X 19 1974 PDF
X 19 1974 PDF
X 19 1974 PDF
‘ Serviqe;manual
. ' 1.974 thru 197*8
""3. 2‘
:
SERVICE
MANUAL
19 74 thru 19 78
GENERAL INFORMATION —
MAINTENANCE — 00
Page
Engine Specifications ................................................................................ 2
Chassis Specification ................................................................................ 3
Electrical Specifications ............................................................................ 3
Weights-Performances ................................................................................ 4
Dimensions ................................................................................................ 4
Capacities .................................................................................................. 5
Identifications ............................................................................................ 6
InSpections and Maintenance .................................................................... 8
Tune-Up .................................................................................................... 9
Fiat Lubricant Specifications .................................................................... I4
Section No. 00
Page 1
General Information
ENGINE
Engine type .............................................................................................. 128 AS.040.4
VALVE MECHANISM
Intake
opens .................................................................................................. 10° B.T.D.C.
Closes .................................................................................................. 54° A.B.D.C.
Exhaust
opens .................................................................................................. 54" 8.3.0.0.
closes .................................................................................................. 10° A.T.D.C.
Valve clearance:
——for checking valve timing .................................................................... 0.020 in. (0.50mm)
—operation clearance, engine cold:
Intake ........................................................................................................ 0.012 in. (0.30mm)
Exhaust ...................................................................................................... 0.016 in. (0.40mm)
Section No. 00
Page 3
General Information
CHASSIS Turning circle diam. about 32 ft. 10 in. (10m)
type 128 AS Steering column of the breakaway mount type with 2
universal joints. Independent and symmetric track rods
CLUTCH to each wheel. Sealed for life joints.
Dry, single-plate type, with diaphragm spring release
mechanism. Hydraulic control.
Clutch pedal free-play about 1% in. (30mm). FRONT SUSPENSION
Independent wheel type. Lower control arms consisting
TRANSMISSION of a cross rod and reaction strut. Sealed for life joints.
Four forward speeds, synchromeshed, and reverse. Telescopic knuckle pillars incorporated in double-
Gear shift lever on floor tunnel. action hydraulic shock absorbers. Coil springs and co-
Gear Ratios: axial buffers.
—first, synchromeshed 3.583 to 1 Caster angle, unladen car +6°30’ to +7°30’
—second, synchromeshed 2.235 to 1 Camber, unladen car 0° to —l"
Toe-in, unladen car +0.080 to +0240 in.
—third, synchromeshed 1.459 to 1
(+2 to +6mm)
——fourth, synchromeshed 0.959 to 1
—reverse 3.714 to 1
WEIGHTS — PERFORMANCES
DIMENSIONS (METRIC)
mm. 490 750 965 1 174 1335 1343 1570 2202 3900
in. 19.3 29.5 38.0 46.1 52.5 52.9 61.8 86.7 153.5
Section No. 00
Page 5
General Information
Capacities — Model X 1/9
QUANTITY
UNIT It kg U.S. Units REFILL
Engine sump and filter (**) 4.25 3.825 4 1/3 qts. see table below
Transmission and axle 3.15 2.85 3 1/3 qts. SAE 90 (not EP) containing anti-wear
additives
Identification Data
iDENTIFlCATION PLATE
”JET
The plate is located on the right side of the front trunk.
b
a—Chassis type (128 AS) a
b—Chassis number
c—Order number of spares
“.6 I“
nLfloAZmlIE -—
‘
I
MAOIIH
"'ALY
4
Inn-unlu-
WWI I‘llil
-
l
C d e
Engine Type and Identification Number — This is punched on chassis Type and Identification Number — This is punched on
crankcase. flywheel end. front trunk rear cross rail (permanent structure) right Side.
F.M.V. Safety Standard 115 Tag — This has type of vehicle and
chassis number. It is located on facia top between instrument F.M.V. Safety Standard 119 Tag —— This has tire data and car
cluster and windshield. capacity. It IS located on right door pillar.
Section No. 00
Page 7
General Information
F.M.V. Safety Standard Conformity Tag — This has month and F.M.V. Regulation Conformity Tag _— This has air pollution con-
year of manufacture, gross vehicle weight rating. gross axle trol spec: scations for correct engll'lE tune-up and adgustments.
vdveighylrlating, chassis number and car type. It is located on left It is located on lower side of engine hood.
our on ar.
Maintenance
Every 300 miles (500km) or weekly —lgnition distributor: clean, check and change if
—Engine oil: check level necessary cap and rotor, change breaker contacts and
—Coo|ing system: check level condenser
—Brake and clutch fluid reservoirs: check level —Carburetor: check throttle/choke valves and control
—Tires: check pressure linkages, adjust as required
—Air pump filter: change cartridge
Every 3,000 miles (5,000) —Exhaust emission control system: check lines, mani-
——Constant velocity joints/steering linkage/suspension fold valves, and air pump, change as required
articulation rubber boots and caps: check efficiency —Fue| evaporative emission control: check compo-
—Battery: check electrolyte level nents and change as required
—-Windshield washer: check level, clean, adjust -——Crankcase emission control system: clean, wash,
and check
Every 6,000 miles (10,000km) —Vacuum hoses and connections: check condition and
—Engine oil and filter: change oil (engine warm) and tightness, change as required
filter ——Transmission and axle oil: check level
NOTE: for stop and go (city) or dusty areas change oil —Cooling system hoses and connections: check tight-
and filter every 3,000 miles (5,000km) ness and change as required
—Air cleaner: replace cartridge _—Front and rear suspensions: check joints and
—Fuel filter: replace unit and check line tightness fasteners
—Drive belts: Alternator/water pump: check and ad- —Constant velocity joints (outboard); check lubrica-
just, change if necessary tion, add grease if required
Air pump: check, change if necessary —Brakes: check for wear and hand brake effectiveness
—lgnition distributor: lubricate through wick, check ——Electrical system: check lights, instruments, horn
and adjust breaker contacts, change if necessary, and wiper for proper operation
check condenser, change if necessary —Accessories, seat belt anchorages, heating and de-
_lgnition timing, dwell angle and CO concentration: frosting controls: check for proper operation
check and adjust as required
-—Clutch: check and adjust Every 24,000 miles (40,000km)
—Tires: check for wear, rotate HActivated carbon trap: change
—Battery: inspect posts and clamps —Ignition distributor: change cap and rotor, check
—Body: lubricate various items advance mechanism and change if necessary
—Whee| alignment: check and adjust if necessary —Spark control modulation device (diaphragm unit,
-——Road test: check operation of engine, transmission, valves. lines): check components and change as
clutch, steering, and brakes required
—lgnition system wiring: check condition of wires and
Every 12,000 miles (20,000km) connections, change as required
—Valve clearance: adjust —Transmission and axle: change oil
—Spark plugs: change -—Starter motor and alternator: check
Section N0. 00
Page 9
Tune-Up
This section contains information needed to perform a tune-up of the engine. Perform the tasks in this section
according to the MAINTENANCE chart.
Example: If doing tune-up at 6,000 miles, clean spark plugs. If doing tune—up at 12,000 miles, change spark
plugs. WIRE GAGE
SPARK PLUGS
, 0.020 TO 0.024
Remove plugs. Inspect plugs for condition. Clean or
replace plugs.
Adjust gap of plugs.
Gap—0.020 to 0.024 in (0.5 to 0.6mm)
NOTE: if you are going to check valve clearance leave
plugs out until clearance is adjusted.
VALVE CLEARANCE
Remove air cleaner. Disconnect throttle rod (3) from
control (4) on valve cover (1). Disconnect hoses to pro-
vide clearance. Remove 6 nuts (2) holding cover.
Remove cover (1).
IGNITION DISTRIBUTOR
Release 2 Spring clips holding cap on distributor. Re-
move cap and rotor. Clean and inspect cap and rotor.
Replace cap and rotor as necessary. Lubricate distrib-
utor by adding a little oil thru wick.
Section No. 00
Page 11
FUEL FILTER
Replace filter (1) by loosening clamps (2) and discon-
necting hoses (3).
Check fuel lines for tightness.
AIR CLEANER
Remove 3 nuts holding cover.
Remove 4 nuts (3) holding air cleaner (2) to carburetor.
Remove nut (4) holding bracket to camshaft cover.
Disconnect hose (5) and hose to bottom of air cleaner
from air cleaner. Disconnect hose from carburetor cool-
ing fan. Remove air cleaner.
Replace cartridge (1). Clean air cleaner.
NOTE: Install air cleaner after adjusting carburetor.
ENGINE OIL
With engine warm, drain oil from engine. Remove oil
filter (1).
Coat seal on filter with engine oil. Thread filter on by
hand until seal touches plate. Turn filter down 3%. turn
more. Fill oil.
1. Oil Filter.
IGNITION TIMING
Hook up tune-up equipment such as scope and Dwell-
Tach.
Start car. Allow engine time to warm up.
Using tach check idle speed. Set idle speed at 850
rpm. Adjust carburetor.
Section No. 00
Page 13
.P ,
ii
metering screw (1) on carburetor as necessary.
“to"
'J
-
Special blue label fluid HD fluid for hydraulic brake Hydraulic brake circuit
circuit SAE J 1703
ENGINE—10
PARTS SERVICE MANUAL &
CATALOG SERVICE TIME Page
CODE SCHEDULE CODE
10 Specifications-Tightening Reference .......................................................... 15
Gr. loo-ENGINE ASSEMBLY
A0.02 100.02 Power Plant Mounts .................................................................................. 25
Gr. 101-MAIN ENGINE COMPONENTS
A1.01 101.01 Crankcase and Cylinder Head .................................................................... 29
A1.02 101.02 Oil Sump and Crankcase Covers ................................................................ 31
A1.03 101.03 Crankshaft and Flywheel ............................................................................ 39
A1.05 101.05 Connecting Rods and Pistons .................................................................... 43
A1.06 101.06 Camshaft Drive .......................................................................................... 41
A1.0'I 101.01 Valve Mechanism ................................................... 49
Gr. 102-FUEL SYSTEM AND EXHAUST
102.01 Fuel Tank and Lines .................................................................................. 55
A2.01
102.02 Fuel Pump and Lines ................................................................................ 57
A2.02
102.04 Carburetor and Air Cleaner ........................................................................ 59
A2.04
102.54 Exhaust Pipe ............................................................................................ 65
[12.54
Exhaust Emission Control System ............................................................ 6'!
A2.58 102.53
Cr. 103-LUBRlCATION
A3.01 103.01 Engine Lubrication .................................................................................... 69
Gr. 104-COOLING SYSTEM
A4.01 104.01 Radiator .................................................................................................... 75
A4.02 104.02 Water Pump and Ducts .............................................................................. 77
A4.09 1 04.09 Fan ............................................................................................................ 79
1 0A Tool Equipment .......................................................................................... 81
Section No. 10
Page 15
Engine: Specifications
CYLINDER BLOCK-CON-RODS
DESCRIPTION IN. MM
Range of undersize big-end bearings for service ...................... 0.010, 0.020, 0.254, 0.508,
0.030, 0.040 0.762, 1.016
Big-end bearings:
—fit clearance ........................................................................ 0.0014 to 0.0034 0.036 to 0.086
DESCRIPTION IN. MM
Piston pin in boss: clearance of new parts .............................. 0.0001 to 0.0003 0.002 to 0.008
Oversize piston ring range, for service .................................. 0.0079, 0.0157. 0.2, 0.4,
0.0236 0.6
Section No. 10
Page 17
Engine: Specifications
CYLINDER HEAD
DESCRIPTION IN. MM
Valve guide bore ...................................................................... 0.5886 to 0.5896 14.950 to 14.977
Outside diameter of valve guide ______________________________________________ 0.5921 to 0.5928 15.040 to 15.058
Valve guide oversize on 0.0., for service .................................. 0.0079 0.2
Inside diameter of valve guides, fitted in cylinder head .......... 0.3158 to 0.3165 8.022 to 8.040
Valve guide fit in head:
winterference ...................................................................... 0.0025 to 0.0043 0.063 to 0.108
Valve stem diameter ................................................................ 0.3139 to 0.3146 7.974 to 7.992
Valve stem fit in valve guide:
—clearance of new parts ........................................................ 0.0012 to 0.0026 0.030 to 0.066
Valve seat angle in cylinder head ............................................ 45“ :5’
Valve face angle _______________________________ 45° 30' :5’
Valve head diameter
intake ................................................................................ 1.417.310.0059 3620.15
exhaust .............................................................................. 1.2205i0.0059 3110.15
Max. valve run-out on a full turn, guided on stem, with
dial indicator set at center of contact face ...................... 0.0012 0.03
Width of valve seats in cylinder head (contact surface):
«——intake and exhaust. about .................................................. 0.0787 2
Inside diameter of valve seats in cyclinder head
intake ................................................................................ 1.1811 30
exhaust .............................................................................. 1.0531 26.75
Lift on CIL of valve (without play) ____________________________________________ 0.3839 9.75
Diameter of tappet bores in head ............................................ 1.4567 to 1.4577 37.000 to 37.025
Outside diameter of tappets .................................................... 1.4557 to 1.4565 36.975 to 36.995
Fit clearance between tappets and bores in head .................... 0.0002 to 0.0020 0.005 to 0.050
Thickness of cap plates:
basic dimension ................................................................ 01575300005 4t0.012
VALVE SPRINGS
INNER SPRING OUTER SPRING
Spring height under a load of 85.5 lbs. (38.9kg)
mm .................................................................................... — 36
in ______________________________________________________________________________________ —— 1.417
Spring height under a load of 32.71 lbs. (14.9kg)
mm .................................................................................... 31 —
in. ...................................................................................... 1.220 —
Minimum allowable load referred to the above height
kg ...................................................................................... 13.5 36
lbs. .................................................................................... 29.8 79.3
DESCRIPTION IN. MM
AUXILIARY SHAFT
Fit between bushings and bores in crankcase .......................... interference fit at all times
Fit between bushings and shaft journals:
—fit clearance
drive end .......................................................................... 0.0018 to 0.0036 0.046 to 0.091
inside end ........................................................................ 0.0016 to 0.0031 0.040 to 0.080
Section No. 10
Page 19
Engine: Specifications
CRANKSHAFT — MAIN BEARINGS
DESCRIPTION IN. MM
Main bearing journal standard diameter .................................. 1.9994 to 2.0002 50.785 to 50.805
Standard main bearing insert thickness .................................. 0.0718 to 0.0721 1.825 to 1.831
Main bearing inserts, for service .............................................. Std. 0.01, 0.02, Std. 0.254, 0.508,
0.03, 0.04 0.3. 0.762, 1.016 U.S.
Rear main bearing seat thrust ring thickness .......................... 0.0909 to 0.0929 2.310 to 2.360
Max. taper of crankpins and journals, after grinding ................ 0.0002 0.005
Flywheel:
—paral|el relationship of driven plate face to crankshaft
mounting face: max. allowable tolerance ................................ 0.0039 0.10
——squa reness of above faces to rotation axis:
Max. allowable tolerance ........................................................ 0.0039 0.10
FUEL SYSTEM
CARBURETOR
Type ........................................................................................ WEBER 32 DMTRA 200
PEI-MARY BAflafinL SESBNDARY BflaaEL
Section No. 10
Page 21
Engine: Specifications
LUBRICATION
OIL PUMP
Type ........................................................................................ gear
Clearance between gears and pump housing inside wall .......... 0.0043 to 0.0071 in. (0.11 to 0.18mm}
COOLING SYSTEM
WATER PUMP
Type ........................................................................................ centrifugal, vane type
Fit between impeller vans and pump housing .......................... 0.031 to 0.051 in. (0.8 to 1.3mm)
Thermostat
—begins opening at ................................................................ 176° to 183° F (80° to 84° C)
—-opening at 205° F (96° C) .................................................... not less than 0.314 in. (8mm)
Bolt, oil pump and fuel pump shaft driven gear .. M 10 x 1.25 R 120 61 8.5
R 50 Znt (Bolt
Nut, alternator to lower support ........................ M 10 x 1.25 R 80 Znt) 36 5
R 50 Znt (Stud
Nut, alternator lower support to crankcase ........ M 10 x 1.25 R 80 Znt) 36 5
Section No. 10
Page 23
Engine: Specifications
Page 25
Page 27
Me -*~
flexible link (1). Swing link to side. " .(71
1. Flexible link. 2. Bolt. 3. Gearshift linkage.
4. Bolts. 5. Shifting tube.
0
Remove bolt holding ground strap (6) at body.
Straighten tabs on exhaust manifold flange.
Remove 4 nuts and locktab plates.
Remove 2 bolts (1) from upper bracket (4) at left end of muffler (2).
Remove 2 nuts holding center support (3) for muffler to crossmember. Remove muffler.
Remove 2 nuts and bolt holding upper bracket (4) to differential case. Remove bracket.
Remove 3 bolts holding retaining ring for axle boot (5) on left side.
Remove 3 bolts holding retaining ring for axle boot on right side.
Slide boots away from differential. Drain excess oil.
CAUTION: Be careful of sharp edges on sheet metal.
1. Bolts. 2. Muffler. 3. Center support. 4. Upper bracket. 5. Axle boot. 6. Ground strap.
Remove nut securing bracket for hand brake cable (7) at forward end of each suspension control arm (3).
Record number of shims (4) at each suspension control arm (3) mounting point.
Remove 4 bolts (6), nuts, and shims (4) securing control arms (3) to body. Swing arm downward out of their
brackets (5).
Move control arms away from differential until axles are free of differential. Secure axles to control arms.
NOTE: The suspension assemblies may be removed by removing wheels and brake calipers and 3 nuts securing
shock absorbers at top.
Straighten lock tabs on 2 bolts (2) on each end of lower crossmember (1). Loosen the bolts.
Lower car until engine is resting on a support.
Remove bolts thru lower crossmember (1).
1. Crossmember. 2. Bolts. 3. Control Arm. 4. Shims. 5. Bracket 6. Bolts. 7. Handbrake cable.
‘
From above, disconnect reaction rod (4) from bracket (3) on engine.
Remove bolt thru (2) front engine mount (1). Raise car slightly and rock engine transmission assembly to clear
front engine mount (1). Carefully raise car while supporting engine.
To reinstall power plant, reverse removal procedures. Refer to Tightening Reference for torque values.
Fill up transmission and cooling system. Run engine and check for leaks.
1. Front engine mount. 2. Bolt. 3. Bracket. 4. Reaction rod.
Page 291‘ .. .
Page 31
Page 33
Page 35
CRANKGASE
Checking Cylinder Bores
Carefully examine cylinder bore surface. If only slight
scoring or scratches are found, dress bores. Use extra
fine emery cloth wrapped around a hone.
Make Sure piston clearance in bore does not exceed
0.006 in. (0.15mm).
Z‘MEASUREMENT
flBLREMENL
__flyflh. _._
'
_ aa.nnn_+_ar..oza
._ __ .____ ___
Page 37
CRANKGASE COVERS
1. Gasket 11. Cover 20. Crankcase
2. Cover 12. Bolt and washer 21. Gasket
3. Washer 13. Gasket 22. Bolt and washer
4. Bolt 14. Nut 23. Cover
5. Gasket 15. Washer 24. Gasket
6. Cover 16. Bracket 25. Cover
7. Seal 17. Stud 26. Seal
8. Seal 18. Cover 27. Washer
9. Washer 19. Gasket 28. Bolt
10. Bolt
.. _.—._._,_‘
Page 39
/|_
0320.2
50.735]
50.805]
ham—D
Maximum allowable misalignment of journals and crankpins, and diagram for checking flywheel contact
surfaces with clutch disc and crankshaft flange.
(A—B-C—E=points for checking alignment and squareness with respect to rotation axis; D=crankshaft-flywhee|—
clutch assembly balancing holes)
('1
he“
g,
,/
1 .825‘
1 .831
-2 C}:
W Main data of crankshaft journals, main bearings, saddle bores, and thrust rings
Page 41
Page 43
1.478
1 .490
1.990 -eE=-——W
'
A= 85.920 to 85.930
C= 85.960 to 85.970—
3.925 E= 85.980 to 85.990
3.937 "
CHECKS
Before assembling, check weight of four pistons.
Pistons must have same weight within 10.088 02.
(12.59.
If necessary, remove metal from base of piston by
milling. Maximum metal than can be removed is 0.177
in. (4.5mm). Milling diameter should be limited to
2.775 in. (70.5mm).
a : 2.232 in. (56.70mm) nominal piston height.
h = 2.055 in. (52.20m) minimum height after milling.
c : 2.775 in. (70.50mm) maximum milling diameter.
Page 45
Iii—I
J
1
IIIIII
S
Iii-Ii!
I
III‘IAIJII
' i
I:-
A -.
_
.
I
y
.‘
.l
.jlccl1ulgl1|ll
I!!!
Downloaded from www.Manualslib.com manuals search engine
III - 1974
Page 41
Camshaft Mechanism
REPLACING TIMING BELT
Set engine on T.D.C., firing on No. 4 cylinder. Check
crankshaft pulley timing mark at T.D.C. on pulley cover.
Check camshaft timing pulley mark aligned with cast
finger of support, visible through hole in cover. Put
car in 4th gear and apply hand brake.
CAUTION: If cam is turned independently of engine,
valves may hit pistons. This will result in engine
damage.
Remove bolts and washers holding timing cover (1).
Remove right guard from under engine. Remove lower
bolt holding cover. Remove cover (1).
Loosen lower bolt on alternator (4). Loosen bolt (5) thru
alternator adjusting bracket (6). Remove water pump
and alternator drive belt (3). Remove water pump drive
pulley (2) from crankshaft.
Remove 2 bolts thru rear of air pump (8) and support
brackets (7). Loosen bolt thru top of air pump. Move
pump and remove drive belt.
1. Timing cover. 2. Drive pulley. 3. Drive belt.
4. Alternator. 5. Bolt. 6. Adjusting bracket.
7. Brackets. 8. Air pump.
Page 49
Valve Mechanism
CAMSHAFT
11
. A l l 1 l
AUXILIARY SHAFT
31.940 _ 35.593
31.960 35.618
Page 51
Valve Mechanism
_ 37.000
, 37,025
i ____ . ]:l
[1.10.014
+ M ._ 30,975
35,995
Model X 1/9
Valve stem to valve guide fit clearance is 0.0012 to
0.0026 in. (0.030 to 0.066mm). E
- — —+.-—. '33:);
15.040
m
8.022
8.040
36 , , 31
' 45°30 :5
INTAKE EXHAUST
Page 53
Valve Mechanism
Page 55
222'60
93????
