeontnrtretarvezcncsaertoeteaserst HOt Sec Ae seasecacsrcnsaesictaaresarerscstnc aarnstns.cestacnes eee Mas

Carnistrate Uarulst late DOME weicronetsatecngcavevupactentesercesiesennateear-sre ree aes

Carburetor tO SPACer STUE 2.ocecalencincvcovasnrescnsuncrcusne ieobiae ceaes teehee aeteae aw Carburetor tos pacer OU tisadian.dxtioqournncomenee cams omen Carburatarspacen topmaniold: bolt-aiieecoek anrtiienss eet oases: RS MUTE CEINIG: FEREL FIU ES ch excess een tienesett nc qusiseVedaadtes nn nhs eas taeal asta aeRO Torque in sequence in two steps: ROMY: tacos ctava deren sewaterisnavr oes ecva tera eras ach htaniocasbavecaccee oe renee memes ee BEN Pe cs curesits xsi wane Be vas eomcevege Phas abeeed Or un seein a ener aca bee gee CFANKSHIale GAMPOE DONE sssscsvtescsecavssersavteretstieninn ncaaeaecede hte teem epen re RSAIMS TES ACL) DUES caseivse coudrc eh corerwea coe tapas sic oetals tara meres ae a eee

5.0 to 7.0 — on engine, temperature normal, curb idle, neutral. 1 pint in 25 seconds — pump to tank return line pinched off, new fuel filter in line. Smallest orifice = not less than 0.220 in |.D.

0.304 to 0.326 in ft-lb 28 to 40 6 to 9 28 to 40 14 to 21 50 to 71 6 to 9 75 to 15

Nm 38 to 54

8 to 12 38 to 54 19 to 28 68 to 96 8 to 12

10 to 14

10 to 20 14 to 19

14 to 21 30 to 36

19 to 28 41 to 49

25 to 30

34 to 41

30 to 36 100 to 120

41 to 49 136 to 162

80 to 90

108 to 122

BSUS her da oven erenee Cesena T aes greene sece cau tc ae GSE ENTS aR SERS Pat NN 2 anes k cies vccv nesec Reet ncte tayfae Some Seer cepa coe Distributgr Clamp DOIt .........sessesseeessossescseestesssesseenseessseciensssnsennseanecuensseanees

50 to 60 80 to 90 14 to 21

Distributor vacuum tube to manifold adapter ..........cccccsseccssseeesceesseeeeeeeees Exhaust manifold to cylinder head bolt, stud Or nut ........eeeeeseeeeeeeeeees Torque in sequence in two steps: SESE Tei ccae Mevaronallicarcciscguchdun pertinent ROETER necRe RE a SLORY. Fy doce sscvsuaidacastesadcannstutiinuse caysousteanae aeeoatcoasSOA eR ie Flywheel to Grankshatt BOlt sic.ccescsctisshotparecsntevctabache eeetadeaerepaeete seeatenties Fuel pump t0- cylinder DIOGK. :is«maciaisccs:sooeeededebe ucecneneee aeeereeeane es, Intake manifold to cylinder head bolt/nut — NOn-Turbo .......cccccscesseeeseesees

5 to 8 lector 23

68 to 81 108 to 122 19 to. 28 7 to 11 22 Gis)

5 to 7 16 to 23 56 to 64 14. to21 14 to 21

7 to 9 221034 73 to 87 19 to 28 19 to 28

5 tory 14 to 21 13 to 18 13 to 18

7 to 9 19 to 28 18 to 24 18 to 24

80 to 90

108 to 122

50 to 60 80 to 90 8 to 18 14 to 21 14 to 21 15 to 25 6 to 8 8 to 10 20 to 25 + turn after gasket contacts surface

68 to 81 108 to 122 11 to 24 19 to 28 19 to 28 21 to 33 5 toa 11 10.43 28 to 33 — oil gasket

Torque cylinder head bolts in sequence

in two steps:

Torque in sequence in two steps: MELISS: di contersayechacass nest usurencseleaaciant oxirotor nee oe cea et nes

Teor Step Z =e NOR TUG asrscartvssrsmsysoancee atincxevacelaale eyeee ee PREY a PULETIUL since ci nc nvanvedzcasso boxe udisudas covetian REE cnt me Intake manifold to cylinder head bolt/nut — Turbo ....c..c.ccccccsecseeeceseseeeeees DASNY DESTING GAD DOLE vncocscuie Sinsncaaccetercems tacos nee tine ieee pa aces tracer ea Torque in sequence in two steps: SRONS Tias iavsbavesac ts navi Godassscacoeeannetesaidnctoni

SF.

;

BACKSTOP

cpl

INTAKE

MANIFOLD

VALVE

Fig. 3.28 EGR intake manifold spacer and components (Sec 33)

OUTLET

Fig. 3.29 Typical EGR valve (Sec 33)

COOLING PVS

MANIFOLD VACUUM FITTING

i} ae CARBURETOR

SOV

DISTRIBUTOR

EGR VALVE

CHECK VALVE EGR/PVS

TO D. A.D. TRANSMISSION

Fig. 3.30 EGR/CSC

system diagram (Sec 33)

Chapter 3 Fuel, exhaust and emissions systems

104

MIXING CHAMBER (MIDBED)

SHELL ASSY.

EXHAUST GASES FROM ENGINE

CONVENTIONAL OXIDATION CATALYST (COC) SECONDARY AIR INLET FITTING

FLOW

AIR FROM THERMACTOR

THREE-WAY CATALYST (Twc)

PUMP

Fig. 3.31 Typical catalytic converter (Sec 33) CHECK VALVE INLET HOSE —

richness of the carburetor mixture, incorrect operation of the thermactor system

or running out of gasoline. AIR BYPASS VALVE INLET HOSE —

Inlet air temperature regulation 19 Inlet air temperature regulation is accomplished by the use of a thermostatic air cleaner and duct system (see Section 3). 20 An additional feature, incorporated on some models, is the cold

temperature

actuated

vacuum

(CTAV)

system.

This is designed

AIR CHECK NaN

to

AIR BYPASS

select either carburetor spark port vacuum or carburetor EGR port vacuum, as a function of ambient air temperature. The selected vacuum source is used to control the distributor diaphragm unit. 21 The system comprises an ambient temperature switch, a threeway solenoid valve, an external vacuum bleed and a latching relay. 22 The temperature switch activates the solenoid, which is open at temperatures below 49°F (9.5°C) and is closed above 65°F (18.3°C). Within this temperature range the solenoid valve may be open or closed. 23 Below 49°F (9.5°C) the system is inoperative and the distributor diaphragm receives carburetor spark port vacuum while the EGR valve receives EGR port vacuum.

VALVE

BYPASS VALVE SUPPORT BRACKET

24 When the temperature switch closes {above 65°F/18.3°C) the three-way solenoid valve is energized from the ignition switch and the carburetor EGR port vacuum is delivered to the distributor advance diaphragm as well as to the EGR valve. The latching relay is also energized by the temperature switch closing, and will remain energized until the ignition switch is turned off, regardless of the temperature switch being open or closed.

Fig. 3.32 Thermactor components (Sec 33) 27

Thermactor 25

This system

is designed

to reduce

the hydrocarbon

A slightly modified system may be used on vehicles which have

dual catalytic converters

exhaust control system and carbon

monoxide content of the exhaust gases by continuing the oxidation of unburnt gases after they leave the combustion chamber. This is achieved by using an engine driven air pump to inject fresh air into the hot exhaust stream after it leaves the combustion chamber. This air mixes with the hot exhaust gases and promotes further oxidation, thus

reducing their concentration and converting some of them into carbon dioxide and water. Thermactor air is also injected into the catalytic converter on vehicles equipped with dual catalytic converter systems. 26 The air pump draws in air through an impeller type, centrifugal fan and exhausts it from the exhaust manifold through a vacuum controlled air bypass valve and check valve. Under normal conditions thermactor air passes straight through the bypass valve, but during deceleration, when there is a high level of intake manifold vacuum, the diaphragm check valve operates to shut off the thermactor air to the air supply check valve and exhausts it to atmosphere. The air supply check valve is a non-return valve which will allow thermactor air to

pass to the exhaust manifold but will not allow exhaust gases to flow in the reverse direction.

—

a vacuum

in the exhaust system; this may incorporate

differential valve (VDV) (Fig. 3.33 and 3.34).

Deceleration valve 28 A deceleration valve is used to provide an enriched mixture when the engine is on overrun with the throttle closed. The valve screws into the intake manifold and has two vacuum outlet ports. When the engine decelerates a vacuum is applied by the control port and the valve opens and allows a fuel/air mixture to by-pass the carburetor and pass directly into the intake manifold.

34

Emission control system — maintenance and testing

1 In view of the special test equipment and procedures thereis little that can be done in the way of maintenance and testing for the emission control system. In the event of a suspected malfunction of the system, check the security and condition of all pneumatic and electrical connections then, where applicable, refer to the following paragraphs for further information.

Chapter 3 Fuel, exhaust and emissions systems

105

AIR CONTROL VALVE

EXHAUST CHECK VALVE

OOH

SO

AIR PUMP

=

BYPASS

DUAL CATALYTIC CONVERTER

EXHAUST MANIFOLD

ENGINE COOLANT TEMP. LOWER THAN 529°C (128° F)

AIR CLEANER MOUNTED TVS

RQ

THERMACTOR AIR MANIFOLD VACUUM

COOLANT PASSAGE

PVS-—52°C (128°F)

Fig. 3.33 Thermactor system with dual catalytic converter temperature below 52° C (1 28° F) (Sec 33) AIR CONTROL VALVE

AIR PUMP

EXHAUST CHECK VALVE

BYPASS VALVE DUAL CATALYTIC CONVERTER

EXHAUST MANIFOLD

ENGINE COOLANT TEMP. HIGHER THAN 52°C (128° F)

=

Saaz

MOUNTED TVS

Cok

COOLANT PASSAGE / PVS-52°C (128°F)

RNG

tHeRmactor AIR

Py

MANIFOLD VACUUM

33) Fig. 3.34 Thermactor.system with dual catalytic converter temperature above 52° C (128° F) (Sec

Electrically assisted choke heater

and reconnect it to the choke lead. If the bulb does not illuminate when the engine is warm, a faulty choke unit is indicated.

ohmmeter is available, disconnect the stator lead from the choke cap terminal and connect it to one terminal of a 12V low wattage bulb (eg, instrument panel bulb). Ground (earth) the other terminal of the bulb and check that it illuminates when the engine is running. If it fails to

PCV system

The only test that can be carried out on this assembly, without 2 special test equipment, is a continuity check of the heater coil. If an no ohmmeter is available, check for the specified resistance. If

for illuminate, check the alternator output and the choke lead continuity. If the bulb illuminates, disconnect the bulb ground terminal

3 Remove all the hoses and components of the system and clean them in parts solvent. Ensure that all hoses are free from any obstruction and are in a serviceable condition. Where applicable, similarly clean the crankcase breather cap and shake it dry. Replace the parts as necessary,

then install them

in the car.

106

Chapter 3 Fuel, exhaust and emissions systems (3) DIAPHRAGM RETURN SPRING HOLDS DIAPHRAGM

UPWARD, CLOSING DUMP VALVE

CUT-OFF OPERATION

@) VACUUM EQUALIZED ON BOTH

SIDES OF DIAPHRAGM, THROUGH BYPASS TIMING ORIFICE

BYPASS TIMING ORIFICE

@® ORIFICE DELAYS INCREASE ABOVE DIAPHRAGM.

(@) DIAPHRAGM IS MOMENTARILY PULLED DOWN.

