INSTRUCTION AND MAINTENANCE MANUAL

FOR ALFA ROMEO 2000

FUEL INJECTION MODELS
U.S.A. VERSION
 IMPORTANT NOTE

The fuel injection system for the 2000 model has been designed not only to
attain high performance and low fuel consumption but also to keep the
exhaust emissions below the levels allowed by U.S.A. regulations.

The low exhaust emission levels have been obtained by improving the distri-
bution and combustion. No devices to burn the unburned gases downstream of
the exhaust valves are required.

Simple and efficient systems for controlling crankcase and evaporative emis-
sions are fitted.

Of course, even with the mentioned systems fitted to the Alfa 2000 the emis-
sions will not continue to meet Federal and State regulations unless the
owner himself provides to have the prescribed servicing, carried out by
authorized Alfa Romeo Dealers and provided that, when remedying troubles or
performing any maintenance works on the engine or fuel feed system, the fac-
tory prescribed procedures are strictly followed.

Alfa Romeo warrants to the ultimate purchaser and each subsequent purchaser
that the vehicle is designed, built, and equipped so as to conform at the
time of sale with all U.S. emission standards applicable at the time of man-
ufacture and that is free from defects in materials and workmanship which
would cause it not to meet these standards within the period of 5 years of
50,000 miles, whichever occurs first. Failures, other than those resulting
from defects in material or workmanship, which arise solely as a result of
owner abuse and/or lack of proper maintenance are not covered by the warran-
ty.

Federal Law prohibits manufactures and dealers from knowingly removing or

rendering an emission control system inoperative or ineffective after sale
and delivery to an ultimate purchaser.
/ Fig. 1 - GENERAL ARRANGEMENT OF FUEL INJECTION SYSTEM

1 Fuel tank 22 Injector

2 Tank filter 23 Throttle lever
3 Electric pump 24 Relay crank – to – throttle rod
4 Pressure relief valve 25 Relay crank – to – control unit rod
5 Main filter 26 Battery
6 Pressure switch 27 Idle air adjuster and equalizer
7 Filter housing 28 Idle air hoses
8 Filter element 29 Idle air supply pipe
9 Manifold gallery 30 Relay crank
10 Intake duct 31a Fuel tank vent pipe
11 Control unit lever 31b Fuel tank vent pipe
12 Average seasonal temperature compensator, hand operated 31c Fuel tank vent pipe
13 Injection pump 32 Throttles
14 Injection pump oil filter 33 Accelerator pedal
15 Calibrated orifice 34 Low fuel pressure warning light
16 Air hose 35 Ignition switch
17 Main crankcase ventilating system hose 36 Sealed filler cap
18 Secondary crankcase ventilating system hose 37 Air inlet valve
19 Oil separator 38 Fuel tank – expansion connection
20 Oil separator draining hose 39 Liquid return hose
21 Suction hose for crankcase ventilating systems 40 Expansion tank (vapor – liquid separator)
 A - FUEL INJECTION SYSTEM

A1 GENERAL

Fuel is supplied to the engine by injection into the intake port of each
cylinder by means of four pumping elements (one per cylinder) whose delivery
is controlled by a control unit. A cam in the control unit provides a
“base” delivery according to the opening of throttles and to rpm range; the
“base” delivery is varied by compensating devices giving proper corrections
for atmospheric pressure, engine temperature, cold starting, initial running
and fuel cut off on deceleration.

A2 FUEL FEED SYSTEM (see fig. 1)

Inserting the key in the ignition switch (35) and rotating clockwise to the
first click will operate the electric pump (3). The gasoline flows from the
fuel tank (1) thru tank filter (2) and main filter (5) and feeds the injec-
tion pump (13).

The excess fuel, acting also as a coolant for the injection pump (13),
before returning to the tank, passes thru a calibrated orifice (15) which
regulates the fuel pressure within the injection pump. A pressure switch
(6) inserted in the delivery pipe will switch on the warning light (34) on
instrument panel if a pressure drop occurs in fuel lines; the pressure
should never by lower than 7.1 psi –(0.5kg/cm²)

A3 AIR INDUCTION SYSTEM (see fig. 1)

The air induction system consists of the housing (7) incorporating two fil-
tering elements (8), directly connected to the intake ducts (10) which
deliver air to the throttles (32); an air hose (16) connects the housing (7)
to a ram intake port at the front of the car (an automatic device provides
for the draining of water possibly entered thru the air intake port).

The accelerator pedal (33) is mechanically linked thru a relay crank (30) to
both the throttle lever (23) and the control unit lever (11). Therefore,
any position of accelerator pedal corresponds to an exact position of throt-
tle and control unit levers.

A4 INJECTION PUMP (see fig. 1)

The injection pump (13), (SPICA AIBB. 4C.S.75), has four variable displace-
ment plungers controlled by the control unit thru a rack. The plungers are
actuated by conn.rods driven by a crankshaft revolving at half engine speed.
The pump is lubricated with the engine oil drawn from the main gallery just
after the main filter.

The lubricating oil, filtered further by a filter (14) in the injection pump
mount, seeps past the plungers, lubricates the various moving parts then
returns to the pan thru a suitable port in the pump mount itself.
A5 COLD START DEVICE

The cold start device incorporates a solenoid which, energized when the
engine is started, enriches the mixture by increasing the injection pump
delivery thru an additional movement of control unit rack

The cold start device cuts off gradually, according to engine temperature,
when the ignition key is released from cranking position.

A6 INITIAL RUNNING DEVICE (see fig. 1)

This device provides for a smooth operation of the engine soon after a cold
start; it consists of a thermostat which, sensing engine coolant tempera-
tures, acts thru a linkage on the control unit rack so as to increase the
injection pump delivery in accord with the decrease in temperature and at
the same time, thru rods (24) and (25) outside the control unit, opens the
throttles so that the engine can be properly fed.

This device cuts off automatically and progressively as the engine warms up
to operating temperature thus restoring the standard idling conditions.

A7 CRANKCASE VENTILATING SYSTEM (see fig. 1)

The exhaust gases and the oil vapors developed during engine operation and
gas vapors from the fuel tank are sucked thru the camshaft cover in the com-
bustion chambers and burned.

The crankcase ventilating system controls gases both at high engine rpms and
at idling speed when the throttles are closed.

The gases and vapors flow from camshaft cover to the oil separator (19) thru
the hose (21), then enter either the main or secondary crankcase ventilating
system according to the opening of throttles (32):

When throttles are fully opened, the vapors are delivered from the oil sepa-
rator (19), thru the main system hose (17), to the manifold gallery (9),
communicating directly with the four intake ducts (10) and, from here, to
the throttle throats; when the throttles are instead closed or partially
opened, the oil vapors are delivered from the oil separator (19) via the
secondary system hose (18), to the equalizer (27), where they are suitably
mixed with fresh air and thence, thru four hoses (28) they are delivered to
the intake ducts downstream of the throttles.

The oil collected in the oil separator (19) returns to the pan via the hose
(20).

