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c.

‘ Serviqe;manual
. ' 1.974 thru 197*8
""3. 2‘
:

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' HUME
X-1I9

SERVICE
MANUAL
19 74 thru 19 78

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FOREWORD
This manual has been written to provide basic information for the proper servicing of the
X 119 passenger car.
The information is grouped in sections. Each section is identified by two-digit numbers.
Each section covers the service procedures for the individual groups and sub-groups. They
are identified by a number. The root of the number is taken from the general sub-group
code now being used for the Parts Catalog and the Service Time Schedule. This number
identifies the service time schedule operation, parts catalog sheet for the part covered
by the service procedure, and the service procedure.
For the time being, sections in the Parts Catalog are identified by a letter code in place
of a two-digit number. Each tab index page contains the correlation between the two codes.

HOW TO USE THE MANUAL


The information identification number consists of five digits, as follows;
a) The first two digits identify the section.
b) The third digit designates the group within the section and is used in conjunction with
the first two.
c) The last two digits indicate an assembly or task consisting of several parts. This number
identifies the sub-group. It refers to the sub-group in both the Parts Catalog and the
Service Time Schedule.
Find the information required as follows:
1) Find the tab index page for the information on the first page of the manual.
2) Find the group and sub-group for the information on the table of contents on the tab
index page.
3) Locate the sub-group containing the information by means of the page number opposite
the sub-group.

UPDATING THE MANUAL


—Revision sheets are supplied together with a revised "Composition of the Manual" sheet.
_Revision sheets can be of two types:
1) Replacement sheets: In this case the new sheet will carry the same page number as the
old one. The bottom right side will read Supersedes page . . . dated . . .”
2) Complementary sheets on topics already dealt with: In this case the additional sheet will
carry the same sub-group number as the sheet on which the topic has been first dealt with.
The page number will be followed by a small letter suffix.
Example: If additional information is needed for information on page 2, the new sheet will be
2a.

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00

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

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Ill - 1974

Section No. 00

Page 1

General Information

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Page 2

ENGINE
Engine type .............................................................................................. 128 AS.040.4

Cycle ........................................................................................................ Four-stroke, gasoline

No. of cylinders .......................................................................................... Four

Bore .......................................................................................................... 3.39 in. (86mm)

Stroke ........................................................................................................ 2.19 in. (55.5mm)

Displacement ................. ........................................................................... 78.7 cu. in. (1290cc)

Compression ratio ...................................................................................... 8.5 to 1

Horsepower rating, S.A.E. net .................................................................... 66.5 HP

at .............................................................................................................. 6,000 rpm

Torque rating, S.A.E. net .......................................................................... 671/4 ft. lbs.

at .............................................................................................................. 4,000 rpm

Arrangement .............................................................................................. central,


transversally mounted

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)

FUEL SYSTEM COOLING SYSTEM


Feeding by mechanical pump. Radiator and expansion tank. Water circulated by cen~
Carburetor: vertical, downdraft WEBER 32DMTRA200 trifugal pump. Controlled by thermostat on cylinder
with starting device (vacuum-operated butterfly valve head outlet duct. Thermostat begins to open at 165° F
choke, accelerating pump, and mechanically-controlled to 170° F (73° to 77° C).
opening of secondary throttle. Four-bladed fan, driven by electric motor. Controlled by
intake manifold with hot water header for mixture thermostatic switch in radiator. Thermostatic switch
pre-heating. at idle. cut-in about 194° F (90° C).
Fuel filter in feed line from pump to carburetor. Paper
cartridge air cleaner with silencer. EMISSION CONTROL SYSTEMS
Engine fuel feed system provided with fuel recircula-
tion (closed circuit) and evaporative emission control
system.
LUBRICATDN SYSTEM Crankcase emission control system (closed circuit) by
Forced circulation by gear pump and pressure limiting recirculation of blow-by gases and oil vapors.
valve. Full-flow cartridge oil filter. Exhaust emission control system (reduces air pollution
Normal oil pressure 64 to 85 psi (4.5 to 6 kg/cm) at from exhaust gases) separate from the crankcase emis-
212° F (100° C). sion control system.

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Ill - 1974

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

DIFFERENTIAL REAR SUSPENSION


Independent wheel type. Lower control arms and tele-
Differential and final drive gears housed in transmis»
sion main case. Final drive by cylindrical, helical- scopic knuckle pillars incorporated in double acting
toothed gears. Final drive ratio 4.076 to 1 (13/53). hydraulic shock absorbers. Coil springs and co-axial
Drive to rear wheels by half-axle swing shafts through buffers. Adjustable cross tie rods.
Camber, unladen car —1°10’ to —2"10’
constant velocity joints, three-lobe type inboard and
Toe-in, unladen car +0360 to +0.510 in.
ball-type outboard.
(9 to 13mm)
BRAKES
Dual hydraulic system on four wheels, independent at
front and rear. Disk type brakes front and rear.
ELECTRICAL SYSTEMS
Voltage 12V
Mechanical hand brake acting on rear wheel calipers.
Battery capacity (at 20 hr.
discharge rate) 60 Amp] hr
WHEELS AND TIRES
Alternator type A124—14V-44A Var. 3
Disk wheels with rim type 41/2JX13
Voltage regulator, BOSCH type ADli14V
Radial tires, size 145HR-13
Starter motor, FIAT type E840.8]12Var.1
Inflating pressure front 26psi—rear 29psi
Spark plugs:
STEERING _ Champion, type NQY
Rack and pinion type. AC, type 42XLS
Ratio: Marelli, type CW 7 LP
“—number of steering wheel turns about 3 Thread size (metric) M14 x 1.25
—corresponding rack travel 4.6 in. (117mm) Gap 0.020 to 0.024 in. (0.5 to 0.6mm)

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Page 4

WEIGHTS — PERFORMANCES

Curb weight (with water, oil, fuel,


spare wheel, tool kit, and accessories): .................................................... 2,010 lbs.
Seating capacity ........................................................................................ 2
Carrying capacity ...................................................................................... 2 persons & 130 lbs
Gross weight, fully laden ............................................................................ 2,440 lbs.
Speed, maximum, on flat road with good surface
(run-in and fully laden):
—First gear .............................................................................................. 28 mph. (45kph)
“Second gear .......................................................................................... 47 mph. (75kph)
—Third gear .............................................................................................. 72 mph. (115kph)
—Fourth gear ............................................................................................ 103 mph. (165 kph)
—Reverse .................................................................................................. 31 mph. (50kph)

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

The maximum height is referred to the unladen car.

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lll - 1974

Section No. 00

Page 5

General Information
Capacities — Model X 1/9

QUANTITY
UNIT It kg U.S. Units REFILL

Fuel Tank 46 —4 12 gals. Leaded or lead free gasolines with octane


rating of at least 91 (Research Method)

Radiator, cylinder jackets


and heating system 6.50 — 6 4/5 qts. Water (*)

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

Steering box 0.140 0.127 1/3 pt. SAE 90 EP oil to MlL—L—2105B

Consta nt—speed joints — 0.095 1/ 5 pt. Lithium-base grease. with molybdenum


(sockets and boots each) disulphide N.L.G.l. No. 2

Brake control hydraulic system


front 0.160 0.160 1/3 pt. DOT 3 Motor Vehicle Brake Fluid to
rear 0.160 0.160 1/3 pt. F.M.V.S.S. No. 116

Clutch control hydraulic


system 0.180 0.180 2/5 pt. Same as brake circuit

Temperature Solvent in bottle


Pure water
above 0" C (32° F) 3% plus high
Windshield washer 50% quality wind-
down to —10° C (14° F)
bottle shield washer
below —10° C (14° F) 100% solvent

TEMPERATURE UNIGRADE OIL MULTIGRADE OIL

Below -—15° C'(5° F) VS 10 W (SAE 10W)


Between —15” C (5“ F)
and 0° C (32° F) VS 20 W (SAE 20W) 10 W—30
Between 0° C (32° F)
and 35° C (95° F) VS 30 (SAE 30) 20 W—40
Above 35° C (95° F) VS 40 (SAE 40) 20 W-40

Do not mix oils of different brands or grades.


(‘) When temperature is close to 32° F (0° C) change to good commercial grade anti-freeze mixture.
the table is the requirement for
(“) Total capacity including sump. filter. and lines is 5% qts US. (4.5 kg). The amount indicated in
periodic oil changes.

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Page 6

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 -—

d—Body paint color number AUTI 3T ELMO - CHAS IS


e—Engine type (128 AS.040.4)
f—TOD paint color number [*— 1’}: or”


I
MAOIIH
"'ALY
4
Inn-unlu-
WWI I‘llil

PAH" COLON Nolol .


l

-
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.

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III - 1974

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.

SPARE PARTS CAR KEYS


When placing orders for parts, be sure to supply the Two sets of two keys are supplied with each car.
following information: —one for the ignition.
—Car model (commercial description). —one for doors and glove box, hood and trunk.
—Chassis type and number. An identification number is stamped in the key head.
—Engine type and number. Duplicates can be made on tool Ap5013 if this number
+—-Number of spares. is known.
—Part number of the item being ordered (as listed in
Parts Catalog).
Orders are basically processed according to the part
numbers.

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Page 8

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

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Ill—1974

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).

1. Cover. 2. Nuts. 3. Throttle rod. 4. Control.

Turn crankshaft until lobe on camshaft for valve being


checked is pointing up and at right angle to valve.
Measure clearance between camshaft and tappet plate.
Clearance: Intake — 0.012 in. (0.30mm)
Exhaust — 0.016 in. (0.40mm)

1. Lobe. 2. Plate. 3. Tappet. 4. Feeler gauge.

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Page 10

Adjust clearance as necessary by replacing tappet


plates (1).
After adjusting, install camshaft cover.
Connect throttle rod and hoses.
Install air cleaner. Install spark plugs.

1. Tappet plate. 2. Tool.

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.

1. Wick. 2. Contact points.

Check contact points (1) for wear and damage.


Check point gap (2).
Gap—0.015 to 0.017 in. (0.37 to 0.43mm)
Adjust point gap.
Check condenser (3). Replace as necessary.
NOTE: Replacement of contact points should be per-
formed on the bench with the distributor removed.

1. Contact point. 2. Pointgap. 3. Condenser.

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III - 1974

Section No. 00

Page 11

FUEL FILTER
Replace filter (1) by loosening clamps (2) and discon-
necting hoses (3).
Check fuel lines for tightness.

1. Fuel filter. 2. Clamps. 3. Fuel hoses.

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.

1. Cartridge. 2. Air cleaner. 3. Nuts. 4. Nut.


5. Hose.

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.

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Page 12

AIR PUMP FILTER


Remove wing nut (1) on bottom of filter housing (3).
Remove filter (2). Install new filter. Tighten nut.

1. Wing nut. 2. Filter. 3. Housing.

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.

1. Idle speed adjustment screw.

Using dwell meterl check dwell.


Dwell should be 55°. Adjust contact points as
necessary.
Using strobe light, check ignition timing. Timing should
be 0“ (TDC). If necessary, loosen nut on distributor
clamp and adjust distributor.

1. 0° (TDC). 2. 5°. 3. 10°.

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III - 1914

Section No. 00

Page 13

.P ,

Disconnect vacuum line (1) from distributor (2). I


r'.._'.
Check that ignition timing moves to about 10" advance.
Connect vacuum line to distributor. Check that timing
returns to O” (TDC) in about 7 seconds.

1. Vacuum line. 2. Distributor.

Hook up exhaust analyzer. Check CO reading on ana-


lyzer. 00 should be 0.5% to 1.5%. Adjust mixture

ii
metering screw (1) on carburetor as necessary.

1. Mixture metering screw.

“to"
'J
-

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Page 14

Maintenance — Model X 1/9


FIAT LUBRICANT SPECIFICATIONS

FIAT TYPE INTERNATIONAL DESIGNATION APPLICATION


VS 40 Oil Low ash content detergent oil Crankcase
(minimum above 32° F (0° C); Type MS-Level MlL-L-2104 B
max. above 95" F (35° C) SAE 40

VS 30 Oil Low ash content detergent oil Crankcase


(minimum above 32" F (0° C); Type MS-Level MIL~L»2104 B
max. below 95° F (35" C) SAE 30

VS 20 Oil Low ash content detergent oil Crankcase


(minimum above 32“ F (—15" C) Type MS-Level MlL-L~2104 B
and 32° F (0“ C) SAE 20

VS 10 W Oil Low ash content detergent oil Crankcase


(minimum below Type MS-Level MlL—L-2104 B Starting motor
5° F (#15" C) SAE 10 W

W 901M Oil SAE 90 EP-meets MlL—L—2105 B Steering housing


requirements

ZC 90 Oil Mechanical transmission oil, Transmission and differential


SAE 90 (not EP),
containing anti-wear additives

S.A.|. Oil Mineral antifreeze oil, Hydraulic shock absorbers


containing greasiness additives

MR 2 Grease Lithium-based grease Constant-speed joint recess


N.L.G.I.-No. 3 and protection boot

MR 3 Grease Lithium~based grease Generator - Hand brake - Ignition


N.L.G.l.-No. 3 distributor - Clutch-control
Hydraulic brake control -
Control arm and steering
rod joints

MR 2 Grease Special castor oil and sodium Brake Calipers


soap-based grease, loaded with
graphite and Mo 32. Must be
compatible with brake fluid and
rubber parts of brake circuit

Special blue label fluid HD fluid for hydraulic brake Hydraulic brake circuit
circuit SAE J 1703

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10

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

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III - 1974

Section No. 10

Page 15

Engine: Specifications
CYLINDER BLOCK-CON-RODS

DESCRIPTION IN. MM

Cylinder bore diameter ............................................................


Cylinder bores are graded into classes with 0.0004” (0.01mm) 3.3858 to 3.3878 86.000 to 86.050
progression.
Auxliary shaft bushing seats, diameters:
—drive end ............................................................................ 1.5236 to 1.5248 38.700 to 38.730
——inside end ............................................................................ 1.3794 to 1.3805 35.036 to 35.066
Crankshaft main bearing seat diameter .................................. 2.1459 to 2.1465 54.507 to 54.520
Length of rear main bearing seat between
thrust ring seats ................................................................ 0.8716 to 0.8740 22.140 to 22.200
Big-end bearing housing diameter .......................................... 1.9146 to 1.9152 48.630 to 48.646

Thickness of standard big-end bearing .................................... 0.0603 to 0.0606 1.531 to 1.538

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

Small»end bore diameter .......................................................... 0.9425 to 0.9438 23.939 to 23.972

Small-end bushing 0.0. .......................................................... 0.9455 to 0.9465 24.016 to 20.041

Small-end bushing fit, interference .......................................... 0.0017 to 0.0040 0.044 to 0.102

Small-end bushing ream bore, fitted


Grade 1 ............................................................................ 0.8663 to 0.8664 22.004 to 22.007
Grade 2 ............................................................................ 0.8664 to 0.8665 22.007 to 22.010

Piston pin-smaIl-end bushing fit:


—clearance of new parts ........................................................ 0.0004 to 0.0006 0.010 to 0.016

Maximum misalignment between CNS of connecting rod


small-end and big-end:
—measured at 4.92" (125mm) from the shank ______________________ :0.0039 10.10

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Page 16

PISTONS — PINS —- RINGS

DESCRIPTION IN. MM

Diameter of standard service pistons, measured


at right angles to C/L of piston pin:
—at 1.08” (27.5mm) from piston skirt edge
Class A .............................................................................. 3.3835 to 3.3839 85.920 to 85.930
Class C .............................................................................. 3.3842 to 3.3846 85.960 to 85.970
Class E .............................................................................. 3.3850 to 3.3854 85.980 to 85.990

Oversize piston range .............................................................. 0.0079, 0.0157, 0.2. 0.4.


0.0236 0.6

Piston boss bore diameter


Grade 1 ............................................................................ 0.8660 to 0.8661 21.996 to 21.999
Grade 2 ............................................................................ 0.8661 to 0.8662 21.999 to 22.002

Piston ring groove width


Top groove ........................................................................ 0.0604 to 0.0612 1.535 to 1.555
Center groove .................................................................... 0.0799 to 0.0807 2.030 to 2.050
Bottom groove .................................................................. 0.1562 to 0.1570 3.967 to 3.987

Standard piston pin diameter


Grade 1 ............................................................................ 0.8658 to 0.8659 21.951 to 21.994
Grade 2 ............................................................................ 0.8659 to 0.8660 21.994 to 21.997
Oversize piston pin range for service ...................................... 0.0079 0.2

Piston ring thickness


—first: compression ring ........................................................ 0.0582 to 0.0587 1.478 to 1.490
-—second: oil ring .................................................................. 0.0779 to 0.0783 1.978 to 1.990
—third: oil ring with oilways and expander ............................ 0.1545 to 0.1553 3.925 to 3.947

Piston fit in bore. measured at right angle to pin,


1.08” (27.5mm) from piston skirt edge
—clearance of new parts ........................................................ 0.0020 to 0.0028 0.050 to 0.070

Piston pin in boss: clearance of new parts .............................. 0.0001 to 0.0003 0.002 to 0.008

Piston ring fit (side clearance)


—first: compression ring, clearance of new parts .................. 0.0018 to 0.0030 0.045 to 0.077
—second: oil ring. clearance of new parts .............................. 0.0016 to 0.0028 0.040 to 0.072
—third: scraper ring, clearance of new parts .......................... 0.0008 to 0.0024 0.020 to 0.062

Ring end gap in bore:


—first: compression ring ........................................................ 0.0118 to 0.0177 0.30 to 0.45
—second: oil ring .................................................................. 0.0118 to 0.0177 0.30 to 0.45
—third: scraper ring .............................................................. 0.0098 to 0.0157 0.25 to 0.40

Oversize piston ring range, for service .................................. 0.0079, 0.0157. 0.2, 0.4,
0.0236 0.6

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III - 1974

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

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Page 18

VALVE MECHANISM — CAMSHAFT

DESCRIPTION IN. MM

Diameter of bearing bores in head:


—drive end ____________________________________________________________________________ 1.1807 to 1.1816 29.989 to 30.014
#intermediate, drive side ...................................................... 1.8890 to 1.8900 47.980 to 48.005
—middle ................................................................................ 1.8968 to 1.8976 48.180 to 48.205
~intermediate. flywheel side .................................................. 1.9047 to 1.9057 48.380 to 48.405
—f|ywhee| end ........................................................................ 1.9126 to 1.9136 48.580 to 48.605

Diameter of camshaft journals:


—drive end ............................................................................ 1.1787 to 1.1795 29.944 to 29.960
-—intermediate, drive side _____________________________________________________ 1.8872 to 1.8878 47.935 to 47.950
—middle ................................................................................ 1.8951 to 1.8957 48.135 to 48.150
—intermediate, flywheel side .................................................. 1.9030 to 1.9035 48.535 to 48.350
—f|ywheel end ...................................................................... 1.9108 to 1.9114 48.535 to 48.550

Fit between bores in head and camshaft journals:


—fit clearance
drive end .......................................................................... 0.0011 to 0.0028 0.029 to 0.070
intermediate, drive side .................................................... 0.0012 to 0.0028 0.030 to 0.070
middle .............................................................................. 0.0012 to 0.0028 0.030 to 0.070
intermediate. flywheel side ................................................ 0.0012 to 0.0028 0.030 to 0.070
flywheel end ...................................................................... 0.0012 to 0.0028 0.030 to 0.070

AUXILIARY SHAFT

Diameter of bushing bores in crankcase:


—drive end ............................................................................ 1.5236 to 1.5248 38.700 to 38.730
—inside end .......................................................................... 1.3794 to 1.3805 35.036 to 35.066

Inside diameter of bushings finished in bores:


—drive and ............................................................................ 1.4041 to 1.4049 35.664 to 35.684
—inside and .......................................................................... 1.2598 to 1.2606 32.000 to 32,020

Diameter of shaft journals:


mdrive end ............................................................................ 1.4013 to 1.4023 35.593 to 35.618
—inside end .......................................................................... 1.2575 to 1.2583 31.940 to 31.960

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

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III - 1974

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

Main bearing seat bore .......................................................... 2.1459 to 2.1465 54.507 to 54.520

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.

Crankpin standard diameter ____________________________________________________ 1.7913 to 1.7920 45.498 to 45.518

Main bearing-to-journal fit:


—c|earance of new parts ........................................................ 0.0016 to 0.0033 0.040 to 0.085

Length of rear main bearing journal,


shoulder-to-shoulder .......................................................... 1.0620 to 1.0640 26.975 to 27.025

Width of rear main bearing seat,


between thrust ring seats .................................................. 0.8716 to 0.8740 22.140 to 22.200

Rear main bearing seat thrust ring thickness .......................... 0.0909 to 0.0929 2.310 to 2.360

Thickness of oversize thrust rings .......................................... 0.0959 to 0.0979 2.437 to 2.487

Crankshaft end play, thrust ring installed:


—clearance of new parts ...................................................... 0.0021 to 0.0104 0.055 to 0.265

Max. misalignment of main bearing journals .......................... 0.0012* 003*

Max. misalignment of crankpins to main bearings journals ...... :0.014 10.35

Max. out-of-round of crankshaft journals


and crankpins, after grinding .......................................... 0.0002 0.005

Max. taper of crankpins and journals, after grinding ................ 0.0002 0.005

Squareness of flywheel resting face to crankshaft centerline:


—Max allowable tolerance with dial indicator set laterally
at a distance of about 1 11/32” (34mm) from crankshaft
rotation axis ............................................................................ 0.0010 0.025

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

*Total indicator reading

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Page 20

FUEL SYSTEM
CARBURETOR
Type ........................................................................................ WEBER 32 DMTRA 200
PEI-MARY BAflafinL SESBNDARY BflaaEL

Bore ........................................................................................ 1.260 32 1.260 32

Main venturi ............................................................................ 0.866 22 0.866 22


Main jet .................................................................................. 0.043 1.10 0.043 1.10
Idle jet .................................................................................... 0.018 0.45 0.024 0.60
Main air corrector .................................................................... 0.079 2.00 0.077 1.95
Idle air corrector ...................................................................... 0.043 1.10 0.28 0.70
Accelerator pump jet ................................................................ 0.020 0.50 — —

Emulsion tube type .................................................................. F 30


Extra fuel device jet ................................................................ — —- 0.027 0.70
Extra fuel device jet ................................................................ — — 0.033 0.85

Choke type .............................................................................. throttle valve


Partial opening of primary throttle valve (choke-on) ................ 0.035” to 0.394” (0.90 to 10mm}

Needle valve seat .................................................................... 0.059 in. (1.50mm)


Float valve: distance between float and cover with gasket,
in vertical position ............................................................ 0.24 in. (6mm)

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III - 1974

Section No. 10

Page 21

Engine: Specifications
LUBRICATION

OIL PUMP
Type ........................................................................................ gear

Pump Drive .............................................................................. by auxiliary shaft

Oil pressure relief valve .......................................................... built into oil pump

Clearance between gears upper side


and cover mating face ........................................................ 0.0008 to 0.0041 in. (0.020 to 0.105mm}

Clearance between gears and pump housing inside wall .......... 0.0043 to 0.0071 in. (0.11 to 0.18mm}

Full flow oil filter with by—pass ................................................ cartridge type

Low oil pressure indicator sending unit .................................. electric

Oil pressure at 185° F (85° C) ................................................ 64 to 85.4 psi (4.5 to 6 kglcm)

COOLING SYSTEM

WATER PUMP
Type ........................................................................................ centrifugal, vane type

Pump Drive ............................................................................ Vee belt

Fit between impeller vans and pump housing .......................... 0.031 to 0.051 in. (0.8 to 1.3mm)

Radiator cooling fan drive ........................................................ electric motor

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)

Water temperature indicator .................................................... electric (tell tale)

Radiator cap valve opening pressure ........................................ 11 psi (0.8 kg/cm)

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Page 22

Engine: TIGHTENING REFERENCE


DESCRIPTION THREAD
(METRIC) TORQUE
MATERIAL FT. LBS. kgm
ENGINE
Se lf-locking bolt, flywheel to crankshaft ............ M 10 x 1.25 R 120 61 8.5
Bolt, breather duct to crankcase ........................ M 8 R 80 Znt 18 2.5
Nut, connecting rod cap bolt .............................. M 9x 1 R 80 (Bolt R 100) 36 5
Bolt, driven sprocket to camshaft ...................... M 10 x 1.25 R 120 61 8.5
R 100 (washer
Bolt. cylinder head hold-down ............................ M 12 x 1.25 Sint. M 8 F and 69 9.5
40 Cmt 3)
R 80 Znt (Washer
. Sint. M 8 F and
Nut, cylinder head studs .................................... M 12 x 1.25 40 Cmt 3) 69 9.5
(Stud R 100)
. R 50 Znt (Stud
Nut, upper to lower cylinder head .................... M 8 R 80 Znt) 14.5 2

Self-locking bolt, main bearing caps .................. M 10 x 1.25 R 100 58 8


. R 50 Znt (Crank-
Nut. drlve pulley on crankshaft .......................... M 20 x 1.5 shaft Ch 705003) 101 14
. . R 50 Znt (Stud
Nut. bearing to belt tensroner support ................ M 10 x 1.25 R 100 Znt) 32.5 4.5 .
. . R 50 Znt (Stud
Nut, Intake and exhaust manifold ...................... M 8 R 80 Znt) 22 3

Bolt, oil pump and fuel pump shaft driven gear .. M 10 x 1.25 R 120 61 8.5

Nut, upper bracket to water pump ....................


