leased,
pedal on control lever has an axial
clearance of GI = 1 f 2 mm.
b
table
adjustement clip 0 in order to give
tbe
and,reinserttheclipinthenewposition.
table
sliding
freelv
in its sheath
table
clearance
check
that the accelerator
If necessary, proceed to adjust the
clearance extracting the
prescribed clearance to the
table,
re-
May
1988
00-14
PA333500883300
Page 30
COMPLETE CAR
CHECKING OF
EMMISSIONS
CHECK
OF
A!D
IDLE,
R.P.M. AND
ADJUSTMENT
EXHAUST EMISSIONS
Effect
the following preliminary
checks:
a. Cleaning and replacement of air
filter
cartridge.
1
Ackleratortable
2
Adjustment
3 Accelerator table sheath
clip
b.lgnition
plugs,
Group 05 - transistorised ignition
/
”
without contacts).
c. Ignition timing.
d. Checking of accelerator control
adjustment (sec Group 04 - Checking
and accelerator control adjustment).
system efficiency: spark
tables,
cap, frotary rotor (see
CAUTION
3.
Cfhe,&king
throttle
a. With accelerator pedal pressed
as
fa~r
accelerator control cam cari
by
If ne’cessarv, proceed to adjustement
by acting on stop screw @ below the
accelerator pedal.
,
--
l
‘..
,_,
on maximum
valve opening
as it
Will
go, check that the
. Gp=l
i2,mm
still rotate
If during engine tune up there is no
extra cooling fan available, keep
checking the therinometer and the
water temperature warning light on
dashboard and immediately suspend
testing if temperature’ goes up,
meaning that engine is overheating.
Single
carburetor models
Check
idle-rpm
follows:
Insert
1.
the
tail
2.
Connect
ter’to the engine.
3. Start the workshop
hauster.
4.
Start
to normal
5. Now check that engine rpm is
within specified value.
and overall CO% as
CO-tester probe @ into
pipe
0.
an
electronic tachome-
the engine and warm it
running temperature.
gas
ex-
UP
1 ‘Tail
pipe
2 CO-tester probe
6.
If!
not within specified value,
adjust
idle-rpm
~
relevant idle-adjusting screw
which~
makes it possible to change
just by turning
@
rpm without changing CO percentage
(Carbcin
7. Verify
monoxide).
that CO percentage
picked up by tester corresponds to
specifi,ed
value and that engine
runs smoothly.
Allowed CO%
1.5 + 1.8
L..,
1
Accelerator pedal
2
Stop screw
PA333500883300
.‘.’:,,
1’
<.
,,’ ,
‘8
Idle-rpm
900 + 1000 r.p.m.
00-X
l
May
1988
Page 31
COMPLETE CAR
If notwithinspecifiedvalueorincaseof’
engine
overhauling or after having cleaned or
replaced the
involving mixture meteringscrew
and
requised. In this instance, proceed as
follows:
,(
1)
metering, screw a and from
tle valve
(2) Tighte~n idling screw @
,way’.
(3)
screw @
screw@ till
present: ~
throjtle
RemoJe
sctew 0.
,Now
tune
up after engine;
carburetor, an adjustment
valve screw 3 is
seals from mixture
act on
‘and
on mixture metering
following conditions are
C!il
throt-
all
throttle valve
the
Mm
750 + boa
CO%
0.5,+
1% total
Double carburetor models
Check idling-rpm, CO% on each
cylinder
1
throttle valves as follows:
Before beginning this test
accelerator
to: Group 04 - Accelerator
Adjustment)
and line-up of carburetor
check
table
adjustment ‘1 Refer
Gable
misalignment (40 mm Hg) between
cylinders of the
Will
be necessary to replace the
carburetor.
4. Make sure that
functioning correctly by grounding
spark plug at a time and checking that
theincreaseinr.p.m. isidenticalforeach
cylinder.
~
same
carburetor then
all
cylinders are
one
it
(4)
Loosen
screw OI
idling speed i$ reached.
(5) Act
screw @
engine running is obtained, while
keeping C$I% within the prescribed
values. ~
(6) Fit
metering ànd’ throttle valve screw
seals.
(7) If further optimizing of idle-rpm
is desired, jus? act on relevant idling
adjusting,screw @
1
2
Idling adjusting screw
3 Throttle
back
Idling mixture me’tering screw
valve adjusting screw
idling
ti,ll
a
900
don
mixturemetering
till
the smoothest possible
~ % CO
into place mixture
.
adjusting
+ 1000
,,
0,5 +
1
rpni
1.
Insert
the tube of the
vacuometer in the appropriate fittings.
2. Starttheengineandrunittonormal
running temperature SO that the
temperature
45oc.
3 With the gear shift in neutral,
the
check
manometers
Correctanydifferencesbetweenleftand
right carburetors by acting on the
throttle valve screws. Should there be
is equal to or greater than
mercury
vacuometer valve and
that‘ the Ap values of the
fall
within 40mm Hg.
mercury
open
1
Electronic rev counter
2
CO tester
If necessary
ing screw of the
until correct functioning is obtained.