A8 FUEL VAPOR RECOVERY SYSTEM AND TANK VENTILATION (see fig. 1)

Gas vapors, emanating from fuel tank (1) both during engine operation and
hot soak period after engine shutdown, are collected in the expansion tank
(40) which acts also as a vapor liquid separator returning the condensate to
the fuel tank via the pipe (39) located at the bottom of the expansion tank.

The pipe (38) serves to make a proper connection between the fuel tank (1),
when fully replenished, and the expansion tank (40).
To prevent gas vapors from escaping in the open air, a sealed filler cap
(36) is provided.

Gas vapors coming to the expansion tank (40) flow out of the separator from
the top and, passing thru the pipes (31a) and (31b), enter the cylinder
head, then, via the pipe (31c) which extends into the cylinder head, get
into the crankcase: during the hot soak period, the crankcase is used as a
storage volume while during engine operation the crankcase is purged of
vapors by the action of the ventilation system as outlined on page 4 at the
beginning of paragraph.

In the event that, after engine shut down, the pressure in the vapor separa-
tor tends to diminish as a consequence of drop in temperature, gas vapors
will flow back thru pipes (31a – b – c) thus keeping the fuel tank (1) and
expansion tank (40) at atmospheric pressure.

A valve (37) on the pipe (31a) allows to keep a constant supply of fuel to
the engine even if an obstruction should occur in the pipe (31a – b – c)
itself.
 B - RECOMMENDATIONS ON THE USE

B1 STARTING THE ENGINE

Under normal conditions:

Insert the key in the ignition switch and turn it clockwise to the first
click; wait a few seconds to make sure the low fuel pressure warning light
goes off.

WARNING: if the warning light does not flash on or stays on, this is an
indication of failure of the indicating device or fuel feed sys-
tem; therefore have them checked as soon as possible.

Turn the ignition key further clockwise to operate the starter.

As soon as the engine fires release the key.

NOTE: automatic devices act as a standard chock usually does, namely,

facilitate the initial running of engine after a cold start
until the proper operating temperature is reached.

As an aid in starting from cold, proceed as per 1) above taking care to

depress slightly the accelerator pedal as soon as cranking motor starts
operating (at the second “click”). After a cold start and particularly when
the ambient temperature is below freezing point, wait a fairly long time
before getting away so as to warm up properly all engine parts and allow the
oil to reach all points requiring lubrication.

Top performance must never be demanded of the car until coolant temperature
is about 158°F (70°C).

When the engine is already hot or with very high ambient temperatures (above
77°F - 25°C) proceed as per 1) above taking care to depress slightly the
accelerator pedal as soon as cranking motor starts operating (at the second
“click”).

CAUTION: owing to the special construction of the injection pump the pump
plungers must on no account be operated directly with a lever or
any other tool.

B2 TEMPERATURE SETTING

To keep a constant fuel/air ratio even when the ambient temperature varies
as the seasons change, the temperature compensator lever on the control unit
shall be shifted to:

“N” (normal) for ambient temperatures exceeding 59°F (15°C).

“C” (cold) for temperatures between 59°F (15°C) and 32°F (0°C).

“F” (freezing) for temperatures below 32°F (0°C).

 Fig. 2 - TEMPERATURE SETTING LEVER

B3 DECELERATION

On deceleration, the injection pump delivery is automatically cut off by

means of an electromagnetic device fed thru a microswitch which, being actu-
ated by a particular profile suitably shaped in the control unit cam, closes
when the accelerator pedal is released; this not only eliminates the
unburned gases in a condition which is critical for the emission levels, but
also favorably affects the fuel consumption.

As the engine speed reaches about 1,300 rpm, the fuel delivery restores to
prevent stopping the engine. Of course, the fuel delivery restores even if
the engine is re-accelerated before it slows down to 1,300 rpm.
 C - REGULAR SERVICING

C1 SCHEDULE OF REGULAR SERVICING REQUIRED TO KEEP THE EXHAUST EMISSION LEVEL

WITHIN LIMITS PRESCRIBED BY U.S. REGULATIONS

In order to maintain the fuel injection system in good operating conditions

and the exhaust emissions below the limits specified by Federal regulations,
the servicing operations listed in the Owner’s Manual and in the Service
Coupon Book must be performed at the prescribed period.

On the following pages, each operation specifically related to the injection

system will be set out in details particularly those requiring the special
tools and facilities the authorized workshops are equipped with.

Index of Servicing Operations

C2 REPLACING THE AIR FILTER ELEMENTS ...............................6

C3 REPLACING THE MAIN FUEL FILTER ELEMENT ..........................6
C4 CHECKING THE SPARK PLUGS (Lodge HL) AND REPLACING ...............7
C5 CHECKING THE ALTERNATOR AND FAN DRIVING BELT ....................7
C6 CHECKING THE VALVE TIMING CHAIN TENSION .........................7
C7a CHECKING THE DISTRIBUTOR AND THE IGNITION TIMING ................8
C7b REPLACING THE DISTRIBUTOR .......................................8
C8 CHECKING THE VALVE CLEARANCE – VALVE TIMING DIAGRAM .............9
C9 REPLACING THE TANK FUEL FILTER ..................................9
C10 CLEANING THE THROTTLE VALVE THROATS .............................9
C11 REPLACING THE INJECTION PUMP OIL FILTER ........................10
C12 CHECKING THE POSITIONING OF THROTTLE-CONTROL UNIT LINKAGE ......10
C13 CHECKING THE POSITIONING AND ALIGNMENT OF THROTTLES ............11
C14 IDLE ADJUSTMENT – MIXTURE AND EXHAUST EMISSIONS ADJUSTMENT .....11
C15 CHECKING THE INJECTION PUMP TIMING .............................13

C2 REPLACING THE AIR FILTER ELEMENTS (see Fig. 1)

To provide room for subsequent operations, the air filter elements shall be
removed as a whole: to do so, remove the pipe 931b); detach the two upper
anchoring straps at manifold side; loosen at the engine side the four clamps
on the intake hoses; free the crankcase ventilation hose (17) from the oil
separator; disconnect the idle hose (29) from the idling air equalizer (27);
remove the hose (16) connecting the air filter housing to the ram intake
port.

Then the cover of the filter housing can be removed and the elements
replaced after having cleaned the inside of air filter housing.

Do not reinstall the air filter on engine at this point.

C3 REPLACING THE MAIN FUEL FILTER ELEMENT (see Fig. 3)

This operation, to be performed after the previous one has already been
accomplished, should be carried out as follows:

Disconnect the battery negative terminal, disconnect the starter positive

cable if necessary.

Fig. 3 - MAIN FUEL FILTER ELEMENT

CAUTION: first of all clean carefully the outside of filter body to make
sure no foreign matter could enter the filter on reassembly.

Slacken the bolt securing the filter to its bracket and remove the filter,

Withdraw the filter element,

Get fid of foreign matter that may have collected in the housing and fit a
ne2w element; also replace the housing gasket if damaged and the sealing
ring on bolt.

WARNING: extreme cleanliness is required in the area of the main fuel

filter.

C4 CHECKING THE SPARK PLUGS (Lodge HL) AND REPLACING

The spark plugs are of the surface gap type with four points and a central
electrode. The only maintenance required is occasional cleaning with a
brush of the central electrode and points. No routine adjustment is neces-
sary of the gap between the electrode and points.

