Alfa Romeo Workshop Manual, Manual Supplement Alfa Romeo Workshop Manual

Page 1
models
@iSl
MANUAL SUPPLEMENT
ASSISTENZA TECNICA
PA333500883300
Lj%-@j.
May
1988
Page 2
Page 3
FOREWORD
This manuals
331.e-m
is intended for
33
1.5
4x4
models 33
lt
complements
models indicated here below:
PA32 7900000000 “WORKSHOP MANUAL
PA3279000004x4 PA3279OOOB R4x4 PA327900000B RK
PA3279OOOOTDOO
PA32 7900003300
Key to
symbols:
“WORKSHOP MANUAL “WORKSHOP MANUAL
“WORKSHOP MANUAL
“WORKSHOP MANUAL
“WORKSHOP MANUAL
means
that the corresponding Group in thti.
(Alfa]
shouldb
specifically in this manual.
1.3
33
1.3
s
33
the manuals referring to
m
-
models
e
referred ta, for àll
m
details
1.5 TI
ihe
corresponding
basic
33
manual
not dealt with
1.7
IE
(Alfa
33
1.7
+
May 1988
II
PA333500883300
Page 4
QUICK REFERENCE INDEX
[Alfa]
4
(Alfa33)
4
COMPLETE CAR
ENGINÈ
FUEL SYSTEM IGNITION, STARTING, CHARGING
SYSTEM
ENGINE
CLUTCH
GEARBOX
MOTION TRANSMISSION
DIFFERENTIAL AND DRIVE SHAFT
ASSEMB LY
FRONT SUSPENSION
FRONT AND REAR BRAKES
MAIN MECHANICAL UNIT
COOLING SYSTEM
,,
. .
.+5-l
‘l=Gi-l
‘pLiil
‘G7i-j
‘pq
-IGRriLq
p-j
::iI: [GR.l
.’
-pq
[GR.l
:pLJi-j
[Alfa]
+
STEERING SYSTEM
REAR
WHEELS AND TIRES
ELECTRICAL SYSTEM
BODY-SHEET METAL PANELS
.DOORS
‘.
I
HOODS
(
\
INTERNAL TRIMMING
EXTERNAL TRIMMING
AIR VENTILATION
III
SUS.PENSION
p3i-j
GR. 25
GR. 28
El
pGq
:[GR.J
pq
pq
[GR.1
[GR:l
May
1988
Page 5
COMPLETE CAR
CONTENTS
/’ L ’
GENERAL VIEWS . . . . . . . . . . , . . . . . . . . . . . 00-2
Dimensions and weights ............
M:ODEL
IDENTIFICATION DATA ................
LIFTING AND TOWING POINT . . . . . . . . . . . (*)
SPECIAL SERVICE TOOLS . . . . . . . . .
INSTRUCTIONS FOR PRE-DELIVERY
EXECUTION AND PERIODICAL
MAINTENANCE COUPONS.. . . . . . . . . . . . . (*)
MAINTENANCE SCHEDULE . . . . . . . . . . . . 00-6
NEW IDENTIFICATION LABEL.. . . . . . . . . .
MODEL VARIATION
FLUIDS AND LUBRICANTS CHARTS . . . . . (*)
RECOMMENDED FUEL AND LUBRICANT . 00-11
APPROXIMATE REFILL CAPACITIES . . . . , 00-12
ENGINE MAINTENANCE . . . . . . . . . . . . . . . 00-13
VARIATIONS ..................
Identification label ................ (*)
Car identification codes . . . . . . . . . . . . (*)
(according to new identification label)
Fuel .............................
Fluids and lubricants ...............
Basic mechanical system.. . . . . . . . . . 00-13
Fuel system Exhaust checking
......................
.................
.‘.
. . . (*)
00-3 00-4 (*)
00-1013
00-1014
00-11
00-11
00-13 00-15
TROUBLE DIAGNOSIS ON IGNITION SYSTEM LE3.2 JETRONIC
(1.7 IE with catalytic converter) . . . . . . . 00-21
ELECTRIC TROUBLESHOOTING PROCEDURE
(1.7 IE with catalytic converter) . . . . , . . 00-27
INJECTION-IGNITION WIRING DIAGRAM
(1.7 IE with catalytic converter) . . . . . . . 00-35
TROUBLE DIAGNOSIS AND CORRECTION
ON INJECTION-IGNITION SYSTEM
(1.7 IE without catalytic converter) . . . .
‘TROUBLESHOOTING PROCEDURE
ON INJECTION SYSTEM
(1.7 IE without catalytic converter) . . . .
TROUBLESHOOPING PROCEDURE
ON IGNITION-SYSTEM
(1.7 IE without catalytic converter) . . . .
INJECTION-IGNITION WIRING DIAGRAM
(1.7 IE with catalytic converter) . . . . . . .
COMPONENTS AND BODY MAINTENANCE (*)
SERVICES DATA AND~SPECIFICATICNS . . 00-36
Engine
Componénts~ancjbody maintenance . .
SPECIAL
m,ai,nf‘enan,ce
SERVlCETOOLS.
SAND
CORRECTION
. . . . . . . . . . . . . (*)
-.:.
. . . . . . . . . . . . :. .
OO-391
00-3516
0035113
OO-35/18
00-36 00-37
PA327900883301
(*) See: “REPAIR MANUAL
[Alfa]
>I
VOLUMES I and II - Group 00
October 1988
Page 6
GENERAL VIEW
i
October 1988
l
-
I
00-2
Page 7
DIMENSIONS AND WEIGHTS
Mode1
ENGINES
WITH
ONE
33,
CARBURETOR
*
T
33 1.3 33 1.3 s 33 1.5
8
ENGINES
WITH TWO CARBURETORS
TI
33
1.5
axa
33 1.7
*
ENGINES
WITH ELECTRONIC
FUEL INJECTION
33 1.7 IE 33 1.7
*
ENGINES
WITH TURBO
COMPRESSOR
33
1.5 TO
Identification
Wheelbase
Track
Overall length
Overhang
Overall width Height funladen)
Min. steering radius
Kerb weiaht
Max. allowed
Payload Max. allowed axle
gross
Max. towing gross weight
Seating cepacity
(A) With ecological in force
(*)
With 1.2
[A)
With
gross
weight
engine
ecological
meterials
not marketed in
materials.
Front
Rear
Front Rear
weight
Front
lac.!,.
for countries
number
all
P
Ca
cp
LU (mm) I
Sa SP
LaHfmm)
Front
Rear
where
countries
(mm)
(mm)
I
h-4
(mm)
(mm) (kg) I-~
(kg)
(kg)
(kg)
(kg) 1
antipollution
908.260
2470
1366
1362
800 760
regulations
908.060 908.080 908.100
908.061 A
1367 1364
1340 1345
910 1335
800 800
1000
are
908.110
908.1OlA
908.220 908.160 908.140
908.170
908.161A
2465
1362 1375
4015 4040
790 760
1612
1370 1345
5500
970
I
I
1395
355
1100
I
I
2 3
908.200A
908.150A
1367 1364
930
1355
800 900
1000
908.180~
908.120
2455
1397 1364
825 760
5350
1010
I
1435
1100
I
Page 8
MODEL VARIATION
Chasris
No.
Identtflcatwn
NO.
Type
approval
NO.
Serial
No
Modal
Body
Drive
-
on certification label and
-
on identification
label
on
identification
label
-
on intermediate
bulkhead label
-
on intermediate
bulkhead label
33+ *
I I
L
908.260
905AB
905AOO
-
L
WITH
ENGINES
ONE
CARBURETOR
33 1.3
5 door saloon
R
-
L R L
908.060
go8,061. / _ ( 908.080 1 _ 1
905Al
G
905AlO
-
33 1.3
905Al
WITH TWO CARBURETORS
s
R
;;;:““‘, 1
H
ENGINES
33 1.5
TI
L R
908.1’0 / 908.220 j -
905A2V
905A20
33 1.5 axa
L
905A2T
R
Type and
Engme
No.
(A) With ecological materials
(*)
With 1.2
engine
serial
NO.
not marked in
Tire dimensions
Rim dimensions
all countries
-
on
block
cylinder
label
0000001
165/70
30586
frofl
SR 13
30587
from
0000001
5%
J x 13”
30588
from
0000001
175/70
RI 3 82T
\
Page 9
MODEL
VARIATION
5
DOOR
STATION WAGON
Chassis
No.
Engine No.
Identification No.
Type approval No.
Serial No
Type and serial No.
Tyres dimensions
Rim dimensions
Drive
-
on certification
label
-
on identification
label
-
on identification label
! -
on intermediate
8
.-
bulkhead label
-
on intermediate bulkhead label
-
on cylinder
block label
L
906.600
905Al
905AlO
l
/
05379411
30168
0000001
I
from
D
r
R
T
-
-
165170XRl3
5%Jx13
908.600
905Al
F
905A10
30587
from
0000001
-
905A2S
905A20
30508
from
0000001
175170R1382T
5%Jxl3
905A2U
905A20
3oda88
0000001
(A) with ecological material
C
Page 10
Chassis
No.
Engine No.
Identification No.
Type approval No.
Serial No.
Type and’sérial No.
Mode1
Body
Drive
-
on certification
label
-
on identification
label
-
on identification label
-/on
intermediate
Ibulkhead label
-Ion
intermediate
jbulkhead label l
-
on cylinder
block label
MODEL VARIATION
z!
--
908.650
905A30
905A30
908.660
905A3F 905A3G
905A30
65407756
3E18
0000001
-
905A4A
905A30
-
30558
from
0000001
905A40
VM82A
from
0000001
Tyre dimensions
Rim dimensions
(A) With ecological material and electronic injection engine for countries where antipollution regulations are in force (A) With ecological material
-
185160R1482H
5XJx14
175/70iY382T
5%Jx13
Page 11
L
Component
FUEL TANK
_
Mode1
APPROXIMATE~ REFILL
CAPACITIES
FUEL RESERVE
With filter
ENGINE OIL SUMP
% P
GEARBOX - DIFFERENTIAL OIL
REAR
D!FFERENTIAL
ENGINE COOLING SYSTEM
CONCENTRATE ANTIFREEZE QUANTITY DEPENDING ON
TEMPEFiATURÈ
ANTIFREEZE QUANTITY READY FOR USE
(‘) The indicated quantity refers to periodical changes.
OIL
+ +
3
+
Without filter
-15’C
(+5’F)
-2O’C (-4’F)
-35’C
(-31°F)
-2O’C (-4’F)
(*)
(*)
3.6 (7.94) 4 (0.88)
3.15 (6.94) 3.5 (0.77)
2.4 (5.29) 2.6 (0.57)
-
-
-
-
-
6.5 (1.43)
-
7.3 (1.61)
2.2 (0.48)
2,6
(0.57)
3.65 (0.80)
7.3 (1.61)
-
3.6 (7.94) 4 (0.88) 3.6 (7.94)
3.15 (6.94) 3.5 (0.77) 3.15 (6.94) 3.5 (0.77)
-’
2.4 (5.29) 2.6 (0.57)’ 2.4 (5.29) 2.6 (0.57)
- -
-
‘-
-
-
-
6.5 (1.43)
7.3 (1.61)
2.2 (0.48)
2,6
(0.57)
3.65 (0.80)
7.3 (1.61)
-
0.9 (1.98)
-
-
-
-
-
6.5 (1.43)
4 (0.88)
1 (0.22)
7.3 (1.61)
2.2 (0.48)
2,6
(0.57)
3.65 (0.80)
7.3 (1.61)
-
4.57 (10.07) 5.25 (1.15)
4.35 (9.59) 5 (1.10)
2.4 (5.29) 2.6 (0.57)
-
-
-
-
-
-
6.5 (1.43)
8
2 (0.44)
24’64 $‘:-]
8 (1.76)
Page 12
COMPLETE CAR
CHASSIS AND BODY MAINTENANCE
TECHNICAL DATA - INSPECTION AND ADJUSTMENT Axles and suspensions
67 k
ô
l tl
II 0
-.
m
+
a
Il
0
k
9
CU
tl
d
II
1
z
I
:
;n
-1
CU
tl
:
0
0
;
II
d
II 2
-
0
2
+I
a
fl
i
II
II
CL
0
0
II
e
?
tl
II
+
-
z tl
Eu
II
>
-
PA3335OOpOS
WO
MAY
1
00-5
1988
Page 13
I
: -.
1
MODEL VARIATION
Charsis
No.
Identification
NO.
Type approval NO.
Serial No
Mode1
Body
ENGINES
WITH
lW0
CARBURETORS
33 1.7 *
l
L l R I L I R I L I R
A
I
(
908.170 (
905A3
-
-
on
certihcatlon
label and
-
on
Ï
identificat!on
label
-
on identification
label
-
on intermediate
bulkhead label
-
on intermediate
bulkhead label
_
go8,161A
908.160
05411704
WITH ELECTRONIC FUEL INJECTION
33
I
I
I I
I
;;;;NX;;, (
l
905A30
05410692
~
A
ENGINES
I
1.7
IE
5
door
I
908.150. / 905.180.