R 50 Znt (Stud
M 8 R 80 Znt) 18 2.5

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

Self-locking nut, alternator R 50 Znt (Bolt 36 5


to upper bracket bolt .................................. M 10 x 1.25 R 80 Znt)
POWER PLANT MOUNTING
Nut for bolt rubber pad to crossmernber, R 50 Znt (Bolt 25 3 35
engine end .................................................. M 10 x 1.25 R 100 Cdt) ' '
Bolt. crossmember, transmission end ................ M 8 R 100 Cdt 14.4 2
. . R 50 Znt (Stud
Nut, rubber pad to transmissmn assembly ........ M 8 R 80 Znt) 18 2.5

Bolt, rubber pad to transmission assembly ...... M 8 R 80 Znt 18 2.5


Bolt. power plant anchor rod .............................. M 8 R 50 Cdt 10.8 1.5
Bolt, rubber pad to crossmember ...................... M8 R 80 Znt 18 2.5

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III -1974

Section No. 10

Page 23

Engine: Specifications

LONGITUDINAL SECTION OF ENGINE THROUGH CYLINDERS

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Ill - 1914

Section No. 100.01

Page 25

Power Plant Mounts


POWER PLANT REMOVAL
Disconnect battery cables (in front luggage com-
partment).
Loosen fuel cap.
Drain cooling system. Remove cap (4) from expansion
tank.
Disconnect hose (3) from air injection valve. Discon-
nect hose (1) from air cleaner. Loosen clamp holding
fresh air duct (5) to fan.
Remove 3 nuts (2) and washers holding cover on
air cleaner. Remove 4 nuts holding air cleaner on
carburetor.
Remove not holding bracket on air cleaner to engine.
Disconnect hose from bottom of air cleaner. Remove
air cleaner with fresh air duct.
1. Hose. 2. Nuts. 3. Hose. 4. Cap.
5. Fresh air duct.

Disconnect hose (1) between air pump (2) and filter.


Disconnect hose (3) from air pump.
Separate heater return hose (5) at coupling joint (4).
Disconnect heater hose from pump.
Disconnect wires from alternator.
Remove 2 bolts holding louvered protection panel
below carbon trap in rear firewall.

1 Hose. 2. Air pump. 3. Hose. 4. Coupling.


5. Heater Hose.

Disconnect choke linkage (2) from carburetor.


Disconnect hoses (l and 5) from carburetor base.
Disconnect Wires (3) from carburetor. Disconnect vent
hose (4) from carburetor.
Disconnect wires from coil to distributor at distributor.
Disconnect wires from oil pressure and water temper—
ature sending units. Disconnect wires from starter.

1. Hose. 2. Choke linkage. 3. Wires. 4. Vent


hose. 5. Hose.

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Remove clamp (5) holding fuel lines to firewall.
Disconnect fuel feed and return hoses from firewall.
Remove stop bolt (1) from accelerator cable (2).
Slide seal (3) off cable. Remove retainer clip (4) from
cable sheath. Remove cable from support.

1. Stop bolt. 2. Accelerator cable. 3. Seal.


4. Retainer clip. 5. Clamp.

Remove bolts holding expansion tank (1) at top and


bottom. Lift tank and allow water to drain into engine.
Disconnect hoses from tank at thermostat. Remove
tank.
Disconnect 2 hoses from thermostat.
Remove cotter pin holding rod from operating cylinder
in clutch shaft. Loosen 2 bolts (3) holding operating
cylinder (2) to transmission. Open bleed screw on
cylinder and allow rod to retract. Swing cylinder out of
way.
1. Expansion tank. 2. Operating cylinder. 3. Bolt.

Working under the car;


Remove remaining bolt holding louvered panel in rear
firewall. Remove panel.
Remove heat shield (2) behind alternator. Remove 3
panels (3) from bottom of engine compartment. Re-
move panels (1) inboard of each rear wheel.

1. Wheel panels. 2. Heat shield. 3. Engine panel.

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lll - 1914

Section No. 100.01

Page 27

Power Plant Mounts


0

Drain transmission/differential. ‘ “U“ L?"


Disconnect connectors for back-up light and seat belt ‘ - '
interlock system. Remove clamps as necessary to allow
wires to come out with engine.
Loosen nurled nut on speedometer cable. Remove
cable from differential. Secure cable out of way.
Remove bolts (4) holding gearshift linkage (3) to shift- 1
ing tube (5). Loosen bolt (2) at transmission end of : .-

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.

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Page 28

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.

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IlI - 1914

Section No. 101.01

Page 291‘ .. .

1' Grankcase and Cylinder Head


CYLINDER HEAD

REMOVING CYLINDER HEAD


(Engine IN CAR)
Drain cooling system. Remove air cleaner.
Disconnect 2 fuel hoses (4) from carburetor.
Pull hoses and grommets out of bracket (5).
Slide spring clip (2) down off ball connector (1) for
accelerator rod (3). Disconnect rod (3) from ball
connector.

1. Ball connector. 2. Spring clip. 3. Accelerator


rod. 4. Fuel hoses. 5. rack t.

Disconnect spark plug cables.


Disconnect vacuum hose for distributor from fitting in
head.
Remove stop bolt (1) from accelerator cable.
Slide seal (3) off cable (2). Remove clip holding cable
on valve cover (4). Remove cable.

1. Stopbolt. 2. Cable., 3. Seal. 4. Valvecover.

Disconnect water outlet hose (1), inlet hose (2), pump-


to-union hose (3), and expansion tank hose (4) from
union (5).
Remove bolt holding reaction rod (6) in bracket. Move
rod out of way.
Disconnect hose (8) from exhaust shroud.

'1. Outlet hose. 2. Inlet hose. 3. Pump-to-union


hose. 4. Tank hose. 5. Union. 6. Reaction rod.

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Disconnect wires to thermostatic switch (4) on car-
buretor.
Disconnect evaporative hose (5) from carburetor.
Disconnect hoses (1 and 3) from air pump (2).
Disconnect exhaust muffler from flange on exhaust
manifold.

1. Hose. 2. Air Rump. 3. Hose.


4. Thermostatic switc. 5. Hose.

Remove bolts and washers holding timing cover (1).


Remove right lower guard from under engine.
Remove lower bolt holding cover. Remove cover (1).
Loosen lower bolt on alternator (5). Loosen bolt thru
alternator adjusting bracket (6). Remove alternator and
water pump drive belt (4). '
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.
Loosen nut on tensioner pulley (2). Remove timing
belt (3).
Remove lower bolt thru belt guard.
Remove cylinder head to crankcase bolts and nuts.
Remove cylinder head.
NOTE: Remove carburetor, intake, and exhaust man-
ifolds with cylinder head. Remove these from head
on bench.
l15;“ Timin cover. 2. Tensioner pulley. 3. Timing
Drive belt. 5. Alternator. 6. Bracket.
7. Brackets. 8. Air pump.

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III ~1914

Section No. 101.01

Page 31

Crankcase and Cylinder Head

To reinstall head, reverse removal procedures. Always


use a new gasket between head and crankcase.
Refer to Tightening Reference for torque values. Torque
cylinder head bolts and nuts in sequence shown in
two steps;
lst step—torque to about 29 ft. lbs.
2nd step—torque to 61.5 ft. lbs.

CHECKING CYLINDER HEAD GASKET SURFACE


Using a straightedge, check the head for distortion.
Lay the straightedge across the diagonals of the gasket
surface and also lengthwise in the middle. The gap
between the head and the straightedge must not ex-
ceed 0.002 inch. lf gap exceeds this reface the cylinder
head gasket surface. Do not remove more material than
necessary. Check depth of combustion chambers to
make sure it has not been reduced below allowable
limits.

CHECKING DEPTH OF COMBUSTION CHAMBERS


Place gauge A.96216 in center of combustion chamber.
Check gap between gauge and head gasket surface.
Use a feeler gauge.
Gap should not exceed 0.01 in. (0.25mm).

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INSPECTING AND REFACING VALVE SEATS
AND VALVES
The valve seats in cylinder head must not have ev-
idence of pitting on contact face. If pitted, they must
be refaced as follows:
Make sure grinding stones have a taper of 45° 15’.
If necessary, dress grinding stones.

1. Mandrel. 2. Stone. 3. Control lever.


4. Tool feed knob. 5. Lock screw. 6. Tool.
7. Graduated scale. 8. Angle adjustment knob.

Select a pilot which has minimum clearance between


it and valve guide. Place pilot in valve guide.
Place stone in mandrel. Place mandrel in grinder.
Grind valve seats. Make sure grinder is not turned on
with stone in contact with seat.

Narrow seat width.


Install a 20° valve seat reamer on mandrel. Insert
mandrel on pilot. Turn on grinder. Carefully narrow
seat.
Remove 20" reamer. Install 75" reamer. Turn on grind-
er. Carefully narrow seat.

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Ill-1974

Section No. 101.01

Page 33

Crankcase and Cylinder Head

Use both 20° and 75° reamers alternately until seat


width of about 0.0787 in. (2mm) is obtained.
L = 0.0787 in. (2mm).

Valve stern must not be distorted or cracked. If neces-


sary replace valve.
Clean carbon from valves. Use wire brush.

If valve face is worn or damaged, reface valves.


Install valve in grinder. Set grinder for the specified
angle of 45° 30’ :5’ upon completion of grinding.
Remove only enough material to true up surfaces.
After refacing, check that the thickness of valve at edge
of head is not less than 0.02 in. (0.5mm).
If necessary to grind valve stem tip to remove traces
of dishing, remove only what is strictly necessary.

1. Valve. 2. Grinding stone. 3. Control lever.

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Page 34

Install valves in seat in cylinder head.


Using gauge A.96219, check that stem tip just touches
control surface of gauge. If there is interference be-
tween stem and gauge reduce stem height by_ grinding.

1. Gauge. 2. Valve stem.

CYLINDER HEAD TORQUEING SEQUENCE


Torque hold down bolts and nuts in sequence shown.
Torque bolts and nuts in gradual steps to 69 ft. lbs.
(9.5kgm).

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ill-1974

Section No. 101.01

Page 35

Crankcase and Cylinder Head


CRANKCASE

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).

1. Dial gauge. 2. Ringgauge.

Zero dial indicator using ring gauge A.96139. JiMEASURlENLEN'L


Check cylinder bores at three points both lengthwise
and crosswise.

Z‘MEASUREMENT

flBLREMENL

The bore class is indicated by letters stamped on the


bottom of crankcase.

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Page 36

Cylinder bore diameter may vary from 3.3858 to


3.3878 in. (86.000 to 86.050mm).
Bares are selected in 0.004 in (0.01mm) classes. F9500
73.590

__flyflh. _._
'
_ aa.nnn_+_ar..oza
._ __ .____ ___

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III - 1914

Section No. 101.02

Page 37

Oil Sump and Crankcase Covers


14

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

Auxiliary shaft seal cover.


1. Cover. 2. Seal. 3. Shaft.

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Page 38

OIL SUMP COVERS


1. Gasket 4. Bolt 7. Oil sump
2. Cover 5. Drain plug 8. Washer
3. Washer 6. Gasket 9. Bolt
4

.. _.—._._,_‘

Crankshaft oil seal, flywheel end.


Arrows indicate that distance between cover gasket
and crankshaft should be equal all around.

Crankshaft cover, timing gear end.


Arrows show indexes for checking centering of cover
with respect to crankshaft.

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Ill - 1974

Section No. 101.03

Page 39

Crankshaft and Flywheel


[—45.4922
| 45.518

/|_
0320.2

50.735]
50.805]

Main data of crankshaft journals, crankpins, and shoulder radius.

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)

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Page 40

('1
he“

g,
,/

1 .825‘
1 .831

-2 C}:
W Main data of crankshaft journals, main bearings, saddle bores, and thrust rings

Clearance between crankshaft journals and bearing: _


should be 0.0020 to 0.0037 in. (0.050 to 0.095mrn)

Torque cap screws for main bearings to 58 ft. lbs


(8kgm).

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Ill - 1974

Section No. 101.03

Page 41

Crankshaft and Flywheel

Check crankshaft and play.


End play should be 0.0021 to 0.0104 in (0.055 to
0.265mm).
If necessary, install oversize thrust rings.

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III -1974

Section No. 101.05

Page 43

Connecting Rods and Pistons


PISTONS-CONNECTING RODS
86.000 3.967 2.030 1.535
86.050 3.987 2.050 1.555
I—

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 "

Main data of cylinder bore, piston, and rings.

Piston class and piston bore class are identified by


letter and number stamped on underside of piston
bosses. Piston pin class is stamped on pin surface.

1. Piston_boss bore class. 2. Piston class letter.


3. Matching number of connecting rod to cylinder.

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.

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Piston pin clearance in boss bore is 0.0001 to 0.0003
in. (0.002 to 0.008mm).
Piston pin clearance in bushing in small end is 0.0004
to 0.0006 in. (0.010 to 0.016mm).
The fit clearance between crankpins and bearings is
0.0014 to 0.0034 in. (0.036 to 0.085mm).

Piston bore is 0.08 in. (2mm) offset.


When assembling piston to connecting rod, make sure
number on connecting rod faces away from side of
piston bore offset. Secure piston pin in piston with
lockring.

1. . Auxiliary shaft. 2. Location of connecting rod to


cylinder matching number.

Before installing rings on pistons, push rings down in


groove. Check clearance with feeler gauge. See
specifications.

1. Ring. 2. Piston. 3. Feeler gauge.

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Ill - 1974

Section No. 101.05

Page 45

Connecting Rods and Pistons

Push rings squarely into cylinder bores.


Using feeler gauge, check ring end gap.
See specifications.
When installing rings, stagger end gaps 120° apart.

Before installing connecting rod~pin-piston assembly


in cylinder, check alignment of big-end and small-end
cHs measured at 4.92 in. (125mm) from shank.
Maximum allowable misalignment is $00039 in.
(:OJOmm).

1. Piston assembly. 2. Expansion blades.


3. Square gauge.

Install assemblies in cylinders according to number


stamped on conencting rods and caps. Install them
with numbers facing toward auxiliary shaft.
Torque big-end cap nuts to 36 ft. lbs (5 kgm).

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III - 1974

Section No. 101.06

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.

Remove cam cover. Check that cam lobes of No. 4


cylinder are pointing up. Remove distributor. Loosen
idler pulley lock nut (1). Push in on support and tight-
en Iock nut. Remove belt (3), starting at idler pulley
(2}.
Install new belt. Start at crankshaft pulley. Twist belt
gently to position it around crankshaft pulley. Do not
kink belt.
1. Lock nut. 2. Idler pulley. 3. Timing belt.

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Keep slack out of belt. Slip belt (2) over camshaft
pulley (1). Camshaft pulley may have to be turned
slightly to align slots with belt cogs. Install belt on
idler pulley (4) last. If this is difficult, recheck belt.
Do not pry belt.
Release idler pulley lock nut (3) and retighten after
tension is on belt. Release hand brake and push car
forward (in gear) one—half turn. Release idler pulley lock
nut (3) to make sure all slack is removed. Retighten
lock nut. Continue pushing car forward until No. 4
cylinder is on firing stroke, cam lobes up.
CAUTION: Never push car backward in gear or allow
engine to rock backyard while pushing car. Slack will
develop in belt, allowing belt to jump timing.
1. Camshaft pulley. 2. Bolt. 3. Lock nut.
4. Idler pulley.

Place belt cover on car. Make sure crankshaft timing


mark is on T.D.C. (3). Check that camshaft mark is
exactly on pointer. If good, torque nut (2) on tensioner
pulley (6) to 32.5 ft. lbs.
Install pulley (4) on crankshaft. Installed drive belt
on air pump. Install drive belt (5) for water pump and
alternator. Adjust belt tension.
Install timing gear cover (1). Install lower right guard.
Install cam cover.
Install distributor. Make sure distributor is set on No. 4
cylinder.
1. Timing gear cover. 2.. Lock nut. 3. T.D.C. mark.
4. Drive pulley. 5. Drive belt. 6. Tensioner pulley.

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III-1914

Section No. 101.01

Page 49

Valve Mechanism
CAMSHAFT

11

EXPLODED VIEW OF VALVE MECHANISM COMPONENTS.


1. Seal 7. Inner spring 13. Intake valve
2. Dowel 8. Outer springs 14. intake valve guide
3. Plates of adjusting valve clearance 9. Lower cups 15. Oil seal
4. Tappets 10. Exhaust valve guide 16. Camshaft
5. Locks 11. Exhaust valve 17. Welch plug
6. Upper cups 12. Flat washer

. A l l 1 l

48.580 48.380 748380 47.980 29.9891


43.505 48.405 43.205 43.005 30.014
. t O . l
-—\_x

48.550 "48.350| 48.150 47.950 29.960


48.535 48.335 48.135 47.935 29.944
Main data on camshaft and bores in housing.

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Page 50

AUXILIARY SHAFT

31.940 _ 35.593
31.960 35.618

Main data of auxiliary shaft and bushing.

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III-1974

Section No. 101.07

Page 51

Valve Mechanism

REPLACING TAPPETS AND VALVE GUIDES


Make sure tappet plate surface in contact with lobes
on camshaft is glass-like and shows no signs of dishing
or pitting.
Check tappet diameter and tappet bore diameter in
housing. Tappet clearance in bore should be 0.002 to
0.020 in. (0.005 to 0.050mm)

_ 37.000
, 37,025
i ____ . ]:l
[1.10.014
+ M ._ 30,975
35,995

be 0.0025 to 0.0043 in. (0.063 to 0.08mm).


Valve guides are press fitted in their bores. Interference should
0.008 in. (0.2mm) oversize.
Valve guides are available for service in the standard size and

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Page 52

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

Replace valve guides if scored or worn. If clearance


between valve guide and stem is excessive, replace
guide.
Use driver A.60153 to remove guide.

When installing guides use drive A.60153 and spacer


A.60153/6A for intake valve guides.
Use driver A.60153 and spacer A.60153/63 for ex~
haust guides.

1. Driver. 2. Spacer for intake valve guide.


3. Valve guide.

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Ill-1974

Section No. 101.07

Page 53

Valve Mechanism

Repiacement guides have inner diameter prefinished


to size.
If press fitting causes minor fault, refinish guide. Use
reamer A.90310.

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I!- TL. ILEII-
I:
E

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Ill - 1974

Section No. 102.01

Page 55

Fuel Tank and Lines


FUEL EVAPORATWE EMISISION CONT’ftIOL SYS'llEM
{5-1 “-

222'60

Position 1. Position 2. Position 3 (safety).


From fuel tank to activated Air from ambient Vapor from tank to ambient
carbon vapor trap. into tank. (excess pressure in the tank).

Fuel tank. Line trom carbon trap to carburetor Safety outlet.


are
are

Liquid vapor separator. (downstream of throttle). Air filter.


Line from separator to 3-way To carburetor bowl. To carburetor (downstream of
valve. . Lines between separator and fuel throttle).
. 3-way control valve. tank. Synthetic fllter.
Inc

93????

Activated carbon trap. Activated carbon.


Line from 3-way valve to carbon Air purge paper filter.
trap. From fuel tank. Fuel vapor inlet from tank.
Hot air purge tube. To activated carbon trap. . Hot air purge Inlet.
In o

Exhaust manifold. Fuel tank air inlet. Fuel vapor Inlet from carburetor.
.

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r-J l-—I

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lll - 1974

Section No. 102.02

Page 5'!

Fuel Pump and Lines


FUEL PUMP REMOVAL
Remove clamps on fuel inlet (1) and outlet (4) lines.
Disconnect lines from pump (3).
Remove two nuts (2) and washers holding pump to
engine. Remove pump.
Remove two gaskets and insulator.

1. Inlet line. 2. Nut. 3. Pump. 4. Outlet line.

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.

1. Cover screw. 2. Lockwasher. 3. Cover.


4. Screw. 5. Filter. 6. Upper body.
7. Diaphragm. 8. Spacer. . 9. Sipnng.
10. Lower body. 11. Pivot Pm. 2. Control lever.
13. Spring.

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Page 58

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.

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III - 1974

Section No. 102.04

Page 59

Carburetor and Air Cleaner


1 i 5
FLOAT LEVEL SETTING
Check that needle valve (2) is screwed down in
housing.
Check that float (9) is free of dents or punctures.
Check that float can turn freely on its hinge.
a=0.236 in. (6mm)=distance between float and cover —'_\
with gasket, in vertical position.

—~.—-'
b=0.590 in. (15mm)=maximum distance of float from
cover face with gasket.
b—a=0.354 in. (9mm):float travel.

1. Carburetor cover. 2. Needle valve. 3. Lug.


4. Valve needle. 5. Return hook. 6. Movable ball.
7. Tang. 8. Float arm. 9. Float. 10. Gasket. 10

1936?

IDLE SPEED ADJUSTMENT


Connect a tachometer to engine.
Start engine and warm it up.
Check that idle Speed is according to specification on
tag.
If necessary, adjust idle speed screw.

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.

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Page 60

69 7o‘ 71l 72I 73 74‘ 7:3) 75 77

EXPLODED VIEW OF CARBURETDR


. Carburetor cover . Screw . Ring . Lever . Cotter pin
1.:

2. Stud . Support Rod . Lockwasher . Choke override


3. Bowel vent valve . Idle screw . Spring Nut Screw
4. Float . Spring . Nut . Bushing . Cover gasket
5. Pin . Spring . Lockwasher . Lever Screw
6. Gasket Idle mixture screw . Washer . Spring . Ring
7. Needle valve Screw . Bushing . Bushing . Ring
8. Venturi _ _ . Accelerator pump cover . Carburetor body . Primary shaft . Washer
9. Air metering jet . Diaphragm . Lever _ lever . Choke override
10. Emulsron tube Spnng . Cotter pm . Washer control
11. Main Jet . Throttle shaft. primary . Secondary throttle . Spring . Screw
12. Idle jet holder . Bushing stop screw . Bushing . Choke throttle
13. ldle jet Lever . Hose . Spring shaft
14. Gasket . Bushing . Throttle . Lever . Choke throttle
15. Acceleration pump . Lockwasher . Screw . Rod . Plug
nozzle Nut . Secondary throttle . Lifter plug . Dust cover
16. Screw 332 Spfing shaft Lifter

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III - 1914

Section No. 10204

Page 61/62

Carburetor and Air Cleaner

IDLE AND TRANSFER

36 15 18 fr}

BE 57
51

71 72
\

53

65

22592

A. Choke « off» - B. Choke «on».

RECIRCULATING DEVICE
ACCELERATING PUMP For mow—3v GASES

22694

15 20 45 22695

5 59 54 48 22693

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CRUISE

6
19:52

19153

. Needle valve. 27. ldler lever. 49. Idler lever.


. Valve needle. 28. Secondary shaft actuating lever. 50. Control rod, valve 51.
4091;.d

. 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.

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III - 1974

Section No. 102.04

Page 83

Carburetor and Air Cleaner


AIR CLEANER REMOVAL AND INSTALLATION
Loosen clamp holding air line (3) to non—return valve (7). Disconnect line from valve. Move line out of the way.
Loosen clamp (5) holding fresh air duct (4) to carburetor cooling fan (6).
Remove 3 nuts (1) and washers holding cover (2) on air cleaner. Remove cover.
Remove nut and washer holding bracket (9) on air cleaner to valve cover.
Disconnect by—pass hose (8) from air cleaner. Disconnect hose from bottom of air cleaner.
Remove 4 nuts holding air cleaner to carburetor. Remove air cleaner and fresh air duct.

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.

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Page 64

CARBURETOR COOLING FAN


The cooling fan is controled by a thermostatic switch
in the carburetor and a relay mounted on the fan
support.

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.

1. Regulator. 2. Fan relay. 3. Fresh air duct.


4. Fan Duct. 5. Support. 6. Fan. 7. Screws.

THERMOSTATIC SWITCH
REMOVAL
Disconnect wires from switch.
Unscrew and remove switch.

1. Switch. 2. Wires.

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lll - 1914

Section No. 102.54

Page 35

Exhaust Pipe
REMOVAL
Remove 4 nuts (1) and lockplate (2) holding pipe (4)
to flange (3) on exhaust manifold.

1. Nuts. 2. Lock late. 3. Fla .


4. Exhaust pipe. p we

Remove 2 bolts and washers holding bracket to top of


exhaust pipe.

Remove 2 bolts (3) and washers holding exhaust pipe r


(1) to crossrail (2). Remove exhaust pipe.