5. Adjust the engine speed to 850
1000 r.p.m. by acting on the throttle
valve screws,
manometer readings
specified values.
6. Using the CO% tester, check that
the exhaust CO emissions are 1.5 - 2.5%.
act
on the mixture
out-of-tune cylinder
checking that the
fall
within the
meter-
-
May 1988#
00-l
WI
PA333500883300
Page 32
TO obtain better CO exhaust emission
adjustment it is necessary to operate
measuring the values cylinder by
cylinder using
C, 3.0054 connected as follows:
1
A. Raise car on lift and disconnect
exhaust manifold from cylinder
heads.
2 A. Now~fitsmall flanges
with relevant gaskets and pipes for
collection, of exhaust fumes - bet-
ween
Bach
and relevant fitting on cylinder
heads. ~
3 A. Connect exhaust manifold
back’
tb cylinder heads.
The other ends of the four collection
pipes emerge in the engine compart-
ment
andi
able
pfugs,
cylinddr CO%.
special
service tool
C.2.0054
exhaust manifold flange
being equipped with suit-
are set up to test
each
COMPLETE CAR
Check
idle r.p.m.
The
procedure
tronic
injection engines with or
out catalytic convertor.
1. Connect the engine to a rev
counter.
2. Connect an exhauster to the
exhaust tail-pipe.
3. Start the engine and run it to
normal running temperature (Engine
oil
temperature
4. With the gears in neutral and the
ancillary
the engine
specified values.
For 1.7 electronic injection engines
with catalytic convertor.
For
1.7 electranic
is valid for 1.7 elec-
75-8OoC).
devices tut out
r.p.m.
\
idle r.p.m. 950 _
check that
falls within the
f100
injection engines
with-
5.
Check
exhaust emission
Procedure
tronic
catalytic~convertor only.
After adjustment of the idle r.p.m.
following the above described
cedure, ~proceed
adjustment (if necessary) of the ex-
haust emissions by operating as fol-
lows. ~
1. Switch on the gas exhauster, start
the engine and run it to normal runn-
ing temperature.
2. With engine on idle and using a
suitable,exhaust gas tester, check that
the percentage of CO and the quantity
of
specified values.
is applicable to 1.7
injection
hydrocarbons
Admissible CO% 0.8 - 1.7
engines
to the check and
are less than the
elec-
without
pro-
c.2.oo!x
7.
Ch,eck
the idle r.p.m. and if
necessary adjust it again repeating
the operations described at step 5.
8.
@-set
the play in the idle levers
to 1 mm by tightening the stop screws
and
th’en
check that the carburetors
open
simultaneously by acting on the
:Point
where the accelerator
attached,
of acceleration (1200 - 1300
Adjust’the stop screwsfurther toobtain
Perfect synchronisation of the carbu-
retors.~
9.
remove
‘effecti’ng
Close the vacuometer valves and
the tubing from the fittings.
short
Sharp
table
spurts
r.p.m.).
is
idle
r.p.m.
800 - 900
5.
If the idle r.p.m.
within these values, adjust by operat-
ing as follows:
(a) Loosen the locknut @ and turn
the screw @ until the correct r.p.m.
is obtained.
(b)
Lock
the locknut
1
Locknut
2
Idle r.p.m. adjustins screw
does
0
not ifaIl
1 Exhaust
2 Probe of exhaust tester
3. Should the CO% be above the
admissile limit it
act on ~ the appropriate screw
itioned
depress the accelerator and
check a resistance value lower than 10
Ohm.
presence
of an infinlte
I
;ES
Check wiring continuity between:
white wire on S6 switch connection
and CU
connecter
ruption, short-circuit on Interference
with other tables.
Check setting and efflciency of
1
Check wiring cxontinuity between
low
wire
on S6 switch connection and
CU
connecter
short-circuit or
1
Gables.
pin 15 for inter-
maxi-
pin 14, for interruption,
interference
with other
yel-
NO
b Restore wiring.
:
TEST No. 5
,00=35/9
PA327900883301
Page 61
COMPLETE CAR
TEST No. 5
Set multimeter to 20
Key rerhoved!
Ciisconnect injection electronic CU
connecter.
:heck
between pin 8 of CU
ind
ground, a reststance’value depen-
ling
on engindcoolant temperature as
Ier
curve
-
CHECK OF ENGINE COOLANT TEMPERATURE SENSOR (CU PIN 8)
KOhm
FS.
-
t
connecter
:heck wiring
.electronic CU
brown wire on S7 temperature
sor; --
G60
sensor
continuity
ground and black wire on 57
connection
between:
connecter
25.
YES
pin 8 and
I
Replace S7
sensor
sen-
NO
1
i
Westore
wiring.
PA32
TEST No.