905A3D
-
33
I
I
saloon
I I
l
-
1.7
I
/
*
-
ENGINE WITH
TURBO COMPRESSOR
33 7.8
I
I
L
05411250
TO
I
905A4
905A40
R
-
Engine No.
(A) With
(*)
Not including numbers
ecological
Type and
NO.
materials
serial
908.200
go8,,50
-
Tire dimensions
Ftim dimensions
that take the serial number
on cylinder
block label
AOOOOOl,
30550
from
0000001
185/60
as with number 908.180
R1482H
305.58
from
0000001*
5%
J x 14”
185/60
R1482H
305.58 from
A000001
VM82A
from
00001
175170
RI 382T
5%
J x 13”
-
Page 14
COMPLETE CAR
MAINTENANCE SCHEDULE
The following schedule is valid for the Italian market only
s
s
I
X X X X
3
-
-
X X X
X X X X X X X X X X X X X
X X X
X
X X
-
-
X
-
X
-
X
-
-
X
-
X
X
-
-
X
-
X
-
X
-
X
3
-
X
-
-
X
-
-
X
-
-
X
X
X
-
X
-
X
X
-
x
X
-
X
-
X
-
X
-
X
-
X
-
X
X
-
-
X
-
-
X
-
-
X
-
-
X
-
-
X
-
-
X
-
-
X
-
X X
-
X
-
X X
-
X X
-
XX X X X
X
X X
-
X X X
X
-
X X
-
X
-
-
X
-
-
X
-
-
X
-
-
X
-
-
X
-
-
X
-
-
X
-
-
X
-
-
X
-
-
ic L-
May
1988
Y
z
8
.z
8
.k
0 P
.­B
" E 2
. .
L
3
;
.-
E
0
2
z c
Fi &
Ty 2
Y
I
6
r.
00-6
"0 E
m
P,
P B 2
E
<u
z
E 2
L9 9
‘0
u:
E
ï
.E P
6
-
2
PA333500883300
" ?
3
> m 2 8
E
Y2
s
ü
m
0
m
yo
0
5
­CO
/
Page 15
2 2
~g ~~
8
si
2
8
;
%
(1)A = 1500+2500
e
(2)To be
s
(3)
g
N.
19 Check
23
24
25
28
29
30
31
32
33
34
35
Check more
terwon
pump and
Replace
Clean
Check
(petrol
Replace fuel filter
Replace
Clean
Check exhaust emissions
1
Check and if necessary adjust ignition timing
lnspect
Replace
Check battery
Lubricate
Greasing of hood and backdoor catches
Check underbody and body work
Test
vehicle
I
I
performed
of and if necessary replace drive
air~conditioner compresser (If fltted)
drwe belt
of alternator and air
and
check
trghtness
Injection
air folter
carburetor
and
clean
spark plugs
electolyte level.
door
Km
in
frenquently
air filter
only)
cartrldge
jets and crankcase ventilation
spark plugs
and
any
element
of au mtake syslem downstream from the air flow
(where
necessary)
hootybackdoor
(621t932
case
every
if driving in
mi)
OPERATION
condltioner compresser
top
up. tlghten
and grease
hinges. Adjust
6 months. Check
very
dust areas
belts
of: alternator.
systembackfwe
termmals
strikers.
oil level
frequentlywhen
(if
shleld
as
fmed)
coolar
gaugl
necessarb
A
(1)
X
X
X
X
refuelling
-
-
20
~10
X
30
40
-5c
-
-
X
-
-
X
-
-
-
-
X
-
X
-
X
-
X
-
X
-
X
X
-
X
X
-
X
-
X
-
X
-
(4) (5)TO be (6)
x
-
X
-
-
-
-
-
-
-
X
-
-
-
-
Check frequently when refuelling
TO be performed in
X
X
--­X
X
X
X
X
X
X
X
X
X
X
performed
80 90
X
X
X
X
X
X
X
X
X
X
X
X
X
every
Km/1000
X
X
12 months
-
13(
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
X
X
I I
X
l I
I I
l I
I I
X
X
X
X
Notes
l
(4)
hillv roads
170
18(
1
.
190 200
-rl
X
X
X
X
X
X
X
+t-
X
-PL--
X
X
IXI
X
-k-l---
X
X
%-t---
X
X
X
X
42
-
-
l
60
7c
-
-
X
-
-
-
-
X
-
-
X
-
X
-
-
X
-
-
-
-
X
-
-
X
-
-
X
-
-
X
-
-
X
-
-
X
-
-
X
-
-
X
-
-
X
-
X
-
-
more frequently when driving under particular stress conditions (sport driving) or on
any
case
.
Page 16
COMPLETE CAR
MAINTENÀNCE SCHEDULE
Th,e
following schedule is not valid for the Italian market and for countries where antipollution
r&julatjons
are in force
a=
-
X
-
-
-
X
-
X
-
-
X
-
-
X
-
X X X
-
-
X
-
-
X
X
-
X
-
X X
-
X
X
-
-
X
-
X
-
-
X
X
-
XX
X
-
XX X X
X X
-
X
-
-
X
X
-
X
-
X
-
X X X X X X X X X X
X
X
-
X
X
-
X
-
X
-
X
X-X
-
X-X
X X
X
-
-
X
-
X
X
-
.x
X
-
X
X
-
X X
X
-
X
-
X X X X
-
X
-
-
X
-
-
X
-
-
X
-
-
X
-
-
X
-
-
X
-
-
X
-
-
X
-
-
X
-
-
X
-
May 1988
oo-7/1
u m
m
2
0
3
s" t
v1 I
Li
r
5
m
-0 k
Y
E
6
-
z
PA333500883300
Page 17
Km/1000
30
40
50
60 70- 80 90
100~
110 120 130
140
150 160
170
180
190
200
Notes
~~
Check tension of and If necessary replace
pump
and air
conditioner compresser (If fltted)
20IReplace drive
21
Replace camshaft drive belts
22
Check fuel
23
Clean and
24
Check
(petrol Inlectlo” only)
25 Replace fuel
I
Replace
26
8
4
I
27
Clean carburetor lets
Check
28
29
Check and if necessary adjust
30
Inspect
bett
of alternator and
system
for leaks
check
air filter
tvghtness
of air
fllter (where
air ftlter cartndge
and crankcase
exhaust emlssions
and
clean
spark
element
mtake system
necessary)
Ignition timtng
plugs
drwe
belts of; alternator.
air conditroner compresser (If fltted)
downstream from the
ventllatlon systembackflre shleld
air flow gauge
coolant
/
Il
I
Il
X
X
I I l
I I I
X
X
X
X
X
X
X
X
X
XX
X
X
X
XX XX
X X
X X X X X
X
XX
X X
XX
X
XX XX
X
X
X
XX XX
X X X
X
X
Replace spark
31
32
Check battery electrolyte
Lubricate door and
33
Greasing of hood and backdoor catches
Check underbody and body work
34
Test
35
(1) A
?
-L
=1000~1500
(2) T O be performed in
when refuelling
(3) Check more frequently if driving in
plugs
vehicle
km
any
level,
top up, tighten and
hoodbackdoor
(621 t932
case
mi)
every
grease
terminala
hinges. Adjust strikers, as necessary.
6 months. Check
very dusty areas
oil level
frequently
X
X
x x
X
X
X
X
X
X
X
1
1 I I I I I I I I 1 I I I I
1x1 lx1 1x1 14 1x1 1x1 1x1 1x1 1x1
I i l I I I l I I I I I I I I I I I
X
(4)
Check frequently when refuelling
(5)
TO beperformed morefrequentlywhendriving underparticularstressconditions
(sphrt driving)
(6)
TO be
X
X
X
Il
$l
or on
in
X
hilly
any
X
performed
X
X
X
X
X
X
VI
X
roads
case
every
X
X
X
il
X
12 months
X
X
X
8
X X
X
X
X
F
X
X
X
Il
I I I I
X
X
(4)
Page 18
COMPLETE CAR
MAINTENA.NCE
SCHEDULE
The following schedule is valid only for those countries where antipollution
E
-
-
-
X
-
-
X
-
-
X
-
-
X
-
-
-
X
-
-
-
X
-
-
X
-
-
-
X
-
-
-
-
X
-
-
-
-
X
X
X X
X
X
-
X
X
X
X
X X
-
X X
X
X X
-
X
-
X
X X
X
X
X X
X
X
X
X
X
X
X
X X
X
32
X
X
X
-
XX
X
X
X
X
-
regul,ations
9
7
X
X
X
-
-
X
­x
X
-
X
X X
X
X
X
X
X
X
-
X
-
X
X
-
X
X
X
-
X X
X
X,
X
are in force
Lu
i
PA333500883300
,
B u
% .3
E
5
E
n n
5
i
il
Y
p:
6
­m
May
00-8
1988
Page 19
u w
COMPLETE CAR
.u
.u
x Ix
X
x
$
.
- _
--_
X
X
X
i-
‘F- f
X
X
X
-
X
-
X
-
X
-
-
X
-
X
-
X
-
-
-
X
-
-
-
-
-
-
X
-
X
X
-
-
X
-
-
X
-
-
X
X
X
X
-
X
-
X
-
-
X
-
X
X
-
-
X
-
-
-
-
X
-
-
X
X
X
X
-
-
-
X
X X
X
-
X
-
-
X
-
L
X
-
-
X
-
-
X
-
-
X
-
-
X
X
-
-
X
-
-
X
X
X
-
X
-
-
X
X
-
X
-
-
-
-
-
-
x ~
-
X
-
-
X
-
-
X
-
X
-
X
-
X
X
X X
X
1
May 1988
PA333500883300
Page 20
No.
34
35
OPERATION
Check
sensor OI oxygen
Replace catalyst of exhaust gas
contents in
exhaüsl
gas
(1)
A
10 20
-
-
30
40
-
-
-
-
-
-
Km11000
I
,
(6)
(1) A=
1000+1500
(2)
Check
(3)
Check more frequently il driving in very dusty
(4)
Check frequently
(5)
TO be performed in
Km
oil
level every 500 km and when refuelling
when
refuelling
any
case every
Iwo
areas
years
TO be performsd more frequently when driving under particular stress codltions (sport driving) or on
(7)
TO be performed in any case every 12 months
(8)
TO be performed in any case every 5 years
Operation relevant to emission control
6)
hilly
roads
Page 21
COMPLETE CAR
-
,/ ,,
The present
programmed maintenance.
periodical maintenance schedule, for all markets, is applicable to vehicles equipped with SERVICE BOOKLET having the new
Replace
Check brake and
oil
in gearbox - differential (and
ine oil
OPERATION
and
oil
filter check
clutch fluid
levels
ti
rear differential
MAINTENANCE SCHEDULE
in
X ( X 1 X 1 X 1
(6)
19
20
?l
‘22
23
/
i..
Check axial
by-pass
Check idle
Check idle
Replace exhaust gas oxygen sensor ( Lambda
vehicies with catalytic converters)
Check integrity and tension of cooling liquid pump, alternator
and
conditioner compresser
PA3279Otj883301
an’d
radial play of supercharger rotor shaft and
valve (only in diesel engine vehicles)
r.p.m.
(petrol versions)
r.p.m.
(diesel engine versions)
(if installated) drive belt
sensor) (only
xxxxxxx
X
in
x x x x x
oo-lO/l
X~
x
x
14
1x1
I
i
lx1
xIxI x Ix1
--lTrl-
x
X
ti
x x
October 1986
Page 22
COMPLETE CAR
N.
24
1
Replace timing belts
Check tightness of fuel supply circuit
25
Check fuel
26 Check
Check tightness of air supply system downstream the air flow
27
meter
(only in fuel injection
Replace fuel
26
Replace air
2g
Clear flamedamper in exhaust gas recycling circuit (except in
30
diesel or fuel injection cars)
31 Check exhaust
Check spark
33
Replace spark plugs (except diesel
33
Check electric connections in engine
34
and positipn of Grease
36
vapour emission
,,
air,filter
cartridge
filter
filter
emission
advance
connectors
dqor
and hood hinges, grease hood locking catches.