If the ceramic insulator is cracked or the electrodes are excessively worn

away, the spark plugs must be replaced.

The spark plugs should be tightened when cold to a torque of 18 – 25.3 lb-ft
 In order to comply with the Federal rule
regarding the control of air pollution
the engine is fitted with LODGE-HL spark
plugs.

These plugs are completely adequate when

the automobile is driven at speeds not
exceeding the limits specified by speed
regulations. If the automobile is driven
at sustained speeds higher than the said
speed limits, LODGE-2L spark plugs must
be used.

(2.5 – 3.5 kgm); lubricate the threads with graphite grease before fitting.

The standard plugs fitted to the engine are LODGE HL. A decal, giving the
specifications for these plugs, is attached under the hood; here below, the
text of the decal is repeated.

Under no condition can substitute spark plugs be used, unless they are
specifically advised and approved by Alfa Romeo. Use of other plugs can
promote serious engine damage, as well as alter emission levels.

C5 CHECKING THE ALTERNATOR AND FAN DRIVING BELT

The belt should be tightened enough to drive the fan and alternator pulley
without slipping and without overloading the bearings.

The tension is correct when, on pressing the belt down, the sag is about ½”
(10-15 mm).

To tighten the belt, unscrew the nut on the adjusting arm and move the
alternator outward.

C6 CHECKING THE VALVE TIMING CHAIN TENSION

Run engine at idling speed; while performing the following adjustment any
revving up of the engine must be absolutely avoided; slacken off the
setscrew securing the chain tensioner; wait a few minutes to allow the ten-
sioner to tighten the chain, then lock the chain tensioner setscrew firmly.

On refitting the camshaft cover, make sure the gasket is in sound conditions
or replace, if necessary. Moderately tighten the cover retaining nuts in
diagonal order.
 To adjust, loosen the screws (1) and (2), insert
a screwdriver in the adjustment slot (3) and pry
the stationary-point plate

S = .017 - .019 in.

Fig. 4 - DISTRIBUTOR POINTS GAP CHECK

Automatic Advance Graph and Specifications of

Marelli S 103 B or S 103 BA Distrubutor

Fig. 5 - DISTRIBUTOR CENTRIFUGAL ADVANCE CURVE

Contact gap.....................................................................................................................................017 - .019”

Contact opening angle ........................................................................................................................30° ± 3°

Dwell Angle..........................................................................................................................................60° ± 3°

Contact Pressure................................................................................................................................18-21 oz
 Condenser capacity test

Should an excessive wear of breaker points be experienced, check that the condenser capacity is not lower
than 0.20 μF i.e. ever 20% less than its rated capacity (0.25 μF) marked on the condenser body.

C7a CHECKING THE DISTRIBUTOR (Marelli S 103 B or S 103 BA) AND THE IGNITION TIM-
ING

Dwell meter should read between 57 and 63 degrees, with new points closed,
corresponding to .017 to .019’ (.43 to .48 mm) gap.

Smear the distributor cam with grease. Check the inside of distributor cap
for any sign of moisture, carbon deposits or cracks and the central power
electrode for free movement in its seat and for effective spring action.
Finally check cap terminals for good conditions.

IGNITION TIMING

The ignition timing should be checked when the engine is warmed up to oper-
ating temperature (coolant exceeding 158°F; 70°C) by using a timing light.

At idle speed the timing should be 5 to 7 degrees ATDC, that is the mark “F”
on the pulley should be in line with the pointer or .04” (1 mm) apart either
side.

With the engine running with no load at 5,000 rpm, the ignition advance
should be 27 to 33 degrees, that is the mark “M” on the pulley should be in

Fig. 6 - IGNITION TIMING

 line with the pointer or .12” (3 mm) apart either side.

Timing at idle speed must be

adjusted with special care as it
affects the emission levels great-
ly.

Timing adjustment (maximum accuracy

required)

If the timing requires adjustment,

proceed as follows:

Unscrew the distributor securing

nut (1) or the stud so as to allow
the distributor to be rotated
together with its supporting clamp,
then rotate the distributor body
counterclockwise or clockwise
accordingly to whether it is neces-
Fig. 7 - IGNITION TIMING ADJUSTMENT
sary to respectively advance “A” or
retard “R” the ignition setting;

Retighten the nut (1), taking care not to move the distributor or body;

Recheck timing.

In the event of reinstallation or renewal of the distributor, refer to the

directions given on paragraph C7b.

C7b REPLACING THE DISTRIBUTOR

When reinstalling or renewing the distributor, perform the following proce-

dure;

Rotate the crankshaft to bring no. 1 cylinder piston to the compression

stroke that is with both valves closed;

By slightly rotating the crankshaft, bring the fixed advance mark “F” on
pulley into line with the reference pointer;

Fit the supporting clamp into the distributor body and tighten the clamp
just snug;

Remove distributor cap and rotate the drive shaft by hand to bring the rotor
arm in line with the contact for no. 1 cylinder;

As a trial installation, place the distributor on engine and move the sup-
porting clamp so that the stud is centered in the clamp slot when the con-
tact-breaker points are about to open for no. 1 cylinder;

Then, remove the distributor with its supporting clamp, taking care not to
disturb the distributor body/clamp setting and lock the clamp in place;

Reinstall the distributor and adjust timing as directed on paragraph C7a.

C8 CHECKING THE VALVE CLEARANCE – VALVE TIMING DIAGRAM

The V-mounted overhead valves are directly operated by two camshafts acting
thru oil bath cups.

When the engine is cold, carefully measure the clearance “G” with a feeler

Fig. 8 - VALVE CLEARANCE AND VALVE TIMING DIAGRAM

gage. If the clearance is not as specified, remove camshafts and valve

cups; measure the thickness “S” of the adjusting pad on each valve stem and
replace it with another of proper thickness so that the clearance is the
correct one shown in the figure 8.

To facilitate this adjustment, the pad are made available in a series of

thicknesses ranging from .05 to .014’ (1.3 to 3.5 mm) in increments of .001”
(.025 mm).

C9 REPLACING THE TANK FUEL FILTER

To replace the tank fuel filter (throw-away type) see 2, fig. 1), located on
the rear underbody of car, proceed as follows:

slacken the bolt on the clamp securing the filter to the underbody;
loosen the clamps securing the hoses to the filter inlet and outlet
adapters; it is advisable to stop the pipe from fuel tank provisionally.

Remove the filter and replace it with a new one by proceeding in reverse
order of removal. Make sure the hoses are properly positioned.
C10 CLEANING THE THROTTLE VALVE THROATS

Clean the valve throats especially at the areas of contact of throttle valve
edges and throat by holding the throttles in full open position and using a
brush soaked in gasoline; the cleaning can be completed by rubbing repeated-
ly the affected areas with a lint-free cloth.

Then, clean in a similar way the throttle valve edges taking care not to
strain the spindles.

C11 REPLACING THE INJECTION PUMP OIL FILTER (see fig. 9)

Clean very carefully the filter housing cover and the surrounding areas to
prevent any foreign matter from entering the filter housing.