Exhaust manifold. Fuel tank air inlet. Fuel vapor Inlet from carburetor.
.
Page 5'!
INSPECTIONS
Check
—attachment screws (4) of upper and lower bodies and
cover screw (1) for looseness.
—Iines for clogging or deterioration.
~—-filter for clogging or deterioration.
—diaphragm and control lever springs for weakness
or distortion.
rdiaphragm for hardening or cracking.
Oil control lever and pivot when reassembling. Lightly
coat new gaskets with grease. Always use new gaskets.
Model X 1/9
ADJUSTMENT
Place gasket (2) on engine. Place insulating support (4)
on engine. Place an 0.012 in. (0.3mm) gasket (3) on
support. Install rod (5) in engine.
Check that dimension A is 0.59 to 0.61 in. (15 to
15.5mm). Install a thicker or thinner gasket (3) to
meet this dimension.
After adjusting the dimension, place gasket (3) on
engine. Place insulating support (4) on engine. Place
gasket (2) on support. Install rod (5) in engine. Install
fuel pump.
NOTE: Gaskets (3) are supplied in 0.012, 0.027, and
0.047 in. (0.3, 0.7, and 1.2mm) thickness.
”I”rt.InSulatI_ ng
1. Pump. 2. Gasket between pump and s
3. Gasket betwet'aqnogupport and crankcase.
support. 5.
Page 59
—~.—-'
b=0.590 in. (15mm)=maximum distance of float from
cover face with gasket.
b—a=0.354 in. (9mm):float travel.
1936?
IDLE co ADJUSTMENT
Connect a tachometer to engine.
Insert sample probe of CO tester in tailpipe.
Start engine and warm it up.
Check that idle speed is according to specification tag.
If necessary adjust idle speed.
Check that CO is according to specification tag. If
necessary adjust idle mixture screw. Recheck idle
speed.
1. idle speed adjustment screw.
2. Idle mixture adjustment screw.
Page 61/62
36 15 18 fr}
BE 57
51
71 72
\
53
65
22592
RECIRCULATING DEVICE
ACCELERATING PUMP For mow—3v GASES
22694
15 20 45 22695
5 59 54 48 22693
6
19:52
19153
. Needle return hook. 29. Screw and lock nut, locating pri- 51. Valve, gasoline vapors discharge
Float. mary throttle valve. from fuel bowl.
. Fuel bowl. . Rotary valve. 52. Fuel bowl vapors discharge duct.
. Float hinge pin. . Blow-by gas passage slot. 53. Accelerating pump actuating
. Calibrated bushing for power fuel . Blow-by gas duct. lever.
passage at high speed. . Calibrated orifice for blow-by gas 54. Accelerating pump diaphragm.
. Power fuel calibrated orifice. suction at idle. 55. Accelerating pump fuel passage.
. Power mixture air passage. Main idling jet. 56. Accelerating pump delivery valve.
10 Air passage calibrated bushing. . Idling fuel passage. 57. Accelerating pump spray nozzle.
Idling air calibrated bushing. 58. Accelerating pump delivery ex-
11. Main air bleeder jet.
. Main idling fuel passage. tension spring.
12. Spray tube.
. Idling mixture calibrated bushing. 59. Diaphragm spring.
13. Auxiliary Venturi.
. Idling mixture adjusting screw. 60. Ball valve.
14 Primary Venturi.
Primary throat transfer orifices. 61. Choke actuating lever.
15. Primary throttle valve. 62. Choke throttle valve.
. Secondary well.
16 Emulsion tube. 63. Fast idle primary throttle opening
. Secondary idling iet.
17. Main jet. cam.
. Secondary air passage calibrated
1B. Main jet well. bushing. 64. Throttles operating lever.
19. Power fuel passage at high speed. . Fuel passage. 65. Calibrated spring.
20. Secondary throttle valve. 66. Vacuum passage.
. Secondary throat transfer orifices.
21. Throttles operating lever. 67. Vacuum line.
. Duct, conveying bowl vapors to
activated carbon filter. 68. Vacuum diaphragm device.
22. Lug.
69. Choke mixture leaning throttleH
23. Primary shaft sector. 47. Suction duct, gasoline vapors
from activated carbon filter. lever.
24. Primary shaft. 70. Throttle valve rod.
48. Cam, controlling accelerator pump
25. Secondary shaft.
and clasing bowl vapors discharge 71. Actuating pin, lever 61.
26. Idler leVer butt. duct. 72. Spring for pin 71.
Page 83
1. Nuts. 2. Air cleaner cover. 3. Airline. 4. Air duct. 5. Clamp. 6. Cooling fan. 7. Non-return
valve. 8. By-pass hose. 9. Bracket.
T
“lBlL.3_...
NOTE: Numbers in circles refer to schematic in
Electrical-55.
3W5
To BATTERY «J
T0 BATTERY
I82
COOLING FAN
REMOVAL AND INSTALLATION
Disconnect wire from terminal 87 of fan relay (2).
Remove fan relay and voltage regulator (1).
Loosen clamp and disconnect flexible fresh air duct (3)
from fan duct (4).
Remove 2 nuts (right front side of support) and 2 bolts
(left rear side of support) holding support to car.
Remove fan and support (5).
Remove 4 screws (7) holding fresh air duct to fan.
Remove 4 screws holding fan to support.
install in reverse order. Make sure black wire from fan
is under mounting nut for fan relay.
THERMOSTATIC SWITCH
REMOVAL
Disconnect wires from switch.
Unscrew and remove switch.
1. Switch. 2. Wires.
Page 35
Exhaust Pipe
REMOVAL
Remove 4 nuts (1) and lockplate (2) holding pipe (4)
to flange (3) on exhaust manifold.
-16
EXHAUST PIPE
Intake manifold Bolt
@WPP’NE"
Page 5':
K
(
6©®®6©0®©
226?!
Model X 1/9
AIR PUMP
REMOVAL AND INSTALLATION
Disconnect hoses (1 and 4) from air pump.
Remove bolts holding timing cover (2).
Remove lower bolt from under engine. Remove cover
(2).
Remove bolts holding support brackets to rear of air .
pump (3).
Remove bolt holding pump to bracket.
Disconnect drive belt. Remove pump.
Install pump in reverse order.
Page 69
Lubficafion
EXPLODED VIEW OF ENGINE LUBRICATION SYSTEMS COMPONENTS
Page 11
Lubficafion
OIL PUMP
REMOVAL
(Engine in Car)
Install support tool on engine.
Remove crossrail supporting engine.
Drain oil sump. Remove bolts and washers holding
sump to engine.
Remove 3 bolts and washers holding oil pump to
engine. Remove pump with suction pipe.
INSPECTION
Clean all parts. Blow parts dry with compressed air.
Check housing (5) and cover (2) for cracks.
Check suction pipe and oil duct for clogging. Blow
clear with compressed air. Make sure dirt and residues
are removed from between relief valve (4) and pump
housing (5).
l _ l,
a).-.
21 (3....
m—.--
no.3
22,5
Model X 1/9
Check gears for wear. Backlash between gears is 0.006
in. (0.15mm). Maximum permissible is 0.01 in.
(0.25mm).
Check gear for tooth to housing clearance. Clearance
should be 0.004 to 0.007 in. (0.11 to 0.18mm). Re-
place gear and housing (if necessory) if clearance
exceeds 0.01 in. (0.25mm).
Page 73
Lubrication
aNKcAsE EMISSION comm SYSTEM
This system ensures that all blow-by gasses and oil fumes are drawn into the inlet manifold and burnt in the
cylinders.
(See detail 4b) At closed throttle the gasses are drawn into the intake manifold through the calibrated orifice
of the control valve incorporated in the carburetor.
(See detail 4a) At wide open throttle, part of the gasses are drawn into the intake manifold through the open
duct of the control valve. The remaining gasses flow directly to the clean side of the air filter.
(-3
9@@.°@®
."-
22610
-
-
Il-
:5-
Page 75
Radiator
REMOVAL
Drain cooling system.
Remove 3 lower screws holding grill to crossrail (4).
Loosen 4 nuts holding plate to body. Remove plate.
Disconnect hoses (5) to radiator. Disconnect connector
for fan and wires from thermostatic switch.
Remove bolt (3) and nut (2) holding crossrail (4) at
each side. Lower radiator out of car. Be carefully of fan.
1. Bleeder.
Page 17
;.»t"'ri...“
Remove protective panels from bottom right side of
engine.
Remove alternator (3) and drive belt.
Disconnect hoses from water pump (2).
v -- ;
Remove 3 nuts (4) and washers holding pipe (5) to
pump (2).
Remove bolt holding support (1) for air pump to water
pump.
Remove 4 bolts (6) holding water pump (2) to engine.
Remove pump.
m
_|
(a)
uh
2. Spacer
3. Screw
4. Coverto housing nuts
5. Bracket
6. Housing
7. Impeller
8. Seal
9. Snap ring
10. Gasket
11. Shoulder ring
12. Grommets
13. Ball bearingr
14. Pulley
15. Pump shaft
NOTE: Fit clearance between impeller (7) and pump
housing (6) should be 0.03 to 0.051 in. (0.8 to 1.3mm).
151413121312 1110 9 7
Model X 1/9
THERMDSTAT
REMOVAL
Drain enough water to lower level below union (1).
Remove air cleaner.
Disconnect hose (2) from bottom of union. Remove 3
bolts and washers holding cover (3) to union (1).
Rernove thermostat and gaskets.
Page 79
TD FUSE-Il—
temperature is 194° F (90° C) or above the switch L-‘NJ
closes. This connects the fan to power thru fuse L. The
fan continues to run until the temperature drops below T0 BATTERY —®—v
185' F (85' C). FAN
3711
Page 81
Tool Equipment
es in cylinder head.
A.60153 Remover and installer, valve guid
W
_V
o A.96216 Gauge, checking depth of combustion chambers.
Section No. 18
Page 83
Clutch
SPECIFICATIONS
TIGHTENING REFERENCE
DESCRIPTION THREAD
(METR'C) MATERIAL TORQUE
FT. LBS. kgm
. . . . R 50 Znt (shank
Nut, operating clnder pIston adjustment ................ M8 R 50 Incl Znt) 18 2.5
Page 85
To:
\\
M
WJ9
6151.5
2'12?
'.
l
l
|
'
SECTION OF CLUTCH ASSEMBLY AND THRUST PAD. SECTION THRU FORKED LEVER AND RELEASE
0.079 in. (2mm) — Gap obtained by adjusting release SLEEVE.
control rod. A — 1% in. (28.5mm) Declutching travel correspond-
0.173 in. (4.4mm) — Maximum displacement from ing to a driven plate displacement of not less than
wear of driven plate linings. 0.071 in. (1.8mm) and a bearing clearance of 0.079
0.335 in. (8.5mm) —- Release travel. in. (2mm).
5 in. (127mm) — Lining I.D. B — 1/2 in. (12.5mm) Travel of clutch release lever
7.145 in. (181.5mm) — Lining 0.0. as a result of plate lining wear.
A Lubrication points
FLUID CHECK
Check fluid level in reservoir. Fluid level should be
up to neck of reservoir.
If level is low check lines for leaking. Check master
cylinder and operating cylinder.
Page 81
Master Cylinder
REMOVAL AND INSTALLATION
Remove steering column. Refer to 412.01.
Disconnect tube from master cylinder. Cap tubes.
Remove two bolts and washers holding cylinder to
support plate.
Pull cylinder out and off rod.
Remove clamp holding hose on cylinder. Remove hose.
Drain oil into container.
Connect hose to new cylinder. Use new clamp.
Position cylinder on support plate.
Make sure rod is in cylinder.
Connect tube to cylinder.
Install bolts thru cylinder and brake cylinder.
Fill reservoir. Operate clutch and check for leaks.
Bleed clutch control circuit.
Install steering column.
l. Reservoir. 2. Hose. 3. Tube. 4. Clamp.
5. Bracket. 6. Bolt. 7. Cylinder. 8. Rod.
9. Pedal.
_"'1\V'v'v""'
Page 89
Operating Cylinder
REMOVAL AND INSTALLATION
Remove union (3) from cylinder (2).
Remove split pin from end of cylinder rod thru shaft (1).
shaft (1).
Hold back on shaft against spring. Remove two bolts
(4) and washers holding cylinder to support plate (6).
Pull cylinder out. Slowly release spring.
Position cylinder (2) on support plate (6) with rod thru
shaft (1). Pry back on spring.
Install two bolts (4) and washers thru cylinder. Install
Split pin thru rod. Place new gasket on union (3). Place
union thru hose (5). Place another new gasket on union
(3). Install union in cylinder.
Bleed cylinder. Adjust cylinder. Fill reservoir.
Clutch
REMOVAL AND INSTALLATION
Remove transmission.
Mark clutch position on flywheel (1).
Remove retaining bolts. Remove clutch.
When installing clutch. place the protruding part of
the hub next to the transmission.
Before tightening clutch to flywheel bolts, center disc.
Use tool AJOZIO. Torque bolts to 11 ft. lbs. (1.5kgm)
Reinstall transmission.
Gr. 212-TRANSMISSION 21
32.01
B2.07
212.01
212.07
Transmission Assembly .......................................................................... 93
Outer Gearshift Controls .......................................................................... 103 27
Gr. 274-DIFFERENTIAL
84.01 274.01 Axle Shafts .............................................................................................. 105
04.04 274.04 Differential Gear Train ............................................................................ 109
21 11-2711 Tool Equipment ...................................................................................... 114
Page 1011102
22719
, 35:1.
-lll"
\"
nmuum§
'W//’/
Section through detent
springs for gear control
rods.
Page 103
1. Bolts. 2. Support.
E E '9
18
)E
K20
8\ \21
23 22
Page 105
Axle Shafts
Page 101
Axle Shafts
Press hub (2) into pillar (1).
Install constant-speed joint in hub.
Install washer and hub nut. Torque nut to 101 ft. lbs.
(14kgm).
Stake hub nut.
B 7
ft
1;.
l _ fl]
9 8
Hub nut
TJE-T‘PPEJl-‘PE‘
Washer
Hub
Bearing ring nut
Bearing
Constant-speed joint
Pillar
Page 109
~-—v--—-—...__‘
DIFFERENTIAL SECTION
Page 111
DIFFERENTIAL BEARING SETTING carrier bearing in its seat. Place shims on top of bear-
ing. Place retaining flange on shims. Using feeler
NOTE: Bearing preload must not be changed unless the gauge measure clearance between flange and trans-
hearings or transmission housing has been replaced. mission housing. If clearance is not 0.003 to 0.005 in.
The bearing on the differential must be preloaded. (0.08 to 0.12mm), add or remove shims to obtain this
Preload is obtained by placing shims between outer clearance. Install two nuts on studs thru flange and
ring of the bearing and the sealing cover. To set pre- tighten nuts. Tum transmission one full turn to set
load, do one of the following: bearings. Loosen nuts and check clearance. Install
If fixture A.95655 is not available, place outer ring of nuts on studs. Torque nuts to 18 ft. lbs. (2.5kgm).
l
]
l / "l
I
d h
Page 113
_ __..fl __ _ _ 21771
217 78
Dial indicator
Transmission case P:Distance between mounting surface for cover (6)
Differential case and outer ring of bearing (1).
Tool A.95655 H=Height of sealing Cover.
1n I :'—rr1 _..
-—--:
HYDRAULIC BRAKES AND HAND
BRAKE SYSTEM
. Master cylinder
‘DCDHOO'l-hWM—I
. Hand brake lever
. Brake fluid reservoir
. Brake pedal
. Stop light switch
. Front brake calipers
. Rear brake "T" connection
. Rear brake calipers
. Hand brake indicator switch
Page 117
Page 119
Pull calipers (1)I brake linings (2), and springs (3) out.
Plug outlet port of reservoir.
On front brakes, remove bolt (6) holding bracket (5)
to caliper.
Remove union thru hose (4). Remove gaskets.
Page 121
Page 123
(MARK)
745 z Ail/E “WAT _
gf-lows'
[0 ON $10!:-
SHOULD 136 U
wfrl/ eweo gCREW, WHEN
REBUiLO/NG— CAMPER
Page 125
Hand Brake
ADJUSTING HAND BRAKE
Press brake pedal a few times.
Starting from released position, pull hand brake lever
up three or four clicks.
Remove cover. Loosen locknut (1).
Tighten the adjusting nut (2) until wheels are locked
(try to turn wheels manually.) Tighten locknut.
Release hand brake. Check that wheels are free to turn.
41
Section No. 41
Page 127
Steering System
SPECIFICATIONS
Type .......................................................................................................... rack and pinion
Ratio:
— Steering wheel turns, lock to lock ...................................................... 3
— Corresponding rack travel .................................................................... 4.606 in. (117mm)
Front wheel toe-in, car laden (*) ................................................................ 0.0787 to 0.1575 in.
(2 to 4mm)
l*) Car laden: two persons plus 44 lbs. (20kg) luggage, with tire inflated to specified pressures.
TIGHTENING REFERENCE
Nut, self-locking, steering arm ball bearing ............ M 10 x 1.25 R 50 Znt (Stud 25.3 3.5
12 NC 3 Carbon)
Nut, upper steering column support .......................... M8 R 50 Znt (Bolt 10.8 1.5
R 50 Sd Stab)
Page 129
Steering Gear
SECTION A-A
STEERING SHAFI'
Disconnect battery.
Remove five screws (1) holding steering column cover
halves (2).
Disconnect three electrical connectors and one wire.
Page 131
Steering Box
’5
Page 133
Steering Box
B 7 I. 6 3 9 \2 1 22662
DISASSEMBLY
Disconnect tie rods from ball joints.
Loosen clamps (2). Drain steering box.
Remove bolts (1) and pads for attaching box to body.
Remove bolts thru cover plate (4). Remove plate,
gasket, spring. shims, and yoke.
Remove bolts thru cover plate (3). Remove plate,
gasket, shims, and drive pinion with bearing.
Page 135
Steering Box
Replace bushing in steering box. Use tool A.74347.
Slide rack in with smooth side towards pinion seat-
ing. When rack is fully home turn rack. until teeth face
pinion seating.
Install pinion so that it mates with rack.
Install top bearing. Press pinion to settle bearings in
place.
\\\’\V
to take up all end play. Measure distance X. Determine
/fi
shim thickness as follows:
Shim = X + 0.0020 to 0.0051 in.
ix
(X + 0.05 to 0.13mm).
NOTE: Shims are available in the following thickness:
0.0047, 0.0079, 0.0098. 0.0984 in. (0.12, 0.2, 0.25,
//
2.5mm)
/
l<
Measure distance Y between box and cover plate.
Shim : Y + 0.0020 to 0.0051 in.
JEN
(Y + 0.05 to 0.13mm).
//|
NOTE: rack yoke shims are available in 0.0039 and
’-_-_-‘
/
0.0059 in. (0.10 and 0.15mm) thickness.
////
//
Assemble spring (5) and seal ring (7) on yoke (8).
Coat surfaces of shims (4) with adhesive liquid.
install shims, cover plate (6), and bolts on box.
g“...
|
‘x
.I
\
iI
(—
x
Page 137
Steering Box
Go modified steering box, lubricate ball joint with oil.
Screw collar of joint onto rack to end of threaded
section. Tighten collar to 54% ft. lbs. (7.5Kgm). Stake
inside collar over edge of rack rod.
0n unmodified steering box, screw nuts (2) on rack
to end of threaded section. Assemble spring and
socket. Lubricate ball joint with oil. Install pin and
adjustable joint.
Tighten joint until a force of 11/2 to 3% ft. lbs. (0.2
to 0.5 kgm) is needed to turn the pins. Check that pins
can describe a rotation cone with an apex angle of
60° 1-1.
Lock the heads in position with nuts (3).
Stake heads as shown.
22682
Steering Linkage
FRONT WHEEL TOE-IN
Check toe-in as follows:
— Set wheels straight-ahead. Make sure steering
wheel spokes are positioned properly.
— Measure distance between rearside of rim’s as
shown. Mark wheel (dimension A).
— Turn wheel 180' until mark is in front (push car
forward).
— Measure distance again (dimension B).
— Dimension A must be 0.0787 to 0.1575 in. greater
than dimension B with a loaded car.
A.14219 Installer. steering gear pinion shaft lower hearing. A7424? Inserter, steering rack rod guide bushing.
44
Section No. 44
Page 139
FRONT SUSPENSION
Type:
Independent wheels. Lower control arms with reaction strut; telescopic
knuckle pillars incorporated with hydraulic shock absorbers; coil
springs and co-axlal buffers.
Steering Knuckles
Caster. unladen car .................................................................................. +6"30’ to +7°30’
—Adiustment: by shims set between reaction struts and supports
Wheels
Camber
angle. unladen car .............................................................................. 0° to -1"
measured at rim edge laden (*) .......................................................... —O.157 to —O.315 in.
(—4 to —8mm)
Toe-in. unladen car .................................................................................. +0080 to +0.240 in.
(2 to 6mm)
“Adjustment by threaded sleeves on track rods.
Tightening of suspension: with car laden (*).
Coil Springs
Length under a load of 474 :22 lbs. (215 :IOkg) .................................. 6.693 in. (170mm)
Minimum permissible load referred to above length .................................. 441 lbs. (200kgl
Coil springs are divided into two classes. color coded as follows;
—yellow, springs which under a load of 474 lbs. (215kg)
haVe a length above .................................................................................. 6.693 in. (170mm)
—green, springs which under a load of 474 lbs. (215kg)
have a length of ...................................................................................... 6.693 in. (170mm)
or less
Shock Absorbers
Type: hydraulic, telescopic, double acting.
Pressure cylinder bore .............................................................................. 1.063 in. (27mm)
Length (measured between upperface of dust shield and
center of upper bolt hole for attachment to knuckle pillar):
—Extended (buffering begins) ................................................................ 13.720 in. 20.079 in.
(348.5 12mm)
—-Retracted .............................................................................................. 8.327 10.079 in.
(211.5 12mm)
Stroke (buffering begins) .......................................................................... 5.393 in. (137mm)
(*l Car laden: two persons plus 44 lbs. (20kg) luggage, with tires inflated to specified pressures.