@) VACUUM INCREASES BELOW DIAPHRAGM

FROM SOLENOID VACUUM VALVE

(@) vacuum To BYPASS

VALVE

Q) HIGHER THAN NORMAL

VACUUM NORMAL

VALVE

VACUUM FROM SOLENOID VACUUM VALVE DURING ENGINE DECELERATION.

VACUUM IN BYPASS VALVE LINE IS OUMPED TO ATMOSPHERE THROUGH FILTER, CAUSING BYPASS VALVE TO DUMP THERMACTOR AIR.

DUMP

OPERATION

VACUUM DUMP VALVE OPENS MOMENTARILY.

Fig. 3.35 Thermactor system bypass valve (Sec 33) NORMAL

CONTROL VACUUM PORT

OPERATION

(4) MANIFOLD VACUUM

PULLS DIAPHRAGM UP,

AIR INLET FROM THERMACTOR PUMP

AIR FROM THERMACTOR PUMP FLOWS FREELY TO EXHAUST MANIFOLD.

AIR OUTPUT TO EXHAUST MANIFOLD

SILENCER AND VENT OPENINGS

@) VENT PORT

SEALED OFF PRESSURE

“DUMP” OPERATION

(@) VALVE SEATS AND

@) WHEN VACUUM SIGNAL

BLOCKS THERMACTOR AIR FLOW TO EXHAUST MANIFOLD.

DROPS

RELIEF OPERATION

(@) EXCESSIVE

PRESSURE UNSEATS RELIEF VALVE.

(3) PARTIAL THERMACTOR

AIR FLOW TO EXHAUST MANIFOLD TO MEET SYSTEM REQUIREMENTS.

(3) VALVE OPENS

TO ALLOW THERMACTOR AIR FLOW TO ATMOSPHERE

() SPRING PULLS

STEM DOWN

(2) PARTIAL THERMACTOR

AIR FLOW TO ATMOSPHERE.

Fig. 3.36 Vacuum differential valve operation (Sec 33)

Charcoal canister 4

The charcoal

canister is located on the right-hand

dash

panel in

the engine compartment. To remove it, disconnect the two hoses, then remove the three nuts securing the canister bracket to the dash panel. Remove removal

EGR

the canister procedure.

and

bracket.

Installation

is the reverse

be removed by using a steel blade or shim approximately 0.028 in (0.7 mm) thick in a sawing motion around the stem shoulder at both sides of the disc. Clean the cavity and passages in the main body; ensure that the poppet wobbles and moves axially before reassembly.

of the

system

5 The EGR valve can be removed for cleaning, but where it is damaged, corroded or extremely dirty it is preferable to fit a replacement (photo). If the valve is to be cleaned, check that the orifice in the

body is clear but take care not to enlarge it. If the valve can be dismantled; internal deposits can be removed with a small power driven rotary wire brush. Deposits around the valve stem and disc can

CTAV system 6 Without special equipment the system circuitry.

Thermactor

it is not possible to carry out tests of

system

7 Apart from checking the condition of the drivebelt and pipe connections, and checking the pump drivebelt tension, there is little that can be done without the use of special test equipment. Drivebelt tension should be checked by an authorized dealer with a special

Chapter 3 Fuel, exhaust and emissions systems

107

tensioning tool. However, this is approximately equal to 4 in (13 mm) of belt movement between the longest pulley run under moderate hand pressure.

CHECK VALVE

Deceleration

valve system

8 Special equipment is required to carry out a complete test on the deceleration valve function and it is recommended that the car is taken to an authorized dealer.

35

Exhaust system, 2.3L — general description

Note: Because of manufacturing changes, the exhaust system on your car may differ from those shown in this manual. If problems arise, refer

to your local dealer or repair shop. Remember that omission or substitution of parts in the catalytic system could affect compliance with emission regulations. 1 All 4-cylinder engines use a single pipe system with a three-part converter. The converter is a bolt-on unit installed between the inlet pipe and the muffler. 2 The exhaust system is usually serviced in four pieces: the rear section of the muffler inlet pipe, catalytic converter, inlet pipe and muffler. 3 Due to the high operating temperatures of the exhaust system, do not work on the exhaust system for at least one hour from last use.

CHECK VALVE CROSS SECTION

a

36

Inlet pipe — removal and installation

1 2 3 4 5 6

Raise and support the vehicle. Support the muffler assembly with a length of wire. Remove the converter-to-inlet pipe mounting bolts. Remove the front hanger mounting screws from the inlet pipe. Remove the nuts securing the inlet pipe to the exhaust manifold. Installation is the reverse of removal with the following precau-

tions. 7 Clean all flange and gasket surfaces. 8 Use new gaskets. Install the entire system loosely, aligning 9 tighten. 10 Check for absence of leaks and noise.

all components,

then

nneT EUEEE EEE EEE

37

Muffler assembly — removal

and installation

Se Raise and support the vehicle. Support the vehicle allowing the 1 rear axle to hang at full extension without the wheel assemblies touching the ground. Remove the nuts securing the converter to the muffler pipe flange. 2 Remove the rear hanger to muffler support screws. 3 Pull the muffler assembly toward the rear and disconnect the 4 catalytic converter. Remove the screws securing the hanger assembly to the muffler 5

support. Installation is the reverse 6 precautions in Section 35.

of removal,

installation

refer to the

ES

38 Catalytic converter — removal and installation a Ee ee 1 Raise and support the vehicle. Remove the screws securing the heat shields to the converter and 2 carefully remove the shield. Be careful of sharp edges. Remove the fasteners securing both ends of the catalytic con3 verter and lower the converter from the car (photo). 4 Installation is the reverse of removal. ee

EEE Ea

39 Exhaust system — general description, 6-cylinder engines a ee All 6-cylinder engines have the same type Single muffler exhaust ee

2

\

be 38.3 When removing the catalytic converter along with heat shield, careful of the sharp edges

system

which

includes

a

muffler,

catalytic

converter

and

various

connecting pipes. The 6-cylinder system is almost identical to that of the 2.3 liter four: refer to Sections 36 through 38 for removal and installation instructions.

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109

Chapter 4 Ignition system Contents Distributor — removal. and installation iesserccxo.cstetespetaccusenes ditherwecrerconsyers

i

Ignition system servicing and Federal regulations .........cccsccssessceeeeees

2

Distributor stator assembly — removal and installation .....0....::008 Distributor vacuum advance unit — removal and installation ......... Engine initial timing setting CSEMOral CASCTULIONN csscteensconctraosevee cancantdeancxuecatacesn cami icsdtoensbee inahnan meena

8 9 6 1

Ignition tiMiNng — PrEPAratiON ....0..::0cccv-.cesescntonancscsessonessncosenaleeeeneean Spark plugs — removal, inspection and installation ..........cccceeceeeeee Spark plug wires — inspection and replaceMent ........ccccceceseeeeeeneeene

5 3 4

Specifications

AWSF-42 AWSF-42 BSF-82 2.3 All 8,cache ssh atesaxestevasicle Me treat oda

ee aus Sapna Cae RM ccaee tee donteee Res ae ete eete

.034 in .050 in

Coil TeV PD cate div a cesvasccicnsavntenmetestom mets Oxon ashanene Coataeas tanate waopbbe aceesmiiaevs stieedberai ta Uae

Motorcraft 8 volt, oil filled

Distributor TY PG iss roccanevs inxopccctuniansvettav onesudwectneneavlavavent ootaeecceebanacys tivvaveseeacsuascesurcesemeesonneie

Automatic

advance...

Direction of rotation ............ ROTO ARMA wiccescs cassesrspseusnencs lh conscon sick kaumbiv ciathaeis vets ores to nenaceite eee Stati: AAV aNC! vsccdteccBinstescdencecddysdasnleoucse epceeakah eotnastvaulasenzdsuee cadenee ene

Solid state, breakerless

Vacuum

and centrifugal

Clockwise 7.5 kv (all models) Refer to Emission Control decal

Firing order De

PIII sscree encan omovies eRaGrar sees Cat eae stoeeissoctre oe Rasen sae ae

Note: All adjustment figures given in these specifications should be double-checked against the vehicle's individual Emission Control decal

Torque specifications Spark plugs

5 to 10 ft-lb 10 to 15 ft-lb

1.

General

description

1 All models are fitted with an electronic (breakerless) type distributor. 2 Mechanically the system is similar to the contact breaker type fitted to earlier models with the exception that the distributor cam and contact breaker are replaced by an armature and magnetic pick-up unit. The coil primary circuit is controlled by an amplifier module. 3 When the ignition is switched on, the ignition primary circuit is energized. When the distributor armature ‘teeth’ or ‘spokes’ approach the magnetic coil assembly, a voltage is induced which signals the amplifier to turn off the coil primary current. A timing circuit in the amplifier module turns on the coil current after the coil field has collapsed.

4 When on, current flows from the battery through the ignition switch, through the coil primary winding, through the amplifier module

and then to ground. When the current is off, the magnetic field in the ignition coil collapses, inducing a high voltage in the coil secondary winding. This is conducted to the distributor where the rotor directs it to the appropriate spark plug. This process is repeated for each power

stroke of the car engine. 5 The distributor is fitted with devices to control the actual point of

ignition according to the engine speed and load. As the engine speed increases two centrifugal weights move outwards and alter the position of the armature in relation to the distributor shaft to advance the spark slightly. As engine load increases (for example when

climbing

hills or accelerating),

pression

causes

the

base

plate

a reduction assembly

in intake to move

manifold slightly

de-

in the

opposite direction (clockwise) under the action of the spring in the vacuum unit, thus retarding the spark slightly and tending to counteract the centrifugal advance. Under light loading conditions (for example at moderate steady speeds) the comparatively high intake manifold depression on the vacuum advance diaphragm causes the baseplate assembly to move in a counter-clockwise direction to give a larger amount of spark advance 6 For most practical do-it-yourself purposes ignition timing is carried out as for conventional ignitions. However, a monolithic timing system is incorporated, and this has a timing receptacle mounted in the left rear of the cylinder block for use with an electronic probe. This latter system can only be used with special electronic equipment, and checks using it are beyond the scope of this manual. 7 Fault finding on the breakerless ignition system, which cannot be rectified by substitution of parts or cleaning/tightening connections, etc. should be entrusted to a suitably equipped Ford dealer since special test procedures and equipment are required.

Chapter 4 Ignition system

2

Ignition system servicing and Federal regulations (all models)

3

1 In order to conform with the Federal regulations which govern the emission of hydrocarbons and carbon monoxide from car exhaust systems, the engine carburetion and ignition systems have been suitably modified. 2 It is critically important that the ignition system is kept in good operational order and to achieve this, accurate analytical equipment is needed to check and reset the distributor function. This will be found at a local repair shop or dealer. 3. Information contained in this chapter is supplied to enable the home mechanic to set the ignition system roughly in order to start the engine. Thereafter the car must be taken to the local dealer or repair shop for final tuning. TERMINAL @ casaee~os sarntenats taornaanily camiancndensic

1

3 4

Pilot bushing — replacement, all MOCEeIS ..........:cceeeeeeeetseeeeseetrensees

9

Clutch

cable —

Clutch pedal — free travel adjustment, 2.3L and Ace4WS) ET 979 eee tence Clutch pedal — free travel adjustment, 3.3L...