Remove the cover and withdraw the element; wash thoroughly the filter hous-
ing with gasoline, then insert the new element in such a way that the spring
faces the cover; renew the cover gasket, if necessary.

To facilitate the air bleed and the quick filling up of filter housing with
oil, slightly tighten the two upper cover retaining nuts, crank the engine a
few seconds (even by means of the starter) until the oil just oozes out;
then lock the nuts fully.

Fig. 9 - INJECTION PUMP OIL FILTER ARRANGEMENT

C12 CHECKING THE POSITIONING OF THROTTLE-CONTROL UNIT LINKAGE

Proceed as follows:

Disconnect the push-pull rods (5) and (6) (see fig. 10), the cable from the
relay crank sheave and the battery negative terminal.

Fit tool A.4.0121 to cable clamp studs (see fig. 11), then adjust idle stop
screw until ball joint just touches reference plane of tool and lock in
position. Also adjust the full throttle stop screw in the same manner.

Fig. 10 - THROTTLE-CONTROL UNIT LINKAGE ADJUSTMENT

1 Lockscrew 12 Main crankcase ventilating system hose

2 Idle air adjuster and equalizer 13 Accelerator arm
3 Adjuster 14 Accelerator pedal
4 Relay crank 15 Limit screw
5 Relay crank-to-throttle rod 16 Control unit lever
6 Relay crank-to-control unit rod 17 Idle air supply pipe
7 Filter element 18 Secondary crankcase ventilating system hose
8 Filter housing 19 Idle air hose
9 Intake duct 20 Throttles
10 Manifold gallery 21 Throttle lever
11 Throttle cable
Now, remove tool and refit throttle cable. Apply grease to cable and pul-
ley.

Check that clearance (see “A” fig. 10) between accelerator arm (13) and
limit screw is .040 - .060” as pressure is applied to the pedal while the
relay crank is prevented from rotating. Adjust screw if necessary.

Fig. 11 - POSITIONING OF RELAY CRANK

Depress the accelerator pedal to the floor and check that the clearance
between the relay crank lug and full throttle limit stop screw is .080”.
Adjust the pedal stop screw on floor as required.

Reconnect relay crank-to-throttle rod (5) (see fig. 10) and adjust its
length so that throttle are just closed when the relay crank is resting on
the idle limit stop screw. “Just closed” can be verified by opening and
closing the throttles by hand with the relay crank very slowly. The throt-
tle plates will be felt touching their bores as they close.

When the relay crank is opened slightly and allowed to close under its
return spring pressure there will be a click as the crank hits the limit
stop screw.
 Reconnect the relay crank-to-control unit rod (6), the battery cable start
the engine and warm it up to 170°F. (77°C).

Check that clearance (free travel, see “B” fig. 10) between control unit arm
and its reference screw is .010 - .024” (0.3 – 0.6 mm) (the closer to
.019”/0.5 mm the better).

WARNING: Never tamper with the sealed reference screw on control unit.

Adjust the length of the rod as required. Twisting the rod ends up to 30°
off a common plane is permitted to obtain desired clearance.

C13 CHECKING THE POSITIONING AND ALIGNMENT OF THROTTLES

To perform this check, the air cleaner body and hoses shall be removed from
the engine and the four adapters of tool no. C.2.0012 connected to the idle
fittings on the throttle valve throats after having removed the four idle
pipes from the fittings: the other end of these adapters shall be connected
to the four columns of mercury gage (tool no. C.2.0014) (see fig. 12).

Fig. 12 - THROTTLES ALIGNMENT CHECKING

 Start the engine and warm it up until the coolant temperature is at least
158°F (70°C); first check that the clearance between control unit lever and
its reference screw is .012 to .024” (the closer to .019” the better) with
hot engine and thermostat actuator fitted.

Now, check that readings on mercury gage columns are much the same (maximum
difference: .4” – 10 mm); if this is not the case, proceed as follows:

- If readings show that vacuum in front pair of cylinders is higher than

in the rear, unscrew the throttle coupling adjusting screw so as to
close the rear pair of throttles.

- If vacuum in front pair of cylinders is lower than that in rear pair,

disconnect the relay crank-to-throttle rod and set the throttle cou-
pling adjusting screw in such a way as to close the front pair of
throttles (screw in the adjusting screw); then, reconnect the relay
crank-to-throttle rod and adjust its length so that the throttle
valves are in the “just closed” condition as outlined in the para-
graph: “Check the positioning of throttle/control unit linkage”.

- If, before commencing the above adjustments, the engine would run
unevenly (lean mixture), make sure the throttle valves are in the
“just closed” position; if not the relay crank-to-throttle rod must be
shortened.

CAUTION: avoid sudden revving up of the engine or too great a vacuum

could take place and the mercury might be sucked out of the gage
columns.

Disconnect adapters and install air cleaner, crankcase ventilation tube,

four idle air tubes, fuel vapor tube and air cleaner-to-equalizer tube.

C14 IDLE ADJUSTMENT – MIXTURE AND EXHAUST EMISSIONS ADJUSTMENT

To insure control of exhaust emissions and proper driveability it is neces-

sary to adjust the idle and operating mixture correctly.

To obtain proper Carbon Monoxide (CO) percentage and HC emissions at idle,

the operating mixture must be properly set.

Operating mixture can only be set with a road test or on a chassis dyno.

For this reason the steps to follow in adjusting idle and mixture are three.

First – the idle speed is roughly set.

Second – the operating mixture is adjusted.

Third – the idle speed and CO are set accurately, HC emissions are
checked.

NOTE: On cars where it is known that the operating mixture is correct,

the second step can be eliminated.
 Fig. 13 - IDLE AIR ADJUSTMENT

FIRST STEP (see fig. 13)

Preliminary Idle Adjustment

The adjustment procedure is as follows:

Warm the engine up to 170°F (77°C).

Remove the air cleaner-to-equalizer block hose and loosen adjuster lock
screw (1).

Connect accurate electronic tachometer. Act on the adjuster (2) until the
engine is idling at as fast a speed as possible, yet with no roughness or
hunting (in any case not slower than 600 rpm).

NOTE: Screw in adjuster to reduce speed; screw out adjuster to

increase speed; use tool A.2.0183.

Tighten lock screw (1) and replace hose.

SECOND STEP

Road Test and Operating Mixture Adjustment

With engine at operating temperature drive the car hard for a few miles
using high revs and low gears to burn off any deposits from the spark plugs.

Drive the car at a constant speeds of 20-25-30 MPH in third gear and accel-
erate very slowly to 40-45 MPH. If any hesitation is felt the mixture is
too lean and the fuel cut off solenoid must be unscrewed to obtain a richer
mixture.
 Fig. 14 - MIXTURE ADJUSTMENT

If, instead, during the road test the acceleration is sluggish and the car
shows other signs of an over rich mixture such as dirty spark plugs or poor
mileage, then the cutoff solenoid must be screwed in until a lean condition
is experienced. Then proceed to screw out the solenoid only until the lean
hesitation disappears.

Adjusting the Fuel Mixture (see fig. 14)

Looking down at the top of the fuel cut-off solenoid there are 8 notches
around the top edge.

Mark one of the notches with respect to a fixed point on the control unit
housing for a reference.

Disconnect the solenoid feed wire.

