Alfa Romeo Workshop Manual, Manual Supplement Alfa Romeo Workshop Manual

models

@iSl

MANUAL SUPPLEMENT

ASSISTENZA TECNICA

PA333500883300

Lj%-@j.

May

1988

Instructions for the insertion of the technical data in the binders

When inserting the updating pages in the

I_Alfa33)

VOLUME Ii binder, it is advisable to proceed as shown

in the diagram below and to follow the order indicated.

CONTENTS

INTRODUCTION

(Elue tard)

VOLUME

I

L

PA

3279OOOOOOOO

VOLUME II

-

i,

LIST

r

R43279000004X4

I

PA3279000BR4X4 PA327900000BRK) PA3279000000AC

\

.:.

(with updating

(with updating list)

PA3279OOOOS

PA327900883300

WOO

list)

De tailed contents:

PA32790000004X4 PA3279000BR4X4 PA3279OOOOOBRK

PA3279OOOOOOAC PA3279OOOOTDOO

PA327900003300

PA3279OOOOSWOO

PA327900883300

“iorkshop

“Workshop Manual “Workshop

‘*installation Instructions “Workshop Manual “Workshop Manual- models

“Workshop Manual models

Manual

Mamal c-33)

(Alfa]

r-33)

[Alfa)

air

f=E& cj{

1.6

3ImEl”

s,pma

-x4]

lm]

giardinetia”

-ml”

m

giardinettaH

conditioner”

wagam

NOTE: For correct interpretation of the issue number, refer to the following code figures:

PA

Ixlx]vlvl

Updating progressive number (N

Models group

according

I

~0, 1,

2 .

..)

code distinouishing

variow

sa:

PA333500883300

binder,

anuals

in the

May

1988

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

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

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

[GR.1

[GR:l

May

1988

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

00-13 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

GENERAL VIEW

i

October 1988

l

-

I

00-2

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)

I

h-4

(mm)

(mm) (kg) I-~

(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

1395

355

1100

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

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

\

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

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

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

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)

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

;

II

d

II 2

-

0

2

+I

a

fl

i

II

CL

0

II

e

?

tl

II

+

-

z tl

Eu

II

>

-

PA3335OOpOS

WO

MAY

1

00-5

1988

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

;;;;NX;;, (

l

905A30

05410692

~

A

ENGINES

I

1.7

IE

5

door

I

908.150. / 905.180.

905A3D

-

33

I

saloon

I I

l

-

1.7

I

/

*

-

ENGINE WITH

TURBO COMPRESSOR

33 7.8

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”

-

COMPLETE CAR

MAINTENANCE SCHEDULE

The following schedule is valid for the Italian market only

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

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

-

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

/

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

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

refuelling

-

20

~10

X

30

40

-5c

-

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

performed

80 90

X

every

Km/1000

X

12 months

-

13(

-

X

I I

X

l I

I I

l I

I I

X

Notes

l

(4)

hillv roads

170

18(

1

.

190 200

-rl

X

+t-

X

-PL--

X

IXI

X

-k-l---

X

%-t---

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

.

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

-

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

-

May 1988

oo-7/1

u m

m

2

0

3

s" t

v1 I

Li

r

5

'ü

m

-0 k

Y

E

6

-

z

PA333500883300

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

I I l

I I I

X

XX

X

XX XX

X X

X X X X X

X

XX

X X

XX

X

XX XX

X

XX XX

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

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

Il

$l

or on

in

X

hilly

any

X

performed

X

VI

X

roads

case

every

X

il

X

12 months

X

8

X X

X

F

X

Il

I I I I

X

(4)

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

32

X

-

XX

X

-

regul,ations

9

7

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

u w

COMPLETE CAR

.u

x Ix

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

-

L

X

-

X

-

X

-

X

-

X

-

X

-

X

-

X

-

X

-

X

-

x ~

-

X

-

X

-

X

-

X

-

X

-

X

X X

X

1

May 1988

PA333500883300

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

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

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

14

1x1

I

i

lx1

xIxI x Ix1

--lTrl-

x

X

ti

x x

October 1986

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

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

converter)