790088330 1
6
oo-35/10
October 1988
Page 62
COMPLETE CAR
r
TEST No. 6
Set multimeter to 200 Ohm F.S.
Di,sco’nnect
Check resistance between CU connec-
CHECK OF ELECTROINJECTORS CIRCUIT
-
injection CU connecter.
Disconnect electroinjectors removing
relevant connectors.
Measure resistance on terminal of
every single
between 14 and 18 Ohm.
Check on single connectors of injec.
tors WIRINGSIDE, that one of two
pins is connected to terminal
S12a
connecter.
injecter,
that
Will
result
87a
relay and the other to pin 3 of CU
of
NO
NO
1’
Replace faulty injectors.
I --
nestore wiring.
Octdber
TEST No.
1988
7
00~35111
PA327900883301
Page 63
COMPLETE CAR
TEST No.
7
‘CHECK
r
OF
,fLlfq
Disconnect infeqtron CU conpector.
With
‘igniiion
check presence of + 12 V between CU
connectdr
key on RUN position,
pin 2 and ground.
+12
V PIN 2
NO
+
Check Integrity of fuse NO. 2.
With ignition key in RUN position,
check presence of
S12b
ground.
Restore wiring between S12b relay
shoe terminal 30 and CU
pin 2.
AiUD
PIN 7 OF CU
+12
main relay shoe terminal 30 and
V between
connecter
NO
With ignition key in RUN position,
,Check presence of + 12 V between
mina1
88 and S12b relay shoe terminal
87.
,YES
ter-
‘Whith
ignitjon key-
‘check
pr’esence
conneotor pin ,7 and ground.
in RUN position
of + 12 V between CU
Restore vehicle wiring betwéen positlve battery and
nal 87.
Restore wiring between pins 2 and 7 of
S12b
relay shoe
termi-. 4
Cheik
NO,
presence of + 12 V between
S12b relay shoe terminal 87 and
ground.
I
Check wirlng continuity between
relay shoe terminal 85, and ground
GSO,
if necessary restore wiring and
,:
check ground G60 integrity.
I
Check continuity of wiring between
pin 86 relay shoe S12b and fuse box.
I
YES
.’ ,”
S12b
’
JO
I
J
l-
:
PA 32 790488330
1
oo-35/12
October 1988
Page 64
COMPLETE CAR
v
TROUBLESHOOTING
FOR
for electronic injection
NOTE:
~
THIS
TROUBLESHOOilNG
DI:AGNOSIS
~ IF AT THE END OF TESTS THE
~ CHECK MAIN MECHANICAL
NESS
OF THE SYSTEM AND
OF AIR INTAKE DUCTS, ETC.
PROCEDURE MAINLY
DEVICES
IGNITION
1.7’engines
SENSO’RS
ANOMALY
AND ACTUATORS
SHOULD REMAIN, IT WI~LL BE NECESSARY TO
SUCH AS VALVES,
-.
PROCEDURi
SYSTEM
without
DEALS’WITH
catalytic cbnverter
THE ELECTRICALIELECTRONIC
CYLINDERS,
ASSOCIATED
COUPLINGS,
TO IT.
TIGHT-
PA327900883301
October
1988
Page 65
THE
ENGhE DOES
NOT START
l
Check the presence of voltage to spark
i’plugs (by attempting ignition).
. .
/ES
NO
*
Set multimeter to 20 V
Key in
RUN
Check presence of + 12 V between igni-
tion
Check presence of + 12 V between ignition CU
position.
coi1
terminal 15 and ground.
connecter
F.S.
pin 3 and ground.
YES
.
Check presence of + 12 v between igni-
tion module (Nl)
ground.
connecter
pin 4 and
YES
Set multimeter to 200 Ohm FS.
Key removed.
Check wiring continuity between igni-
tion module
ground.
(Nl) connecter
pin 2 and
.
NO
NO
NO ,
Check vehicle, system functionaiity (eg:
continuity between ignition coil termi-
c
nal 15 and starting block; starting block
supply and functionality).
Restore wiring between CU (N20) con-
c
nectar pin 3 and
Restore wiring between ignition module
(Nl) connectai
nal 15.
coi1
(AS) terminal 15.
pin 4 and coil
(Aa)
i
termi-
spark
and
Check ignition distributor functionality
and integrity:
cap:
- tables;
-
distribution brushes;
-
Hall
effect
sensor.
YES
.
Set multimeter to 200 Ohm F.S.
Disconnect Hall sensor
ignition CU connecter.
Check wiring continuity between:
. ignition CU
ned
nectar (wiring side).
. ignition CU pin 4 and yellow wire on
Hall sensor
. ignition CU pin 12 and black wire on
Hall sensor
connecter
table
braid on Hall sensorcon.
connecter
connecter
connecter
pin 2 and
(wiring side).
(wiring
side).
and
cree.
NQ
Replace anomalous components (cap,
* tables,
brushes, sensor, etc.).
Restore wiring.