GOSCEIOUON

Specifications

Type MEMMCSES NITE ca seach ncsor-ssdeefdsuotseotag-een sesh ddeeunsedeonenvaasandsesoasisoctsasesecasssseonssonses

cp os ardseagincantag tenenseictios sas consicohsccutieatchagraorn

TE

Single dry plate, diaphragm spring

Cable

Friction plate diameter a test oS AAy. acesviesShae sd asaechCdusvi oan nesstvivenns a AW SO apne ae eta suchnanniesosnvocnanatoggeestaspitnossavarasvevs a

8.5 in (215 mm) 9.0 in (229 mm)

Friction plate color identification 5 0 ed teOae retecotta aci gpnak eleth tense sccteceseaaesackccuspevnnsevsteosscdeecsousasonbes EMULE Sf. LDQvhcds:. scat ae asisa«< Soekde raterascent dustyeseavccvasabeatitagiteceseaevasrrensueneeroseves SUMMING EGY INILAT SUN UR Po Oyen dee cte es sce thee Dace ogee tert teestceasokseutosadestovssesstsnaevonnsaceodureaaute

Clutch pedal free travel CEE, GIP MEE EE TOE

Ruea NNN

eo

occcesticstessurtessectee cca:tesssvcceyyssudaeoucunserasecenovonadee

BAMTTET RESO ais fost coer nccecctevsonscaccee-sncteccseceusevcseseccccachersscasceseacstovsueravcosvseseroess

tn)

eT

4 REQ'D.

VIEW Z

VIEW Y VIEW P

Fig. 7.34 Selector lever assembly and linkage (Sec 22)

accessible after removal of the selector lever housing plug. lever Disconnect the shift lever at the base of the hand control 2 (adjustable end of rod). 3. Place the hand control lever in ‘D’. housing in Place the selector lever on the side of the transmission 4 the fully from back ‘clicks’ two counting by ed determin be can ‘D'. This forward position.

NEUTRAL START SWITCH

GAUGE PIN (NO. 43 DRILL)

selector hand Now attempt to reconnect the shift rod to the 5 should slide in control lever by pushing in the clevis pin. The pin release the lock nut without any side stress at all. If this is not the case, by screwing the length effective its adjust and rod shift the on adjusting link in, or out.

THREE

HOLE

SS 25 Selector linkage — adjustment (C4)

eee

2 1.

and support on Chock the front wheels, jack up the rear of the car firmly based axle stands. position. Move the transmission selector lever to the ‘D’ 2

Fig. 7.35 Adjusting neutral start switch (Sec 23) nonNote: The neutral start switch on the C3 transmission is wear adjustable and any fault will be due to a malfunctioning switch,

on the internal actuating cam or faulty wiring. If the switch is suspect,

and tighten replace it with a new one. Always use a new O-ring seal to the specified torque.

eee ee cae (C3) ent adjustm — linkage 24 Selector 1

ey EEE

. To do this, First check that the selector lever is correctly adjusted

between the lever pawl use feeler gauges to check the end-clearance

0.005 and 0.010 in and the quadrant notch. This should be between lock nut which is cable the adjust y, necessar If mm). 0.25 and (0.13

shift rod retaining 3. Working under the car loosen the manual lever nut. the fourth detent Move the manual lever to the ‘D’ position. This is 4

position from the rear of the transmission unit. lever in the ‘D’ With transmission selector lever and manual 5 setting of 10 — positions tighten the retaining nut to a torque wrench

12 ft-lb (13 — 16 Nm).

n SSS n 26

Kick-down

rod — adjustment

1

Disconnect

the downshift

rod return spring and hold the throttle

shaft lever in the wide open position. detent stop. Hold the downshift rod against the through 2

e of 0.050 Adjust the downshift screw so as to provide a clearanc 3 tip and the throttle ~ 0.070 in (1.27 — 1.78.mm) between the screw shaft lever tab. Reconnect the downshift lever spring. 4

152

27

Chapter

7 Transmission

Intermediate band (C3 and C4) — adjustment

1 The intermediate or front band is used to hold the sun gear stationary so as to give the second gear ratio. If it is not correctly adjusted there will be noticeable slip during first to second gearchange or from third to second gearchange. The first symptoms of these conditions will be very sluggish gearchange instead of the usual crisp action. 2 To adjust the intermediate band, undo and remove the adjustment screw lock nut located on the left-hand side of the transmission case. Tighten the adjusting screw using a torque wrench set to 10 ft-lbs

pinion carrier stationary. If it is not correctly adjusted there will be a noticeable malfunction of the automatic transmission unit, whereby there will be no drive with the selector lever in the ‘R’ position, also associated with no engine braking on first gear when the selector lever is in the ‘L’ position.

2 To adjust the rear band undo and remove the adjusting screw lock nut located on the left-hand side of the transmission case. Tighten the adjusting screw using a torque wrench set to 10 ft-lb (13.5 Nm) and then slacken off the adjustment screw exactly 3 turns. A new lock nut should be fitted and tightened to a torque wrench setting of 35 — 45 ft-lb (47 — 61 Nm).

(13.5 Nm) and then slacken off the adjustment screw 14 turns. A new lock nut should be fitted and tightened to a torque wrench setting of 35 — 45 ft-lb (47 — 61 Nm).

28

Low and reverse band (C4 only) — adjustment

1 The low and reverse band or rear band is in action when ‘L’ or ‘R’ position of the selector lever is obtained to hold the low and reverse

29

Fault diagnosis — automatic transmission

As has been mentioned elsewhere in this Chapter, no service repair work should be considered by anyone without the specialist knowledge and equipment required to undertake this work. This is also relevant to fault diagnosis. If a fault is evident carry out the various adjustments previously described and if the fault still exists consult the local garage or specialist.

Chapter 8 Driveshaft, rear axle and differential Contents 9 Z 10 5 Ss

Pinion oil seal — removal and installation ......ccccscceeeeteneteeeeneees Rear axle and differential — GESCTrIPTION .......cccescsscesseeeeseeteeteeteeatteees Rear axle oil — draining and Filling ..........ccccsceseseereeneteeensetecseetseneess Rear universal joint — removal, service and/or replacement .......... Universal joints — inSpection ..........scesssesesesesereeesenenseeeseeesesessssesseesecesees

8 Axleshaft —TFEMOVaAl ANA FEPIACEMENE .2se... nc cessescscecsrvenesnersresesoressess sen Differential cover — removal and installation 6 re Driveshaft — balance .......... sevnnnnseeneeceenannnnnessssenessens 1 Driveshaft — general description Bar eteN rere hecyaiessesnsnsndevause es 2 Driveshaft — removal and installation 4 Front universal joint — removal, service and/or replacement.........

Specifications

Driveshaft

TYPO suPRrssereatedqgtanisassencnsnoncessseussaver

Four link design absorbers

with

coil springs

and

hydraulic

telescopic

shock

Steering MN Cons ca cisnnccecssscascassnzeestoosese Gear ratio

Rack and pinion 24.9 straight ahead 21.7 at full turn

MIN EETAEE 2 sfe ied ea codssescrcee insss cs cos Renedsacbktte>se¥atnonacahessscsessebencnsssuscetuennssacerocsatase

5 oz (approx. 0.31 pints U.S.)

Tires

Refer to the tire information decal located on the front of the L.H. door

pillar As above

Torque wrench settings Front suspension Lower arm to crossmember Sway bar MOuNting ClaMp .....ceesseesereeeeees SOMA yh ssctettraent Sway bar to lower arm........... Spindle to SHOCK Strut ......c.cscsccsesccssesssssersseescneseseercesessenenesesees Sway bar mounting bracket to Underbody .........:eeseseseereeees BEEINOANT MO SPINE .........:cc0se.csdsserseotdassncecseceonse BNOCK UPper MOUNT (3 NUTS) ...42........sseessescessersenees Steering gear to crossmember MHE-FOd EN to SPINle .....ccec..ccsscesesceesssassceessnesssseseeserenescnenserssssessrtsctesesceeeenneaes

Rear suspension Shock absorber to upper mount Brake backing plate

Shock lower mount Wheel lug nut ..cccscscscsscsssesssssssesesnenessessanentensssensnnsncarsnsarencsnenssnsssnsesennenensnnenesess

ft-lb

Nm

200 to 220 14 to 26 9 to 12 150 to 180 35 to 50 80 to 120 60 to 75 90 to 100 35 to 47

271 to 298 19 to 39 12 to 16 203 to 244 47 to 68 108 to 163 81 to 102 122 to 136 47 to 64

14 to 26 20 to 40 40 to 45 ZOutonddS

19 28 54 90

to to to to

35 54 74 156

Chapter 10

178

All fasteners not listed, use the following torque wrench

and steering

Suspension

settings:

Metric thread sizes

ft-Ib

Nm

6 to 9

14 28 50 80

BIN N= Flo o|— Bie glo Dla FINS

1.

General

1 The front suspension fitted to all models is modified MacPherson strut comprising a shock absorber/strut assembly, coil spring, and lower A-arm. 2 Each front wheel rotates on a spindle, the upper end mounted to the lower strut and the lower end to the A-arm. The lower spindle is

is attached

to the

body

21 40 71 140

19 to 28 38 to 54 68 to 96 109 to 154

5 to 8 12 to 18 221Onas 25 to 35

7 to 10 17 to 24 30 to 44 34 to 47

6 to 9 12 to 18

9 to 12 17 to 24

14 to 20

19 to 27

Ze 27 40 40 55

30 37 55 55 75

AoE to 36 to 55 to 60 to 80

to to to to to

43 51 74 81 108

5 rear axle 6

description

attached with a balljoint. 3 The upper end of the strut through an insulator bushing.

to to to to

9 to 12

Each rear wheel, hub and brake drum assembly is bolted to the axle shaft flange and the wheel and axle shaft rotates in the rear housing. The rear axle housing rests on a spring assembly suspended from hangers integral with the body. Location of the axle assembly is controlled by four pressed steel arms. Two of the arms connect the

bodywork to the axle housing center, two others connect the housing at the outer ends of the axle. Rubber insulated shock absorbers are fitted at each side. 7 The steering gear is rack and pinion type with power assistance as

structure

optional. The steering wheel is connected to the gear through a collapsible shaft and flexible couplings. 8 A tie-rod is attached to each end of the rack joint which allows the

4 The coil spring mounts between the front frame crossmember and the lower A-arm. To control body roll in corners a front stabilizer bar is fitted.

tic-rod to move

with any deflection in the front suspension unit. The

;

SHOCK STRUT INSULATOR

SHOCK

NO.

STRUT

2 CROSSMEMBER

i

0.

ae

es |)

Pi

Olmto’ aaa....< Ss

xe

‘

J

ee

\ INTEGRAL SPINDLE & BRAKE im

STANDARD FRONT STABILIZER BAR

LOWER

“A” ARM

ASSEMB LY

Fig. 10.1 Front suspension layout and components (Sec 1)

a

Z

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180 Chapter 10 Suspension and steering Fn

eee ieee

rack and pinion assembly ends are sealed by rubber bellows. 9 Couplings attached to the tie-rods are retained on the rack and pinned with roll pins. The rack, housing, valve assembly and rack

10 Clean the inner and outer bearing cone and roller assemblies and wipe dry with a clean lint-free rag. 11 Carefully inspect the cone and roller assemblies for signs of wear

piston are rebuildable. 10 The steering column is of the safety type. A locking mechanism

or damage

actuated

by depressing

the button

is

located on the steering column.

This prevents inadvertent locking of the steering wheel by blocking the actuator out of the lock position. 11 The outer column tube terminates just below the attachment to the brake support bracket. Energy absorption is accomplished by the lower column mounting bracket. There is no shift tube in this assembly

12 The steering shaft has a machined bar with grooves in the lower half designed to accept two anti-rattle clips. The lower shaft comprises an upper section that is a formed tube to fit into the upper shaft. 13

The column is secured to the brake support brackets bolted to the

flanges on the brake support. The lower column attaching collar contains a sintered iron ring with internal protrusions. These protrusions act as a guide which deforms the outer tube as the column collapses.