Loosen the rind nut at the bottom of solenoid (tool A.5.0177) taking care
not to rotate the solenoid.

Move the solenoid only one notch (1/8 of a turn), in our out, depending on
whether mixture is rich or lean.

Retighten ring nut and connect feed wire. Check reference marks to insure
that solenoid has been moved one notch.

Install air cleaner, idle air tubes, crankcase breather tubes, air inlet and
road test.
 THIRD STEP

Idle Speed and CO Adjustment, HC Emission Checking

This operation must be done with an accurate electronic tachometer with

engine at normal operating temperature immediately after the road test.

The readings of values of carbon monoxide (CO) and unburned hydrocarbons

(HC) at the exhaust must be taken exclusively with NDIR instrumentation.

Following manufacturer’s instructions install and calibrate the NDIR analyz-

er; attach the tachometer.

Idle speed must not be lower than 600 RPM (it is recommended not to exceed
700 RPM.

CO percentage must be 0.8 – 2.0% ( the closer to 1% the better)

If adjustments are necessary remove the air cleaner-to-equalizer block hose,

loosen the adjuster lock screw (1) (see fig. 13) and adjust the equalizer
adjuster accordingly:

screw in to decrease RPM and increase CO

screw out to increase RPM and decrease CO

Tighten lock screw and replace hose.

Check idle HC emissions that must not exceed 400 ppm.

N.B. Should higher level of HC emissions be experienced after having

performed the idle adjustment as above directed, the cause may
be found in an improperly operating ignition system component
(spark plugs, breaker points, condenser, terminals, etc.) or in
the formation of deposits in the combustion chambers (particu-
larly those fouling the spark plugs).

To burn off such deposits, drive the car hard for a few miles using high
revs and low gears.

C15 CHECKING THE INJECTION PUMP TIMING

To check the injection pump timing, proceed as follows:

- unscrew the attaching nuts and remove the pump drive belt cover;

- turn the crankshaft over (by shifting into a top gear and pushing the
car slowly) and inspect the belt throughout its length for sound con-
ditions;

- turn the crankshaft over again so as to bring the reference mark “I”
in line with the pointer; remove the spark plug from cylinder no. 1
and check that the exhaust valve is still open (if closed, turn the
crankshaft over by one more revolution);
- check that the reference mark on the splined pulley and the pointer on
the pump body are aligned.

NOTE: reference mark and pointer can be out of alignment within a tol-
erance of about ± 0.2” (5 mm) corresponding to half pitch of the
pulley splines.

If the pump is out of timing:

- take the drive belt off the pump pulley

- line up the reference marks of the injection pump and refit the drive
belt by rotating the pulley in either direction to engage the nearest
spline.

On completion of the timing procedure, re-install the drive belt cover.

 D - INJECTION PUMP REPAIRS

Only the following repairs are permitted. For any other work the injection
pump must be repaired by Alfa Romeo, Inc.

D1 REMOVAL OF THE INJECTION PUMP

After having removed the air cleaner (see relevant directions) perform the
following steps:

- disconnect the negative battery terminal;

- disconnect the lead from cold starting device solenoid and the loose
junction on the wire feeding the microswitch of fuel cut-off solenoid;

- remove the two screws on the thermostat actuator mounting flange and
the two screws clamping the actuator pipe anchoring grommet (do not
remove the thermostat bulb); then withdraw the actuator from the con-
trol unit, taking care not to distort excessively the pipe;

- disconnect the fuel hoses from injection pump;

- detach the push-pull rod from the control unit.

Proceed by timing the injection pump with the engine (instant in which fuel
injection starts); to do this, bring the no. 1 piston at 70°BTDC of the
induction stroke by aligning the mark “I” cut in the crankshaft pulley with
the pointer on crankcase front cover (doing so will facilitate the reinstal-
lation on the injection pump to the engine).

Finally, unscrew the three attaching nuts and remove the drive belt cover;
then take the drive belt off the injection pump pulley.

Now, perform the removal of the injection pump proper as follows:

- fully slacken the injection pipe nuts on pump outlet fittings (use the
wrench tool no. A.5.0164), without removing the pipes;

- unscrew the nuts on the two bolts attaching the pipe cluster plate and
the injection pump slanting bracket;

- loosen the two screws attaching the control unit to its bracket at the
engine mount;

- unscrew, from the underside of car, the four nuts (use tool A.5.0167
for the front ones) attaching the injection pump support to the engine
front cover.

Withdraw the injection pump and its support as a unit by tilting it suit-
ably.
D2 REINSTALLATION OF THE INJECTION PUMP

To reinstall the injection pump, reverse the removal procedure.

The tightening torque of the injection pipe fittings is about 18 lb-ft (2.5
Kgm). After re-tightening, check for leaks.

In case of injection pump renewal, the new injectors, supplied with the new
pump, must be installed on the engine in place of the old ones. The new
injectors bring a location number and must be installed accordingly.
The tightening torque of the injectors is 20.2-23.1 lb-ft (2.8-3.2 Kgm).

Make sure the pump base-to-engine block gasket and O-ring are in place.

CAUTION: Owing to the special construction of the injection pump, the

pump plungers must on no account be operated directly with a
lever or any other tool.

If for any reason, the crankshaft has been rotated or the injection pump
drive belt needs replacement, follow this procedure to time the injection
pump and reinstall the drive belt:

- Turn the crankshaft over (by shifting into fourth and pushing the car
either forward or backward), so as to bring the no.1 piston to the
T.D.C.; remove the spark plug from cylinder no. 1 to check that both
valves, intake and exhaust, are in the open position (overlap stage),
(if the valves are closed, turn the crankshaft over by one more revo-
lution).

In this condition, the mark P on the crankshaft pulley shall line up with
the pointer.
 - Push the car slowly backward so as to rotate the crankshaft counter-
clockwise by 70 degrees, i.e. in such a way that mark “I” on crank-
shaft pulley and pointer line up.

N.B.: Should the injection pump drive belt need replacement, loosen
the bolt 1 and the nuts 2, move alternator toward the crankcase
and take the alternator drive belt off. Replace the injection
pump drive belt with a new one; to install the new drive be3lt,
first mount it onto the crankshaft splined pulley.

- Then, rotate the injection pump splined pulley by hand to align the
reference mark on the pulley with the pointer on pump body and mount
the toothed belt onto the pump pulley; slightly turn the pulley in
either direction to engage the nearest spline.

N.B.: Reference mark and pointer can be out of alignment within a tol-
erance of about ±0.2” (5 mm) corresponding to half pitch of
splines.

Refit:

- The spark plug.

- The alternator drive belt, if previously removed (and adjust tension).

- The pump drive belt cover.

- After refitting, road test the car, adjust idle and test CO and HC
emissions.

D3 REPLACEMENT OF THERMOSTATIC ACTUATOR (see fig. 10)

Remove air filter elements and described in C2.

Drain one gallon of coolant from cooling system and remove thermostatic
 actuator assembly.

The actuator can be checked by measuring the protrusion of the piston. The
measurement is made from the end of the piston to the face of the mounting
flange.

With the bulb at a temperature of 20°C, the piston protrusion should be 23±
1 mm.