SPECIFICATIONS
REAR SUSPENSION
Type:
Independent wheel. Lower control arms; telescopic knuckle pillars
incorporated in hydraulic shock absorbers; coil springs and co—axial
buffers. Adjustable cross tie rods.
Wheels
Camber
anglel unladen car .............................................................................. +1°10’ to —2°10’
measured at rim edge, laden (*) .......................................................... —0.433 in. to ~0.590 in.
(—11 to —15mm)
Shock absorbers
Type; hydraulic, telescopic, double acting.
Pressure cylinder bore .............................................................................. 1.063 in. (27mm)
Length (measured between upper face of dust shield and center
of upper bolt hole for attachment to knuckle pillar):
Hextended (buffering begins) .................................................................. 16.771 10.079 in.
(426 22mm)
—Retracted .............................................................................................. 11.378 $0.079 in.
(289 :m)
Stroke (buffering begins) .......................................................................... 5.394 in. (137mm)
l”) Car laden: two persons plus 44 lbs. (20kg) luggage. with tires inflated to specified pressures.
Section No. 44
Page 141
FRONT SUSPENSION
Nut, wheel hub (stake) ...................................... M 20 x 1.5 C40 Norm-Cdt 112 15.5
(Hub 38 CD 4 Bon)
Nut, self-locking, R50 Znt (Pin
steering knuckle ball joint ................................ M 12 x 1.25 40 NiCrMi 2 R 58 8
Bon R 90 to 105
Nut, self-locking, R 50 Znt (Strut
strut to bracket ................................................ M 12 x 1.25 C 30 Bon R > 70) 50.6 7
Nut, strut to control arm .................................... M 12 x 1.25 R 50 Znt (Bolt 50.6 7
R 80 Znt)
Nut, shock absorber — R 80 Znt (Bolt
to body upper mounting pad ............................ M 6 R 100 Cdt) 7.2 1
Bolt, brake caliper to steering knuckle ............ M 10 x 1.25 R 80 Posf. black 36.2 5
Stud bolt, wheel .............................................. M 12 x 1.25 C 35 R Bon Znt 50.6 7
black
Nut, self-locking, R 80 Znt (Bolt
front control arm to body .................................. M 10 x 1.25 R 100 Cdt) 29 4
TIGHTENING REFERENCE
REAR SUSPENSION
C 40 Norm. Cdt
Nut with stacking collar, wheel hub .................. M 20 x 1.5 (Hub 38 CD4 Stp 112 15.5
Bon Nitr Morb)
Nut, self-locking, control arm pivot pin ............ M 14 x 1.5 R 80 Znt (Pin 72.3 10
R 80 Znt)
Bolt, brake caliper to knuckle pillar .................. M 10 x 1.25 R 80 Post. black 36.2 5
Connector. rear wheel brake hose .................... 3/8—24 UNF-3A AB 40 PR Cdt or 14.4 2
OOCR Cdt
Page 143
FRONT SUSPENSION
Remove wheel.
Remove bolts (1) and plate (2) holding strut to pillar
(3).
Remove bolt holding control arm (4) to bracket (5).
Remove nut (3) holding tie rod ball joint (1) to steering
arm (2). Remove ball joint.
Page 145
Front Suspension
Place control arm (4) in bracket (5).
Install boltI washer, and nut.
Place strut on control arm. Place plate (2) on strut.
Install bolts (1) thru strut and control arm and install
nuts.
Tighten nuts (1, 2, and 3) and bolt (4) with car laden
as follows:
NUT TORQUE
{1) 58 ft. lbs. (8kgm)
(2) 51 ft. lbs. (7kgm)
(3) 29 ft. lbs. (4kgm)
(4) bolt 29 ft. lbs. (4kgm)
Model X 1/9
Front Suspension
Page 141'
Front Suspension
FRONT WHEEL ALIGNMENT
Install and adjust alignment equipment. Follow in-
structions provided with equipment. Set up equipment
to check caster.
Caster, unladen car +6°30’ to +7°30’-
Adjust caster by adding or removing shims between
reaction struts (2) and supports ( 1)
Remove shims to increase caster.
If car has been in an accident, set up equipment to
check camber.
NOTE: Camber cannot be adjusted and does not cause
tire wear.
Camber, unladen car, 0” to —1
For toe-in of front wheels see Steering Linkage. 412.10
iii ll
COIL SPRINGS
Fixture A.74241 must be used to remove and install
springs on shock absorbers.
Page 149
Washer
Washer
Rubber bushing
Control arm
Rubber bushing
Washer
Spacer
Bolt
Nut
I—‘t—l
Pillar
Page 151
Page 153
REAR SUSPENSION
Page 155
Rear Suspension
Install wheel.
Lower car to ground.
With car laden. torque nuts (1, 2. and 3).
Nut (1) Shock absorber, 43 ft. lbs. (6kgm)
Nuts (2 and 3} Control arm, 72 ft. lbs. (10kgm)
1. Reaction rod.
Page 151
CONTROL ARM
VIEW OF CONTROL ARM ATTACHMENT POINTS.
Page 159
Shock Absorbers
REMOVAL AND INSTALLATION
FRONT AND REAR
Remove three nuts (2), lockwashers, and washers hold-
ing absorbers (1) at top.
Remove two bolts and nuts (1) holding absorber (2)
to pillar (3).
l..'""1
‘
L
'l'“
\q
1. Shock absorbers. 2. Nuts.
Shock Absorbers
DISASSEMBLY AND ASSEMBLY
Place shock ab50rber up right in vice. Remove threaded
plug (2). Remove inner cylinder (3) from outer cylinder
(1), ~..__..z h
NOTE: New inner cylinders are supplied dry. You will
have to fill them. Use either of the following methods. 6)
Method A
Place stem (1) of inner cylinder (2) in vice. Extend
Cylinder. Carefully and gently tap around and under
valve (3) to remOve it.
Pour fluid into cylinder (2) until full. Add remaining
fluid to outer cylinder (4). install valve (3) by carefully
tapping it around edge. insert cylinder (2) into cylinder
(4). Assemble absorber using new ring seal (7) and
Cap (6). Screw threaded plug (5) on absorber.
Method B
Place outer cylinder (1) in vice. Fill cylinder with oil.
Insert inner cylinder (2) until partly submerged in oil.
Firmly hold stem (3) of cylinder (2) and using vice-
grips, slowly pull stem (3) out to its full extension.
The piston will draw the oil into the cylinder.
Assemble absorber using new ring seal (6) and cap
(5}. Screw threaded plug (4) on absorber.
After assembling, operate unit manually. Extending and
compressing it two or three times to bleed it.
Page 163
Wheels
FRONT WHEEL HUB
REMOVAL AND INSTALLATION
Jack up car. Remove wheel.
Disconenct brake calipers (5) and support bracket (6).
Remove bolt (1) and centering stud (2) holding disc
(3) and plate (4).
Remove nut (1) holding tie rod (2) to pillar (3). Remove
ball joint from pillar. Use tool.
Remove nut (4) holding control arm (5) to pillar (3).
Remove ball joint from pillar.
Remove two nuts (6) and bolts holding shock absorbers
(7) to pillar. Remove pillar.
Page 165
Wheels
Stake ring nut as shown.
Tool Equipment
55
Section No. 55
Page 157
Electrical: Specifications
IGNITION
Secondary winding ohmic resistance (at 68 F, 20 C) ........ 5670 to 6930 ohms 6500 to 8000 ohms
SPARK PLUGS
Ac-DELco MARELLI CHAMPION
Type ---------------------------------------- 42-x|_s cw 78 LP N9Y
Thread (metric) ........................ M14 x 1.25 M14 x 1.25 M14 x 1.25
Gap ........................................ 0.020 to 0.024” 0.020 to 0.024" 0.020 to 0.
(0.5 to 0.5mm) (0.5 to 0.6mm) (0.5 to 0.6mm)
Starting Motor
Voltage ...................................................................................................... 12
Section No. 55
Page 169
Electrical: Specifications
Solenoid
—Coi| resistance at 77" F (25" C) ............................................................ 0.39 t 0.02 ohms
—Contact stroke ...................................................................................... 0.1129 to 0.1586 in.
(2.87 to 4.03mm)
—Core stroke ............................................................................................ 0.480 to 0.602 in.)
(12.2 to 15.3mm)
Lubrication
—Drive unit splines .................................................................................. VS 10 W oil
(SAE 10W)
—Contact face of middle disk and driving sleeve .................................... FIAT MR 3 grease
ALTERNATOR
Type .......................................................................................................... FIMM A124»14V-44A Var 3
Nominal voltage ........................................................................................ 12
Cut-in speed at 12V at 77° F (25° C) ........................................................ 1,000 i 50 rpm
Current output at 14V to battery at 7000 rpm and
thermal rate, not below ...................................................................... 44A
Max. current output .................................................................................. 53A approx.
Ratio
engine ................................................................................................
1:2
alternator ............................................................................................
BATTERY
Nominal voltage 12
Nominal capacity (at 20 hour
discharge rate) 60 AH
RELAYS
WIRING DIAGRAM
REFER ND. RELAYS. SYSTEM/CONTROL LOCATION
UGHHNG
SAE STANDARD
Headlights, high and low beams .............................................................. “Sealed beam”
headlight unit 7031
Front parking and rear tail lights ................................................................ No. 67 (4cp)
Side marker lights, front and rear .............................................................. No. 158 (2cp)
Front and rear turn signal, stop, back-up, and license plate lights ............ NlBBRm
Instrument cluster lighting
Fuel reserve indicator red
Battery charge indicator red
Low oil pressure indicator red
High beams indicator blue
Parking and tail lights indicator green
Turn signal indicator green
Brake system effectiveness and hand ............ No. 158 (2cp) red
brake ”0N” indicator
Vehicular hazard warning signal indicator red
Fasten belts indicator
ldeogram illumination optical
fiber light source
Cigar lighter light
Vehicular hazard warning light switch light ........................................ 12V 1.2 W
Courtesy lights .................................................................................... 12V 5W
Section No. 55
Page 171
Electrical: Specifications
CONTROLS
Courtesy light
—toggle type switch ................................................................................ on center console
—door jam switch .................................................................................... on door pillars
FUSES
FUSES
2 three-Amp fuses
8 eight-Amp. fuses
2 sixteen-Amp. Fuses
1 eight-Am- fuse PROTECTED CIRCUITS
in separate holder
Stop lights. Electric pump, windshield washer.
Back-up lights. Fuel gage and fuel reserve indicator.
Brake system effectiveness and hand brake Engine water temperature gage.
A(*) ”0N” indicator. Heater fan motor.
(8 Amp) Ignition-Belt interlock system. Windshield wiper.
Turn signal and indicator. Fasten belts indicator.
Tachometer. Fasten belts buzzer relay.
Oil pressure gage and indicator.
Actuators, retractable headlights.
(8 ABm ) Interlock system electronic control unit.
p Fasten belts and remove key buzzer.
C(*)
(8 Amp) Left headlight high beam.
D(*) . . .
(8 Amp) nht headlight high beam.
N . .
(3 Amp) Retractable headlights control relay (on opening).
Section No. 55
Page 173/174
®
@
28/1 l6—Amp fuse 51. Twelve-indication instrument cluster 89. Courtesy light
28/2 3—Amp fuses 53. Oil pressure gage 93. Fuel gage sending unit
38 28/3 8~Amp fuses 54. Engine water temperature gage 98. Tail, turn signal, stop and back-up lights unit
30. Turn signal flasher 56. Tachometer l 98/1 Rear side markers lamps
32. Vehicular hazard warning signal flasher 57. Fuel gage i 99. License plate lamp
33. Instrument cluster light resistor 61. Fuel reserve indicator 1 104- Thermostatic 5Wit0h for engine fan motor
35. Windshield wiper motor 63. Low oil pressure indicator i 126. Fasten belts and remove key buzzer
37. Two-speed heater fan motor 64. Turn signal indicator l 128- High beam motor relays
37/1 Engine fan motor 55_ Fasten belts indicator i 128/2 Relay for buzzer
39. Relay for engine fan motor 65/1 Vehicular hazard warning indicator 128/3 Starter relay
40. ldeogram lighting potentiometer 65/2 Brake system effectiveness and hand brake ”ON" indicator 128/4 Relay for carburetor fan motor
unit 42. Turn signal indicator switch 66. Battery charge indicator i 161. Light source, optical fiber illumination
lg unit 42/1 High/low beams change-over switch 67. Parking and tail lights indicator 180. Concealed headlight motors
42/2 Wiper/washer three-position switch 69. High beams indicator 182. Carburetor fan motor
cator switch 44. Steering lock ignition switch 74. Cigar lighter with housing indicato 189. Interlock system eiectronic control unit
etor fan relay 46. Lighting switch (controls concealed headlight motors) 76. Hand brake ON switch 1 194. Button switch on seat belts
47. Instrument cluster lights switch 79. Horn button ‘ 194/1 Strip switch in passenger’s seat cushion
47/1 Courtesy light switch 84. Washer pump motor 194/2 Gear-engaged signal button switch
49. Heater fan motor three-position switch 87. Courtesy light jam switch 194/4 Strip switch in driver’s seat cushion
50. Vehicular hazard warning signal switch with light 87l1 Remove key indicator jam switch (driver's door) 195. interlock by-pass switch
l
Page 115
Ignition
IGNITION DISTRIBUTOR
Check automatic centrifugal advance.
Mount distributor on test bench.
Rotate distributor at 300 to 400 rpm. Read on grad-
uated disc angle at which one of the sparks occurs.
Gradually increase speed and take readings of the
number of degrees of spark advance.
Compare findings with diagram.
D.
Page 117
Ignition
IGNITION COIL
Check resistance of primary winding.
Resistance at 68° F (20° C) must be as follows:
Marelli Martinetti
3.1 to 3.4 ohms 3 to 3.3 ohms
Page 179
Starting
STARTER
DISASSEMBLY AND ASSEMBLY
Disconnect wiring from solenoid terminal by removing
nut {4).
Remove nuts (2) and washers holding solenoid (3).
Remove solenoid.
Remove dust cover (5) on commutator end.
111213 14 15
27
Starter assembly
Bushing 12. Lockwasher 23. Bush spring
PPPWHP‘QPP’PL"
Page 181
Starting
CHANGING BRUSHES
Loosen not on bolt thru brush cover. Remove cover.
Remove screw and washer holding brush wire in
terminal.
Lift brush spring and remove brush.
Install new brushes. insert ends of springs in recesses
in brushes.
Install screw and washer thru brush terminal.
Install brush cover.
REFACING COMMUTATOR
Reface commutator on a lathe.
Make sure run-out does not exceed 0.0004 in.
(0.01mm).
After refacing. undercut mica to a minimum depth of
0.04 in. (1mm).
SECTION A-A
SECTION 3-3
SECTION C-C
Cross section through plnlon Section through pole ghoul Section through commun—
drlua. and field winding. tor and frame and View 01 brushes.
Page 183
Alternator
Page 185
Lighting
HEADLIGHTS
ADJUSTMENT
CAUTION: Motor will retract headlight if cap is turned.
All headlight adjustments should be made with the
car unloaded at 16 ft. (5m) from the screen. When
using headlight alignment equipment, refer to instruc-
tions provided.
9425
1. Adjustment screw.
REPLACEMENT
Remove three screws holding frame to body. Remove
frame.
Loosen three screws thru ring. Turn ring to left and
remove ring.
Remove plug from headlight. Remove headlight.
FUSES
Fuses A thru H, 8-Amp Fuses I and L, 16-Amp Fuses
M and N, 3-Amp Fuse in separate holder, 8-Amp.
Page 187
lHIllIlll
able. Lr buzzer.
14. Air temperature control lever. . Accelerator pedal. High beams indicator (blue).
15. Radio housing blanking lid. . Service brake pedal. Parking and tail lights indicator
. Clutch pedal. (green).
16. Vehicular hazard warning signal
switch. 31. Fusebox. Tachometer.
17. Loudspeaker grill, optional radio. Fuel reserve Indicator (red).
1B. Drop tray button (with lock). . Fuel gage.
Front trunk latch release handle Odometer.
ls housed in tray recess. Trip recorder zeroing knob.
19. Heater outlet flap. Oil pressure gage. Engine water temperature gage.
20 Courtesy light switch. Brake system effectiveness indi- Battery charge indicator (red).
21. Front ash tray. cator (red). Back window demister indicator
. Gearshift lever. Spare indicator. (amber).
. Cigar lighter. Speedometer. Low oil pressure Indicator (red).
II 1
To BUZZER ‘—
® @3 @1
“it” A
mesons:
"" I .— lwi.
TD snares LI—I— ‘I'D isnmou
TERMINAL 56 MITCH
® @
TERMINAL 50
CHECKOUT
NOTE: This checkout is to be used with the troubleshooting procedure and diagram in the Supplement. Use
this procedure if test box is not available.
The connectors for the control box have been given number for reference (C16-white conector, 017-red con-
nector). The wires are also numbered W1 thru W6 and R1 thru R6. The prOCedures refer to wire numbers in-
stead of color since some variation in wire color coding does occur. The table below lists the wire colors and
numbers being used at the time this manual was written.
RED CONNECTOR — Cl7 WHITE CONNECTOR — C16
R1 — pinklyellow W1 — blue/red
R2 — red/white W2 — light blue/red
R3 — whitefblack W3 — red
R4 — yellow/black W4 — brown/white
R5 — grayfyellow W5 — violet/black
R6 — greenfwhite W6 — light blue/white
Page 189
70
71
Page 191
GENERAL INFORMATION
Body
GENERAL INFORMATION air controls are in center panel. Four adjustable out-
lets, one at each end and two in center panel.
Two-door unitized body.
Interior trim and seats are imitation leather.
Front doors hinged at front. Side window with two Arm rests in padded plastic on doors.
safety glass panes, i.e. fixed quarter window and drop
window controlled by regulator. Rear view mirrors inside and outside.
Doors have outside key handles and inside locking
devices. Outer door handles have spring-loaded release
Sun visors are padded and adjustable.
grips.
Rear window is fixed safety glass. Carpeting in passenger compartment. Rubber mats in
luggage compartment.
Luggage compartments in front and rear. Front com-
partment unlatched by latch in glove compartment. Engine compartment lid has key lock located in driver's
Rear compartment key lock located in left door column. door column.
Tool kit and jack located in rear compartment.
Air louvers in both sides for letting air into engine
Front seats are adjustable bucket-type with tiltable compartment.
back for access to rear of seats.
Ignition key lock with anti-theft device.
Spare wheel housed behind passenger’s seat.
Seat belts with ignition interlock and warning system.
Instrument panel has plastic padding.
Instruments and switches on driver's side. Heat and Removable hard top.
‘ 7 lair-F HF‘J ‘
\
\
M \
I-Iu ---#w L_umg
”-1d
\ 3
fl‘-hF
.r-
*ur-
I I ‘ ‘21 \ n-
J _ x x I H I a”
-.=r=4 '
‘Pm~“w ma.
‘n HF?JfiH+*HFL
*I‘im-‘Tl‘ ’ H
h_.“anurmm=h,T
-'H-I filler-r” ‘Ffl'fl Hill; I
‘. rultihrn*fi.T— I
_
\ \
aura
.—...—.—r
_'I—
Page 193
Instrument Panel
REMOVAL AND INSTALLATION
Remove 5 screws (1) holding cluster (2) to panel (3).
Slide cluster out part way. Disconnect 3 electrical
connectors and speedometer cable.
Remove instrument cluster.
Page 195
Instrument Panel
35‘——J ;_34
Page 197
Section No.701.04/.05 l
l
Page 199/200 E
/.. 431.5
Section A-A
\7 ‘ 920 2202.5 mm = 86.7124 in 188 mm = 7.4015 '
695
920 mm = 36.2205 in 164
840 mm = 33.0708 in 163.5 '
154 790 mm = 31.1024 in 158.5 6 '
735 mm = 28.9370 in 154 6. '
730 mm = 28.7402 in 143.5 mm = 5.6496 in
716 mm = 28.1890 in 142.5 mm = 5.6105 in
695 mm = 27.3622 in 123.5 mm = 4.8622 in
658 mm = 25.9055 in 118.5 mm = 4.6653 in
lLf
647 mm = 25.4724 in 116 mm = 4.656991n
.
634 mm = 24.9606 in 113 mm = 4,4433 in
632 mm = 24.8819 in 105 mm = 4.1333 in
596 mm = 23.4646 in 103 mm = 4.0551 in
588 mm = 23.1496 in 85 mm = 3.3454 in
32% mm = 533233; E" 63 mm = 2.6771 in
. mm = .
497 mm = 19.5669 in
481.5 mm =18.9567 in
m _
2:, m." = 332;: :2
-
Section B-B
@fi
. Reference line.
@“NOMw-IQ
. Car centreline.
'. Radiator suspension mounting.
. Front suspension front mounting.
634
. Front wheel static centre.
. Front wheel axis.
. Front control arm rear mounting.
. Steering box mounting.
. Front shock absorber upper mounting.
. Crossmember front mounting, power plant suspension.
Section D-D . Rear control arm front mounting.
a‘..-'....—a
dauawnao
Section No.701.04l.05
Page 201
Page 203
Hard Top
Adjust hard top for proper alignment by loosening 4
screws (1) holding stricker plate (2) and shifting plate
(2).
Page 205
Doors
WINDOW ADJUSTMENT
Loosen screws (1) (2 places).
Rest window (2) on rubber pad (3).
Set regulator handle in “wide open" position. Tighten
screws (1) hard. After adjustment, the glass must be
able to run full length of its travel. Control cable must
wind and unwind properly on regulator pulley.
Page 201
Doors
EXPLODED VIEW OF DOOR
1. Clip 14. Handm 27. Lock cylinder
2. Lock cover 15. Bok 28. Pin
3. Door panel 16. Lockwasher 29. Spfing
4. Screw 17. Washer 30. Pawi
5. Lockwasher 18. Lever 31. Stricker plate
6. Hinge half 19. Lockwasher 32. Lockwasher
7. Pin 20. Lock 33. Screw
8. Lining 21. Rod 34. Screw
9. Door check 22. Rubberflng 35. Lockwasher
10. Hinge half 23. Knob 36. Door
11. Pin 24. Rod 37. Channel
12. Bolt 25. Nut 38. Rod
13. Screw 26. Handle
Page 209
Windshield
REMOVAL AND INSTALLATION-
Remove wiper blades. Remove instrument panel (3).
