Haynes Vauxhall Nova Owners Workshop Manual 1850109540, 9781850109549

Citation preview

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Vauxhall Nova Owners

Workshop Manual John S Mead Models covered All Vauxhall Nova models, Saloon and Hatchback,

including GTE, GSi and most special/limited editions 993 cc, 1196 cc, 1297 cc, 1389 cc & 1598 cc

Does not cover Diesel engine models or all aspects of the limited edition Sport Also covers major mechanical features of Van (909-1W12)

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Haynes Publishing Sparkford Nr Yeovil Somerset BA22 7JJ England Haynes Publications, Inc 861 Lawrence Drive Newbury Park California 91320 USA

3

Restoring and Preserving our Motoring Heritage Few people can have had the luck to realise their dreams to quite the same extent and in such a remarkable fashion as John Haynes, Founder and Chairman of the Haynes Publishing Group.

Acknowledgements Thanks are due to Champion Spark Plug, who supplied the illustrations showing spark plug conditions, to Holt Lloyd Limited who supplied the illustrations showing bodywork repair, and to Duckhams Oils, who provided lubrication data. Certain other illustrations are the copyright of Vauxhall Motors Limited, and are used with their permission. Thanks are also due to Sykes-Pickavant, who provided some of the workshop tools, and all those people at Sparkford who helped in the production of this manual.

Since 1965 his unique approach to workshop manual publishing has proved so successful that millions of Haynes Manuals are now sold every year throughout the world, covering literally thousands of different makes and models of cars, vans and motorcycles. A continuing passion for cars and motoring led to the founding in 1985 of a Charitable Trust dedicated to the restoration and preservation of our motoring heritage. To inaugurate the new Museum, John Haynes donated virtually his entire private collection of 52 cars. Now with an unrivalled international collection of over 210 veteran, vintage and classic cars and motorcycles, the Haynes Motor Museum in Somerset is well on the way to becoming one of the most interesting Motor Museums in the world. A 70 seat video cinema, a cafe and an extensive motoring bookshop, together with a specially constructed one kilometre motor circuit, make a visit to the Haynes Motor Museum a truly unforgettable experience. Every vehicle in the museum is preserved in as near as possible mint condition and each car is run every six months on the motor circuit. Enjoy the picnic area set amongst the rolling Somerset hills. Peer through the William Morris workshop windows at cars being restored, and browse through the extensive displays of fascinating motoring memorabilia. From the 1903 Oldsmobile through such classics as an MG Midget to the mighty ‘E’ type Jaguar, Lamborghini, Ferrari Berlinetta Boxer, and Graham Hill's Lola Cosworth, there is something for everyone, young and old alike, at this Somerset Museum.

© Haynes Publishing 1994

A book in the Haynes Owners

Workshop

Manual Series

Printed by J. H. Haynes & Co. Ltd.; Sparkford, Nr Yeovil, Somerset BA22 7JJ, England 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.

ISBN 1 85010 954 0 British Library Cataloguing in Publication Data A catalogue record for this book is available from the British Library We take great pride in the accuracy of information given in this manual, but vehicle manufacturers make alterations and design changes during the production run of a particular vehicle of which they do not inform us. 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.

%

Haynes Motor Museum Situated mid-way between London and Penzance, the Haynes Motor Museum is located just off the A303 at Sparkford, Somerset (home of the Haynes Manual) and is open to the public 7 days a week all year round, except Christmas Day and Boxing Day. Telephone 01963 440804.

Contents Page

Acknowledgements

2

About this manual

4

Introduction to the Vauxhall Nova

4

General dimensions, weights and capacities (also see Chapter 13, page 229) eee | Ge Ree ss ee ee ete Buying spare parts and vehicle identification numbers er is 8 cr meme e sh e eemee eran General repair procedures ee rcs en Tools and working facilities

ee

ee

eg

ig ah 2 es

en

a

ree

iia ee ai

aS Sa pe

Recommended lubricants and fluids

Re

Ns

a

I

Se

i ae re

Sart

Chapter 2 Cooling system (also see Chapter 13, page 229) Sn Chapter 3 Fuel and exhaust systems (also see Chapter 13, page 229) OC Chapter 4 Ignition system (also see Chapter 13, page 229) Oe Chapter 5 Clutch (also see Chapter 13, page 229) nn ea Chapter 6 Transmission (also see Chapter 13, page 229) nn a Chapter 7 Driveshafts (also see Chapter 13, page 229) Chapter 8 Steering gear a ee OO a Chapter 9 Braking system (also see Chapter 13, page 229) a aa ee SS Tg ODES GE DE SI 229) page 13, Chapter see (also Chapter 10 Electrical system rr Ed eS a = is see Chapter 13, page 229) (also Chapter 11 Suspension ee ee eee ee

0

SEI

=

eee

eee

a

a

Index

between pages 32 and 33 Spark plug condition and bodywork repair colour pages

12

S*E 13

eee 14

eee 20

ee

nee

23

57 Sa EEES EEE: 64 ———— 85

nnn

96 EEE SERDESEERINGSESSEaEES 104 man nee aE nn EEaESSRE aDR RnR 127

een ne

131

ann

142 Dem ane SET CET NEST = 160

Chapter 12 Bodywork (also see Chapter 13, page 229) ERERISSEE RIE cana cane i i ee Ee is models later Chapter 13 Supplement: Revisions and information on ETT i ee nnn ee aI SSaETpE asa Sma =e ese TIS ara ereecee ee ee ee eee eo See Conversion factors RISES

SE

Co ors evan me

see er NE nee eOS

Fault diagnosis a ee. Be Chapter 1 Engine (also see Chapter 13, page 229) Ee

8

11

ean

sees seo ca A ne lc a ER RS Ba SE Safety first! Fe ee eet ie et erent 229) page 13, Chapter see (also Routine maintenance eS eee ee eae

[Bey

a

9

Jacking, towing and wheel changing Ree Sa Spee cee

li Ng

eee

ee

ee

6

eee

ee ee Re

193

209 EEE 229 TD 343 EC

Sapa

344

About

this manual

Its aim The aim of this manual is to help you get the best value from your vehicle. It can do so in several ways. It can help you decide what work must be done (even should you choose to get it done by a garage), provide information on routine maintenance and servicing, and give a logical course of action and diagnosis when random faults occur. However, it is hoped that you will use the manual by tackling the work yourself. On simpler jobs it may even be quicker than booking the car into a garage and going there twice, to leave and collect it. Perhaps most important, a lot of money can be saved by avoiding the costs a garage must charge to cover its labour and overheads. The manual has drawings and descriptions to show the function of the various components so that their layout can be understood. Then the tasks are described and photographed in a step-by-step sequence so that even a novice can do the work.

[ts arrangement The manual is divided into thirteen Chapters, each covering a logical sub-division of the vehicle. The Chapters are each divided into Sections, numbered with single figures, eg 5; and the Sections into paragraphs (or sub-sections), with decimal numbers following on from

the Section they are in, eg 5.1, 5.2, 5.3 etc.

Introduction

It is freely illustrated, especially in those parts where there is a detailed sequence of operations to be carried out. There are two forms of illustration: figures and photographs. The figures are numbered in sequence with decimal numbers, according to their position in the Chapter — eg Fig. 6.4 is the fourth drawing/illustration in Chapter 6. Photographs carry the same number (either individually or in related groups) as the Section or sub-section to which they relate. There is an alphabetical index at the back of the manual as well as a contents list at the front. Each Chapter is also preceded by its own individual contents list. References to the ‘left’ or ‘right’ of the vehicle are in the sense of a person in the driver's seat facing forwards. Unless otherwise stated, nuts and bolts are removed by turning anti-clockwise, and tightened by turning clockwise. Vehicle manufacturers continually make changes to specifications and recommendations, and these, when notified, are incorporated into our manuals at the earliest opportunity.

We take great pride in the accuracy of information given in this manual, but vehicle manufacturers make alterations and design changes during the production run of a particular vehicle of which they do not inform us. 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.

to the Vauxhall

After a controversial launch early in 1983, origins, the Nova quickly established itself as a the small car market. The Vauxhall Nova is General Motors UK lished Opel Corsa and shares many mechanical

owing to its Spanish leading contender in version of the estabcomponents with the

Astra/Cavalier range. The model line-up includes two- and four-door Saloon and three-

Nova

and five-door Hatchback versions, availabie with a choice of 1.0 litre ohv and 1.2, 1.3 or 1.6 litre ohc engines. Various levels of trim and optional equipment are available depending upon the model selected from the range. In keeping with current design trends, the Nova is of straight-

forward

design

components

and

construction

and service points.

with

easy

access

to

major

uoojes BAON [Jeyxnep

dimensions, weights and capacities

General

For information applicable to later models, see Supplement at end of manual Dimensions Overall length: SSILC Lag ear UsSuiolaloe eld eh Mee Overall width: (Ss [Poor dines eas Ee TOts(alaa poem Overall height: Sea6late

acca a eee anoa aa cat cea adoresca dank he eTowns incembera doulas amnesia Sac ene aren RR eee mere merece en rece rien cto

3955 3622

Se ear te ED EE ee Pe SR Son

1540 mm 1532 mm

(60.6 in) (60.3 in)

TO

1360

mm

(53.5 in)

ap Ae os one Ionvaone

1365 2343

mm mm

(53.7 in) (92.2 in)

ape ert aren

1320

mm

aero

1307 mm

SSE

eRe Rn

RBS

ee

Pea cee Teeny aE OM Rp

EEE

yr Ear OE aee

een tren ear SAE eT es OCDE e Picea

SPSS LALO Ts(O..SeC RE CPR ote a Ce CRE rr Le i peer ER BAVA PERS SSS eee aero acs Sis eu cea D ag NRG Caco va FUR a ona Retr SWE Track: Tad (nee Rena eee es RE ae Oe a RE SE ates 7 ae ep 18(Gf Bae oe GRR RD CEN BEEPS SPE OTS Pon To Tacit NGHEU SUNTRETG CEERI Ce eee ae ae

er

Tisch pasa a a vac oh Sovava dev eenpee eeepc ba ¢evesucteesnacusendsenaauceue

144

mm mm

mm

(155.7 in) (142.6 in)

(52.0 in)

(51.6 in) (5.7 in)

Weights Kerb weight: A LCSCLEL SGV.