1. Exhaust pipe. 2. Crossrail. 3. Bolts.

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Page 66

-16

EXHAUST PIPE
Intake manifold Bolt
@WPP’NE"

Bolt Exhaust pipe


Washer Bolt
Lockwasher Nut
Nut Lockplate
Support bracket . Stud

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lll - 1974

Section No. 102.58

Page 5':

Exhaust Emission Control System

K
(

6©®®6©0®©

226?!

EXHAUST EMISSION CONTROL SYSTEM


Intake line with filter Air distributor line
EPWPPP!‘

Pump discharge safety valve . Non-return valve


Air pump Vacuum line for carburetor diaphragm
Intake manifold . Air injector
Exhaust manifold . Vacuum control thermova Ive
Diverter valve .mmwm
Vacuum line for diverter valve Distributor advance disphragm control unit

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Page 68

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.

I. Hose. 2. Timing cover. 3. Air pump.


4. Hose.

AIR INJECTION MANIFOLD


REMOVAL AND INSTALLATION
Remove air cleaner for access.
Remove bolt and nut holding clamp (1) on non-return
valve (2) to bracket on engine.

1. Clamp. 2. Non-return valve.

Remove 2 bolts (2) holding manifold (1) to engine.


Disconenct 4 injectors from engine.
Remove manifold with non-return valve (3).
Remove valve from manifold.
Install manifold in reverse order.

1. Manifold. 2. Bolts. 3. Non-retum valve.

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Ill-1914

Section No. 103.01

Page 69

Lubficafion
EXPLODED VIEW OF ENGINE LUBRICATION SYSTEMS COMPONENTS

Bolt 11. Shaft 21. Flame trap 30. Pipe


PPWFP‘P‘PPP!‘

Washer 12. Pin 22. Hose 31. Washer


Filter 13. Bushing 23. Hose 32. Bolt
Oil pump 14. Bushing 24. Clamp 33. Gasket
Gasket 15. Washer 25. Switch 34. Washer
Sending unit 16. Dip stick 26. Boot 35. Lockwasher
Pipe 17. Bolt 27. Boot 36. Bolt
Bushing 18. Clamp 28. Washer 37. Pipe
Seal 19. Oil cap 29. Bolt 38. Connector
Gear 20. Gasket
l—l

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Page 10

ENGINE LUBRICATION DIAGRAM


1. Oil filler pipe 8. By-pass valve
2. Oil mist outlets for camshaft lobes and tappets 9. Oil pump
3. Camshaft 10. Oil pressure relief valve
4. Auxiliary units drive shaft 11. Oil pump suction pipe
5. Filterto engine components oil line 12. Oil return pipe
6. Oil pump and distributor drive gear oil duct 13. Oil mist outlet for cylinder walls
7. Full-flow oil filter

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III - 1914

Section No. 103.01

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.

1. Oil return pipe from breather body.


2. Oil return pane from rear saddled bore.
3. Flywheel an cover plate. 4. Oil pump.
5. Timing gear end cover plate.

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).

1. Pump shaft. 2. Cover. 3. Valve spring.


4. Relief valve. 5. Housing.

Check spring for relief valve for cracks and loss of


elasticity.
Check spring load.
A=seated length
B=5eated length
C=minimum length of working spring

l _ l,
a).-.

21 (3....
m—.--
no.3
22,5

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Page 72

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).

Check clearance between top face gears and cover


mating face. Clearance should be 0.008 to 0.041 in.
(0.020 to 0.105mm). if more than 0.006 in. (0.15mm),
replace gears or pump.
When oil pump is assembled turn drive shaft and check
for binding.

OIL FILTER REPLACEMENT


A clean filter is necessary to ensure good engine
lubrication.
Remove filter.
Before installing, coat seal with engine oil.
Thread filter on by hand until seal touches plate.
Thread filter down % turn more.

1. Oil pressure sending unit. 2. Oil filter.

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lll - 1914

Section No. 103.01

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

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I- III.- _'I- I-—-- l—I'I“ il‘l

......-.- --'I'-- wmflfi ' .


'-""'_:‘.'_"'I"'.......p:...."' -- -:.:*
all

-
-
Il-
:5-

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Ill - 1974

Section No. 104.01

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. Fan. 2. Nut. 3. Bolt. 4. Crossrail.


5. Hose.

INSPECTING COOLING SYSTEM


Fill radiator and expansion tank.
Open heater controls. Start car.
Open bleeder on top of radiator.
NOTE: Bleeder is accessible from inside the front
luggage compartment.

1. Bleeder.

Connect tester to radiator cap. Build up pressure.


Check that vent opens at 11 psi (O.8kg[sq.cm.).

1. Tester. 2. Union. 3. Cap.

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Ill ~ 1974

Section No. 104.02

Page 17

Water Pump and Ducts


WATER PUMP
REMOVAL AND INSTALLATION

;.»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.

1. Support. 2. Water um. 3. Alternator.


4. Nut. 5. Pipe. 1? gots.

Longitudinal section of water pump


1. Pump cover
N

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

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Page 78

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.

1. Union. 2. Hose. 3. Cover.

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Ill - 1974

Section No. 104.09

Page 79

Fan FAN RELAY (3:9)


r——=
ELECTRIC FAN OPERATION
The electric fan is controlled by a relay. The relay is
controlled by a thermostatic switch. When water 30/51 as
TEL
35' B?
THERMAL
SWITCH

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

EXPLDDED VIEW OF FAN REMOVAL


1. Fan motor 9. Gasket 16. Washer
2. Fan 10. Conveyor 17. Nut
3. Washer 11. Washer Relay
4. Nut 12. Lockwasher 19. Thermostatic switch
5. Plate 13. Nut 20. Gasket
6. Washer 14. Nut 21. Lockrin g
7. Lockwasher 15. Lockwasher . Spacer
8. Nut

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Il]l.l|.l

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III -1974

Page 81

Tool Equipment

es in cylinder head.
A.60153 Remover and installer, valve guid
W

A.90310 Reamer, valve guide bore.

_V
o A.96216 Gauge, checking depth of combustion chambers.

A.96219 Gauge, checking height of valve stem.

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CLUTCH—18
PARTS SERVICE MANUAL &
18
CATALOG SERVICE TIME Page
COD E SCHEDULE CODE
13 Specifications—Tightening Reference ___________________________________________________________ 83
31.02 181.02 Clutch Release Hydraulic Control ............................................................... 85
31.03 181.03 Master Cylinder ......................................................................................... 88
31.04 131.04 Operating Cylinder ..................................................................................... 89
31.05 181.05 Clutch ......................................................................................................... 90

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Ill-1914

Section No. 18

Page 83

Clutch
SPECIFICATIONS

Type .......................................................................................................... single plate, dry


Control ...................................................................................................... hydraulic
Release mechanism .................................................................................. diaphragm spring
Clutch disc ................................................................................................ with friction linings
Lining O.D. ................................................................................................ 7.145 in. (181.5mm)
Lining I.D. ................................................................................................ 5 in. (127mm)
Maximum runout of clutch disc linings ...................................................... 0.01 in. (0.25mm)
Clutch pedal free travel, corresponding to a clearance of
0.079 in (2mm) between diaphragm spring and release sleeve, about ........ 1 in. (25mm)
Travel of release spring corresponding to a minimum pressure
plate displacement of 0.071 in (1.8mm) .................................................. 0.335 in. (8.5mm)
Master cylinder bore ..................................................................................
$41 in.
Operating cylinder bore ............................................................................
13/4 in.

TIGHTENING REFERENCE

DESCRIPTION THREAD
(METR'C) MATERIAL TORQUE
FT. LBS. kgm

Bolt. clutch to flywheel .............................................. M 6 R 100 Cdt 10.8 1.5

Bolt. clutch release fork ............................................ M 8 R 80 Znt 18 2.5

. . . . R 50 Znt (shank
Nut, operating clnder pIston adjustment ................ M8 R 50 Incl Znt) 18 2.5

Bolt, operating cylinder ____________________________________________ M 8 R 80 Znt 18 2.5

Bolt, operating cylinder support plate to


transmission case ................................................ M 8 R 80 Znt 18 2.5

Stud nut, operating cylinder support plate to


transmission case .................................................. M 8 R 50 Znt 18 2.5
(stud R 80 Znt)

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Page B4

CLUTCH COVER AND CLUTCH DISC WITH LININGS

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Ill-1974

Section No. 181.02

Page 85

Clutch Release Hydraulic Control

To:
\\
M
WJ9

6151.5
2'12?
'.
l

l
|
'

:44n 5N0 0F splewe— 6059 4002”


k
UP T'owmeps AEF‘T‘ 901,: OF CA8
T3 40A 4905'
RIGHT 9015 0F CA2 AM!) Down!

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

CLUTCH RELEASE HYDRAULIC CIRCUIT.


1. Master cylinder
2. Operating cylinder
3. Nut and counter nut, clutch release travel adjust-
ment.
a —— 6.692” (170mm) Pedal release travel.

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Page 86

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.

BLEEDING CLUTCH CIRCUIT


Connect a bleeder hose to bleeder screw on operat-
ing cylinder. Place other end of hose in container filled
with fluid. Loosen screw on operating cylinder.
Push pedal in and release it until all air bubbles stop.
stop.
Push pedal in and hold it down. Remove hose. Tighten
bleeder screw. Fill reservoir.

1. Bleeder screw. 2. Operating cylinder.

CLUTCH PEDAL RELEASE TRAVEL


The clutch pedal travel should be about 6.692 in.
(170mm).
lf travel is not right, loosen nut (1). Turn screw (2)
out to reduce travel. Turn screw (2) in to increase
travel.

1. Lockout. 2. Adjustment screw. 3. Clutch pedal.

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Ill - 1974

Section No. 181.02

Page 81

Clutch Release Hydraulic Control


OPERATING CYLINDER ADJUSTMENT
Measure from floor to clutch pedal. Push clutch in
until pressure is felt.
Measme from floor to clutch pedal again. The differ—
ence sh0u|d be about 11.: in.
pedal again. The difference should be about 111 in.
If travel is not right adjust the operating cylinder rod
end.
NOTE: To insure proper adjustments, the car must be
driven on a road test.

1. Operating cylinder. 2. Adjustment not. 3. Throw


out bearing shaft.

CLUTCH RELEASE CONTROL COMPONENTS


1. Reservoir 14. Shaft 27. Clip
2. Bracket 15. Spring 28. Bolt
3. Lockwasher and nut 16. Nut 29. Cotter pin
4. Tube 17. Nut 30. Bracket
5. Master cylinder 18. Bolt 31. Washer
6. Clamp 19. Washer 32. Bolt
7. Washer 20. Operating cylinder 33. Fork
8. Throw out bearing 21. Bracket 34. Rubber ring
9. Bolt 22. Washer 35. Tube
10. Clutch 23. Nut 36. Washer
11. Spring 24. Gasket 37. Screw
12. Seal 25. Connector 38. Cover
13. Bushing 26. Hose 39. Pedal

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Section No. 181.03
Page 88

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""'

EXPLODED VIEW OF MASTER CYLINDER


1. Lockring 4. Gasket 7. Cylinder 10. Seal
2. Seal 5. Connector 8. Spring 11. Gasket
3. Boot 6. Lockplate 9. Seal 12. Plunger

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Ill - 1974

Section No. 181.04

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.

1. Throw out bearing shaft. 2. cylinder. 3. Union.


4. Bolt. 5. Hose. 6. Support plate.

EXPLODED VIEW OF OPERATING CYLINDER


1. Spring 4. Housing 7. Boot 10. Seal
2. Washer 5. Bleeding screw 8. Seal 11. Bushing
3. Lockring 6. Rod 9. Piston

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Page 90

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.

1. Flywheel. 2. Clutch assembly. 3. Tool

18A Tool Equipment

70210 Pilot. aligning driven plate.

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TRANSMISSION—D|FFERENTIAL—21I27
PARTS SERVICE MANUAL
CATALOG SERVICE TIME
00 0E SCHEDULE CODE
21-27 Specifications-Tightening Reference ........................................................ 91

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

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III-1974

Section No. 212.01

Page 1011102

Bpsodomstsr sprokat support


so ction .
1
Longitudinal section of
gearshift rod.

22719

Longitudinal section of transmission.

, 35:1.
-lll"
\"
nmuum§
'W//’/
Section through detent
springs for gear control
rods.

Soctlon through gear control lugs.

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Ill - 1914

Section No. 212.07

Page 103

Outer Gearshift Control

REMOVAL AND INSTALLATION


Remove dust boot off support.
Remove 3 bolts (1) and washers holding support (2)
in car. Lift support.

1. Bolts. 2. Support.

Remove pin (3) holding rod (2) to gear shift-lever (1).


Remove dowl (4), bushing, and washer. Lift gearshift
lever (1) out of car.

1. Gearshift lever. 2. Rod. 3. Cotter pin.


4. Bowl.

Remove bolt (1) and nut holding flexible rod (3) to


transmission rod (2). Remove boot (4). Pull rod out of
carfrom rear.
To install gearshift controls. reverse the above
procedure.

1. Bolt. 2. Transmission rod. 3. Flexible rod.


4. Boot.

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Page 104

ADJUSTING GEARSHll-‘T LINKAGE


Place the transmission in neutral.
Loosen two bolts (2) holding rod (3) to flexible rod (1).
Shift flexible rod (1) in the elongated holes until gear-
shift lever is in center of guide plate and is straight up
and down. Tighten bolts (2).

1. Flexible rod. 2. Bolts. 3. Rod.

E E '9
18

)E
K20
8\ \21
23 22

GEARSHIFT CONTROL ASSEMBLY


1. Dowel 7. Boot 13. Support 19. Bushing
2. Rubber bushing 8. Bolt 14. Boot 20. Bolt
3. Washer 9. Guide 15. Plate 21. Plate
4. Cotter pin 10. Cap 16. Flexible rod 22. Bolt
5. Gearshift lever 11. Ball socket 17. Nut 23. Rod
6. Knob 12. Spring 18. Lockwasher

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Ill - 1974

Section No. 274.01

Page 105

Axle Shafts

REMOVAL AND INSTALLATION


Remove wheel. Remove 2 bolts and nuts (1) holding
shock absorber (2) to pillar.
Remove nut (5) holding ball joint for control arm (4)
in pillar. Remove ball joint from pillar.
Remove nut holding ball joint for strut (3) in pillar.
Remove ball joint from pillar.

1. Nut. 2. Shock absorber. 3. Stmt rod.


4. Control arm. 5. Nut.

Drain some oil from transmission.


Remove 3 bolts (1) and washers holding all seal boot
(2) to differential.
Pull axle shaft and wheel hub out of differential.

1. Bolts. 2. Oil seal boot. 3. Axle shaft.

Remove brake caliper (1) and support bracket from


pillar.
Remove bolts holding plate (2) and disc (3) to hub.
Remove plate and disc.

1. Caliper. 2. Plate. 3. Disc.

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Page 106

Remove clamp (1) holding boot (2) to constant-speed


joint. Pull boot back to uncover joint. Clean grease off
joints.
Remove lockring (3) from constant-speed joints. Use
pliers.
Remove axle shaft from joints.

1. Clamp. 2. Boot. 3. Lockring.


4. Constant-speed joint.

Remove hub nut and washer.


Pull constant-Speed joint out of hub.
Using a press remove hub from pillar.
Remove ring nut holding bearing in pillar. Use tool
A.57123. Remove hearing from pillar. Use tool 8015.

1. Lever. 2. Socket. 3. Ring nut tool.


4. Pillar.

Install bearing in pillar. Use tool 8015.


Screw a new ring nut in pillar to hold bearing. Torque
nut to 43 ft. lbs. (6kgm). Use tool A.57123 and torque
wrench.
NOTE: Always use a new ring nut after disassembling
pillar.

1. Pillar. 2. Ring nut. 3. Tool.

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III-1974

Section No. 274.01

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.

1. Pillar. 2. Hub. 3. Driver. 21. Tool.

Install brake disc and plate. Secure disc with 2 bolts.


Install brake caliper and support bracket.
Install axle shaft in constant-speed joint (1).
Install snap ring (2). Make sure snap ring is seated
correctly in groove in axle shaft. Move shaft in and out
to make sure snap ring is in groove.

1. Constant’speed joint. 2. Snap ring.

Grease constant-speed joint sockets and boot. Use no


more than 3% 025. of grease. Install boot over joint.
install clamp.
Place axle shaft in differential. Place ball joint of
control arm (4) in pillar. Secure ball joint with out (5).
Place ball joint of strut rod (3) in pillar. Secure ball
joint with nut.
Install 2 bolts and nuts (1) thru pillar and shock
absorber (2):
Torque suspension bolts with car laden. Refer to
Specifications, 44.
Install 3 bolts and lockwashers holding oil seal boot
to differential.

1 Nut. 2. Shock absorber. 3. Strutrod.


4. Control arm. 5. Nut.

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Page 108

B 7

ft
1;.
l _ fl]

9 8

LEFT AXLE SHAFT ASSEMBLY


1. Tripode joint 4. Flange 7. Snap ring 10. Sealing ring
2. Circlip 5. Oil seal boot 8. Constant-speed joint 11. Bushing
3. Axle shaft 6. Boot 9. Boot clamps
Arrow indicates shoulder which boot (6) should be in contact with after installation.

Hub nut
TJE-T‘PPEJl-‘PE‘

Washer
Hub
Bearing ring nut
Bearing
Constant-speed joint
Pillar

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Ill - 1974

Section No. 274.04

Page 109

Differential Gear Train

~-—v--—-—...__‘

DISASSEMBLY AND ASSEMBLY


Remove inner race of bearings from half-cases. Use
three-arm puller with extraction brackets.

Remove eight bolts holding half-cases together.


Remove lockplate from pinion shaft.
Drive pinion shaft out of half case.
Remove side gear, pinion gears, and thrust washers.

1. Side gears. 2. Pinion gears. 3. Driver.


4. Pinion shaft. 5. Half-cases.

Wash all parts.


Check teeth for damage and wear. Check contact
pattern.
Check pinion shaft and pinion bores for damage.
Check side gears and counter bores in half cases for
damage.
Check bearings for wear or damage.
Check thrust washers for wear or damage.
Repair or replace damaged parts.

1. Bearing. 2. Half-case. 3. Thrust ring.


4. Side gear.

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Page 110

DIFFERENTIAL SECTION

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III - 1974

Section No. 214.04

Page 111

Differential Gear Train


Place thrust washer and side gear in half case carrying
Speedometer drive teeth. Place pinions in case. Install
pinion shaft in case.
Place side gear and thrust washer in other half case.
Place cases together, Align reference marks.
Place ring gear on case. Place Iockplate for pinion shaft
in place. Install eight bolts. Torque bolts to 51 ft. lbs.
(7kgm).
Check backlash between side gears and pinions.
Backlash must not exceed 0.004 in. (0.1mm)
Install two bearings on case. Use proper driver on
inner rings of bearings.

1. Half-case. 2. Pinion shaft. 3. Lock plate.


4. Ring gear. 5. Speedometer teething.

EXPLDDED VIEW OF DIFFERENTIAL ASSEMBLY


1. Bearing 5. Half case 9. Thrust washer 13. Lockplate
2. Half case 6. Ring 10. Pinion gear 14. Bolt
3. Sun gear 7. Bearing 11. Pinion shaft 15. Gears and case
4. Pinion gear 8. Ring gear 12. Thrust ring

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Page 112

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

1. Shims. 2. Retaining flange. 3. Transmission housing. 4. Bearing.

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III - 1914

Section No. 214.04

Page 113

Differential Gear Train


lf fixture A.95655 is available. apply a load of 770 lbs. Add 0.0031 in. (0.08mm) to value on indicator to
(350kg) to settle bearings. Place fixture A.95655 with determine thickness of shims. Choose a shim with a
dial indicator on surface for sealing Cover. Set dial in- thickness as close as possible to this value.
dicator finger against outer ring of bearing. Zero
indicator. NOTE: Shims are supplied in the following thicknesses;
Without changing the indicator, place fixture on sealing 0.0196, 0.0236, 0.0275, 0.0315, 0.0354, 0.0394,
cover with finger on cover and case surface. Value on 0.0433 in. (0.50, 0.60, 0.70, 0.80, 0.90, 1.00,
indicator is difference between distance "P" and height 1.10mm).
“H".

_ __..fl __ _ _ 21771

217 78

Bearing 6. Sea ling cover


S—"PP’PE‘

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.

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Page 114

Place shim on outer ring of bearing. Install cover.


Torque attaching nuts to 18 ft. lbs. (2.5kgm).

21A-2'IA Tool Equipment


AJOZM Compressor, countershaft spring washers

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BRAKES—33
PARTS SERVICE MANUAL &
CATALOG SERVICE TIME Page
CODE SCHEDULE CODE
33 Specifications-Tightening Reference ........................................................ 115
Gr. 331-WHEEL BRAKES
01.02 331.02 Hydraulic Brake System .......................................................................... 117
01 .30/ .32 331 .30/ .32 Front and Rear Wheel Brakes .................................................................. 119
01.31 331.31 Front Brake Calipers ................................................................................ 121
01.33 331.33 Rear Brake Calipers ................................................................................ 123
01.35 331.35 Hand Brake .............................................................................................. 125
33A Tool Equipment ...................................................................................... 125 33

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Page 116

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

— FRONT WHEEL BRAKES

— HEAR WHEEL BRAKES

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Ill - 1914

Section Nu. 331.02

Page 117

Hydraulic Brake System


BRAKE MASTER CYLINDER
REMOVAL AND INSTALLATION
Remove steering column. Refer to 412.01.
Disconnect hoses from reservoir.
Remove nuts and washers holding cylinder to support.
Pull cylinder off rod. Remove hoses from cylinder and
switch assembly. Drain fluid into container.
When installing cylinder, make sure you connect hoses
properly. Bleed brake system.
OVERHAUL
Carefully inspect cylinder bore and piston surfaces.
They should have a mirror~like finish without any kind
of roughness. The cylinder bore can be honed to
prevent leaks or excessive wear of seals and pistons.
Do not increase size of bore.
1. Washer. 2. Bolt. 3. Bolt. 4. Washer.
5. Switch. 6. Master cylinder. 7. Nut.
8. Washer. 9. Nut. 10. Washer. 11. Support.

EXPLODED VIEW OF MASTER CYLINDER


1. Spring 6. Gasket 11. Spacer 16. Spacer
2. Boot 7. Gasket . 12. Seal 17. Piston
3. Housing 8. Screw 13. Spring 18. Spacer
4. Lockplate 9. Gasket 14. Spring 19. Seal
5. Connection 10. Piston 15. Seal 20. Spring

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Page 118

BLEEDING HYDRAULIC SYSTEM


Fill reservoirs with proper fluid.
Clean all bleeder screws. Remove dust caps.
Connect bleeder hose to fitting on caliper. Submerge
other end of hose in clean container filled with brake
fluid.
Loosen bleeder screw a few turns.
Press brake pedal quickly, Release pedal and allow
it to return slowly.
Repeat until all air bubbles stop.
Press brake pedal and hold it down.
Remove bleeder hose and tighten bleeder screw. Clean
up spilled fluid.
Install dust caps.
Repeat for other wheels. Make sure fluid level in
reservoirs are filled.
Caliper. 2. Bleeder hose.

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III-1974

Section No. 331 Jill/.32

Page 119

Front and Rear Wheel Brakes


REPLACING WHEEL BRAKE CALIPERS
Remove cotter pins (1) from locking blocks (2).
Remove locking blocks (2).

1. Cotter pin. 2. 'Locking blocks. 3. Caliper.


4. Spring. 5. Support bracket.

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.

1. Caliper. 2. Brake Iinin. 3. Spring.


4. Hose. 5. Bracket. . Bolt.

On rear brakes, disconnect hose (1) from caliper (2).


Remove gaskets.
Disconnect hand brake cable (3) from rear caliper (2).

1. Hose. 2. Caliper. 3. Hand brake cable.

The minimum allowable thickness of brake linings is


about 0.079 in. (2mm).
Make sure new brake linings are the same type on each
pair of wheels. Linings are marked for identification.

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Page 120

BRAKE nlsc INSPECTION


Without removing disc, set up dial indicator as shown.
Rotate disc.
——maximum acceptable runout (dial indicator reading)
is 0.0059 in. (0.15mm).
If runout exceeds iimit or if disc is scored or dam-
aged, reface disc. Minimum thickness after refacing
is 0.368 in. (9.35mm). Minimum thickness from wear
is 0.354 in. (9mm).

REFACING BRAKE DISC


If disc is worn or has deep scores, they can be
refaced. After refacing minimum thickness is 0.368
in. (9.35mm).

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Ill - 1974

Section No. 331.31

Page 121

Front Brake Caliper

FRONT BRAKE CALIPER AND BRACKET COMPONENTS


1. Cotter pin
2. Caliper locking block
3. Spring
4. Caliper support bracket
5. Lining pad
6. Lining retainer spring
7. Cylinder housing
8. Dust boot
9. Piston
10. Seal
11. Bleeder screw and dust cap
12. Cylinder
13. Spring and dowel
14. Complete caliper

OVERHAUL FRONT CALIPER


Remove cover (5). Depress dowel using thin rod (3).
Separate cylinder (2) from support (4).
Apply compressed air to brake. hose port (1). Blow
piston out. Remove seal.