Refer to 701.02. _
Remove inside weatherstrip (1).
If glass is damaged, remove outside moulding. Cut
layer of sealant between glass and windshield opening
fence with steel wire.
If glass can be reused, find internal resistance ter-
minals (2) for the sealant. They are on bottom center of
windshield. Connect 24V source to terminals for a few
minutes to soften the sealant. Push glass very carefully
from inside to remove it.
if sealant cannot be soften, remove trim from wind-
shield. Very carefully cut sealant from windshield.
Clean surfaces of windshield, weatherstrip, and open-
ing fence. 1. Weatherstrip. 2. Terminals. 3. Instrument panel.
Page 211
Back Window
Page 213
LID LOOK
REPLACEMENT AND ADJUSTMENT
Remove 4 screws and bolt holding grill (1) on right side
of car.
Remove 2 bolts (3) and washers holding lock (2) in car.
Work lock out thru grill opening.
28
29
24
30
Page 215
LID LOCK
REPLACEMENT AND ADJUSTMENT
Remove 2 bolts (3) and 4 washers holding lock (4)
in car. Disconnect cable (1) from lock. Disconnect
plastic cable (2) from lock.
When installing lock, position lock for proper operation.
Tighten 2 bolts.
NOTE: The pull for the plastic cable is in engine
compartment.
KEY LOCK
REPLACEMENT
Remove screws (2) holding cables in levers (1). Remove
screw (3) holding assembly (4) in door frame. Remove
assembly.
Feed cables into levers. Pull cables and levers until
lids release. Hold cables and feed them into levers.
Install screws (2) in levers (1).
Install screw (3) thru assembly (4).
1. Stricker plate
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Lid
Hinge
Washer
Lockwasher
Bolt
Bolt
Lockwasher
Washer
Lock
Spring
12. Lockwasher
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Washer
Bolt
Cable
Rubber ring
Washer
Lockwasher
Screw
Lockwasher
Screw
Lock cylinder
l.
23. Handle
24.
25.
26.
27.
28.
29.
30.
31.
Washer
Fork
Screw
Washer
Weather strip
Bushing
Stay
Pin
Page 21')l
LID LOOK
REPLACEMENT AND ADJUSTMENT
Remove 2 bolts (2) and 4 washers holding lock (1)
in car.
Disconnect cable (3) from lock (1).
When installing look, position lock for proper operation.
Tighten 2 bolts.
Page 219
Front Seats
FRONT SEAT
. Fore and aft adjuster lever
FP‘PPPE‘J"
ELECTRICAL SYSTEM
TROUBLE SHOOTING
Page 221
TABLE OF CONTENTS
SECTION
PAGE
Battery Charge Indicator Stays On After Engine Starts
222
Indicator Does Not Light With Ignition Switch On And Remains Off 224
With Engine Running
Battery Boils Over, Lights Burn Out Repeatedly
226
Battery Does Not Stay Charged
226
DJ
m
ii l l
I! _ BATTERY
‘35-
FUSE BOX o C_
0
000000
:3
5 l
”:5; |
(
{x
....-
INSTRUMENT
PANEL
BATTERY CHARGE
INDICATOR
VOLTAGE
REGULATOR
I ' mi i
U _ _ ALTERNATOU
Page 222
CHECK
ALTERNATOR REPAIR DRIVE
DRIVE
IF OK
IF OK
CH ECK VOLTAGE
REPAIR
AT CIRCUIT WIRE
BOARD
IF OK
CHECK CIRCUIT
BOARD FOR
DEFECTS
Page 223
2.a. Get voltmeter. Connect red meter lead to black/violet wire at alternator. / / ‘BLACK LEAD
Connect black lead to ground. ALTERNATOR
b. if meter reads voltage, go to step c. If meter does not read voltage, replace
alternator.
Page 224
CHECK
CHECK CIRCUIT ALTERNATOR
TO ALTERNATOR CIRCUIT
TO GROUND
IF OK IF NOT
IF OK
REPLACE
REPAIR WIRE ALTERNATOR
IF NOT
OK
CHECK CIRCUIT
BOARD FOR
DEFECTS
Page 225
Turn ignition switch off. Connect red meter lead to black/violet wire in CONNECTOR C7
connector C7. Connect black lead to ground.
BLACKI'VIOLET
NOTE
Connector C7 is a 6 pin connector. It is the middle connector
on the instrument panel.
If meter reads 10 ohms or less, go to step 2. If meter reads more than 10
ohms, go to step 3.
RED LEAD
TOGROUND
Locate bulb holder for battery charge indicator. Turn bulb holder to left BULB
and remove it from circuit board. Pull bulb out of holder. HOLDER
Install new bulb. Install holder in circuit board.
Turn ignition switch on. Check indicator. If indicator is lit, install in-
strument panel.
If indicatorvis not lit, check connector C7, circuit board, and bulb holder BULB
for defects. Repair or replace defective part.
CIRCUIT
BOARD
3.a. Go to engine compartment. Connect red meter lead to black/violet wire at BLACK LEAD \
/
If meter reads 10 ohms or less, repair black/violet wire from alternator to T0 GROUND
connector C7.
NOTE BLACKNIOLET
The wire runs from connector C7. connector C13, regulator WIR E “l'l \
terminal D+ to alternator terminal D+. /
/ RED LEAD
“5:3“
Page 226
BOLTS
BLACKNIOLET WIRE
Page 227I'228
VOLTAGE
ALERNATOR REGULATOR
BATTERY D_ 3 WHITE/BLACK ‘_D_
fill]H][l[l|].*
—_~ 3+
0F *
0+ BLACK/VI 0L E T CW
STARTER0<
J
dz;
I—
[LI
_l
9
>
“N.
5 cs
4
a: LIGHT BLUE/ m LIGHT BLUE/RED
BLACK L’J
- FUSEA
’P Al‘ I
o 6 6 O
(:7
O O O
BATTERY
CHARGING C
INDICATOR I5/54
J
IGNITION SWITCH
III'I-‘IJII --I.'
J
unl-
.
..
. u.”
._-
I.
“E
II
i...
_:
J.— .I"
h.
'1
iiul—l .3
.
I
II
E
-|'
r
‘L'
I'
1.11
u
nil Ian-.1
a
I.
-2;
.
.
illrfi-uL—rm
E”
I.
....I
I
I'
T. .
l- I. __I
.
.
Page 229
STARTING SYSTEM
TABLE OF CONTENTS
SECTION PAGE
Starter Will Not Crank Engine 230
Starter Cranks Slowly 235
BATTERY I
IIIIGNITION 300003 U
SWITCH - _
_- __-:I
_ .' |:|
€32.
Ué-EEI w
__.J
Page 230
STARTING SYSTEM
START CAR
FROM OUTSIDE
IF NOT OK IF OK
CHECK POWER
TO RELAY
TURN ON
HEADLIGHTS
OPERATE STARTER
IF NOT OK SWITCH
REPLACE
REPAIR WIRING IGNITION SWITCH
CHECK
CONNECTIONS CHECK BATTERY
CHECK GROUND
CHECK OUTPUT AT STARTER
FDR RELAY IF 0K
OF RELAY
REPLACE
IF NOT OK IF OK IF NOT OK BATTERY
CHECK CABLE
TROUBLESHOOT T0 STARTER
CHECK VOLTAGE REPLACE CHECK BATTERY
SE AT BE LT
SYSTEM
AT STARTER RELAY
REPLACE
IF NOT OK STARTER
IF OK
REPLACE
RECHARGE OR
STARTER REPLACE
REPAIR WIRING CHECK
CONNECTIONS BATTERY REPLACE CABLE
AT STARTER
R EPLACE
START ER
Page 231
STARTING SYSTEM
STARTER WILL NOT CRANK ENGINE (ACCESSORIES)
1.3. If starter runs but will not crank engine, starter drive is defective. Repair
starter drive.
MAri‘u) AW
b. Turn outer lighting switch on. If headlights do not come on or are dim, x; (START)
troubleshoot headlights.
IOFF AND
Turn ignition switch to start. If lights dim slightly, go to step 3.
no
IGNITION SWITCH
to ground.
Have someone start car. If meter reads less than 8 volts. go to step i.
lI
’ TO GROUND
RED LEAD
If meter reads 8 volts or more, get ohmmeter. Connect red lead to terminal
86 (light blue/white wire). Connect black lead to ground. f...- /
If meter reads 5 ohms or less, go to step 9. RELAY
“3% 9
If meter reads more than 5 ohms, troubleshoot seat belt interlock system.
RED LEAD BLACK
EAD
"To GROUND
TERMINA’L 86 H
RED
WIRE)
TO GROUND
Page 232
STARTING SYSTEM
RED LEAD
TO GROUND
m. If meter reads less than 8 volts, check connector C12 for looseness, dirt, or CONNECTOR (:12
corrosion. Check red wire (position 1) to ignition switch for breaks. Repair
or replace wire or connector.
n. If wire and connector are good, replace ignition switch.
Page 233
STARTING SYSTEM
q. Connect red meter lead to terminal 50 (red wire) of starter. Connect black
lead to ground.
r. Have someone start engine. If meter reads less than 8 volts, repair red wire
to relay.
M TO
A
RELAY -__._
(Rem—m.
I/ /"'__
fl-t
1.280 GOOD
1.100 OR LESS, WEAK
d. If battery load test indicates a good battery, recharge battery. SET TO NORMAL
12V CHARGE
Page 234
STARTING SYSTEM
e. If starter connections are good and battery checks satisfactory, solenoid or MOUNTING
starter drive are defective and must be bench checked.
HOLDDOEN NUT
POST
/CLEANING
Page 235.!'236
STARTING SYSTEM
STARTER CRAN KS SLOWLY
1.a. Check battery condition with hydrometer. TERMINAL
b. Check battery connections for looseness or corrosion. CLEANING
c. Recharge battery or clean and retighten connections as required.
POST
/ CLEANING
TO RELAY——__
// /"‘_
Page 2373238
STARTING SYSTEM
BATTERY
gum DUDE] 3°
§8 5O _
co STARTER
L1} Ea .—-——.p TO INTERLOCK SYSTEM
' RED 37C 0
RED /WHITE
“We—l
| Ll} ORANGE/WHITE _ E
2 RED :85:
3 W
0
II
(D
CI2 m; I I
Z
3
O
II
III
30
0
LL!
0:
IGNITION 50
SWITCH
Page 239
IGNITION SYSTEM
TABLE OF CONTENTS
SECTION FAG E
Engine Will Not Start 240
Engine Misses at Idle (Rough Idle) 247
Engine Runs But Lacks Power Or Misses at High Speeds 250
Timing Ignition With Timing Light 25 1
Engine Stalls 257
l c:—
t ‘ /‘\
[Ir 1 °°°°éfl IGNITION SV'VITCH
. l
I BATTERY I ',
U U
u a...“
Page 240
IGNITION SYSTEM
IGNITION TROUBLESHOOT
ENGINE DOES
SWITCH TO ENGINE STARTING
START NOT CRANK
I
TROUBLESHOOT
FUEL SYSTEM
ENGINE CRANKS
7
IF NOT OK CLEAN OR
REPLACE SPAR K
CHECK PLUGS
CHECK AND REPLACE 7
SPARK AT DISTRIBUTOR CAP
DISTRIBUTOR ROTOR OR LEADS
2 3
IF NOT OK
CHECK VOLTAGE
AT COIL BATTERY CHECK RESISTANCE
TERMINAL 4
4
CHECK
IF NOT OK POINTS AND
CONDENSER
ADJUST TIMING
CHECK VOLTAGE REPAIR WIRE 6
AT IGNITION SWITCH FROM SWITCH
TO COIL
IF NOT OK
REPLACE
IGNITION
SWITCH
Page 241
IGNITION SYSTEM
4
ENGINE WILL NOT START '+B”TERMINAL 4;,
“3,
La. Turn ignition switch to start. If engine will not crank, 90 to Starting
troubleshooting.
b. If engine cranks, connect a remote starter switch as shown. Turn off igni-
tion switch.
c. Disconnect lead from a spark plug. Hold lead about 1/2 inch from engine.
Use insulated pliers.
d. Crank engine and check for spark. lf spark is strong, troubleshoot fuel
system. If there is no spark or it appears weak go to step 2.
COlL
Page 242
IGNITION SYSTEM
CHECK FOR CRACKS
3.a. Remove distributor cap. O \..
b. Check distributor cap for cracks. Check distributor carbon button for
defects or corrosion.
0. Check rotor contacts for defects or corrosion.
CLEAN H€§§§§f
AND DRY (a "Eb
d. Replace or clean rotor or cap if found faulty. If cap and rotor are good, SEE TABLE
check resistance of each high tension lead that showed weak or no spark. If OF RESISTANCE
resistance is greater than values shown, replace leads.
Lead No. Resistance (Ohms)
1 450
2 500
3 550
4 750
e. If leads are good, carefully examine distributor cap sockets for dirt, corro-
sion, or damaged terminals. Check each end of the high tension lead also.
H.T. LEAD
+B TERMINAL
4.a. Connect coil lead to top of coil. Disconnect remote starter switch from
coil. Turn ignition switch on.
b. Get voltmeter. Connect red meter lead to +3 terminal of coil. Connect
black lead to ground.
c. Crank engine. If meter does not read voltage, go to step 5.
Page 243
IGNITION SYSTEM
PINK WIRE
T0 GROUND
If meter reads less than 8 volts, remove 5 screws thru steering column
cover. Remove cover.
Get voltmeter. Find connector C12.
NOTE
Connector 012 is located on right side of steering column. It is
a 4 pin connector.
Connect red meter lead to light blue wire in connector-C12. Connect black BLUE/RED
lead to ground. WIRE
If meter reads voltage, repair pink wire from connector 012 to connector
C14.
If meter does not read voltage, check light blue/red wire to ignition switch.
If wire is good, replace ignition switch.
RED LEAD
V
TO GROUND
Page 244
IGNITION SYSTEM
Check face of points for condition. If burned and pitted, replace points. METAL
If material has transferred from one point to the other, condenser is defec‘ TRANSFER
tive and must be replaced.
BURNED
Make sure condenser lead is not worn or broken. Make sure connection is
clean and tight at terminal.
Check black wire from coil to distributor for damage. Replace wire, if
necessary.
If wire is good, check points as directed in steps k. thru 9. Then set the
timing.
Crank engine until rubbing block is at peak of cam lobe. 517—- c_:_AM LOBE
Loosen breaker plate Iockscrew. -
Insert screwdriver in adjust slot. Adjust points so gap is 0.015 to 0.017 in.
{0.37 to 0.43mm) when checked with feeler gage.
Tighten breaker plate screw. Gap must not change when gage is removed. FEELEIIRMGAGE
GAP 0015 To
0.017 (0;? T0 0.43MM)
Page 245
IGNITION SYSTEM
q. Measure tension of breaker moveable arm. If less than 16.6 ounces. replace
breaker points. MOVABLE
BREAKER ARM
16.6 oumces a
MINIMUM somel
WORN
TOO HOT
REPLACE IMPROPER TYPE
OILY
CLEAN AND
7.3. Remove spark plugs. Check condition. REPLACE CHECK ENG'NE
b. Clean or replace plugs, if necessary.
SHORTING AT CRACKED
ELECTRODE INSULATOR
IGNITION SYSTEM
Page 247
IGNITION SYSTEM
CHECK PLUGS
FOR MISFIRE
IF OK IF NOT OK
1.a. Short or remove one spark plug lead at a time to locate misfiring cylinder.
b. If misfiring cylinder is located, turn ignition switch off and go to step c. If
misfiring cylinder is not located, 90 to step 2.
Page 248
IGNITION SYSTEM
METAL TRANSFER
[B !| BURNED
2.a. If misfiring can not be located, remove distributor cap. Check points for
burning, pitting or improper gap.
b. If point condition and gap are good, check spark plug leads, distributor
cap, and rotor for defects. Replace any defective part.
c. If leads, cap, and rotor are good, check for side play in distributor shaft.
Remove distributor for overhaul or replacement if excessive play is de-
tected.
Page 249
IGNITION SYSTEM
d. If distributor is not defective, check coil for proper secondary resistance. H.T. SOCKET
RED LEAD
Make sure ignition switch is off.
e. Disconnect high tension lead from top of coil. Disconnect light blue/red
wire from +B terminal of coil.
f. Connect red meter lead to top of coil. Connect black lead to +3 terminal ,
of coil. Resistance should be as follows: 3 BLACK LEAD
Coil Resistance (Ohms) +3 TERMWAL .
Marelli 5,670 to 6,930
Martinetti 6,500 to 8,000
g. If coil resistance is not within range specified, replace it. If test is good,
replace condenser.
h. Restart engine and check idle speed. If missing is still apparent, go to
FUEL SYSTEM OR COMPRESSION CHECK.
CONDENSER
Page 250
IGNITION SYSTEM
CHECK
DISTRIBUTOR
CENTRIFUGAL
ADVANCE
IF OK IF NOT OK
Page 251
IGNITION SYSTEM
LOCK NUT
DISTRIBUTOR COUPLING
NOTE 1
Rotor should be about in No. I firing position. Make sure No.
1 piston is on the firing stroke. . DISTRIBUTOR/CAP
e. Rotate distributor by hand until test light comes on. This corresponds to
points opening. Repeat several times until the exact point at which points
just start to open is sure.
I. Tighten distributor lock nut.
Be careful not to move distributor while tightening lock nut on coupling of
crankcase. If point gap was set properly, ignition should be timed at this _ .
point. *—
h. Reinstall plug and lead.
i. Reinstall distributor cap.
TO POWER
SOURCE BLACK LEAD
TO GROUND
e. Apply chalk or other whitener to marks on drive pulley and timing gear U j ' \ l 1 (ml /
cove“ TIMING MARKS
IGNITION SYSTEM
E LOCK NUT
DISTRIBUTOR COUPLING
9. Start engine. Allow engine to idle at 850 RPM. Aim timing light beam at W I \ L I (GH/
drive pulley. ‘ TIMING MARKS
h. lf ignition is properly timed, marks on pulley and cover shall appear in
line.
_ \
$59)?
MARKS ALIGNED
i. If marks are not in line, turn distributor body until alignment is good.
j. Tighten nut on clamp for distributor on crankcase. Recheck timing after \
tightening.
k. If engine still lacks pDWer or misses at high speed, check CARBURETION
AND FUEL SUPPLY or go to ENGINE MISSES AT IDLE. LOCK NUT
omtnmutoe coupuNG
ENGINE STALLS
1.a. Check battery terminals for Iooseness or corrosion. Clean to bright condi.
tion and tighten.
BATTERY. TERMINALS
(CLEAN AND BRIGHTI
Page 2531’254
IGNITION SYSTEM
b. Check connections of all high tension leads for good connections. Remove
corrosion, dirt, or moisture. Replace if defective.
CONNECTIONS
DISTRIBUTOR
H.T. LEAD
" COIL
TERMINALS
c. Check primary wire to ignition switch. Wire to coil must not be bare at any TO IGNITION SWITCH
point.
d. If condition still occurs, check CARBURETION or COMPRESSION. If
these are good, repeat procedures under ENGINE WILL NOT START. LT. BLU El
BLACK WIRE
@t
IGNITION SYSTEM
HIGH TENSION
LEADS
DISTRIBUTOR
CONDENSER
[:3 : , A H A COIL
II]
:1
—BATTERY
:1 SPARK
— PLUGS
[:1
CI4 JEI
13:}
BROWN
IGNITION
SWITCH
I:
.|.|.._|F
I.. I
II...II
Ifilml
all—"Ii
l
I
I-II: —I‘-"-
Downloaded from www.Manualslib.com manuals search engine
ELECTRICAL SYSTEM TROUBLESHOOTING
Page 257
THERMOSTATIC
SWITCH COOLING FAN
COOLING FAN
RELAY
II I
II I | :
I; : BATTERY
BOX $00003 U
FU_.SE
CE??? ___—::I ‘
6:13? I
CARBURETOR CARBURETOR
THERMOSTATIC “H"
SWITCH
CARBURETOR __
FAN RELAY
Page 258
IF NOT OK REPLACE
CHECK FUSE FUSE
O
IF
IF OK
FAN DOES
NOT RUN
TO FAN RELAY
IF OK
CHECK RELAY
000
'F NOT 0" _|.._
REPLACE RELAY
IF OK
IF OK
REPLACE
FAN
Page 259
Get voltmeter. Connect red meter lead to terminal 86 (light blue/black FAN RELAY BLACK
wirel of cooling fan relay. Connect black lead to ground. LEAD
NOTE
Cooling fan relay is mounted in compartment for left head-
TERMINAL 86
light motor. It is the forward relay.
\/
lf meter reads voltage, go to step 2. If meter does not read voltage, repair
light blue/black wire from relay to connector C7.
RED LEAD
2.a. Connect red meter lead to terminal 30/51 (violet wire) of relay. Connect COOLING FAN RELAY
black lead to ground.
If meter reads voltage, go to step c. If meter does not read voltage, repair _
a?
violet wire from relay to fuse box. ‘ BLACK LEAD
VIOLET WIRE
T-ERMINAL
3or51 \
’ ll
4] T0 onoume
RED LEAD
Connect red meter lead to terminal 87 (light blue wire) of relay. Connect BLACK LEAD
black lead to ground.
If meter reads voltage, go to step h. If meter does not read voltage, get
ohmmeter.
FAN RELAY
Page 260
8. Connect red meter lead to terminal 85 (white/black wire) of relay. Con- -LACK LEAD
nect black lead to ground.
f. If meter reads more than 5 ohms. go to step 9. If meter reads 5 ohms or
less replace relay. FAN RELAY
9. If meter reads more than 5 ohms, check white/black wire from relay to R _.-____:_-.——--'-""""'-F-
thermostatic switch. Check black wire from switch to ground. Repair wire.
h. Find connector C21. Connect red meter lead to light blue wire. Connect CONN ECTOR C21
black lead to ground.
NOTE
Connector C21 is a 2 pin connector. It is located above the
cooling fan.
i. If meter reads voltage, go to step j. lf meter does not read voltage, repair
light blue wire from connector C21 to relay. LlGHT BLUE RED
WIRE LEAD
TO GROUND
1. Get ohmmeter. Connect red lead to black wire in connector C21. Connect CONNECTOR 021
black lead to ground.
k. If meter reads more than 5 ohms, repair black lead to ground.