2

Front wheel

bearings — removal and replacement

1 Chock the rear wheels, apply the parking brake, loosen the front wheel nuts, jack up the front of the car and support on firmly based axle stands. Remove the roadwheel. 2 Refer to Chapter 9 and detach the disc brake caliper. 3 Carefully remove the grease cap from the hub. 4 Withdraw the cotter pin and lift away the nut lock, adjusting nut and plain washers from the spindle. 5 Lift away the outer bearing cone and roller assembly. 6 Remove the disc from the wheel spindle. 7 Using a screwdriver or tapered drift remove the grease seal. This must not be used again but always replaced. 8 Remove the inner bearing cone and roller assembly from the hub.

9 Remove grease from the inner and outer bearing cups and inspect for signs of wear, scratching or pitting. Damage of this kind means that the bearings must be replaced, using a tapered drift. The outer bearing cups can be removed.

which,

if evident,

mean

that

complete

the rollers. 16 Place the inner bearing cone and roller assembly in the inner cup. 17 Apply a smear of grease to the lip of the grease seal and replace

using a suitable diameter drift. Ensure the seal is correctly seated. 18 in a 19 with 20 21 the

Refit the disc onto the wheel spindle taking care to keep the hub central position so that the grease retainer is not damaged (photo). Replace the outer bearing cone and roller assembly. Follow this the plain washer and adjustment nut. Adjust the wheel bearing as described in Section 3. Fit a new cotter pin and bend the ends around the castellations of nut lock to prevent interference with the radio static collector in

the grease cap (if equipped). 22 Replace the grease cap, tapping

in position

OUTER

with

a soft faced

hammer. 23 Refer to Chapter 9 and replace the caliper. 24 Refit the wheel and secure. Lower the car to the ground. Before driving the vehicle, pump the brake pedal to restore normal brake pedal travel.

3

Front wheel bearings — adjustment

1.

Front wheel bearings should be adjusted if the wheel is loose on

the spindle or if the wheel does not rotate freely. 2 Chock the rear wheels and apply the parking brake. Jack up the front of the car and support on firmly based stands.

HUB AND ROTOR ASSEMBLY

NUT

assemblies

cup, 12 Clean the spindle and lubricate with fresh grease. 13 If the inner and/or outer bearing cups were removed the new cups should be fitted using a suitable diameter drift. Make sure they are replaced the correct way round and also correctly seated (Fig. 10.4). 14 Pack the inside of the hub with fresh grease until it is flush with the inside diameter of both bearing cups. 15 With each bearing cone and roller assembly clean off old grease, pack with fresh grease taking care to work the grease well in between

GREASE RETAINER

ADJUSTING

race

must be obtained. Do not use a new cone and roller assembly in an old

OUTER BEARING cuP

INNER BEARING CONE AND ROLLER

BEARING

CONE AND ROLLER

GREASE

WHEEL ASSEMBLY WASHER

COTTER PIN

Fig. 10.3 Exploded view of front hub (Sec 2)

Chapter 10

Suspension and steering

|

181

® a>

eri

\

y

LN

/

Z)

We

,

WITH WHEEL ROTATING, TORQUE ADJUSTING NUT, TO 17-25 FT-LBS (24-33 Nem)

BACK ADJUSTING NUT OFF 1/2 TURN

@ — \

y

YZ TIGHTEN ADJUSTING NUT TO 10-15 IN-LBS

INSTALL THE LOCK AND A NEW COTTER PIN

(1.2-1.6 Nem)

Fig. 10.5 Wheel bearing nut adjustment sequence (Sec 3)

castellated flange of the nut. 9

Check that the wheel

rotates freely and then replace the grease

cap and hub cap. Lower the car to the ground.

ee ee ee Ee ee Sway bar link insulators — removal, inspection and installation ee nn eee 1 Raise the vehicle and support with jack stands. Remove the nut, washer and insulator from the top of the 2 stabilizer bar bolt. Remove the bolt, washers and spacers. Note their location for 3

a 4

reinstallation. Inspect the insulators for cracks or breakage, replace as necessary. 4 Install the stabilizer bar insulators by reversing the above pro5 cedure. 6 Tighten the attaching nut to 9 to 12 ft-lb (12 to 16 Nm).

eee EE a 5 ~

2.18 The hub should be centered as it is installed so that the spindle threads and grease retainer aren't damaged

3. 4

Sway bar — removal and installation

Ce

Remove the hub cap and ease off the grease cap from the hub. Wipe the excess grease from the end of the spindle. Remove the

cotter pin and nut lock. Slowly rotate the wheel and hub assembly and tighten the 5 adjusting nut to the specified torque wrench setting to seat the bearings. Using a box wrench back off the adjustment nut by one half of a 6

turn and then retighten the adjusting nut to a torque wrench setting of 10 to 15 |b-in or finger-tight (Fig. 10.5). 7 The castellations on the nut lock on the adjusting nut must be aligned with the cotter pin hole in the spindle. Fit anew cotter pin and bend the ends of the cotter pin around the 8

1 Raise the vehicle and support with jack stands. Loosen the bolt securing the sway bar to the sway bar link. 2 Loosen the bolts at the sway bar insulator attaching clamps 3 (photo). 4 When all tension has been removed from the sway bar bolts, complete their removal and lift out the sway bar. Check the plastic bushings for grooves or cracks. 5

Replace

necessary.

as

Installation is the reverse of removal with the following precau6 tions: Coat any rubber/metal junction with a rubber lubricant to avoid 7 galling. Replace any bolt used either at the attaching clamp or the sway 8 bar link. 9 Torque the attaching brackets to 14 to 26 ft-lb (19 to 35 Nm). Torque the stabilizer link bolts to 9 to 12 ft-lb (12 to 16 Nm).

182

Chapter 10

Suspension

and steering

5.3 Sway bar attachment clamp bolts loosened

_6.5A Loosen the tie-rod nut a few turns sothat

6.5B Using a small bearing puller to

to permit bar removal

the threads will be protected during removal

disconnect the tie-rod

SPRING COMPRESSOR TOOL IN POSITION SHOWING UPPER AND LOWER PLATE LOCATION

>

6

Front coil spring — removal and installation

1 2

Raise the vehicle and support with jack stands. Remove the wheel and tire assembly.

3 Disconnect the stabilizer link from the lower A-arm. 4 Disconnect the steering coupler bolts. 5 Disconnect the tie-rod from the steering spindle, using a ‘pickle fork’ (small-bone wedge) or bearing puller (photos). 6 Using a spring compressor, available from most tool rental shops, insert as shown and compress the spring. When installing the compressor, turn the end piece to hold as much of the spring as

possible (photo).

iY

7

Tighten the spring compressor until the spring is loose in the seat.

8

With an assistant, support the inboard end of the arm and remove

the two bolts securing it to the front crossmember. A hydraulic jack is

>

| a ‘a

— he oak.

a

the safest way of providing the support. 9 Carefully lower the jack to remove the spring. 10 Carefully remove the compressor to relieve spring tension. 11 Installation is the reverse of removal, with the following precautions: 12 Check that the spring is fully seated onto the spring perch before releasing the compressor. 13 Retorque the lower A-arm bolts to 120 to 180 ft-lb (203 to 244 Nm). 14 Torque the tie-rod nut to 35 to 47 ft-lb (47-64 Nm). 15 Check for binds and loose bolts before driving the car.

7

Strut — replacement

1

Raise the vehicle and support with jack stands.

2

Insert the ignition key and turn to the unlock position to allow free

movement of the front wheels. 3 Inside the engine compartment on the top of the inner fender, loosen the strut mount nut. Using a screwdriver on the shaft will keep the strut from turning. 4 Remove the wheel assembly. 5 Remove the brake caliper, rotor assembly, and dust shield. 6 Remove the two lower nuts and bolts securing the strut to the spindle.

7

Remove

The

struts

leakage, or rust 8 Installation 9 Torque the 10 Torque the

244

6.6 Make sure that the spring compressor plates are fully seated before applying pressure

the upper strut nut.

are

not

rebuildable;

should

there

be

evidence

of

on the shaft or cracks, they must be replaced. is the reverse of removal. strut upper nuts to 60 to 75 ft-lb (81 to 102 Nm). lower strut mount bolts to 120 to 180 ft-lb (203 to

Nm).

©

Spindle — removal

1. 2 3

Raise the vehicle and support with jack stands. Remove the wheel assembly, rotor, brake caliper, and dust shield. Remove the tie-rod end.

4 5

Remove Loosen

this time.

and installation

the cotter pin from the balljoint nut. the nut two or three turns, but do not remove

the nut at

Chapter 10

Suspension

and steering

183

a

6 Strike the side of the A-arm to relieve the stud pressure. 7 Position a floor jack under the A-arm and compress the coil spring until working clearance is obtained. 8 Remove the two nuts and bolts securing the spindle to the strut and the loosened balljoint nut. Remove the spindle. 9 Installation is the reverse of the removal instruction sequence. 10 Place the spindle on the balljoint stud and install the nut fingertight. 11 Position the strut to the spindle and install the two bolts and nuts. Tighten to 150 to 180 ft-lb (203 to 244 Nm). 12 Tighten the balljoint nut to 80 to 120 ft-lb (108 to 163 Nm). 13 Remove the floor jack. 14 Install the stabilizer link and torque the nut to 9 to 12 ft-lb (12 to

16 Nm). 15 Attach the tie-rod and torque the nut to 35 to 47 ft-lb (47 to 64 Nm). Install the cotter pin. 16 Install the brake caliper, dust shield, rotor and wheel assembly. 17 Remove jack stands.

9

Steering rack and pinion — removal and installation

1 Raise the vehicle and support with jack stands. Disconnect the battery negative cable. 2 Disconnect the flexible coupling at the input shaft. 3 Remove both tie-rod ends, referring to Section 6. 4 Mark the position of the steering coupler halves. Remove the bolts. 5 Loosen the bolts securing the steering rack to the front crossmember. 6 Disconnect the two steering pressure lines. Plug the open ends to prevent contamination.

7

Remove the nuts from the mounting bolts (loosened in step 5) and

lower the rack. 8 The steering rack assembly is a rebuildable unit; however, due to its complexity and need for special factory tools, any repair is best left to a qualified technician. 9 To install, position the rack unit on the front crossmember and install the mounting nuts and bolts. Do not tighten. 10 Reconnect the tie-rod ends and tighten to 35 to 47 ft-lb (47 to 64

Nm). 11

Position the wheels in a straight-ahead position.

12 Center the steering wheel and reconnect the steering coupler. The indexing flat on the input shaft should be pointing down when inserted into the flexible coupling. Check for alignment of the marks made

during disassembly. Install the bolts and tighten to 20 to 37 ft-lb (28 to 50 Nm). 13

Torque the rack mounting

bolts to 80 to 100 ft-lb (109 to 135

Nm). 14 Connect the steering hydraulic lines. The manufacturer recommends their replacement if they are disconnected. New lines are available from your local dealer or parts store. Tighten all connections firmly. 15 Remove the vehicle from the jack stands. Turn the ignition to the OFF position and re-connect the negative battery cable. 16 Start the car operating the steering in both directions. Check for leakage from the hydraulic lines. Fill the fluid reservoir to the recommended level. 17 Because the alignment is critical for tire wear and economy, recheck the alignment. Refer to a dealer or alignment shop for this service.