WARNING: Before taking the above measurement, keep the bulb at the speci-
fied temperature (20°C) for about 5 minutes.

Before installing the new actuator, the screw in the control unit upon which
the actuator acts should be checked for position.

Disconnect the long rod (6) (see fig. 10) from the control unit lever.

Install a 27 mm dummy thermostat (Tool no. A.4.0158).

With the 27 mm dummy thermostat in, place the clearance “B” between the con-
trol unit lever and reference screw2 should be .5 mm (.020”). Unscrew the
screw under the actuator to decrease the clearance or screw it in to
increase the clearance.

Install the new thermostatic actuator, connect long rod and refit cooling
system.

Start and warm up engine and adjust clearance between control unit arm and
reference screw to .012-.024” (the closer to .019” the better).

Replace air filter elements.

D4 REPLACING THE FUEL CUT OFF SOLENOID (See fig. 16)

To renew the solenoid, proceed as follows:

Remove the air cleaner.

Disconnect the terminal of solenoid feed wire.

Keep a record of the projection “A” of solenoid body from the ring nut top.

Slacken the ring nut with the special tool no. A.5.0177 taking care not to
cock the solenoid.

Unscrew the solenoid by hand and take it away.

Test the solenoid by energizing it with a 12 Volt D.C. supply.

When energized, the solenoid plunger must protrude by .193 - .205” (4.9 -
5.2 mm); when the solenoid is de-energized, the plunger must back up fully
with no sluggishness.

Repeat the test several times, each time rotating the plunger to make cer-
tain it moves freely in any position.
 Fig. 16 - FUEL CUT-OFF SOLENOID REMOVAL AND SETTING

- If the solenoid is operating properly, screw it in again to the pro-

jection previously recorded (tighten the ring nut before checking for
correct dimension “A”.

- If the solenoid is not operating properly, change it with a new one

and screw it in until projection “A” (ring nut tightened is 1 inch
(25.4 mm).

- Reconnect the feed wire

- Refit the air cleaner

Road test the car to check that drivability is satisfactory:

- If the solenoid has not been renewed and the driveability is not com-
pletely satisfactory, this may be due to a slight misalignment of the
solenoid on reinstallation; in this case, merely unscrew the solenoid
by one eighth of a turn (one reference notch as suitably provided).

- If the solenoid has been renewed and the driveability is not satisfac-
tory, unscrew the solenoid by one notch at a time until the appropri-
ate carburation is obtained.

- If the solenoid has been renewed and if the driveability is satisfac-

tory, screw in the solenoid by one notch at a time until slight hesi-
tations take place; at this point, unscrew the solenoid by one notch
so as to put it back into the next former setting giving good drive-
ability.

CAUTION: When tightening or slackening the ring nut, take care not to
rotate the solenoid or it will go out of correct setting.

Reset idle speed and CO as described in C 14/3.

D5 REPLACEMENT OF COLD START SOLENOID AND PLUNGER REMOVAL (See fig. 17)

Removal

Remove the injection pump as described in D1. Remove the side and rear
inspection plates from the control unit. Then remove the cotter key (3) and
the clevis pin (4) attaching the solenoid to the plunger shaft (5). Measure
the distance “H” from bottom of solenoid to control unit.

Fig. 17 - COLD START DEVICE AND ITS PLUNGER

Loosen the solenoid lock nut (2) and unscrew the solenoid (1). Then check
that the plunger shaft (5) moves up and down freely.

NOTE: If it is necessary to remove the plunger shaft (5), unscrew the

plug (8) from underneath and withdraw the plunger shaft.

Check that the diameter of plastic plunger is .5335” (13.55 mm).

Replace the plunger or reduce its diameter if required.

Installation

The height of the cold start solenoid above the control unit housing governs
 the operation of the cold start device. It is essential that it be careful-
ly adjusted or serious damage may occur to the control unit.

Fit the plunger shaft (5) and the plug (8) in reverse order of removal.

Install the solenoid (1) and lock the nut (2) to same solenoid height “H” as
previously measured.

Connect the plunger shaft (5) to the solenoid with the clevis pin (4). Then
install the cotter key (3).

To adjust solenoid height “B” a .7490” (19mm) dummy thermostat (tool no

A.4.0159) has to be installed.

Measure the clearance “A” between the pin (6) on the lever actuated by the
solenoid and the arm (7) which it actuates. Refer to the figures.
Clearance must be .008” - .012”. Screw the solenoid out to decrease the
clearance and screw in to increase clearance.

Tighten solenoid lock nut (2) and install inspection plates.

Assemble pump to engine as described in D1.

D6 TESTING THE INJECTORS

Since the operating conditions of the injectors are not so heavy (being
located in the air intake ports and therefore not subject to the high pres-
sures and temperatures of the combustion chamber) and since the life of the
injectors is expected to be the same as that since the life of the injectors
is expected to be the same as that of the car, they should undergo a test
only when the cause for malfunctions is unquestionably attributed to the
injectors themselves.

To test the injectors use a handpump like that for testing Diesel injectors
but supplied with gasoline and provided with a pressure gage whose top dial
reading is 700 - 1000 psi (50 - 70 kg/cm²).

The procedure for checking the spray shape, injection pressure and leaks is
as follows:

- connect the test pump pipe to the injector inlet fitting which has a
12 x 1.5 mm metric thread.

- pump quickly to prime pump and injector.

- pump slowly until injector nozzle opens. This must take place at 360
400 psi (25 - 28 kg/cm²) for new injectors and at no less than 260 psi
(18 kg/cm²) for used injectors.

- again pumping slowly, bring the pressure to 15-30 psi (1 - 2 kg/cm²)

below the rating pressure taken as directed above and make sure that
there is no drip from the nozzle within five seconds.

- pump quickly and check that the spray is narrow, deeply plunging and
has good vaporization even at minimum delivery. At a distance of 4”
(100 mm) from the nozzle orifice, the spray cone diameter should be
 about .8” (20 mm). If the injector does not meet these requirements,
replace it with a new one.

- the injectors must be tightened in place with a torque of 20.2 - 23.1

lb-ft (2.8 - 3.2 kgm).

N.B. To remove the injectors, use the wrench tool no. A.5.0165.

D7 REPLACING THE ALTITUDE COMPENSATOR (in car)

Proper adjustment of the barometric capsule is critical for proper operation

of the pump.

In order to make the adjustment you must have an accurate barometer in your
shop which has been set to compensate for your elevation above sea level.
Your barometer will have directions for doing this and it is essential that
they are followed.

Proceed as detailed below after having removed in this sequence:

- The air cleaner.

- The relay crank-control unit rod.

- The rear inspection cover from the control unit.

- The altitude compensator with its mounting flange.

CAUTION: Do not move the control unit input lever (even better tape it in
place) nor disturb the inside devices of control unit or serious
damage and out-of-adjustment may result.

Measure the dimension “A” (see

fig. 18) between the mounting
flange face on which the spring
rests and the top of bellows.
Such a dimension should fall
between .35 and .41” (9 - 10.5
mm) when the temperature set-
ting lever is in “N” position.

Loosen the locknut and unscrew

the capsule taking care not to
rotate the setting lever with
respect to the mounting flange.