I. If meter reads 5 ohms or less, check wires to fan for defects. Repair wires
or replace fan.
BLACK
iii?
WIRE
\
RED LEAD
T0 GROUND
SWITCH
Page 261
d. Get voltmeter. Connect red meter lead to terminal 30/51 (brown wire) of (SEEING FAN RELAY
carburetor cooling fan. Connect black lead to ground.
NOTE we}. ff
-
The relay for the cooling fan is located on support for carbu- ll BLACK LEAD
retor cooling fan. BROWN WIRES
e. If meter reads voltage, go to step 3. If meter does not read voltage, repair I ,
brown wire to fuse box. ETERMINAL‘
RED LEAD
2.a. Connect red meter lead to terminal 86 (brown wire) of relay. Connect
black lead to ground.
b. If meter reads voltage, go to step c. If meter does not read voltage, repair BLACK LEAD
brown wire between terminals 86 and 30/51. FAN RELAY
'--...___ ________.______--"_—-
BROWN WIRE
I f
TERMINAL 86
Page 262
RED WIRE
BLACK LEAD
Get ohmmeter. Connect red lead to terminal 85 (gray/red wire) of relay.
Connect black lead to ground. GROUND
If meter reads more than 5 ohms. go to step 9. If meter reads 5 ohms or
less, replace relay. FAN RELAY
If meter reads more than 5 ohms, check gray/red wire from relay to ““--. ff.-
thermostatic switch. Check white/black wire from switch to ground. Check ll
ground terminal. Repair wire or ground connection. GRAY/RED WIRE
TERMINAL 85‘
3.a. Go to fan motor. Check red wire from fan to relay for defects. If wire is
damaged, repair wire.
Check black wire from fan to ground. If wire is damaged repair wire. GROUND
NOTE
Wire is grounded at relay mount.
Check ground terminal for dirt, corrosion, or looseness. Clean and tighten
ground terminal. Repair ground wire.
If wires and ground terminal are good, replace fan motor.
BLACK WIRE
vgme ll
GRAY/RED
WIRE
Page 2631264
GRAY/REL WIRE
Page 265/266
ENGINE
COOLING
FAN
LIGHT BLUE 3’ T
BLACK THERMOSTATIC
_I_ SWITCH @
WHITE/BLACK Y
BLACK
_|_L
CARBURETOR ‘BLACK
COOLING :|__
FAN
RE
LIGHT
BLUE
-—___C_87 37—0,
WHITE/BLACK, 85 CARBURETOR I
~ ENG'NE COOLING FAN
COOLING RELAY £GREY/RED
LIGHT BLUE / BLACK FAN
————C«-
86 '] RELAY TE BLACK
VIOLET/C 30/5I 30,5] WHIJT-
LIGHT BLUE/BLACK
BR WN
C7
LIGHT BLUE/BLACK
I
T (
FUSE L H FUSE A
fix/
T
:1;
RED
IGNITION
SWITCH
Page 267
TABLE OF CONTENTS
SECTION PAGE
Driver's Seat Circuit Faulty 268
Driver’s Seat Belt Circuit Faulty 269
Passenger's Seat Circuit Faulty 269
Passenger's Seat Belt Circuit Faulty 270
Transmission Switch Circuit Faulty 270
Seat Belt Indicator and Buzzer Circuit Faulty 272
Starter Relay Circuit Faulty 273
By-Pass Switch Circuit Faulty 274
Key Warning Buzzer Will Not Work 276
Key Warning Buzzer Will Not Stop With Door Closed and Key In 277
f— _ _ SEAT BELT
TRANSMISSION
fl__
SWITCHW
BUTTON SWITCH
U__ _ _ __
STARTER
RELAY
I
SEAT
SWITCH
CONTROL FUSE A
{BOX FUSE B
I BUZZER
SEAT BE LT
ALARM INDICATOR
INSTRUMENT PANEL
Page 268
2.a. Disconnect connector under driver's seat. Using jumper wire, connect 2 CONNECTOR UNDER
SEAT
wires in connector together.
b. If meter reads 0 ohms or test light comes on, replace switch in driver's seat.
JUMPER
c. If meter reads infinity (ml or light is still out, connect jumper wire to YELLOWIBLACK WIRE
yellow/black wire in connector and to ground.
d. If meter reads 0 ohms or light comes on, repair black/violet wire from
connector to ground or ground connection. K
e. If meter still reads infinity or light remains out, repair yellow/black wire \\
from connector under seat to connector 09 and to connector C17.
JUMPER
NOTE
Connector 09 is a 6 pin connector. It is located behind center
console. TO GROUND
Page 269
21 mmmmmnmmmUMHrwdNmkmflmflmwwfiOomm CONNECTORUNDER
or light remains on, repair pink/yellow wire to connector C9 and to con- RUG
nector 017.
NOTE
Connector C9 is a 6 pin connector. It is behind center console.
2.a. Disconnect connector under passenger’s seat. Using jumper wire, connect 2 CONNECTOR UNDER
wires from control box in connector together. SEAT
b. If meter reads 0 ohms or test light comes on, replace switch in passenger's
seat
JUMPER
Page 270
c. If meter still does not read 0 ohms or test light is still out, connect jumper WH'TE/BLACK W'RE
wire to white/black wire in connector and to ground.
d. If meter reads 0 ohms or test light comes on, repair black/violet wire from
connector to ground or ground connection.
e. If meter reads infinity or light remains out, repair white/black wire from JUMPER
connector under seat to connector CQ and to connector C17.
NOTE
Connector 09 is a 6 pin connector. It is behind center console.
T0 GROUND
2.a. Disconnect connector behind spare wheel passenger's seat. If meter reads 0 CONNECTOR UNDER
ohms or light remains on with belt pulled out, repair white/red wire to RUG
connector 09 and to connector C17.
NOTE
Connector CS is a 6 pin connector. It is behind center console.
b. If meter reads infinity or test light goes out, replace switch in seat belt.
Page 271
TRANSMISSION SWITCH
l_ —_
If meter reads infinity or test light goes out, connect connector C22.
Disconnect wires from transmission switch.
orsconmem' WIRES ‘f
H
NOTE
Switch is located toward rear of crossrail.
If meter reads infinity or test light goes out, replace switch in transmission.
|f meter does not read infinity or test light remains on, repair wire from
switch to connector C22.
TRANSMISSION SWITCH
l
Page 272
CIRCUIT
BOARD
cl. If indicator works but buzzer does not, open driver’s door with key in- REm
stalled. lf buzzer will not work, go to KEY WARNING BUZZER trouble-
e.
shooting.
If buzzer works with door open, get ohmmeter. Connect red meter lead to
RED'LEAD| fBLACK
EAD
terminal 3OI’51 (black wire) of buzzer relay. Connect black lead to ground.
f. If meter reads 0 ohms, go to step 9. If meter does not read 0 ohms, repair V
To GROUND
l
TERMINAL 30/51 H
BUZZER
g. Disconnect blue/red wire from terminal 85 of relay. Connect red meter
HRELAY
lead to wire. Connect black lead to ground.
h. If meter reads 0 ohms, replace relay. If meter does not read 0 ohms, repair
blue/red wire from relay to connector CB.
TERM‘INAL 85
NOTE.
Connector CS is middle connector at instrument panel. It is an kfiw LEAD
BLUE/neck
8 pin connector.
W'RE' BLACK LEAD
TO GROUND
2.a. Check other indicators in instrument panel. If indicators do not work, BLUE/RED
repair orange wire from buzzer relay to fuse A. WIRE
b. If other indicators work, repair blue/red wire from connector C16 to C6.
NOTE
Connector CS is middle connector at instrument panel. It is an
8 pin connector.
CONNECTOR C6
Page 273
3.a. If only buzzer will not go off, disconnect white/black wires from terminal BUZZER
87 of buzzer relay. if buzzer will not go off, go to KEY WARNING RELAL
""--. #5;—
BUZZER troubleshooting. If buzzer goes off, replace relay.
NOTE TEfiiimNAL 85
Buzzer relay is located forward of fuse box.
II TERMINAL 87
If both buzzer and indicator will not stop disconnect blue/red wire from
terminal 86 of relay. If indicator goes off, replace relay.
WHITEIBLACK WIRE
If indicator did not go off, connect wire to relay. Remove instrument CONN ECTOR C6
paneL
Disconnect connector C6 from instrument panel. If indicator goes out,
replace instrument panel.
NOTE
Connector 06 is the connector in the middle. It is an 8 pin
connector.
If indicator does not go out, repair blue/red wire from connector C16 to
connector C6 and to buzzer relay.
INSTRUMENT PANEL
f
STARTER RELAY CIRCUIT FAULTY STARTER
1.3. Go to starter relay in drop tray area. Get jumper. RELAY
b. Connect jumper to terminal 86 (light blue/white wire) of starter rela,.
Connect other end of jumper to ground.
Try to start car. If car will start, repair light blue/white wire from relay to TER‘MINAL 86
connector C16. JUMPER
LT. BLUE/WHITE
WIRE
TO GROUND II
Get voltmeter. Connect red meter lead to terminal 85 (orange/white wire) ____--"'
STARTER
of starter relay. Connect black lead to ground.
Try to start car. If meter does not read voltage, troubleshoot starter
/ RELAY
circuit. %/
BLACK____
LEAP
T0 GROUND
Page 274
e. Disconnect black/violet wire from by~pass switch. Using jumper, connect BY-PASS SWITCH
wires together.
1‘. If meter reads 0 ohms or test light comes on, replace by-pass switch.
9. If meter reads infinity or test light does not come on, repair black/violet '
ii
wire to ground or ground connection.
JUMPER
2.3. Disconnect light blue/red wire from by-pass switch. If meter reads infinity
BY-PASS SWITCH
or test light goes out, replace by-pass switch.
is. If meter does not read infinity or test light stays on, repair light blue/red
wire from switch to connector 09 and to connector C16.
NOTE
Connector CS is a 6 pin connector. It is behind center console.
Page 275
CHECK SEAT
BELT SYSTEM
IF NOT OK IF NOT OK IF 0K
CHECK DOOR
JAM SWITCH
IF OK
\
IF OK IF NOT OK
CHECK VOLTAGE
AT BUZZER
REPAIR WIRE REPLACE SWITCH
IF OK IF NOT OK
CHECK IGNITION
CHECK GROUND SWITCH IF
TO BUZZER NOT
OK REPLACE SWITCH
IF NOT OK
CHECK VOLTAGE
FROM FUSE
BOX
IF OK
\
REPLACE BUZZER REPAIR WIRE
To RELAY REPAIR WIRE
TO RELAY
REPAIR WIRE
TO FUSE BOX
Page 276
2.a. Operate headlights. lf headlight motors won't work, replace fuse B. RED LEAD
b. Put key in ignition switch. Open door. Get voltmeter.
c. Connect red meter lead to terminal 4 (red/white wire) of buzzer. Connect
black lead to ground.
NOTE
Buzzer is located on left side of driver's footwell.
d. If meter reads voltage, go to step e. If meter does not read voltage, go to
step 9.
TERMINAL4
BLACK LEAD l
TO GROUND
RED LEAD
e. Get ohmmeter. Connect red meter lead to terminal 3 (white/black wire).
/
Connect black lead to ground.
f. If meter reads 5 ohms or less replace buzzer. If meter reads more than 5
ohms, repair white/black wire to buzzer relay. _.———
TERMINAL 3
L— BLACK LEAD
TO GROUND
er. BLACKfl TO
9. Remove 5 screws in steering Column cover. Remove cover. Get ohmmet GROUND
LEAD
h. Disconnect connector C15. Connect meter leads to wires in Connector. RED
Make sure you use connector half from ignition switch.
WIRE
NOTE
Connector C15 is a white 2 pin connector. It is located on
right side of column.
i. If meter does not read 0 ohms, check connector C15 and wires to ignition
switch.
switch for defects. If wires and connector are good, replace ignition
RED LEAD
CONNECTOR C15
Page 2771278
If meter reads 0 ohms, get voltmeter. Connect red lead to red wires in CONNECTOR C15
connector C15. Connect black lead to ground.
If meter reads voltage, repair red/white wire (position 1) from connector RED LEAD
C15 to buzzer.
If meter does not read voltage, repair red wire (position 2) from connector
015 to fuse box.
BLACK LEAD
KEY BUZZER WILL NOT STOP WITH noon CLOSED WHITEIBLACK WIF5_I_.E
.
AND KEY IN
1.a. Open door. Remove jam switch. Make sure wire does not touch metal.
b. If buzzer does not stop, repair white/black wire from switch to relay and
to buzzer. GROUND
C. If buzzer stops; check jam switch for dirt or corrosion. If switch looks
good, install it.
d. Close door and check buzzer. If buzzer is on, replace jam switch.
\5 JAM WITCH
Page 279/280
______._. BUZZER
A B I- RELAY
A A HAZZARD
FUSES U U i {BUZZER i FLASHER
' IGNITION 87 35 30/51 “K
SWITCH WHITE/BLACK I BLACK BLACK—~——_-L
5 S . BLUE/RED ___
<2: 0: _ LI LU Lu ORANGE SEAT BELT
0: '3 '3 '3
E
<36 INDICATOR _
O E E C10 0
‘32
€18 E SEAT BELT INTERLOCK
g CONTROL BOX
CH CH C7
L_—._’JL J_—’__l LJULJL JLJ UUL JUL)
WHITE/BLACK €16 . 017 I
DOOR DRIVER , s GRAY/
SWITCH SEAT BELT BROWN/WHITE __:_ YELLOW
SWITCH RED I \
_ RAY/BLACK 3 GRAY/~— K
PASSENGER’S LIGHT BLJE BLACK C8
_ _. DRIVER'S SEAT /WH|TEI
‘ SEAT
SWITCH SWITCH WHITE/RED "‘ I WHITE/RED-
__ "J I BLACK/VIOLET
PINK/YELLOW J
PASSENGER'S
-——- SEAT BELT
T SWITCH
WHITE/BLACK :3 WHITE/BLACK
TRANSMISSION T
SW'TCH C22 09 —-L|GHT BLUE/BLACK
GREEN/WHITE 3 GREENNVHITE :3 €13 GREEN/WHITE
“ YELL O w~
I——-————BLACK/VIOLET fl I—_GRAWYELLOW 'J /ORANGE/WH|TE GRAY/
—J _I_ LOW OIL TO STARTER <—-—RED—8fl 85 86 30 I RED—> TO BATTERY
PRESSURE
SWITCH _;g;— I
BY—PASS
SWITCH
-—J
______,a- I
STARTER RELA
BLACK/VIOLET
I
I
I
I
Page 281
INTERIOR LIGHTS
TABLE OF CONTENTS
SECTION PAGE
COURTESY LIGHT
\: HAND BRAKE
SWITCH
COURTESY LIGHT
I
INSTRUMENT PANEL
SIINITCH LIGHITS SWITCH
9 s34-EINSTRUMENT
‘i’
I
‘ C._.__ firm
PANEL
I .—..
HAZARD WARNING/
l5;
INDICATOR ,
HAND BRAKE ON
INDICATOR
Page 282
INTERIOR LIGHTS
CHECK DOORS
IF NEITHER DOOR
IFNOT OK WORKS LIGHT, REPAIR
WIRE FROMSWITCH
TO CONNECTOR
IF OK
IF LIGHT WORKS
WITH EITHER DOOR
CHECK JAM
SWITCH
IF OK
IF NOT
REPAIR WIRE
IF OK
REPLACE SWITCH IF NOT OK
REPAIR WIRE
REPLACE SWITCH
Page 283
INTERIOR LIGHTS
If light works with one door, close door that works. Open other door.
“PT“PD-
Get ohmmeter. Connect red meter lead to white/black wire at light. Con- RED LEAD
nect black lead to ground. WHITEIBLACK WIRE
If meter reads 5 ohms or less, replace light.
3"?
If meter reads more than 5 ohms, repair white/black wire from light to
interior light switch.
BLACK LEAD
TO GROUND \
Page 284
INTERIOR LIGHTS
BRAKE INDICATOR LIGHT WILL NOT WORK
WITH LEVER PULLED UP
La. Depress brake pedal. lf stop lights do not work, replace fuse A.
b. Turn on directional indicators. lf lights work, go to step 2. If lights do not
work, check windshield wipers.
C. If wipers do not work, troubleshoot wipers. lf wipers work, check circuit
board for defects. If board is good, repair orange wire from circuit board
to connector C18 for wiper motor.
ORANGE/WHITE
2.a. Get ohmmeter. Find connector C14.
WIRE
NOTE
Connector C14 is located behind center console. It is a red 8
pin connector.
Connect red meter lead to orange/white wire in connector. Connect black
lead to ground.
BLACK RED
If meter reads 5 ohms or less, 90 to step e. LEAD
If meter reads more than 5‘ohms, check orange/white wire from connector
C14 to switch at hand brake. Check ground at switch.
NOTE
The hand brake switch can be checked by removing cover over TO GROUND
hand brake.
BU LB
CIRCUIT
BOARD
Get ohmmeter. Connect red meter lead to orange/white wires in connector CONNECTOR CB
C8. Connect black lead to ground. ORANGE/WHITE
NOTE
Connector CS is a 6 pin connector.
If meter reads more than 5 ohms, repair orange/white wire from panel to
connector C14. If meter reads 5 ohms or less, check circuit board and
connector CB for defects.
GROUND
Page 285
INTERIOR LIGHTS
INSTRUMENTS LIGHTS WILL NOT WORK
BULB
‘l.a. If only one instrument light is out, remove instrument panel. Replace bulb.
HOLDER
b. Turn on outer lighting switch. If parking lights do not work, replace fuse
J
G. If headlights do not work, troubleshoot LOW BEAMS.
c. Check parking light indicator. If indicator is lit go to step 2.
:11
d. If indicator is not lit, operate windshield washer. If washer does not work,
:1 BULB
go to step f.
CIRCUIT
BOARD
BLACK WIRE
2.a. If lights work on high setting but not low, go to step 3. BROWN WIRE
b. If lights do not work at all, pull panel light switch out.
c. Get voltmeter. Connect red meter lead to terminal I (brown wire) of
switch. Connect black lead to ground.
d. If meter does not read voltage, repair brown wire from switch to connector
CS and to connector C10.
NOTE
Connector C5 is an 8 pin connector. Connector 010 is a 4 pin
connector. They are under the steering column cover.
e. If meter reads voltage, connect red meter lead to terminal U (orange/white _ BLACK LEAO
wirel. Connect black lead to ground. iORANGE/nTE
f. If meter reads voltage, repair orange/white wire to resistor holder or m
whitefred wire from holder to connector CB. TO
NOTE GROUND
Resistor holder is accessible by removing ash tray and holder.
9. If meter does not read voltage, replace switch.
Page 286
INTERIOR LIGHTS
3.6. Remove ash tray and holder.
b. Remove resistors from holders. \ RESISTOR
c. Using ohmmeter, check for circuit thru resistors. If either resistor shows ~(ff?
open (infinity), replace resistor.
d. If resistors are good, check holders and wire from switch to holder and
from holder to other holder.
HOLDER
d. Check cigar lighter light. If light is on, go to step 2. 3‘; 1"(ff-1";(."r. '
[0‘:0”a"); ‘5‘," '1
1' 15:15..
e. If light is off check fuse G. If fuse is good, repair yellow/black wire from
rh eostat to fuse box.
FUSE G
2.a. Get voltmeter. Pull rheostat out. connect red meter lead to terminal L
lyellowlred wire). Connect black lead to ground.
b. Rotate rehostat. If meter does not read voltage, replace rheostat.
c. If meter reads voltage, repair yellow/red wires to bulb holders.
RED/YELLOW
WIRE
BLACK LEAD
TO GROUND
Fhm fl”
INTERIOR LIGHTS
VEHICLE WARNING INDICATOR LIGHT BULB
WILL NOT WORK HOLDER
‘l.a. If warning lights are working, remove 5 screWs thru instrument panel.
Disconnect 3 connectors and speedometer cable.
Turn light socket to left. Replace bulb. Install socket. Connect connectors.
c. Turn warning light switch on. If light flashes, install instrument panel. BU LB
CIRCUIT
BOARD
CONNECTOR
If light still does not flash, get voltmeter.
e. Connect red meter lead to yellow/red wire in connector C6. Connect black
lead to ground.
NOTE
Connector CS is an 8 pin connector.
f. If meter does not read voltage, go to step 2.
If meter reads voltage, check connector and circuit board for defects.
Repair or replace board or connector as necessary.
T0 YELLOWIRED
GROUND W'RE
BL
T0 GROUND
Page 288
INTERIOR LIGHTS
DIRECTIONAL INDICATOR LIGHT WILL BULB
NOT WOR K HOLDER
La. If directional lights are working, remove 5 screws thru instrument panel.
Disconnect 3 connectors and speedometer cable.
b. Turn bulbholder to left. Replace bulb. Install bulb.
c. Connect connectors. Turn directional indicators on. lf indicator is flashing BU LB
install instrument panel.
CIRCUIT
BOARD
CONNECTOR C6
d. If light still does not work, get voltmeter.
e. Connect red meter lead to violet/white wire at connector C6. Connect VIOLETIWHITE
black lead to ground.
NOTE
Connector CS is an 8 pin connector.
f. If meter does not read voltage, go to step h.
g. If meter reads voltage, check connector, circuit board, and bulb holder for
defects. Repair or replace parts as necessary.
BLACK LEAD
TO GROUND
TWHITE w lRE
VlOLE/ LEAD
RED
h. Find directional flasher.
NOTE
Flasher is mounted in a clip above the fuse box.
i. Connect red meter lead to terminal P (violet/white wire) of flasher. Con
nect black lead to ground.
i. If meter reads voltage, repair violet/white wire from flasher to connrctor
CB. FLASHER
k. If meter does not read voltage, replace flasher.
T0
GROUND
I
o 0 HI”
x I,
o ’
Lu :4
o O <
.1
Z <
3% Eg m'2
CO
o ‘ .
9 I
g 'I
.J
Lu T I
BUZZER
RELAY > I
I
ORANGE I
I
I
BROWN I
I
cm \ FUSE II
I LIGHT
m I BLUE/WHITE RESISTORS
<
(D
Z
II
I D
Lu
I /
0
I
a
x
0
g
I-
E
3 C18
Ein
B 0 C5 a T
I:g E?<2: E“E g
BRIDWN g I?