(condition

I

I I

X

x

x x x ‘X

X X X

x x x x x

I

IxIxIxl’x

/XI

X

lx1

‘X 1

X

x

xl

Note

140 160

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

x x

ihen

case every

case every 2 years

1,2

months

drivlng particular in stress

October 1988

oo=s 0/2

PA327900883301

P

NEW IDENTIFICATION LABEL

/@@&

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

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

905AlO 905A20

LEFT

905Al

H

905AZV

/

905AZT

05.455.737

30566 30567

:

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

MO~DEL

VARIATIONS

8 0

zî

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

905A3

1

WITH ELECTRONIC FUEL INJECTION

33 1.7

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

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”

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

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

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

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

-.

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

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

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

COMPLETE CAR

If notwithinspecifiedvalueorincaseof’ engine overhauling or after having cleaned or

replaced the

involving mixture meteringscrew and requised. In this instance, proceed as

follows:

,(

1)

metering, screw a and from tle valve (2) Tighte~n idling screw @

,way’.

(3)

screw @

screw@ till

present: ~

throjtle

RemoJe

sctew 0.

,Now

tune

up after engine;

carburetor, an adjustment

valve screw 3 is

seals from mixture

act on

‘and

on mixture metering

following conditions are

C!il

throt-

all

throttle valve

the

Mm

750 + boa

CO%

0.5,+

1% total

Double carburetor models

Check idling-rpm, CO% on each cylinder

1

throttle valves as follows:

Before beginning this test

accelerator

to: Group 04 - Accelerator

Adjustment)

and line-up of carburetor

check

table

adjustment ‘1 Refer

Gable

misalignment (40 mm Hg) between cylinders of the

Will

be necessary to replace the

carburetor.

4. Make sure that functioning correctly by grounding spark plug at a time and checking that theincreaseinr.p.m. isidenticalforeach

cylinder.

~

same

carburetor then

all

cylinders are

one

it

(4)

Loosen

screw OI idling speed i$ reached.

(5) Act

screw @ engine running is obtained, while keeping C$I% within the prescribed values. ~

(6) Fit

metering ànd’ throttle valve screw seals.

(7) If further optimizing of idle-rpm

is desired, jus? act on relevant idling

adjusting,screw @

1

2

Idling adjusting screw

3 Throttle

back

Idling mixture me’tering screw

valve adjusting screw

idling

ti,ll

a

900

don

mixture metering

till

the smoothest possible

~ % CO

into place mixture

.

adjusting

+ 1000

,,

0,5 +

1

rpni

1.

Insert

the tube of the

vacuometer in the appropriate fittings.

2. Starttheengineandrunittonormal running temperature SO that the

temperature 45oc.

3 With the gear shift in neutral,

the

check

manometers

Correctanydifferencesbetweenleftand

right carburetors by acting on the throttle valve screws. Should there be

is equal to or greater than

mercury

vacuometer valve and

that‘ the Ap values of the

fall

within 40mm Hg.

mercury

open

1

Electronic rev counter

2

CO tester

If necessary ing screw of the until correct functioning is obtained.

5. Adjust the engine speed to 850 1000 r.p.m. by acting on the throttle valve screws, manometer readings specified values.

6. Using the CO% tester, check that the exhaust CO emissions are 1.5 - 2.5%.

act

on the mixture

out-of-tune cylinder

checking that the

fall

within the

meter-

-

May 1988#

00-l

WI

PA333500883300

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

COMPLETE CAR

Check of ,e#hahst emissions

The Nprocedure is

,tronic injeckion engines with catalytic

convertor.

After adjustment of the idle r.p.m. following the’ above described

cedure, pr@ed

adjustmentI

haust emi.ssions by operating as lows.

This sempl~ified

with

TESTER

‘Use wiring~

illustrated ih thecircuitdiagram below:

3 WAY MIN AND MAX

1, Warm

2. Rem’otie wiring

connecter

4.