10

Rear suspension coil spring — removal and installation

Note: Springs must always be replaced in pairs. 1 Raise the vehicle and support it securely on jack stands under the frame so that the rear suspension is fully extended. Remove the rear wheels. 2 Remove the rear stabilizer bar, if equipped. 3 Support the axle under the differential so that the shock absorbers are compressed about one inch. 4 With a jack under the lower suspension arm pivot bolt, remove the bolt and nut. 5 Slowly lower the jack to relieve the spring pressure. Remove the

spring and insulator (if equipped) (photos). 6 To install, place the upper and lower spring insulators (if equipped) in position. Tape in place if necessary. Position the spring on the lower suspension arm spring seat so that the pigtail on the lower arm is at

the rear and pointing toward the left side of the vehicle (Fig. 10.10). 7 Raise the jack slowly until the spring is compressed and the pivot bolt holes are in alignment. 8 Install the pivot bolt and nut with the nut facing outwards. The manufacturer recommends using new bolts and nuts. Do not tighten

NO. 2 CROSSMEMBER

RUBBER

INSULATOR

SPINDLE

INSULATOR WASHER

GRIP TIE ROD IN THIS AREA ONLY FOR SETTING TOE. DO NOT GRIP ON TIE ROD THREADS.

Fig. 10.7 Steering gear components (Sec 9)

ARM

184 (SEDANS)

TORQUE 19-35 Nem (14-26 FT-LBS)

55-74 N-m (40-55 FT-LBS) 95-135 Nem (70-100 FT-LBS}

55-94 N-m (55-70 F T-LBS)

95-135 Nm (70-100 FT-LBS)

on ™_

/ ps

&.. \

i Sg /

s

th

.

=

-s

4 a

ZA

, ia

‘

le 4?

VIEW Y

= t

ee

/

95-135 N-m (70-100 FT-LBS)

Fig. 10.8 Rear suspension components (Secs 10 and 12)

Chapter 10

Suspension

VERTICAL

and steering

SHOCK

UPPER SUSPENSION

ABSORBER

185

OUTBOARD

OF RAILS

ARM

LOWER SUSPENSION ARM WITH INTEGRAL SPRING SEAT

10.5A Lower the jack to release the spring

10.5B Removing the spring

the nuts to torque specifications until the vehicle weight is lowered onto the suspension. 9 Install the rear sway bar, if equipped. 10 Remove the support from the pivot point and axle and install the rear wheels. 11 Lower the vehicle so that its weight is resting on the suspension and torque tighten lower suspension arm pivot bolts.

be replaced. \f your shock absorbers stand up to the bounce test, craw! beneath 2 your car and visually inspect the shock body for signs of fluid leakage, punctures or deep dents in the metal of the body, and that the shock absorber is straight from several angles. If the piston rod is bent, you

nD 11 Shock absorbers — inspection i 1 The most common test of the shock absorber’s damping is simply to bounce the rear corners of the vehicle several times and observe

by whether or not the car stops bouncing once the action is stopped the you. A slight rebound and settling indicates good damping, but if vehicle continues to bounce several times, the shock absorbers must

will not be able to see that it is. A bend in the shock body or signs of the upper portion of the shock body rubbing on the lower section will let you know. Replace any shock absorber damaged, in spite of proper damping indicated 3. When you have removed a shock absorber, and push it back in several times to check throughout the travel of the piston rod. Replace

which is leaking or in the bounce test. pull the piston rod out for smooth operation the shock absorber if

it gives any signs of hard or soft spots in the piston travel. When you install a new shock absorber, pump the piston rod fully 4 in and out several

sections of the unit.

times to lubricate

the seals and fill the hydraulic

186

Chapter 10

Suspension

and steering

PIG-TAIL

FRONT

OF

CAR

VIEWB

ws Fig. 10.10 Rear spring installation diagram. Lower pigtail must

Rear shock

absorber

— removal

8

and installation

Note: Shock absorbers should always be replaced in pairs. 1 The upper shock absorber bolt is accessible inside the trunk on 2door models or after the removal of interior trim panels on 3-door

models.

Remove

absorber

nut, washer

2

Chock

remove

the

rubber

cap

(2-door)

and

i

:

\

ON

.

7 ‘Install the inner washer and insulator on the upper attaching stud and extend the shock absorber upward into position in the upper mounting hole.

point to the left of the vehicle (Sec 10)

12

4

12.4 Removing the lower shock absorber nut and washer after compressing the shock absorber

remove

the

Tighten the lower mounting nut to 40-55 ft-lb (55-74 Nm).

9 Lower the vehicle and install the insulator, washer and Tighten to 14-26 ft-lb (19-35 Nm). 10 Replace the rubber cap (2-door) or trim panels (3-door).

nut.

shock

and insulator.

the front wheels,

raise the car,

support

it securely

and

13

Power steering — general description

the rear wheels.

3 From underneath the car, reach up and compress the shock absorber by pulling it down from the upper shock tower hole. 4 Remove the lower shock absorber nut and washer (photo).

5

Remove the shock absorber and inspect it (Section

6

To install, compress the shock absorber, place the lower mounting

eye on the mounting tighten.

stud

and

install the washer

and

11). nut.

Do not

1 The power steering systems available on these cars have a pulleydriven Ford Model Cll type pump. This pump delivers fuel to a servo assisted rack and pinion gear assembly. 2 Servo assistance is obtained through a piston mounted on the rack

and running in the rack tube. The degree of assistance is controlled by a spool valve mounted concentrically with the input and pinion shaft. 3. The power steering pump incorporates an integral fluid reservoir.

16-24 N-m (12-18 FT-LBS)

16-24 N-m

ms (12-18 FT-LBS)

ie

2 REQO 9.5-14 N-m (84-120 IN-LBS) f

PUMP ASSY

BRACKET

40-62 N-m (30-45 FT-LBS) 40-62 N-m (30-45 FT-LBS)

PULLEY

Fig. 10.11 Typical power steering pump installation (Sec 14)

LD

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3A00HD NO 1331S8NH ONIH331S°NO 133HM LSNW 38 NI 3NI1 HLIM XHVW NO dOl ON340 ONINSILS LIVHS OL INITdN ONIH33LS 133HM S3NOdS A1H3dOud ‘OLS 8 ‘1dO 133HM SIH1L SI OL 38 V AAJ “NOILVY3d0

a

ONIHND3IS “-N

OF-2Z

Chapter 10

Suspension and steering

4 Because of the complexity of the power steering system it is recommended that servicing etc, is limited to that given in the

following Sections. In the event of a fault occurring it is recommended that repair or overhaul be entrusted to a specialist in this type of work.

14

Power steering — bleeding ea

ee

eee

1 The power steering system will only need bleeding in the event of air being introduced into the system, ie, where pipes have been

disconnected or where a leakage has occurred. To bleed the system proceed as described in the following paragraphs. 2 Open the hood and check the fluid level in the fluid reservoir. Top up if necessary using the specified type of fluid. 3 If fluid is added, allow two minutes then run the engine at approximately 1500 rpm. Slowly turn the steering wheel from lock-tolock, whilst checking and topping-up the fluid level until the level remains steady, and no more bubbles appear in the reservoir. Clean and refit the reservoir cap, and close the hood. 4 a

15 Power steering pump — removal and installation ________ ee 1 Loosen the pump adjusting bolt and retaining bolts. Push the pump in toward the engine, and remove the drivebelt. 2 3. Disconnect the power system fluid lines from the pump and drain the fluid into a suitable container. Plug, or tape over, the end of the lines to prevent dirt ingress. 4 If necessary, remove the alternator drivebelt(s) as described in 5 Chapter 2. Remove the bolts attaching the pump to the engine bracket and 6 remove the pump. Note: On some engine installations it may be necessary to remove the pump complete with bracket. Replacing is a direct reversal of the removal procedure. Ensure 7 that the fluid lines are tightened to the specified torque, top-up the system with an approved fluid, adjust the alternator drivebelt tension. ee cc eee”

16 Steering wheel — removal and installation pe 1 Disconnect the battery negative cable. Pull out on the steering wheel hub cover (2- and 3-spoke) or push 2 the emblem out from behind (4-spoke). 3 Remove the steering wheel attaching nut. Remove the steering wheel with a suitable wheel puller. Do not 4 strike the end of the steering column with a hammer or use a knockoff type of puller as this will damage the collapsible steering column bearing. 5 When reinstalling align the marks on the steering shaft with those on the wheel. Make sure that the wheels are pointed straight ahead in relation to the steering wheel position. Install the steering wheel nut and tighten to 30-40 ft-lb (41-54 6

Nm).

Align the hub cover pins or springs with their holes or slots in the 7 steering wheel and push into place.

TURN DOWNWARD TO

TURN UPWARD

INCREASE ROD LENGTH

a

17 Steering column — removal and replacement a 1 Disconnect the battery negative cable. 2 Remove the steering wheel as described in Section

LEFT-HAND SLEEVE

mens 16.

Disconnect the flexible coupling at the steering input flange and 3. disengage the safety strap assembly. Remove the column trim shrouds which are held in place by five 4 self-tapping screws Remove the steering column cover and hood release which is 5 located directly under the column. Disconnect all of the steering column switches and mark their 6 positions for ease of reassembly. Remove the four screws attaching the dust boot to the dash panel. 7 Remove the four attaching nuts which hold the column to the 8 brake pedal support. Lower the column to clear the four mounting bolts and pull it out 9 so that the U-joint assembly passes through the dash panel clearance hole. 10 Refer to Chapter 11 for removal of the ignition lock and switch. 11 When reinstallating the safety strap and bolt assembly to the steering gear input shaft, make sure that the strap is positioned to prevent metal-to-metal contact. Also, the flexible coupling must not be distorted when the bolts are tightened. By prying the shaft up or down with a suitable pry bar the insulator can be adjusted so that it is

installed 12 The the dust the dash

flat. rest of reinstallation is a reversal of removal. Be sure to install boot over the steering shaft before inserting the shaft through panel.

i

18 Steering angles and front wheel alignment Eee ape ea A Accurate front wheel alignment is essential for good steering and 1 tire wear. Before considering the steering angle, check that the tires are correctly inflated, that the front wheels are not bent, the hub bearings are not worn, or incorrectly adjusted and that the steering linkage is in good order, without slackness or wear at the joints. Toe-in is the amount by which the distance between the front 2 inside edges of the roadwheels (measured at hub height) is less than the distance measured between the rear inside edges. 3. Front wheel alignment (toe-in) checks are best carried out with modern setting equipment but a reasonably accurate alternative is by means of the following procedure. Place the car on level ground with the wheels in the ‘straight4 ahead’ position. Obtain or make a toe-in gauge. One may easily be made from a 5 length of rod or tubing, cranked to clear the sump or bellhousing and having a setscrew and lock nut at one end.

6 With the gauge, measure the distance between the two inner wheel rims at hub height at the front of the wheel. Rotate the roadwheel through 180° (half a turn) by pushing or 7 pulling the car and then measure the distance again at hub height between the inner wheel rims at the rear of the roadwheel. This measurement should either be the same as the one just taken or

TURN UPWARD TO INCREASE ROD LENGTH

pray DOWNWARD TO DECREASE ROD LENGTH

Cagyipo age TO DECREASE ROD LENGTH

189

RIGHT-HAND SLEEVE

Fig. 10.14 Toe adjustment of steering track rods (Sec 18)

190

Chapter 10 Suspension and steering

a

greater by not more than 0.28 in (7 mm). 8 Where the toe-in is found to be incorrect slacken the lock nuts on each trackrod, also the flexible bellows clips and rotate each trackrod by an equal amount until the correct toe-in is obtained. Tighten the trackrod-end lock nuts while the balljoints are held in the center of their arcs of travel. It is imperative that the lengths of the trackrods are always equal otherwise the wheel angles on turns will be incorrect. If new components have been fitted, set the roadwheels in the ‘straightahead’ position and also centralize the steering wheel. Now adjust the

lengths of the trackrods by turning them so that the tie-rod-end balljoint studs will drop easily into the eyes of the steering arms. Measure the distances between grooves on the inner ends of the that they are equal. This is adjustment must be carried out this Section.

the centers of the balljoints and the trackrods and adjust, if necessary, so an initial setting only and precise as described in earlier paragraphs of

19

Wheels

and tires

1

Check the tire pressures weekly (when they are cold).