:I:
8 g 012 I
E I
E
\I
¥ Z i g
LU 0
LLJ
OC) c7
I .
O O C8 Z
2 < <(
2 c3)
_I c: m S g
W E O O O O
m m
I—
E
E
E$ oO o0 LA“ I? qLI AU
'
AU
E 2 INT Q. INSTRUMENT
Q g <2: 0 CLUSTER
3 g m LIGHT
m m o SWITCH
o———-J
IGNITION
CREE C9 m SWITCH
JAM
E SWITCH
E I
E BLACK—G@——l BLACK
E YELLOW/E LACK
'2'
O
PARKING m
:
;
BRAKE n I
SWITCH YELLOW/BLACK—
__—_.__C A I ’ 7% JAM E
PANEL — + I U
—: LIGHT I SW'TCH g
023 RHEOSTAT I YELLOW/RED )__J
Page 291
EXTERIOR LIGHTS
TABLE OF CONTENTS
SECTION
PAGE
Left or Right High Beam Will Not Work
292
Headlight Motors Will Not Work
295
Left or Right Low Beams Will Not Work
298
Parking Lights, Side Marker Lights, and License Plate Lights 303
Will Not Work/Parking Light Indicator Out
Brake Lights Will Not Work 307
Back-Up Lights Will Not Work 308
Vehicle Warning Lights Will Not Work 309
Directional Lights Will Not Work 310
LICENSE PLATE
LIGHT
BACK UP
LIGHT PARKING LIGHT
DIRECTIONAL
INDICATOR
i SIDE—MARKER TG-IQ
I I
DIRECTIONAL SWITCH
DIRECTIONAL INDICATOR
Page 292
EXTERIOR LIGHTS
TURN ON LIGHTS
CHECK BOTH
HIGH BEAMS
AND INDICATOR
CHECK PARKING
LIGHT INDICATOR
IF NOT OK
IF NOT OK
TROUBLESHOOT
LOW BEAMS
TROUBLESHOOT
PARKING LIGHTS
CHECK HIGH/
LOW BEAM
SWITCH
IF NOT OK
CHECK BULB
REPLACE BULB
REPLACE LAMP IF BAD
OD
IF GO REPLACE SWITCH
REPAIR WIRING
TO FUSE BOX
REPAIR
WIRING
Page 293
EXTERIOR LIGHTS
I” §
e“
IGNITION
SWITCH
2.a. Remove 5 screws and remove cover from steering column. CONNECTOR C5
b. Find connector C5. Get voltmeter. GREEN wm E
NOTE RED
Connector C5 is an 8 pin connector. It is located on left side LEAD
of steering column.
c. Connect red meter lead to green wire in connector. Connect black lead to
ground.
d. If meter does not read voltage, check green wire to switch. If wire is good,
replace switch. Ԥ,
e. If meter reads voltage, check connector for defects. If connector is good, BLACK LEAD
repair green Wll'e to fuse box.
TO QROUND
3.a. if one high beam is out, disconnect plug from lamp. Connect plug to good
lamp. lf high beam does not work go to step d.
CAUTION
Be very careful working around the headlights. Do not turn
the top of the motor to raise or lower the headlight.
b. If high beam lights, remove 3 screws thru trim and remove trim. Loosen 3
screws thru frame. Turn frame to left and remove frame and lamp.
c. Connect plug to lamp. Position new lamp in frame. Position frame on
screws. Turn frame to right. Tighten screws thru frame. Install trim.
Page 294
EXTERIOR LIGHTS
GREEN/BLACK WIRE
d. Get voltmeter. Disconnect plug from lamp.
e. Connect red meter lead to green/black wire (left beam) or green wire (right l[LEFT BEAM)
GREEN WIRE
beam) in plug. Connect black lead to ground.
(RIGHT BEAM)
f. If meter reads voltage check plug for dirt or defects. BLACK
If meter does not read voltage, repair wire from plug to fuse box.
,
9 w“ LEAD
"/‘—""'- To
A regy‘1frtfifi3uno
M12."
"RED‘LEAD
4.3 Check parking light indicator. If indicator is on, go to step b. If indicator is BULB
out, troubleshoot PARKING LIGHTS. HOLDER
b. Remove 5 screws thru instrument panel. Pull panel out. Disconnect 3
connectors and speedometer cable.
c. Turn socket for indicator to left. Remove bulb. Install new bulb. Connect
connectors to panel.
BULB
d. If indicator is lit, install instrument panel.
mncun
BOARD
BLACK LEAD
TO GROUND
Page 295
EXTERIOR LIGHTS
If only one motor will not raise light, go to step 2. If both motors will
not raise lights, get voltmeter. Find connector C19.
//
NOTE
Connector C19 is a 4 pin connector. it is in left headlight
motor compartment. BLACK LEAD
Connect red meter lead to gray/yellow wires in connector. Connect black
lead to ground.
If meter reads voltage, repair light blue wire from fuse box to terminal 87 GRAY/YEL
of left motor relay. WIRE TO GROUND
If meter does not read voltage, connect red meter lead to gray/yellow wire BLACK LEAD
in back of fuse N. Connect black lead to ground.
If meter reads voltage, repair gray/yellow wire from fuse box to connector GRAYfYEL
C19. WIRE
T0 GROUND
“WE-'31!
If meter does not read voltage, check fuse box and brown wire from fuse G
airmail
to fuse N for defects.
—__RED LEAD
lf meter reads voltage, go to step d. If meter does not read voltage, repair ll
light blue wire from relay to connector C19.
TERIMINAL 87
GROUND
RED LEAD
Page 296
EXTERIOR LIGHTS
BLACK LEAD
Set outer lighting switch off. Disconnect connector C19 (left motor) or
020 (right motor). GRAY/YEL ‘
NOTE
:ow__IR_E—-—-F"'*-———=- '=
Connectors are 4 pin connectors. They are in compartment for “ TD
motors. GROUND
Connect jumper wire between gray/yellow and gray/black wire in cone
nector.
Connect red meter lead to green wire in Connector. Connect black lead to
ground.
If meter did not read voltage, leave jumper on wires. Go to step 4.
If meter reads voltage, check connector and wires from motor for defects.
Check black wire under motor mounting bolt for defects. If wires and
connector are good, replace motor.
If meter reads voltage, go to step e. If meter does not read voltage, repair GREEN/WHITE WIRE
‘H..______..---"'
green/white wire from connector 020 to C19.
TO
GROUND
BLACK LEAD
Disconnect connector C19 (left motor) or C20 (right motor). Connect
jumper wire between green/white and gray/black wires in connector. GREEN/WHITE
NOTE vwne
Connectors are 4 pin connectors. They are in compartments TO
for motors. GROUND
Connect red meter lead to green wire in connector. Connect black lead to
ground.
If meter does not read voltage, leave jumper on wires. Go to step 4.
If meter reads voltage, check connector and wires from motor for defects.
Check black wire under motor mounting bolt for defects. If connector and
wires are good. replace motor.
Page 297
EXTERIOR LIGHTS
4.a. Connect red meter lead to terminal 30/51 (green wire) of motor relay. QELAY
Connect black lead to ground.
b. If meter reads voltage, repair green wire from relay to connector. TEST LIG T
RED LEAD LEAD
/'TO GROUND
TERMINAL 30/51
BLACK LEAD
c. If meter does not read voltage, connect red meter lead to terminal 85
(gray/black wire) of relay. Connect black lead to ground.
d. If meter does not read voltage, repair gray/black wire from relay to con-
Rector. MOTOR RELAY
/ . WIRE
RED LEAD
e. If meter reads voltage, get ohmmeter. Set outer lighting switch off. BLAC K LEAD
f. Connect red meter lead to terminal 86 (black wire) of relay. Connect black' GROUND
lead to ground.
9. If meter reads 5 ohms or less, replace relay.
MOTOR R ELAY
h. If meter reads more than 5 ohms, check black wire from terminal 86 to
terminal 87b and to ground.
BLACK WIRE
TERMINAL 85‘
RED LEAD
Page 298
EXTERIOR LIGHTS
TURN ON LIGHTS
CHECK BOTH
LOW BEAMS
CHECK PARKING
LIGHT INDICATO'
IF NOT OK IF {I IF NOT OK IF OK
IF NOT OK IF 0K IF OK IF NOT OK
IF OK
Page 299
EXTERIOR LIGHTS
b.
beams.
If left low beam is out, check fuse E. If blown, replace fuse. If fuse is good, hes/M: :s’: MI
I. I“ a,“I: ”’9\
u" ‘9‘."3“"‘:)"3" Au“
go to step 2.
If right low beam is out, check fuse F. If blown, replace fuse. If fuse is
good, go to step 2. FUSE E FUSE F
if both low beams are out, turn on high beams. If high beams work, go to
step 3. If high beams do not Work, 90 to step 4.
Check parking light indicator, if indicator is out go to step 5.
CAUTION
Be very careful working around the headlights. Do not turn
the top of the motor to raise or lower the headlight.
2.a. Disconnect plug from headlight lamp. Connect plug to new lamp. If lamp
will not light, 90 to step d.
If lamp lights, disconnect plug. Remove 3 screws thru trim and remove
trim. Loosen 3 screws thru frame and turn frame to left. Remove frame
and lamp.
install new lamp. Place frame on screws and turn frame to right. Place trim
on and install 3 screWs.
Get voltmeter. Disconnect plug from lamp. Connect red meter lead to gray GRAY/BLACK WIRE
wire (right beam) or gray/black wire (left beam). Connect black lead to (LEFT BEAM)
ground. GRAY WIRE
If meter does not read voltage, repair wire to fuse box. (RIGHT BEAM)
If meter reads voltage, check plug for dirt or defects.
Remove 5 screws thru steering column cover. Remove cover. Get voltme-
ter.
Connect red meter lead to gray/red wire in connector C5. Connect black
lead to ground.
NOTE
Connector 05 is an 8 pin connector.
If meter reads voltage, check connector for defects. lf connector is good.
GRAY/'RED -
repair red/gray wire to fuse box.
If meter does not read voltage, check wire to switch. lf wire is good,
WIRE >
replace switch. BLACK LEAD
TO GROUND
Page 300
EXTERIOR LIGHTS
4.3. Remove 5 screws thru steering column cover. Remove cover. Get volt~ CONNECTOR C5
meter. GREEN WIRE
Connect red meter lead to green wire in connector C5. Connect black lead RED
b.
to ground. LEAD
NOTE '
Connector C5 is an 8 pin connector.
c. If meter does not read voltage, go to step e.
d. If meter reads voltage, check wire from connector to switch. If wire is
good, replace switch. fl §v
BLACK LEAD
TO GROUND
e. Pull outer lighting switch out. Connect red meter lead to green wire (termi-
‘h.C onnect bac
na |I ) o f swrtc Ikldtea 0 groun d. BLACK LEAD
f. If meter does not read voltage, replace switch.
9. If meter reads voltage, repair green wire from switch to connector C5. TO GROUND I) RED
5.a. Pull outer lighting switch out. Make sure wires do not touch panel. BLACK R ED; LEAD
b. Get voltmeter. Connect red meter lead to terminal H (black wire) of
switch. Connect black lead to ground.
c. If meter does not read voltage, go to step e.
d. If meter reads voltage, replace switch.
TO GROUND
R ED LEAD
e. Remove 5 screws thru steering column cover. Remove cover.
f. Connect red meter lead to black wire in connector C12. Connect black
lead to ground.
NOTE
Connector C12 is a 4 pin connector.
9. If meter reads voltage, check wire and connector for ignition switch. If
good, replace ignition switch.
h. If meter reads voltage, repair black wire from connector C5 to outer light-
ing switch.
TO GROUND
Page 301/302
EXTERIOR LIGHTS
I \T I 30/5I
I V I
I I am: 30/5 87/b I I
l l as w \ 5 | 2 |
2 L ,
I I s G5
m
Do
In
3
UJ
_I
m
3
_l
—-_——_'__"' 4.555! on J— _-‘__‘_'_‘"‘_
T o> o "‘ T
_ < S 393 -
_l I _.
5 C) no .1 BLACK 5
5 S
e E
>4 Z Z 2 )1 ¥ 2 Z x Z
EjEE 5::
>. IJJ Lu ,>- >- o In Lu 0 >- I.“
EE:
mm c)
BEE:
Q) (Dean) 0000 new
g g fl GRAY/YELLOW E z E
5 5 GRAY L—GRAY/BLACK— 5 I: g
m 3 [BLACK GREEN/WHITE GREEN/WHITE ‘9 c: 0
E GREEN
I”
n:
O
O<I l GREEN/BLACK
HIGH BEAM
INDICATOR
06
O O a
FUSES 8 8""
O O K?
o o
E _ E M _
aIn E
;
gn:
< P“
E
0 WHITE
LIGHT BLUE
BROWN
GREEN GREEN
-—B ROWN BLACK ————————- BLACK
IGNITION
SWITCH
HIGH/LOW
BEAM SWITCH
Page 303
EXTERIOR LIGHTS
PARKING LIGHTS, SIDE MARKER LIGHTS, AND LICENSE f
PLATE LIGHTS WILL NOT WORK/PARKING LIGHT —-*—"“ .
INDICATOR OUT ..._...._ '
1.a. Turn outer lighting switch on. Check parking lights, side marker lights,
and
parking light indicator. SWITCH
. If only one bulb is out, go to step 2.
c. If all lights are out, check headlights. lf headlights are out,
troubleshoot
LOW BEAMS. lf headlights are on, go to step 3.
d. If any combination or all of the left rear side marker and parking
lights,
right license plate light and right front parking light and side marker light
are out, go to step 4.
e. If any combination or all of the right side marker and parking lights, left
PARKING LIGHT
license plate light and left front parking and side marker lights are out go
INDICATOR
to step 5.
f. If only parking light indicator light is out, go to step 6.
The rear side marker lights are reached from inside the trunk. SOCKET
Rosa—Sm
Pull bulb holder out of fender. Pull bulb out of holder. Replace bulb.
If new bulb will not Work, go to step In.
The front side marker lights are reached from inside the headlight motor
compartment.
Pull bulb holder out of fender. PUII bulb out of holder. Replace bulb. 5'“. BULB
f”
”BULB HOLDER
9. Rear parking and stop bulbs can be reached by removing 4 screws and the STOP AND PARKEG LIGHTS
lens.
h. Replace the parking light bulb. If bulb still does not work, go to step In.
9' I“? If;
It‘ll.
EXTERIOR LIGHTS
i. The license plate light bulbs can be reached by removing the screw and
pulling the lens out.
j. Replace the bulb. If the bulb will not work, go to step m.
k. The front parking lights can be reached by removing 2 screws and the lens.
I. Replace the bulb. If the bulb still does not work, go to step m.
m. If bulb did not work, check socket for dirt, corrosion, or defect. Check SOCKET
wires to next light for break. Repair or replace any damaged part.
BULB
3.a. Pull outer lighting switch out of dash panel. Make sure wires do not touch RED LEAD
switch housing.
b. Get voltmeter. Connect red meter lead to terminal L (brown wire) of
switch. Connect black lead to ground.
c. If meter reads voltage, repair brown wire from switch to fuse box.
d. If meter does not read voltage, replace outer lighting switch.
BROWN WIRE a
T0 GROUND
Page 305
EXTERIOR LIGHTS
If all left rear side marker and parking lights, right license plate light and
right front parking and side marker lights are out. check fuse H. Replace
fuse if blown.
If fuse is good, repair yellow/red wire from fuse box to connector C14.
NOTE
Connector C14 is a red 8 pin connector. It is behind center
console.
If left rear side marker and parking lights and right license plate light are YELLOW/RED WIRE
out, find connector C14.
NOTE
Connector 014 is a red 8 pin connector. It is behind center
console.
Check connector for tightness. If connector is good, repair yellow/red wire
from connector C14 to side marker.
If left rear parking light and right license plate light are out, repair yellow/
red wire from side marker to parking light.
CONNECTOR C14
If right front parking and side marker lights are out, check connector C4 BLACK LEAD
for tightness.
NOTE
Connector C4 is a 3 pin connector. It is in the left headlight
motor compartment. TO GROUND
If connector is good, get ohmmeter. Connect red meter lead to black wires
in connector. Connect black lead to ground.
If meter reads 3 ohms or less, repair yellow/red wire from connector C4 to RED LEAP
connector CM.
lf meter reads more than 3 ohms, repair black wire from connector C4 to
connector for headlight.
_ , . . . -
If all. the-right reer Slde marker and parking lights, left license plate light, ”'T—Tf— — —.. — '— i,
l‘fiz‘fi'fi'fi‘fiF(17.31 In
parking light indicator, and left front Side marker and parking lights are ‘E‘Ill fifth/h .‘ifu'fiIi:-"}?h‘l§
but, check fuse G. Replace fuse G if blown. K‘I‘x‘ik‘:‘.‘x‘"."fi‘.'\'r‘:‘\"r'FR‘BK'I‘L'?‘
EXTERIOR LIGHTS
If right rear side marker and parking lights and left license plate light are YELLOW WIRE
out, check connector (:14 for tightness. If connector is good, repair yellow
wire from fuse box to connector 014.
NOTE
Connector C14 is a red 8 pin connector. it is behind center
console.
If right rear parking light and side marker light are out, repair yellow/black
wire from right license plate light to parking light.
If parking light indicator and left front parking and side marker lights are
out, repair yellowlblack wire from fuse box to Connector C6.
NOTE RED LEAD
Connector C6 is an 8 pin connector for the instrument panel.
If indicator is lit and other lights are out, check connector C2 for tightness.
NOTE
Connector CZ is a 3 pin connector. It is in left headlight motor BLACK
compartment. LEAD
If connector is good, get ohmmeter. Connect red meter lead to black wires
in connector. Connect black lead to ground. BLACK WIRE
If meter reads 3 ohms or less repair yellow/black wire from connector CZ
to connector C6. If meter reads more than 3 ohms, repair black wire from T0 GROUND
connector C2 to headlight connector.
If indicator light is out, remove 5 screws thru instrument panel. Pull panel BULB
out. HOLDER
Disconnect 3 connectors and speedometer cable from panel.
Turn socket to left and remove bulb holder from panel. Pull bulb out.
Replace bulb. Install bulb holder.
Connect connectors to panel. Check indicator. If indicator is lit, install BULB
panel. If light is not lit, check circuit board and connector for defects.
CIRCUIT
BOARD
Page 307
EXTERIOR LIGHTS
2.a. Remove 4 screws and lens from parking light. Remove bulb. Install new _'L BRAKFT LIGHT
bulb.
b. If light works, install 4 screws and lens.
c. If light does not work, remove bulb. Check that brass terminal inside
socket and wall of socket are bright and shiny. If not clean them.
d. If light still does not work, check red wire connection to socket. If right
brake light does not work, check red wire from left brake light.
Page 303
EXTERIOR LIGHTS
if both lights are out, check fuse A. If fuse is blown, replace it.
If fuse is good, get voltmeter. Connect red meter lead to light blue/white RED LEAD
wire in connector C14. Connect black lead to ground.
NOTE
égA BLACK LEAD
—- {/0
Connector C14 is a red 8 pin connector. It is behind center
console.
*. /\/ T0 GROUND
If meter reads voltage, 90 to step d. If meter does not read voltage, repair
light blue/white wire from connector C14 to fuse box.
\ k‘.\’~"~:{\
LIGHT BLUE/
WHITE WIRE
Locate connector for back-up light switch. Get jumper. BACK UP LIGHT
NOTE SWITCH
Connector for back-up light switch is located on left forward ‘CONNECTOR
side of transmission. It is a 2 pin connector.
Connect jumper to wires in switch. If light works, check wires to switch. If
wires are good, replace switch.
If light does not work, repair light blue/white wire from connector to light
on left side.
JUMPER
Page 309
EXTERIOR LIGHTS
VEHICLE WARNING LIG
HTS WILL NOT WORK
l.a. ._
If only one light is out,
go to DIRECTIONAL LIG \
b. If all lights are not flas HTS troubleshooting.
hing, go to step 2.
c. If lights on one side are
not working, turn on dire
side. ctional lights for that
d. If directional lights
are not working, 90 to
troubleshooting. If ligh DIRECTIONAL LIGHT 42
ts are working, 90 to step 3. S
\\
HAZARD WARNING
SWITCH
éLACK LEAD
TO onqgivp ;.
EXTERIOR LIGHTS
2.3. Check brake lights. If brake lights do not work, go to BRAKE LIGHTS BLACK
troubleshooting. l
b. If lights work, pull hazard switch out. Get voltmeter.
c. Connect red meter lead to terminal I (2 orange wires) of switch. Connect
black lead to ground.
d. If meter does not read voltage, repair orange wire from switch to stop light T0
switch. GROUND
ORANGE
HAZARD
SWITCH
e. If meter reads voltage, connect red meter lead to other orange wire at
switch. Connect black lead to ground. ORANGE
f. If meter does not read voltage, replace hazard switch. WIRE BLACK LEAD
TO GROUND
Page 311
EXTERIOR LIGHTS
If meter reads voltage, go to directional flasher. VIOLET m RED
NOTE file LEAD
Flasher is located in a clip above fuse box.
Connect red meter lead to terminal L (violet wire) of flasher. Connect
black lead to ground.
If meter reads voltage, 90 to step 3. - h 1 BLACK
l l LEAD
\L __
HER To
FLAS GROUND
if meter did not read voltage, connect red meter to terminal ORANGE RED
+ (orange
wire) of flasher. Connect black lead to ground. WIRE ,--’-” LEAD
If meter reads voltage, replace flasher.
If meter does not read voltage, repair orange wire from flasher to
hazard
switch.
BLACK l“ I,
LEAD
Q ELASHEH
l \.. _ l
TO GROUND
Remove 5 screws thru steering column cover. Remove cover. VIOLET WIRE
Connect red meter lead to violet wire in connect CS. Connect black
lead to
ground. BLACK LEAD
NOTE
Connect 05 is an 8 pin connector.
If meter reads voltage, check violet wire and connector from direction
switch. If connector and wires are good, replace switch.
al &
C: 'k
A
T0 GROUND
If meter does not read voltage, repair violet wire from connector to
flasher.
RED LEAD
CONNECTOR C5
If lights do not work, repair light blue/black wire (left side) or light blue
wire (right side) from connector C5 to connector C14.
a?