OPERATION
contrai circuit (if installed)
engines)
(where foreseen)
cartridge
(only in vehicles with catalytic
(except diesel models)
engines)
compartment
and hoods)
I
I
converter)
(condition
I
I I
X
X
x
x x x ‘X
X X X
x x x x x
I
IxIxIxl’x
/XI
X
X
lx1
‘X 1
X
x
xl
Note
140 160
X
x
X
-
x x
x
X
X
X
X
x
~X
X
J
x/
180 200
X
x(xI
36 1 Test vehicle
(1) A =
1500 - 2500
(2) Check (3) Check more frequently if driving in (4) Check frequently when refuelling
Km
oil level
every year and when refuelling
very
dusty
areas
Ix
1x1
xl xl x
(5) TO be performed more frequently
conditions (sport drlving) or on mountain roads (6) TO be (7) TO be performed in
replaced
in
any
any
x x
ihen
case every
case every 2 years
1,2
months
drivlng particular in stress
October 1988
oo=s 0/2
PA327900883301
Page 23
P
NEW IDENTIFICATION LABEL
/@@&
I
I
'6
L
1 - Homologation code
2 - Body marking
3 - Engine type mumber
4 - Base type and vehicle version
-- ALFA LANCIA
-
Ul2-
-
HOTORE-ENGiNE
.
VERSIONE-VERSION
, N’ PER
ti’
FOR
RICAfl8I SPARES
INDUSTRIALE
5 - Serial number with relation to finished units: necessary
when ordering spare parts, for identification of tion or assemply plant and as of modifications.
6 Marking of correct value of smoke absorption
tient
(for diesel engines’only).
S.P.A.
QI 1
*
--
--
1 2
I
3
,fl ,5
/
produc-
reference
for introduction
coeffi-
‘<.._E
‘.
BODY
‘8
ZAR/
,905AOO
(1)
PA3q7900883301
MARKING
+ 05455.737
,
(2).
(1) - Constructor identification code (2) - Vehicle (3) -
l
I
0040/3
Chassis
mode1
serial
number’
October 1988
Page 24
Mode1
MODEL VARIATIONS
(According to E.E.C. markings adopted on new identification labels)
I
ENGINES WITH ONE
33+
*
CARBUTEROR
33
1.3 33 1.3 s
ENGINES WITH TWO CARBURETORS
33 1.9
l-l
33
1.5
PXI
Body
Drive
vehicle type No.
Chassis serial No:
Engine type and serial No.
-
on identification label
-
on
Sérvice
front cross member, right side,
horizantal
-
on service compartment
front cross member, right side, horizontal plane
-
on special
rised block
on engine block,
Upper
flywheel side
compartment
plane.
right part
LEFT
905AP
905AOO
30565
0000001
5
DOOR
SALOON
LEFT
905Al
I
G
I
I
905AlO 905A20
LEFT
905Al
H
905AZV
/
905AZT
05.455.737
30566 30567
:
0000001
0000001
30588
0000001
8
2 ;
g .’ St
2
0
4
3’)
With 1.2 engine
commercialised
Tyre dimensions
Rim
dimensions
only in certain countries.
165/70
SR 13
5%
J x 13”
I
175/70 R13
62T
Page 25
MO~DEL
VARIATIONS
8 0
vehicle type No.
Chassis serial No.
Mode1
Body
Drive
(Accordinb to
T
-r
-
on identification
label
-
on service compartment
front cross member, right side, horizontal plane.
-
on service compartment
front cross member, right side, horizontal plane
E.E.C. marking adopted on new identification
ENGINES WITH TWO
CARBURETORS
33 9.7
fi
. .
lefilright
I
I
905A3
1
WITH ELECTRONIC FUEL INJECTION
33 1.7
I
I
I
leftlright
. .
905A30
I!i
5
DOOR
ENGINES
905A3D
05.455.737
label+
33 1.7 +
SALOON
I l
leftlright
ENGINES WITH
TURBO COMPRESSOR
331.8TO
left
I
I
905A4
905A40
OF
0 0
2 QJ
-
-on
special
raised block
on
qgine
Engine type and serial No.
Tyre dimensions
Rim dimensions
(‘)
Excluding Nos. 908.2201908.150 which take serial No. A000001 as with No. 908.180.
Upper
flywheel side
block,
right part
I
185/60 RI 482H
30550
from
0000001
305.58 from
0000001*
I
185/60
R1482H
305.58
from
A000001
VM82A
175170
from
00001
R1382T
I
5%
5’lz
J x 14”
J x 13”
Page 26
COMPLETE CAR
,:,--
FUEL
For
RECOMMENDED FUEL AND
coke@
engine functioning the specification is for premium grade or unleaded petrol: RON 2 95.
LUBRIC&NTS
00-l 1
For models 33
1~7
+and
,33
1.7 IE with electronic injection and catalytic convertor only unleaded petrol to the following
specifikations must be used:
~
-
Octane Number (Research method) R.O.N. 2 95 (for Switzerland, Sweden versions)
-
Octane
Number (Research method) R.O.N. 2 91 (for Australia version)
WARNING:
._
Never mneither damage
TO preuent the tank from being accidentally filled with
permit, the entry of only
even a small quantity of fuel
delivery
in an emergency nor in
to’the exhaust gas catalyzer.
special
filler spouts fitted exclusively on unleeded petrol pumps. Should the tank be filled with
lead
petrol, do not start the engine, but proceed to the
system.
small
quantities use conventional
lead
lead
petrol. TO
petrol, the inlet filler has been designed in
complete
d6
SO
Will
result in permanent
such
emptying of the tank and the
a way as to
FLUloS AND LUBRICANTS
Type
,’
Oil
except:
Application
Engine - 01
Gearbox - 13
Differential
Classification
API
SF/CC Sint 2000
MIL L461528
CCMC
G2Dl
SAE J 306a
APIGL-5
SAE
Rotra
SAE
AGIP
lOW/40
MP
8OW190
Name
IP
Sintiax
SAE
lOW/40
Pontiax HD
SAE
8OW/90
SHELL
Super Plus~
Motor
Oil
SAE
15W15b
Spirax
HDI
SAE
SOWl90
Notes
Envikmental
temperature
-lS+t40%
Environmental
temperature
-
30 f t
40%
May 1988
00-11
PA3335008833pO
Page 27
8
3
~~~
APPROXIMATE REFILL
CAPACITiES
Mo&is
,
Components
FUEL TANK
FUEL RESERVE
ENGINE OIL SUMP
GEARBOX -
REAR DIFFERENTIAL OIL (
ENGINE COOLING SYSTEM CONCENTRATE ANTIFPEEZE
QUANTITY DEPENDING ON TEMPERATURE ANTIFREËZE QUANTITY READY
FOR USE
(0)
The indicated
(*) Not marketed in all countries with 1.2 engine.
DIFFERENTIAL OIL
LIXU
quantity
refers to periodical changes
models)
Measurement unit
With
filter-
Without filter
-
15oc
-
20
-
35°C
-20%
PI
(0)
oc
33,
x 33
33 1.5 axa
386
3,15
2‘4
03
Kg
-
-
-
1.3
33 1.3 533 1.5
33
‘1.7 +
33
1.7 IE
-
-
Liters
50
63
4
3.5
2,6
1,o
7,3
22 Z6
3,65
7,3
TI
331.BTO
Kg
-
4.57
4,35
2,4
- -
-
-
-
i,.
2
,^ - -
Liters
50
6,5
5,25
5
2,6
7,5
2
2,64
4
7,5
Page 28
COMPLETE CAR
ENGINE MAINTE#NANCE ~
BASIC ‘MECHANICAL
SYSTEM
CHECK AND POSSIBLE ADJUSTMENT OF VALVE CLEARANCE
As
for
Alfa
33
!n
engine ‘with hydrauliç tappets which
does
not require any
adjuste’ment of valve clearance
CHEtiKING, REPLACING AND
ADJUS-kING
BELTk
Alternatix
trol
bkt,
As for
&Alfa]
1.7
engines
the tension value to be measured with
the
appropriate
78+8?
Replzki~g
gine bn car
As for
[Alfa),
the
pr&&dure
modeLis tp be applied
except for the 1.7
check
DRIVE
and water pump
except for 1.3 - 1.5
with
one
carburetor where
tool is:
N(8 +9 kg)
timing belts with
only
for 1.7
for the,
engines
a-1
or
con-
en-
Before
connect
wiring from the stick.
extracting
the minimum
the
COOLING SYSTEM
Proceed as per the table referring to antifreeze fluid composition provided in “System
Refill”,
which has to be changed as
fOllOWS. for 1.7
Minimum
side
temperature
Concentrated
freeze
Std. No.
3681-69956
-
Diluting drinkable water
Ready-to-use anti- freeze Std. No.
3681-69958
[Alfa]
engines
out- OC
(Imp Gal) (0.48) (0.57)
(Imp Gal) (1.12) (1.03)
(Imp Gal) -(1.61)
-15
(OF)
(+ 5)
anti-
I
2.2 2.6
I
5.1 4.7
I -
7.3
dipstick, dis-
oil level sensor
except for
-iO
-35
(-
4)
(-31)
3.65
(0.80)
3.65
(0.80)
-
-
1.0RelFase
clips which secure caver
1 to container.
2. Lift caver enough to remove tridge without damaging sleeve
3.
Clean the cartridge thoroughly. by
car-
0.
blowing’low pressure compressed air
in the
o&posite
direction with respect
to the normal air flow.
1 Air fiker caver
2 Corrugated sleeve
CHANGiNG
AND
ENGINE OIL
~REPLACING
FILTER
As
p,e( IAlfa referripg to the
has
to’
be modified as follows:
for 1.7 engines
ENGItiE
Engine ;oil sump
li?Wl
Cil filte; ducts
Periodical change (engine
for
PA~335Q0883300
~ Capaclty
and
sum,p
I
OIL
inner
and
except for the table
refill
capacities.which
QUANTITY
at max
filter)
OIL
oil
I
(Imp. Gal.)
(ci?)
0.6
(0.13)
4.0
(0.88)
CYLINDER COMPRESSION TEST
As per
(Alfa331
.
FUEL SYSTEM
CHECK, CLEANING AND REPLACEMENT OF AIR
FILTER
As per electronic injection require the following
CARTRIDGE
(Alfa]
except for
engines
procedure.
which
do-13
1.7
4. Clean the cartridge container.
5.
Insert
the cartridge into container
positioning
downwards and hook the
again.
the protruding part
caver
clips
Replace the element at the re-
commended intervals (see: Vehicle
Maintenance Schedule).
.
FUEL~ FILTER REPLACEMENT
As p&
electronic
require the following
I
IAlfa33]
injection
exce,pt for 1.7
engines
procedure.
May
which
1988
-.
Page 29
COMPLETE CAR
1. Unscrew tubes
@
and 0’ fit-
tings and recover the gaskets.
ProPerly’p!ug’fittings
fuel
outletl
to prevent
2. Loosen clamp @ and remove
filter @.
3.
that the arrow printed on
~
Remou;nt
the new
filter
filter
in order
body be
positioned towards fuel delivery direc-
tion.
4.
Complete
the filter assembly
oper-
ating in opposite order in respect to
removal.
E,ffect
checking as follows:
1. Circuit pressure checking
a. Disconnect fuel delivery tube downstream from the damper
b.
Connect a gauge by
means
T adaptor between damper @ and tube @ previously disconnected. c. Detach tube @ from pressure
gauge
0.
This is in order to avoid that any pos-
sible anomalies on idle rotation speed
could
cause unusual readings.
d.‘ Start the engine; at idle speed check
that fuel pressure value is:
280 i320
KPa
(2.8 c 3.2 bars; 2.9 + 3.3 Kg/cm’)
e. Reconnect tube @ to pressure gauge; at idle, fuel pressure should drop of 0.5 bars approximatively and then
rise again
open.
Should thisoccur, please
when throttle valve
any possible tube @ depression
leaks.
@
@
of a
Will
check
2. Checking on circuit tightness
a. With pressure gauge plugged, and with engine on tube immediately downstream from
pressure gauge, de?ecting a pressure increase up to
(4
(do not let value)
b. With pressure on 2.5 bars
that fuel delivery tubes and fittings do
not show leaks. c. If fuel pressure does not reach this value and if no leaks are detected
check
the
ooeration.
idle,throttlethedelivery
400
KPa
bar’s;
4.1
Kg/cm*)
the
pressure exceed this
filter and/or
the pump
check
CHECKING AND POSSIBLE
ACCELERATOR CONTROL
ADJUSTMENT
As for
ctronic injection the following procedure
(Alfa]
except for 1.7
engines
which require
ele-
1
Filter sup,port
2
Fuel
3 Fuel
4 Fuel
CHECKING
inlet
filter
outlet
tube
clamp
tube
&EL
SUPPLY
PRESSlJliE AND’CIRCUIT
TIGHTNEh
As for
electronïc ~ injection require
[-33)
the
except for 1.7
engines
following procedure
which
1 Depression tube 2 Fuel pressure gauge 3 Throb damper 4
Tube delivery to
fuel distribution manifold
1. Check Checkthattheacceleratorcontrolcable slides
2. Check a. With the accelerator pedal
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
Acklerator table
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
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~fit small 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
4. It
thatidle’r.p.m.fallswithinthespecified values850f50r.p.m.andif
the “ldle
repeated.
tail-pipe
Will
be necessary to
iIn
the debimeter.