1
-I
October
1988
PA 32 790088330
1
Page 66
YES
Check wiring
sconnected ignition CU (N20)
and ignition CU
. ignition module conneètor pin 3 and
ignition CU pin 1
-
ignition CU
tion module
_
ignition module
white wire on ignition
continuity
(Nl) connecter
connecter
connecter
connecter
(after having
connecter
between:
pin 13 and igni-
pins 5 and 6
pin 1 and
coi1
terminal 1.
IYES
Check ignition
rifying values listed hereunder:
primary winding resistance: from 0.5
to 1.5 Ohm;
-
secondary winding resistance: from 6
1
to 12 kOhm.
,,YES
coi1 (A6)
functionality
cli-
ve-
l
J
NO
Restore wiring.-
Replace ignition coil.
Disconnect white wire on
(signal for
that there is no short-circuit towards
ground.
speed
coi1
indicator) and check
terminal 1
YES
,Eventually replace ignition module
andlor ignition CU
l
(N20).
(Ni)
I
October 1988
I
Page 67
ADVANCE
TEST No.
Connect stroboscopic gun and check:
-
with
cold englne
the piescribed value;
-
with
bot engine,
value.
1
‘VARIATION
CHECK
i
advance higher
prescribed advance
than
If any
variation
exists,
but outslde the
(L24)
l
and ,read
and
check an advance va-
sensor con-
advance value.
Wlth engine’ running steady disconnect
engine coolant temperature
hemor
Connect to ground the brown-white wjre
of the sensor
riation with respect to that previously
~read.
‘8
Check
sensor
-
with, hot
between
,J-
with,cold engine read infinite
~ ce between
(L24) functionality.
engin?
read
sensor
pin and ground;
sensor
pin and ground.
aporox.‘O
resistan-
Ohm
Disconnect ignition CU connecter (N20).
NO
l Check wiring continuity between
tion CU co.nnector pin 7 and
brown-white wire.
YES
.
Replace ignition CU (N20).
NO
b
Replace
sensor
(L24).
,q-iiiqq
igni-
sensor
‘:O.ctober 191
YES
TEST No. 2
OO=
J
PA32 790088330 1
Page 68
Discinnect minimum
thrdttle opening switch
read advance value.
Short-ctrcuit pin 15 (white wire) with pin
16 (black wire) and check an advance variation with respect to thevalue previou-
sly
read.
and
maximum
connecter ahci
Check wiring continuity between:
.
connecter
NO
1
ximum throttle opening switch S6 and
ground G60.
.
connecter
ximum throttle opening switch S6 and
ignition CU
pin 16 of minimum and ma-
pin 15 of minimum and ma-
N20 connecter
pin 6.
YES
T
Semove short-circuit between pin 15
and pin 16.
Read
advance value.
Short-circuit pin 14(y@low wire) with pin
16 (black wire) and
riatton‘wlth respect to value previously
read.
cheok
an advance
YES
Chsck
nimum
i
1
adjustment
mand
+vibhi6.
and efficiency of mi-
maximum throttle opening
’
va-
1
I
‘YES
!.
I
Replace ignition CU (N20).
I
Check
wliing
connecter
.
ximum throttle opening switch S6 and
ignition CU
continuity between:
pin 14 of minimum and
connecter
pin 14.
ma-
71
tlace
ignition CU ( N20).
1
PA327900883301
00=35/1:7
October 1988
I
Page 69
COMPLETE CAR
~INJk.CTl~hl -
1,
for electronic injection 1.7
r
IGNITION
engines
without catalytic
WIRl,NGi
DIAGRAM
converter
i
only
PA
32
79008#3~01
Page 70
Features
33+ *
331.3
33cl
s
33 1.5
7-I
33 1.7 IE
~~
33 1.5 axa
Vehicle static loading arrangement (1
c
Front wheel alignment
Rear wheel alignment
Front wheel
Front toe-out angle
Whael rim diameter
8
I
Flair wheel toc-in
Front wheel camber (3)
Rear wheel camber (3)
Front wheel
Steering lock(3)
* Not marketed with 1.2
(1) Load vehicle, move it upand down on suspensions a few rimes. Checking operations must be performed with vehicle
for driving.
(2) When turning a steering
(3) These values are referred to a vehicle in nominal driving condition, i.e. with static load
(4) With rim 5
toeout
caster
‘/2
J x 14”
(2)(3)
(3)
engine
in
side
all
j
countries
rod joint by
mm
mm
mm
mm
Outer angle
Inner
an&
360’.