Insert

strument

connecter.’

5. Check the state of the and proceed to adjust the screw of the

potentiometer located in the plugged

seating.

when LED is this setting h’as be&n obtained replug the seating

(if necessary) of the ex-

engines

typle

CONN,ECi’OR

~up

side,connectorandthe

Of the instrument.

~ the cormector of the in-

it$

?he

the

~“ON” time of the flashing

eqtial

valid

for 1.7

”

to the check and

procedure

equipped with FIAT wiring.

ir&rument

FOR

{WITCH

3 WAY CONNECTOR FIAT TESTER

engine

min.,,and

the 3

tiaytroublediagnosis

correct setting is obtained

to the “OFF’ time. When

of,the

“CO” screw.

is for use

No. C. 90034

470

OHVS 112

max switches

3 way

LED’diode

elec-

‘I ,.

pro-

fol-

Disconnect the’ wiring ,of the

1.

Lambda sensor.

2. Using the spanner A-5.021 2, screw the plug! 0 located at the inlet of the catalytic silencer box

A-5.02127

”

W

PIN C

1,

Plug for sampling

2. Catalytic

silencer box

3. Fit

th’e

tool

for sampling exhaust gases and

nect

it with tube @ to the exhaust

gas tester

/

exhatist gas

C.2.0051

un-

@

on thefitting

con-

4 Start with the engine running on idle CO% and the quantity of unburned hydrocarbons are less than the

fied values.

When the engine is in its normal runn-

ing state a?d the lambda probe is

disconnecte~d,

ing to the total

lytic exhaust head shall be included

in the range’mentioned below.

volume % CO: 0.8 (min) to 1.5 (max)

5. Should

the

ary to act on the adjusment screw

located iin seating.‘,lt ,will

to check the specified

and if it

cedure

Once the re-plugg te seal and reconnect the lambda

sensor.

the

engine and check that

the value correspond-

emiskons

lthe

specified

values, it Will be necess-

the debimeter in the plugged

that

the idle r.p.m.

valupsof

does

described at the previous step.

setting

the’seating

before the

CO% not

then be necessary

ndt to follow the

has been effected,

900-1050

with the

fall

within

falls

apropria-

the

speci-

cata-

within

r1p.m.

pro-

As an alternative to the above

cedure, orjerate

May

1;988

as

fol’lows.

pro-

2

Catalytic

2 Tube

silencer box

connected

to

00-16

exhaust

gas

tester

PA333500883300

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

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

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

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

,’

COMPLETE CAR

c

:ii

II

1

October

1988

00-22

PA327900883301

COMPLETE CAR

r

~

THE ENGINE

During a start attempt, check the correct

Ch& the:presmwxo’fxoltgge

.plugs

Check the efficiençy 6f

filter ai/

fjow sensor.

DOES

NOT START

inrake,

rhrottle body.

to

tiucts,

Effect an electronic and functional test

Check ignition system:

tion distributor, spark

sociated tables.

integrity of

plugs and

igni-

as-

PA33350b883300

00-23

May

1988

THE ENGINE STARTS WITH DIFFICULTY

1

COMPLETE CAR

May

1988

00-24

PA333500883300

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

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

COMPLETE CAR

~ ‘ELECTRICAL

for electronic injection 1.7

NOTE: TflI6

TROUBLESHOOTING MAINLY DEALS WITH THE OF SYSTEM AND SENSORS AND ACTUATORS ASSOCIATED TO IT.

&ATTHE

biAI;N

AIR

END OFTESTTHEANOMALY

MECHANICAL DEVICES SUCH AS. VALVES,

IINTAKE

DUCTSi,

ETC.

TROUBLESH00TlNG

engines

SHOULDREMAIN,‘lTWILLBENECESSARYTOCHECK

with catalytic

ELECTRICAL/ELECiRONIC DIAGNOSIS

CYLINliERS,

PROCEDURE

convektor

COUPLINGS TIGHTNESS OF

.May~

1988

00-27

PA333500883300

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

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

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

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

ignitibn coil.ignitibn coil.