740 kg (1631

Ibs)

FPL THESRC eeeTION Ec oceet rtoc sa seton sos ee cat ta cue ven Se ckachias ees sceMbenwes Chenminay ayaa yteearrd

Sete ste ia o os acne oe huh ec ae thes dace beara Vas eo ace taa RRR SN

ae ravenna:

735

Ibs)

ME SodCITE TVLGIGN LS eo oe oes

750 kg (1653 Ibs)

seo Gots iene ar caer behead eS U aUA AAU SURSIUNaGE OD Sree oR ees OTe n

kg (1620

Pe eter TEETER BATCHIS sere soe ie se teeoes sos os dame so cona areata ener caurdncarens ce nase

750 kg (1653

SSP THCColSeaie eRe aio ats sy ee ca ean ars sna Poe asclay Lei en AseMar ere anepey Tadowena teeta (BM EfanQoa Cl ee je ee naar ee Pep rrr en ater ae cane

770 kg (1698 Ibs) 834 kg (1839 Ibs)

IEC EEEAEN

FIRE PEACIG Oe

tect coc aha

ccs acne ai ts eotvaigsshivvncarnlivinanesaaeateetoaseethemetds

Maximum caravan/trailer towing weight: SEN OVEETNIES ee a area re Re MSIE eriicicau a thous docu clos to veut a Dattane came ag Rees TeDe TICLS eee eee a eee alas yas Chavos naar avinURN gees STEERER SCAN CIV CHE Nairn ere eo eae haley cals Nae cunt ed cna henyasnahe camer then lay reas ee

Maximum

tow ball socket VertiCal IO .....c1.scccessssscersvoestsovesssotvasseconsonraas

Ibs)

80 kg (176 Ibs)

Braked trailer 400 kg (882 Ibs) 650 kg (1433 Ibs) 800 kg (1764 Ibs) 50 kg (110 Ibs)

Capacities USN SECATTR — — gees ka pT Cooling system:

era ete eee deo errata

WO MmOcels Tareceree ee rere 2-1

3 arr

eran dad eas tiwsSdve zou resracsbacroneaeeeddViTee

et aa eave case cad canbere ref wia Ferd idoins stoeravtserardeasatordsvesat

6 sO cels error rere wetness

eta ces traak ta sen rer sap eveeucecueiner’

Engine oil (with filter change): TOuimmadels icc vciscchoreadeateeete tT aaa Ne) and’ 1.3

TOMO

rewn ore by Cera eR Natt sn ai inussec Nl esptasy MOAGIS svete cael rer rarar teal raeteaaencts eh crtttess ctucscatsdterss cca

ONS. and 1,3 MVOC elSit sic svcertersatee peso eer ere cbsere ak eee caer aeter ede xe aS PRIOMITI@OLOIS: icv cs dears ssivscectsiarseeteecetoaxenal teva en anyease teneteam aaaaria taeda aie Transmission:

FOUGES CCE ITIOCEIS: ..si:.scsyescescscveceseontasecnavoudtants teMercervopitaemnnraas neagssytefaerie FIVSES DECC SIMO GEIS os.seis nase concvcs 10a phi avcsntandnasoeenes oeeey meee fen peaks Ge tee artes

42 litres (9.2 gal)

5.5 litres (9.7 pt) 6.1 litres (10.7 pt)

2.5 litres (4.4 pt) 3.0 litres (5.3 pt) 3.5 litres (6.2 pt) 0.75 litres (1.3 pt) 1.0 litre (1.8 pt)

1.75HY litres (3.1 pt) 1.85 litres (3.3 pt)

Unbraked trailer 400 kg (882 Ibs) 400 kg (882 Ibs) 400 kg (882 lbs)

Buying spare parts and vehicle

identification

Buying spare parts Spare parts are available from many sources, for example: Vauxhall garages, other garages and accessory shops, and motor factors. Our advice regarding spare part sources is as follows: Officially appointed Vauxhall garages — This is the best source of parts which are peculiar to your vehicle and are otherwise not generally available (eg complete cylinder heads, internal gearbox components, badges, interior trim etc). It is also the only place at which you should buy parts if your vehicle is still under warranty; nonVauxhall components may invalidate the warranty. To be sure of obtaining the correct parts it will always be necessary to give the storeman your vehicle’s engine and chassis number, and if possible, to take the ‘old’ parts along for positive identification. Remember that some parts are available on a factory exchange scheme — any parts returned should always be clean. It obviously makes good sense to go straight to the specialists on your vehicle for this type of part for they

are best equipped to Supply you.

Other garages and accessory shops — These are often very good places to buy materials and components needed for the maintenance of your vehicle (eg spark plugs, bulbs, drivebelts, oils and greases,

number Vehicle identification number plate and engine locations

numbers touch-up paint, filler paste, etc). They also sell general accessories, usually have convenient opening hours, charge lower prices and can often be found not far from home. Motor factors — Good factors will stock all of the more important components which wear out relatively quickly (eg clutch components, cylinders/ brake systems, exhaust valves, pistons, /pipes/hoses/seals/shoes and pads etc). Motor factors will often provide new or reconditioned components on a part exchange basis — this can save a considerable amount of money.

Vehicle identification numbers The Vehicle Identification Number is located inside the engine compartment on top of the front end panel. The plate is marked with the vehicle chassis and designation number and the colour code. Also shown is the maximum gross weight for the car. The engine number is stamped on a flat machined on the engine cylinder block. The chassis number is stamped on the body floor panel between the driver’s seat and the door sill.

Chassis number location

General

repair procedures

Whenever servicing, repair or overhaul work is carried out on the car or its components, it is necessary to observe the following procedures and instructions. This will assist in carrying out the operation efficiently and to a professional standard of workmanship.

Joint mating faces and gaskets Where a gasket is used between the mating faces of two components, ensure that it is renewed on reassembly, and fit it dry unless otherwise stated in the repair procedure. Make sure that the mating faces are clean and dry with all traces of old gasket removed. When cleaning a joint face, use a tool which is not likely to score or damage the face, and remove any burrs or nicks with an oilstone or fine file. Make sure that tapped holes are cleaned with a pipe cleaner, and keep them free of jointing compound if this is being used unless specifically instructed otherwise. Ensure that all orifices, channels or pipes are clear and blow through them, preferably using compressed air.

Oil seals Whenever an oil seal is removed from its working location, either individually or as part of an assembly, it should be renewed. The very fine sealing lip of the seal is easily damaged and will not seal if the surface it contacts is not completely clean and free from scratches, nicks or grooves. If the original sealing surface of the component cannot be restored, the component should be renewed. Protect the lips of the seal from any surface which may damage them in the course of fitting. Use tape or a conical sleeve where possible. Lubricate the seal lips with oil before fitting and, on dual lipped seals, fill the space between the lips with grease. Unless otherwise stated, oil seals must be fitted with their sealing lips toward the lubricant to be sealed. Use a tubular drift or block of wood of the appropriate size to install the seal and, if the seal housing is shouldered, drive the seal down to the shoulder. If the seal housing is unshouldered, the seal should be fitted with its face flush with the housing top face.

Screw threads and fastenings Always ensure that a blind tapped hole is completely free from oil,

grease, water or other fluid before installing the bolt or stud. Failure to do this could cause the housing to crack due to the hydraulic action of the bolt or stud as it is screwed in. When tightening a castellated nut to accept a split pin, tighten the nut to the specified torque, where applicable, and then tighten further to the next split pin hole. Never slacken the nut to align a split pin hole unless stated in the repair procedure. When checking or retightening a nut or bolt to a specified torque setting, slacken the nut or bolt by a quarter of a turn, and then retighten to the specified setting.

Locknuts, locktabs and washers Any fastening which will rotate against a component or housing in the course of tightening should always have a washer between it and the relevant component or housing. Spring or split washers should always be renewed when they are used to lock a critical component such as a big-end bearing retaining nut or bolt. Locktabs which are folded over to retain a nut or bolt should always be renewed. Self-locking nuts can be reused in non-critical areas, providing resistance can be felt when the locking portion passes over the bolt or stud thread. Split pins must always be replaced with new ones of the correct size for the hole.

Special tools Some repair procedures in this manual entail the use of special tools such as a press, two or three-legged pullers, spring compressors etc. Wherever possible, suitable readily available alternatives to the manufacturer's special tools are described, and are shown in use. In some instances, where no alternative is possible, it has been necessary to resort to the use of a manufacturer's tool and this has been done for reasons of safety as well as the efficient completion of the repair operation. Unless you are highly skilled and have a thorough understanding of the procedure described, never attempt to bypass the use

of any special tool when the procedure described specifies its use. Not only is there a very great risk of personal injury, but expensive damage could be caused to the components involved.