1. Brake hose port. 2. Cylinder. 3. Thin rod.


4. Support. 5. Cover.

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Page 122

Check piston (2) and caliper cylinder (1) for scoring


or binding.
Install seal (4) in caliper. Place piston in caliper.
Push piston in until it bottoms.
Install dust cover (3). Make sure dust cover is seated
in groove in caliper body.
Place spring and dowel in cylinder. Slide support on
cylinder. Press dowel down and slide support over
dowel. Make sure dowel is seated in support.

1. Cylinder. 2. Piston. 3. Cover. 4. Seal.

Place springs (4) and linings on support bracket (5).


Place caliper (3) on bracket. Install locking blocks
(2} and cotter pins (1).
Connect hoses to caliper and reservoir.
Bleed brakes.

1. Cotter pins. 2. Locking blocks. 3. Caliper.


4. Spring. 5. Support bracket.

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III - 1974

Section No. 331.33

Page 123

Rear Brake Caliper


REAR BRAKE CALIPER AND BRACKET COMPONENTS
1. Cotter pin 9. Hand brake shaft 16. Piston
2. Caliper locking block 10. Pawl 17. Seal
3. Spring 11. Plunger 18. Dust boot
4. Lining pads 12. Spring washers 19. Complete caliper
5. Lining retainer spring 13. Spring washers 20. Bleeder screw
6. Rubber boot 14. Seal 21. Bleeder boot
7. Locking ring 15. Caliper cylinder 22. Support bracket
8. Spacer

OVERHAUL REAR GALIPER


Remove dust boot (1).
Unscrew piston [3) from plunger.
Use screwdriver in slot in plunger. Remove seal.

1. Dust boot. 2. Caliper. 3. Piston. 4. Seal.

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Remove locking ring (7) from shaft (1). Remove shaft.
Remove plunger (5), seal (4) and spring washers (3).
Place plunger (5) with seal (4) and spring washers
(3) in caliper (9).
Place hand brake shaft (1) in boot (2).
Place shaft and pawl (6) in caliper (8). Install locking
ring (7).
Coat lever and plunger with grease.

1. Shaft. 2. Rubber boot. 3. Sprin washers.


4. Seal. 5. Plunger. 6. Pawl. Locking ring.
8. Caliper.

Install seal in caliper cylinder.


Screw piston (1) on plunger until it is seated.
-
MKE sure mark (2) on piston is on side of caliper with bleed
"'""" fitting (5).
Install rubber boot (4). Make sure boot is seated in
groove in caliper.

1. Piston. 2. Mark. 3. Caliper. 4. Rubber


boot. 5. Bleed fitting.

(MARK)
745 z Ail/E “WAT _
gf-lows'
[0 ON $10!:-
SHOULD 136 U
wfrl/ eweo gCREW, WHEN
REBUiLO/NG— CAMPER

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III - 1974

Section No. 331.35

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.

1. Lock nut. 2. Adjusting nut.

HAN D BRAKE LINKAGE


1. Ratchet 9. Cable 17. Bolt 25. Clip
2. Rod 10. Boot 18. Cable 26. Washer
3. Spring 11. Caliper 19. Lockwasher 27. Swinging arm
4. Button 12. Pulley 20. Nut 28. Tierod
5. Rubber ring 13. Spacer 21. Clamp 29. Clip
6. Lever 14. Gasket 22. Bolt 30. Washer
7. Washer 15. Support 23. Nuts 31. Lockring
8. Bolt 16. Washer 24. Pin 32. Pin

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Page 126

33A Tool Equipment


A.56126 Wrench. brake line connectors

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STEERING SYSTEM — 41
PARTS SERVICE MANUAL 8|
CATALOG SERVICE TIME
COD E SCHEDULE CODE Page
41 Specifications-Tightening Reference ........................................................ 12'?
Gr. 412—STEERING SYSTEM
02.01 412.01 Steering Gear .......................................................................................... 129
D232 412.02 Steering Box ............................................................................................ 131
02.10 412.10 Steering Linkage ...................................................................................... 13B
41A Tool Equipment ........................................................................................ 138

41

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Ill-1914

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)

Pinion bearing .......................................................................................... ball


Bearing adjustment .................................................................................. by shims set between
pinion cover and upper
ball hearing

Rack to pinion lash adjustment ................................................................ by shims set between


cover for rack center
pawl and gear housing
Turning circle diam. .................................................................................. 32.80 ft. (10m) about

Track rods ................................................................................................ adjustable with fixed


end ball joints
Lock angle:
— outer wheel .......................................................................................... 28°
— inner wheel .......................................................................................... 32° 40'

Front wheel toe-in, car laden (*) ................................................................ 0.0787 to 0.1575 in.
(2 to 4mm)

Steering column ........................................................................................ three sections with


two universal joints

l*) Car laden: two persons plus 44 lbs. (20kg) luggage, with tire inflated to specified pressures.

TIGHTENING REFERENCE

DESCRIPTION (THREAD) TORQUE


(METRIC) MATERIAL FT. LBS kgm

Nut, steering wheel to column ................................ M 16 x 1.5 R 50 Znt (shaft 36.2 5


C 30 Norm)

Nut, track rod ball bearing ........................................ M 14 x 1 R 50 Znt 36 5

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, steering box to body bolt , .............................. M 8 R 50 Znt (Bolt 18 2.5


R 80 Znt)

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Page 128

Nut. universal joint .................................................. M8 R 80 Znt (Bolt 18 2.5


R 100 Cdt)

Nut, upper steering column support .......................... M8 R 50 Znt (Bolt 10.8 1.5
R 50 Sd Stab)

STEERING COLUMN AND GEAR DISASSEMBLED.


1. Bolt 8. Steering wheel 15. Pad 22. Clamp
2. Washer 9. Nut 16. Gasket 23. Pad
3. Retainer 10. Bushing 17. Steering box 24. Clamp
4. Support 11. Steering column 18. Nut 25. Lockwasher
5. Nut 12. Bushing 19. Lockwasher 26. Nut
6. Lockwasher 13. Cover 20. Bolt 27. Pad
7. Washer 14. Screw 21. Shaft

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Ill - 1974

Section Nu. 412.01

Page 129

Steering Gear

SECTION A-A

CROSS SECTION OF STEERING COLUMN

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Page 130

STEERING SHAFI'
Disconnect battery.
Remove five screws (1) holding steering column cover
halves (2).
Disconnect three electrical connectors and one wire.

1. Screw. 2. Cover halves.

Remove two nuts (1) and washers holding column


to dash board at top.
Remove two bolts (2) and washers holding column
at bottom of dash.
Slide shaft off steering box shaft.
Remove complete column from car.

1. Nut. 2. Bolt. 3. Steering shaft.

Remove horn button. Remove steering wheel nut and


washer. Remove steering wheel.
Remove bolt (1) and nut thru turn signal selector
unit (2). Slide unit off shaft.
If necessary to separate lower shaft (3) from upper
shaft, remove bolt and nut holding universal joint (4)
to lower shaft.

1. Bolt. 2. Turn signal selector. 3. Lower shaft.


4. Universal joint.

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Ill-1974

Section No. 412-02

Page 131

Steering Box

REMOVAL AND INSTALLATION


Remove bolt (1) and nut holding universal to pinion
shaft on steering box.
Remove three screws (2) holding gasket cover to
steering box.

1. Bolt. 2. Screw. 3. Universal joint.

Jack up car. Remove wheels.


Remove nuts (1) holding ball joints in pillars.
Remove tie rods (2) from pillars (3).

1. Nut. 2. Tie rod. 3. Pillar.

Remove four bolts (1) holding steering box (2) to body.

1. Bolt. 2. Steering box.

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Page 132
511' i 1‘

’5

1. Ball joints 7. Clamps


2. Adjustable ball joints 8. Rubber pads
3. Lock nuts for adjustable ball joints 9. Steering housing
4. Rubber bellows 10. Spring
5. Rod and rack 11. Ball pin cup
6. Bushing

A=Travel 4.606 = 0.059 inches (117 i 1.5mm)


60° : 1" ball joint stroking angle

UNMODIFIED RACK AND STEERING GEAR CROSS SECTION

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Ill - 1974

Section No. 412-02

Page 133

Steering Box

B 7 I. 6 3 9 \2 1 22662

1. Ball joints 6. Clamps


2. Ball joint heads 7. Resilient pads
3. Rubber bellows 8. Steering gear housing
4. Rod and rack 9. Ball joint socket
5. Bushing

A:Trave| 4.606 1 0.059 inches (117 x 1.5mm)


oc=BaI| joint stroking angle 62" i 4°.

MODIFIED RACK AND STEERING GEAR CROSS SECTION

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Page 134

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.

1. Boots. 2. Clamps. 3. Cover plate. 4. Cover


plate. 5. Ground wire.

NOTE: On steering box with modification, ball joints


have a threaded collar. If the joint is removed, it must
be replaced. Therefore, remove only one joint when
removing rack.

Place steering box in vice.


On modified box, straighten stake on collar and ball
joint. Unthread ball joint.
0n unmodified box, straighten stakes on ring nuts (2).
Unscrew nuts.
Slide off ball joints with sockets and springs.
Slide rack out of steering box.
Remove lower bearing for drive pinion.

1. Rack. 2. Ring nut. 3. Adjustable head for ball-


joint. 4. Ball pin.

NOTE: Arrows show where ring nuts must be staked.

REASSEMBLY AND ADJUSTMENT


Place steering box in horizontal position with pinion
cover facing up. Make Sure all oil is drained from box.
Install lower bearing for drive pinion. Use tool A.74219
to install bearing.

1. Bearing. 2. Installer tool. 3. Housing.

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Ill - 1974

Section No. 412432

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.

1. Tool A.74347. 2. Bushing. 3. Bushing tabs.


4. Slots in housing for bushing tabs. 5. Housing.

Apply enough force to the outer ring of tap bearing

\\\’\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)
/

install shims. Coat gasket and bolts for cover plate


with adhesive liquid. install gasket, plate (1), washers, *"Il 'l il‘ialiliv
and bolts. Install seal (2).
Check that pinion turns freely without sticking even
without centering yoke installed. The pinion rolling
force should not be more than 0.3 ft. lb. (0.04kgm).

1. Cover plate. 2. Seal. 3. Rack.

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Page 136

Steering Box —— Model X 1/9


Determine the thickness of the rack yoke shim as
follows:
Set rack in half-way position.
install rack yoke in its seat.
Turn pinion 180° in both directions to settle fit be—
tween it and rack.

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

STEERING BOX SECTION ACROSS DRIVE PINION.


1. Drive pinion shaft 6. Yoke cover plate 10. Drive pinion lower bearing
2. Cover plate 7. Seal ring 11. Drive pinion upper bearing
3. Gasket 3. Rack yoke 12. Drive pinion shims
4. 'Rack yoke shims 9. Rack 13. Seal
5. Spflng

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lll - 1914

Section No. 412-02

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.

1. Rack. 2. Ring nut. 3. Adjustable head for ball


joint. 4. Ball pin. 5. Ground wire.

Slip boots over ball joints. Slip ends of boots over


steering box.
Position clamping screws as shown.
Fill steering box with oil as follows:
— Turn steering fully to the right.
-— Jack car up on left side.
— Release boot on left side (driver's side).
—— Insert specified quantity of oil. Use a syringe.
— Replace boot and clamp in position.
— Lower car.
NOTE: When steering box is fully assembled, drive
pinion should start turning with a torque of 1% to
2 ft. lbs. (0.195 to 0.288 kgm).

22682

MODIFIED STEERING BOX

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Page 133

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.

Adjust toe-in as follows:


— Loosen nut (1).
—— Turn ball joint (2) in or out using wrench flats until
proper toe-in is obtained.
— Do not change position of steering wheel spokes.
— Tighten nut (1).

1. Nut. 2. Ball joint.

A.14219 Installer. steering gear pinion shaft lower hearing. A7424? Inserter, steering rack rod guide bushing.

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SUSPENSION AND WHEELS — 44
PARTS SERVICE MANUAL &
CATALOG SERVICE TIME
CODE SCHEDULE CODE
44 Specifications-Tightening Reference ........................................................ 139
Gr. 443-SUSPENSION AND WHEELS
03.01 443.01 Front Suspension .................................................................................... 143
D3.02 443.02 Front Shock Absorbers and Bars .............................................................. 149

03.05 443.05 Rear Suspension ...................................................................................... 153


D3.05 443.06 Rear Shock Absorbers and Bars .............................................................. 151r
03.10 443.10 Shock Absorbers ...................................................................................... 159
03.16 443.16 Wheels ...................... ............................................ .................................. 163
44A Tool Equipment ...................................................................................... 166

44

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Ill - 1974

Section No. 44

Page 139

Suspension and Wheels


SPECIFICATIONS

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.

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Page 140

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)

Toe-in, unladen car .................................................................................. +0.360 to +0.510 in.


—Adjustment: by threaded sleeves on reaction rods. (+9 to +13mm)
Tightening of suspension: with car laden (*).
Coil Springs
Length under a load of 562 :22 lbs. (255 iIOkg) .................................. 7.874 in. (200mm)
Minimum permissible load referred to the above length ............................ 518 lbs. (135kg)
Coil Springs are divided into two classes, color coded as follows;
—yellow. springs which under a load of 562 lbs. (255kg)
have a length above .................................................................................. 562 lbs. (255kg)
7.874 in. (200mm)
—green, springs which under a load of 562 lbs. (255kg)
have a length of ........................................................................................ 7.874 in. (200mm)
or less
Springs having same color code should be used.

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)

WHEELS AND TIRES


Wheels ...................................................................................................... disc type
rim size .............................................................................................. 4V2Jxl3 in.

Tires .......................................................................................................... radial ply


size ...................................................................................................... 145HR-13"

Tire inflation pressure .............................................................................. Front 26 psi - Rear 29 psi

l”) Car laden: two persons plus 44 lbs. (20kg) luggage. with tires inflated to specified pressures.

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III - 1974

Section No. 44

Page 141

Suspension and Wheels


TIGHTENING REFERENCE

DESCRIPTION THREAD TOROUE


(METRIC) MATERIAL FT. LBS. kgm

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

Nut, self-locking, shock absorber-to~body R 80 Znt (Bolt


steering knuckle bolt ........................................ M 10 x 1.25 R 100 Cdt) 43.4 6
Nut, shock absorber top mounting .................... M 12 x 1.25 R 50 Znt 43.4 6
Ring nut, front wheel bearing ............................ M 62 x 1.5 R 50 Znt (knuckle 43.4 6
38 CD 3 Stp Bon)
Bolt, strut support ............................................ M 10 x 1.25 R 80 Znt 29 4
Bolt, input conenctor on front wheel M 10 x 1.25 C 4 MF Trf Bon
brake cylinder Cdt Bright 21.7 3

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Page 142

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)

Stud bolt. wheel ................................................ M 12 x 1.25 C 35 R Bon Znt 50.6 7


black

Nut, self-locking, cross reaction rod R 80 Znt (Bolt


to control arm bolt ............................................ M 14 x 1.5 R 80 Znt) 50.6 7

Nut, self-locking, ball joint to R 80 Znt (Pin 40


knuckle pillar .................................................... M 14 x 1.5 NiCrMo 2 Bon 72.3 10
R 90 to 105)

Nut for bolt, clamp on R 50 Znt (Bolt


cross reaction rod SleeVe .................................. M 8 R 80 Znt) 14.4 2

Nut, self-locking, control arm pivot pin ............ M 14 x 1.5 R 80 Znt (Pin 72.3 10
R 80 Znt)

Nut, self-locking, shock absorber


top mounting .................................................... M 12 x 1.25 R 80 Znt 43.4 6

Nut, self-locking shock absorber R 80 Znt (Bolt


to knuckle pillar bolt ........................................ M 10 x 1.25 R 100 Znt) 43.4 6

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

Ring nut, wheel bearing .................................... M 62 x 1.5 R 50 Znt (Knuckle 43.4 6


38 CD 4 Stp Bon)

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Ill-1974

Section No. 443.01

Page 143

FRONT SUSPENSION

REMOVAL AND INSTALLATION


If brake caliper (1) needs inspection, leave caliper
attached to suSpension.
To do this, plug outlet from brake fluid reservoir and
disconnect brake fluid hose (2) from caliper.

1. Caliper. 2. Brake hose.

Remove wheel.
Remove bolts (1) and plate (2) holding strut to pillar
(3).
Remove bolt holding control arm (4) to bracket (5).

1. Bolts. 2. Plate. 3. Pillar. 4. Control arm.


5. Bracket.

Remove nut (3) holding tie rod ball joint (1) to steering
arm (2). Remove ball joint.

1 Balljoint. 2. Steering arm. 3. Nut.

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Page 144

Disconnect shock absorber (1) by removing three nuts


(2) and washers. Lower suspension assembly out of car.

1. Shock absorber. 2. Nuts.

Coil springs are marked with a yellow strip or red


strip. Make sure new ones are color matched. See
Section 44.
if hub bearing must be replaced. see Wheels, 443.16.
When installing suspension do not fully tighten control
arm attachments and sway bar attachments. These
bolts and nuts must be tightened with car under load.

1. Shock absorber. 2. Pillar. 3. Control arm.


4. Steering arm.

Place assembly in car. Install washers and nut (2)


on three bolts on top of shock absorber (1).
Torque nuts to 8 ft. lbs. (1 kgm).

1. Shock absorber. 2. Nuts.

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III — 1974

Section No. 443.01

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.

1. Bolts. 2. Plate. 3. Pillar. 4. Control arm.


5. Bracket.

Place ball joint (1) of tie rod in pillar.


Install not (3).
Install wheel. Install brake caliper.
Lower car. Fill brake fluid reservoir.
Bleed brakes.

1. Ball joint. 2. Steering arm. 3. Nut.

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)

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Page 146

Model X 1/9

Section through shock


absorber top mounting.

a = -o°4o' to 4°20: camber I“)


3 = 13° about: king pin inclinatiOn ('J

P) Data referred to laden car.

Front Suspension

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III-1974

Section No. 443.111

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

1. Support. 2. Reaction strut.

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Page 148

iii ll
COIL SPRINGS
Fixture A.74241 must be used to remove and install
springs on shock absorbers.

Make sure screws (1) are touching retainer (2). One


screw at each end must be in the recess in retainer (2).

Lower View of tool A.74241


1. Spring retainer clearance screws. 2. Spring retainer.
3. Coil spring.

Compress the spring.


Hold shock absorber stud with wrench A.57020 (3).
Remove nut attaching retainer (2) to shock absorber.

1. Clearance screws. 2. Upper retainer. 3. Wrench.

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III-1974

Section No. 443.02

Page 149

Front Shock Absorbers and Bars


CONTROL ARM
Check rubber bushings. If worn remove them by drilling
out spacer.
Replacing control arm rubber bushings. Arrow shows
stacking to be removed for removal of bushings.

Check ball joints for excessive play and damage to


swivel and rubber boot. If worn or damaged, replace
complete control arm.

EXPLODED VIEW OF CONTROL ARM COMPONENTS.


Nut
E‘PEDpt’NQP'P'PD-‘t"

Washer
Washer
Rubber bushing
Control arm
Rubber bushing
Washer
Spacer
Bolt
Nut
I—‘t—l

Pillar

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Page 150

Install rubber bushings in control arm as follows:


Place washer, bushing (1), and spacer (3) on pilot of
tool.
Place tool (2) thru control arm (4). Place bushing (1)
and washer on tool.

1. Bushing. 2. Tool. 3. Spacer. 4. Control


arm.

Place pilot on tool.

1. Control arm. 2. Tool. 3. Pilotoftool.


4. Washers. 5. Rubber bushings.

Press bushing into control arm and stake spacer. Use


a press under a load of 2200 to 2600 lbs. (1000 to
1200kg).
Stake one side and then the other. 1

t1. I Centering pin. 2. Fixture 3. Spacer centering


oo
-
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Ill - 1974

Section No. 443.02

Page 151

Front Shock Absorbers and Bars


STRUT BAR
STRUT BAR ATTACHMENT POINTS.
.

1. Bolt. 2. Plate. 3. Support. 4. Control arm. 5. Pillar. 6. Strut bar.


Inspect bar for distortions. If distortions are minor,
straighten bar. If necessary, replace bar. Inspect rubber
pad and ring for wear.
d-hmmu

EXPLODED VIEW OF STRUT BAR ATTACHMENTS TO BODY AND CONTROL ARM.


1. Nut 6. Lockwasher 11. Lockwasher 15. Nut
2. Washer 7. Bolt 12. Bolt 16. Bolt
3. Cup 8. Rubber ring 13. Bolt 17. Washer
4. Rubber pad 9. Strut bar 14. Pillar 18. Support
5. Spacer 10. Lockplate

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III - 1974

Section No. 443.05

Page 153

REAR SUSPENSION

REMOVAL AND INSTALLATION


If brake caliper (1) needs inspection. leave caliper
attached to suspension. To do this, plug outlet from
brake fluid reservoir and disconnect hose (2) from
caliper.
Remove wheel.
Disconnect parking brake cable (3) from caliper.

1. Caliper. 2. Hose. 3. Parking brake cable.

Remove exhaust pipe. Refer to 102.56.


Note number of shims and position on control arm.
Remove nut. washer. and bolt (1) holdn arm (3) to
bracket (2} at front of suspension. Retain shims be-
tween arm and bracket.

1. Bolt. 2. Bracket. 3. Control arm.

Remove nut. washer, and bolt (1) holding arm (3) to


bracket (2) at rear of suspension. Note number of
shims and position. Retain shims between arm and
bracket.
Remove hub nut (4) and washer.

1. Bolt. 2. Bracket. 3. Control arm. 4. Hub


nut.

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Page 154

Remove 3 nuts (1) and washers holding shock absorber


at top.

1. Nuts. 2. Shock absorber.

Slide suspension assembly off constant speed joint


shaft. Position axle shaft so that it cannot come out of
differential.
For disassembly of hub from pillar, refer to 274.01

1. Pillar. 2. Axle shaft.

NOTE: Always use a new hub nut.


Install shims as noted during removal.
Loosely attach arm (2) to brackets (3).
Raise assembly and mount hub on constant speed
joint.
Insert upper attachment of shock absorber (4) in holes
in body. install 3 nuts and spring washers.
Place washer on axle shaft. Thread nut (1) on shaft.
Torque nut to 101 ft. lbs. (l4kgm).
Stake nut. Use tools A.74140/1 and A.74140/3.
Install exhaust pipe. Refer to 102.56.

1. Nut. 2. Control arm. 3. Brackets. 4. Shock


absorber.

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III - 1974

Section No. 443.05

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. Shock absorber mounting nuts. 2. Control arm front


bolt. 3. Control arm rear bolt.

REAR WHEEL ALIGNMENT


Install and adjust alignment equipment. Follow in-
structions provided with equipment. Set up equipment
to check camber.
Camber, unladen car, —1°10’ to #2°10’
Check toe-in
Toe-in, unladen car +0.360 to +0.510 (+9 to +13mm)
Adjust toe-in by Iengthing or shorting reaction rod.

1. Reaction rod.

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Page 156

"‘ = -2° 120': camber (*3


a = 12° : king pin inclination ('1
(') Data referred to iaden car.

1. Shock absorber front mounting


adjustment shims.
\~_ 2. Shock absorber rear mounting
\. adjustment shims.

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Ill - 1974

Section No. 443.06

Page 151

Rear Shock Absorbers and Bars


COIL SPRINGS
See Front Suspension Components, 443.01 for infor—
mation on coil springs.

CONTROL ARM
VIEW OF CONTROL ARM ATTACHMENT POINTS.

1. Bolt. 2. Support. 3. Control arm. 4. Ball Joint. 5. Support. 6. Pillar.

EXPLODED VIEW OF CONTROL ARM.


1. Nut 5. Bolt 9. Bolt 13. Bushing
2. Washer 6. Nut 10. Pillar 14. Control arm
3. Washer 7. Washer 11. Nut 15. Bushing
4. Washer 8. Washer 12. Boot

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I'M;
III'IIII—NII_
I
II
II
II
IIII1III]
Illl

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Ill - 1974

Section No. 443.10

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.

Use Tool A.74241 to remove coil spring from absorber.


Refer to Front Suspension Components, 443.01.
Check absorbers for operation. If absorbers fail to meet
specifications replace them.

1. Bolts. 2. Shock absorbers. 3. Pillar.

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Page 160

FRONT SHOCK ABSORBER ATTACHMENTS


Bolt
Rubber pad
Shock absorber
Cup
Washer
Nut
Nut
Lockwasher
Washer
Pad
. Spacer
. Washer
. Thrust plate
Rubber ring
. Nut

REAR SHOCK ABSORBER ATTACHMENTS


Bolt
Nut
Shock absorber
Rubber pad
Thrust plate
Rubber ring
Washer
Spacer
Pad
Cup
. Washer
. Lockwasher
Nut
Washer
Nut

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III-1974

Section No. 443.10

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)

1. _ Outer cylinder. 2. Threaded plug. 3. Inner


cylinder.