M - H dimension changes by 2 mm (0.079
340
A=-12Ys0
B =
27?$’
I
in)
A + B = 490 + 245 = 735 N
(50 +
25=
75
kg)
C=490
N
(50
kg)
A=-12Z;s
B =
41:‘s”
M-H=4+2
a= 10a= 10’
365 (4)
a=-20’?10’
p=-10’30
y = 2” t 30
6,=
27'50
6,
=
330
45'
p - oo f
fully
I
25
set up
340
I
--1055’+30
P
A- -
2:';
B =
+33
t;s
M-H = 2 f 2
a = Oo f 25’
y-
lOi30’
6,
=
29038'
a2
= 35010
Page 71
‘,
,’
7,
COMPLETE CAR
_
Tool number
,A.3.0156
18
A.4.0146
l
SPECIAL
Tool
Puller
of pin from stub axle
Tool for suspension height check
SE#RVICE
name
TOOLS
Refer to
page
-
A.4.0149
~
;
A.4.0150
88,
A.4.0206
,
.,
,
A.50195
Tool for suspension height check
Probe for suspension height check
(to be used with A.4.0146 - A.4.0149
Magnetic adapter for suspension height check
(to be used with A.4.0146 - A.4.0149)
Magnetic adapter for suspension height check
(to be used with A.4.0146 - A.4.0149)
Toothed wrench for locking
camshaft pulley
-
-
A.5.0212
c.2.0051
i
I
x.
PA33;3500883300
Wrench for exhaust gas sampling plug
Fitting for exhaust gas sampling
00-14
May
1988
Page 72
~._....~
~DRIVE
UNIT
~INSTALLATION
Removal
REMOVAL
AND
.......................
(1.7 I.E. with catalytic
ter); .............................
~ Installation (1.7 with catalytic
Removal
verter)
(1.7 I.E. without catalytic
...........................
jnstallation (1.7 without catalytic
‘verter)
.
Supply and adjustment
...........................
.............
SEPARATION AND ASSEMBLY
0F ‘THE
UNITS....;.
ENGINE’DISASSEMBLY
..
Preliminaries
~
,:Engine
unit
..................
................
.....................
.......................
Pistons and connecting rods ........
cylinder heads
....................
Crankshaft .......................
CHECKS
.
AND
INSPECT~ONS
Cylinder heads and valves
............
...........
Camshaft support .................
Camshaft ........................
i
Crankshaft
.......................
Main and connecting rod bearings ...
Pistons and connecting rods
Flywheel
Cylinder
.........................
block
......,..............
Piston - cylinder wall-fit .............
ENGINE ASSEMBLY
...................
ENÛINE
MAIN MECHANICAL UNIT
conver-
converter) OI:7
con-
con-
........
OI-2
01-2
01-8
01-811
01-811
(*)
01:9
01-12
OI:12
(*),
(*)
(*)
01-14
01-14
(*)
(*)
(*)
(*)
(*)
(*)
(*)
(*)
(*)
‘, ,,
*
Precautions
Cylinder heads..‘.
Pistons and connecting rods
Crankshaft
Engine unit
‘ENGINE LUBRICATION SYSTEM
Description
Oil
pump
Otl
filter .......
HYDRAULIC TAPPETS
Operation description
. . . . . . . . . . . . . . . . . . . . . . 01-14
.................
........
....
.#.
.................
.......................
.........
.......................
.........................
.‘.
.................
.................
..............
Differences from mechanical
tappets. .......
General1
specifications .............
.‘.
.................
SERVICE DATA AND SPECIFICATIONS
(for petrol’engines only)
‘Technical
data ....................
.Inspection and adjustment
.............
..........
General, specifications .............
Tightening torques ................
SERVICE DATA AND SPECIFICATIONS
(for diesel
Technical data
Inspection and adjustment
General1
Ttghtening
engines
only) ............
....................
..........
specifications .............
torques ................
TROUBLE DIAGNOSIS AND
CORRECTIONS
SPECIAL
SERVICE
........................
TO,OLS
..............
01-14
(*)
(*)
01-14
(*)
(*)
(*)
(“1
(*)
(*)
(*)
(*)
01-18
01-18
01-19
01-35
01-35
01-36
01-36
01-37
(*)
(*)
(*)
(*)
(*) Refer to “VORKSHOP MANUAL
“VOLUME I and VOLUME II - Group 01
October 1988
Page 73
ENGINE MAIN MECHANICAL UNIT
11,
,
,DRIVE
UNITREMOVAL ANDIINSTALLATION
,’
These
REMO:$AL
1.7
LE.
with
ca’talytic converter
During enghte,removal
necessary to remove engine and
box -
differential’as
vehicle on
‘,
first
WARNING: ~
Great tare
with a hot engine.
~ ~1.
Preliminary operations
a.
Operatimg
ment, withdraw knob from gear lever,
then remove the two protective rubber
gaiters from gear lever.
b.
Remove fhe hood.
c.
Workingi
compartment,
ground
For
‘, hgure
,’ 9.
Air
‘8 removal.
a. Unhook air
move
b.