Tools and working facilities drives are included in the set. We recommend the 4 in square-drive

Introduction A selection of good tools is a fundamental requirement for anyone contemplating the maintenance and repair of a motor vehicle. For the owner who does not possess any, their purchase will prove a

considerable expense, offsetting some of the savings made by doingit-yourself. However, provided that the tools purchased are of good quality, they will last for many years and prove an extremely worthwhile

investment.

To help the average owner to decide which tools are needed to carry out the various tasks detailed in this manual, we have compiled three lists of tools under the following headings: Maintenance and minor repair, Repair and overhaul, and Special. The newcomer to practical mechanics should start off with the Maintenance and minor repair tool kit and confine himself to the simpler jobs around the vehicle. Then, as his confidence and experience grow, he can undertake more difficult tasks, buying extra tools as, and when, they are needed. In this way, a Maintenance and minor repair tool kit can be built-up into a Repair and overhaul tool kit over a considerable period of time without any major cash outlays. The experienced do-ityourselfer will have a tool kit good enough for most repair and

overhaul procedures and will add tools from the Specia/ category when he feels the expense is justified by the amount of use to which these tools will be put. .

type, as this can be used with most proprietary torque wrenches. If you cannot afford a socket set, even bought piecemeal, then inexpensive tubular box spanners are a useful alternative. The tools in this list will occasionally need to be supplemented by tools from the Special list.

Sockets (or box spanners) to cover range in previous list Reversible ratchet drive (for use with sockets)

Extension piece, 10 inch (for use with sockets) Universal joint (for use with sockets) Torque wrench (for use with sockets) ‘Mole’ wrench - 8 inch Ball pein hammer Soft-faced hammer, plastic or rubber

Screwdriver - 6 in long x & in dia (flat blade) Screwdriver - 2 in long x 2 in square (flat blade)

Screwdriver - 14 in long x 4 in dia (cross blade) Screwdriver - 3 in long x ¢ in dia (electricians) Pliers - electricians side cutters Pliers - needle nosed Pliers - circlip (internal and external)

Cold chisel - + inch Scriber Scraper Centre punch Pin punch Hacksaw Valve grinding tool

Steel rule/straight-edge

Maintenance

and minor repair tool kit

The tools given in this list should be considered as a minimum repair operarequirement if routine maintenance, servicing and minor purchase of the nd recomme We n. undertake be to are tions other); although combination spanners (ring one end, open-ended the advantages of more expensive than open-ended ones, they do give the both types of spanner.

Combination

spanners - 10, 11, 12, 13, 14 & 17mm

Adjustable spanner - 9 inch Spark plug spanner (with rubber insert) Spark plug gap adjustment too/ Set of feeler gauges Brake bleed nipple spanner

Screwdriver - 4 in long x i in dia (flat blade) Screwdriver - 4 in long x + in dia (cross blade) Combination pliers - 6 inch Hacksaw (junior) Tyre pump Tyre pressure gauge

Repair and overhaul tool kit

anyone undertaking any These tools are virtually essential for are additional to those given in and , vehicle motor a to repairs major list is a

\ist. Included in this the Maintenance and minor repair these are expensive they will gh Althou . comprehensive set of sockets larly if various as they are so versatile

The tools in this list are those which are not used regularly, are their expensive to buy, or which need to be used in accordance with l jobs manufacturers’ instructions. Unless relatively difficult mechanica many of are undertaken frequently, it will not be economic to buy clubbing these tools. Where this is the case, you could consider a joint make to club) motorists’ a joining (or friends with together garage purchase, or borrowing the tools against a deposit from a local or tool hire specialist. The following list contains only those tools and instruments freely by the available to the public, and not those special tools produced will find You network. dealer its for y specificall rer manufactu vehicle the text occasional references to these manufacturers’ special tools in job of this manual. Generally, an alternative method of doing the the

vehicle

manufacturers

special

tool

is given.

However,

is the sometimes, there is no alternative to using them. Where this have case and the relevant tool cannot be bought or borrowed, you will to entrust the work to a franchised garage.

Wire brush (small) Funnel (medium size)

invaluable

Special tools

without

Oil can Fine emery cloth (1 sheet)

be found

Allen keys Selection of files Wire brush (large) Axle-stands Jack (strong scissor or hydraulic type)

- particu

Valve spring compressor Piston ring compressor Balljoint separator Universal hub/bearing puller Impact screwdriver Micrometer and/or vernier gauge Dial gauge

Stroboscopic timing light

Tools and working facilities

10

eee

Universal electrical multi-meter

A

Sabai

2

Spanner size

Jaw gap (in)

Dwell angle meter/tachometer

8 mm

0.315

ae

jack Trolley ; ; ; Light with extension lead

0.344

1 in AF; £ in Whitworth

aoe i 0394

2 see 3Wacen

0.433

11 mm

0.438

% in AF

always aim to purchase items which meet the relevant national safety

0.445 0.472 0.500 0.512 0.525 0.551

2 in Whitworth; 3 in BSF 12 mm + in AF 13 mm 1 in Whitworth; & in BSF 14 mm

standards. If in doubt, ask the proprietor or manager of the shop for advice before making a purchase.

0.563 0.591

Buying tools

For practically all tools, a tool factor is the best source since he will have a very comprehensive range compared with the average garage or accessory shop. Having said that, accessory shops often offer excellent quality tools at discount prices, so it pays to shop around. There are plenty of good tools around at reasonable prices, but

:

Care and maintenance of tools

;

2 in AF 15 mm

0.600

& in Whitworth; ¢ in BSF

0.625

2 in AF

0.630

16 mm

Having purchased a reasonable tool kit, it is necessary to keep the

0.669

17 mm

tools in a clean serviceable condition. After use, always wipe off any

0.686

Yin AF

dirt, grease and metal particles using a clean, dry cloth, before putting

0.709

the tools away. Never leave them lying around after they have been

0.710

used. A simple tool rack on the garage

0.748

19 mm

all normal

0.750

3 in AF

wrenches and sockets in a metal box. Any measuring instruments, gauges, meters, etc, must be carefully stored where they cannot be

0.813 0.820

8 in AF % in Whitworth; + in BSF

such

as screwdrivers

and

or workshop

pliers is a good

idea.

wall, for items

18 mm

2 in Whitworth; % in BSF

Store

0.866

22 mm

Take a little care when tools are used. Hammer heads inevitably become marked and screwdrivers lose the keen edge on their blades from time to time. A little timely attention with emery cloth or a file will

0.875 0.920 0.938

Z in AF + in Whitworth; 2 in BSF 18 in AF

soon restore items like this to a good serviceable finish.

0.945

24 mm

damaged

rusty.

or become

1.000

Working facilities

1 in AF

1.010

2 in Whitworth; 2 in BSF

Not to be forgotten when discussing tools, is the workshop itself.

1.024

26 mm

If anything more than routine maintenance is to be carried out, some form of suitable working area becomes essential.

1.063 1.100

14 in AF; 27 mm 2 in Whitworth; 2 in BSF

It is appreciated that many an owner mechanic is forced by circumstances to remove an engine or similar item, without the benefit of a garage or workshop. Having done this, any repairs should always

Tt 1.181 1.200

14 in AF 30 mm 1 in Whitworth; 3 in BSF

be done under the cover of a roof. Wherever possible, any dismantling should be done on a clean, flat

{|PLEO) 1.260

32 mm

Any workbench needs a vice: one with a jaw opening of 4 in (100 mm) is suitable for most jobs. As mentioned previously, some clean dry storage space is also required for tools, as well-as for lubricants,

14 in AF

workbench or table at a suitable working height.

1.300

3 in Whitworth; ¢ in BSF

1.313 1.390 1.417

12 in AF 8 in Whitworth; 2 in BSF 36 mm

cleaning fluids, touch-up paints and so on, which become necessary. Another item which may be required, and which has a much more general usage, is an electric drill with a chuck capacity of at least 3 in (8 mm). This, together with a good range of twist drills, is virtually essential for fitting accessories such as mirrors and reversing lights. Last, but not least, always keep a supply of old newspapers and

1.438 1.480 1.500 1.573 1.614 1.625

1% in AF < in Whitworth; 1 in BSF 14 in AF 40 mm; }?2 in Whitworth 41 mm 12 in AF

clean, lint-free rags available, and try to keep any working area as clean as possible.

1.670 1.688

1 in Whitworth; 17% in AF

1.811

46 mm

:

14 in BSF

;

1.813

1.860

1¢ in Whitworth; 14 in BSF

size

1.875 1.969 2.000

1Z in AF 50 mm 2 in AF

Spanner jaw gap comparison table

133 in AF

Jaw gap (in)

Spanner

0.250

z in AF

2.050

14 in Whitworth; 13 in BSF

0.276 0.313

7 mm % in AF

23165 2.362

55 mm 60 mm

11

Jacking, towing and wheel changing Jacking Use the jack supplied with the vehicle only for wheel changing during roadside emergencies (photo). Chock the wheel diagonally opposite the one being removed. When raising the vehicle for repair or maintenance, preferably use a trolley or hydraulic jack with a wooden block as an insulator to prevent damage to the underbody. Place the jack under a structural member at the points indicated, never raise the vehicle by jacking up under the engine sump, transmission casing or rear axle. If both front or both rear wheels are to be raised, jack up one side first and securely support it on an axle stand before raising the other side. To avoid repetition, the procedure for raising the vehicle in order to carry out work under it is not included before each relevant operation described

If the car is fairly new, the roadwheels and tyres will have been balanced on the vehicle during production. In order to maintain this

balance then the position of the roadwheel in relation to the mounting hub must be marked before removing the wheel.