Will
then be necessary to check
itdoesnot
r.p.m.
Check”
Will
have to be
p9s-
PA333500883300
00-l SI2
May
1988
Page 33
Page 34
CHECK
OF THE IDLE R.P.M.
‘For
Carry
r.p.mi
the
devices tut out,
Unlock ‘the locknut and turn the
adjusting screw 0 until the fied value
is encountered.
ANiD
ADJUSTMENT
@m-l
out
the adjustment of the idle
with the engine warmed
g~ears
in neutral and
920 + 960
only
all
ancillary
operating as follows.
r.p.m.
speci-
1
w
up,
COMPLETE CAR
1.
Put the vehicle on auto lift.
2. Working from en ine room, dis-
connect connectors 1
lambda probe and disengage wiring from clips.
Q
and @ of
1 Adjusting screw
CAkYTlC
MUFFLER
REPLACEMENT
This
:procedure
jection 1.7
muffler only.
When Km stated on “Chart of Vehicle
Mainten:ance’ Operations” are verecl, please proceed to replace lytic muffler as follows:
1.
&t
the vehicle on auto lift.
2.
Loosen
~
3.
Unscrew the three bolts on flange
@
contiecting catalytic muffler and
exhaust manifolds.
4. Unscrew catalytic muffler
from split rings @ and remove it dis-
engaging it from rear track of exhaust
pipe.~
is for electronic in-
engines
with catalytic
clamp @ bolt.
co-
cata-
@
1 Catalytic muffler 2 Supporting split ring
3. Clamp
4. Flange connecting catalytic muffler - exhaust manifold
5.
Install
working with opposite order in respect to flange connecting exhaust manifold.
6.
ing, there are no leaks connections and that the exhaust
system is not
a new catalytic muffler
removal,
fitting a new gasket on
Check that, with the engine
from’
unusually
noisy
runn-
pipe
LAtiBDA ;PROBE
REPLACEMENT
This
procedure
injection 1.7
convertor
At km stated on “Chart of vehicle
Maintenance Operations” replace lambda probe as follows:
is valid for electronic
engines
with catalytic
only.
Lambda
probe
1 2 Lanibda probe signal connecter
3 Working from below the vehicle, unscrew Lam,bda probe 0 and remove it.
1 Laibda
probe
4. On installation, spread the probe body thread with grease R. Seez or Bosch 5.964.080.1005 and tighten
iifully
5. Reconnectthewiringofthelambda probe.
resistance
connecter
Gori Never
PA3335kJ883300
00-l 7
May 1988
Page 35
COMPLETE CAR
CHECK ON AIR SUPPLY
SISTEM
TIGHTNESS DOWNSTREAM FROM THE
AIR
FLOW SENSOR
This procedure is for electronic injec-
tion 1.7
vertor
Makesurethatallpipefixingclampsare fully,tightened
Start engine at idle r.p.m., then
ally
stream
Should air inlets to ‘engine undetected by
sensor, some variations of idle r.p.m.
Will take place
TO
leaks in the air supply system, spread
some
engines
0nly.i
deform;
ease’the
pipings#and
from
,the’re
suds
on involved pipes.
with catalytic
sleeve
the air flow
be
any
faulty pipes with
location of
sensor
any
possible
con-
manu­down-
TROUBLiZ?HOOTING
PROCED~URE TO CHECK FUEL
$UPPLi/
This procedure is valid for electronic
injection i
convertor
This procedure is to be effected when reaching the km stated on “Chart of Vehicle if the
-
-
-
a.
applicances are available in order tobe
able to operate safely.
FYSTEM TIGHTNESS
-78
engines with catalytic
pnly.
Ma,intenance
foll,owing
Petroli
Visual signs of leaks from system fittings and connections.
Effectithe procedure stated in
.graph”FuelEngine-CheckonFuel
Supply
Tightness” -steps 1. and 2..
completing it with what follows:
Make’
sure
Operations”,and
symptoms occur:
smell.
,Pressure
and Circuit
that
fire-fighting
para-
b. Warm engine up to normal run-
ning speed.
c. Disconnect ignition.
d. Effect a visual check. of fuel system components and fittings in
order to locate leak origin.
e. Check the whole system ing pipes, fittings, components) using a gas detector.
f.
Close to leak area,
a tester pointer
This test with tester must be effected slowly in order to compensate for the time delay of tester response.
Following leak location, follow
9.
procedure steps d.
eliminatethe
ponents or properly tightening ed
clamps.
h. On completion of operation, start the engine letting it idle run for few minutes and then switch ignition off.
Repeat test as per steps c. and
i.
to check that diagnosis is correct and
reaction.
leakreplacingfaultycom-
.h
_,_<-
and/or
(connect-
one Will
e. then
note
loosen-
d.
repair is efficient.
1.
At end of whole procedure, road test for make a final test to be sure of system integrity.
about
30 minutes and then
TROUBLESHQOTING
PROC.EDURE
TO CHECK FUEL
VAPOUR EMISSIONS
CHECKING SYSTEM
TIGHTNESS
Possible causes could be:
-
Leaks of vapour from system
components, accessories and connections.
a. Disconnect pipe 80from dump valve 9
n
air source to the
with a gauge
nected.
b. Pressurize the system with compressed air to reach a pressure of.
2.49
KPa
(0.025 bars;
0.0255 Kg/cm2; 254 mm
and then close the
cari’‘’ (reach the specified value,
the compressed air supply system and check the system tightness (with gas deteetor).
connection.
c. Measure pressure drop in system (it must not iexceed
0.125
KPa
(0.00125 bars;
0.0127
in’ 10 minutes).
(
d. If within 10 minutes the pressure drop exceéds this value, locate leak spreading pipes with suds or using gas
detectorl
K&cm2;
12.7 mm
e. When there are leaks, some soap bubbles
f. Should the leak corne from filling union
If after replacing cap, tightness is
stored, this
otherwise replace the union.
Will,
area,
means
appear.
first replace the cap.
that cap was faulty,
g. Replace faulty components or tighten loosened clamps.
h. Repeat procedure b. and c. to
check diagnosis efficiency.
1.
If after effecting the above tioned process, leaks still exist, diagnostic procedure to check the supply system tightness of fuel in­jection system.
con-
HzO)
If
one
open
Hz0
fuelcap
men-
effect
. . .
re-
May.
1988 ~
i
00-18
PA333500883300
Page 36
COMPLETE CAR
1
Fuel vapour
2
D&ompression pipe for dump valve control
3
Air delivery pipe
4
‘Fu!el
~
l
tank
s&on
pipe
Fuel vapour exhaust pipe
5
Compensation valve
6
Fuel vapour separator
7
Fiel
vapour recovery pipe
a
9
Dump valve Fuel vapour
10
filter.
PA333500883300
00-19
May
1988
Page 37
DIAGNOSTIC AND CORRECTIVE INTERVENTIONS
ON LE3.2 JETRONIC
INJECTION SYSTEM
Procedures
for electronic injection 1.7
and diagrams
engines
with catalytic
~
converter only,
PA 32 790084330 1
00-21
October 1988
Page 38
,’
COMPLETE CAR
c
:ii
II
1
October
1988
00-22
PA327900883301
Page 39
Page 40
THE ENGINE STARTS WITH DIFFICULTY
1
COMPLETE CAR
May
1988
00-24
PA333500883300
Page 41
IRREGULAR IDLE RPM
COMPLETE
CAR
Check for correct air
Check that on a suckins ducts don’t
Effect
electrical
troubleshooting from
ANObjlALIES
Checkicorrect fuel system pressure and
ignition system efficiency (spark
timing;
etc.).
Checklthat no leaks do exist in air
take ducts
flow.
throngh
IN ACCELERATION AND BURSTS IN RELEASING
plugs,
iri-
P
YES
Check
G60
ground efficiency.
YES
Check minimum & maximum opening No. 4 ‘of
electrical
troubleshooting.
PA333500883300
00-25 May 1988
Page 42
EXCESSIYE’FUEL CONSUMPTION
Check correqt functionality of the engine
water
tempqature
wiring by effpcting test No. 5 of
cal
troublpshooting.
sensor and relevant
electri-
YES
COMPLETE CAR
Check valve clearance of engine
UNCORRECT
Check functionality of Lambda probe by effecting electrical troubleshooting
procedure. ~
Zonnect
a CO-tester upstream, from
:he
catalyst disconnect Lambda probe
md verify a CO value increase.
Reconnect Lambda probe and CO value
DISCHARGE EMISSIONS
lqwering.
timing.
check
a
Check valve clearance, air supply
system for
Check catalhst
May
1988’
leaks
in air intake
muffler.
ducts.
00-26
Page 43
Page 44
NO
During
Lheck
fuel system pressure
-
Connect a pressure gauge to fuel
circuit
-
Try a prolonged starting and check
pressure
?.
bars and 3.2 bars.
NOTE: The pump must even with the only key in the “MAR- CIA”’ running position.
presence
turn
for a few
between 2.8
F
-i
seFonds
a starting, check +12-V on fuel
pump
terminals.
Check fuel
/
throttlings.,
filter
and any possible duct
YES
c
NO
Check G4 Fuse (15 Ohm)
t--
Check that negative terminal of pump is at ground.
YES
i
L
YES
s-1
Check efficiency of pressure gauge.
YES
c
Check circuit downstream from relay
S12a up
to fuel
pump,
terminal 87 of the
Eliminate ground connections on pin 12
of CU
connecter.
beginning from
same r,elay.
Check that relay S1.2.a is energized.
YES
c
Check that fuel pump
I
Probable failure on electronic CU.
Go on with diagnosis.
rotates.
YES
r
:heck electrical circuits consisting of:
(
terminal 30 of relay S12.b and ground = 12 V terminal 85 of relay S12.b and ground = 12 V terminal 86 of relay S12.b and
I
I
ground = 12 V terminal 87 of relay S12.b and
ground=12V
.
Search for
fauhin
l
NO
c
vehicle
1
wiiing.
r
TEST No. 1
Page 45
COMPLETE CAR
TEST’No. 2 - CHECKINGS ON GROUNDS (PIN 4 AND 5 OF CU)
l Set
hwltimeter
to 200 Ohm FS.
mi
Check
cohtinuitir
-
pin, 4 of CU’connector and
gr?und;
-
pin 5 of CU connecter and
grqund.
between:
YES
G60
G60
Check
also
G60 grounds functionality.
P
TEST:
No. 3 - CHECK CONNECTION TO RPM SIGNAL (CU PIN 1)
Set
~multimeter to
,a
Electronic CU
I
Checb wiring continuity between pinChecb wiring continuity between pin
1 of CU connecter and terminal 1 of
1 of CU connecter and terminal 1 of
ignitibn coil.ignitibn coil.
200 Ohm
FS.
connecter discon-
(ES
I
NONO
u
t-d
Restore wiring.
Restore wiring.
TEST No. 4
PA333500883300
May
1988
Page 46
,’
TEST
COMPLETE CAR
Ntj. 4 -
CHECK ON MIN. & MAX. OPENING THROTTLE SWITCH (CU PIN 15,AND 14)
l Set molfimeter
Insert
multimeter
connecter pin 15 and ground.
Check the ~existance’of a resistance
value lower than 10 Ohm. Press accelerator and check an in-
finite
resietance value.
L
fo
200 Ohm
probes between CU
F.S.
T
NO
Check setting and efficiency of mini­mum opening switch.
YES
i
Check wiring continuity between:
-
black wire on S6 switch connection
and ground;
-
white wire on S6 switch connection and CU connecter pin 15.
t
-i
NO
l
Restore wiring.
l
Insert connector
Check resistance
Fully dep
check a
10 Ohm
L
Ihi
rn~
meter probes between
oir
1
14 and ground.
thr
presence of an ilue. 1s
the accelerator and
‘rc
stance value
ES
lover
infinite
than
NO
Check setting and efficiency of maxi­mum opening switch.
YES
I
Check wiring continuity between wire on S6 switch connection and CU
connecter pin 14.
yellow
NO
-4
F
J
Restore wiring.
TEST No. 5
00-30
PA333500883300
Page 47
COMPLETE CAR
,s
r
,-
TEST No. 5 I CHECK ON ENGINE WATER TEMPERATURE
l
Set~multimeter
. Disconnect electronic CU
Check between pin 6 of CU
pendipg
as
pe,r curve.
to 20
KOhm F.S.
connecter.
connec-
on engine water temperature
NO
Check wiring continuity between:
-
electronic brown wire on S7 temperature
sensor;
-
G60 ground and black wire on S7
sensor
C,U
connecter pin 6 and
connection.
SENSOR
(CU PIN 8)
1
,,’
Replace S7
YES
I
sensor
TEST No. 6
PA333500883300
00-31
,'
May
1988
Page 48
8,
;
TEST No! 6 -
1’
INJECTOR
COMPLETE CAR
SYSTEM CHECKING
Check resistance vector
pin 3and terminal 87 of S12.a
relay.