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.

1. Stem. 2. Inner cylinder. 3. Valve. 4. ‘ Outer


cylinder. 5. Threaded plug. 6. Cap. 7. Ring
seal.

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Page 162

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.

1. Outercylinder. 2. Inner cylinder” 3. Stem.


4. Threaded plug. 5. Cap. 6. Ring seal.

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Ill - 1914

Section No. 443-16

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).

1 Bolt. 2. Centering stud. 3. Disc. 4. Plate.


5. Calipers. 6. Support bracket.

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.

1. Nut. 2. Tie rod. 3. Pillar. 4. Nut.


5. Control arm. 6. Nut. 7. Shock absorber.

Remove nut and washers holding hub to pillar. Press


hub out of pillar. Use tool 8015.

1. Tool. 2. Hub. 3. Pillar.

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Page 164

Remove ring nut holding bearing in pillar. Use tool


A.57123. Pull bearing out of pillar. Use tool 8015.

1 Tool. 2. Pillar. 3. Bearing.

Install bearing in pillar. Use tool 8015.

1. Tool. 2. Bearing. 3. Pillar.

Screw a new ring nut (2) in pillar. Torque nut to 43.4


ft. lbs. (6kgm). Use tool A.57123 and torque wrench.
NOTE: Always use a new ring nut after disassembling
pillar.

1. Pillar 2. Ring nut. 3. Tool.

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III - 1974

Section No. 443-16

Page 165

Wheels
Stake ring nut as shown.

Install hub in pillar. Press hub in. Use a press.


Install two washers and a nut. Torque nut to 101 ft. lbs.
(14kgm). Stake nut.

1. Pillar. 2. Hub. 3. Driver. 4. Tool.

Attach pillar to shock absorber with two bolts and nuts.


Attach control arm (5) to pillar (3).
Install brake caliper and disc on hub.
Install wheel. Lower car.
Attach tie-rod (2) to pillar.
Torque nuts shown with car loaded. Refer to Specifi-
cations, 44.

1. Nut. 2. Tie rod. 3. Pillar. 4. Nut.


5. Control arm. 6. Nut. 7 Shock absorber.

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Page 166

Tool Equipment

A.74241. Compressor. coil springs.

n.15123. Wrench. ring nut. fl

8015. Remover, hub bearing.

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ELECTRICAL—55
PARTS SERVICE MANUAL 8:
CATALOG SERVICE TIME
000 E SCHEDULE CODE Page
_. 55 Specifications .......................................................................................... 167
Wiring Diagram ........................................................................................ 174
Gr. 551-IGNITION
F1.01 551.01 Engine Ignition ........................................................................................ 175
Gr. 552-STARTING
F2.01 552.01 Engine Starting ........................................................................................ 179
Gr. 553-ALTERNATOR
F3.01 553.01 Alternator ................................................................................................ 183
Gr. 554-LIGHTING
F4.01 554.01 Lighting-Fuses ........................................................................................ 185
Gr. SSS-ACCESSORIES
F5.03 555.03 Instruments and Controls ........................................................................ 187

55

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lll - 1974

Section No. 55

Page 157

Electrical: Specifications
IGNITION

Firing order ................................................................................................ 1-3-4-2


Ignition distributor .................................................................................... DUCELIER
Type .......................................................................................................... 4481A
Static advance .......................................................................................... 0
Centrifugal advance .................................................................................. 28° 1- 1° 30’
Vacuum advance correction ...................................................................... 10" i 1" 30’
Breaker contact pressure .......................................................................... 15.9 i 1.8 oz. (450 t 50 gr.)

Contacts gap .............................................................................................. 0.0145 to 0.0169


("0.37 to 0.43mm)

Terminal to ground insulation at 500Vdc .................................................. about 50 M ohms


Condenser capacity at 50 to 1000Hz ........................................................ 0.22 to 0.23 MF
Opening angle ............................................................................................ 35” i- 3"
Closing angle ............................................................................................ 55° t 3"
lGNlTION con.
MARELLI MARTINETTI
TYPE -------------------------------------------------------------------------------- BE 200 B c. 52 3
Primary winding ohmic resistance (at 68 F, 20 C) ............ 3.1 to 3.4 ohms 3 to 3.3 ohms

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)

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Page 168

Starting Motor

Type .......................................................................................................... E8¢0.8/12 Var. 1

Voltage ...................................................................................................... 12

Nominal output ............................. .. 0.8KW

Direction of rotation, pinion side .............................................................. clockwise

No. of poles .............................................................................................. 4

Field winding ............................................................................................ series

Engagement .............................................................................................. Free wheel

Drive ...................................................................... . ................................... Electromagnetic

Diameter inside pole shoes ........................................................................ 2.175 to 2.182 inches


(55.25 to 55.42mm)
Diameter of armature ................................................................................ 2.140 to 2.142 inches
(54.35 to 54.40mm)
Control ...................................................................................................... electromagnetic

Bench Testing Data


—Running test (at 77° F - 25° C)
Amperage .............................................................. . 170
Torque developed .................................................................................. 2.89 = 0.14 ft. lbs.
(0.40 i 0.02Kgm)
Speed .................................................................................................... 1900 rpm
Voltage .................................................................................................. 9.5
—Stall test (at 77° F - 25° C)
Amperage .............................................................................................. 315
Torque developed .................................................................................. 6.37 i- 0.22 ft. lbs.
(0.88 : 0.03kgrn)
Voltage .................................................................................................. 7 i 3
—No—load test (at 77° F — 25° C)
Amperage, not above ............................................................................ 30
Speed .................................................................................................... 7000 i 1000 rpm
Voltage .................................................................................................. 11.9
—lnner resistance on starting (at 77° - 25° C) .......................................... 0.022 t 0.001 ohms
Check of Mechanical Characteristics
—Brush pressure (unworn) ........................................................................ 2.5 to 2.9 lbs. (1.15 to 1.3kg)
—End clearance, armature shaft .............................................................. 0.0039 to 0.0197 in.
(0.1 to 0.5mm)
#Mica undercut depth ............................................................................ 0.039 in (1mm) minimum
——Free wheel efficiency: static torque to rotate pinion slowly .................... 1.5 to 1.9 in. lbs.
(1.7 to 2.2kglcm)

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III-1974

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.

Max. speed, steady .................................................................................... 13,000 rpm


Rotation, drive end .................................................................................. clockwise

Ratio
engine ................................................................................................
1:2
alternator ............................................................................................

Rectifier Diode Characteristics


type .................................................................................................... 6, Power 3, excitation
Permanent normal current .................................................................. 25A 1A
Reverse voltage .................................................................................... 150V 150V
Reverse current with 150V do at 266° F (130° C) ................................ 2mA 2mA

Voltage Regulator Test and Setting


Type .................................................................................................. BOSCH ADlll4V
Alternator speed for test and setting .................................................. 4,000 to 5,000 rpm
Battery capacity .................................................................................. 60Ah
2nd stage testing current .................................................................... 0.8 to 1.0A
2nd stage regulating voltage ................................................................ 14.2 i 0.4V
lst stage testing current ...................................................................... 2 to 2.2A
lst stage regulating voltage, lower than the voltage
read for the 2nd stage by .............................................................. 0.2 to 0.7V
Resistance between positive terminal and ground at
77° F i 18” F (25° C i 10 ”C) ...................................................... 85 i— 4.5 ohms

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Page 170

BATTERY

Nominal voltage 12
Nominal capacity (at 20 hour
discharge rate) 60 AH

RELAYS

WIRING DIAGRAM
REFER ND. RELAYS. SYSTEM/CONTROL LOCATION

15 Horn right headlight motor compartment


39 Radiator cooling fan motor left headlight motor compartment
128 (2 relays) Headlight motors headlight motor compartments
128/ 2 Seat belt and remove key warning buzzer left side behind fuses
128.13 Starter right side panel above drop tray
128M Carburetor fan motor fan motor support, engine compartment
30 Turn signal flasher left side behind fuses
32 Vehicular warning flasher left side behind fuses

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

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III-1974

Section No. 55

Page 171

Electrical: Specifications

CONTROLS

High beam switch ...................................................................................... by lever below steering wheel


Outer lighting control switch .................................................................... on instrument panel
Instrument cluster light switch ........................... on center console

Vehicular hazard warning signal switch ...................................................... on center console

Courtesy light
—toggle type switch ................................................................................ on center console
—door jam switch .................................................................................... on door pillars

Turn signal ................... by lever below steering wheel


—-nominal number of cycles per minute.................................................. 60 to 120
ldeogram illumination intensity rheostat .................................................... on center console

Heater fan switch (2 Speed, 3 position) .................................................... on center console

Windshield wiper switch ............................................................................ by lever below steering wheel


—-type ______________________________________________________________________________________________________ crank gear
—sweeps per minute
low speed ........................................................................................ 48
high speed ...................................................................................... 75
—brush pressure on glass ........................................................................ 19 to 23 oz (550 to 650 gr)

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.

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Page 172

D(*) . . .
(8 Amp) nht headlight high beam.

(Blimp) Left headlight low beam.

F(*) Right headlight low beam


(8 Amp) '
Front left parking light. Light source, ideograms optical fiber
Parking and tail lights indicator. illumination.
G(*) Rear right side marker light. Cigar lighter spot light.
(8 Amp) Rear right tail light. Light source, heater fan ideogram
Front left side marker light. illumination.
License plate light (one bulb only).
HW Front right parking light. Rear left side marker light.
(8 Am ) Front right side marker light. License plate light (one bulb only.
p Rear left tail light.
| Cigar lighter.
(16 Amp) Vehicular hazard warning signal and indicator.
L Engine fan motor.
(16 Amp) Horns and relay.
M . + .
(3 Amp) Retractable headlights con.rol relay (on closmg).

N . .
(3 Amp) Retractable headlights control relay (on opening).

28/3 Carburetor fan motor and relay.


(8 Amp) Courtesy light.
UNPROTECTED CIRCUITS
Alternator circuit. Engine fan motor relay field winding. Ignition. instrument
cluster lights. Starting. Starting motor relay field winding. Battery charge
indicator.

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i
ill - 1974

Section No. 55

Page 173/174

Electrical: Wiring Diagram


IGNITION OUTER LIGHTING OUTER SIGNALLING 5 AND lNDiCATORS ACCESSORIES

®
@

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

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Ill-1974

Section No. 551.01

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.

1. Distributor. 2. Graduated disc. 3. Plug for disc.


4. Stroboscopic switch. 5. Plug for distributor breaker.

The distributor is driven at one-half engine speed. To


ae
U

plot advance curve double both rpm and advance


l
on o I
ADVANCE DEGREES
N

degrees. Match curve against diagram shown in figure.


VERSUS ENGINE

Check distributor contacts openings and closing angle:


N
.
G

—open-contact angle — 35° 1- 3"


—-dwell (closed-contact) angle — 55° 1- 3“
n
_u
_.

D.

.1000 2000 3000 i000 5000


900 1500 l”’00

Check that contact gap is 0.0145 to 0.0169 in. (0.37


to 0.43mm).
Check that contact pressure is 15.9 i 1.8 oz. (450 i
50 gr.).
Refer to General Information for Ignition Timing.

1. Point gap. 2. Contact.

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Page 176

EXPLDDED VIEW OF IGNITION DISTRIBUTOR


Contact breaker plate 13. Washer 25. Condenser
Star gear 14. Screw 26. Screw
Washer 15. Rubber ring 27. Washer
Screw 16. Spfing 28. Nut
Clip 17. Cam 29. Lockwasher
Contact breaker points 18. Clip 30. Fiber washer
Washer 19. Washer 31. Terminal
Clip 20. Clip 32. Bolt
Rotor 21. Washer 33. Washer
Spring contact 22. Screw 34. Pin
. Cap 23. Vacuum valve 35. Seal
Clip 24. Washer 36. Gear

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Ill - 1974

Section No. 551.01

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

Check resistance of secondary winding.


Resistance at 68“ F (20" C) must be as follows:
Marelli Martinetti
5670 to 6930 ohms 6500 to 8000 ohms

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.1.

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Ill - 1914

Section No. 552.111

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.

1. Pinion. 2. Nutsforsolenoid. 3. Solenoid.


4. Terminal nut. 5. Dust cover.

Remove screws (9) holding terminals on brushes (1)


in brush holder. Lift brushes (1) lightly. Rest brush
Spring ends against side face of brushes.
Remove nuts and washers holding brush holder support
to frame. Remove support. Retain thrust washers on
end of pin.

1. Brush. 2. Brush spring. 3. Terminal.


4. Pinion and head. 5. Drive pinion. 6. Frame.
7. Commutator end head. 8. Pole shoe mounting screws.
9 Brush terminal clamping screw.

Slide frame off pinion end.


Remove cotter pin holding pin for shifting fork (6) in
head (1).
Remove pin and fork (6).
Remove armature (3) from head (1).

1. Pinionend head. 2. Drive pinion. 3. Armature.


4. Thru-boits. 5. Commutator. 6. Shifting fork.

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Page 180

To disassemble drive, remove snap ring holding stop


ring (6). Remove parts in proper order.
Reassemble starter in reverse order.

1. Thrust washer. 2. Plain washers. 3. Armature.


4. Drive sleeve. Sleeve spring. 6. Stop ring.
7. Drive pinion. Plain washers. 9. Plain washers.

111213 14 15

27

Starter assembly
Bushing 12. Lockwasher 23. Bush spring
PPPWHP‘QPP’PL"

Support 13. Washer 24. Brush


Cotter pin 14. Solenoid 25. Armature
Rubber pin 15. Lockwasher 26. Nut
Fork pin 16. N ut 27. Bolt
Shifter fork 17. Washer 28. Drive unit
Insulator 18. Screw 29. Ring
Screw 19. Bushing 30. Lockring
Plunger 20. Screw 31. Washer
Spfing 21. Collar 32. Washer
HH

Nut 22. Screw 33. Field winding

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Ill - 1974

Section No. 552.01

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.

1. Brush. 2.. Brush spring. 3. Terminal.


4. lOn and drive. 5. Drive inion. 6. Frame.
7. Commutator and head. 8. ole shoe mounting screws.
9. Brush terminal clamping screws.

REPLACING FIELD GOILS


Disassemble starter to remove frame (4). Remove
screws (3) and remove field coils (5) and pole shoes.
Heat replacement coils to 122° F (50° C). Install coils
and shoes. Tighten screws (3) hard up to restore air
space.
Check pole shoe inside diameter. it must be between
2.175 and 2.182 in. (55.25 to 55.42mm).
Reassemble starter.

1. Coil terminal to brushes. 2. Coil terminal to solenoid.


3. Pole shoe mounting screw. 4. Frame.
5. Field coil.

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).

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Page 182

'Ar— BP— t|—-—


Longitudinal section of stutter assembly.

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.

E 8443.8/12 Var. 1 STARTER ASSEMBLY

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Ill - 1974

Section No. 553.01

Page 183

Alternator

EXPLODED VIEW OF ALTERNATOR


Blower 11. Condenser 21. Clip
PEDPOHP‘EJ‘PPJPE‘

Pulley 12. Washer 22. Seal


Bolt 13. Screw 23. Plate
Lockwasher 14. Screw 24. Key
Washer 15. Lockwasher 25. Screw
Support 16. Washer . Washer
Plate 17. Brush holder 27. Bea ring
Screw 18. Seal 28. Seal
Stator Bea ring 29. Lock washer
Support 20. Rotor 30. Nut
|_|

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Ill-1974

Section No. 554.01

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

Turn headlights on low beams.


Adjust horizontal alignment by turning screw.

1. Adjustment screw.

Adjust vertical alignment by adjusting rod.

1. Motor. 2. Cap. 3. Adjusting rod.

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Page 186

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.

1. Frame. 2. Screws. 3. Headlight.

RETRACTABLE HEADLIGHT MOTOR


REPLACEMENT
Remove bolt (1) holding arm (2) to motor shaft.
Remove three bolts (3) and washers holding motor (5).
Disconnect electrical connector. Remove motor (5).
When installing, place ground wire for motor under
mounting bolt (3).

1. Bolt. 2. Arm. 3. Bolts. 4. Cap.


5. Motor. 6. Adjusting rod.

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.

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III - 1974

Section No. 555.03

Page 187

Instruments and Controls


10 ii 12 14 15 13 17 1
l

lHIllIlll

Location of instruments and controls

. Panel side air outlets. adjustable.


. Lighting switch. three-position.
. High/'Low beams change-over
switch lever.
Turn signal switch lover.
. Instrument cluster. I ,--"
.,
. Horn button.
. Steering lock ignition switch.
. Windshield wiper/‘washer switch
lever. three-position.
Air diffuser. windshield. 24. Hand brake lever. To release, Trip recorder.
F97“?

thumb in the button on top of Cluster panel mounting screws.


. Two-speed heater fan switch,
three-position. hand grip.
Turn signal arrow indicator.
11. Air volume control lever. . Choke knob.
Vehicular hazard warning indi-
as

12. Heater outlet flap lever. I: . Ideogram illumination intensity cator.


rheostat.
13. Panel center air outlets,_adiust- Fasten belts indicator (red) and
| . instrument cluster light switch.
one.

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).

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Page 183

Instruments and Controls


SEATBELT INTERLOCK SYSTEM
TOFDSEA

II 1

To BUZZER ‘—

® @3 @1

@ @r ~—b- 'rn Isumou


KEY WARNING

To Low on. 4—— ®

“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

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Ill . 1974

Section No. 555.03

Page 189

1974 FIAT MODELS


SEAT BELT INTERLOCK CHECKOUT
1—DPERATION d. If any reading is faulty, go to PASSENGER’S
a. Sit in driver’s seat. Buckle seat belt. Start car. SEAT SWITCH CIRCUIT.
If car will not start and seat belt warning light
6—PASSENGER’S SEAT BELT SWITCH
does not come on, go to step 2 and 8 of check-
out. If car will not start and light comes on,
a. Leave black lead connected to ground. Connect
go to step 2 and 3. red lead to 1R in connector C17.
b. Place transmission in each gear in turn. If b. With belt retracted, meter should read 0 ohms.
c. Pull belt out and buckle it. Meter should read
seat belt warning light comes on, go to step 2
and 6. infinity (7.).
0. Shut off engine. Have someone sit in passen- d. If any reading is faulty, go to PASSENGER'S
SEAT BELT SWITCH CIRCUIT.
ger's seat with belt buckled. Try to start car.
If car will not start, go to step 2 and 5. 7—TRANSMISSIDN SWITCH
d. Shut off engine. Unbuckle seat belts. Depress a. Leave black lead connected to ground. Connect
by-pass switch. Try to start car. If car will not red lead to 6R in connector 017.
start. go to step 2 and 11. b. Place gearshift lever in neutral. Meter should
2—PREPARATIDN read infinity (7.).
a. Obtain volt/ohm meter and jumper wire 6 6. Place gearshift lever in other gears in turn.
inches long. Meter should read 0 ohms in any gear.
b. Locate control box. The box is located above d. If any reading is faulty, go to TRANSMISSION
glove tray. SWITCH CIRCUIT.
c. Disconnect two connectors 016 (white) and
C17 (red) from control box.
8—INDICATDR AND BUZZER RELAY CIRCUIT
a. Get jumper wire. Connect one end of jumper to
3—DRIVER’S SEAT SWITCH ground. Connect other end to 1W in connector
3. Connect black lead of ohmeter to ground. Con- C16.
nect red meter lead to 4R in connector C16. b. Insert ignition key. Turn key to ON position.
Set meter to X1. c. Check that indicator and buzzer come on.
b. With seat empty meter should read infinity (7:). d. If indicator and buzzer do not come on, go to
c. Have someone sit in seat. Meter should read SEAT BELT INDICATOR AND BUZZER CIRCUIT.
0 ohms.
d. If readings are faulty. go to DRIVER’S SEAT 9—STARTER RELAY CIRCUIT
CIRCUIT. a. Leave one end of jumper connected to ground.
Connect other end to 6W in connector 016.
4—DRIVER’S SEAT BELT SWITCH
b. Try to start car. Car should start.
a. Leave black lead connected to ground. Connect
c. If car will not start. go to STARTER RELAY
red lead to 2R in connector 017.
CIRCUIT.
b. With belt retracted, meter should read 0 ohms.
c. Pull belt out and buckle it. Meter should read 10—OIL PRESSURE SENDER CIRCUIT
infinity (-1.). a. Get ohmmeter. Connect black lead to ground.
d. If any reading is faulty, go to DRIVER’S SEAT Connect red lead to 53 in connector 017.
BELT SWITCH CIRCUIT. b. Meter should read 0 ohms. If meter reads more
5—PASSENGER'S SEAT SWITCH than 0 ohms, check that oil pressure light is on
3. Leave black lead connected to ground. Connect with ignition key on and engine off.
red lead to 3R in connector C17. c. If light is off, troubleshoot oil pressure indicator.
b. With seat empty, meter should read infinity d. If light is on. repair graylyellow wire from con-
(:0) nector C7 at instrument panel to connecter
c. Have someone sit in passenger's seat. Meter 017.
should read 0 ohms. e. Leave ignition switch in ON position.

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Page 190

I1—BY-PASS SWITCH CIRCUIT Connect red lead to 4W in connector 016.


a. Leave black lead connected to ground. Con- . Meter should read voltage.
nect red lead to 2W in connector 016. .lf meter does not read voltage. check wire
. Meter should read infinity (7.). from connector 016 to instrument panel con»
. Have someone hold switch down. Meter should hector. Repair wire.
read 0 ohms. .Connect red lead to 3W. Meter should read
. If any reading is faulty, go to BY-PASS SWITCH voltage.
CIRCUIT. .lf meter does not read voltage, check that
ignition key warning system works. If system
IZ—CONTROL BOX GROUND CIRCUITS works, repair wire from connector C16 to fuse
a. Leave black lead connected to ground. Connect B.
red lead to 5W in Connector 016.
b. Meter should read 0 ohms. If meter reads more 14—CONTROL BOX
than 0 ohms. check 5W from connector to a. If only one or two checks were performed and
ground Connection in front of control box. the fault was not found, perform all the checks.
Check ground connection. b. If all checks are good. check wiring from
connectors to control box. Check connectors.
13—CONTROL BOX POWER CIRCUITS c.lf wiring and connectors are good replace
a. Get voltmeter. Connect black lead to ground. control box.

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BODY—70-71
PARTS SERVICE MANUAL 8:
CATALOG SERVICE TIME
00 DE SCHEDULE CODE
_. 70-71 General Information ................................................................................ 191
Gr. 701 BODY SHELL
L1.02 701.02 Instrument Panel .................................................................................... 193
L1.05 701.05 Body Shell .............................................................................................. 197
L1.08 701.08 Hard Top ................................................................................................ 203
L1.09 701.09 Doors ...................................................................................................... 205
L1.18 701.18 Windshield .............................................................................................. 209
L1.20 701.20 Back Window .......................................................................................... 211
L1 .23 701.23 Luggage Compartment ............................................................................ 213
L127 701.27 Air Intakes and Lids ................................................................................ 21'!
Gr. 711 INTERIOR TRIM AND SEATS
M1.01 711.01 Front Seats .............................................................................................. 219

70
71

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III - 1974

Section No. 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.

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Ill - 1914

Section No. 701-02

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.

1. Screw. 2. lnstrurnent cluster.


3. Instrument panel.

Remove 4 screws ( 1) holding panel (2) on right side of


instrument panel (3). Remove panel (2).
Remove light switch from left side of instrument panel.

1. Screw. 2. Panel. 3. Instrument Panel

Remove 5 screws (1) thru bottom of steering column


cover (2). Remove cover.

1. Screws. 2. Steering column cover.

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Page 194

Remove 4 bolts (1) and washers (2 behind instrument


cluster, 2 behind panel on right side). Pull instrument
panel (2) out towards you. Lift panel up and out of car.

1. Bolt. 2. instrument panel.

Place panel in car. Align defroster outlet with duct.


Slide clips (1) in top of panel (2) into clamps (3) on
body. Install 4 bolts, lockwashers, and washers (2
behind instrument cluster, 2 behind panel on right
side) thru panel into body.

1. Clips. 2. Panel. 3. Clamps.

Place instrument cluster (1) into position in panel.


Connect electrical connectors and speedometer cable
to cluster. Secure cluster with 5 screws (2).
Install panel on right side of instrument panel with
4 screws.
Install steering column cover with 5 screws.
Install lighting switch in instrument panel.