Release but do not remove each roadwheel bolt and then raise the vehicle with the jack. Remove the bolts and take off the wheel.

in this manual.

It is to be preferred and is certainly recommended that the vehicle is positioned over an inspection pit or raised on a lift. Where such equipment is not available, use ramps or jack up the vehicle as previously described, but always supplement the lifting device with axle stands.

Towing Towing hooks are welded to the front and rear of the vehicle and should only be used in an emergency, as their designed function is as lash-down hooks, for use during transportation. When being towed, remember to insert the ignition key and turn it to Position

|. Expect to apply greater pressure to the footbrake, as

servo assistance applications.

will

not

be

available

after

the

first few

brake

Wheel changing To change a roadwheel, first prise off the wheel trim or remove the roadwheel bolt plastic caps.

Rear towing hook

Prise off the wheel trim or the wheel bolt plastic caps to gain access to the wheel retaining bolts

12

Recommended Component

or system

Engine (1)

Transmission

(2)

lubricants and fluids

Lubricant type/specification

Duckhams

recommendation

Multigrade engine oil, viscosity range

Duckhams OXR, OS, Hypergrade Plus or

SAE 10W/40 to 20W/50, to API-SG

Hypergrade

Gear oil, viscosity SAE 80, to API-GL3 or GL4, or GM special oil 90 188 629

Duckhams Hypoid 80, or Hypoid 75W/90S

L 6368

Cooling system (3)

Antifreeze to GME

Brake hydraulic system (4)

Hydraulic fluid to SAE J1703 or DOT 4

Duckhams Universal Antifreeze and Summer Coolant Duckhams Universal Brake and Clutch Fluid

Safety first! Professional motor mechanics are trained in safe working procedures. However enthusiastic you may be about getting on with the job in hand, do take the time to ensure that your safety is not put at risk. A

moment's lack of attention can result in an accident, as can failure to observe certain elementary precautions. There will always be new ways of having accidents, and the following points do not pretend to be a comprehensive list of all dangers; they are intended rather to make you aware of the risks and to encourage a safety-conscious approach to all work you carry out on your vehicle.

Essential DOs and DON'Ts DON'T rely on a single jack when working underneath the vehicle. Always use reliable additional means of support, such as axle stands, securely placed under a part of the vehicle that you know will not give way. DON'T attempt to loosen or tighten high-torque nuts (e.g. wheel hub nuts) while the vehicle is on a jack; it may be pulled off. DON'T start the engine without first ascertaining that the transmission is in neutral (or ‘Park’ where applicable).and the parking brake applied. DON’T suddenly remove the filler cap from a hot cooling system — cover it with a cloth and release the pressure gradually first, or you may get scalded by escaping coolant. DON'T attempt to drain oil until you are sure it has cooled sufficiently to avoid scalding you. DON’T grasp any part of the engine, exhaust or catalytic converter without first ascertaining that it is sufficiently cool to avoid burning

you. DON'T DON’T mouth, DON’T below). DON’T straight DON'T

allow brake syphon toxic or allow them inhale dust

fluid or antifreeze to contact vehicle paintwork. liquids such as fuel, brake fluid or antifreeze by to remain on your skin. — it may be injurious to health (see Asbestos

allow any spilt oil or grease to remain on the floor — wipe it up away, before someone slips on it. use ill-fitting spanners or other tools which may slip and cause

injury. DON’T attempt to lift a heavy component which may be beyond your capability — get assistance.

DON'T tush to finish a job, or take unverified short cuts. DON’T allow children or animals in or around an unattended vehicle.

DO wear eye protection when using power tools such as drill, sander, bench grinder etc, and when working under the vehicle. — DO use a barrier cream on your hands prior to undertaking dirty jobs easier dirt the making as well as infection from skin your protect it will to remove afterwards; but make sure your hands aren't left slippery. a health Note that long-term contact with used engine oil can be hazard. of the DO keep loose clothing (cuffs, tie etc) and long hair well out way of moving mechanical parts. vehicle — DO remove rings, wristwatch etc, before working on the especially the electrical system. load rating DO ensure that any lifting tackle used has a safe working adequate for the job. over articles left DO keep your work area tidy — it is only too easy to fall

lying around. well, when working DO get someone to check periodically that all is alone on the vehicle. that everything is DO carry out work in a logical sequence and check ds. afterwar d tightene and ed assembl y correctl that of yourself and DO remember that your vehicle's safety affects others. If in doubt on any point, get specialist advice. unfortunate enough IF, in spite of following these precautions, you are possible. as soon as n attentio medical seek , to injure yourself

Asbestos

products — such as Certain friction, insulating, sealing, and other converters, gaskets, brake linings, brake bands, clutch linings, torque taken to avoid inhalation etc — contain asbestos. Extreme care must be to health. \f in doubt, us hazardo is it of dust from such products since assume that they do contain asbestos.

13 Fire

Remember at all times that petrol (gasoline) is highly flammable.

Never smoke, or have any kind of naked flame around, when working on the vehicle. But the risk does not end there — a spark caused by an electrical short-circuit, by two metal surfaces contacting each other, by careless use of tools, or even by static electricity built up in your body

under certain conditions, can ignite petrol vapour, which in a confined space is highly explosive. Always disconnect the battery earth (ground) terminal before working on any part of the fuel or electrical system, and never risk spilling fuel on to a hot engine or exhaust. It is recommended that a fire extinguisher of a type suitable for fuel and electrical fires is kept handy in the garage or workplace at all times. Never try to extinguish a fuel or electrical fire with water. Note: Any reference to a ‘torch’ appearing in this manual should always be taken to mean a hand-held battery-operated electric lamp or flashlight. It does NOT mean a welding/gas torch or blowlamp.

Fumes

Certain fumes are highly toxic and can quickly cause unconscious-

ness and even death if inhaled to any extent. Petrol (gasoline) vapour

comes into this category, as do the vapours from certain solvents such as trichloroethylene. Any draining or pouring of such volatile fluids

should be done in a well ventilated area.

When using cleaning fluids and solvents, read the instruction carefully. Never use materials from unmarked containers — they may give off poisonous vapours. Never run the engine of a motor vehicle in an enclosed space such as a garage. Exhaust fumes contain carbon monoxide which is extremely poisonous; if you need to run the engine, always do so in the open air or at least have the rear of the vehicle outside the workplace. If you are fortunate enough to have the use of an inspection pit, never drain or pour petrol, and never run the engine, while the vehicle is standing over it; the fumes, being heavier than air, will concentrate in the pit with possibly lethal results.

The battery

Never cause a spark, or allow a naked light, near the vehicle's battery. It will normally be giving off a certain amount of hydrogen gas, which is highly explosive. Always disconnect the battery earth (ground) terminal before working on the fuel or electrical systems. If possible, loosen the filler plugs or cover when charging the battery from an external source. Do not charge at an excessive rate or the battery may burst. Take care when topping up and when carrying the battery. The acid electrolyte, even when diluted, is very corrosive and should not be allowed to contact the eyes or skin. If you ever need to prepare electrolyte yourself, always add the acid slowly to the water, and never the other way round. Protect against splashes by wearing rubber gloves and goggles. When jump starting a car using a booster battery, for negative earth (ground) vehicles, connect the jump leads in the following sequence: First connect one jump lead between the positive (+) terminals of the two batteries. Then connect the other jump lead first to the negative (-) terminal of the booster battery, and then to a good earthing

(ground) point on the vehicle to be started, at least 18 in (45 cm) from

the battery if possible. Ensure that hands and jump leads are clear of any moving parts, and that the two vehicles do not touch. Disconnect the leads in the reverse order.

Mains electricity and electrical equipment When

using an electric power tool, inspection

light etc, always

ensure that the appliance is correctly connected to its plug and that, where necessary, it is properly earthed (grounded). Do not use such appliances in damp conditions and, again, beware of creating a spark or applying excessive heat in the vicinity of fuel or fuel vapour. Also ensure that the appliances meet the relevant national safety standards.

Ignition HT voltage

A severe electric shock can result from touching certain parts of the ignition system, such as the HT leads, when the engine is running or being cranked, particularly if components are damp or the insulation is defective. Where an electronic ignition system is fitted, the HT voltage is much higher and could prove fatal.

Routine

maintenance

For modifications, and information applicable to later models, see Supplement at end of manual Maintenance is essential for ensuring safety and desirable for the purpose of getting the best in terms of performance and economy from your car. Over the years the need for periodic lubrication has been greatly reduced if not totally eliminated. This has unfortunately tended to lead some owners to think that, because no such action is required, the items either no longer exist, or will last forever. This is certainly not the case, it is essential to carry out regular visual examination as comprehensively as possible in order to spot any possible defects at an early stage before they develop into major expensive repairs. The following service schedules are a list of the maintenance requirements and the intervals at which they should be carried out, as recommended by the manufacturers. Where applicable these procedures are covered in greater detail throughout this manual, near the beginning of each Chapter.