Read
from~8 to
between CU con-
5 Ohm.
.
NO Disconnect qecfors
- connectors. Measure reslstance
,
single injecter.
14 and 18 Ohm.
Checkon singleconnectorsof injectors
WIRING
connected to
and the
that
SIDE,
that
terminal 87 of S12.a
other to
pin 3 of CU
removmg
on
termmal
Will result
one
I YES
of
JWO
connecter.
relevant
of
every
between
pins be
relay:
NO
-
I
NO
-
Replace faulty injectors.
Repairwiring fautt
May 198b
ES
Y
~
I
TEST No. 7
00-32
PA333500883300
Page 49
l
- Set multimeter to 20 V F.S.
l
~Electronic
nected.
-CU
ëonmector discon;
c
With ignition key on RUN position, check presence of + 12 V between
connecter pin 2 and ground.
L
II
J
NO
Check integrity of fuse No. 2. With ignition key in RUN position check
presence of + 12 V between S12.b main
relay shoe terminal 30 and ground.
Restore wiring between S12.b relay shoe terminal 30 and CU connecter pin 2.
m
Check presence of + 12 V between ter-
mina1
86 and S12.b relay shoe terminal
87.
7
1
I
Check wiring continuity between S12.b relay
groud G60. if necessary restore wiring.
With ignition keyin RUNposition,check
presance
pin 2. If necessary, restons wiring.
of +
shoe
12Von
terminal 85. and
1
OYES
1
G67 connection
NO
l
c
With ignition key in RUN position check presence of + 12 V between CU connecter pin 7 and ground.
YES
1
TEST No.
6
Restore wiring bëtween pins 2 and.7
of ECU connecter.
Check presence of
512.6 relay shoe
ground.~
Replace 512 relay.
I
+12
V between
terminaIL 67~ -and
IYES
7
I I
7
I
I
Check vehicle wiring (e.g. wiring tween G67 connection and
nection, between G99a connection and Gl fuse holder box, integrity of fuse
No. 7 and relevant supply from starting
l block.
Check presence of + 12 V between:
-m G67 connection pin 3 and ground.
G67 connection pin 4 and ground.
Ifnecessary
Check vehicle wirina between positive
battej
tion
rester;
and pin 3
and4
G99a con-
wiring.
NO
on G67 connec-
be-
Page 50
~
1,
TEST
With
probe.
N{.
8 - CilECK ON LAMBDA PROBE (CU PIN 13)
,,
Conmct
l Set multimeter to 20 V F.S.
presence
resistance
wiring side
startect
engine check the
:of
,12 V on preheatlng
termlnals
‘connecter
of Lambda
to CU.
,i
‘,,
COMPLETE CAR ~
NC
-
Check G4 (7.5 A) fuse integrity.
NO
-
Restore wiring retative to heating
resistance
- Disconriect connecter of Lambda probe.
-
Set multimeter to 200 Ohm FS.
-
Check heating resistance func-
tionality
tween 3
I
-
- Takemout
connactor (wiring
-
With’ ivehicle warmed up and
running check between connec-
-
key removed.
-
Disconnect CU connecter.
- Checkcontinuity
resistance preheating
maa,suring
Ohmland
Set multimeter to 2 V FS.
cap from Lambda probe
tion point of Lambda probe and
groubd~
for a voltage value
twee,n
30 mV and 1
‘,
sidesconnector pin 13 and lambda
probe oonnection point.
a value be-
20 Ohm.
YES
side).
mV.
between wiring
be-
NO
B
l
9
Replace Lambda probe group.
I
/
Replace Lambda probe.
NO
ti
Restore wiring.
l
1
END
OF
ELECTRIWELECTRONIC
TROUliLESHOOTING
~
If test tesults were positive, but fault
still
remains, try replacing in the
order: ~
-
CU!
-
Air fl+w
sensor.:
00-34
PA333500883300
Page 51
COMPLETE CAR
r
INJECTION -
for electronic injection 1.7
IGhiITION W’IRISNG l3IAGRA.M
engines
with catalytic convertor
only
?A3i35’00883300
1
i i
I fi
Ii
IIIII
May
1988
Page 52
COMPLETE CAR
~DIAGNOSTIC AND CORRECTIVE INTERVENTIONS
ON LE3.2 JETRONIC ~
INJECTION/IGNITION S’YSTEM
Procedures
for electronic injection 1.7
and diagrams
engines
without catalytic
converter
only
PA 42 790088330 1
00-3511
October 1988
Page 53
Page 54
THE
,ENGINE’DOES
*
Check the presence of voltage to spark plugs
.]I
Effect troubleshooting procedure on injection
NOT START
YES
PAd27900883301
00.3513
October 1988
Page 55
‘T,HE EN~INE ~TART wtTti BIFFICULT?
Effect
Check air su$plyI system for leaks In
tntake
ducts or.c(ogged
filter
and fuel
troubleshooting procedures on
~
~8
Check functiona’lity of extra air valve.
WITH COLD ENGINE
With hot engine, 3 mins. after ignition throttle extra air valve pipe and verify that RPMs at minimum diminish noti- Ceably.
, With cold engine, 2 mins. after ignition
throttle extra ‘air valve pipe and verify that RPMs at minimum diminish noti-
Replace
extra’air
valve.
NO
I
Y
With engine’running verify presence of
+ 12 V on
extra air valve.
connecter
l
on wiring slde of
l
YES
t
I
October
1988
00-3514
Check wiring
-
extra air valve and
-
extra air valve and fuel pump relay
S12a terminal 87b ,
continuity
between:
G60
ground;
PA 32 790088330
1~
Page 56
IRRkGULAR
IDLE RPM
EXCESSIVE FUEL CONSUMPTION’
Check for correct air flow through throttle body. Check that there are no leaks in the air intake
duc+
and that the air
tien
system and injection system.
filter is
YES
not clogged.
ANOMALIES IN ACCELERATION AND BURSTS JN RELEASING
Check correct fuel system pressure and
Effect troubleshooting procedures for igni-
shooting procedures for
lant temperature sensor and relative wirlng
procedures for injection system.
YES
Ckeck
electromtector trghtness.
1
YES
inlection
system.
Check that there are no leaks in the air inta-
_III
PA 32 790088330 1
October 1988
Page 57
COMPLETE CAR
/’
NOTE:
THIS
TROUBLESHOOTING MAINLY DEALS WITH THE
OF
TH~E SYSTEM
IF
AT.~THE CHEF!
NESS OF
~
END
MAIN
AIR
TROUBLESHOOTING PROCEDURE ~
FOR INJECTION SYSTEM ~
for electronic injection 1.7
AND
INTAKE DUCTS, ETC.
SENSORS
OF.
TESTS THE
MECHANICAL’ DEVICES
AND ACTUATORS
ANOMALY
engines
SHOULD REMAIN, IT WILL BE NECESSARY TO
SUCH AS VALVES, CYLINDERS,
without catalytic
ELECTRICALIELECTROikIC
ASSOCIATEb
converte;
TO IT. ~
COUbLINGS, TIGHT-
DIAGNOSIS
PA327900883301
00.3516
October 1988
Page 58
COMPLETE CAR
>’
TEST1
i-
No.1
‘,
/
Check fuel’ system pressure. .
Connect a pressure gauge to fuel cir&t.
-
Try~a
prolonged starting and check pressure presence between 2.8 bars and 32 bars.
NOTE:
~
The pu’mp,must turn for a few seconds
even, wjth
ning, position.
the key in the
CHECK OF FUEL PUMP CONTROL
-
NO
“MARCIA” run-
l-
During a starting, check + 12 V on fuel
l pump terminals.
Check fuel throttlings.
Check efficiency of pressure gauge.
‘ES
Replace fuel-pump.
YES
.
filter
and any possible
YES
.
YES
v
dUCt
_:,
NO
Check G4 Fuse (15 A)
I
YES
v
Check that negative terminal of pump is
at ground.
,
YES
v
i
.,
-
Remove key.
-
Disconnect connecter of injection ECU
-
Put at ground pin 12 of the same con-
nectar.
-
Rotate key to RUN position.
.
Check that relay
S12a
is energized.
-
YES
Check circuit downstream ,from. relay
S12a
up to ‘fuel pump, beginning from terminal 87b of the same relay, and the circuit of terminal 30 of the relay itself.
I
I
t--/
I
NO
Check that fuel pump
NO
v
/
i
Restore wiring.
Eliminate ground connections on 12 ECU connecter.
L
Replace relay
S12a.
Probable failure on ECU Go on with diagnosis.
Check electrical circuits consisting of:
_
terminal 85 of relay S12b and ground
i
ov
_
terminal 86 of relay S12b and ground
= 12v
w
rotates.
YES
4
1
Ohober
TEST Na. 2
1988
1
00.3517
NO
Restore wiring of terminals 85 and 86 of relay
S12a.
PA327900883301
Page 59
YEST
No. 2,
COMPLETE CAR
-
CHECKING OF GROUNDS (PIN 4 AND 5, OF CU)
Disconnect
Check
-
pin 4 of CU
-
pin 5 of CU connecter and ground.
TEST No.
!Injection
CU
conti@ity
petween:
c,onnector
3’
-
CHECK CONNECTION TO RPM
~,
Disconnect
Iljection
CU connecter.
connecter.
and ground;
Restore wiring between:
-
pin 4 of CU connecter and
-D- pin 5 of CU connecter and G60 ground:
Check also G60 grounds functionally.
SIGNAL’(CU
G60
ground;
PIN 1)
Check wiring contlnuity between pin 1 of
CU
connecter’
I
/EOll
and terminai 1 of ignition
‘ES
TEST No. 4
NO
w
Restore wiring.
I
PA327900883301
00=35/8
October 1988
Page 60
COMPLETE -CAR
TEST No. 4
Set multumeter to 200 Ohm FS.
-Fi
Key removed.
~ Dlsconnect injection electronic CU~ Dlsconnect injection electronic
j:
:
Insert
multimeter probes between CU
connecter pin 15 and ground.
Check the existante of a reslstance
vajlue~lower
Piess accelerator and check an infinl-
Itel
resistance value.
CHECK ON MIN. 81 MAX. THROTTLE
-
than 10 Ohm.
CU
1)
1
q?
Check setting and efficiency of
I
Chech wiring continuity between:
-
black
wire
and ground.
OPENING’SWITCH
mini-
YES
1
bn S6 swifch connection
(CU PIN 15 AND 14)
1
I
NO
.‘l
b Restore wlring.
I
Insert
multimeter probes between
connecter pin 14 and ground.
Check the resistance value.
1 Fully
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 WIRING SIDE, 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 sensor con.
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
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= 10 a= 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
UNIT REMOVAL AND IINSTALLATION
,’
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 vapour fllter
*
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
8 Suspension left strut
Exhaust
manlfolds
1988
10 Engine oil drain plug 11 Reverse light 12 Muffler central
*
13 Exhaust manifold-catalytic muffler fixing bolts
l 14 Catalytic muffler
15 Gear box differential oil drain plug 16 Constant velocity joint screws 17 Bracket screws supporting engine anti-shock supportlng bar 18 Exhaust manifold
(*)
For models with catalytic
OI-6
converter,
table
silencer
only
flange
nuts
PA327900883301
Page 78
ENGINE MAIN
~
r
MECHANICAL,,UNIT
g. Unsciew
0:
ber
and remove the two bolts
connectimng t’o
the left
the front cross
$rut @
.
mem-
h. Swing the front cross member
round
as shown in the illustration
allok the
drive unit to be taken
out
downwards.
i.
Unscrew fixiqg the to tbe
1.
Remove
supbort to
and remove the two screws
drivce
unit rear support
body.
boit
fixing engine central
body, unloosened at
0
step
12. m.
l!ower
column
uhit out from the engine
I’
‘1 ,,
:l
~
lift
and take the drive
comp,artment.
Ih$T;ALLATION
11.7 IIE w;ith
catalytic con-
v,erter
to
1 Rear support of gearbox
1
Boit
2 Central support
b. With referdnce to figure
01.6,
rotate
the front
complet@
with stabilizing bar in
at’
page
crossme,mber
moun-
ting position and fix it with bolt @
@
then
fully
strut and
0.
c. Tighten screws 4 fixing the
tighten bolts
0
engi-
to
@
2 Pin 3 Rear support securing screw 4 Bolt securing gearbox
h.
Insert
the
side
rear support
rod @ into support
on right side longitudinal member
@
first and
ne front support. d. Tighten !he foilowing
to !he
specified torque.
Tightening torques
0
* cro&nember
bar
bïacket to body
66,5 + 83,3
components
an6 stabilizing
N.m
(6,s + 8,5 kg.m)
1.
ereliminary
Operations
CAbTiON: Dribe
unit assembly must be
me:d
in
such
a way that the gfearboz
perfor-
rear support and the engine front sup­port are not respectively upwards and
longitudinally preloaded.
a.