1. Instrument cluster. 2. Screws.

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III - 1914

Section No. 701-02

Page 195

Instrument Panel

36“”, J “r“ L____33

35‘——J ;_34

VIEW OF INSTRUMENT PANEL COMPONENTS


1. Washer 16. Plate 31. Hinge
2. Lockwasher 17. Screw 32. Pin
3. Bolt 18. Screw 33. Washer
4. Gasket 19. Lockwasher 34. Screw
5. Duct 20. Pin 35. Lockwasher
6. Gasket 21. Lock 36. Bolt
7. Rubber bushing 22. Lock cylinder 37. Washer
8. Rubber bushing 23. Latch 38. Spring clip
9. Screw 24. Duct 39. Hinge
10. Gasket 25. Hinge 40. Screw
11. Duct 26. Rubber bushing 41. Cover
12. Gasket 27. Screw 42. Cover
13. Spacer 28. Washer 43. Duct
14. Clip 29. Catch 44. Switch housing
15. Duct 30. Tray

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Ill - 1914

Section No. 101.041.05

Page 197

Body Shell-Sheet Metal


Damages due to accidents are very different in nature front and rear wheels is the first thing to check. Mis-
and extent. It is impossible to provide detailed infor- alignment is apparent when there is no parallel rela-
mation on what should be done to repair bodies be- tionship between the axes of front and rear wheels or
cause each accident may result in repair procedures for when rear wheels do not follow in the tracks of the
that particular case. front wheels. You should first check to make sure the
In order to repair a damaged body, it is essential that misalignment is not caused by damage to front and
you become thoroughly familiar with the body con- rear suspension, steering linkage, etc.
struction and know how the various assemblies or if the body proves to be bent, you may restore it to its
sections are welded together. In most cases you will proper dimensions by checking the mounting points of
have to remove some parts to gain access to parts re- mechanical units to the underbody. They must be the
quiring repairs. If the body is severly damaged, you same as given in the illustration on the next page.
should remove all interior trim which are easily re- Extreme care is required in checking dimensions. Any
moved. This will provide better access during repair distortions must be corrected until the proper dimen-
and alignment operations. It will also save you time in sions are obtained.
measuring checking, and placing jacks for straighten-
ing and aligning the body. Dust And Water Leaks
After repairing the body and before installing interior
Alignment trim you should inspect all points where dust and
The body is of unitixed construction and therefore the water are likely to get into the interior of the car. Seal
body and underbody are one unit. The alignment of points of possible leakage with sealing cement.

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1
III - 1974 l

Section No.701.04/.05 l
l
Page 199/200 E

Body Shell-Sheet Metal

/.. 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
-

4715 'Section 0-6 .


477.5 mm =18.7992 In
55.5 mm = 21850 'In
:._4 2-“, 52 mm = 2047,, in
429 mm = 16.8898 in = ' " .
418 mm =15.4567 In = '
408 mm = 16.0630 In _
406 mm = 159843 In :
405 mm = 159449 In ‘
399.5 mm = 15.7283 In
378 mm = 133313 In
354 mm = 1 . In
335.5 mm = 13.2087 In 40 mm =
333 mm =13.11o2 m 33 mm =
302 mm = 11.8898 in 31 mm =
293.5 mm = 11.5551 in 285 mm =
290.5 mm =11.4370 in 23 mm =
222.5 mm = 8.7598 in 21 mm =
220 mm = 8.6614 in 17 mm =
195 mm = 7.6771 in 8 mm =

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

. Power plant side mounting.


. Rear wheel axis.
. Rear wheel static centre.
. Rear control arm rear mounting.
. Crossmember rear mounting, ‘power plant suspension.
. Power plant suspension rear mounting.
. Rear shock absorber upper mounting.

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Ill - 1974

Section No.701.04l.05

Page 201

Body Shell-Sheet Metal


BODY SHELL INNER COMPONENTS
1. Crossrail 5. Joining element 9. Battery seat
2. Wall 6. Cover 10. Framing
3. Nut 7. Bracket 11. Side panel
4. Lockwasher 8. Framing 12. Wall

1. Air intake wall 6. Joining element 11. Reinforcement


2. Air intake case 7. Framing 12. Reinforcement
3. Reinforcement 8. Joining element 13. Reinforcement
4. Framing 9. Reinforcement 14. Framing
5. Windshield framing 10. Framing 15. Joining element

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Page 202

BODY SHELL INNER COMPONENTS


1. Boxed panel 4. Side panel 8. Wheel box
2. Wall 5. Wall 9. Reinforcement
3. Joining element 6. Joining element 10. Side panel
7. Side panel

BODY SHELL OUTER COMPONENTS


Panel Panel 17. Panel
2. Panel 10. Panel 18. Seat
3. Panel 11. Panel 19. Joining element
4. Channel 12. Panel 20. Joining element
5. Hood channel 13. Panel 21. Panel
6. Panel 14. Panel 22. Door opening panel
7. Windshield panel 15. Hood channel 23. Panel
8. Panel 16. Panel

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Ill - 1974

Section No. 701.08

Page 203

Hard Top
Adjust hard top for proper alignment by loosening 4
screws (1) holding stricker plate (2) and shifting plate
(2).

1. Screws. 2. Stricker plate.

EXPLDDED VIEW OF HARD TOP COMPONENTS


1. Screw 8. Weather strip 15. Covering
2. Stricker plate 9. Weather strip 16. Plug
3. Screw 10. Hard top 17. Weather strip
4. Support 11. Lug 18. Moulding
5. Lock 12. Screw 19. Joint
6. Screw 13. Screw 20. Lock
7. Moulding 14. Stricker plate

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III -1974

Section No. 701.09

Page 205

Doors

REMOVING DOOR PANEL


Pry out plug (1) in top of arm rest (2). Remove 3
screws holding arm rest (2) in door.
Remove screw and door handle (4).
Unscrew lock button (3).
Pry back cover (5) on window crank (6). Push crank
toward center of regulator and pull crank off.
Pryr off top covering (7).
Pry door panel out.

1. Plug. 2. Arm rest. 3. Lock button.


4. Door handle. 5. Cover. 6. Window crank.
7. Covering.

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.

1. Screws. 2. Window. 3. Rubber pad.

To adjust tension of cable (1), loosen nut (2) on adjust-


able pulley. Move pulley in slot (3) to set tension.
Tighten nut (2).

1. Cable. 2. Nut. 3. Slot.

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Page 205

DOOR LOCK ADJUSTMENT


To adjust outside doorhandle, turn adjustable head (1)
of tie rod (2).

1. Adjustable head. 2. Tie rod.

To adjust the inside door handle (1), loosen 3 screws


(2) and shift the handle (1).

1. Door handle. 2. Screws.

To adjust stricker plate (1) for door lock, mark its


position. Loosen 2 screws (2) and shift plate (1).

1. Stricker plate. 2. Screws.

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Ill - 1914

Section No. 701.09

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

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Page 208

EXPLODED VIEW OF DOOR


1. Doorsill moulding 14. Screw . Screw
2. Weather strip 15. Pad . Weather strip
3. Bolt 16. G lass . Pad
4. Washer 17. Guide Nut
5. Boot 18. Plate . Washer
6. Channel 19. Screw . Sheave
7. Glass 20. Weather strip . Washer
8. Weather strip 21. Cover Bolt
9. Pillar 22. Boot . Lockwasher
10. Pad 23. Weather strip . Nut
11. Weather strip 24. Channel . Ornament
12. Clip 25. Washer Handle
13. Plate 26. Lockwasher . Window regulator

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III - 1914

Section No. 101.18

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.

Set glass in position in fence. Center glass so that


distance between glass and fence is even all around.
Place Spacers (1) to hold glass in position.
Check that glass is centered with respect to the fence.
Use gauges (4). Insert 4 or more spacers (3) to hold
glass. Glue spacers to opening fence. Make sure they
are right size to enable a continuous bead of adhesive
to be applied,

%. Spacers for centering glass on fence. 2. Moltoprene.


Spacer for resting glass on fence.
4: Reference gauges. 5. Windshield glass.

A = 0.15 in. (4mm)

Apply 4 strips of tape to glass. Cut strips at edge of


glass. Remove glass and place it on a stand.
Apply self-adhesive moltoprene (0.39 x 0.39 in. (10 x
10mm) thick) along inside prometer of glass about 0.6
in. (15mm) from edge. This is to prevent adhesive
from getting into car.

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Apply a thin coat of primer to edge of glass. fence seat,
and inner part of outside weatherstrip.
Apply sealant along inside prometer of glass. Form a
bean of about 0.36 in. (10mm) in diameter.
Be careful to avoid variations in bead sections and
air bubbles between bead and glass.

Apply sealant to inner part of outside weatherstrip.


Be careful to avoid variations in bead sections and air
bubbles between bead and glass.
Place glass in fence, resting it on the spacers. Align
taps on glass and car. Remove taps. Apply a thin coat
(0.39 in. (10mm) wide) of primer to outer edge of glass.

Apply outside weatherstrips. Join end with butt joints.


Press strips until they are in place. Use a spring-type
fixture to apply pressure to weatherstrips. After 24
hours. remove strip of moltoprene. Remove excess
sealant by scraping along fence. Remove the fixture.
Install parts removed. Clean glass surfaces.

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Ill - 1974

Section No. 701.211

Page 211

Back Window

REMOVAL AND INSTALLATION


Remove engine compartment lid. Refer to 701.27.
Remove air scoops on either side by removing 4 screws
(1 screw is under trunk lid). Remove gas cap.
Remove 6 bolts (2) holding weatherstrip (3) to body.
0n cars with rear window defogger, disconnect 1 wire
each side from window.

1. Gas cap. 2. Bolts. 3. Weatherstrip.

Pull rubber seal (1) around window towards center of


window. Slide seal out from under window (2) at edge.
Pull window down. Remove top rubber seal. Remove
window.
Place rubber seal on top of window.
Place window in frame (3) and push it up into place.
Slide rubber seal (1) under window. Make sure window
is in center of seal and seal overlaps frame (3).

1. Rubber seal. 2. Window. 3. Frame.

Install weatherstrip (2) with 6 bolts (3).


Install air scoops (1) on either side.
On cars with rear window defogger, connect 1 wire
each side to window. Install engine compartment lid.

1. Air scoops. 2. Weatherstrip. 3. Bolts.

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III - 1914

Section No. 101.23

Page 213

Luggage Compartment Lid

FRONT LUGGAGE COMPARTMENT LID


REPLACEMENT AND ADJUSTMENT
Remove bolts (2) and washers holding lid (1) to hinges
(3). Remove nut and washers holding support rod (4)
to lid (1).
When installing lid. tighten bolts thru hinges enough to
permit the lid to be shifted. Close lid and check for
proper alignment. Shift lid as necessary. After lid is
positioned properly, tighten bolts.
Install support rod.

1. Lid. 2. Bolts. 3. Hinge. 4. Support rod.

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.

1. Grill. 2. Lock. 3. Bolts.

Disconnect cable (1) from lock (3).


Remove 2 nuts (2) and washers holding lock to bracket
(4}. When installing, tighten bolts enough to allow lock
to be shifted. Check lock for operation and shift lock
as needed. Tighten 2 bolts.

1. Cable. 2. Nuts. 3. Lock. 4. Bracket.

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Page 214

VIEW OF FRONT LUGGAGE COMPARTMENT LID GOMPARTMENTS.

28

29
24
30

1. Stricker plate 11. Washer 21. Lockwasher


2. Lid 12. Latch cable 22. Washer
3. Spring washer 13. Cable 23. Lockwasher
4. Washers 14. Spflng 24. Nut
5. Lockwasher 15. Lock 25. Hinge
6. Nut 16. Washer 26. Nut
7. Rod 17. Lockwasher 27. Hinge
8. Lock bracket 18. Nut 28. Bolt
9. Washers 19. Compartment rubber seal 29. Washer
10. .Bolt 20. Bolt 30. Washer

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Ill - 1974

Section No. 701.23

Page 215

Luggage Compartment Lid

REAR LUGGAGE CDMPARTMENT LID


REPLACEMENT AND ADJUSTMENT
Remove bolts (3) holding lid (5) to hinges (4). Unhook
center prop (1). Remove lid. Remove prop (1), cotter
pin, washers, and bushing (2).
When installing lid, check position. Shift lid on hinges
to obtain proper alignment. Tighten bolts holding lid
to hinges.

1. Prop. 2. Bushing. 3. Bolts. 4. Hinge.


5. Lid.

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.

1. Cable. 2. Plastic cable. 3. Bolts. 4. Lock.

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. Lever. 2. Screw. 3. Screw. 4. Assembly.

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Page 216

VIEW OF REAR LUGGAGE CDMPARTMENT LID COMPONENTS.

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

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Ill - 1914

Section No. 701.27

Page 21')l

Air Intakes and Lids


ENGINE COMPARTMENT LID
REPLACEMENT AND ADJUSTMENT
Remove bolts (4) and washers holding lid (5) to hinges
(3). Unhook center prop (2). Remove prop (2), cotter
pin. washers, and bushing (1).
When installing lid, check position. Shift lid on hinges
to obtain proper alignment. Tighten bolts holding lid
to hinges.

1. Bushing. 2. Prop. 3. Hinge. 4. Bolts.


5. Lid.

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.

1. Lock. 2. Bolts. 3. Cable.

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Page 218

EXPLDDED VIEW OF LID COMPONENTS AND AIR INLETS


1. Grill 14. Bushing . Screw
2. Screw 15. Cotter pin . Cable
3. Grill 16. Grill . Cable
4. Washers 17. Conveyor . Gasket
5. Nut 18. Gasket . Conveyor
6. Hinge 19. Gasket . Gasket
7. Washer 20. Wall . Air intake
8. Lock washer 21. Conveyor . Wall
9. Bolt 22. Bolt . Clip
10. Center prop 23. Lock . Screw
11. Washer 24. Screw . Screw
12. Lid 25. Screw . Washer
13. Stricker plate 26. Grill

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Ill - 1974

Section No. 711.01

Page 219

Front Seats

To remove seats, disconnect spring from bracket under


seat. Disconnect connector for seat switch.
Raise lever. Slide seat off floor tracks.

1. Spring. 2. Track. 3. Connector. 4. Bracket.

FRONT SEAT
. Fore and aft adjuster lever
FP‘PPPE‘J"

Seat release lever


Back hinge
Track
Spfing
Seat Belt interlock wires
Front seat release lever

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ELECTRICAL SYSTEM
TROUBLESHOOTING
Page
Battery and Charging System ................................................................ 221
Starting System ...................................................................................... 229
Ignition System ...................................................................................... 239
Radiator and Carburetor Cooling System ______________________________________________ 25'!
Seat Belt Interlock and Remove Key Warning System ............................ 26‘!
Interior Lights .......................................................................................... 281
Exterior Lights ........................................................................................ 291
Instruments ............................................................................................ 31-;
Accessories ............................................................................................ 329
Fuses ...................................................................................................... 339

ELECTRICAL SYSTEM
TROUBLE SHOOTING

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ELECTRICAL SYSTEM TROUBLESHOOTING

Page 221

BATTERY AND CHARGING SYSTEM

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

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ELECTRICAL SYSTEM TROUBLESHOOTING

Page 222

BATTERY AND CHARGING SYSTEM

BATTERY CHARGE INDICATOR STAYS ON AFTER ENGINE STARTS

CHECK
ALTERNATOR REPAIR DRIVE
DRIVE

IF OK

CHECK VOLTAGE REPLACE


AT ALTERNATOR ALTERNATOR

IF OK

CH ECK VOLTAGE
REPAIR
AT CIRCUIT WIRE
BOARD

IF OK

CHECK CIRCUIT
BOARD FOR
DEFECTS

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ELECTRICAL SYSTEM TROUBLESHOOTING

Page 223

BATTERY AND CHARGING SYSTEM


BATTERY CHARGE LIGHT STAYS ON AFTER
ENGINE STARTS
1.a. Go to engine compartment. Check that alternator drive belt is not broken.
lf broken, replace it.
b. Check that alternator drive belt is not loose. (More than 1/2 inch play.) If
loose, move alternator to tighten belt. If not loose, go to step c.
c. Start engine. Be sure alternator shaft is turning. If not turning, replace
alternator. If belt and alternator O.K. go to step 2.

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.

c. Remove 5 screws thru instrument panel. Disconnect Speedometer cable


from panel. Do not disconnect connectors.
d. Connect red meter lead to black/violet wire in connector C7. Connect
black lead to ground.
NOTE
Connector C7 is in middle of instrument panel. It is a 6 pin
connector.
e. If meter does not read voltage, repair black/violet wire from connector C7
to regulator and from regulator to alternator.
f. if meter reads voltage, check connector C7, circuit board, and bulb holder
for defects. Repair or replace defective part. RED LEAD
TOGROUND

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E LECTR ICAL SYSTEM TROUBLESHOOTING

Page 224

BATTERY AND CHARGING SYSTEM


INDICATOR DOES NOT LIGHT WITH IGNITION SWITCH ON AND
STAYS OFF WITH ENGINE RUNNING

CHECK
CHECK CIRCUIT ALTERNATOR
TO ALTERNATOR CIRCUIT
TO GROUND

IF OK IF NOT

IF OK

REPLACE
REPAIR WIRE ALTERNATOR

REPLACE BULB IF OK JOB COMPLETE

IF NOT
OK

CHECK CIRCUIT
BOARD FOR
DEFECTS

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ELECTRICAL SYSTEM TROUBLESHOOTING

Page 225

BATTERY AND CHARGING SYSTEM

INDICATOR DOES NOT LIGHT WITH IGNITION SWITCH


ON AND STAYS OFF WITH ENGINE RUNNING
1.a. Check that horns work. If horns do not Work, repair light blue/black wire
from connector C12 to fuse A. 1 .
=‘.-..-‘.-.
[L].
r'
NOTE '(zé’i
I I u

Connector C12 is a 4 pin connector located under steering


column cover.
If horns work, remove 5 screws thru instrument panel. Pull panel out.
Disconnect speedometer cable from panel.
INSTRUMENT PANEL

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 \

alternator. Connect black lead to ground.


If meter reads more than 10 ohms, replace alternator.

/
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“

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E LECTR ICAL SYSTEM TROUBLESHOOTING

Page 226

BATTERY AND CHARGING SYSTEM

BATTERY BOILS OVER. LIGHTS BURN OUT

1.3:. Go to voltage regulator. REGU LATOR


b. Check that voltage regulator mount bolts are tight.
c. Check that wire connections are clean and tight.
d If bolts are tight and connections are tight and clean, replace voltage
regulator.

BOLTS
BLACKNIOLET WIRE

BATTERY DOES NOT STAY CHARGED


La. Check that battery cells are filled with water. If battery needs water, fill
cell and charge battery. it cells are full, charge battery. Go to step b.
b. Get hydrometer. Measure specific gravity of each cell. If specific gravity is
below 1.100 on any cell or cells, check battery with a carbon pile load. If
battery O.l<. go to step 2. If load test indicates battery is no good, replace
it.

Get multimeter. Set up meter to measure amps.


Make sure all switches are off. Close doors.
Disconnect battery positive cable. Connect black meter lead to cable. Con- ‘23:»
nect red meter lead to battery positive post.
If meter reads 0 amps, replace voltage regulator.
If meter moves, check wiring between battery and ignition switch, and
between ignition switch and fuse box. Check ignition system wiring.

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ELECTRICAL SYSTEM TROUBLESHOOTING

Page 227I'228

BATTERY AND CHARGING SYSTEM

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

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ELECTRICAL SYSTEM TROUBLESHOOTING

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

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ELECTRICAL SYSTEM TROUBLESHOOTING

Page 230

STARTING SYSTEM

STARTER WILL NOT START CAR

START CAR
FROM OUTSIDE
IF NOT OK IF OK
CHECK POWER
TO RELAY
TURN ON
HEADLIGHTS
OPERATE STARTER
IF NOT OK SWITCH

'F 0" IF NOT


0K LIGHTS VERY DIM
OR GO OUT

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

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ELECTRICAL SYSTEM TROUBLESHOOTING

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

If lights are very dim or go out, go to step 4.


If lights remain bright, try to start car from outside of car. If starter starts
ST LOCK)
engine, starting precedure or seat belt interlock system faulty.
If starter does not run, go to step 2.

IGNITION SWITCH

Get voltmeter. Go to interlock relay.


RELAY
NOTE
TERMmE/L 30151
Eta-i... 'f
Interlock relay is mounted under instrument panel above drop
tray.
Connect red lead to terminal 30/51 (red wire) of relay. Connect black lead RED WIRE LEAD
BLACK

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

Get voltmeter. Connect red lead of meter to terminal 87 (red wire) of


relay. Connect black lead to ground. fi'fi
Have someone start engine. If meter reads 8 volts or more, go to step 0. If
meter reads less than 8 volts, check orange/white wire between terminals 1I|ERMINAL 87
30 and 85. If wire is good, replace relay.
BLACK LEAD RED
' {LEAD
I

RED
WIRE)
TO GROUND

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ELECTRICAL SYSTEM TROUBLESHOOTING

Page 232

STARTING SYSTEM

i. Remove 5 screws thru bottom of steering column cover. Remove bottom


ofcoven

j. Find connector (:12. RED WIRE


NOTE
Connector C12 is located on the right side of the steering
column. it is a 4 pin black and white connector.
k. Connect red meter lead to red wire (position 1) to relay in connector C12. 3
Connect black lead to ground.
I. Turn ignition switch to start. If meter reads 8 volts or more, repair red BLACK LEAD
wire to relay. 4

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.

0. Go to starter. Connect red meter lead to terminal 30 of starter. Connect


black lead to ground.
p. if meter reads less than 8 volts, repair wire to battery.

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ELECTRICAL SYSTEM TROUBLESHOOTING

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.

s. If meter reads 8 volts or more, check connections at starter and solenoid


terminals. Remove, clean, and tighten. T0 BATTERY
t. Turn ignition switch to start. If starter will not run, replace starter. (BLACK)

M TO
A
RELAY -__._
(Rem—m.
I/ /"'__

3.a. Check connections at starter terminals.


Remove, clean, and retighten.
P'

c. Check condition of battery with hydrometer. If specific gravity of any cell


is below 1.100, check battery with a carbon pile load. If load test indicates
battery is no good, replace it.

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

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ELECTRICAL SYSTEM TROUBLESHOOTING

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

4.3. Check battery connections for corrosion or lobseness. TERMINAL


b. If necessary, clean posts and terminals with a wire bristle brush. Tighten
CLEANING
connections.

POST
/CLEANING

6. Check battery condition with hydrometer. SET TO NORMAL


d. If specific gravity of any cell is below 1.100, check battery with a carbon 12V CHARGE
pile load. If load test indicates battery is not good, replace battery.
e. If load test indicates battery is good, recharge battery.
f. If battery and cables check good, starter is possibly shorted internally and
must be removed and bench checked.

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ELECTRICAL SYSTEM TROUBLESHOOTING

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

d. Check connector C12 for dirt, looseness, or corrosion.


CONNECTOR C12
NOTE
Connector 012 is located on right side of steering column
under column cover. It is a 4 pin connector.
e. Repair or replace connector as necessary.

1‘. Check terminals at starter for looseness or corrosion. Clean


and reinstall.
9. if starter continues to crank slowly after each point has been
checked and TO BATTERY
found good, condition may be caused by recently over
hauled or tight (BLACK)
engine or possibly too heavy an oil in crankcase at
temperatures below
40°F.

TO RELAY——__

// /"‘_

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‘1'

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ELECTRICAL SYSTEM TROUBLESHOOTING

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

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ELECTRICAL SYSTEM TROUBLESHOOTING

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...“

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E LECTRICAL SYSTEM TROUBLESHOOTING

Page 240

IGNITION SYSTEM

ENGINE WILL NOT START

IGNITION TROUBLESHOOT
ENGINE DOES
SWITCH TO ENGINE STARTING
START NOT CRANK
I
TROUBLESHOOT
FUEL SYSTEM
ENGINE CRANKS
7

CHECK SPARK CHECK SPARK


INTENSITY AT PLUGS
SPARK PLUGS
2

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 SPARK AT REPLACE LEAD


COIL HIGH TENSION FROM COIL TO
TERMINAL DISTRIBUTOR
2
REPLACE COIL
IF NOT OK
4

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

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ELECTRICAL SYSTEM TROUBLESHOOTING

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.

2.3. Take coil to distributor lead out of distributor.


b. Hold lead about 1/4 inch from engine. Use insulated pliers.
c. Crank engine and check for spark. If spark is present, 90 to step 3.

d. If spark is not present, connect lead to distributor. Disconnect lead from


top of coil.
e. Hold lead about 1/4 inch from terminal on coil. Use insulated pliers.
f. Crank engine and check for spark. If spark is not present, go to step 4. If
spark is strong, replace lead from coil to distributor. COlL LEAD

COlL

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ELECTRICAL SYSTEM TROUBLESHOOTING

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.

d. If meter reads voltage, get ohmmeter. Turn ignition switch off.


e. Connect red meter lead to +3 terminal of coil. Connect black lead to
distributor side of coil.
f. Meter should read as follows:
Coil Resistance (Ohms)
Marelli 3.1 to 3.4
Martinetti 3 to 3.3

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ELECTRICAL SYSTEM TROUBLESHOOTING

Page 243

IGNITION SYSTEM

5.a. Get voltmeter. Find connector 014.