2

Frequently inspect the tire walls and treads for damage and pick

out any large stones which have become trapped in the tread pattern.

3 If the wheels and tires have been balanced on the car then they should not be moved to a different axle position. If they have been balanced off the car then, in the interests of extending tread life, they can be moved between the front and rear on the same side of the car and the spare incorporated in the rotational pattern. 4

Never mix tires of different construction or very dissimilar tread

patterns. 5 Always keep the roadwheels tightened to the specified torque and if the bolt holes become elongated or flattened, replace the wheel. 6 Occasionally, clean the inner faces of the roadwheels and if there is any sign of rust or corrosion, paint them with metal preservative paint. Note: Corrosion on aluminum alloy wheels may be evidence of a more serious problem which could lead to wheel failure. If corrosion is evident. consult your local authorized dealer for advice. 7 Before removing a roadwheel which has been balanced on the car, always mark one wheel stud and bolt hole so that the roadwheel may be refitted in the same relative position to maintain the balance.

Chapter 11

Electrical system

Contents

Alternator — fault diagnosis and repair Alternator — general description ............ SET TLAST NECTUAVICES css chan cc saahacrocesesxenarbe

INSTRUMENT

SCREW (4 REQ’D)

PANEL

PANEL

MOULDING o

7

PANEL

ASSEMBLY

SCREW (3 REQUIRED)

Fig. 11.14 Instrument panel pad components (Secs 25 and 26)

ASSEMBLY

Chapter 11

WIRING

27

ASSEMBLY

INSTRUMENT

+ IGNITION

CLUSTER

CONNECTION (LOWER)

COIL

201

Electrical system Tachometer

— removal

and installation

ee

1 Remove the instrument cluster. 2 Remove the mask and lens assembly. 3 Remove the three nuts securing the tachometer head to the cluster housing. 4 Lift the tachometer from the cluster. 5 The tachometer is fully electric and is not repairable. Should the

tachometer require replacement, be sure that the 4/6/8 cylinder mode screw is adjusted to match the correct number of cylinders of the engine. Once set it requires no further adjustment TACHOMETER

WARNING

LAMP

PRINTED

FUSE 10 AMP.

CIRCUIT

WIRING ASSEMBLY—

TO IGNITION SWITCH

nn

ee UUEnd

IUES IEEE

ERR

28 Oil, fuel, amp and temperature gauges — removal and installation

ne TO IGNITION

SWITCH

—

GROUND

1 2

Remove the instrument cluster. Remove the two retaining screws for removed. 3. Lift the instrument from the cluster. 4 Installation is the reverse of removal.

the

instrument

to

be

Fig. 11.15 Tachometer wiring diagram (Sec 27) eT

29 1

Instrument cluster printed circuit — service precautions ee ee es ee 2 The printed circuit that comprises the ‘wiring’ of the instrument

panel should be handled as little as possible to avoid damage to the circuit sheet (photos). 2 Should the printed circuit sheet require removal, proceed as

follows: Loosen the special nuts securing the circuit sheet to the instru3 ment cluster back. Lift out the instrument lights. Carefully lift the sheet from around the mounting studs with a dull4 tipped tool. Do not allow the removal tool to scratch the surface of the circuit sheet. Lift the sheet a little at a time across the entire cluster back in 5 order that the sheet is not pulled or creased.

For refitting, place the circuit sheet to the back of the cluster. Push 6 the sheet gently onto the mounting studs. 7

Use a small socket to push the circuit sheet to bottom on the stud

against the cluster housing.

Install the smaller printed circuit sheet

first.

Snug the special lock nuts, do not overtighten 8 circuit sheet.

and stress the

a

29.1A Instrument cluster after removal. The printed circuit is on the reverse side

30 Turn signal flasher unit — removal and replacement a Ne 1 The turn signal flasher unit is fitted on the main fuse panel which

is located in the lower ieft of the instrument panel behind a trim panel. 2. The flasher unit simply plugs into the fuse panel and is retained by a spring clip. Toremove, grip firmly and pull straight out, taking care not to bend 3 the connector tabs. 4 Replace using the reverse procedure.

ED 31

Hazard warning lights flasher unit — removal and replacement

ED signal turn the to adjacent fitted is unit flasher warning hazard The 1 unit and the removal and replacement procedure is the same as that

described in the previous Section. ne eaEEE EEE

Speedometer

32

cable — removal and replacement EEE

Inner Cable 1

Working behind the instrument panel disconnect the speedometer

cable from the rear of the speedometer head. Carefully pull the speedometer inner cable out from the upper end 2 of the speedometer cable outer casing.

29.1B Instrument cluster printed circuit

3 undo

If the inner cable is broken, raise the car and working underneath and

remove

the

bolt

that

mounting clip to the transmission.

secures

the

speedometer

cable

i

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ff

oh _ J

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202

Chapter 11

203

Electrical system SPEEDOMETER

DRIVEN

GEAR

RETAINER

EMERGENCY FLASHER|

vi

“Ale Dice eat 7

eee

V

As ( teen ANG

SPEEDOMETER DRIVEN GEAR

ea erae

FA JE

‘4 »

SPEEDOMETER

CABLE

ee he einen FRONT VIEW

MOUNTING

MOUNTING

Fig. 11.17 Fuse panel and circuit breaker (Secs 30 and 37) 7

Turn signal back-up lamps 75 amp. fuse

7

Courtesy lamps 15 amp. fuse

2

Heater (std.) 15 amp. fuse

8

Cigar lighter - horn

3

air conditioning 30 amp. fuse Instrument panel lamps 5 amp. fuse

20 amp fuse 9 Radio 15 amp. fuse 10 Warning lamps 10 amp.

4

Accessory- A/C clutch 25 amp. fuse

P

Windshield wiper/washer 6 amp.

6

circuit breaker Stop lamps — emergency warning 15 amp. fuse

Fig. 11.18 Speedometer connection at transmission (Sec 32) TO SET TIME:

fuse 17

5

CLIP

BOLT

Turn signal flasher

712 Electric choke 25 amp.

fuse

TO SET E/T (ELAPSED TIME): PUSH RECESSED SWITCH WITH BALLPOINT PEN

PULL BUTTON OUT UNTIL 1T UNLOCKS.

C@ TO ADVANCE HOURS @ TO ADVANCE MINUTES

PUSH SAME BUTTON ALL THE WAY UNTIL 1T STOPS, THEN RELEASE.

PULL BUTTON OUT TO ZERO E/T. IF IT DOES NOT COME OUT, UNLOCK IT BY PUSHING IT IN FIRST. RELEASE IT AND THE ELAPSED TIME CLOCK WILL START.

TO SET DATE:

PUSH THE E/T BUTTON ALL THE WAY IN FOR CONTINUOUS ELAPSED TIME DISPLAY. PUSH AGAIN TO RELEASE.

Fig. 11.19 Digital clock Elapsed Time (E/T) setting procedure (Sec

33)

the Remove the speedometer cable shaft and driven gear from 4 transmission. shaft Remove the driven gear retainer and the driven gear and 5 from the cable. the end of Remove the lower part of the broken inner cable from 6 the outer casing. sequence Refitting the new speedometer inner cable is the reverse 7 to removal. outer casing. Lightly lubricate the inner cable and insert into the 8 ensure that to end the turn inserted been all nearly has When the cable driven gear. the squared end is engaged with the speedometer

Outer cable

9 Working behind the instrument panel disconnect the speedometer cable from the rear of the speedometer head.

REPEAT

ABOVE

WITH DATE

RECESSED SWITCH

BUTTON

EXCEPT

& ADVANCES MONTH © ADVANCES DATE

Fig. 11.20 Digital clock time and date setting procedure (Sec 33) in the 10 Push the outer cable and grommet through the opening dashboard panel. all its 11. Raise the car and working underneath detach the cable from retaining Clips. earlier in 12 Disconnect the cable from the transmission as described this Section and withdraw from under the car (Fig. 1 1.18). to 13 Refit the speedometer cable using the reverse procedure removal. nS LEE

33 Electric clock — removal and replacement Caen LEE Disconnect the battery ground terminal. 1 Remove the screws securing the top of the instrument panel trim, 2 unsnap the lower trim fingers from the panel and remove the trim.

Chapter 11 Electrical system 204 eee eee Undo and remove the screws that secure the clock to the 3 instrument panel. 4 Lift out the clock and disconnect the feed wire and bulb socket. 5 Replace the clock using the reverse procedure to removal.

Clock adjustment 6

Adjustment of the clock is automatic. Should the clock run too fast

or too slow it is only necessary to reset the clock to the correct time. This action will automatically reset the adjuster.

34

Ignition switch — removal and replacement

35

eee

Ignition switch lock cylinder — removal and replacement

1 For safety reasons, disconnect the battery ground terminal. 2 Remove the horn pad and steering wheel as described in Chapter 10.

3

Insert a wire pin in the hole located inside the column halfway

down the lock cylinder housing. 4 Move the selector lever to the PARK

position (automatic transmission) or the reverse position (manual gearbox) and turn the lock cylinder with the ignition key inserted to the RUN position. 5 To remove the lock cylinder press the wire pin while pulling up on the lock cylinder.

1 The ignition switch is located on the upper side of the steering wheel under the shroud and is operated by a rod connected to the keyactuated lock cylinder. 2 Remove the steering column shroud. 3 Disconnect the battery ground cable. 4 Pull apart the ignition switch electrical connector.

5

6

To fit the lock cylinder insert it into its housing in the flange casing.

Turn the retaining 7 Turn 8 Refit

key pin the the

to the OFF position. This action will extend the cylinder into the cylinder housing.

key to ensure correct operation in all positions. steering wheel and horn pad.

Using a ¢ inch drill, drill out the two ‘break off head’ bolts which

connect the switch to the lock cylinder. 6 Remove the bolts using an ‘easy out’ tool. 7 Remove the pin that connects the switch plunger to the actuating rod and lift away the switch. 8 To adjust the switch during installation, slide the carrier to the

LOCK position. Insert a .O50 inch drill bit through the switch housing into the carrier so that the carrier can’t move. 9 To hold the mechanical parts of the column in the LOCK position, move the selector lever to PARK (automatic transmission) or to the reverse position (manual transmission). Turn the key to the LOCK position and remove the key. 10 New replacement switches are supplied pinned in the LOCK position by a plastic pin inserted in the end of the switch. 11 Position the hole in the end of the switch up to the hole in the

36

Seat belt and ignition warning buzzers — removal and replace-

ment 1

Disconnect the negative battery terminal.

2

The seat belt warning

buzzer,

and

key-in-the-ignition

warning

buzzer are located behind the right-hand side of the instrument panel.

3

Remove the three screws retaining the top of the right-hand side

trim panel, unclip the lower fingers, and lift off the panel.