Raise
the drive unit wi!h the column
lif{er used for disassembly until the
is ai
centre ,support the
halfway point of the body slot and
tighten the relevant
axis
0
boit
about
0.
PA327900883301
,
l
Screws fixing stabiliting bar
to
strut
14,7 i 23,5
(1,5 + 2,4 kg.m)
l
Screws connecting semishaft . differential shafts (in
oil)
33 + 36 N.m
(3,4
+
3,7 kg.m)
e. With remove
reference lift
to following figure
and loosen lower b&t
vant poitit fixing it to body
screwS 0.
g. Retighten lower nut
01-7
N.m
‘engine
and’tighten
@
@
1
Ri,ghl cylinder
2
Right side
3
Support
4
Side
rod (engine antishock bar)
5
Front screw
6
Rear screw
2.
Reinstallation
head
longitudinal member
of reverse light
table
and of exhaust pipe
a.
Reconnect the reverse light
table
gearbox switch.
b. Remount
verse order with respect
new gaskets between mainfolds and
engine
exhaust mainfolds in re-
to removal,
cylinder heads and between
mainfolds and catalytic muffler.
October 1988
to
Page 79
3.
Reassembty
Lower the auto lift and, with
Nto
figure on
~trical ‘cables’working
,to
that described under “Removal”
‘,step
11. ~ ~
of electrical
oage
01-4, reconnect
in reverse order
tables
reference
elec-
~
For fol!owing procedhes steps, refer
Gto
Figure
‘,4.
Reassembly of, clutch control
‘Refit
“ly
tighten it. ~
,5.
Reassembly of air intake manifold
;Refit
‘nifolds, fitting n~èw :ten securingi
Mind that the manifold~ serve
01-3.
hose ~@
to;clutch pump and ful-
inlet manifold
gaskets, then
nuts.
centr&nuts ontwo sides
@
also
to fix
hose
on intake
brackets
ma-
tigh-
of
ENGINE MAIN MECHANICAL
h.
Remount hood.
i. Remount the battery negative
termi-
nal.
1.
Operating inside the passenger
partment
refit the gear lever knob and
com-
rubber gaiters on the gear lever.
REMOVAL
1.7 IE without
During
engine is necessary to remove engine and gearbox-differential unit as a single unit. Put the vehicle on the auto lift and engage first gear.
WARNING: Great tare is required when operating on a hot engine.
catalytic,converter
removal
from the car, it
IdIT
l
Pipe@ from supply manifold @ .
l
Pipe@ , from throttle body and pi­pe
0
fro,m
pneumatic gauge on
ignition distributor
l
Pipe@ , from idle RPM setting fit-
0.
ting.
l
Pipe
8
, from supply manifold
l
Pipe
0
ply manifold
5.
Removal
of cooling circuit pipes
unscrewing
@
fitting,on syp-
@
Operate as described at Step 5 page
01-2.
6.
Removal
of fuel supply
hose
Operate as described at Step 6 page
01-2.
6.
Completio’n
of reassembly
a. Reconnect injectionlignition wiring in reverse
‘:der ,ib. Reponnect ti-ie~
‘lever ‘0
c. Reconnect
spectively to damper
‘order
to that described
“Removal” 1 Step 8.
accelerator
on thr,ottle’body.
hoses
‘@
and 8
Q0.and
table
pressu-
un-
to
re-
re gauge
d. Reconnect pipelines of engine ling system
pin
reverse ordxer to that
coo-
described under “Removal”’ - Step 5. e. Reconnect fuel vapour and air in pi-
pelines in ‘reverse order to that descri­bed under “Removal” - Step 4.
:f.
Reconnect
#,plugs and’
tables’
supplying spark
reinstall the ignition distri-
‘butor cap ~ 0 .
g.
Reinstall
flow
ve@
bed under
air
sensor i
filter caver
‘0
and corrugated
0
in reverse order to that descri-
“Removal’: -
Step 2.
, air
slee-
1. Preliminary operations
Operate as described at Step 1 page
o-2
For the following
procedure
steps
fer to Figure at page 01-9.
2. Air
filter,
air flow
sensor
and sleeve
removal
Operate as described at Step 2 page
01-2.
3.
Removal
of spark plugs supply
ca-
bles
Operate as described at Step 3 page
01-2.
4.
Removal
of air pipes
Disengage the following pipes, sconnecting them from stated
compo-
nents:
re,
di-
7.
Removal,
of accelerator control
ca-
ble
I
Operate as described at Step 7 page
01:2.
8.
Removal of: ignitionlinjection tables
a.
Unscrew two screws and remove lenoid starters b. Disconnect
@
from body.
connection @ bet-
ween ignitionlinjection wiring and
so-
ve­hicle wiring.
c. Disconnect
connecter @
from
throttle body’switch @ .
9.
IRemoval
of supply manifold
Operate as described at Step 9 page
01-2.
10.
Removal
of clutch control
hose
Operate as described at Step 10 page
01-2.
OI=8
PA32 790088330 1
Page 80
ENGINE MAIN
:MECHANICAL
UNIT
11.
Removal
Operatè as described at step 11 page
‘01-5 with reference to Fig. page 01-4.
12.
~Loosening
support
Operate as described at step 12 page
03-5.
For’following Figure at page
13.
:Oil
(if required, as a tion to be
scr/bed
14.‘Removal
a. Disconnect exhaust gas manifolds
from
screwk-rg
b.
Discqnnect exhaust pipe on vehicle
rear side unscrewing screw of
ting clip to final trunk of exhaust pipe and remove it from elastic support.
of electrical
nut of engine central
procedure
01-6.
drain’ing
function
carried out,
at step 13 page
of exhaust pipe.
right and left engine heads,
the relevant fixing nuts 18.
tables
steps refer to
of interven-
operate as
015).
connec-
de-
un-
INSTALLATION
1.7 IE without catalytic
1.
Preliminary operations
Operate as described at step 1’ page 01-7.
2. Reinstallation of reverse light table and of exhaust pipe.
a. Reconnect reverse light
gearbox switch. b. Remount exhaust manifold ting in reverse order to
new gaskets between manifolds and
engine heads.
3. Reassembly of electrical tables.
Lower the auto lift and, with reference to figure on page 01-4, reconnect
trical
tables
working in reverse order
to that described T “Removal” step 11.
For following,procedure steps, refer to Figure
07-3.
converter
table
removal,
to
opera-
with
elec-
6. Completion of reassembly
a.
R,econnect
in reverse order to that described der
!‘Removal”
b. Reconnect accelerator ver @ ON THROTTLE BODY. c. Reconnect spectively to damper re gauge
d.
Reconnect pipelines of engine ling system in reverse order to that
scribed
e. Reconnect plugs and reinstall ignition distributor
Cape 0
f.
Reinstall
flow ve
G9
bed under “‘Removal” step 2. g. Remount hood.
h.
Remount battery negative terminal.
i.
Operating inside the passenger
partment
rubber gaiters in the gear lever.
injectionlignition wiring
step 8.
table
hoses
8.
under “Removal” step 5.
tables
.
air
filter caver
sensor
0
and corrugated
in reverse order to that
refit the gear lever knob and
and @
@
and pressu-
@
supplying spark
0
to le-
coo-
, air
slee-
descri-
com-
REFILLING AND
ADJUSTEMENTS
un-
re-
de-
Removal
Disconnect reversing light
from gearbox switch.
16.~ moval’
Operate as ‘described at step 16 page
dl-~5.
of
,reversing
Mechanical disconnection and
of drive unit.
‘8
light table
table
11
re-
4. Reassembly of clutch control
Refit
hose @
ly tighten it.
5. Reassembly of air intake manifold
Refit inlet manifold @ on intake nifolds, fitting new gaskets, then ten securing nuts.
Mind that the central nuts on two des of manifold serve
0
to clutch pump and
also
fix
hose
ful-
ma-
tigii-
si-
brackets
a.
Refill
engine and gearbox­differential with type and quality of oil recommended.
WARNING:
Before refilling with
that the engine pump drain plug and
gearbox drain
back
on.
plug’have
oil,
make sure
been screwed
OI-811
October 1988
Page 81
Page 82
2
-2 2
8
0
!i
Outer
parts
1 Electroinjectors~ 2 Fuel supply manifold 3 Lifting brackets 4 Supply manifold 5 Fuel puise damper 6 Fuel pressure gauge 7 Intake manifolds 6 Supplementary air solenoid valve 9 Gasket
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 - alternatorpump belt 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
$j33%00883300
1
Main bearings
2
Woodroff key
3
Thrust half-ring
4
Oil
pump gear
5
Bush
6
Seal ring
7
R,ear
caver
Oil
vapour separatar filler inlet
8 9
Flywheel
10
Washer
11
Lock
ring
Pin
12
,Ol-11
13
Compression rings
14
Oil
scraper ring
15
Oil
pump
16’
Oil
sump
17
Engine
oil
16
Main bearing caps
19
Piston
20
Connecting rod
21:
Connecting rod bearings
Connectini rod cap
22
Crankshaft
23
drain
plug
T N.m
0
May
(k9.m)
1988
Page 85
PRELIMINARY
OPERi+TION,S
1.
Remove
#drive
unit from car
ac-
cording t8 procedures: Drive Unit
Removql An4
2.
Remove
and
clutcq uni?
to ‘proc&d,ures: Separation and
semblv, of the’ Units (sec: “WORKSHOP
MANUiL c-1’
Installation.
Qearbox - differential unit
from engine according
-
,’
Group O-l
).
As-
ENG$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
$iring
from engine
wiring
con-
tem-
sensor
1
Bracket
2
DalrIper
3 Fuel pressure 4
Intake
5
Bracker
6
Injecter
7 Fuel
,3.
Sequentially
parts:
-
Oil
filter @ &ing suitable
ner.
-
Dipstick @ for minimum pressure
-
Thermal switch @ from
cylinder
gauge
manifold
supply hose
remove’the followinb
check
head.
span-
right
4.
qlistributor.
(1) from cylinder heads.
(2) Loosen distributor @ securing nut @ and withdraw distributor from rear caver.
1
Ignition distributor
2
Distributbr securing nut
~
5. Remoue alternator. (1) Loosen securing bolts @ fixing alternator @ and remove drive (2) Remove bolts and take
Oil
tor (2).
(3) Unscrew screws @ and remove
bracket @ and @ .
Remoie
spark plugs and ignition
Unscrew and remove spark plugs
i
belt.
out alterna-
2; Reniove (1;) Unsciew
@
pressure gauge
(2)
ing
fuel
(3) Remove fuel it from (4)
fuel distribution manifold.
fixi,ng screws from bracket
supporting damper @ and
@
Uns,crew
screws (two per
side) fix-
bradkefs @ which support the
hose 0.
hose
disconnecting
fouy
Rehove
injectors
four injectors @, ex-
@.
tracting, them from thermal switches
May19i8,
1
Oilfilter 2 Pressure switch 3 Dipstick 4 Thermal switch
OI-12
,B :
Bolt ~
1
Alternator
2
Screws
3’
Bracket
4 5
Bracket
PA333500883300
‘,’
Page 86
“,
6. tem
~ ~
Flem&e
union.
ENGINE
sleeve and cooling sys-
MAIhI
‘MECHANICAL
‘,
‘8,
UNIf
T!
9.
P’ropeed
as per
(Alfa331
step 11 to end, but for step 21
from
“Re-
move Cylinder Heads”, which should
(1)L~o~enclampsfixingfollowingcool-
,ing s’ys’tem
-
-
-
(2)
hoses:
Hqse, @ connecting between
thermostat and union
Hose 0, connecting between
ihkrmostat’and
Hdse' ,@'
s$f a,nd
Rehove
union
connecting
right manifold.
hose @ and @ .
‘0
@ thermo-
1
Union
2 Screws
be modified as follows: (1)
Unscrew the six screws @ which
secure
cylinder (2) Remove heads shaft Supports and the gaskets on
headsto,
‘along
engine block.
with
cam-
en-
gine bldck.
7. Remove thermostat.
Remove screw @ fixing thermostat
@
on cylinder block and remove it.
1
Screws securing heads and camshafi
ports:to
engine block
~
CYLINDER
Procedure
HEADS
is as per
[=33)
taking
sup-
into account that camshaft supports have no caver. Therefore, on head supports disassembly, recover the
oil
still present in the supports.
8,
1
Ho’se &necting
2 Un~ion 3 H+e connecting thermostat-union 4 Thermostat
5
Hose
connecting thermostat - right
!Ol’d
thermostat-union
mani-
1 Screw 2 Thermostat
8. Remove intake manifolds (1) Unscrew
each
intake manifold and remove
all,
three nuts securing
them from heads with relevant gaskets. (2) If necessary, remove water tem- perature transmitters from
hanifolds.