RED LEAD
NOTE
Connector 014 is located behind center console. It is an 8 pin
connector.
Connect red lead to pink wire from coil. Connect black lead to ground.
If meter reads 8 volts or more, repair pink wire to coil.

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

Remove distributor cap and rotor. MOVABLE BREAKER ARM


With ignition switch on, crank engine with remote starter switch.
Watch points to see if they open and close fully. lf points do not open and
close fully go to step k.
Check spark at points. If spark is strong. set timing (See ENGINE RUNS
BUT LACKS POWER, step 2).
If spark is weak, check condition of moveable breaker arm and rubbing
block. If visibly defective, remove and replace points. Be sure all connec-
tions are cleaned and tight.

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ELECTRICAL SYSTEM TROUBLESHOOTING

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)

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ELECTRICAL SYSTEM TROUBLESHOOTING

Page 245

IGNITION SYSTEM

0. Rotate cam, then recheck gap.


p. Check distributor shaft for side play (up and down play is normal). If you
feel excessive side play, remove distributor for overhaul.
NOTE
After the car accumulates mileage, the distributor may wear
and permit slight side play.

CHECK SIDE PLAY OF


DISTRIBUTOR SHAFT

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

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ELECTRICAL SYSTEM TROUBLESHOOTING
Page 246

IGNITION SYSTEM

Check gap. Reset gap. if necessary. WIRE GAGE


0.9

Reinstall plugs. Connect leads. 0.020 TO 0.024


If plugs were good or if engine still will not start, troubleshoot fuel system.

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ELECTRICAL SYSTEM TROUBLESHOOTING

Page 247

IGNITION SYSTEM

ENGINE MISSES AT IDLE (ROUGH IDLE)

CHECK PLUGS
FOR MISFIRE

IF OK IF NOT OK

CHECK POINTS CLEAN, REGAGE,


DISTRIBUTOR AND OR REPLACE
LEADS BAD PLUG

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.

CHECK SPARK PLUG


\
LEAD TO ENGINE

NOTE REVERSE CHECK


Misfiring is detected by no change in the idle RPM when lead
is shorted or removed.
c. Remove plug. Check plug for dirt, damage, and gap. If plug is good, 90 to
step d. If plug is not good, clean, gap or replace plug.
(1. Remove plug from firing cylinder. Reverse plugs and reinstall. OOD
e. Start engine. See if misfiring is in cylinder with suspect plug by repeating PLUG
shorting in step La.
f. If so. replace with new plug. SUSPECT
PLUG <

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ELECTRICAL SYSTEM TROUBLESHOOTING

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.

CHECK FOR ERACKS


0

b. If point condition and gap are good, check spark plug leads, distributor
cap, and rotor for defects. Replace any defective part.

AND DRY a "

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.

CHECK SIDE PLAY OF


DISTRIBUTOR SHAFT

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ELECTRICAL SYSTEM TROUBLESHOOTING

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

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ELECTRICAL SYSTEM TROUBLESHOOTING

Page 250

IGNITION SYSTEM

ENGINE RUNS BUT LACKS POWER OR MISSES AT HIGH SPEED

CHECK
DISTRIBUTOR
CENTRIFUGAL
ADVANCE

IF OK IF NOT OK

CHECK AND REPAIR OR


ADJUST TIMING REPLACE
DISTRIBUTOR

1.a. Remove distributor cap. Check movement of centrifugal advance. Be sure


advance mechanism is free to move without binding.
b. Check that mechanism returns to original positiOn when hand pressure is
removed. if advance operates normal, go to step 2.
c. if advance does not return, check springs. Connect or replace damaged or
disconnected springs. Check return operation.
d. If springs appear good, remove them. Move mechanism by hand and check
for binding. If binding is felt, distributor must be replaced.
NOTE
When replacing distributor, be sure to note position of rotor
before removal. New distributor must be installed in exact
CHECK SIDE PLAY OF
same position. Check timing after installing distributor.
DISTRIBUTOR SHAFT

2.a. If advance operates normally, proceed with timing. [us-r.


T0 GROUND
b. Connect a test lamp to coil distributor terminal and ground. Remove dis- TERMINAL ‘-
tributor cap.
c. Turn ignition switch on.

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ELECTRICAL SYSTEM TROUBLESHOOTING

Page 251

IGNITION SYSTEM

d. Turn crankshaft by hand until timing mark on drive pulley is at position .\


near mark on timing cover. Loosen distributor lock nut.

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.

TIMING IGNITION WITH TIMING LIGHT


La. Slide No. 1 spark plug lead caver back on lead.
b. Connect one lead of timing light to No. 1 spark plug. NO. 1 PLUG
c. Connect black lead to ground. CONNECTION
d. Connect red lead to power source. \X

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

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ELECTRICAL SYSTEM TROUBLESHOOTING
Page 252

IGNITION SYSTEM

f. Loosen nut on clamp for distributor at crankcase. \

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

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ELECTRICAL SYSTEM TROUBLESHOOTING

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

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ELECTRICAL SYSTEM TROUBLESHOOTING

Page 2551' 256

IGNITION SYSTEM

HIGH TENSION
LEADS

DISTRIBUTOR
CONDENSER

[:3 : , A H A COIL
II]
:1

—BATTERY
:1 SPARK
— PLUGS
[:1

CI4 JEI
13:}

BROWN

r—-1_.\ LT. BLUE/ RED

IGNITION
SWITCH

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4- '-|-"I'|.'l"lII' r-l'll'llli'
I-II-I. '

I:

.|.|.._|F
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II...II
Ifilml
all—"Ii
l

I
I-II: —I‘-"-
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ELECTRICAL SYSTEM TROUBLESHOOTING

Page 257

RADIATOR AND CARBURETOR COOLING SYSTEMS


TABLE OF CONTENTS
SECTION PAGE
Engine Overheats—Radiator Cooling Fan Will Not Run 259
Radiator Cooling Fan Runs All The Time 260
Carburetor Cooling Fan Will Not Run 261
Carburetor Cooling Fan Runs All The Time 262

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

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ELECTRICAL SYSTEM TROUBLESHOOTING

Page 258

RADIATOR AND CARBURETOR COOLING SYSTEMS

IF NOT OK REPLACE
CHECK FUSE FUSE

O
IF
IF OK

JUMPER THERMO- FAN RUNS REPLACE


STATIC SWITCH SWITCH

FAN DOES
NOT RUN

CHECK VOLTAGE 'IF NOT OK


REPAIR WIRE
‘F

TO FAN RELAY

IF OK

CHECK RELAY
000
'F NOT 0" _|.._
REPLACE RELAY

IF OK

CHECK GROUND IF NOT OK


REPAIR WIRE
CIRCUIT

IF OK

REPLACE
FAN

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ELECTRICAL SYSTEM TROUBLESHOOTING

Page 259

RADIATOR AND CARBURETOR COOLING SYSTEMS


ENGINE OVERHEATS—RADIATOR COOLING FAN
WILL NOT RUN
JUMPER
1.a. Blow horn. If horn blows, go to step b. If horn will not blow, go to HORN
troubleshooting and check fuse L.
b. Turn ignition switch on. Check battery charge indicator. If indicator is on.
go to step c. If indicator is out with engine not running, troubleshoot
CHARGING SYSTEM.
Go to thermOstatic switch in radiator. Get jumper.
CAUTION
In next step, if switch is bad, fan will run. Keep clear of fan.
Connect jumper to terminals on switch. If fan runs, replace switch. If fan
does not run, 90 to step 9:. Leave jumper on switch. SWITCH

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

LIGHT BLUE WIRE

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ELECTRICAL SYSTEM TROUBLESHOOTING

Page 260

RADIATOR AND CARBURETOR COOLING SYSTEMS

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.

GROUND “I 1\ RED LEAD


TERMINAL 85

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

RADIATOR COOLING FAN RUNS ALL THE TIME WH GEIBLACK WIRE


1.a. Disconnect white/black wire from thermostatic switch. If fan stops, re—
place switch.
b. If fan still runs, 90 to fan relay.

SWITCH

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ELECTRICAL SYSTEM TROUBLESHOOTING

Page 261

RADIATOR AND CARBURETOR COOLING SYSTEMS


c. Disconnect white/black wire from terminal 85 of cooling fan relay. If fan FAN R E LAY
still runs. replace relay. R ,_-—_:--'-_-"---—
d. If fan stops, repair white/black wire from relay to switch.
‘ TERMINAL 85

CARBURETOR COOLING FAN WILL NOT RUN


1.a. Turn courtesy light on. If light works, go to step b. If light won’t work,
troubleshoot COURTESY LIGHT.
b. Get jumper. Go to thermostatic switch.
NOTE
Thermostatic switch is located on rear of carburetor.
CAUTION
ln next step, if switch is bad, fan will run. Keep clear of fan. THERMOSTATIC
c. Connect jumper to terminals on switch. If fan runs, replace switch. If fan SWITCH
does not run, 90 to step d. Leave jumper on switch.

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

GROUND RED LEAD

TERMINAL 86

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ELECTRICAL SYSTEM TROUBLESHOOTING

Page 262

RADIATOR AND CARBURETOR COOLING SYSTEMS


Connect red meter lead to terminal 87 {red wire) of relay. Connect black
lead to ground. BLACK LEAD
If meter reads voltage, go to step e. If meter does not read voltage, go to
step 3.
FAN RELAY

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‘

T“- RED LEAD

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

CARBURETOR COOLING FAN RUNS ALL THE TIME THERMOSTATIC


SWITCH
NOTE
The carburetor cooling fan will run after the engine is shut off,
even with the ignition key removed. This is normal.
Le. Disconnect gray/red wire from thermostatic switch. If fan stops replace
switch.
b. If fan still runs. 90 to carburetor cooling fan relay.

GRAY/RED
WIRE

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ELECTRICAL SYSTEM TROUBLESHOOTING

Page 2631264

RADIATOR AND CARBURETOR COOLING SYSTEMS


c. Disconnect gray/red wire from terminal 85 of relay. If fan still runs, re- FAN RELAY
place relay.
(1. If fan stops, repair gray/red wire from relay to switch.

GRAY/REL WIRE

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ELECTRICAL SYSTEM TROUBLESHOOTING

Page 265/266

RADIATOR AND CARBURETOR COOLING SYSTEMS

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

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ELECTRICAL SYSTEM TROUBLESHOOTING

Page 267

SEAT BELT INTERLOCK AND REMOVE KEY WARNING SYSTEM

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

Sistine ©/ \© 6 SEAT BELT


SWITCH

SEAT BELT REMOVE KEY


ALARM BUZZER ‘5‘“? g/JAM SWITCH
RELAY—H III ]?

CONTROL FUSE A
{BOX FUSE B
I BUZZER
SEAT BE LT
ALARM INDICATOR
INSTRUMENT PANEL

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ELECTRICAL SYSTEM TROUBLESHOOTING

Page 268

SEAT BELT INTERLOCK AND REMOVE KEY WARNING SYSTEM

SEAT BELT INTERLOCK SYSTEM


NOTE
Before troubleshooting the interlock system, perform the checkout in the Shop Manual using either the test
box or volt/ohm meter. When a fault is found leave test equipment connected.

DRIVER'S SEAT CIRCUIT FAULTY


La. if meter did not read 0 ohms or test box light is out with someone in seat,
go to step 2.
b. If meter did not read infinity (W) or test light is on with seat empty,
disconnect connector under driver's seat. \
c. If meter reads 0 ohms or test light remains on, repair yellow/black wire
from connector under seat to connector 09 and to connector C17.
NOTE CONNECTOR UNDER
Connector C9 is a 6 pin connector. it is behind center console. SEAT
d. If meter reads infinity or test light goes out, replace switch in driver's seat.

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

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ELECTRICAL SYSTEM TROUBLESHOOTING

Page 269

SEAT BELT INTERLOCK AND REMOVE KEY WARNING SYSTEM

DRIVER'S SEAT BELT CIRCUIT FAULTY P'NK/YEI—LOW W' FIE


1.3. if meter did not read infinity or test light is on with seat belt pulled out,
go to step 2.
b. If meter did not read 0 ohms or test light is out with belt retracted,
disconnect connector under rug behind driver's seat.
c. Using jumper wire, connect wire from control box to ground. If meter “JUMPER
reads 0 ohms or light comes on, replace switch in seat belt.
d. If meter reads infinity or light remains out, repair pink/yellow wire from T0 GROUND
connector to connector CQ and to connector 017.
NOTE CONNECTOR UNDER
Connector 09 is a 6 pin connector. It is behind the center SEAT
console.

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.

PASSENGER'S SEAT CIRCUIT FAULTY


1.a. If meter did not read 0 ohms or test light is out with someone in seat, 90
to step 2.
b. if meter did not read infinity (W) or test light is on with seat empty,
disconnect connector under passenger’s seat.
c. If meter reads 0 ohms, or test light remains on, repair white/black wire
from connector under seat to connector C9 and to connector C17.
NOTE
Connector C9 is a 6 pin connector. It is behind the center CONNECTOR UNDER
console. SEAT
d. If meter reads infinity or test light goes out, replace switch in passenger's
seaL

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

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ELECTRICAL SYSTEM TROUBLESHOOTING

Page 270

SEAT BELT INTERLOCK AND REMOVE KEY WARNING SYSTEM

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

PASSENGER'S SEAT BELT CIRCUIT FAULTY RED/WHITE WI BE


1.3. If meter did not read infinity (6°) or test light is on with seat belt pulled
out, go to step 2.
b. If meter did not read 0 ohms or test light is out with belt retracted,
disconnect connector behind spare wheel.
c. Using jumper wire, connect white/red wire to ground. If meter reads 0 HJUMPER
ohms or light comes on, replace switch in seat belt.
d. if meter reads infinity or test light remains out, repair white/red wire to T0 GROUND
connector C9 and to Connector C17.
NOTE
Connector 09 is a 6 pin connector. It is behind center console.

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.

TRANSMISSION SWITCH CIRCUIT FAULTY


1.3. If meter did not read infinity (GO) or test light is on with gearshift in CONNECTOR C22
neutral, go to step 2.
b. If meter did not read 0 ohms or test light did not come on with gearshift in
any gear, connect iumper wire to wires in connector 022.
NOTE
Connector C22 is a 2 pin connector. It is located on bottom
forward side of engine.
c. If meter reads 0 ohms or test light comes on, remove jumper. Go to step e.
d. If meter reads infinity or test light remains out, go to step h. JUM ER

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Page 271

SEAT BELT INTERLOCK AND REMOVE KEY WARNING SYSTEM

Locate switch in transmission. Connect jumper wire to wires in switch. if ~~ ——-—.___


if // —_.
NOTE
Switch is located near crossrail.
g , JUMPER __F
. I; {"47
If meter does not read 0 ohms or test light remains out, repair wires from l

switch to connector C22.


|f meter reads 0 ohms or test light comes on, replace switch.

TRANSMISSION SWITCH
l_ —_

Connect jumper wire to green/white wire in connector and to ground. GREEN/WHITE


If meter reads 0 ohms or test light comes on, repair black/violet wire to WIRE-
/
ground or ground connection.
If meter does not read 0 ohms or test light remains out, repair green/white JUMPER
wire to connector C9 and to connector C17.
NOTE
Connector 09 is a 6 pin connector. It is behind center console.

BLACK/VIOLET
TO GROUND WIRE

2.a. Disconnect connector C22. CONNECTOR 022 :


NOTE
Connector 022 is a 2 pin connector. It is located on bottom
forward side of engine.
If meter does not read infinity (W) or test light remains on, repair green/
white wire from connector C22 to connector C9 and to connector C17.
NOTE
Connector 09 is a 6 pin connector. It is behind the center
console.

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

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ELECTRICAL SYSTEM TROUBLESHOOTING

Page 272

SEAT BELT INTERLOCK AND REMOVE KEY WARNING SYSTEM

SEAT BELT INDICATOR AND BUZZER


CIRCUIT FAULTY BULB
HOLDER
La. If indicator and buzzer will not go off, go to step 3.
b. if buzzer works but indicator does not, replace bulb in indicator. If indi-
cator still does not work, check circuit board for defects.
c. If both indicator and buzzer will not work, go to step 2. BULB

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

black wire to ground or ground connection.

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

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Page 273

SEAT BELT INTERLOCK AND REMOVE KEY WARNING SYSTEM

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. %/

If meter reads voltage, replace relay.


TERMINAL 85
1 ORANGE!
WlillTE WIRE

BLACK____
LEAP
T0 GROUND

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ELECTRICAL SYSTEM TROUBLESHOOTING

Page 274

SEAT BELT INTERLOCK AND REMOVE KEY WARNING SYSTEM

BY‘PASS SWITCH CIRCUIT FAULTY BYPASS SW'TCH


1.a. If meter did not read infinity (in) or test light was on with switch released,
go to step 2.
b. If meter did not read 0 ohms or test light was out with switch depressed,
disconnect light blue/red wire from by-pass switch.
c. Using jumper, connect light blue/red wire to ground. If meter reads 0 ohms
or test light comes on, go to step 8. LT. BLUE/
d. if meter reads infinity or test light remains out, repair light blue/red wire RED WIRE
from by-pass switch to connector C9 and to connector C16.
NOTE JUMPER
Connector 09 is a 6 pin connector. It is behind center console.
TO GROUND

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.

LIGHT BLUE! RED WIRE

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ELECTRICAL SYSTEM TROUBLESHOOTING

Page 275

SEAT BELT INTERLOCK AND REMOVE KEY WARNING SYSTEM

KEY BUZZER WILL NOT WORK

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

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ELECTRICAL SYSTEM TROUBLESHOOTING

Page 276

SEAT BELT INTER LOCK AND REMOVE KEY WARNING SYSTEM

KEY BUZZER WILL NOT WORK


1.a. Try to start car without seat belt buckled. If buzzer does not work, go to
step 2.
b. If buzzer works, remove screw thru door jam switch. Check screw, hole,
and switch for dirt. Clean as necessary.
c. Disconnect white/black wire from switch. Touch wire to ground.
d. If buzzer works replace switch. If buzzer does not work, repair white/black
wire from switch to relay for buzzer.

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

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ELECTRICAL SYSTEM TROUBLESHOOTING

Page 2771278

SEAT BELT INTERLOCK AND REMOVE KEY WARNING SYSTEM

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

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ELECTRICAL SYSTEM TROUBLESHOOTING

Page 279/280

SEAT BELT INTERLOCK AND REMOVE KEY WARNING SYSTEM

______._. 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

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ELECTRICAL SYSTEM TROUBLESHOOTING

Page 281

INTERIOR LIGHTS
TABLE OF CONTENTS
SECTION PAGE

Courtesy Light Not On With Door Open 283


Brake Indicator Light Will Not Work With Lever Pulled Up 284
Instrument Lights Will Not Light 285
Optical Fiber Illumination Will Not Work 286
Vehicle Warning Indicator Light Will Not Work 287
Direction Indicator Light Will Not Work 288

COURTESY LIGHT

\: HAND BRAKE
SWITCH

COURTESY LIGHT
I
INSTRUMENT PANEL
SIINITCH LIGHITS SWITCH

JAM SIWITCH C19 JAM SWITCH

9 s34-EINSTRUMENT
‘i’
I

‘ C._.__ firm
PANEL
I .—..
HAZARD WARNING/

l5;
INDICATOR ,
HAND BRAKE ON
INDICATOR

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ELECTRICAL SYSTEM TROUBLESHOOTING

Page 282

INTERIOR LIGHTS

COURTESY LIGHT NOT ON WITH DOOR OPEN

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

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ELECTRICAL SYSTEM TROUBLESHOOTING

Page 283

INTERIOR LIGHTS

COURTESY LIGHT NOT ON WITH DOOR OPEN


1.3. Set courtesy light switch on. If light does not work, go to step 2.
b. if light works, check light with one door and then other.
C. if light does not work with either door, repair black wire from connector
013 to courtesy light switch.
NOTE
Connector 013 is an 8 pin connector. It is located behind
center console.
COURTESY LIGHT
SWITCH

If light works with one door, close door that works. Open other door.
“PT“PD-

Remove screw and jam switch.


Remove wire from switch. Hold wire to ground.
If light does not work, repair black wire from switch to connector C13.
NOTE
Connector C13 is an 8 pin connector. it is located behind
JAM
center console.
SWITCI-
lf light works, check screw, switch, and door pillar for dirt and corrosion.
Clean as necessary.
Install switch. If light will not work, replace switch.

Check fuse in separate holder. Replace fuse if blown.


If fuse is good, check bulb in light. Replace bulb if defective. WIRE
If bulb is good, get voltmeter. Connect red meter lead to violet/white wire
at light. Connect black lead to ground.
If meter reads voltage, go to step f.
If meter does not read voltage, repair violet/white wire from light to con-
nector 013.
NOTE
Connector C13 is an 8 pin connector. It is located behind
BLACK LEAD
center console.
TO GROUND

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 \

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E LECTRICAL SYSTEM TROUBLESHOOTING

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.

Remove 5 screws thru instrument panel. Disconnect 3 connectors and BULB


speedometer cable. Pull panel out. HOLDER
Replace bulb. Connect connectors to panel.
If indicator is not lit, go to step h. It indicator is lit, install instrument
paneL

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

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ELECTRICAL SYSTEM TROUBLESHOOTING

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

e. . . board for defects.


If washer works, check crrcurt . (\ M
Repair or replace board. CONNECTOR (:10
f. If washer does not work, operate horn. If horn does not work, go to
HORN WILL NOT BLOW troubleshooting.
g. If horn works, repair black wire from connector CB to connector C10.
NOTE INSTRUMENT PANEL
Connector C8 is a 6 pin connector for the instrument panel. \CONNECTOR ca
Connector C10 is a 6 pin connector under the steering column
COVET.

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.

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ELECTRICAL SYSTEM TROUBLESHOOTING

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

OPTICAL FIBER ILLUMINATION WILL BULB HOLDER


NOT WORK \-
1.a. If_ all switch lights and heater panel lights are out, rotate rheostat. If lights
work at any point, replace switch.
b. If only switch lights or heater panel light is out, replace bulb.
NOTE
Optical fiber bulb is located behind center console on left side
below heater. \‘L/ are:
replace optical fiber for that
c. If only one or two switch lights are out,
switch.

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

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ELECTRICAL SYSTEM TROUBLESHOOTING

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

2.a. Find warning light flasher. Get voltmeter.


NOTE YELLOW/RED FLA§HER
Warning light flasher is mounted forward of fuse box under
rug.
b. Connect red meter lead to terminal P (yellow/red wire) of flasher. Connect
black lead to ground.
c. If meter reads voltage, repair yellow/red wire from flasher to connector
C6.
d. If meter does not read voltage, replace flasher.

BL
T0 GROUND

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E LECTR ICAL SYSTEM TROUBLESHOOTING

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

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ELECTRICAL SYS'ILEM TROUBLESHOOTING
I
I I
Page 289/290

INTE IOR LIGHTS


éRAKE
FUSES m jWITCH

I
o 0 HI”
x I,
o ’
Lu :4
o O <
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g 'I
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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
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3 C18

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E$ oO o0 LA“ I? qLI AU
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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

VOLET/WHITE VIOLET/WHITE _ (2%)

WHITE/BLACK WHITE/BLACK—-—C———®-—-——)————-J CIGAR


(I? I LIGHTER

EféUSTTESY HEATER HAZZARD


PANEL WARNING
LIGHT SWITCH
0- }——BLACK LIGHT _
T— ‘ I BLACK
EOéIFIIESY 7 BLACK I J-
SWITCH I I
I ._

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ELECTRICAL SYSTEM TROUBLESHOOTING

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

BACK-UP LIGHT SWITCHI

DIRECTIONAL SWITCH

HAZARD WARNING HIGH/LOW


ISWITCH BEAM SWITCH
OUTER
I \E LIGHTING SWITCH
-
LT
i I?“ “—2-!
BRAKE LIGHT_—---*[‘) 13:0
SWITICH I WARNING HAZARD
. DIRECTIONAL I , FLASHER
' FLASHER ' SIDE MARKER
U HEADLIGHT IJ L'GHT
MOTOR RELQI
1— LJ
HEADLIGHTS
O\/O'
PARKING LIGHTS

DIRECTIONAL INDICATOR

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ELECTRICAL SYSTEM TROUBLESHOOTING

Page 292

EXTERIOR LIGHTS

LEFT OR RIGHT HIGH BEAM WILL NOT WORK

TURN ON LIGHTS
CHECK BOTH
HIGH BEAMS
AND INDICATOR

CHECK FUSE INDICATOR OUT CHECK LOW


BEAMS

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

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ELECTRICAL SYSTEM TROUBLESHOOTING

Page 293

EXTERIOR LIGHTS

LEFT OR RIGHT HIGH BEAM WILL NOT WORK


1.a. Turn ignition switch on. Turn on outer lighting switch. if low beams work
go to step b. If low beams do not work, troubleshoot LOW BEAMS. HIGH BEAMS ON
b. Turn on high beams. See if either high beam or indicator is lit. . / : é‘

I” §

e“
IGNITION
SWITCH

c. if both high beams and indicator are out, go to step 2.


cl. If left high beam and indicator are out, check fuse C. Replace fuse if
blown.
e. it right high beam is out, check fuse D. Replace fuse, if blown. If fuse is
good, go to step 3.
f. If indicator is lit and left high beam is out, go to step 3.
9. if left high beam is lit and indicator is out, go to step 4.
h. if front parking lights are out, troubleshoot PARKING LIGHTS.