Q“
as
L
HAZARD
SWITCH
Page 312
EXTERIOR LIGHTS
5.3. If one light is out, remove 2 screws thru lens (rear lights) or 4 screws (front
lights). Remove lens. Replace bulb.
b. Try lights. If working, install lens.
c. If not working, turn on parking lights. If parking lights do not work,
ground wire or ground connection is bad. Troubleshoot PARKING
LlGHTS.
d. If parking lights work, remove bulb. Get voltmeter. Hold red meter lead to BULB SOCKET
center contact. Hold black lead to ground.
e. If meter reads voltage, replace socket.
f. If meter does not read voltage, repair wire from socket to connector.
EXTERIOR LIGHTS
DIRECTION DIRECTION
Q INDICATOR INDICATOR Q
I
m
3 2
x I
: E 5
In 5| 5‘ S
'i m
'5:
59 II DIRECTION 9
—I
INDICATOR
HAZARD FLASHER
STOPLIGHT WARNING
SWITCH FUSES A A FLASHER
C213) u A 0 sq
#1 P 2 + 5 ' - 04
I l l
IJ‘ | \J‘ \J \J
I I 5” 5;
T R
E$ '5 > 5 g 03
I j 3 <2
as2 5
E gR ‘
'—
5
<
I 5'
\ j
5‘
\
EnI 3 WHITE
’i
(D D
—I DIRECTION
(_ INDICATOR
C—
r L_ BACK—UP
In: SWITCH
E
a
8; IE?“
0:
I f
II
BACK—UP I‘ BACK—UP
STOPLIGHT L'GHT LIGHT
DIRECTION I D'RECT'ON
INDICAToR
INDICATOR
STOPUGHT
EXTERIOR LIGHTS
SIDE 02 C4 / SIDE
MARKER BL _ \ MARKER
f BLACK ACK __ . l
< I:)—-— 1 /_ :D
7 ”k YELLOW j YELLOW——-"
/ aln-(IJBREAM HIGHBEAM
I
MOTOR
/ RELAY RELAY C3 \
YELLOW q A \
I
I
I
BROWN i
’I‘ I- }
FUSES I
»H
,06 II
I
Y V
YELLOW/BLACK
YELLOW/BLACK I BLACK 2
0 cos 3
I:
O O In
0 O I ILL/NA
xS I m BRI EFING
I’I‘ I I
O 0
S '85 SWITCH
E g a I
E 9 E I
j :I‘ j I
w w w I IGNITION
> > > : SWITCH
A C14 UMENT PANEL
SIDE SIDE
MARKER YELLOW/RED_ MARKER
YELLOW/RED PARKING [———‘C—>
>—BLAcK—_L LIGHT —
INDICATOR §ITC
’ E1 ‘ VIOLET/BLACK
\
3
9
.I
“;
hYELLOW/BLACK YELLOW/BLACK
YELLOW/RED \,I
X
® <9 m
LIC’NSE
PARKING PLA E PARKING
LIGHT LIG TS LIGHT
Page 317
INSTRUMENTS
TABLE OF CONTENTS
SECTION PAG E
Temperatu re Gage Inoperative 318
Fuel Gage Inoperative 320
Low Fuel Warning Inoperative 321
Oil Pressure Gage Inoperative 322
Low Oil Pressure Warning Inoperative 324
Tachometer Inoperative 325
___ I
Q I
FUEL GAGE
SENDING UNIT
LOW
OIL PRESSURE
LOW FUEL
-|ND|CATOR
FUEL GAGE<11":- j
TACHOlI/IETER
I I WATER OIL PRESSURE
u : INDICATOR GAGE
DJ
Page 318
INSTRUMENTS
INSTRUMENTS
IF NOT OK IF OK
CHECK POWER
TO INSTRUMENT
IF NOT OK IF OK
IF NOT OK u: 0K
Page 319
INSTRUMENTS
If gage does not work properly, locate connector C13. Get jumper.
NOTE
Connector C13 is a white 8 pin connector. It is behind center
console.
If gage reads cold all the time, go to step 2. If gage reads hot, disconnect
connector 013.
Check gage. If gage moves to cold, repair green wire from connector C13
to sending unit.
CONNECTOR C13
CONN ECTOR C6
If gage does not move to cold, connect connector 013.
Remove 5 screws thru instrument panel. Pull panel out. Disconnect con-
nector C6.
NOTE
Connector CS is an 8 pin connector.
it gage moves to cold, repair green wire from connector C6 to connector
C13.
If gage does not move, check connector, and circuit board for detects. If
connector and board are good, replace temperature gage.
GREEN WIRE
INSTRUMENT PANEL
Connect jumper between green wire in connector 013 and ground. 40 GROUND
If gage moves toward hot, repair green wire from connector C13 to sending
n
unit. JUM/PER {gins
GREEN WIRE
INSTRUMENTS
C. If gage does not move. connect connector C13. Remove 5 screws thru CONNECTOR C6
instrument panel. Pull panel out.
Connect jumper to green wire in connector C6.
NOTE
Connector C6 is an 8 pin connector.
If gage moves toward hot, repair green wire from connector 06 to con-
nector C13.
If gage does not move. check connector CB, circuit board for defects. if
connector and circuit board are good, replace temperature gage.
If gage does not read properly, locate connector C13. Get jumper. LIGHT BLUE/
NOTE YELLOW WIRE
Connector 013 is a white 8 pin connector. It is behind center
console.
If gage reads full all the time, go to step 2. If gage reads empty, connect
jumper to light blue/yellow wire in connector and to ground.
if gage moves toward full, repair light blue/yellow wire from connector
013 to sending unit.
If gage does not move. connector connector C13. Remove 5 screws thru LIGHT BLUE!
instrument panel. Pull panel out. YELLOW WIRE
Connect jumper to light blue/yellow wire in Connector 06 and to ground. CONNECTOR CG
NOTE
Connector C6 is an 8 pin connector.
if gage moves toward full, repair light blue/yellow wire from connector C6
to connector 013.
If gage does not move, check connector and circuit board for defects. If
connector and circuit board are good, replace fuel gage.
Page 321
INSTRUMENTS
LIGHT BLUE!
2.a. Disconnect connector C13. Check gage. YELLOW WIRE
b. If gage moves toward empty, repair light blue/yellow wire from connector
C13 to sending unit.
CONNECTOR CI 3
If gage does not move, connect connector. Remove 5 screws thru instru— LIGHT BLUE/
ment panel. Pull panel out. YELLOW WIRE
Disconnect Connector C6. Check gage.
NOTE
Connector CS is an 8 pin connector.
if gage moves toward empty, repair light blue/yellow wire from connector
C6 to Connector C13.
lf gage does not move, check circuit board for defects. If circuit board is
good, replace fuel gage.
If light did not work properly, locate connector C14. Get jumper.
NOTE
Connector C14 is an 8 pin connector. It is behind center con-
sole.
if light is on all the time, go to step 2. If light is off, connect jumper to
red/black wire in connector and to ground. (1/ \ ,
If light comes on repair red/black wire from connector C14 to sending
unit.
TO GROUND
Page 322
INSTRUMENTS
h. If light did not come on, connect connector. Remove 5 screws thru instru- (
ment panel. Pull panel out. Disconnect speedometer cable and three con- _ I! / BULB
nectors. HOLDER
i. Turn bulb holder for warning light to left and remove bulb. Install new
bulb.
i. Connect connectors to instrument panel. Check light. If light is on, install
instrument panel.
k. If light is out check circuit board and connector for defects. if they are
good. connect jumper to red/black wire in connector C6 and to ground. («CIRCUIT
l. lf light comes on repair red/black wire from connector C6 to connector BOARD
C14. lf light does not come on, replace bulb holder.
CONNECTOR C14
c. if light did not go out, connect connector 014. Remove 5 screws thru RED/BLACK
instrument panel. Pull panel out. WIRE
d. Disconnect connector C6. Check light.
NOTE
Connector CS is an 8 pin connector.
e. if light goes out. repair red/black wire from connector C6 to connector
C14.
f. If light did not go out. check circuit board and bulb holder for defects.
CONN ECTOR CS
Page 323
INSTRUMENTS
f. If gage does not read properly, connect connector. Locate connector C13. CONNECTOR C13
NOTE
Connector C13 is a white 8 pin connector. It is behind center
console.
g. If gage reads high, disconnect connector. If gage moves towards low pres-
sure, repair gray/black wire from connector C13 to connector for sending
unit.
11. if gage does not move, remove 5 screws thru instrument panel. Pull panel
out.
i. Disconnect connector CB. If gage moves, repair gray/black wire from gage
to connector C13.
j. If gage does not move, check connectors, circuit board, and gage. Replace
defective part.
INSTRUMENT PANEL
GRAYIBLACK WIRE
2.a. Connect jumper between gray/black wire in connector C13 and ground.
b. If gage moves towards high pressure, repair gray/black wire from connector
C13 to connector for sending unit.
«v.4: /' T0
JUMPER GROUND
c. If gage did not move, remove 5 Screws thru instrument panel. Pull panel GRAY/BLACK
out. WIRE
(I. Connect jumper between gray/black wire in connector CB and ground.
NOTE CONN ECTOR CB
Connector CB is a 6 pin connector.
e. If gage moves towards high pressure, repair gray/black wire from connector
C13 to connector CG.
f. If gage does not move, check connector and circuit board for defects. If
connector and board are good, replace oil pressure gage.
T0 GROUND /
Page 324
INSTRUMENTS
f. If light goes out, repair gray/yellow wire from connector C13 to sending
unit.
CONNECTOR C13
9. If light stays on, remove 5 screws thru instrument panel. Pull panel out. CONNECTOR C7
h. Check connector C7, circuit board, and bulb holder for defects. If they are
good, repair gray/yellow wire from connector C? to connector C13.
GRAY/YEL LOW
WIRE
2.a. Connect jumper to gray/yellow wire in connector C13 and to ground. GRA‘Yv/‘YRELLOW
b. If light comes on, repair gray/yellow wire from connector C13 to sending
unit.
GROUND
Page 3251325
INSTRUMENTS
If light does not come on, remove 5 screws thru instrument panel. Pull
panel out. BULB
Disconnect 3 connectors and speedometer cable from panel. Turn bulb HOLDER
holder for indicator light to left. Replace bulb.
Connect connectors to panel. If light comes on install panel.
lf light does not come on, connect jumper to gray/yellow wire in con-
nector C7 and to ground.
If light comes on, repair gray/Yellow wire from connector C7 to connector
C13. (ea-CIRCUIT
©
If light does not come on, check connector and circuit board, and bulb BOARD
holder for defects.
COIL
e. Find connector C13. Connect red' meter lead to brown/white wire in RED LEAD
"Ch
connector. Connect black lead to ground.
a)
NOTE ,4. i ,
Connector C13 is a white 8 pin connector. It is behind center
L if; . "3
console.
Increase and decrease engine speed. If meter readings increase and decrease é???”
go to step it. Eel-$BROWN/WHITE
If readings are not good, repair brown/white wire from connector C13 to “d WIRE
coil.
BLACK LEAD
TO GROUND
Remove 5 screws thru instrument panel. Pull panel out. Connect red meter CONNECTOR C6
lead to brownfwhite wire in connector CB. Connect black lead to ground. BROWN/WHITE
NOTE
Connector C6 is an 8 pin connector.
Increase and decrease engine speed. lf meter readings increase and decrease
check circuit board and connector for defects. If board and connector are
good, replace tachometer.
If readings are not good, repair brown/white wire from connector C6 to
connector C13.
TO GROUND
Page 327/328
INSTRUMENTS
TEMPERATURE
DISTRIBUTOR UNIT SENDING
GAGE
OILPRESSURE 2 LOW
I”; SEND'NG UN” 5 g OILPRESSURE
I 3 d INDICATOR
E FUSE A E z t
g >' LU >-
0 4: Lu <
n: It I: c:
no 0 o 0
ORANGE '
013 SEAT BELT
J U U J ALARM RELAY
_—_I
E
Lu
E
5
3
a
3
3 Lu
2 E Z i g
E <>z 31 <>z <
L:
a: L: a: 0:
m o o w o
I ca c7 I
O o O
'0 O O O C|O
l O O O Q
_— LI.)
- 0
Z
<(
RED/BLACK g
LIGHT BLUE/YELLOW
c14'
WATER TEMPERATURE
OIL PRE URE GAUGE
GAUGE
06
RED/BLACK LIGHT BLUE/YELLOW ‘
ACHOMETER
I
FUEL GAGE
SENDING UNIT GAUGE
|
I
INSTRUMENT
PANEL
Page 329
ACCESSORIES
TABLE OF CONTENTS
SECTION
PAG E
Horn Will Not Stop Blowing
331
Horn Will Not Blow
332
Windshield Washer Pump Will Not Work
333
Windshield Wipers Will Not Work
333
Heater Fan Will Not Work
335
FAN SWITCH
C 5.2) WASHER
~13
'' PUMP
L——_ __ _ _ :33:
q \
© '
Page 330
ACCESSORIES
ACCESSORIES
IF NOT
OK
IF 0K
IF NOT OK IF NOT OK
IF OK IF NOT OK
Page 331
ACCESSORIES
\\ is
GRAYIBLACK\WIRE
5/ GRAWBLACK
WIRE
J;
b. Check instrument panel lights. If lights will not work, repair black wire
WSW—151
from connector C10 to ground.
NOTE r m.-ofw‘ff‘c»
or.ne‘j‘ie'p‘}
ew"w“‘fl‘cl'
in]
Connector C10 is located under steering column cover. it is a 6
pin connector.
If both horns will not blow check fuse L. Replace fuse if blown. FUSE L_
lf fuse is good, get voltmeter. Connect red meter lead to terminal 1 (violet
wire) of horn relay. Connect black lead to ground.
NOTE VIOLET WIRE
Horn relay is located in right headlight motor compartment. RED LEAD
If meter reads voltage go to step f. If meter does not read voltage, repair
light blue wire from relay to fuse box.
TO GROUND
Page 332
ACCESSORIES
f. Connect red meter lead to terminal 4 (light blue wires) of horn relay.
Connect black lead to ground. /
g. If meter reads voltage, repair light blue wires from relay to horns.
RED LEAD
\
BLACK LEAD
TO GROUND
\\ \
LIGHT BLUE WIRE
h. If meter does not read voltage, get ohmmeter. Connect red meter lead to GRAY/BLACK WIRE
terminal 3 (gray/black wire). Connect black lead to ground.
~ i. Press horn button. If meter reads 5 ohms or less, replace relay. D LEAD
T0 GROUND
k. Connect a jumper between gray/black wire in connector C5 and black BLACK WIRE
wires in connector C10.
NOTE
Connector C5 is an 8 pin connector. Connection C10 is a 6 pin
connector.
I. If horns blow, check gray/black wire from connector C5 and black/violet
wire from connector C10 to horn button. Check horn button. Repair or
replace parts or wires as necessary. GRAWBLACK
m. If horns do not blow, repair gray/black wire from connector CB to relay. WIRE
CONNECTOR CS
2.a. Get voltmeter. Connect red meter lead to terminal on horn. Connect black
lead to ground. Press horn.
b. If meter does not read voltage, repair wire from horn to relay.
c. If meter reads voltage, remove horn and bracket. Check bracket, horn, and
body for dirt or corrosion. If ground connection is good, replace horn.
BLACK
LEAD
Page 333
ACCESSORIES
e. Get ohmmeter. Connect red meter lead to black wire at pump. Connect BLACK WIRE
black lead to ground.
f. If meter reads 5 ohms or less, replace pump.
If meter reads more than 5 ohms, repair black wire from pump to connec-
tor C18 for Windshield Wiper motor. BLACK/ l
l ILEAD /RED
Klm5;]LEAD
' TO GROUND
2.3. Remove 5 screws in steering column cover. Remove cover. RED LEAD
' b. Connect red meter lead to green/black wire in separate connector. Connect BLACK LEAD
black lead to ground.
c. If meter reads voltage, repair green/black wire from connector to pump.
d. If meter does not read voltage, check green/black wire from connector to .____._.
switch and yellow/black wire from connector 010 to switch. If wires are T0 GROUND DCFT
good, replace switch.
. . NOTE
Connector C210 is a 6 pin connector.
GREENIBLACK
WIRE
ACCESSORIES
Remove 4 screws and bolt holding grill on left side in front of windshield.
Disconnect connector 618. Get voltmeter. Set switch to speed that will
not work.
NOTE
Connector C18 is located under grill on left rear side of lug—
gage compartment. lt is a 6 pin connector.
Connect red meter lead to red wire (low speed) or gray wire (high speed) in
connector. Connect black lead to ground.
If meter reads voltage, check wires to motor. lf wires are good, replace 'v GRAY WIRE
motor.
CONNECTOR C18
If meter does not read voltage. remove 5 screws thru steering column GRAY WIRE
cover. Remove cover. (HIGH SPEEDI
Connect red meter lead to red wire (low speed) or gray wire (high speed) in
connector C10.
NOTE
Connector C10 is a 6 pin connector.
lf meter does not read voltage, check wires to switch. If wires are good
replace switch. RED WIRE
If meter reads voltage, repair red wire (low speed) or gray wire (high speed) (LOW SPEED)
from connector C18 to wiper motor connector 018.
CONNECTOR C10
3.a. Remove 4 screws and bolt holding grill on left side in front of windshield. ORANGE RED LEAD
Remove grill. WIRES
NOTE
Connector 018 is located under grill. it is a 6 pin connector.
Connect red meter lead to orange wires in connector. Connect black lead
to ground. l:v
If meter reads voltage, go to step e. If meter does not read voltage, go to BLACK LEAD
step i.
9
TO
GROUND
Get ohmmeter. Connect red meter lead to black wire in connector. Con- RED LEAD
nect black lead to ground.
lf meter reads more than 5 ohms, repair black wire from connector 018 to
connector CB.
NOTE
Connector CS is a 6 pin connector for the instrument panel.
r‘
4.)
TO GROUND
Page 335
ACC ESSO R I ES
g. If meter reads 5 ohms or less, remove 5 screws thru steering column cover. YELLOW/BLACK
Remove cover. WIRE
h. Check connector C10 and yellow/black wire from connector to switch for
defects.
NOTE
Connector C210 is a 6 pin connector.
i. If connector and wire are good, replace switch.
1. Operate windshield washer. lf washer works, repair orange wire from con-
nector C10 to connector C18.
NOTE
Connector 010 is a 6 pin connector. It is located under the
steering column cover.
k. If washer does not work, operate the seat belt system buzzer. If buzzer
does not work, go to SEAT BELT INTER LOCK troubleshooting.
I. If buzzer works, repair orange wire from terminal 86 of buzzer relay to
connector C10.
c. If lights work, get voltmeter. Pull switch out. Make sure wires do not touch E ORANGE WIRE
dash panel. D
d. Connect red meter lead to orange wire at switch. Connect black lead to
ground.
e. If meter reads voltage, 90 to step f. If meter does not read voltage, repair
orange wire from switch to hazard warning switch.
GROUND
Page 336
ACCESSORIES
t. Connect red meter lead to light blue/black wire at switch. Connect black BLACK LEAD
lead to ground.
9. Set switch to low speed. If meter reads voltage, go to step h. If meter does
not read voltage, replaCe fan switch.
h. If meter reads voltage, check ground connection for heater for dirt, corro~
sion, and tightness. Tighten and clean, if necessary. HEATER
NOTE /\
The ground terminal is located on mounting bolt for heater on GROUND "'--_..
left rear side of heater. “-5....“
i. If ground is good, check black wire from fan motor to ground. If wire is
good, replace fan motor. k \
BLACK WIRE
2.a. lf fan did not work in one speed, set switch to that speed. Get voltmeter. BLACK RED WIRE
. Pull switch out. Make sure wires do not touch panel. LEAD (HIGH SPEED)
c. Connect red meter lead to red wire (high speed) or light blue/black wire
[low speed) at switch. Connect black lead to ground.
d. if meter reads voltage, go to step e. If meter does not read voltage, replace
switch.
TO
GROUND
e. If meter reads voltage, find connectors for wires from switch. Connect red Ur—I”
meter lead to red wire (high speed) or light blue/black wire (low speed).
Connect black lead to ground. fig ;
NOTE RED WIRE
The connectors are one wire connectors. They are located be— HIGH SPEED
tween heater and steering column.
f. If meter does not read voltage, repair wire from connector to switch.
g. If meter reads voltage, check wires to heater for damage. Repair wires or fig I E
replace heater.
LT BLUEIBLACK
WIRE
LOW SPEED
ACCESSORIES
I
i
I
I
I
HORN HORN
HORN
RELAY
”—1 _
—: Ifi _
L A WINDSHIELD fl3 4
A WIPER WINDSHIELD
A puMp LIGHT BLUE LIGHT BLUE 4| II: WIPER
A—BLACK BLACK x MOTOR
FUSES U :2 BLACK
E LIGHT BLUE/BLACK “\LIGHT BLUE
V " > LIGHT BLUE/WHITE
< \& GRAY
-
T TI VIOLET 5
3 ><> > >q>
2 3| C F D
<(
[I
O —GREEN/BLACI<
ORANGE
BLACK
BUZ } ORANGE———————J
ZER
RELAY WHITE / BLACK \ I: LIGHT BLUE/WHITE
I RED
>0 CS ‘ I
uRAY
f‘
CIo K \
ORANGE KO?) STOPLIGHT
fly GREEN BLACK SWITCH
\
YELLOW/BLACK //V‘OLE BLACK
BLACK \‘x 1/ /WHITE ORANGE
///: RED VEHICULAR HAZARD
cs E3 Clo Wr/G RAY WARNING SWITCH
‘ m 1 w w ,v t ORANGE
WIRER/WASHER
:4
o
E_I SWITCIII
o I
a?
;
E
g 0
I
g j O——J
O m AL
HEATER
r r 0/0 FAN
? (P SWITCH
I T
HORN
BUTTON T IED
LIGHI BLUE/BLACJK
I HEATER I
FAN
Page 339
FUSES
TABLE OF CONTENTS
SECTION PAGE
Page 340
FUSES
FUSE LOCATION
FUSE SIZE (Amps) PROTECTED CIRCUITS
A 8 Stop lights Fuel gage and indicator
Back-up lights Engine water temperature gage
Hand brake and brake system effectiveness Heater fan motor
indicator Windshield wiper
Seat belt interlock control box Fasten belts indicator
Turn signal and indicator Fasten belts buzzer relay
Tachometer Windshield washer
Oil pressure gage and indicator
16 Cigar lighter
Vehicular hazard warning signal and indicator
Page 341
FUSES
FUSE A BLOWS REPEATEDLY
1.a. If fuse blows when windshield wipers are turned on, go to step 5. I m rear; ' .'
b. If fuse blows when windshield washer is operated, go to step 6.