Screw in the new capsule until

the dimension previously taken
is obtained. Then slightly
tighten the locknut.

Fig.18 - ALTITUDE COMPENSATOR

NOTE: If, because of any reason, the dimension “A” does not fall with-
in the specified limits, screw in the new capsule to a dimension
of .37” (9.5 vmm) irrespective of the dimension previously read.

Install capsule and mounting flange assembly on the control unit making sure
the setting lever spring is properly positioned and the setting lever itself
is in “N” position.

Refit the rear inspection cover and the rod.

Start the engine and warm it up until the coolant has reached a temperature
of no less than 158° F (70° C) then race the engine a few times up to 4,000
rpm and fully release the throttle pedal each time.

Stop the engine, again remove the rear inspection cover and (with the aid of
a suitable mirror and a lamp to light the inside of control unit) see
whether the wire at the end of link engages the notch corresponding to the
actual atmospheric pressure as listed below (notches to be counted starting
from the top of the notched lever).

- atmospheric pressure falling between 29.9 - 30.7 in Hg. The wire

should engage the 7th notch.

- pressure falling between 29.1 - 29.9 in Hg. The wire should engage
the 8th notch.

- pressure between 28.3 - 29.1 in Hg. The wire should engage the 9th
notch.

- pressure between 27.6 - 28.3 in Hg. The wire should engage the 10th
notch.If the above conditions are not fulfilled, adjust the position of the

Fig. 19 - ENGAGING WIRE AND NOTCHED LEVER

 capsule so that, when the engine is started again (before that refit the
rear inspection cover on control unit) and the warming up procedure (racing
the engine followed by a complete release of accelerator) is repeated, the
wire positions itself correctly. Screw in the capsule to cause the wire to
engage notches of higher numbers and unscrew the capsule to engage notches
of lower numbers. Keep in mind that a rotation of about 150 decrees corre-
sponds to one notch.

Tighten securely the locknut on the capsule, place the temperature setting
lever in the position corresponding to the ambient conditions and reinstall
the air cleaner.

D8 CHECK THE RELATIONSHIP BETWEEN THROTTLE ANGLES AND CONTROL UNIT LEVER ANGLES

Perform this check when the engine is cold. The air cleaner must then be
removed from engine (see under “Replace the Air Cleaner Elements”), the pro-
cedure for disconnecting the rods (5) and (6) (see fig. 10) must be repeated
as well as the removal of thermostatic actuator (taking care not to distort
excessively the small pipe).

At this point, check the positioning of linkage at idle and full throttle
setting with the special tool no A.4.0121 and fit the dummy actuator, tool
no A.4.0120. Reconnect the rod and check for a clearance “A” of .012 to
.024” (the closer to .019” the better) between the control unit lever and
its reference screw (if necessary, adjust the rod length by acting on the
threaded clevis).

WARNING

Never tamper with the seal on the reference

screw of control unit input lever as this
will result in loss of any benefit under
warranty.

Fit the fixed protractor tool no C.6.0140 onto rear end of control unit,
using the cover attaching screws, and the pointer tool no.C.6.0141 aligned
with the zero on the scale (see fig. 20), to take readings use the suitable
built-in light mirror.

Reconnect the rod (5), and check for a proper closure of throttles as
directed under “Check the Positioning of Throttle/Control Unit Linkage”.
 Fig. 20 - CHECKING THE CONTROL UNIT LEVER ANGLE

Place the movable protractor tool no. C.6.0142 on the spindle of rear throt-
tle valve pair and set to zero in correspondence of the pointer tool no
C.6.0143 (see fig. 21)

FIG. 21 - CHECKING THE THROTTLE OPENING ANGLES

Install the tool no. A.2.0181 using the cable sheath clips and gradually
rotate the relay crank by acting on the adjuster (See fig. 22).

Fig 22 - ADJUSTING THE RELAY CRANK

Open the throttle valves to predetermined angles (2,4,6 degrees - see table)
and read the corresponding rotations of control unit lever.

α ß Tolerance on ß
0° 0°
2° 8° 13’
± 20’
4° 14° 40’
6° 20° 09’
10° 29° 30’ ± 1°
15° 39° 20’
20° 47° 54’
25° 55° 33’
30° 62° 30’
35° 68° 51’ ± 2°
40° 74° 41’
50° 84° 55’
60° 93° 25’
70° 100° 12’
82° 106° 08’

α − Throttle Rotation Angle

ß - Control Unit Lever Rotation Angle
 In the event the throttle angles and control unit lever angles are out of
the specified relation, it is likely that checking procedure has not been
perfectly accomplished. Therefore, try once more. If again it will not
satisfy, inspect carefully any component of control linkage, or parts
directly affecting it, replace any defective part and repeat the procedure.

When the above checks are over, lengthen the rod (6) until there is a clear-
ance of .035 to .051” (0.9 - 1.3 mm) or 1° to 1° 30’ between the control
unit lever and reference screw.

On completion of adjustment, reinstall the standard thermostatic actuator

and check for a clearance of .012 to .024” (.3 to .6 mm) with a hot engine
(coolant temperature above 158° F - 760° C) between the control unit lever
and its reference screw. If necessary, adjust the length of rod (6) by act-
ing on the clevis thread.

D9 REPLACING THE ROTATING SEAL AND THE MOTOR OF THE ELECTRIC PUMP (See fig. 23)

Remove the electric pump unit from the car. Loosen the screws (1) securing
the motor to the pump assembly and remove the motor. Take the seal (3) out
of pump body. Lubricate the seal housing and install a new seal (3) with
the aid of the suitable tool (no. A.3.0476). To do this, position a thin
strip of foil (no more than 0.05 mm thick and about 5 mm wide) over the
drain hole so as to prevent damaging the outer edge of the seal being
installed. After the seal has been fitted, the foil strip can be slipped
off. Also replace the muting face (7) and the “O” ring (6) on motor shaft
with new ones.

Fig. 23 - REPLACING THE ROTATING SEAL OF THE ELECTRIC PUMP

Re-assemble the motor to the pump body taking care that the coupling at the
shaft end properly engages the key in the gear.

WARNING: The rotating seal must be renewed whenever the pump is over-
hauled and/or the pump motor is replaced with a new one.
Re-install the pump and check whether the seal settled properly within 20
minutes of pump operation. Fuel ceasing to drip from the drain hole indi-
cates that the seal has settled down.

Should the fuel dripping fail to stop within the above mentioned lapse of
time, the seal must again be inspected.
 E - TROUBLE SHOOTING

The following chart lists several malfunctions, possible cause for each of
them and remedies.

If deficiencies or malfunctions are experienced in the fuel system,it is

absolutely essential to make sure they are not caused nor affected by the
incorrect operation of the ignition system. In fact, it is impossible to
distinguish “a priori” whether a failure of fuel or ignition system is the
cause for the deficiencies. Therefore, first inspect the ignition system
for the following and remedy, if necessary.

- spark plugs for proper operation and type.

- contact-breaker points conditions and gap.

- ignition coil for continuity or leakage.

- ignition distributor for correct timing using a timing light. Adjust

timing or replace the ignition distributor, if necessary.