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.

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ELECTRICAL SYSTEM TROUBLESHOOTING

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

e. If indicator is not lit, disconnect connector CB. Get voltmeter.


CONNECTOR ce
NOTE GREENIBLACK
Connector CS is an 8 pin Connector.
f. Connect red meter lead to green/black wire in connector. Connect black
lead to ground.
9. If mater does not read voltage, repair green/black wire from connector C6
to fuse box.
l1. If meter reads voltage, check Connector, circuit board, and bulb holder for
defects.

BLACK LEAD
TO GROUND

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ELECTRICAL SYSTEM TROUBLESHOOTING

Page 295

EXTERIOR LIGHTS

HEADLIGHT MOTORS WILL NOT WORK


1.a. If motors will not raise lights, check fuses B and N. lf fuses are good, go to
step c.
b. If motors will not lower lights, check fuses B and M. If fuses are good, 90
to step 3.
If motors will not raise lights, check parking lights. If lights are out, go to
PARKING LIGHTS troubleshooting.

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

If left motor will not work, go to step f. [BLACK LEAD


If right motor will not work, get voltmeter. Connect red meter lead to
terminal 87 (light blue wire) of motor relay. Connect black lead to ground. MOTOR RELAY
NOTE
Relay is mounted in compartment for right headlight motor. RM

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

LIGHT BLUE WIRE

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ELECTRICAL SYSTEM TROUBLESHOOTING

Page 296

EXTERIOR LIGHTS

Connect red meter lead to gray/yellow wire in connector C20. Connect


black lead to ground.
NOTE
Connector C20 is a 4 pin connector. It is in compartment for
right motor.
If meter reads voltage, go to step f. If meter does not read voltage, repair
grayr‘yellow wire from connector 020 to connector C19.
GRAY/YEL
WIRE TO GROUND

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 only left motor will not work, go to step e.


If right motor will not work, get voltmeter.
Connect red meter lead to green/white wire in connector C20. Connect
black lead to ground.
NOTE
Connector C20 is a 4 pin connector. It is in compartment for
right 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.

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ELECTRICAL SYSTEM TROUBLESHOOTING

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

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ELECTRICAL SYSTEM TROUBLESHOOTING

Page 298

EXTERIOR LIGHTS

LEFT on RIGHT LOW BEAM WILL NOT WORK

TURN ON LIGHTS
CHECK BOTH
LOW BEAMS

ONE BEAM BOTH BEAMS


OUT OUT

CHECK PARKING
LIGHT INDICATO'

IF NOT OK IF {I IF NOT OK IF OK

CHECK VOLTAGE TURN ON HIGH


AT IGNITION BEAMS
SWITCH

IF NOT OK IF 0K IF OK IF NOT OK

REPLACE LAMP REPAIR WIRING REPLACE IGN'T'ON


SWITCH

CHECK HIGH/ CHECK OUTER


LOW BEAM LIGHTING SWITCH
SWITCH

IF OK

REPLACE SWITCH REPAIR WIRING REPLACE SWITCH

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ELECTRICAL SYSTEM TROUBLESHOOTING

Page 299

EXTERIOR LIGHTS

LEFT OR RIGHT LOW BEAM WILL NOT WORK


I.a. Turn on ignition switch. Turn on outer lighting switch. Check both low

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

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ELECTRICAL SYSTEM TROUBLESHOOTING

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

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ELECTRICAL SYS TEM TROUBLESHOOTING

Page 301/302

EXTERIOR LIGHTS

HIGH/LOW CONCEALED HIGH/LOW


BEAM _ CONCEALED HEADLIGHT BEAM
CONCEALED —— HEADLIGHT MOTORS CONCEALED
HEADLIGHTS‘ MOTORS
[_ HEADLIGHT MOTOR RELAYS
I HEADLIGHTS

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

’ c1lK ww] l‘ 7”" JCI9 I km: 1020 I J\JU ]c3

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

STAN/\cs C12 Ll LTV


OUTER
_| $ 6 g LIGHTING
o SWITCH
I.“

< I3 _l3 5 BLACK .


I a: i
O (9 a: tn
9 d
c INT

IGNITION
SWITCH
HIGH/LOW
BEAM SWITCH

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ELECTRICAL SYSTEM TROUBLESHOOTING

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”

If new bulb will not work, go to step m.


rh

”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.

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ELECTRICAL SYSTEM TROUBLESHOOTING
Page 304

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.

LICENSE PLATE LIGHT

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

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ELECTRICAL SYSTEM TROUBLESHOOTING

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'?‘

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ELECTRICAL SYSTEM TROUBLESHOOTING
Page 306

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

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ELECTRICAL SYSTEM TROUBLESHOOTING

Page 307

EXTERIOR LIGHTS

BRAKE LIGHTS WILL NOT WORK


1.a. If only one light is out, go to step 2. If both lights are out, check fuse A. If G5, 1:37:51: [‘37: T}: ‘\‘l
fuse is blown, replace it. o'r"“".-‘. if 54555-1 [ff-‘5 £6"- 9d
b. If fuse is good, turn on directional lights. lf lights do not work, repair —- ‘ ‘ ' A ‘ ' ‘ ‘c ‘ “ ‘
orange wire from fuse box to brake switch.

c. Go to brake light switch mounted above brake pedal. Connect jumper


between terminals on switch.
cl. Turn on ignition switch. If brake lights work, replace brake light switch.

e. Find connector C14. Get voltmeter. RED WIRE


NOTE
Connector C14 is a red 8 pin connector. It is behind center
console.
f. Connect red meter lead to red wire in connector. Connect black lead to BLACK LEAD
ground.
9. If meter reads voltage, repair red wire from connector 014 to left brake
light.
h. If meter does not read voltage, check connector C14 for defects. If con- RED LEAD
nector is good, repair red wire from connector to brake light switch. T0 GR-OIJND

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.

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ELECTRICAL SYSTEM TROUBLESHOOTING

Page 303

EXTERIOR LIGHTS

BACK-UP LIGHTS DO NOT WORK


1.3. If both lights are out, go to step 2.
b. If only one light is out, remove 2 screws and lens. Turn bulb to left and
remove it.
C. Install new bulb. If bulb lights, install lens. If light does not work, check
bulb holder for defects.

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

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ELECTRICAL SYSTEM
TROUBLESHOOTING

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

2.a. Check fuse l. Replace


fuse if blown.
b. Get voltmeter. Conne
ct red meter lead to term
switch. Connect black lead inal H (red wire) of haz
c.
to ground. ard
If meter reads voltage,
go to step e. BLACK LEAD
d. If meter does not rea
d voltage, check cigar
lighter for operation.
If lighter

e. Connect red meter lea


d to terminal V (red
lead to ground. wire) of switch. Conne
ct black
f. If meter does not read
voltage, replace hazard
switch.

g. If meter reads voltage,


go to hazard warning ligh
t flasher.
NOTE
Flasher is located forwa
rd of fuse box under FLA_SHE R
h. Connect red meter lead rug.
to terminal P (red wire) -
lead to ground. of flasher. Connect black
i. If meter reads voltage,
replace flasher. If me
repair red wire from flas ter does not read volt
her to switch. age,

éLACK LEAD
TO onqgivp ;.

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E LECTRICAL SYSTEM TROUBLESHOOTING
Page 310

EXTERIOR LIGHTS

3.a. Get voltmeter. Go to hazard flasher. LT. BLUE/BLACK WIRE


NOTE . (LEFT SIDE}
Flasher is located forward of fuse box under rug.
1'). Connect red meter lead to terminal 2 (light blue/black) for left side or
terminal 5 {light blue) for right side. Connect black lead to ground.
c. if meter reads voltage, repair light blue/black wire (left side) or light blue
wire {right side) from flasher to connector C5.
cl. If meter does not read voltage, replace flasher.

DIRECTIONAL LIGHTS WILL NOT WORK


‘l.a. Turn ignition switch on. Set directional switch for one side and then the /
other.
b. If none of the directional lights are working, 90 to step 2.
c. If only one side is not working, 90 to step 4.
d. If only one light is not working, go to step 5.

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

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ELECTRICAL SYSTEM TROUBLESHOOTING

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 one side is not working, turn hazard switch on.


If lights are working, check connector 05 and wires from directional
switch. If connector and wires are good, replace switch.
—__

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

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ELECTRICAL SYSTEM TROUBLESHOOTING

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.

' RED LEAD


BLACK LEAD

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-A A w,_._LU__,_
ELECTRICAL SYS EM TROUBLESHOOTING
Page 313/314

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

D m ORANGE —] I RED m_I o5


g ‘2’ o :2 LI! I— Lu '5: m
Lu 0 D “J (5 IE (3
< m < 4 A z _ _
m
O \ J a: g < I —'

E$ '5 > 5 g 03
I j 3 <2
as2 5
E gR ‘
'—

5
<

I 5'
\ j

5‘
\

EnI 3 WHITE
’i
(D D

3 'LIGHT BLUE/WHITE— E :L‘ifiEAMS


LIGHTBLUE ‘ , __
LIGHT BLUE/B LACK ‘
LIGHTB LUE z z”OJ
3 8 LIGHTER
CIGAR
C9 \
|f f
ICI4 R 5
j S
E g
O i
m
x °° E
3o E
_, I:B E
E um I“
33 33 I| I ”U
.1 __I .I 3
.1 HV HAZ A R D
e
co
._ S m comm .— 6 WARNING
‘5‘ DIRECTION '5: I; E '5 3 SWITCH
g I
El 3 _l INDICATOR <2 <9 (2 ‘2 9
+- E SWITCH “G T c5; 3 -J 4 >
I I H BLUE | INSTRUMENT PANEL
9 g 0 /BLACK ;
- —' o VIOLET )
o LIGHT BLUE ‘

—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

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ELECTRICAL SYS‘ EM TROUBLESHOOTING
I
Page 315/316

EXTERIOR LIGHTS

PARKING I ' PARKING


LIGHT I LIGHT
BLACK 3 YELLOW/RED
BLACK BLACK

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 \

/ BLACK BLACK—J \—BLAICK——l BLACK BLACK YELLOW/RED


YELLOW/BLACK ! _ _

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

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ELECTRICAL SYSTEM TROUBLESHOOTING

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

OIL PRESSURE_WATER TEMPERATURE


SENDING UNIT SENDING UNIT

___ 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

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ELECTRICAL SYSTEM TROUBLESHOOTING

Page 318

INSTRUMENTS

INSTRUMENTS

IF NOT OK IF OK

CHECK POWER
TO INSTRUMENT

IF NOT OK IF OK

REPAIR WIRE CHECK CIRCUIT


TO FUSEBOX TO SENDING UNIT

IF NOT OK u: 0K

REPAIR WIRE REPLACE


TO SENDING UNIT INSTRUMENT

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ELECTRICAL SYSTEM TROUBLESHOOTING

Page 319

INSTRUMENTS

TEMPERATURE GAGE INOPERATIVE


1.a. Check indicators in instrument panel. If indicators are not working, replace
fuse A.
b. Disconnect green wire from sending unit. Touch wire to ground. Check
gage.
(2. Gage should read cold with wire disconnected and hot with wire touched GREEN
WIRE
to ground.
if gage works properly, replace sending unit. TO GROUND
SENDING
UNIT

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

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ELECTRICAL SYSTEM TROUBLESHOOTING
Page 320

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.

FUEL GAGE INOPERATIVE


1.a. Check indicators in instrument panel. If indicators are not working, replace
fuse A.
b. If gage reads empty, make sure tank is full.
c. Disconnect 4 hoses from top of fuel tank on forward left side of engine
compartment. Remove 4 screws thru cover. Remove cover.
d. Disconnect light blue/yellow wire from terminal T of sending unit. Touch
wire to ground. Check gage.
Gage should read empty with wire disconnected and full with wire touched
to ground. if gage reads properly, replace sending unit.

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.

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ELECTRICAL SYSTEM TROUBLESHOOTING

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.

LOW FUEL WARNING INOPERATIVE


1.a. Disconnect 4 hoses from top of fuel tank. Remove 4 screws thru cover.
Remove cover.
b. Disconnect red/black wire from terminal W of sending unit. Touch wire
to ground. Check indicator.
C. Warning light should go out with wire disconnected and come on with wire
touched to ground.
If light works properly, replace sending unit.

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

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ELECTRICAL SYSTEM TROUBLESHOOTING

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.

2.a. Disconnect connector C14. Check light.


I). 11‘ light goes out, repair red/black wire from connector C14 to sending unit.

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

OIL PRESSURE GAGE INOPERATIVE lGRAYlB ACK WIRE


1.a. Check indicators in instrument panel. If indicators are not working, replace
fuse A.
b. Locate connector for sending unit. Get jumper.
NOTE
Connector is located on forward side of engine below distrib-
utor. JUMPER
c. Disconnect connector. Connect jumper to gray/black wire in connector
and to ground.
cl. Check gage. Gage should move towards high pressure with wire jumped to
ground and to low pressure with connector disconnected.
e. If gage reads properly, replace sending unit. T0 GROUND

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ELECTRICAL SYSTEM TROUBLESHOOTING

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 /

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ELECTRICAL SYSTEM TROUBLESHOOTING

Page 324

INSTRUMENTS

LOW OIL PRESSURE WARNING INOPERATIVE


1.a. Check indicators in instrument panel. lf indicators are not working, replace
fuse A.
b. Disconnect gray/yellow wire from sending unit. Touch wire to ground.
c. Check indicator light. Light should be out with wire disconnected and on GRAY/YELLOW
with wire touched to ground. If light works properly, replace sending unit. WIRE
TO GROUND
SENDING
UNIT

d. If light does not work, locate connector C13. Get jumper.


NOTE
Connector C13 is a white 8 pin connector. It is behind center
console.
e. If light is out all the time, go to step 2. If light is on all the time. discon-
nect connector.

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

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ELECTRICAL SYSTEM TROUBLESHOOTING

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.

TACHOMETER INOPERATIVE BLACK LEAD


D'ST- T0 GROUND
1.a. Check other instruments. If not working, replace fuse A. TERMINAL ‘
b. If working, get voltmeter. Connect red meter lead to terminal D (brown/
white wire) of coil. Connect black lead to ground.
Start engine. Increase and decrease engine speed. Check that meter reading
increases and decreases.
If meter readings are good. go to step e. If readings are not good, check
green/black wire to distributor.

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

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ELECTRICAL SYSTEM TROUBLESHOOTING

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

L W OIL PRESSURE LOW FUEL


IN ICATOR INDICATOR

INSTRUMENT
PANEL

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ELECTRICAL SYSTEM TROUBLESHOOTING

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

WINDSHIELD WIPER AND


WASHER SWITCH

HORN BUTTON SWITCH

FAN SWITCH
C 5.2) WASHER
~13
'' PUMP
L——_ __ _ _ :33:
q \
© '

m MOTOR WINDSHIELD WIPER


' l MOTOR
I I | l

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E LECTRICAL SYSTEM TROUBLESHOOTING

Page 330

ACCESSORIES

ACCESSORIES

IF NOT
OK

IF 0K

CHECK VOLTAGE REPAIR WIRE


AT ACCESSORY

IF NOT OK IF NOT OK

CHECK GROUND REPLACE SWITCH


AT ACCESSORY

IF OK IF NOT OK

REPLACE REPAIR WIRE


ACCESSORY

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ELECTRICAL SYSTEM TROUBLESHOOTING

Page 331

ACCESSORIES

HORN WILL NOT STOP BLOWING A


HORN RELAY
/
1.3. Disassemble horn button and reassemble. Use new parts if necessary.
b. If horns do not stop blowing, disconnect gray/black wire from terminal 3
of horn relay.
C. lf horns do not stop blowing, replace relay.
NOTE
Relay is located in right headlight motor compartment.

\\ is
GRAYIBLACK\WIRE

If horns stop blowing, connect wire to relay. CONNECTOR CS


gun.

Remove 5 screws thru steering column cover. Remove cover.


Disconnect connector C5. If horns do not stop blowing, repair gray/black
wire from connector C5 to relay.
NOTE
Connector C5 is an 8 pin connector.
lf horns stop blowing, replace horn switch.

5/ GRAWBLACK
WIRE

HORNS WILL NOT BLOW


1.3. If only one horn will not blow, go to step 2.

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

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ELECTRICAL SYSTEM TROUBLESHOOTING

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

' CONNECTOR C10


i. If meter reads more than 5 ohms, remove 5 screws thru steering column
COVBI'. Remove cover. JUMPER

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

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ELECTRICAL SYSTEM TROUBLESHOOTING

Page 333

ACCESSORIES

WINDSHIELD WASHER PUMP WILL NOT WORK GREENIBLACK WIRE


1.a. Turn on windshield wipers. lf wipers do not work go to WINDSHIELD
WIPER.
b. If wipers work, get voltmeter. Go to washer pump.
NOTE
Pump is located in front of windshield on left side.
c. Connect red meter lead to green/black wire at pump. Connect black lead
to ground. Operate washer switch. \ \4 n ._
d. If meter reads voltage, 90 to step e. If meter does not read voltage, go to WASHER PUMP
step 2. T06)
cnouwo/

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

WINDSHIELD WIPERS WILL NOT WORK


1.a. Set wiper switch to low speed. Set wiper switch to high speed.
b. If wipers work in one speed but not the other, go to step 2.
c. lf wipers do not work at all, go to step 3.

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ELECTRICAL SYSTEM TROUBLESHOOTING
Page 334

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‘

952.921? LAC K<D

4.)
TO GROUND

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ELECTRICAL SYSTEM TROUBLESHOOTING

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.

HEATER FAN WILL NOT WORK


1.a. If fan works in one speed but not the other, go to step 2.
b. If fan will not work, turn on hazard warning lights. If lights will not work,
go to HAZARD WARNING LIGHTS troubleshooting.

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

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ELECTRICAL SYSTEM TROUBLESHOOTING

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

RED / LIGHT BLUE/


LEAD BLACK WlRE
ILOW SPEED)

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

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I

ELECTRICAL SYSil'EM TROUBLESHOOTING


I
I
Page 337/338

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

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ELECTRICAL SYSTEM TROUBLESHOOTING

Page 339

FUSES
TABLE OF CONTENTS
SECTION PAGE

Fuse A Blows Repeatedly 341


Fuse B Blows Repeatedly 348
Fuse C Blows When High Beams Are Turned On 349
Fuse D Blows When High Beams Are Turned On 350
Fuse E Blows When Headlights Are Turned On 350
Fuse F Blows When Headlights Are Turned On 350
Fuse G Blows Repeatedly 351
Fuse H Blows Repeatedly 353
Fuse l Blows Repeatedly 354
Fuse L Blows Repeatedly 355
Fuse M Blows Repeatedly 356
Fuse N Blows Repeatedly 356

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ELECTRICAL SYSTEM TROUBLESHOOTING

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

Retractable headlights motor


Interlock control box
Fasten belts and remove key buzzer

Left high beam and indicator

Right high beam

Left low beam

Right low beams

Left front parking light Light source, ideograms optical fiber


Parking light indicator illumination
Rear right side marker light Cigar lighter spot light
Rear right tail light Light source, heater fan ideogram illumination
Front left side marker light
License plate light (one bulb only)

Front right parking light Rear left side marker light


Front right side marker light License plate light (one bulb only)
Rear left tail light

16 Cigar lighter
Vehicular hazard warning signal and indicator

16 Engine fan motor


Horn and relay

Retractable headlights control relay (on closing)

Retractable headlights control relay (on opening)

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ELECTRICAL SYSTEM TROUBLESHOOTING

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

If fuse blows when gearshift is placed in reverse, go to step 8.


If fuse blows when fan is turned on, go to step 4.
if fuse blows when directional indicators are used, 90 to step 9.
FUSE A

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

Disconnect connector C10. CONNECTOR


NOTE
Connector 010 is a 6 pin connector.
lf meter reads less than 9 ohms, go to step f. If meter reads 9 ohms or
more, check connector C10 and 2 yellow/black wires to wiper switch. If
connector and wires are good, replace switch.

YELLOW/BLACK WIRE

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ELECTRICAL SYSTEM TROUBLESHOOTING

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.

Disconnect plug from directional indicator flasher terminal +.


an

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.

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ELECTRICAL SYSTEM TROUBLESHOOTING

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

r. Remove 5 screws thru instrument panel. Remove instrument panel. Dis-


connect connector C7.
NOTE
Connector C7 is a 6 pin connector.
5. If meter does not read indininity go to step t. If meter reads infinity, check
circuit board and connector for defects. Repair or replace defective parts.

INSTRUMENT PANEL

t. Disconnect orange wires from terminal 86 of buzzer relay. If meter reads


infinity (0°) replace relay. ORANGE WIRE
u. If meter does not read infinity, wiring is defective.
NOTE
One orange wire goes to brake light switch, hazard switch, and
fan switch. The other wire goes to buzzer relay, connector
C10, C18, C7, and 016.

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

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ELECTRICAL SYSTEM TROUBLESHOOTING

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.

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ELECTRICAL SYSTEM TROUBLESHOOTING

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

Remove 5 screws thru steering column cover. Remove cover.


Disconnect greenlblack wire in single connector.
Eb

If meter reads infinity, check wire to switch. If wire is good replace


switch.
If meter does not read infinity, repair green/black wire to 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

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E LECTRICAL SYSTEM TROUBLESHOOTING

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.

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ELECTRICAL SYSTEM TROUBLESHOOTING

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

. if meter reads 2 ohms or less, disconnect connector C4. If meter reads


CONNECTOR C4
infinity, check light blue wire from connector C4 to light.
NOTE
Connector C4 is a 3 pin connector. It is in compartment for
right headlight motor.
. lf meter does not read infinity, disconnect light blue wire from hazard
flasher.
. lf meter reads infinity, replace flasher. If meter does not read infinity,
wiring is defective.
NOTE
One light blue wire goes to hazard flasher. The other wire goes
to connector Cl 5 and to connector C4.

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ELECTRICAL SYSTEM TROUBLESHOOTING

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

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ELECTRICAL SYSTEM TROUBLESHOOTING

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.

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ELECTRICAL SYSTEM TROUBLESHOOTING

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

FUSE E BLOWS WHEN HEADLIGHTS ARE HEADLIGHT


TURNED ON PLUG \
1.3. Disconnect plug from left headlight. Check plug for short.
b. If plug is good, check fuse box for short at gray/black wire.
c. If fuse box is good, repair gray/black wire from fuse box to plug.

FUSE F BLOWS WHEN HEADLIGHTS ARE HEADLIGHT


TURNED ON PLU G

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

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ELECTRICAL SYSTEM TROUBLESHOOTING

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

If meter reads less than 4 ohms, go to step e. If meter reads 4 ohms or


more, replace license plate light.

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.

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ELECTRICAL SYSTEM TROUBLESHOOTING

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.

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ELECTRICAL SYSTEM TROUBLESHOOTING

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 \”

Connector C14 is a red 8 pin connector. It is behind center


TO
Console.
EEEEIEIE E—GRQUND

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.

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l
ELECTRICAL SYSTEM TROUBLESHOOTING

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.

h. Connect red/yellow wire to flasher. Remove 5 screws thru instrument


panel. Pull panel out.
i. Disconnect connector CB. If meter does not read infinity, repair red/
yellow wire from flasher to connector CB.
1. lf meter reads infinity, check connector and circuit board for short to
ground.

CONNECTOR C 6

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ELECTRICAL SYSTEM TROUBLESHOOTING

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; \\

meter lead to wires. Connect black lead to ground. l


l‘ .
\_
b. II meter reads 3 ohms or more, replace relay. If meter reads less than 3
ohms, disconnect wire from right horn.
wine

§
\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

BLACK LEAD \I\\ “


TO GROUND \ .

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ELECTRICAL SYSTEM TROUBLESHOOTING

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

FUSE N BLOWS REPEATEDLY


BLACK GRAY/YELLOW
1.a. Discmnect gray/yellow wire from fuse N. Connect red meter lead to wire. LEAD WIRE
Connect black lead to ground.
b. Disconnect connector C19. If meter reads infinity, go to step 2. RED LEAD
NOTE
Connector C19 is a 4 pin connector. It is in compartment for
left headlight motor. TO GROUND
c. If meter does not read infinity, disconnect connector C20. lf meter reads
"MEJEEMDJIIII
infinity, go to step 2. If meter does not read infinity, repair gray/Yellow
I

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

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