4 Remove the buzzer retaining clips and lift out the buzzer. Disconnect the wiring connectors. 5 Refit the buzzer using the reverse procedure.

actuator and install the connecting pins. 12 Install new ‘break off head’ bolts and tighten them until the heads

37

break off. 13 Adjust the pin to release the drill bit used for adjustment. 14 Remove the plastic locking pin re-connect the electrical connector, steering column shroud and battery negative cable. 15 Check for proper operation.

1. The fuse panel is located behind a removable cover in the left side of the instrument panel. 2 Most of the electrical circuits are protected by fuses and fuse identification is given in the caption to Fig. 11.17. If a fuse blows always trace the cause and rectify before replacing the fuse.

Fig. 11.21

Fuses

Removing ignition switch lock cylinder (Sec 35)

Chapter 11 nn

205

Electrical system

EEUUUEEEEEnEEENEEEEERENESEERIE EERE

EEE

push the boss onto the spindle.

38 Windshield wiper blades — removal and replacement The windshield wiper blades fitted can be one of two types. With the bayonet type the blade saddle slides over the end of the arm and is engaged bya locking stud. With the side saddle pin type a pin on the arm indexes into the side of the blade saddle and engages a spring loaded clip in the saddle.

Bayonet type — TRICO’ 1 To remove a ‘TRICO’ blade press down on the arm to disengage the top stud. 2 Depress the tab on the saddle to release the top stud and pull the blade from the arm.

Bayonet type — ‘ANCO’

3 To remove an ‘ANCO’ blade press inwards on the tab and pull the blade from the arm.

Saddle pin type — ‘TRICO’ 4

Toremove

a pin type ‘TRICO’ blade insert a screwdriver into the

spring release opening of the blade saddle, depress the spring clip and

40 Windshield wiper mechanism — fault diagnosis and rectification 1

Should the windshield wipers fail, or work very slowly, then check

the terminals on the motor for loose connections, and make sure the insulation of all the wiring is not cracked or broken, thus causing a short circuit. If this is if order then check the current the motor is taking by connecting an ammeter in the circuit and turning off the wiper switch. Consumption should be between 2.3 and 3.1 amps. 2 |f no current is passing through the motor, check that the switch is Operating correctly.

3. If the wiper motor takes a very high current check the wiper blades for freedom of movement. If this is satisfactory check the gearbox cover and gear assembly for damage. 4

|f the motor takes a very low current ensure that the battery is fully

charged. Check the brush gear and ensure the the commutator. If not, check the brushes for and, if necessary, renew the tension springs. worn they should be replaced with new ones. substitution if this unit is suspect.

brushes are bearing on freedom of movement If the brushes are very Check the armature by

pull the blade from the arm. i

SEU UEEEEEE EEE

i 39 Windshield wiper arm — removal and replacement ee

41 Windshield wiper motor — removal and installation ee 8S SS eS ee ee Ee 1 Remove the air vent grille, loosen the two nuts and disconnect the

Before removing a wiper arm, turn the windshield wiper switch on 1 and off to ensure the arms are in their normal parked position parallel with the bottom of the windshield. 2 To remove the arm, swing the arm away from ‘the windshield, depress the spring clips in the wiper arm boss and pull the arm off the spindle. 3 When replacing the arm, position it in the parked position and

wiper pivot shaft and link assembly from the motor drive arm ball.

2 Undo and remove the three bolts securing the motor to the engine compartment firewall. 3. Disconnect the multi-pin connector from the main wiring harness and lift away the motor.

4

Refitting the windshield wiper motor is the reverse sequence to

removal.

WIPER SWITCH ASSEMBLY

WIRING

HARNESS

Fig. 11.22 Wiper switch installation (Sec 43)

206

Chapter

11

Electrical system 5

42 Windshield wiper pivot shaft and link assembly — removal and installation

1 2 3

Disconnect the battery ground cable. Remove the air vent grille (see Chapter 12). Remove the linkage drive arm clip and disconnect the drive arm

from the motor crank pin. 4 Remove the two bolts retaining the right pivot shaft to the cowl and the large nut, washer and spacer from the left pivot shaft. 5 Before reinstallation, make certain that the motor is in PARK. The

distance

between

the wiper blades

should be between

and

windshield

lower

14 and 34 inches. The right-hand

molding

pivot shaft

should be torque tightened to 60-85 in-lb (7-9 Nm) and the left-hand pivot nut should be tightened to 70-100 in-Ib (8-12 Nm). 6 The remainder of reinstallation is a reversal of removal.

43

Windshield wiper switch — removal and installation

1 2

Disconnect the battery ground cable. Remove the four screws holding the steering column

shroud

in

connector. 4 Remove the two wiper switch attaching screws (Fig. 11.22). Remove

Installation is the reverse of removal.

Windshield washer reservoir and pump — removal and

replacement

place. Separate by grasping the top and bottom of the shroud and pulling apart. 3. Using a flat bladed screwdriver, push off the wiper switch

5

correct reassembly.

6 Undo and remove the output arm retaining nut, output arm, spring washer, flat washer, Output gearshaft assembly, thrust washer and parking switch lever and washer in that order. 7 Remove the brushplate and switch assembly and finally remove the switch contact to parking lever pin from the gear housing. 8 Thoroughly clean all parts and then inspect the gear housing for signs of cracks, distortion, or damage. 9 Carefully check all shafts, brushes and gears for signs of scoring or damage. 10 If the brushes are worn they should be replaced with new ones. 11 Any serious fault with the armature such as a breakdown in insulation necessitates a new motor assembly. 12 Reassembly of the windshield wiper motor is the reverse sequence to dismantling and will present no problems provided that care is taken.

45

6

Suitably mark the position of the output arm relative to the shaft

to ensure

the wiper switch.

44 Windshield wiper motor — dismantling, inspection and reassembly

1 Remove the wiring connector plug and washer hose. 2 Undo and remove the retaining screws and lift the washer and motor assembly away from the left-hand side fender apron. 3 To remove the pump motor from the reservoir, pry out the retaining ring and carefully pull the motor out of the reservoir recess (see Fig. 11.24). 4 The motor and pump assembly cannot be repaired, and if faulty must be replaced with a new unit. 5 When refitting the motor into the reservoir, make sure the projection on the motor body is lined up with the slot in the reservoir.

6

Press on the motor retaining ring and refit the reservoir assembly

to the car using the reverse procedure to removal. 1

Undo and remove the gear cover securing screws and lift away the

ground terminal and cover (Fig. 11.23). 2 3. 4 the

Carefully remove the idler gear and pinion retainer. Lift away the idler gear and pinion and recover the thrust washer. Undo and remove the two long motor through-bolts, and separate housing, switch terminal insulator sleeve and armature.

46

Horn — fault diagnosis and rectifiation

1. If the horn works badly or fails completely, check the wiring leading to the horn plug located on the body panel next to the horn

SPRING WASHER OUTPUT

SPACEK WASHER

ARM

GEAR

HOUSING

ARMATURE SHAFT END PLAY SPRING PARK SWITCH TO PARKING LEVER PIN

PARKING LEVER

SWITCH

GEAR

_

PARKING SWITCH LEVER PLATE

COVER

CAM RIDER OUTPUT GEAR AND SHAFT

3 BRUSH PLATE AND SWITCH ASSEMBLY

ARMATURE

MOTOR HOUSING AND MAGNET ASSEMBLY

Fig. 11.23 Wiper motor components (Sec 44)

IDLER GEAR AND PINION

Chapter 11

207

Electrical system WIRING

SEER VOR

ASSEMBLY

re

DRY LUBE HERE

MOTOR

ASSEMBLY

MOTOR

AND SHAFT

ASSEMBLY

SCREW AND WASHER ASSEMBLY HAND PRESS COMPONENTS TOGETHER RETAINING

RING

Fig. 11.24 Windshield washer reservoir and motor (Sec 45)

ear oe ———

? C30

itself. Also check that the plug is properly pushed home and is in a clean condition free from corrosion etc.

2

Check that the horn is secure on its mounting and that there is

nothing lying on the horn body. 3. If the fault is not an external one, remove the horn cover and check the leads inside the horn. If they are sound, check the contact breaker contacts. If these are burnt or dirty clean them with afine file and wipe all traces of dirt and dust away with a solvent-moistened rag.

EE

47 Turn signal light circuit — fault diagnosis and rectification ee Should the flasher unit fail to operate, or work very slowly or rapidly, check out the turn signal circuit as detailed below, before

assuming that there is a fault in the unit. 1 Examine the turn signal light bulbs, both front and rear, for broken filaments. |f the external flashers are working but either of the internal flasher 2 warning lights have ceased to function, check the filaments in the warning light bulbs and replace with a new bulb if necessary. If a flasher bulb is sound but does not work check all the flasher 3 circuit connections with the aid of the relevant wiring diagram at the end of this Chapter. 4 With the ignition switched on check that the correct voltage is reaching the flasher unit by connecting a voltmeter between the ‘plus’

terminal and ground. If it is found that voltage is correct at the unit connect the two flasher unit terminals together and operate the turn signal switch. If one of the flasher warning lights comes on this proves that the flasher unit itself is at fault and must be replaced as it is not possible to dismantle and repair it.

=—-

Fig. 11.25 Rear window wiper installation (Sec 49)

48

Rear window washer — removal

and installation

Remove the screws securing the left rear trim panel and remove 1 the panel. Disconnect the electrical connector and reservoir supply hose. 2 3

Using a small standard screwdriver, pry the motor assembly from

its mounting position. Remove the washer screen and seal. Flush any foreign 4 from the reservoir or motor. Installation is the reverse of removal. 5

matter

ET

49

Rear wiper and motor — removal and installation

ee

Raise the wiper arm off the rear window. Pull the slide latch and 1 lift away the wiper arm. Remove the pivot shaft nuts and washers. 2

3 4 5 rear 6 7

Remove the liftgate trim screws and panel. Disconnect the electrical plug to the wiper motor. Remove the three screws securing the motor and linkage tu the liftgate. Remove the motor and linkage as an assembly. Installation is the reverse of removal.

208

Identification of wiring diagram ground codes Ground codes

G-101 G-401 G-402 G-403 G-405 G-501 G-502 G-601 G-602 G-603 G-904 G-905 G-906 G-907 G-908 G-1000 G-1001 G-1003 G-1004 G-1005 G-1100 G-1101 G-1400

Location On dash behind battery Eyelet on 14290 near L.H. headlamp Eyelet on 14398 near R.H. headlamp Eyelet on 15A808 near transmission indicator lamp Eyelet on 14334 for grounding dome lamp In 14405, on deck lid striker plate

In 14401, behind glove box Part of heater motor assembly, located in engine compartment or R.H. side of dash panel Part of A/C clutch, located on compressor

Under mounting bolt of solenoid valve Eyelet on 13412, or 14A549, near license lamps Eyelet on 4405 In 14A303, under shield near seat Eyelet on 13B440 In 9A340, near inertia switch Eyelet on 18C617, mounted to instrument panel Eyelet on 18C620 attached to R.H. inner panel Eyelet on 14025 to L.H.front door inner pane! Eyelet on 18C617

Eyelet on 9A839 speed control Eyelet on 17N400 rear window wiper motor Eyelet on 17A413 for rear windshield washer pump motor

Part of W/S wiper governor

209

Identification of wiring diagram splice codes

Splice codes S-102

Location In 14305, near T/O to starter relay

S-104 S-105

In 14A435, near connector to starter motor relay In 14401, near T/O to windshield wiper switch