Disconhect
from air flow
c. Disconnect pi e @ from oil va-
pour separator 1 .
d. Disconnect
sleeve
e. Unscreèw the three fixing screws of
air flow
f. Loosen
throttle body @ .
g. Remove air
te with air
@.
h. Unsc&the three support @ fixing
nuts and bolts and remove the support
from body. ~
~the
,geas
~
dis
required when dealing
from passenger compart-
from inside the engine
disconnect the battery
table.
followhg
procedure steps, refer to
at
pa/7e 101-3.
filter, ~airflow sensor
~
filter
elenent.
multiple
sensor
a.
sensor
s)eeve
fl~ow sensor
,.,
from car, it is
gear-
single unit. Put the
auto lift and engage
,,
and sleeve
filter caver
6
#metaI,
0
@
filter
0
connecter
‘0.
fitting @ from
to support
fixing
clamp
caver
00comple-
and sleeve
and
@I
procedures
re-
0
to
are for electronic injection
b.
Disgonnect
cap @ and remove it
leads from engine.
4.
Removal
Disengage the following pipes,
sconnecting them from stated
nents:
.
Pipes @ and @ from supply
manifold @ .
.
Pipe @ from throttle body and pipe 0 from pneumatic gauge on
ignition distributor
.
Pipe 0 from metal fitting
.
Pipe 8 from idle rpm setting fit-
ting.
.
Pi e68
30.
.
Pipe 0 unscrewing fitting on
supply manifold
5.
Removal
a.
Unscrew and remove the
pansion tank plug.
b.
Raise
ring to Figure at
right hand drain plug and then
hand drain plug
der
block
screw on the plugs
ning and relower the car.
Put a
to
collect
c. From the part stated, disconnect
the followin
l Sleeve
radiator and remove it.
l Sleeve
engine.
l
Hose@ from throttle body @ .
.
Hose @
rear
the ignition distributor
complete
of air
a.nd
fuel
vapour
@
from supply manifold
@
of cooling system piping
the car from beneath, refer-
page,Ol-6,
under the cycin-
0
and drain off the
again
suitable conteiner
the
coolant.
hoses
&a
@
from the union on the
from T fitting on engine
side.
under the car
and sleeves:
from thermostat and
with
pipes
compo-
63
coolant
iemove the
the
coolant;
after drai-
ex-
left
,A.7 engines
di-
~
b.
Disconnect
w-w
7.
Removal
ble
a.
Rotate
and withdraw the pawl on control ca.
ble end. ~b. Remove split ring and draw the
celerator
ker.
6.
Removal
a:
Disconnect the two Lambda proble
cpnnections8
from
clamps.
b. Unscrew the two fixing screws and
remove the solenoid starters
body.
c. Disconnect
ween injectionlignition wiring and
hicle wiring.
d:
Disconnect
switch on throttle body @ .
9.
Removal
Unscrew the three.fixing nuts to the
two supply manifold @ ends and
move it with jts relevant gaskets,
plete with throttle body.
The two central nuts also fix the
engine
right
the
Suitably plug the intake manifold
on engine.
10.
Removal
a.
Extract
b. Unscrew ‘the pipe fitting @ of
clutch pump and withdraw the
from service tank sheet.
hose
0
from pressure
8.
of eccelerator control
the accelerator lever
table
sheath from the
of
ignitionlinjection
@a
and disengage
@
connection
connecter @’
of supply manifold
Iqfting brackets
side
the
bracket
oil
dipàstick is also fixed.
of the clutch control
the fuseholder box
@ bet-
from the
supporting
ca-
8
brac-
wiring
table
from
com-
I;
on
hose
@.
hose
ac-
ve-
re-
‘, 3., Removal
,’ bles.
a. Disconnect high voltage
from spark
bctober
‘of
plugs
1988
spark’
plugs supply ca-
and coil.
tables
6.
Removal
a. Discinnect
a.
of fuel
hose
01-2
hoses
@
from damper
PA 32 790088330
1
Page 74
LO,dTION
As for
OF
DSIVE
UNIT ENGINE MOUNTINGS
ENGINE MAIN
MEC~HANlCAL,
UNIT
,
..
ENGINE CO,MPARTMENT.
Engine 1.7
‘i
Electronlc Injection
LOCATION COMPONENTS
1
Coolant
delivery
hose
2,
Englne
3
4,
5,
6
7 Injection wlrlng
0
9 Corrugated
10 ~ Throttle body
11 ~ Vacuum plpe to set pneumatlc
12
* 13,
14
* 45 ~
~ ~ advanoe
PA3F7900883301
Ilftlng brackets
Alr~flowllnjectlon
Coollng
system breather pipes
Akflow sensor
Alr!flow sensor
Throttle body swltch conneotor
advancs
Ignltlon dlstrlbutor
Akdelivery tube to fuel
flltsr
Metal
flttlng
Vaouun dellvery tube for pneumatfc
control Ignltlon dlstrlbutor
.’
