123 0
English Pages 276 Year 1981
—~ ({rerry Davey) (Cras
Digitized by the Internet Archive in 2020 with funding from Kahle/Austin Foundation
https://archive.org/details/mercurycapriowneOOOOlewi
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)
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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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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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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
EO
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
©ES
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
§
Blower motor
Sender A.T.C.WatertempindSW
c€i6 +E13
wi
3
Bios 4
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testeNN taste ED OO0-- O—51° Bk
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FUSE
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FUSE LINK
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$-115 12
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38 Bk-@ ———-@—38 / $202 ~ FUSE LINE
Bx @ ——
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BATTERY
? c-110 BK O 6-101
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F-1 F 3
BLANK
F-5 F-6
(20 AMPICIGAR BLANK COMPARTMENT»
F-9 F-10 ee
AMP AMP
115 (25
RADI,
IGNITION
F-14
(30 AMP)
F-15 F-16 F-17)
(20 AMP) BLANK BLANY
SWITCH,
A/C MBDE
4 O°
S-111
297 BK iG H-— ———— >
4+ >——
—
_——
SWITCH
BeSU TIONS S-START
R-RUN Dereck A-ACCY
FLASHER BACKUP LAMPS
O-@FF
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:
ai
it
2
acon
;
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a
SWITCH
SWITCH
SWITCH
TURN SIGNAL
a
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& A/C CONTROLS -PRNDL.
HEATER MODE SWITCH
ee
—
be
IGNITION
QSH RECEPTACLE HEATER
3 >—16 P16 ———
-t > >—687 bY-y ————_——‘+ ea7 oe ote a °
ee
as
.LUGGAGE BOX
.DAME MAP GLOVE LAMPS
HEADLAMP ON” WARNING BUZZER, (20 AMP IEMERGENCY WARNING FLASHER.STBPLAMP BLANK
F-B8
c 302
C-302
IN CONSOLE
-CLOCK
LIGHTER-HORN
(15 AMP ICBURTESY
F-?
|
a
af
BLANK
F-4
£
CHART
110 AMP FUSE! WARNING LAMPS .DUAL BRAKE .@IL PRESSURE WATER TEMPERATURE .SEQT BELT CARBURETOR THROTTLE EMISSION CONTROL SOLENOID.
0
|
FUSE
BLANK
F-2
ets
ees: eee feast 0Sere
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pe
13 517 BK-W ——S
POWER DOQR LOCKS
27 Y——4S
HEATED BACKLITE
37 Y ———4_HEATED 80
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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
‘
;