(3) If necessary, working on bench,
(3)
$nscrew
‘..
fixing union m@ on cylinder block,
the,n
and take
;reniove union.
out
screws
@
unscrew the two fixing screws and remove valve from right manifold.
supplementary,
iniake
air solenoid
p.2.0226
1 Camehafl
2 Cylinder head
support
PA3!3500883300
cil-13
May
1988
I
Page 87
~
,’
l ‘,
ENG!NE
MAIN MECiiANICAL
UNIT’ ;
8’
These procedures are for electronic injection 1.7
WARNING~
,Procedures-described
are
stik ,valid(
‘lows.
~
,For technfcal
engtne,
data of 1.7 injection
please refer to “Service
for
(Alfa]
except for what fol-
Data and Specificattons”.
18
These
1’
procedures
WARNING !,
~
Procedures
’L~ are
here
described for
still~ valid
beloW,.
IAlfa33)
‘but ‘for what stated
~ For technical data of 1.7 injection engine, please refer to “Service
Data’
and
~Specifications”.
WARNIhGS
Lubricate,
1.
ings and
sembly.’
2.
lock
3.
slipbing
surfaces before as-
~ ~
Use new gaskets, seal rings and
rings!.
Scred’
sprews’ and
:.
‘with ensine
nuts
oil
to speci-
fied tightening torque.
4.
Apply:
specified sealant to
ponents, likted
.
Oil sump, block side
Mastics
DOvV C,GRNING
here below.
rclass:
3522-00040
Silastick 732
RTV ~
.
Watar tubes,.plugs, caps,
heads and block.
Mast,ic class 3524-00011
Loctite 601
Before applying ‘sealants eliminate
any
possible trace of old sealants by
degreasing the surfaces.
(green)
cylinder
CHECKS AND INSPECTIONS
engines
,l
with CatalYtiC
cup is
CYLINDER HEADS
etching, or unusual wear.
AND VALVES
2.
As per
(A-33)
except
on which cams work is free of unusual wear.
CUPS
1. Check that outside surface of
ENGINE ASSEMBLi(
are for electronic injection 1.7
-
Lubricate thoroughly before inserting them into shaft support @ seats.
-
On reassembly of camshaft sup­port on head, make sure the cam- shaft is in rest position (no cam engaged; valves
-
Secure
camshaft support to head
bear-
with gasket the four nuts in crosswise order to the
temporay
$
: Temporarytightening, torque
between
Nuts securing camshaft sup­ports to cylinder head
+ 115 N:.
+
1.5 Kg.m)
-
com-
Before fitting rear caver port, insert 0.10 + 0.15 I engine
oil
into support’ itself.
engines vvith
cups @
cam-
closed).
tightening
torque specified.
m
onto
sup-
catalytic
ENGINE, UNIT
As per
mentioned
l Step 15.
(1) Turn crankshaft No. 1 Center in the explosion. stroke; this correct positioning is further ensured
by
the matching with the rear caver
CO~ve~or CnlY
free,
of any trace of sizing,
Check fhat the
convertor
(Alfa]
cups Upper
only
but modifying the
iteps.
Install cylinder heads
till
cyltnder, is set!
“T’“~
notch @ on the flywheel
at
reference @
0.
plane
the piston in
Top’ Dead
on the
CYLIN~I~R
Operate
per
c-33)
the
following:
HEAD
as
taking into
stated
account
1 Camshaft
2 Hydraulic tappets cup
Ol-,14
1
‘7”
2
Reference
3
Cylinder
notch
block
rear
caver
PA333500883300
Page 88
(2) Set the camshaft in rest position (no
ca”
engaged; valves
(3)
F,it the~cylinder
shaft
sipport
and
~ifis&the appropriat’e
on the cylinder
closed).
heads with
gasket.
crank-
,block,
8’
~
ENGINE MAIN MECHANICAL U~NIT
‘,
Proceed
as
‘per (Alfa]
from
Step;(t).
l
Step
18.
‘Installé
timing belts.
(1)
Fit~
camshaft drive pulleys and
tighttin ‘he’
torque being caeeful, at the same time, to
toothecj
$
:
retaining screw to specified
stbp~ ptlley
Tightening
rotation by
spanner
A.5.0195.
torque
tieans
of
Camshaft pulley retaining
scr3v.
+
70
~ 83 ~
(6.4
‘8
(2)
Vdrify that the crankshaft’s
lar
$ositiM co’rresponds
Dead @enter
explb<ion stroke (alignment between
notch
;‘T”
on flywheel and rear caver
refererce mark).
(3)
R;!ate
wise
(,seen
order io
backwarc(s’so
ing
rotati&.
(4)
the topth and the two adjacent milled
groovys of the left timing pulley are visibleithrough
rear
tiove
again?
~
,Pysifion
gIuard 0,
N.m
+
7.1
Kg.m)
anqu-
to the Top
of cylinder No. 1, in the
crankshati
from rear side) by
piston of cylinder No. 2
a,s
to prevent valves
piston
the left camshaft SO that
the appropriate hole on
counterclock-
during
45O
strik-
camshaft
in
2
b
1
Timing
belt
rear
2 Left timing pulley
(5) Realign notch with the fixed reference mark (piston of cylinder No. 1 ‘at T.D.C. in the
plosion stroke) and, keeping shafts in
this position, fit the left
pulleys.
The belt ging
side,
qover
“T”
on flywheel ~
,ex-
timihg
belt cinto
shall
be fitted with its
drag-
opposed to straighteners,
under tension.
(6) Loosen the nut securing the belt straightener SO that it spring load on the belt. (7)
Rotate the crankshati
piston of cylinder No. 1 as to prevent valves striking against
piston itself when positioning the
shaft.
(6) Position the right-hand camshaft
SO that the
milled grooves of right-hand pulley are
ate hole
the crankshaft back in the position, dicated in Step (2) and fit the timing
belt
toot,h
and the two adjacent
visiblesthrough
on rear guard 0; then bring
onto
pulleys.
cari exert~the
45O
to move
backwards#so
cam-
tiniing
the
appropri-
CAUTION: Pulley tends to to correct interacts cylinder No. 3. For appropriate er to keep the pulley in position for
rotate
with respect
position sincb
With
the intake
thisreason,
wrench
A.5.0195 in
belt installatic@.
camshaft
&lve
of
use
ord-
the--correct
in-
1
Timing
belt
2 Right-hand timing pulley
(9) Verify that distance “S” between
timing belt and contour of engine front
support is not less than the minimum value prescribed.
rear guard
Minimum distance “S” between
timing belt and engine front
support:
9 mm
(11)
Rotate
crankshaft in jhe function-
ing-direction SO as to permit belts to
assume their final position. (12) Rqtate crankshaft until piston of cylinder No. 1 plosion stroke. (Notch “T” on flywheel
alignerj with reference mark). Then,
further’rotate the crankshaft counter-
clockw’ise (seen
notch v on flywheel is aligned with the
reference mark (right-hand camshaft
in rest position, no cam engaged).
‘is
at its T.D.C. in the ex-
from rear side) until
l
PA3d3500883300
May
1988
Page 89
!
(13) Loosen the nut of right-hand belt
straighten~er,,
then tighten it to the
prescribed torque,
ENGINE MAIN MECHANICAL UNIT,
1
Cooling
fluid
pump
2 Screws
pulley
;’
~
: Tightening torque
: . Water temperature sender
(for temperature gauge)
+
41
N.m
+ 4.2 Kg.m)
y:4
. Water temperature sender
(for injection CU). Max
torque
15N.m
(1.5 Kg.m)
(3) Fix thermal contact on right head, tightening screwto specified torque.
CAUTIOk
,’
Dr$ing
~
~this
operation, do not press
the belt’straightener to prevent alter-
‘i’
ing the
straightener
$
~load,
envisaged for belt
~itself.
: Tightening, torque
Nut securing belt straightener (on
cold
engine)
+B 46’N.m
37
(3.d
‘1
(14)
Starting~
responding to notch V on flywheel,
~ 1’
tate the, crankshaft
~
lutton
in the counterclockwise direc-
tion
(seen
4.7 Kg.m)
f
from the position cor-
one
complete revo-
from rear
side)
until notch
ro-
V is realigned with the reference mark
~
(left-hand ca’mshaft in rest position; no
~ cam engaged).
(15) Repeat Step
(13)
for the left-hand belt stnaightener. (16) At the end of operations, recheck
’‘,the correspondence of timing refer-
ence
marks on pulleys with the
ap-
propriate holes on timing belts rear guards
:and
with notch
“T”
on
flywheel,i aligned with the reference
mark. ~
23. Screw switch to signal minimum ure, tightening it to specified torque. ~
: Tightening torque
@J
24 Fit intake (1) If
you
supplementary air solenoid valve on right intake manifold. (2)
Insert
with new gaskets on stud of two heads, then fix them with associated nuts.
@
: Tightening torque
onto block,
Pressure switch
+
41
33 (3.4
Nuts securing intake
4.2 Kg.m)
i’
manifold.
previously removed it, fit
intake manifolds
pressure
oil
N.m
‘,
com$ete
press-
manifolds
24 N-m
+ 2.4 Kg.m)
25. Fit the union, temperature ders, thermal switch and thermostat! (1) Fit union on
scyews on intake manifolds.
block,
tightening
sen-
8 .:
Tightening torque
Thermal contact screw on right head
+ 41 N-m
33
+ 4.2 Kg.m)
(3:4
(4)
Connect
thermostat to right intake manifold through sleeve, then fix ther­mostat on engine
,26.
Refit hoses of cooling system.
‘Mount
sleeve @ connecting ther-
;mostat @ ~0 ‘left
to union @ and sleeve
which connects thermbstat @ to
intake,
manifold 0; tighten all
block.
screws of isleeve screwing clamps.
2
/-o
‘~
fr0ceed~a.s per [Alfa]
20 inciuded, then complete
bly
oper&ng
as stated
~
21.
Fit:
front plastic
belts.
~
22.
Mo&t
pulley @ on
and
tighkn
it with screws
May 1988
up to Step
below.
covers
reassem-
of timing
pump hub
0.
: Tightening torque
@J
Union kecuiing screws
24
N.m
+
2.4 Kg.m)
(2) Fit water temperature senders on intalte manifolds.
01-16
1
Hose
2 Left intake manifold 3 Union 4
Hose
5 Thermostat
PA333500883300
Page 90
~
27. Fitloil filter by manually tightening it and insert dipstick.
,
28. Bi
means
‘ner
fit
‘cording
$
:
Tightening
of a suitable box
Fpark
plugs tightening them
t9 specified torque.
torque
span-
ac-
Spark plugs:
i5
+
34
N.m
~ (2.5 + 3.5
829. Fii
alternator and control belt.
‘(1)
Fecure bracket @ and @ to en-
gin?
fiont
caver and tighten the two
relevant screvis
(2)
‘POsition
ports &d tighten bolts @ without
locking them. (3)
K&y
drive belt on relevant pulleys.
alternator on engine
alternator and water pump
Kg.m)
0. sup-
fully
ENGINE MAIN MECHANICAL UNiT
(4) Adjust belt tension according to specified value and then lock bolts
Load: 8 Kg Arrow: 15 mm
1 Bolts 2 Alternator 3 Screws
4 Bracket 5 Bracket
30.
,Retiount
manifolds, replacing relevant O-rings, and fix
31. Position injection wiring on engine and reconnect it to stated nents:
-
supplementary air solenoid valve
-
power module on distributbr
-
engine water temperature
-
injectors.
32.
Fil1
gine
oil
AGIP Sint 2000 SAE
IP
Sintiax SAE
SHEEL
injectors on intake
lfuel
manifold.
compo-
sensor
the engine with specified en-
and with specified quantity.
lOW/40
iOW/40
Super Plus
Motor Oil
SAE
15Wl50
Oil
quantity
required for complete
lrefill
(sump,
oil
filter
channels):
4.1 litre
and
QI-17
May 1988
Page 91
1200f
1350
1500
Features
Cycle
L
Numbers of cylinders and arrangement
Otto 4 stroke
4
horizontally
opposad
1700
305.58
305.58
A
Cylinder identification
Bore - Stroke Displacement
Combustion chamber
Compression
Power DIN
Max
Torque
DIN
Piston
~mean
Cylinder compression (2)
ratio
speed
volume
Max Specific
(1)
kPa
(bar; Kglcm’) Min. pressure Max difference in pression between cylinders
Dil pressura (3)
(1)
At max power output rpm.
(2)
Values to be read in these conditions:
-
engine at operating temperature
-
fully opened throttles
-
engine cranked by starter
kPa
(bar);
-
min on idle
-
min on max
-
max on
kg/cm*)
r.p.m.
r.p.m.
idle r.p.m.
motor,
mm
cm3
cm3
kW (HP)
N.m (Kg.m)
mis
sparking
80x 59
80 x
1186
37
9
50 (68)
42 (57.3)
at 6000
80
r.p:m.