. to
CU
sensor
fixlng
screws
support
multiple connecter
sleeve
radiant
vapour
16
011
tube
vapour recovery
17
011
separator
vapour
unlon)
15
Fuseholder box
19
Ploe
of clutch control
sistern
* 20
Lambda probe connectlon
21
Retum
oloe
radiant‘
22
Sleevs
of return
radlator
23 Pressure gauge
24 Fuel dellvery
25
Exoess
fuel
26
Damoer
27
Servobrake vacuum
25 Vacuum pipe for fuel vapourfllter
*
29 Vacuum plpe for fuel pressure
_ wwe
of
coolant
coolant from
tube
return
(oil~fllllng
hvdraullc
from
tube
pipe
OI-3
30
Alr
supply
malnfold
box)
31 Accslerator throttle control lever
32
Supplementary air
33
Idle regulatlon by;pass
34 Collant dellvery
35 Connectlon between
wlrlng and
36
lnjectlon
r=~;~1.7 fE
wlrlng
oovsr
wlth
37 Alr fllter
3; F$vapour
,r)
(air Intake
feed tubs
slseve to
vshiole
wlrlng
solenold
fllter
catalytlc converter
tube
radlator
IhJeotlon
starters
October 1988
Page 75
ENGINE MAIN
MECHANICAL UN’1-i ”
Il
Starter
energizing table
?Starter
supply bablbs
3 Odometrlc
‘4
Engine
compartmeht wirlng
5Ground Gable wlring
I~6’Power
module on ianition
distributor -
7 Engine
coolant
indicator table:
0 Englne
coolant
sensor table
9
Col1 low.voltag& table
10
Electrlc
fan
contact consent
11 Foglamps
12 Horn
tables’
13
Front’optlcql gioups
14
Alternatorz
warning
‘15
Ilgot
Eleotrical
16 Mln. level
17
19 Englne min.
fan supply
E;g;;e
max. oi/ pressure warning
table
Octoberd988
sensor table
temperature
minimum level
~
tables
for thermal
cablbs
supply
arid alternator
supply
table
oil s8nsor table
tables
oil,
pressure warning
tables
01-4
1.7 IE with catalytic
1.7 IE without catalytic
VIEW OF Et+GiNE COMPARTMENT LOCATION OF WIRING
converter
converter
PA327900883301
Page 76
,,
ENGINE MAiN MECHANlCAL: UN!IT
r
~
41; aemoval
For
at
page’O#l-4.
a. ‘Disconnect the following electrical
tables, removing them from stated
component:
9 tables
.
tables
l
tables
l
table
mum level
.
low
l
tables @
l
l
dable @ ,removing the pressure
l
temperature
l
. table’
~ terminal.
l ~
table @
oil pressure handcontact.
.
l
l
engine cylinder
b.’ Release
a@
in’ order not to obstruct their
b.1 Disc’onnect
connection, located in service tank.
of electrical tables
folhwing’removals,
8
, from optical groups.
0
, from foglamps con
nectors.
, from horns.
0
6 , from the movable
0
nection
of engine
sensqr.
voltage
, from thermal contact
of electric fan consent on racliator.
~
16
tables
r+ct,ions
mountetl connecter
table
Gable
from
Gable
temperature thermal contact.
iable @
bround table @
cje.
disengage them from the engine
, from electric fan
0
0,
from engine collant
0,
movable connection.
0,
, from engine minimum
0,
, from oil level dipstick.
all wiring from wireblock
odometer
refer to figure
con-
coolant
mini-
tables @
sensor.
energizing the starter
supplying the starter
from engine maximum
from coil.
on alternator.
unscrewing the
block
nuts, rear
table @
con-
removal.
si-
12. Loosening nut of engine central
support
With
reference
loosen bolt
0
to the body without removing it.
1 Boit
2 Central support
For following
Figure at page 01-6.
13.
Oil
draining
(if required, as a function
‘intervention to be c’arried
a.
Raise
b. Unscrew cap @ and drain engine
oil. Rescrew the cap, when this
tion has been com leted.
c. Unscrew cap 16 and drain gear
box-differential oil. Rescrew the cap
when this operation has been comple-
ted.
14.
Removal
a. Disconnect mainfolds @ from
gine right and left heads, unscrewing
the relevant fixing nuts.
b. Unscrew the three bolts@
necting discharge mainfolds @ to
catalytic muffler @ and
them recovering the gasket.
to the following figure
0
fixlng central support
procedure
the car on auto lift.
of exhaust pipe
steps, refer to
6
ofI ”
~
out)
‘,
i
opera-
en-
con-
disconnectm
c. Remove the discharge mainfolds
@
lrecovering
drawing from bottom the wirlng of
lambda probe, previously
ted.
15.
Removal
Disconnect reversing light
from gearbox switch.
16. Mechanical disconnection and
moval of drive unit
a. Unscrew screws
and
mleft
shafts of the dlfferential, and
ge the semishaft.
b. Unscrew to
screw
support
lumn lifter under the drive unit. This
column lifter
ble supporting bracket R.4.0156 to
ke part of the drive unit weight.
c. Lqosen and remove the two screws
@ ~fixing
cross member.
the gaskets and with-
disconnec-
of reversing light
@
semishafts to rlght and left
bracket attachment
0’
on the engine antishock
bracket
and position a
Will
be fitted with a
the engine front support to
table
table 0
fixing right
disenga-
suita-
re-
co-
ta-
T-
~
TL
d.