S-106

In 14398, near T/O alternator regulator

S-109

In 15K702, near T/O to starter motor relay

S-110

In 14401, near T/O to W/S/Wiper switch

S-111

In 14401, near T/O to windshield wiper switch

S-112 S-115 S-116 S-202 S-206

In In In In In

S-301

In 14401, near T/O to 14290

S-302 S-303 S-304 S-305 S-306 S-307 S-401 S-404 S-406

In In In In In In In In In

S-408

In 14398, near T/O to R.H. front side marker lamp

S-501 S-502 S-503 S-504 S-505 S-508 S-510 S-511

in In In In

S-701 S-702

In 14401, near T/O to headlamp switch In 14A200, near T/O to 14A285

S-703 S-704

In In In In In

In In In In

S-802 S-803 S-804 S-805 S-806

14401, 14398, 14398, 14398, 14401,

near near near near near

T/O T/O T/O T/O T/O

to to to to to

radio starter starter starter printed

relay relay motor relay circuit

14401, near T/O to radio 14401, near T/O to transmission 14305, near T/O to electric choke 13A705, near T/O to diode 13A705, near T/O to diode 14290, near T/O to diode 14290, near T/O to L.H. parking lamp 14290, near T/O to ground 14405, near T/O to R.H. tail lamps 14398, near T/O to L.H. tail lamps 14405, near T/O to license lamp 14405, near T/O to 14401 14405, near T/O to L.H. tail lamps 14405, near T/O to R.H. rear stop and turn light 18C617, near heated backlite warning lamp 13412, or 14A549 or 198516 14335, near T/O to dome lamp

14024, near T/O to power door lock switch 14024, near T/O to power door lock switch

14401, near T/O to printed circuit 14398, near T/O to R.H. headlamp 14401, near T/O to seat belt warning buzzer In 14401, near T/O to back up lamp switch Mode switch in 19049, near T/O to A/C

S-807

Blower resistor in 19049, near T/O to A/C

S-808 S-809

In 9E724, near ground eyelet In 14290, near grommet

S-810 S-904 S-905

In 14290, near T/O to W/S wiper motor In 14405, near T/O to L.H. license lamp In 14303, R.H. side of I/P

S-906 S-907 S-908

In 14A303, under shield near seat In 14290, near starter relay In 14290, near starter relay

S-1002 S-1003 S-1004

In 144318, near T/O to 14401 In 14A318, near T/O to cigar lighter In 18C618, near T/O to L.H. license lamp

S-1005

:

In 14A318, near T/O to clock in console

210 Key to wiring diagrams — 1979 models (Figs. 11.26 thru 11.45) Pa

:

Component

cae color key Primary aes Tan Red

Brown

Br 7 R

Pink

Pk

Orange Yellow

O Y

ant ee acs

Diag

Gatee

Dome/map switch ; BDI B3 Dual brake warning indicator3 C3 8 Engine compartment C14 8 Glove box switch els Heater backlite warning ind 5 Heater controls illumination

7

D3

Component

Diag

Pieienine

3

Water temperature indicator3 Sensor 2 Exhaust gas oxygen

013 F1 813

Servo Speed control Solenoid

F5

Dark green

Dg

Hi beam indicator

4

F4

A/C Clutch

7

°Eta

Light green

Lg

\/P Ash tray illumination

re

D1

Carb throttle emissioncont

3

F4

Dark blue

Db

L.H. Backup

5

ES

Carburetor float bowl vent

3

£&3

Light blue Purple

Lb p

L.H. Front side marker L.H. Hi beam head

4 :

D9 ae

Carburetor floatbowl vent fe valve control

3 2

D5 E15

L.H. Lo beam head

4

D10

R.H. Front radio receiver

6

D8

L.H. Front park i

:

a

a Front radio receiver

'

L.H. License

be

|

Hash

(H)

peaker

L.H. Stop and pari

ms is understood and has

mI

no color key Component

Diag

Alternator

40 Amp

2

m s a Ammeter Amplifier

Ri 2 Nd

Speed control

Heated

Battery 12 Volt 12 Volt Capacitor Radio ignition interference

Radio ignition interference Choke Electric Radio receiver suppression

L.H. Stop and park

Sees

Radio receiver

6

D1

L.H. Turn indicator

42

ES

Radio receiver

6

D6

Luggage compartment PRNDL Illumination (floor)

Se 7

Eas A8&

Radio receiver Radio receiver rear seat

6 ~ €i¢ 6: FZ

R.H. Backup

5

E3

Radio receiver rear seat

6

F4

R.H. Front side marker

4

D16

Radio receiver rear seat

6

F6

R.H. Hi beam head

4

D115

Radio receiver rear seat

:

a

6

Efe

R.H. R.H. R.H. R.H.

G5

R.H. Stop and park

8

£16

R.H. Turn indicator 4 Seat belts warning indicator 3. Stereo indicator 6

5

E16

License Lo beam head Front park & T/S Stop and park

5 4 7. 5 5

G7 D114 awhyfi} €E6

7

VAte

Back window heater control 5

A13

F7 D13 A8

Backup lamp Backup lamp Courtesy lamp

5 5. 8

B3 ..Be A6

Courtesy lamp

8

AT

Dual brake warning Gear shift neutral Gear shift neutral Headlamp Headlamp

3. 3. 5 1 4

SEZ VEG ee C10 G2

Headlamp

8

A4

Heater blower Heater mode

7 7

1G AY

Lighter

Cigar Modulator Breakerless ignition Motor Blower

pe

MG

B3 ee

2

F3

Jaen

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2

D11

Blower

Jip

le 2

D2

Starter W/S Washer pump

Tao 10 €9

2

Radio receiver rear seat Radio receiver rear seat Switch A/C Mode

E7

1 2

2

a

adio receiver

"B i i Ws

16

Armature Luggage comp doorlatch Backlite

At

Pr

10

C14

3

B5

W/S Washer pump

10

F14

Ignition

1

D5

Clock Coil

8

\Ci5

W/S Wiper W/S Wiper

10 105,

E10 E12

Ignition Ignition key warning

3 8

D8 £6

Ignition Control AM Radio RR speaker

2

D11

1

B3

AM Radio

L.H. Power door lock Luggage comp door lock Oil pressure

5 8 Z

D9 A116 E16

6

B2

Park brake signal lamp

AM Radio

aS

R.H. Power door lock

3

are 2 *F6 2 £6

AM with stereoraperadio AM/FM Monaural radio AM/FM Monaural radio AM/FM/MPX Radio

7 6 7 6

D8 B3 E6 B4

4. 4

AM/FM/MPX Radio Cassette AM/FM/MPX

7

D6

Radio

6

volume

6

D4

Distributor 2.3 Liter breakerless 2.8 Liter breakerless 8 Cyl 302 breakerless Flasher

Emergency warning Turn signal

SCF B6

Gauge

Fuel Water temp Governor

Sab 2 3 B2

W/S Wiper Heater

Engine block

Horn High pitch Lamp A/C & Heater controls illum Clock illumination Cluster illumination (2) Cluster illumination (5)

10

C14

3

D116

4

Panel Fuse Receiver

Dis

Rear window washer Rearhatchcourtesylamp Seat belt buckle Seat belt warning indicator

10 8 3 3.

C10 C13 D114 B14

Seat belt warning indicator Speed control

8 10

C6 See

B7

Stoplamp

4

B5

10 4 9

A5 C5 C5

B11

Stereo tape/ AM/FM/MPX Radio Stereo tape/ AM/FM/MPX

6

A12

Stoplamp Turn and emergency signal Turn and emergency signal

Radio

7

DEF

W/S/W Washer

10

W/S/W Washer

10

B14

A/C Control

7

“ia

Tachometer 3 Thermostat A/C Evaporator 7 Valve Carburetor solenoid vacuum 7

Diz

Regulator

Alternator

2

€1

Instrument cluster voltage Relay

3

C5

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7 D4 Te yer too

Back window heat control Starter motor Starter motor Resistor Blower motor

5 1 2

B14 B4 B6

7

bg

-

D11

3.

F2

Console ash tray illumination7

B8

Dome Dome

D9 D10

8 8

D15

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Blower motor

Sender A.T.C.WatertempindSW

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F-9 F-10 ee

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F-14

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F-15 F-16 F-17)

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SWITCH,

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297 BK iG H-— ———— >

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HEATER MODE SWITCH

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QSH RECEPTACLE HEATER

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HEADLAMP ON” WARNING BUZZER, (20 AMP IEMERGENCY WARNING FLASHER.STBPLAMP BLANK

F-B8

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C-302

IN CONSOLE

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LIGHTER-HORN

(15 AMP ICBURTESY

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110 AMP FUSE! WARNING LAMPS .DUAL BRAKE .@IL PRESSURE WATER TEMPERATURE .SEQT BELT CARBURETOR THROTTLE EMISSION CONTROL SOLENOID.

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Chapter 12

Bodywork

Contents Air vent grille — removal and reinstallation .......ccsccscsesesssessseseesesesees

31

Hatchback

Auxilliary hood catchy = adjuUstrnennt cess: tsasis-tseoccesacneserapncsteercscesoecnesesess Blower motor and wheel assembly — removal and reinstallation. Console, — removal/and): Install ation’ secc.scsesss-tyevepsvapresceestuswsevencsvanceeseaces

8 28

Heater — removal and reinstallation Hood — removal and installation .............0 Hood: latch, — adjustment 5.:..gpcesa

REINFORCEMENT

& e NUT

—T

—

*

os

(—

SCREW

INSERT

80-1.69 N-m (7-15 IN-LBS) SCREW

SCREW 6-8 N-m (4-6 FT-LBS)

HEADLAMP poor.

REINFORCEMENT

Fig. 12.19 Body front nosepiece and components (Sec 29)

Chapter 12

261

Bodywork

ae,

2

3.

1

Remove the screws securing the bumper cover assembly. Refer to

(Fig. 12.21) for their location. 2

While

supporting

the bumper

from falling, remove

the six boits

holding the bumper to the isolator assembly (photos).

30 Rear bumper assembly — removal and reinstallation

the bolts are removed

When

5

Installation is the reverse of removal.

6

can be lifted away.

After installing the metal bumper, check for 153 inches (39.05

cm) from the bottom

Lift the bumper cover assembly up and off.

the bumper

4

of the bumper to the ground.

NUT AND

RETAINER ASSEMBLY

o

y fo

BOLT TIGHTEN 34-51 N-m (25-38 FT-LBS)

ee

BOLT TIGHTEN 34-51 N-m (60-90 FT-LBS)

INSULATOR BOLT TIGHTEN 34:51 N-m (25-38 FT-LBS)

BRACKET

Fig. 12.20 Front bumper installation (Sec 29)

30.3A Mark the bumper bolt locations with paint for ease of reinstallation

30.3B While removing the bolts, have someone

help hold the bumper

30.3C Lift the bumper away from the vehicle

262

Chapter

12

Bodywork

31.4 Lift the air vent grille up about 3 inches and remove the windshield washer nozzle 3

Remove

the three sheet metal screws securing the air grille.

31

Air vent grille — removal and reinstailation

4 Lift the grille about 3 inches and disconnect the windshield washer nozzle hose (photo).

1 2

Unclip the rear hood air seal. Remove the passenger side wiper arm assembly.

5 6

BOLT AND

NUT AND

WASHER —

RETAINER ASSY. —

ISOLATOR

Remove the air vent grille. Installation is the reverse of removal.

5

AND BRACKET

BOLT —

34-51 N-m

82-122 N-m

(25-38 FT-LBS)

(60-90 FT-LBS)

NUT — 90-2.25 N-m

(8-20 FT-LBS)

COVER ASSY.

BUMPER ASSY. —

SCREW AND WASHER

;

———_—_—_ —

+»

Fig. 12.21 Rear bumper and cover assembly (Sec 30)

-90-2.25 N.m (8-20 IN-LBS)

.

ail

‘

;