Check ignition timing Check carburettor adjustment Check steering and suspension for wear, and gaiters and bellows for damage Check transmission oil level Check drivebelt tension and condition Check brake hydraulic hoses and pipes for damage or corrosion Check the operation of all electrical equipment, also check the wiring and connectors Check the condition of the screen wash/wipe systems Inspect all joint faces and seals for damage, deterioration or leakage

Every 18000

Check engine oil level (photos). Check operation of all lights, flashers and wipers Check coolant level (photo) Check washer fluid level(s), adding a screen wash such as Turtle Wax High Tec Screen Wash Check tyre pressures (cold), not forgetting the spare (photo)

- Every 9000 first

miles (15000

km) or six months,

miles (30 000 km) or 12 months, whichever comes

first

Weekly or before a long journey

whichever comes

In addition to, or instead of, the work specified in the previous schedule Check exhaust system condition and security of mountings

Check Check Check Check Check Renew Check

rear wheel bearing adjustment the front wheel alignment clutch pedal adjustment handbrake adjustment and condition of linkage headlamp beam alignment brake hydraulic fluid (annually, regardless of mileage) coolant antifreeze concentration

Renew engine oil and filter (photos) Renew

air cleaner element (photo)

Check and adjust valve clearances (1.0 models only) Clean, adjust or renew distributor contact breaker lubricate distributor cam (1.0 models only) Renew the spark plugs Lubricate controls, hinges and locks (photo) Adjust rear brakes and check lining wear Renew carburettor fuel filter (10S engine) Inspect tyres for damage and wear (photo) Check front disc pads for wear Check brake hydraulic fluid level (photo)

Every 36 000 miles (60 000 km) or 2 years, whichever comes first points

and

In addition to the On ohc engines, necessary, adjust is renewed if its

work specified in the previous schedules check the condition of the timing belt and, if the belt tension. It is recommended that the belt condition is in any way suspect.

Every 2 years, regardless of mileage Renew coolant

Bh

0.75 litre (1.3 pt) separates the MAX and

Top up Or refill the oil through the filler on

MIN marks on the dipstick

the rocker cover

Gy,

Maintain the level in the cooling system up to the KALT fevel, when the engine is cold

Check the tyre pressures with an accurate

gauge

Engine oil filter location

aynlg 3 panf> platy

XN

Checking tyre tread depth

Top up the brake hydraulic fluid through the filler neck in the master cylinder reservoir

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20

Fault diagnosis Introduction The

vehicle

owner

who

does

his or her own

maintenance

according to the recommended schedules should not have to use this section of the manual very often. Modern component reliability is such that, provided those items subject to wear or deterioration are inspected or renewed at the specified intervals, sudden failure is comparatively rare. Faults do not usually just happen as a result of sudden failure, but develop over a period of time. Major mechanical failures in particular are usually preceded by characteristic symptoms over hundreds or even thousands of miles. Those components which do occasionally fail without warning are often small and easily carried in the vehicle. With any fault finding, the first step is to decide where to begin investigations. Sometimes this is obvious, but on other occasions a little detective work will be necessary. The owner who makes half a dozen haphazard adjustments or replacements may be successful in curing a fault (or its symptoms), but he will be none the wiser if the fault recurs and he may well have spent more time and money than was necessary. A calm and logical approach will be found to be more satisfactory in the long run. Always take into account any warning signs or abnormalities that may have been noticed in the period preceding the fault — power loss, high or low gauge readings, unusual noises or smells, etc — and remember that failure of components such as fuses or spark plugs may only be pointers to some underlying fault.

The pages which follow here are intended to help in cases of failure to start or breakdown on the road. There is also a Fault Diagnosis Section at the end of each Chapter which should be

consulted if the preliminary checks prove unfruitful. Whatever the fault, certain basic principles apply. These are as follows:

Verify the fault. This is simply a matter of being sure that you know what the symptoms are before starting work. This is particularly important if you are investigating a fault for someone else who may not have described it very accurately. Don’t overlook the obvious. For example, if the vehicle won't start, is there petrol in the tank? (Don’t take anyone else's word on this particular point, and don’t trust the fuel gauge either!) If an electrical fault is indicated, look for loose or broken wires before digging out the

test gear. Cure the disease, not the symptom. Substituting a flat battery with a fully charged one will get you off the hard shoulder, but if the underlying cause is not attended to, the new battery will go the same way. Similarly, changing oil-fouled spark plugs for a new set will get you moving again, but remember that the reason for the fouling (if it wasn't simply an incorrect grade of plug) will have to be established and corrected.

Don’t take anything for granted. Particularly, don't forget that a ‘new’ component may itself be defective (especially if it's been rattling round in the boot for months), and don’t leave components out of a fault diagnosis sequence just because they are new or recently fitted. When you do finally diagnose a difficult fault, you'll probably realise that all the evidence was there from the start.

We tryhander

Carrying a few spares can save you a long walk!

Fault diagnosis Electrical faults Electrical faults can be more puzzling than straightforward mechanical failures, but they are no less susceptible to logical analysis if the basic principles of operation are understood. Vehicle electrical wiring exists in extremely unfavourable conditions — heat, vibration and chemical attack — and the first things to look for are loose or corroded connections and broken or chafed wires, especially where the wires pass through holes in the bodywork or are subject to vibration. All metal-bodied vehicles in current production have one pole of the battery ‘earthed’, ie connected to the vehicle bodywork, and in

21

to wait while considering:

parts are obtained.

The

items below

may

be worth

Clutch and throttle cables Cylinder head gasket Alternator brushes Tyre valve core One

of the

motoring

organisations

will be able

to advise

on

availability of fuel etc in foreign countries.

nearly all modern vehicles it is the negative (—) terminal. The various electrical components — motors, bulb holders etc — are also connected to earth, either by means of a lead or directly by their mountings. Electric current flows through the component and then back to the battery via the bodywork. If the component mounting is loose or corroded, or if a good path back to the battery is not available, the circuit will be incomplete and malfunction will result. The engine and/or gearbox are also earthed by means of flexible metal straps to the body or subframe; if these straps are loose or missing, starter motor, generator and ignition trouble may result. Assuming the earth return to be satisfactory, electrical faults will be due either to component malfunction or to defects in the current supply. Individual components are dealt-with in Chapter 10. If supply wires are broken or cracked internally this results in an open-circuit, and the easiest way to check for this is to bypass the suspect wire temporarily with a length of wire having a crocodile clip or suitable connector at each end. Alternatively, a 12V test lamp can be used to verify the presence of supply voltage at various points along the wire and the break can be thus isolated. If a bare portion of a live wire touches the bodywork or other earthed metal part, the electricity will take the low-resistance path thus formed back to the battery: this is known as a short-circuit. Hopefully a short-circuit will blow a fuse, but otherwise it may cause burning of the insulation (and possibly further short-circuits) or even a fire. This is why it is inadvisable to bypass persistently blowing fuses with silver foil or wire.

NEGATIVE

18in. MIN

DISCHARGED BATTERY

BOOSTER BATTERY

Jump start lead connections for negative earth vehicles — connect leads in order shown

Spares and tool kit Most vehicles are supplied only with sufficient tools for wheel changing; the Maintenance and minor repair tool kit detailed in Too/s and working facilities, with the addition of a hammer, is probably sufficient

for

that

repairs

those

most

motorists

would

consider

attempting at the roadside. In addition a few items which can be fitted without too much trouble in the event of a breakdown should be carried. Experience and available space will modify the list below, but the following may save having to call on professional assistance: Spark plugs, clean and correctly gapped HT lead and plug cap — long enough to reach the plug furthest from the distributor Distributor rotor, condenser and contact breaker points (where

applicable)

‘

Drivebelt(s) — emergency

Engine fails to turn when starter operated Flat battery (recharge, use jump leads, or push start) Battery terminals loose or corroded Battery earth to body defective Engine earth strap loose or broken Starter motor (or solenoid) wiring loose or broken Automatic transmission selector in wrong position, switch faulty

or inhibitor

Ignition/starter switch faulty Major mechanical failure (seizure) Starter or solenoid internal fault (see Chapter 10)

type may suffice

Spare fuses Set of principal light bulbs Tin of radiator sealer and hose bandage Exhaust bandage Roll of insulating tape Length of soft iron wire Length of electrical flex Torch or inspection lamp (can double as test lamp) Battery jump leads Tow-rope

Ignition water dispersant aeroso! Litre of engine oil Sealed can of hydraulic fluid Worm drive clips

If spare fuel is carried,

Engine will not start

a can designed for the purpose should be

A first aid kit used to minimise risks of leakage and collision damage. ory in the UK, are and a warning triangle, whilst not at present compuls to the above. obviously sensible items to carry in addition carry additional When touring abroad it may be advisable to , could save having spares which, even if you cannot fit them yourself

Starter motor turns engine slowly Partially discharged

battery

(recharge,

use jump

leads, or push

start) — see Chapter 10 Battery terminals loose or corroded Battery earth to body defective

Engine earth strap loose Starter motor (or solenoid) wiring loose Starter motor internal fault (see Chapter 10)

Starter motor spins without turning engine Flat battery

Starter motor pinion sticking on sleeve Flywheel gear teeth damaged or worn Starter motor mounting bolts loose

Engine turns normally but fails to start Damp or dirty HT leads and distributor cap (crank engine and check for spark) - try moisture dispersant such as Holts Wet Start Dirty or incorrectly gapped distributor points (if applicable) No fuel in tank (check for delivery at carburettor) Excessive choke (hot engine) or insufficient choke (cold engine)

Fault diagnosis

22

Fouled or incorrectly gapped spark plugs (remove and regap, or renew) Other ignition system fault (see Chapter 4) Other fuel system fault (see Chapter 3) Poor compression (see Chapter 1) Major mechanical failure (eg camshaft drive)

i

Engine noises X

.