200 Ohm

FS.

connecter discon-

(ES

I

NONO

u

t-d

Restore wiring.

TEST No. 4

PA333500883300

May

1988

,’

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

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

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

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

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-

~

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

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

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

COMPLETE CAR

October 1988

00-3512

PA327900883301

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

‘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~

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

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

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

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

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

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

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

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

1’

Replace faulty injectors.

I --

nestore wiring.

Octdber

TEST No.

1988

7

00~35111

PA327900883301

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

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

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 ,

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

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

YES

Check wiring sconnected ignition CU (N20) and ignition CU . ignition module conneètor pin 3 and

ignition CU pin 1

-

ignition CU

tion module

_

ignition module

white wire on ignition

continuity

(Nl) connecter

connecter

(after having

connecter

between:

pin 13 and igni-

pins 5 and 6

pin 1 and

coi1

terminal 1.

IYES

Check ignition rifying values listed hereunder:

primary winding resistance: from 0.5

to 1.5 Ohm;

-

secondary winding resistance: from 6

1

to 12 kOhm.

,,YES

coi1 (A6)

functionality

cli-

ve-

l

J

NO

Restore wiring.-

Replace ignition coil.

Disconnect white wire on (signal for

that there is no short-circuit towards

ground.

speed

coi1

indicator) and check

terminal 1

YES

,Eventually replace ignition module

andlor ignition CU

l

(N20).

(Ni)

I

October 1988

I

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

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

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

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

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

‘,

,’

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

~._....~

~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-

........

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

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

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

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

PA327900883301

,,

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

dable @ ,removing the pressure

l

temperature

l

. table’

~ terminal.

l ~

table @

oil pressure handcontact.

.

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

,;

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

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

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

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

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

,,s

,’

l

ENGINE MAIN

MECHANICAL UNIT: ,‘~

ENGINE OIL

Type:

AGIP Sint 2000 SAE

lb;

Sintiax

+A! lOWI40

SHELL Super Plus

15w150

~

Oil quanrity

for full refilling

(lump, filter and duc&):

loWl40

Motor Oil

SAE

GEARBOX-DIFFERENTIAL OIL

Type:

AGIP Rotra MP SAE

IP Pontiax HD SAE

SHELL Spirax HD SAE

8OW/90

8OW190

8OW/90

Quantity:

2,4 kg

b. Effect cooling system refilling with speciasl fluid (See: Group 00 - Engine Maintenance - Basic Mechanical

Stern).

c. Effect the setting of the accelerator control

table

(see: Group 00 - Engine

Maintenance - Engine Supply).

Sy-

d. Bleed the clutch hydraulic system

and top up said circuit (as per Alfa 33 Group 12). e. Start the engine and, when at normal running temperature,

check

correct engine idle rpm running, the correct ignition timig and CO percentage at exhaust. For engine tuning see Group 00 -

Engi-

ne Maintenance.

. .

-

,,

pctober 1988

OI-812

PA32 790088330 1

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-

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

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

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

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

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

‘,’

“,

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

~

,’

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

(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

!

(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

~

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

1200f

1350

1500

Features

Cycle

L

Numbers of cylinders and arrangement

Otto 4 stroke

4

horizontally

opposad

1700

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.

idle r.p.m.

motor,

mm

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)

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

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

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

n

For countries

(0) Crankshafl (*) Not

marketed

where

in

all

antipollution

countries.

rotation ACW

seen

regulations

from

m

are in force

flywheel side.

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

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

+

86,970 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

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)

I

1700

1,478 + 1,490

2,978 + 2,990

0,30+0.50

0,30

f

0,50

+

0,25 0,50

8,

m,‘,

(

i, ,’ fi ,.,

‘i

,l

~ ~

~

‘ENGINE MAIN MECHANICAL

~

UNIT

l

~

‘1

hpac?ion

8’

1, ~

data

,’

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

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

~

,‘,’

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

~ ~

?’

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