If fuse blows when brake pedal is depressed, go to step 7.
rhpap
Set all switches off. Set gearshift in neutral. Pull hand brake on. ORANGE WIRES
Remove fuse A. Disconnect 2 orange wires from back of fuse box. Get
ohmmeter.
Connect red meter lead to wires. Connect black lead to ground. m 7 RED LEAD
if meter reads 9 ohms or more, go to step 3. If meter reads less than 9
ohms, go to step 2. __—————212EUIIJ
WWWW WWW
/
mg
n n 2.n LEAD
/
TO GROUND
2.a. With meter connected to wires, disconnect connector 016 from seat belt
interlock control box.
NOTE
Connector C16 is a red 6 pin connector.
lf meter reads 9 ohms or more, replace control box.
If meter reads less than 9 ohms, remove 4 screws thru steering column
cover. Remove cover.
CONNECTOR C16
YELLOW/BLACK WIRE
Page 342
FUSES
1‘. Pull hazard switch out of panel. Disconnect 2 orange wires from switch. ORANGE ORANGE
If meter reads less than 9 ohms, go to step 1. If meter reads 9 ohms or WIRES
more. connect orange wires to switch.
h. Disconnect orange wire from switch. If meter reads less than 9 ohms,
replace switch.
i. If meter reads 9 ohms or more, connect orange wire to switch. Install
switch.
k. If meter reads 9 ohms or more, replace flasher. lf meter reads less than 9
ohms, repair orange wire from flasher to switch.
\. -'
FEASI-IE
l. Full fan switch out of panel. Disconnect orange wire from fan switch. FAN
m. If meter reads 9 ohms or more, replace switch. SWITCH
ORANGE
WIRE
n. if meter reads less than 9 ohms, disconnect connector C18 for windshield CONNECTOR C18
wiper motor.
NOTE
Connector 018 is located just forward of windshield on left LT BLUE/
side. BLACK WIRE
o. If meter reads 9 ohms or more, check light blue/black wire from connector
to motor. If wire and connector are good, replace motor.
Page 343
FUSES
p. If meter reads less than 9 ohms, disconnect orange wires from brake light I \\
switch. BRAKE LIGHT
q. If meter reads 9 ohms or more, replace switch. If meter reads less than 9 SWITCH
ohms, go to step r.
ORANGE WIRE IR
INSTRUMENT PANEL
3.3. Connect orange wires to fuse box. Disconnect light b|ue/white wire from wag}; EVLI‘RE’
fuse box. Connect red meter lead to wire. Connect black lead to ground.
b. Disconnect connector 014. I RED LEAD
NOTE
Connector C14 is an 8 pin connector. It is behind center con- / 1 1m"!—r-—."—|
sole 0 n n n BLACK flu
c. If meter reads 5 ohms or less, go to step d. If meter reads more than 5 [r1 n n n n n I‘LEADl
ohms, repair light blue/white wire from connector C14 to fuse box.
TO GROUND
Page 344
FUSES
Connect connector C14. Find connector for back-up switch. Disconnect BACK-UP LIGHT
connector. CONNECTOR
NOTE
Connector for back-up switch is on forward left side of engine.
If meter reads infinity, check wires to switch. If wires and connector are
good, replace switch.
If meter does not read infinity, wire is defective. Repair light blue/white
wire from fuse box to connector C14 and to connector for back-up switch.
LIGHT BLUE/
WHITE WIRE
Pull fan switch out. Disconnect red wire from switch. Connect red meter LIGHT BLUE] RED WIRE
lead to wire. Connect black lead to gr0und. BLACK WIRE
lf meter reads less than 3 ohms, check red wire from switch to motor for
short to ground.
If meter reads 3 ohms or more, disconnect light blue/black wire from
switch. Connect red lead to wire. Connect black lead to ground.
If meter reads 3 ohms or more, replace switch. BLACK
If meter reads less than 3 ohms, check light blue/black wire to motor for RED LEAD
short to ground.
If rneter reads less than 3 ohms on either wire and the wires look good, LEAD It ,/ I
replace motor.
GROUND
Remove grill on left side in front of windshield. Disconnect connecter C18 BLACK LEAD
for windshield wiper motor. 1 RED LEAD
Connect red meter lead to red wire in connector. Connect black lead to
ground. TO GROUND
If meter reads infinity, go to step d. lf meter does not read infinity go to
step f.
Connect red meter lead to gray wire in connector. Connect black lead to
ground.
If meter reads infinity, check connector and wires to motor for shorts. If
connector and wires are good, replace windshield motor.
If meter did not read infinity, remove 5 screws thru steering column Cover.
Remove cover.
With meter connected to wire in connector C18, disconnect connector C10
for wiper switch.
If meter reads infinity, check connector and wires to switch. If wires and
connector are good, replace switch.
If meter does not read infinity, repair red or gray wire from connector C18
to connector C10.
Page 345
FUSES
6.a. Disconnect green/black wire from washer pump. Connect red lead of
ohm- GREEN/BLACK WIRE
meter to wire. Connect black lead to ground.
If meter reads infinity, replace pump.
If meter does not read infinity, leave meter connected to wire. _ A %
.BLIACKLEA
‘: D
RED! LEAD
TO GROUNDI
WWASH ER PUMP
GREENIBLACK
WIRE
7.a. Disconnect red wire from brake switch. Get ohmmeter. Connect red meter l \\
lead to wire. Connect black lead to ground. BRAKE LIGHT SWITCH
If meter reads 3 ohms or more, replace brake switch. If meter reads less
than 3 oh ms, disconnect connector C14.
NOTE BLACK
Connector 014 is an 8 pin connector. It is behind the center LEAD
console. R_ED LEAD
lf meter reads less than 3 ohms, repair red wire from connector C14 to II
brake switch. If meter reads 3 ohms or more, connect connector C14.
\
TO GROUNP Q
RED WIRE
Remove 4 nuts and washers holding left tail light assembly in car. Discon- PARKING LIGHT
nect red wires from assembly.
If meter reads 3 ohms or more, replace assembly.
lf meter reads less than 3 ohms, remove right tail light'assembly. Discon»
nect red wire from assembly.
lf meter reads 3 ohms or more, replace assembly. If meter reads less than 3
ohms, repair red wire from connector C14 to left tail light and to right tail
light.
RED WIRES
Page 346
FUSES
8.a. Disconnect connector for backup switch. Get ohmmeter. Connect rec BACK-UP SWITCH
meter lead to white wire in connector. Connect black lead to ground. CONNECTOR
NOTE
Connector for back up light is on left forward side of engine.
If meter reads 1 ohm or more, replace switch in transmission.
If meter reads less than 1 ohm, disconnect connector for left backup light.
If meter reads 1 ohm or more, replace tail light assembly. WHITE RED
If meter reads less than 1 ohm, remove right tail light assembly. Disconnect WIRE LEAD
x
white wire from assembly.
lf meter reads 1 ohm or more, replace assembly. If meter reads less than 1
ohm, repair white wire from switch connector to left tail light and to right
tail light assembly. TO GROUND
If fuse blows when directional indicators are turned on, turn on hazard LIGHT BLUE/
warning lights. lf fuse l blows, go to step c. BLACK WIRE
If fuse I does not blow, replace directional indicator switch.
Flemove 5 screws thru steering column cover. Remove cover. Get ohm-
meter.
Connect red meter lead to light blue/black wire in connector C5. Connect
black lead to ground.
NOTE
Connector 05 is an 8 pin connector.
If meter reads more than 1 ohm, go to step 10. If meter reads 1 ohm or BLACK LEAD
less, disconnect connector C15. TO GROUND
NOTE
Connector C15 is a 2 pin connector. It is behind the center
console.
LIGHT BLUE]
BLACK WIRE
lf meter reads more than 2 ohms, go to step 9. If meter reads 2 ohms or
less, go to step i.
Connect connector 015. Disconnect light blue/black wire from left rear
directional indicator.
If meter reads 3 ohms or less, repair light blue/black wire from connector
C15 to indicator light. If meter reads more than 3 ohms, replace tail light
assembly. 0
DIRECTIONAL
SIGNAL
Disconnect connector C2. If meter reads infinity (0°) go to step k. If meter
does not read infinity, disconnect light blue/black wire from hazard
flasher.
NOTE
Connector C2 is a 3 pin connector. It is in compartment for
left headlight motor.
lf meter reads infinity, replace flasher. If meter does not read infinity,
repair light blue/black wire from connector 05 to connector C15 and to
Connector C2. The other wire runs to the hazard flasher.
Check connector C2 and light blue/black wire from connector to direc— CONN ECTOR C 2
tional indicator for short. If wire is good, replace light.
Page 34?
FUSES
10.8. Connect red meter lead to light blue wires in connector CS. Connect black CON NECTOR CS
lead to ground. Disconnect connector C15.
NOTE
Connector 015 is a 2 pin connector. It is behind center con-
sole.
1: i i ,5» :
. if meter reads 2 ohms or less, go to step e. If meter reads more than 2 r I J
r g It If
ohms, connect connector C15. C:
| . k
. Disconnect light blue wire from directional indicator on right rear side.
. If meter reads 2 ohms or less, repair light blue wire from connector C15 to BLACK“ LEAD LIGHT BLUE
light. If meter reads more than 2 ohms, replace light. T0 GROUND WIRE
Page 348
FUSES
FUSE B BLOWS REPEATEDLY REDHWIRE
1.a. If fuse blows when headlights are raised, go to step 2.
b. Disconnect red wire from back of fuse box. Connect red meter lead to red ifleeo LEAD
wire. Connect black lead to ground.
l ZE
*3 DJE E
Disconnect connector C16 from seat belt interlock control box. Ellfll' _EIIE_
NOTE [W n l'lFl nr‘in
\F'l nnflnnrnnn
Connector C16 is a red 6 pin connector.
If meter reads infinity (0°), replace control box. l
FUSE B
BLACK LEAD
TO GROUND
If meter does not read infinity, remove 5 screws thru steering column
cover. Remove cover.
Disconnect connector C11. If meter reads infinity (0°), check wires and RED
connector for ignition key switch. WIRE
NOTE
Connector C11 is a 2 pin connector.
lf meter does not read infinity, repair red wire from fuse box to connector
C11 and to connector C16.
CONNECTOR C11
Disconnect light blue wire from fuse box. Connect red meter lead to light
blue wire. Connect black lead to ground. RED LEAD
Disconnect light blue wire from terminal 87 of relay (left headlight). If
meter reads more than 20 ohms, replace relay.
if meter reads less than 20 ohms disconnect light blue wire from terminal i 2 mt n Lg-EFIICEEE
87 of relay (right headlight). {mill} ” m DiDllfijEj
If meter reads infinity, replay relay. lf meter does not read infinity, repair LiGI—TT BEUE WIRE. “ V‘ n
\j_____
light blue wire from fuse box to relay (left headlight) and to relay (right BLACK LEAD
.
headlight).
T0 GROUND
Page 349
FUSES
FUSE C BLOWS WHEN HIGH BEAMS RED LEAD BLACK LEAD
ARE TURNED ON at
La. Remove fuse C from fuse box. Get ohmmeter. Disconnect thin green/black
wire to high beam indicator from fuse box.
b. Connect red meter lead to wire. Connect black lead to ground. If meter
reads more than 10 ohms, o to ste 2.
9 p GROUND
GREENIELTACK
WIRE._
c. Remove 5 screws thru instrument panel. Pull panel out. Disconnect Con-
nector C6 from instrument panel.
d. If meter reads infinity, check connector and circuit board for a short to
ground.
e. If meter does not read infinity, repair green/black wire from fuse box to
connector CS.
INSTRUMENT PANEL
2.3. Disconnect large green/black wire from fuse box. Connect red meter lead GREENIBLACK
to wire. Connect black lead to ground.
b. Disconnect plug for left headlight. Check plug for damage.
c. if plug is good, check fuse box for short. If fuse box is good, repair wire
from fuse box to plug.
Page 350
FUSES
FUSE D BLOWS WHEN HIGH BEAMS ARE HEADLIGHT
TURNED ON PLUG
1.a. Disconnect plug for right headlight. Check plug for damage.
b. If plug is good, check fuse box for short.
c. If fuse box is good, repair gray wire from fuse box to plug. FUSE o Elgl
s...
1.3. Disconnect plug from right headlight. Check plug for short.
b. If plug is good, check fuse box for short at gray wire.
c. if fuse box is good, repair gray wire from fuse box to plug.
‘lEl-UIEIEIEI
I-II
Page 351
FUSES
FUSE G BLOWS REPEATEDLY YELLOW/BLACK WIRE
1.a. Disconnect single yellow/black wire from back of fuse box. Get ohmmeter.
b. Connect red meter lead to wire. Connect black lead to ground. If meter
reads 4 ohms or more, go to step 2.
Z-EIEEL
MIME
_BLACK LEAD__._1'
TO GROUND
YELLOW/BLACK
If meter reads less than 4 ohms, pull rheostat out. Disconnect yellow/black WIRE
wires.
If meter reads 4 ohms or more, replace rheostat.
If meter reads less than 4 ohms, disconnect light socket from cigar lighter.
If meter reads 4 ohms or more, replace lighter.
If meter reads less than 4 ohms, repair yellow/black wire from fuse box to
rheostat and to lighter.
YELLOW YELLOWJ’BLACK
2.a. Disconnect yellow and yellow/black wires from fuse box. Connect red
meter lead to wires. Connect black lead to ground. WIRE WIRE
Disconnect Connector C14. lf meter reads less than 4 ohms, go to step 3.
NOTE
Connector C14 is a red 8 pin connector. It is behind center con-
sole.
If meter reads 4 ohms or more, connect 014. Disconnect connector for left
JLlLJli'pJLiLJEEI-Eeo
license plate light. ‘B’T—‘AMCEHEAD_JI'_‘Il_ r1 \ O
TO GROUND
Remove right rear tail light assembly. Disconnect yellow/black wires. YELLOWIBLACK
If meter reads 4 ohms or more, replace assembly. If meter reads less than 4 WIRE
ohms, disconnect yellow/black wire from side marker light.
If meter reads 4 ohms or more, replace light socket. lf meter reads less
than 4 ohms, repair yellow wire from connector C14 to left license plate
light and yellow/black wire from license plate to tail light and to side
marker light.
Page 352
FUSES
3.a. Disconnect connector 02. if meter reads 5 ohms or more, go to step c.
NOTE
Connector C2 is a 3 pin connector. It is in compartment for 3‘05 MAR\KER
left headlight motor.
b. If meter reads less than 5 ohms, disconnect yellow/black wire from left © ©@
side marker light. if meter reads 5 ohms or more replace side marker light
socket.
c. Remove left front parking light. Check yellow/black wire from connector YELLOW/BLACK
CZ to light assembly. fl/w‘ RE
d. If wire is good, replace assembly. \
e. If meter reads less than 4 ohms, remove 5 screws thru instrument panel. CONNECTOR C 6
Pull panel out.
f. Disconnect connector CB. If meter reads infinity, check connector and
circuit board for defects.
9. If meter does not read infinity, wireing is defective.
NOTE
Yellowr‘black wire runs from fuse box to connector CB and to
connector C2 and to left side marker light. Yellow wire runs
from fuse box to connector C14.
Page 353
FUSES
FUSE H BLOWS REPEATEDLY YELLOW/RED BLACK
1.3. Disconnect yellow/red wire from fuse H. Get ohmmeter. WIRE LEAD
b. Connect red meter lead to wire. Connect black lead to ground.
c. Disconnect connector 014. If meter reads 1 ohm or more, go to step 2. RED \”
n T)“ n [H
n n n (p n
— FUSE H
d. If meter reads less than 1 ohm, disconnect connector C4. If meter reads 5
\
ohms or more, check parking light and yellow/red wire from connector C4
for short to ground. SIDE MARKER
e. If meter reads less than 5 ohms. disconnect yellow/red wire from front
right side marker light.
f. If meter reads infinity, replace side marker light socket. If meter does not
read infinity, repair yellow/red wire from fuse box to connector 014, C4
and front right side marker light.
2.a. Connect connector C14. Disconnect yellow/red wires from left rear side
marker light. If meter reads 1 ohm or more, replace light socket.
b. If meter reads less than 1 ohm, remove left tail light assembly. Disconnect
yellow/red wires from assembly.
YE LLOW/ R ED
WIRE
c. If meter reads 1 ohm'or more, replace assembly. If meter reads less than 1 LICENSE PLATE
ohm, disconnect connector for right license plate light. CONNECTOR
d. If meter reads 1 ohm or more, check wire to license plate light. If wire is
good, replace light.
e. If meter reads less than 1 ohm, repair yellow/red wire from connector C14
to left side marker light, left tail light, and right license plate light.
Page 354
FUSES
RED WIRE
FUSE I BLOWS REPEATEDLY
1.a. If fuse blows when hazard warning lights are turned on, go to step 2.
b. Disconnect red wire from fuse I. Connect red meter lead to wire. Connect
black lead to ground.
c. Disconnect red wire from terminal H of hazard switch. If meter reads
infinity, replace switch.
(1. If meter does not read infinity, check cigar lighter for short to ground. If
lighter is good, repair red wire from fuse to lighter and to hazard switch.
T0 GROUND— FUSE |
2.a. If fuse blows when hazard lights are turned on, turn on directional lights. RED WIRE
If they blow a fuse, go to FUSE A troubleshooting.
b. Disconnect red wire from terminal V of hazard switch. Connect red meter
lead to wire. Connect black lead to ground. R ED
c. If meter reads 10 ohms or more, replace hazard switch. LEAD
TO HAZARD
GROUND SWITCH
. If meter reads less than 10 ohms, disconnect red wire from hazard flasher. RED WIRE
e. If meter reads infinity, go to step f. If meter does not read infinity, repair
red wire from switch to flasher.
f. Connect red wire to flasher. Disconnect red/yellow wire from flasher.
If meter reads 60 ohms or more, go to step h. If meter reads less than 60
ohms, replace flasher.
HAZA— n F
lie.
CONNECTOR C 6
Page 355
FUSES
FUSE L BLOWS REPEATEDLY PURPLE WIRE
La. if fuse blows when engine is running hot, go to step 2. If fuse blows when
horn is used, go to step 3.
\
b. Disconnect one purple wire. Connect red meter lead to wire. Connect
RED LEAD
black lead to ground.
c. If meter does not read infinity, go to step d. If meter reads infinity, BLACK \%
disconnect other purple wire. Connect red meter lead to it.
LEAP.,fi“—"—‘
nnI-i flnflfl
lnnnn on
_.__L_._\_
FUSE L
TO GROUND—
d. Disconnect purple wire from terminal 30/51 of fan relay. If meter reads COOLING FAN RELAY
infinity, replace relay.
e. If meter does not read infinity, disconnect purple wire from terminal 1 of
horn relay.
f. If meter reads infinity, replace relay. If meter does not read infinity, repair
purple wire to fan relay or purple wire to horn relay.
TERMINAL 30/51
2.3.
-'
Disconnect light blue wire from terminal 87 of fan relay. Connect red
BLACK LEAD
meter lead to light blue wires. Connect black lead to ground.
b. If meter reads 3 ohms or more, replace relay. If meter reads less than 3
FAN RELAY
ohms, disconnect connector C21.
NOTE
Connector C21 is a 2 pin connector. It is above the fan motor.
c. If meter reads infinity, check wire to fan motor. lf wire is good, replace
motor.
(I. If meter does not read infinity, repair light blue wire to connector C21.
3.a. Disconnect light blue wires from terminal 4 of horn relay. Connect red r I; \\
§
\x I
c. If meter reads 7 ohms or more, replace horn. lf meter reads less than 7
ohms, disconnect wire from left horn.
d. If meter reads infinity, replace horn. If meter does not read infinity, repair
wires to horns.
\. REDI LEAD
Page 356
FUSES
FUSE M BLOWS REPEATEDLY GREEN/WHITE WIRE
1.a. Disconnect greenl’white wire from fuse M. Connect red meter lead to wire. RED LEAD l
Connect black lead to ground.
b. Disconnect connector C19. If meter reads infinity, go to step 2.
NOTE
BLACK i"\
Connector C19 is a 4 pin connector. It is in compartment for LEAD 5:151:11.
left headlight motor. [1 war“ ” Fifi-"O
MLDHH ".
c. If meter does not read infinity, disconnect connector C20. If meter reads
infinity, go to step 2. lf meter does not read infinity, repair green/white
wire from fuse box to connector C19 and C20. ___.FUSE M
NOTE TO GROUND
Connector C20 is a 4 pin connector. It is in compartment for
right headlight motor.
GRAY/BLACK WIRE
2.a. Connect red meter lead to gray/black wire in connector for headlight
motor. Connect black lead to ground. 3 .
b. If meter reads 25 ohms or more, check wires to headlight motor. If wires
are good, replace motor.
c. If meter reads less than 25 ohms, disconnect gray/black wire from terminal N 'RED LEAD
35 of relay.
d. If meter reads infinity, replace relay. If meter does not read infinity, repair BLACK LEAD ‘1", _ “j
I
r
gray/black wire from connector to relay.
TO GROUND
n l'll‘lni'l nn 0
wire from fuse box to connector C19 and C20. Hnn'nnnnnin;
NOTE ' /
/
Connector C20 is a 4 pin connector. It is in compartment for _._FUSE N ...
right headlight motor.
GRAY/BLACK WIRE
2.a. Connect red meter lead to gray/black lead in connector for headlight
motor. Connect black lead to ground.
b. If meter reads 25 ohms or more, check wires to headlight motor. If wires
are good, replace motor.
c. If meter reads less than 25 ohms, disconnect gray/black wire from terminal R . -'
ENI'FIED LEAD
i \i‘
85 of relay.
d. If meter reads infinity, replace relay. If meter does not read infinity, repair
gray/black wire from connector to relay. BLACK LEAD ii r _ .9
l
TO GROUND