.

Pre-ignition (pinking) on acceleration Incorrect grade of fuel Ignition timing incorrect

Distributor faulty or worn Worn or maladjusted carburettor Excessive carbon build-up in engine

Engine fires but will not run Insufficient choke (cold engine) Air leaks at carburettor or inlet manifold Fuel starvation (see Chapter 3) Ballast resistor defective, or other ignition fault (see Chapter 4)

Engine cuts out and will not restart

Whistling or wheezing noises Leaking vacuum hose Leaking carburettor or manifold gasket Blowing head gasket

Tapping or rattling Incorrect valve clearances (where applicable)

Engine cuts out suddenly — ignition fault Loose or disconnected LT wires Wet HT leads or distributor cap (after traversing water splash) Coil or condenser failure (check for spark) Other ignition fault (see Chapter 4)

Engine misfires before cutting out — fuel fault Fuel tank empty Fuel pump defective or filter blocked (check for delivery) Fuel tank filler vent blocked (suction will be evident on releasing

cap)

Worn valve gear Worn timing chain or belt

Broken piston ring (ticking noise)

Knocking or thumping Worn fanbelt < Peripheral component fault (generator, water pump

etc)

Worn

perhaps

big-end

bearings

(regular

heavy

knocking,

less

under load) Worn

main bearings (rumbling and knocking, perhaps worsening

under load)

Carburettor needle valve sticking

Piston slap (most noticeable when cold)

Carburettor jets blocked (fuel contaminated) Other fuel system fault (see Chapter 3)

Engine cuts out — other causes Serious overheating Major mechanical failure (eg camshaft drive) Engine overheats

Ignition (no-charge) warning light illuminated Slack or broken drivebelt — retension or renew

(Chapter 2)

Ignition warning light not illuminated Coolant loss due to internal or external leakage (see Chapter 2) Thermostat defective Low oil level Brakes binding Radiator clogged externally or internally Electric Engine Ignition Mixture

cooling fan not operating correctly waterways clogged timing incorrect or automatic advance too weak

malfunctioning

Simple test lamp is useful for tracing electrical faults

Note: Do not add cold water to an overheated engine or damage may result

Low engine oil pressure

Gauge reads low or warning light illuminated with engine running Oil level low or incorrect grade Defective gauge or sender unit Wire to sender unit earthed Engine overheating Oil filter clogged or bypass valve defective Oil pressure relief valve defective Oil pick-up strainer clogged Oil pump worn or mountings loose Worn main or big-end bearings Note: Low oi/ pressure in a high-mileage engine at tickover is not necessarily a cause for concern. Sudden pressure loss at speed is far more significant. In any event, check the gauge or warning light sender before condemning the engine.

SN fis K / ree

O

1

SS H. 12167

Crank engine and check for a spark. Note use of insulated tool

Chapter 1 Engine manual For modifications, and information applicable to later models, see Supplement at end of Contents

e ee ee e S Ber Part A: 1.0 litre engine

Ancillary components — removal and refitting ..-scccceseeresrerereerenreneens Camshaft and tappets — removal and refitting ......--.-ccserereseeesreneeees Crankshaft and main bearings — removal and refitting .........---+ Crankshaft rear oil seal — removal and refitting .....--.ssescceseeercers Cylinder head — OVErHAUl ..-..ccececeeceeseesesseseressesnssnenesssensnententenssnssscsscsstess Cylinder head — removal and refitting .....-----ecverereereeernerereeresessnsrssens Cylinder head and pistons — decarbonising Engine — removal and refitting ..-.-cccecrsseserseeseeresseescssenssssnsesensnsencanence Engine components — examination and FEMOV ALON ccesecseceeserctrseasenes

Engine dismantling and reassembly — GENEL ...cecccecersrsrerscsnneeeseseres

Engine lubrication system — general GESCrIPTION ......--sereecececeeeererenees Engine/transmission mountings — removal and refitting .........+ Flywheel — removal and refitting -...2----cecsereeeereeseessenesnrsrnsenennrensennees

General GESCription .....:.-cccsccccesscesesssscenssnsnsnssnsassnsssnesnensnnsansarassncesensots Maintenance and inspection ......-:c:ceccceceeeeecescsercrsssssensessasnsnsrscnsnsnsssnses Oil PUMP — OVETMAUI «0... cecrereereereerrernernernsenesnteneennssnsanserssasensnnsananaeasentsts Oil purnp — removal and refitting ...-----ecreereereeresrecnecnssrneennsenneenssenntes eeseeeenes Operations possible with the ENGINE iM tHE CAP ....ecseeseseerserr Operations requiring engine TEE TCUE., Suse eee ee PTT Ree LOOPED Pistons and connecting rods — removal and refitting -..-..-----s ees Sump — removal and refitting ..------cccsecseeseensenccsnsssecsnscessenennsesssesss erserees .-crecersvcoreserres FEFITLING and removal — components Timing gear Valve clearances — AGjUStMENT ....-.eeeesececeeesetererssnersrssasssecessnecensnerertss

Part B: 1.2 and 1.3 litre engines

ereesserreesenersees Ancillary components — removal and TOFILTING .----cencessses and reassembly... Camshaft housing and camshaft — dismantling

6 18 20 19

74 5 23 17 16 1 2 13 12 3 4 1D 11 14 7

29 33

31 Camshaft toothed belt — removal, refitting and adjustment.......... + 44 Crankshaft and main bearings — removal and refitting .....-.--.-41 Crankshaft front oil seal — removal and refitting .......-ccscsececerreseeen eseseeerenees ...-....cecsccs refitting and removal — seal oil rear t Crankshaf Cylinder head — Overhaul ......eesesecsesssecseessensenrenesnscntcnscsnssncencenennsnnnens Cylinder head — removal and refitting ...---- eer Cylinder head and pistons — decarbonising ......::2:+ Engine — removal and refitting .....---.-seccecneseensenssesncsnecsecssssncanennnenacens Engine components — examination and renovation Engine dismantling and reassembly — QENESAI .......sseeceeecseseeceereesesees Engine lubrication and crankcase ventilation systems — general GESCTIPTION ...secsecseessecsessesscsssssssscseenensensensensenecssenenssansencencascnecoscesasczscnaseasecs Engine/transmission mountings — removal and refitting .....-..... Flywheel — removal and refitting ..-..--.-secsesseeseeneenerserecsssnnsnnesncenennens General GESCription ......cssececsesecsecesseescsecsssrensenssesnssesnssscnsasensanenesnsneescarense® Maintenance and inspection ......cc.cececeseseresensesesessscesessscnssesensnsnesnererscazens Oil pressure regulator valve — removal and SLA RLA® beoseceaneare Prereecos: Oil PUMP — OVEFNAUL ......-eccecseerecneereenrerserennsesseneenennentcnnsacenccnscnsenenncnnennenees Oil pump — removal and refitting .......cecrecseeseenerereeneesecsssenecsenneanennns Operations possible with the engine TW fa To of) prreerperreerery orcs tinage Operations requiring ENGiNe FEMOVA ...-..--ecssereeeererernecssnssrneeseensennes Pistons and connecting rods — removal and refitting .....-:-.sersene Sump — removal and refitting .......-s-ssccecseesecseesseseesteneensensesssnsnsnscassnseses

Part C: All engines Fault diagnosis — ENGINE ....-ssessessereserrssessecsseseessenesneeneatentensenessssessscassess

47 42 40 24 25 30 38 37 26 #27 39 36

48

ee e e e Specifications Note:

only these are quoted for ured to metric dimensions and tolerances and therefore The engines fitted to No va models are manufact

error. critical sizes, to avoid the risk of conversion

Part A: 1.0 litre ohv engine General aa

crew

2ST meron logrrn a ovwensrsencoansncencnasevecerndnennessers‘crnteie

2FC SES eng doz cnrnaee woventoseeezoascannnzavateavarezestconsttcersOtsth erga ayes es ?#0Hne 277 eberbsnonenscensasennrercevensarePne enseaerat rarnvoser doce cx pas SN I A AEE HHA att crte cnmntnosnn oer ncvh cncoeerene cate eeepc eo a AN nsassesessstttt ett nnssecssesnnsssssecen Compression £Aatio -.nvsecccrereescerers LIe tAtterenn rnceininrennnsacensnsrcettne nencnne mencnnt cmc ce coe eset lee RAR peu eeeee steneersteee"

essnsenserssesssensenssenrennensssen Location Of No 1 cylinder .......ce----cvsss ncetttttte CBO becetrcncensnsssccensntcenen hart WOU) soos, cesvzercosecortscecennnsarer

cylinder, in-line, overhead valve (S denotes high compression) mm mm 993 cc 9.2:1 1-3-4-2 At timing cover end 33 kW (45 bhp) at 5400 rpm

Four 10S 72.0 61.0

24

Chapter 1

ne

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Oversize bore size (NoMiInal 0.5 MM) .cecsssssssssesssseessssesenssesssseesesseesesseessneee