Loosen and remove the remaining
screws
cross member to body.
e.
traverse to right strut.
f. Unscrew and remove the
connecting the front cross member to
the
stru~t
0
and 0 fixing the front
Loosen bolt @ connecting front
Ileft
strut @ ; then disengage the
from the cross member.
,RA.0156
bol; @
PA j2 790088330
1
01-5
October 1988
Page 77
,;
ENGINE MAIN
MECHANICAL UFflT’
8’
“,
VIEW OF UNDERPART OF VEHICLE - LOCATION OF
,COMPONENTS
1 Screws fixing cross member to body
2 Cross member to right strut connecting bolt
,3
Stabillzlng bar
,4 Screws
7 Cross member to body flxlng screws
,9
October
flxing engine front support to crossmember
5 Coolant drain plugs
6 Cross member to left strut connecting bolt
10 Coolant temperature sender (for indicator)
11 Gasket
12
Coolant temperature sender (for CU)
13 Dipstik
14 Single contact min. oil pressure
15 Ignition distributor with power module
16 Union
17 Coolant pump
16 Front protection of drive belts
19 Water pump pulley
20 Water - alternatorpumpbelt
21 Alternator
22 Thermostat
23 OIl
filter
24 Max. engine temperature thermal contact
m
v
8+10
(0,8+1) '
d-
Page 83
ENGINE
M’AIN
MECHANICAL UNIT
Interna1
‘parts
1 Jockey puylley
2’Timing belt
3 Right tlmin pulley
4 Timing belt rear
5 Englne front
6’ Crankshaft seal ring
Engine block
7
Spacer
6,
Timlng
9
Water-pump-alternator
10
Spacer
11
Washer
12
Valve
13
Cylinder head
14
caver
caver
Pulley
pulley
J5+8’
(0.5 +
0,8)
15
Valve guide
,16
Lower spring seat
‘17
Washer
cap
19
Seal
19
Springs
,20
Spring seat
821
Cotters
22 cup
23
Camshaft Support
24
Camshaft
25
Covei
26
Gasket
27
Seal ring
26 Timing belt front
~
(8,3
caver
+
8,8)
l
I
~
October
.
1988
OI-10
PA327900883301
Page 84
ENGINE
MAIN MECHANICAL
,$JNIT
Interna1
parts
$j33%00883300
1
Main bearings
2
Woodroff key
3
Thrust half-ring
4
Oil
pump gear
5
Bush
6
Seal ring
7
R,ear
caver
Oil
vapourseparatarfillerinlet
8
9
Flywheel
10
Washer
11
Lock
ring
Pin
12
,Ol-11
13
Compression rings
14
Oil
scraper ring
15
Oil
pump
16’
Oil
sump
17
Engine
oil
16
Main bearing caps
19
Piston
20
Connecting rod
21:
Connecting rod bearings
Connectini rod cap
22
Crankshaft
23
drain
plug
T N.m
0
May
(k9.m)
1988
Page 85
PRELIMINARY
OPERi+TION,S
1.
Remove
#drive
unit from car
ac-
cordingt8 procedures: Drive Unit
Removql An4
2.
Remove
and
clutcq uni?
to ‘proc&d,ures: Separation and
semblv,of the’ Units (sec: “WORKSHOP
MANUiL c-1’
Installation.
Qearbox - differential unit
from engine according
”
-
,’
Group O-l
).
As-
ENG$E ‘UNIT
The
engin?
is on the stand without inlet
manifold
tables, a,nd
rehoved
1.
(1)
nectors $om
-
-: pow&r
-
Disenglge viring
remove
#and’
with no spark plugs,
distributor cap already
on
engine removal.
,l
Re’mpval
Di&onnect
supplementary
peiature
engine
Imje&ors’
,of
fnjection
injection wiring
following components:
air valve
module on ignition
tiater
temperature
from wire clips and
$iring
from engine
wiring
con-
tem-
sensor
1
Bracket
2
DalrIper
3 Fuel pressure
4
Intake
5
Bracker
6
Injecter
7 Fuel
,3.
Sequentially
parts:
-
Oil
filter @ &ing suitable
ner.
-
Dipstick @ for minimum
pressure
-
Thermal switch @ from
cylinder
gauge
manifold
supply hose
remove’the followinb
check
head.
span-
right
4.
qlistributor.
(1)
from cylinder heads.
(2) Loosen distributor @ securing
nut @ and withdraw distributor from
rear caver.
1
Ignition distributor
2
Distributbr securing nut
~
5. Remoue alternator.
(1) Loosen securing bolts @ fixing
alternator @ and remove drive
(2) Remove bolts and take