43
at 6000 r.p.m.
111
at 3200 r.p.rir. at 3600 r.p.m.
1
1.8
117.68 + 274.60
411.89 +
(3)
(“)
(4
plugs
removed
Laft
head
672
1351
80 x 67.2
1351
42,2 39.7
84 x 67,2
1490
44
93
58 (79) 63 (86)
(58,4)
(1?,3)
47 (64)
at
6800 r.p.ni.
119
(12.1)~
at 4000
13,4
r.p:m.~
at 66Oq
133 (13.6)
at 4000 r.p,m.
13
1029.6 (10,3;
77 (105)
51 (70)
r.p.ti.
10,5)
98 (0,98; 1)
l
(1,18 +
2,75;
1,2 + 2,8)
568,81
(4.12 + 5.69; 4,2 +
5,8)
_
Values to be Not marketed in
read
at engine operating temperature
all
countries
(oil
at
For countries where antipollution regulations are in force.
/
Right head
87x72
1712
49.5
86,7 (118)
50,6
(69,8)
at 6800 r.p.m.
148 (15)
3600 r:p.m:at
90% = 194oF)
87x72
1712
49,5
~9
79 (110) 77 (105)
46 (64) 44,9 (61.3)
at 6800
at 4600
148
r.p.ti.
at 6600 r.p.m.
(15,4)
145
r.p.ni.
at 4600 r.p.m.
14,4
196 (1,96; 2) 441 (4,41; 4,5) 490 (4,90; 5.0)
(15,2)
Page 92
ENGINE
MAIN
MECHANICAL UNIT ~’
<--,;,
INSPEOTIdN AND ADJUSTMENT
CAMSHAFT SYSTEM
.-.
LEFT SUPPORT
Camshaft
Inta
ke
Tap~e!
clearance
Value~of
timing marks
on camshaft supports
*
‘voté
marketed in
AllIvaIlues are with engine
~
all
countries
cold
Exhaust
Right support
Left support
Single carburetor engines
1200 * 3g5.85
545.766
1350 1350
305.86
Unit: mm (in)
Double carburetor engines
1500
305.87 305.88
546.232
035 + 0,40
0.45 + 0.50 ~
23O
23O
I
1’
Rear
guard for right - hand timing belt
i’
Camshaft
Tappet clearance
Camshafi pulley alignment reference position (with T-shaped notoh on
#flywheel
alignad with the reference mark on engine
rear~cover, explpsion ,stroke).
A ‘For countries where antipollution regulations are in force
(:) ~ Engine with hydraulic tappets (with take-up of
(‘T) Tooth with
(*
l
with the piston of cylinder No. 1 at T.D.C., in the
8,
‘)
~ Tooth with
two - ..,red two
grooves on right-hand camshafi pulley, in correspondence with the
milled grooves on the left-hand camshaft pulley in correspondence with
2
slack)
T-shaped notch
Intake
Exhaust
right-hand pulley
left-hand pulley
,on
flywheel
r
Double ~
carburetors engines
‘8
1’
1700
~ 305.50 ~
‘580.429
,’
‘;
8,
related hole
;the
related
3
Rear guard for left - hand timing belt
I
Electronic injection angines
)
1700
~ 305.58
581.191
0
(Y
0 r?
(**)
(***)
on rear guard @ of timing pulley.
hole
on rear guard @ of timing pulley.
Unit: mm (in)
1700
305.58
a
549.315
May
1988
Page 93
n
For countries
(0) Crankshafl (*) Not
marketed
where
in
all
antipollution
countries.
rotation ACW
seen
regulations
from
m
are in force
flywheel side.
Page 94
CYliItjDkR BLOCK
ENGINE MAIN MECHANICAL
QNI,T
~
Inspection
i ,,
‘,S
C$n,der
;bore “a”
‘1
Out-etsquare between cylinder bore centreline and benfreline
Taper and
Cylindei bore surface roughness
Cylinder bore grinding angle
i;
of main bearings
out-of-round
limit
data
Oversize
(0) Area
for dimension check
Glass A Class B Class C
Glass D Glass
E
1st 2nd 3rd
Standard
Max
1200*-1350
305.85186187
80,00+80,01
80.01
+60.02
60.02 t80,03
80.03
C80.04
80,04+80,05
80,20 +
80.21
80,40 + 80,41
80,60 + 80,61
Engines
305.8%
84,00 f 84.01
84.01 + 84.02
84,02 + 84,03
84.03
84,04 t 84,05
84,20 + 84,21 84,40 f 84,41 84,60 i 84,61
(0,541) ’
goo+
63,663
1500
G84.04
0,05
0.01
0,02
1200
+63,673
10-Z
Unit: mm
1700
305.50-305.58
87,000 + 87,010 87,010 f 87,020
87,020 i 87,030
87,030 + 87,040 87,040 f 87,050
87,200 f 87,210
,87,400 f
87,410
87,600 + 87,610
width
of rear main bearing support
(*)
,Nbt
marketed in all countries.
~ PA333500883300
63,673 f 63,683
23.68 i
‘Y
-
i3,73
May
1988
Page 95
Unit: mm (in)
ENGINES
‘L
Inspection data
C!as$
A (Blue) Class B (Pink)
Glass
Standard
Oversize
First compression ring groove height
Second compression ring groove height
“c”
“d”
C (Green) Class D
(Yellow)
Class E (White)
I
1st
2nd 3rd
1200-1350
305.85 (1)
305.86 (2-3)
305.87 (2-3)
79,960+79,970 79,970+79,980 79,980+79,990
79,990 + 80,000
80,QOO + 80,010
!
80i154
+ 80,170 80,354 + 80,370 80,554 t-80.570
83,960+83,970
83.970i83,980 83,980f83,990
83.990+84,000 84,000f84,010
84,154+84,170 84,354f84,370 84,554 + 84,570
1,525 ~+ 1,545
1,775 ; 1,795
1500
305.88 (3-4)
Pistone Borgo 86,960 + 86,970 86,970 + 86,980 86,980 + 86,990 86,990 + 87,000
87,909
87,150 + 87,170 87,350+ 87,370 87,550 + 87,570
1,515
305.50 (5-6)
305.58 (5-6)
+ 87,010
+~1,535
1700
L
Pistone Mondial
86,950
t
86,960
86,960
+
86,970 86,980
86,990
87,144~+
87,344 + 87,360 87,544 + 87,560
1
86,970
+
86;980 + 86,990 +
87,000
87,160
1,535 f 1,555
1,775 + 1,795
86,950+86,960 86,960+86,970 86,970+96,980
86,980+86,990
86,990f87,000
87.144t87.160
87,344 t 87,360 87,544 f 87,560
1,535 t 1,555
1700 A
305.58 (6)
Oil
scraper~ring groove
Pin-Seat
A For countries vvhere antipollution
(1) H = 7.6 mm
(2)
(3) H = 16.5 mm BORGO (4) H = 15.5 mm
2 c.2 0
(5) H q 6,0 mm (6) H = 13.9 mm MONDIAL
bore
H=11,7mm
“b”
height
~MONDIAL
” ”
‘le”
regulations
Piston
. .
” .,
,, ”
are in force
fILO?
+ 4,035
3,015 + 3,035
21,004 + 21,008
Page 96
Unit: mm (in)
Inspection data
Ring thickness “b”
Ring gap “a” (1)
(1) TO be measured inside the cylinder
(?)
Borgo ring
(3.l
Gostze ring
Not marketed in
(‘)
all
countries
I
1200 *
305.85 305.86 - 305.87 305.88 305.50-305-305.58
First compression ring 1,478
Second compression ring
Oil scraper ring
First compression ring 0,30++
Second compression ring,
Oil scraper ring
Limit
gap for
each
ring
b6iëm6r
inside a ring gauge
I
0.45 0.30 045
0,30+0,45 0,30+0,45
0,25t
0,40
Engines
1350 1500
~1,490
1,728 + 1,740 1,728 + 1,740
3,978 f 3,990
1
0,30+0,50
0.30+0,50
0,25+0,40
0.25+0,50
(2) (3)
(2) (3)
(2) (3)
I
1700
1,478 + 1,490
2,978 + 2,990
0,30+0.50
0,30
f
0,50
+
0,25 0,50
Page 97
8,
m,‘,
(
i, ,’ fi ,.,
‘i
,l
~ ~
~
‘ENGINE MAIN MECHANICAL
~
UNIT
l
~
‘1
hpac?ion
8’
1, ~
data
,’
Pin
diarndter
Pin-piston
‘1
slack
“a”
Unit: mm (in)
I
1200
305.85
*
1350
305.86 - 305.87
Engines
20,996’+
o,oo$
21,000
+
0,12
1500
305.88
305.50
1700
-
305.58
Mai
1988
OI-24
PA333500883ilOO
Page 98
ENGINE
MAIN MECHANICAL~,
UNI-r
COh$ECTlNG
Connecting
.,
ROD AND CONNECTING ROD
‘i,
rod (1)
Inspection data
Small end bush bore diameter “a”
~
F$end
bore diametar “b”
Connpc$ng
rod bearings
‘BEARINGS
1200*
305.85
1350
305.86/87
21,007+21;015
52,696 + ,53.708
Engines
Unit: mm (in)
1500
305.88
l
1700
305.50/58
Unit: mm (in)
1st
2nd 3rd 4th
T
ones
(Std No. 542 128)
1,956+ 1,962
+:2,089
2,083 2,210
+‘2,216
2,337+ 2,343
l
Inspection data
Standard
Conneqting,
thickness
i
(1)
If thd connecting rods are completely
If the connecting rods are partially
(*)
~
Net
l l
marketed in
rod bearing
“a”
all
countries
removed.
replaced
O\iersize
usa post-modificatin
it is
still
possible to mount pre-mobification’ones (Std. No. 535.022)
.-
PA33@5!0883300
OI-25
May
1988
Page 99
~
,‘,’
FLYWHEEL
‘8
ENGINE MAIN’
MECHANICAL
18
UNIT
l
1’
Inspection’dete
Parall,elism bof
with
‘a
108 mm (3.94 in) radius)
the’driven
plete.contact
flywheel-to-cranksheft
support face (as
Maximum outof-flat of driven plate contact face
3urfece~roughness
(1)
im
~
~
The quamtity of material removed bv grinding dimension “b”,
fece
of driven plate contact face
of the register for the clutch
lit-oit.
(“1
No! marketed
in
all countries
face
caver,
1200 *
305.85
305.86/87
,”
8,
~ ,’
compared
read
et
must be
the
seme
both on clutch driven plate contact
SO
that dimension “a” is kept constant., Dimension
Unit: m (in)
Engine
1350 a 500 1700
~ 24,0 + 24.2
>
20.95
305.88
G
0.2
305.50/58
OS@
0.02 ~
2.10-3
fece
and on the
“c”
must not be
lowerthan
the specified
l l
,Myy
_
1988
,
OI-26
PA333500883300
Page 100
~ ~
?’
CRA$lKSHAFT,
~
Cranlishaft
ENGINE MAIN
THRUST RINGS AND MAIN
1 Flywheel
2 Gear tooth beginning
Inspection date
Standard
MECvANICALs UNI$
BEARINGS
locating dowel
line
1200
*
305.85
305.86187 305.88
Eng/ne
1’350
59,944 + 59,957
1500
Out of. round
Taper
Unit: mm
1700
305.50/58
X - Y
A-B
(in)
ye,in jpurnal
‘8
Crank;pin
1’
Rd&
Fillet tadii “r”
Length of fillet radli portions
Ly”th
&rface
X-;V &ality A-p of main’ journals and crankpins
diameter
diameter “e”
main jciurnel
of
parallel
roughness of main journals and crankpin
and limit for taper
“d”
length “c”
portion “a”
Undersize
Standard
Unders’ize
Standard Oversize Front and
journals
Rear main journal Crank pins
;Front main
‘If”’
Central main journal
Rear main journal
I
centre1
joucnals
lst*
2nd 3rd
4th
Blue Red
1st
2nd 3rd 4th
main
~ ~
,i
49,984 ‘: 49,992
28,764 + 28,804
59,690+59,703 59,436f59,449 59,182+59,195 58,928+58,941
49,992 4 50,000
49,733d 49,479
49,225 + 49,238
48.971 +
49,746
$49.492
48,984
28.51 + 28.55
1,8?2
1,5+1,7
2.8 ~+ 3
.i
2,ll 7
2.81
24.05 % 24.15
24.22 + 24,32
0.16. 103
O,qOS
o.o;
(1)
MAX.
error of parallelism between crankpins
m,,
Max.
(“J
No/ marketed
misalignment
among main
in
all countries
journsls
and,main journal6
PI-27
0,015
0.02
0.25
May
1988
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