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0.020 to 0.046 mm 0.010 to 0.036 mm 0.00 to 0.0315 mm 0.25 and 0.50 mm _

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44.971

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Chapter 11

Suspension

For modifications, and information applicable to later models, see Supplement at end of manual Contents

Control arm balljoint — removal and refitting .......ccecccsseesesseseeseeeeee Peatl CICHAGNOSIS:— SUSPENSION vescicccesveossecesscosacobsdssubucesseievutussacichcacseesonsea: Front anti-roll bar — removal and refitting ......cccccccccsecesscesesesesesveeees Front hub bearings — removal and refitting-......ccccccccsssssessscsesessseees Front suspension control arm — removal and refitting .........0.000 Front suspension strut — dismantling and reassembly ............0:00000 Front suspension strut — removal and refitting .........:ccccecesseeeeeeeee Front suspension tie-bar — removal and refitting ........:ccceeseeeseees ResaAUN CAE S CME LLOM case, cesvz cece nex ase vunes savssavarascabnsthviesicssactieassussadesaousvantsecaaes NEAIMECTIANCE ONNLII143NWE aa a 1

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Key to Fig. 13.70 Comp

Description

E1 E2 ES E4 E5 E6 E7 E8 E9 E10 E11 E13 E14 E15 E16 Et? E19 E24 E25 E26 E30 E31 E32 E33 E34

Parking lamp — left

F1 to

F18 E24 F22 F36 G1 G2 G3 G6 G7 H1 H2 H3 H4 H5 H6 H7 H8 H9 H10 H11 H12 H13 H14 H16 H17 H19 H20

Tail lamp — left Lamp - number plate Parking lamp — right Tail lamp — right Lamp — engine compartment High beam - left High beam - right Low beam - left Low beam - right

Lights — instrument Lamp — trunk compartment

Lamp — passenger compartment Lamp - glovebox Lamp - cigarette lighter Reversing lamp - left Back window - heated Fog lamp - rear Heating mat - front seat, left Lamp - switch, light Heating mat - front seat, right Lamp - symbol insert, switch Lamp - clock Lamp - ashtray Lamp - heater control Fuse in fusebox Fuse — washer unit, headlamps Fuse (in fusebox)

Fuse - filter heating Battery

Alternator Battery — diesel Generator - diesel Sensor - engine revolution Receiver Signal horn Talltale — turn signal lamp Telltale — oil pressure Telltale — clutch, brake fluid & parking brake Telltale - hazard warning system Charging indicator light Telltale — high beam Stop-lamp - left Stop-lamp - right Turn signal lamp - front left Turn signal lamp - rear left Turn signal lamp - front right Turn signal lamp - rear right Telltale — preheating time Telltale — turn signal lamp, trailer Buzzer — headlamps-on warning Telltale - choke

Current track 201 202 212 210 211 205 217 218 220 221 206 280 281 290 288 291 293 229 363 207 367 205 286 287 205 Various

318, 389 137 434 101 116 401 411 to 413 423 284 333 261 269 267 257 116, 414 219 252 253 259 260 263 264 423 255 214,215 156

Comp

Description

H30 H33 H34

Telltale — engine, TBI Auxiliary turn signal lamp - left Auxiliary turn signal lamp — right

a

K1

Relay — back window, heated

K2 K8

Flasher unit Relay — interval, wiper windshield

K9

Relay - time delay, washer unit, headlamps

Current track 184 258 262 293, 294

256 310 to 313,

381 to 384 316 to 318, 387 to 389

K10

Flasher unit-— trailer

K15 K20 K30

Timing control — injection unit, fuel 451 to 460 Ignition model - ignition coil, HE1 162 to 164 Relay - interval, wiper, back 326 to 328, 395 to 297 window Relay — central locking, door 337 to 343 Relay — dashpot 140, 141 Relay — mixture preheating 136, 137 Ignition module — ignition coil, EZ 11 437 to 440 Timing control —- EST/EZ 11 144 to 151, 440 to 449 Control unit - TB1 178 to 193 Relay — pump, fuel 195, 196 Relay — running light 236 to 242 Control unit — dim-dip light 244 to 248 Relay — injection unit, fuel 463 to 466 Relay — coasting, fuel cut-off 159 to 161

K37 K44 K45 K52 K53 K57 K58 K59 K62 K68 K72 K75 K76 K77 K78

255, 256

K79 K80 | L2

Relay — Control Relay — Relay — Relay — Relay Ignition Ignition

L3

Ignition coil- HE1, inductive sensor

M1 M2

Starter Motor - wiper, windshield

M3 M4 M5

Motor — blower, heated Motor — blower, radiator Pump - washer, windshield

M8 Mg M12

Motor — wiper, back window Pump - washer, back window _ Starter - diesel

M14

M15 M19 M20 *M21 M24 M29 M32

M33

idling control unit — preheating time sensing resistor pre resistor charging indicator filter heating coil coil - HE1, hall sensor system, EZ 11

160, 1643172173 105 to 107 302 to 305, 308 to 311, 373 to 376, 379 to 382 297 to 299 109, 409 372, 378 323 to 325, 392 to 394 398

window lifter, front right central locking, door, rear left central locking, door, rear right fuel washer, headlamps mirror — adjustment, right central locking, co-driver door

Power unit - idling

154 424 427 430 418 434 193 439

121, 122, 147, 148,

Motor — window lifter, front left

= Motor Motor Motor Pump Pump = Outside Motor -

153, 418 to 426, 429, 413 to 433, TAZ, 438,

405 to 406 351,353

355,357 339, 342 339, 342 196, 463 318, 389 346 to 348 339, 342

188 to 191

307

Key to Fig. 13.70 (continued) Current track

Comp

Description

M55 P1 P2 P3 P4 ES: P7 P8 P9 P10 EAl2 P14 P23

Pump - washer, windshield and back window Fuel indicator Temperature indicator — cooling agent Clock Sensor - fuel Sensor — temperature, cooling agent Tachometer Gauge - oil pressure Voltmeter Sensor - oil pressure

P24 P30 P33 P34 R1 R2 R3 R5 R7 R12 R19 R21 R22 S1 S2 $2.1 $2.2 S3 $5 $5.2 $5.3 S6 S7 $8 So $9.1 SoZ

Sensor - oil temperature, EST Temperature sensor — cooling agent Lambda sensor Sensor - throttle valve position Resistor cable Carburettor preheating Cigarette lighter Glow plugs Mixture — preheating Automatic choke Preresistor — blower, radiator Sensing resistor Pre-resistor — glow plugs Switch - starter Switch assembly - light

$9.3 $9.5

Sensor - temperature, cooling agent Sensor — distance

146 to 148,

187 to 189 149 185 193 90 to 192 112 27 289 425 to 427 137 126 409 427 430 106, 107, 405, 406

Switch - light Switch - light, passenger compartment Switch — blower & back window, heated Turn signal switch assembly Switch - low beam Switch — turn signal distributor - reversing lamp - stop-lamp assembly — wiper unit

Switch - wiper, windshield

Switch - wiper, back window, interval

Switch — wiper, back window and

Control switch - brake fluid Switch — parking brake Switch - oil pressure Switch — lamp, trunk compartment Contact switch — door driver Contact switch — door, co-driver Switch — lamp, glove-box

209, 210 281 295 to 299 219, 220 262, 263 112 to 114 291 253

302 to 306, 372 to 375

Switch - wiper, windshield, interval

washer unit

$11 $13 S14 S15 $16 S17 $18

458 177, 178, 417, 418

Vacuum sensor — intake manifold

Ignition Switch Switch Switch

329 271 273 285 DTA 273 276 278 277 278

308 to 311, 378 to 382 396, 397

327 to 329

268 267 269 280 282 283 290

Comp

S22 $29 $30 $37 $41 S44 S46 - $47 $50 $52 S60 S64 S68 $73 $74 $75 $78 S88 $91 $114 U12 U12.1 U12.2 X1 X2 X10 X11

Description Switch — foglamp, rear Switch - temperature, cooling agent Switch — heating mat, front seat left Switch — window lifter, front left Switch — central locking, driver's door Switch — throttle valve Switch — heating mats, front seats

228, 229 109 362, 363 351 to 354 337, 338 159, 455, 456 365 to 367 214,215

Contact switch - door and headlamps-on warning 156 Switch — bowden cable, choke 256 to 260 Switch — hazard warning 140, 153 Switch — clutch pedal 333 Switch — signal horn 345 to 348 Switch — outside mirror adjustment 136 © Switch - temperature, mixture preheating 444 Switch — engine (housing) 444 Switch — temperature, engine oil 355 to 358 Switch — window lifter, front right 409, 410 Switch — temperature, cooling agent, radiator Switch - oil pressure, TBI

Switch — temperature, cooling agent, engine Filter heating assembly Switch —- temperature Heating resistor Socket - trailer Connector - auxiliary users Connector — ignition adjustment Connector — wiring harness, TBI, 5 pins

X13 X17 X18 X19

Test connector Connector - instrument Connector - wiring harness, HEI, 3 pins

X27 X28 X29 Y5 Y6 Y7 Y11 Y14 Y15 Neti, Y18 Y23

Plug connection - alternator, 3 pins Plug connection, 3 pins Plug connection, 2 pins Solenoid valve — fuel Slide valve - auxiliary air