Should any of the troubles listed be experienced, it is recommended to clean

thoroughly the affected areas of both engine and engine compartment with a
suitable solvent. This to the purpose of preventing any foreign matter from
entering, on removal or reinstallation, the mechanical components and
specifically the fuel feed circuit.

Soon after cleaning, inspect the mechanical units for loose attaching or
joining parts, the pipes for loose fittings and the brackets for sound con-
ditions.

E1 ALFA ROMEO SPICA PUMP POLICY

Injection pumps are not to be opened for any reason. An exchange pump serv-
ice is available for complete pump units. Pumps that have been tampered
with will forfeit any core valve.

Always before removing a pump consult your Alfa Romeo representative or zone
office.

E2 TROUBLE CHART

TROUBLE POSSIBLE CAUSE REMEDY

Low fuel pressure warning light Fuse no. 6 blown Replace fuse
does not flash on when ignition
key is turned. Warning light bulb burnt Replace bulb

Pressure switch faulty (jammed Check switch and replace, if nec-

open) essary.
 TROUBLE POSSIBLE CAUSE REMEDY

Low fuel pressure warning light Pressure switch faulty (jammed Replace switch
stays on (fuel pump operates closed)
properly) - Inspect fuel lines
Low fuel pump outlet pressure doe - Replace filter (See C3)
to: - Clean filter and replace ele-
ment (see C2)
- Tank to pump lines clogged or - Check relief valve and
air seeping thru them replace, if necessary
- Tank fuel filter clogged
- Main fuel filter clogged Have fuel pump checked or
- Main filter pressure relief replaced (See D9)
valve defective or stuck open

Fuel pump delivery too low

Low fuel pressure warning light Fuse blown (in the additional Replace fuse
stays on (fuel pump fails to fuse box)
operate) Check and reconnect
Electric wires to pump discon-
nected Have the pump checked or replaced
(see D9)
Fuel pump faulty

Engine will not start from cold Solenoid-actuated cold start - Check electric connections
device fails to operate - have the device checked or
replaced
Smoky exhaust after starting Cold start solenoid plunger stuck Have the plunger checked (See D5)

Engine misfires: rough idle One injector defective Trace the cylinder by grounding
each spark plug and replace the
Injection pipe fittings leaking injector, if necessary.

Injection pipes cracked Tighten fittings

Check and replace, if necessary.

Idle too slow but even. Too rich a mixture Adjust idle as directed in C14

Idle CO too high (engine runs

smoothly)
Idle too slow and rough (engine One of the hoses connecting idle Reconnect or replace the hose, if
runs unevenly) equalizer to throttle throats is necessary and adjust idle as
obstructed (by buckling) cracked directed in C14
or disconnected from a fitting.

Idle too fast and rough (engine Too lean a mixture due to air Check the hoses for sound condi-
runs unevenly; hunting also takes leaking through one of the hoses tions and leaks and adjust idle
place) connecting idle equalizer to as directed in C14
throttle throats or even to an
idle equalizer improperly adjust-
ed.

Idle HC too high Too rich or too lean a mixture. Adjust idle as directed in C14.

Ignition system not in perfect Check ignition system.

working order. Heavy deposits in
combustion chambers and spark With a hot engine, drive the car
plug fouling due to particular hard for a few miles using high
driving conditions such as short revolutions and low gears to burn
rides preventing proper warming off any deposit.
up.
 TROUBLE POSSIBLE CAUSE REMEDY
Too fast an idle and smoky Faulty thermostatic actuator. Replace thermostatic actuator
exhaust. (See D3)

Engine keeps running at idle but Altitude compensator faulty Replace altitude compensator (See
stops on accelerating. D7)

Idle too fast Accelerator linkage fails to Check:

return fully
- flexible cable
- linkage joints and pivot pins
for free movement
- pedal return spring for sound
conditions
- pedal and linkage limit stop
for proper adjustment

Clean linkage joints and pack

with grease

Unsatisfactory drivability; hesi- Control linkage out of adjustment Check throttle/control unit link-
tations age (See C12)
Fuel pump outlet pressure too low
(warning light comes on while Check and replace, if necessary,
running at high speed) tank fuel filter and/or main fil-
ter element
Injector defective
Refer to remedies as under
Injection pump or control unit “Engine misfires; rough idle”
defective
Have them checked and replaced,
Temperature setting lever improp- if necessary, by an authorized
erly positioned workshop

Position the lever correctly

Unsatisfactory road performance Temperature setting lever improp- Position the lever correctly
erly positioned
Check throttle/control unit link-
Control linkage out of adjustment age (See C12)

Fuel pump outlet pressure too low Check and replace, if necessary,
(warning light comes on while tank fuel filter and/or main fil-
running at high speed) ter element

Air induction clogged Check and replace air cleaner

elements, if necessary
Injector defective
Refer to remedies as under
Injection pump or control “Engine misfires; rough idle”
unit/defective (defective carbura-
tion) Have them checked and replaced,
if necessary, by an authorized
workshop

Excessive fuel consumption Fuel feed circuit leaks Check pipes, fittings, seals and
replace defective parts
Thermostatic actuator defective;
also refer to causes as under Have the thermostatic actuator
“Too fast an idle” checked and replaced, if neces-
sary, by an authorized workshop
Defective carburation (See D3)

Have the injection pump adjusted

by an authorized workshop
 TROUBLE POSSIBLE CAUSE REMEDY
Engine stalls in positions other Defective altitude compensator or Have the altitude compensator
than idle excessive vibrations of injection checked (See D7); also check
pump and control injection pump and control unit
brackets for sound conditions and
firm attachment.
Engine stalls flat Injection pump driving belt bro- Replace belt (check for proper
ken injection pump timing). (See D2)

Engine does not slow down to idle Both throttles and control unit Check:
on deceleration (fast idle) lever fail to return fully on
deceleration - flexible cable
- linkage joints and pivot pins
for free movement
- pedal and linkage return
springs for sound conditions
- pedal and linkage limit stops
for proper adjustment
- clean linkage joints and pack
them with grease suitable for low
temperatures

Detonations in the exhaust pipe Fuse no. 6 blown Replace fuse

on deceleration
Feed wire disconnected at fuel Re-connect wire
cut off solenoid
Reconnect junction
Loose junction of fuel cut off
device feed wire disconnected Have the fuel cut off solenoid
checked and replaced, if neces-
Defective fuel cut off solenoid sary

Defective fuel cut off device Have the fuel cut off device
microswitch checked by an authorized workshop

Engine stops: Fuel cut off solenoid stuck in Have the fuel cut off solenoid
cut off position or sluggish in checked and replaced, if neces-
- wholly or occasionally on backing up sary.
deceleration in neutral
- occasionally or wholly when
re-accelerating after a decelera-
tion

Engine fires again suddenly and

with delay when re-accelerating
after a deceleration

Noisy electric fuel pump Line between pump and main filter Reset the line making certain it
distorted or forced in the rubber is centered in the rubber mount-
mounting or against the recovery ings without forcing against the
pipe recovery pipe

Tank filter and hoses improperly Check that the filter is properly
fitted fitted and that hoses have a cor-
rect run