Y24 NSZ Y39 Y41 Y42

Current track

Connector - wiring harness, Jetronic, 7 pins

198, 199

420 433, 434 433 434 Various Various 150, 151 181, 184, 196, 199 183, 186, 187 Various 160, 162, 163 437, 438,

463, 411 to 419 to 406,

466 413 422 431 431 461

450, 457 Solenoid valves — fuel injection 441, 443 Hall sensor 145 to 147, 169 to 172 Inductive sensor — EST 120, 121 Inductive sensor with ignition module

Solenoid valve - idle cut off Solenoid valve - dashpot ignition distributor — HEI, inductive sensor system Ignition distributor - EST Injection valve - TBI Solenoid valve - coasting, fuel cut off Solenoid valve - idling control Inductive sensor — HEI

Not all items fitted to all models

e at time of writing Note: No specific diagram for 1.6 G TE/GSi models was availabl

Wiring code as for 1985 models Refer to Chapter 10, Section 42 for explanation of use -

128 140 124, 167

150,175, 445 179

161 153 163, 164

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Description

E1 E2 E3 E4 E5 E6 E7 E8 E9 E10 E11 E13 E14 E15 E16 E17 E19 E24 E25 E26 E30 E32 E34 E37 E40

LH parking lamp LH tail lamp Number plate lamp

F1 to

Fuses (in fuse box)

RH parking lamp RH tail lamp

Engine compartmentlamp LH main beam RH main beam LH dipped beam RH dipped beam Instrument illumination Luggage area light

~

Courtesy light Glovebox light Cigarette lighter illumination LH reversing lamp Heated rear window Rear foglamp LH seat heater Light switch illumination RH seat heater Clock illumination Ashtray illumination Driver's vanity mirror illumination Passenger’s vanity mirror illumination

Current track

Comp

Description

201 202 212 210 211 319 215 217 216 218 376, 377 257 261 276 274 277 279 224 358 207 362 2y2 368, 370 260 259

H4 H5 H6 H7 H8 H9 H10 H11 H12 H13 H14 H15 H16 H18 H19 H20 H21 H30 H33 H34 K1 K2 K8 K15 K20 K30 K37 K57 K58 K59 K62 K63 K68 K72 K76 K77 K78 K79 K80 K84 K91 K97 K100

Oil pressure warning light Brake warning light Hazard warning flasher repeater light No charge (ignition) warning light Main beam warning light LH stop-lamp RH stop-lamp LH front direction indicator LH rear direction indicator RH front direction indicator RH rear direction indicator Fuel level warning light Glow plug preheating warning light Horn Headlight warning buzzer Choke warning light Handbrake warning light Engine management warning lamp LH direction indicator repeater RH direction indicator repeater Heated rear window relay

Various

F11, Ris; F14, F16 to

F18 F21 F27 F36 F41 F43 G1 G2 G3 G6 H1 H2 H3

Fuse — headiamp washers Fuse — horn Fuse — filter heating (Diesel) Fuse — glow plugs (Diesel) Fuse - oxygen sensor Battery Alternator Battery — Diesel Alternator — Diesel Radio Horn Direction indicator warning light

318 333 432 425 527 101 109 401 411 to 413 269 to 271 331 375

Current track 373 370 249 372 378 243 244 250 251 254 253 388 380 332, 333 264, 265 380 382 380 249 255 279, 280

Flasher unit

247

Wiper delay relay 310 to 313 Timing control unit 484 to 495 Ignition module and coil 138 to 140, 435 to 437, 464, 465 Rear wiper delay relay 325 to 327 Central locking relay 337 to 343 Injection control unit 178 to 196 Fuel pump relay 198, 199, 461, 462 Day running lamp relay 227 to 233 Dim-dip control unit 236 to 240 Horn relays 332)595 Injection control unit relay 496 to 499, 527 to 530 Engine speed relay 135 to 137 Glow plug control unit (Diesel)

418 to 424

Sensor resistor relay Pre-resistor relay Charging indicator relay Filter heating relay Ignition control unit Engine management control unit Headlight washer delay relay Engine management control unit

424, 427, 413 to 431, 469 to 502 to 316 to 441 to

425 428 416 432 482 526 318 459

320 %

Key to Fig. 13.72 (continued)

Comp L1 M1 M2 M3 M4 M12 M14 M15 M19 M20 M21 M24 M32 M33 M39 M40 M55 P1 P2 P3 P4 P5 P7 P8 P9 P10 P11 P12 P14 P23 P24 P30 P32 P33 P34 P35 R1 R2 R3 R5 R12 R19 R22 S1 $2 $2.1 $2.2 $3 $5 $5.2 $5.3 S6 $7 S8 S9 $9.1 $9.2 $9.5 $11

Description

Current track

Ignition coil 117, 128, 136, 172, 437, Starter 104 to 106, Windscreen wiper motor 302 to 305, 308 to Heater blower motor 283 to Radiator fan motor 113, Rear wiper motor 323 to Starter - Diesel 404, LH front window motor 346, RH front window motor 350, LH rear door locking motor 339, RH rear door locking motor 339, Fuel pump 199, 462, 496, Headlight washer pump Front passenger door lock motor 339, Idle speed control unit

465 206 311 285 408 325 405 347 351

342 342

529 318 342 189 to 192, 443 to 446,

LH headlamp levelling motor

514,515 292 to 294

RH headlamp levelling motor

296 to 298

Windscreen and tailgate washer pump 328 Fuel gauge 384 Temperature gauge 390 Clock 271 Fuel gauge sender 384 Temperature gauge sender 390 Tachometer 386 Oil pressure 392 Voltmeter 387 Oil pressure sensor 392 Air flow meter 517 to 521 Coolant temperature sender 493,512 177, 178, 417, 418, 440, 441 Distance sensor 187 to 189, 453 to 455 Vacuum sensor Oil temperature sensor 473 Coolant temperature sensor 185, 451 Exhaust oxygen sensor 526, 527 Exhaust oxygen sensor 196, 454 Throttle position sensor

190 to 192, 456 to 458,

509, 510 Crankshaft position sensor 521 to 523 Resistor cable had Carburettor heater 124 Cigarette lighter 275 Glow plugs 425 Automatic choke 123 Cooling fan resistor 408 Glow plug resistor 428 Ignition/starter switch 105, 106, 404, 405 Light switch Lighting switch 207,210 Interior light switch 261 Heater blower/heated rear window switch 281 to 285 Multi-switch Dipswitch 216, 217 Direction indicator switch 253, 254 Distributor (contact breaker) 117 Reversing light switch 277

Stop-light switch Wash/wipe switch Windscreen wiper switch Windscreen wash/wipe switch Windscreen wiper delay switch Brake fluid level switch

Current track

Comp

Description

$13 S14 $15 S16 $17 $18 S22u $29 $30 $37 S41 S44 S47 S50 $52 S55 S64 S78 S88 $98 $114 U12 U12.1 U12.2 V1 YS Y6 Y7 Y10 Y17 Y23

Handbrake switch Oil pressure switch Luggage area light switch

Y¥32 Y33 Y34 Y39 X2 X3 X4, X5 X6, X7

Fuel injector Distributor Fuel tank vent valve Coasting fuel cut-off solenoid 338, 347, 356, 358 Auxiliary user (in fuse box) Main wiring harness and starter connector 105, 106, 109 Main wiring harness and horn connector 332

X8

382 373 257 262 263

Driver's door switch Front passenger door switch Glovebox light switch Rear foglamp switch Coolant temperature switch Seat heater switch (driver only) LH front window switch

276 222,224 113 357, 358 346 to 349 337, 338

Driver's door lock switch

Throttle valve switch Headlamp buzzer switch Choke switch Hazard warning switch Front passenger seat heater switch : Horn switch RH window switch

135, 490, 491 264, 265 380 247 to 251 360 to 362 331 350 to 353

408, 409 291,293 420

Cooling fan switch Headlamp levelling switch Coolant temperature sensor Filter heating (Diesel)

Temperature switch (Diesel)

431

Heating resistor (Diesel) Diode

432 371

Fuel solenoid valve Auxiliary air valve Fuel injection solenoids

410 495 485 to 492, 518 to 525 438 to 444, 468 to 474

Distributor (Hall sensor) Idle cut-off solenoid Distributor (electronic)

125 127 to 131, 139 to 143, 168 to 175 179, 446 501 520 137

Main wiring harness and headlamp washer

wash/wipe connector

x9 X10

X11

316, 317

connector Main wiring harness and tailgate 324, 325

Main wiring harness and radio connector 269 to 271 Main wiring harness plug connector +99, 202, 211; 224, 244, 251, 253, 277, 279, 322, 326, 327, 382, 384, 462, 496 Main wiring harness engine management system connector 181, 184, 199, 372, 447, 450, 462

X13

Test connector

X15 X17 X18

Octane number connector Instruments connector Main wiring harness and ignition

182, 183, 451, 452, 469,

470, 480, 502, 503 195, 458, 459, 475, 516 370 to 390 134, 136, 139

system connector

244

X19

Main wiring harness and fuel injection 389, 477 to 483, system connector 496, 505, 506, 509, 512, 529

302 to 304 308, 311 308, 311 370

X27 X29 X30

Main wiring harness and alternator connector

411 to 413

Main wiring harness and starter connector

405, 410

Coolant temperature switch

408, 409

Not all items fitted to all models

Note: Refer to Chapter 10, Section 42 for explanation of use. Wiring code as for 1985 models

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