Haynes Austin Montego 1.3 & 1.6 1984 to 1985 Owners Workshop Manual 1850100667, 9781850100669

Citation preview

ASS Y

MK@ NEC

@kes er.

1984 to 1985 1275 cc 05 1598 cc

'

>

6 if 8 gi

Driveshaft inner constant velocity joint Suspension crossmember Engine oil drain plug Anti-roll bar clamp

10

Front jacking point

11

Access panel

12 13

Front snubber cup Front jacking bracket/towing hook

Rear underbody view (1.6 litre model)

Exhaust intermediate silencer

Handbrake cable adjuster Handbrake cable connectors rear silencer

Exhaust ROMs

Rear Rear Rear Rear ANDA

jacking bracket/towing hook suspension strut lower mounting axle mounting pivot bolt brake hose

9 10 11 12

Rear Fuel Fuel Rear

axle transverse member tank rear mounting bolts tank front mounting bolts jacking point

Routine

16

maintenance

eee er occurs first Every 250 miles (400 km) or weekly — whichev ee eee ee

Engine, cooling system and brakes

Check the oil level and top up, if necessary (photos) y (photo) Check the coolant level and top up, if necessar Check

fluid level in the master

the brake

necessary

cylinder

and top up, if

(photo)

Lights and wipers

wipers and Check the operation of all interior and exterior lights, washers Check and, if necessary, top up the washer reservoir

Tyres Check the tyre pressures Visually examine the tyres for wear

or damage

ESS ee Se — whichever occurs months 12 or km) 000 (20 miles 000 12 Every first

2

ee

Engine (Chapter 1) Renew

the engine oil and filter (photos)

Check and, if necessary, adjust the valve clearances on 1.3 litre models Visually check the engine for oil leaks and for the security and condition

of all related components

Cooling system

o

: B

1.3 litre models

1.6 litre models

1 Dipstick

2

(Chapter 2)

Check the hoses, hose clips and visible joint gaskets for leaks and any signs of corrosion or deterioration Check and, if necessary, top up the cooling system and alternator drivebelt pump Check the condition of the water

Oil filler and dipstick details

A

and attachments

and renew if worn. Adjust the Rarer

;

Oil breather/filler cap

... and top up if necessary (1.6 litre model shown)

aoe

tank

2

Top up the brake fluid at the master cylinder

reservoir

Sump drain plug location on 1.3 litre

models ...

and 1.6

a

litre

del

Sa

Routine

Oil filter location on 1.3 litre models

Fuel and exhaust system

17

Top up the carburettor piston damper with engine oil

(Chapter 3)

Renew the air cleaner element Visually check the fuel pipes and hoses for security, chafing, leaks

and corrosion Check the fuel tank for leaks and any signs of damage or corrosion Top up the carburettor piston damper (photo) Check the operation of the accelerator and linkage Check and, if necessary, adjust the carburettor slow running characteristics Check the exhaust system for corrosion, leaks and security

Ignition system

maintenance

Suspension,

Gearbox filler plug location (5-speed gearbox)

steering, wheels and tyres (Chapter 117)

Check the front and rear suspension struts for fluid leaks Check the condition and security of the steering gear, steering and suspension

joints, and rubber gaiters

Check the front wheel toe setting Check and adjust the tyre pressures Check

the tyres for damage,

tread depth and uneven

wear

Inspect the roadwheels for damage Check the tightness of the wheel nuts

Bodywork (Chapter 12)

(Chapter 4)

Remove, clean and reset the spark plugs Clean the distributor cap, coil tower and HT leads, and check for tracking

Carefully inspect the paintwork for damage and the bodywork for corrosion Check the condition of the underseal Oil all hinges, door locks and the bonnet release mechanism with a few drops of light oil (not the steering lock)

Clutch (Chapter 5) Check

the operation

Road test

of the clutch and clutch pedal

Gearbox (Chapter 6) Visually check for oil leaks around the gearbox joint faces and oil seals Check and, if necessary, top up the gearbox oil (photo)

Automatic

transmission

Check the operation of all instruments and electrical equipment Check the operation of the seat belts Check for any abnormalities in the steering, suspension, handling or road feel Check the performance of the engine, clutch and transmission Check the operation and performance of the braking system

(Chapter 7)

Visually check for oil leaks around the transmission joint faces and oil seals Check Check

and, if necessary, top up the automatic transmission and, if necessary top up the final drive gear oil

Driveshafts (Chapter 8)

fluid

é

Check the driveshaft constant velocity joints for wear or damage and check the rubber gaiters for condition

Braking system (Chapter 9) Check visually all brake pipes, hoses and unions for corrosion, chafing, leakage and security Check and, if necessary, top up the brake fluid Check the operation of the brake warning indicators Check the brake servo vacuum hose for condition and security

Check the operation of the hand and footbrake Check the front brake pads for wear, and the discs for condition Check the rear brake shoes for wear, and the drums for condition

Electrical system (Chapter 10) Check the condition and security of all accessible wiring connectors, harnesses and retaining clips Check the operation of all electrical equipment and accessories (lights, indicators, horn, wipers etc) Check and adjust the operation of the screen washer and, if necessary,

top up the reservoir

Clean the battery terminals and smear with petroleum jelly Have the headlamp alignment checked and, if necessary, adjusted

Every 24 000 miles (40 000 km) or 24 months — whichever occurs first In addition following:

to all the items

in the annual

service,

carry out the

Engine (Chapter 1) Renew the engine oil filler cap on 1.3 litre models Clean the engine breather filter on 1.6 litre models Check and, if necessary, adjust the valve clearances on engines

1.6 litre

Cooling system (Chapter 2) Flush the cooling system and renew the antifreeze solution Renew the water pump and alternator drivebelt

Fuel system (Chapter 3) Check and adjust the carburettor idle speed and mixture settings

/gnition system (Chapter 4) Renew the spark plugs Check and, if necessary, adjust the ignition timing on 1.3 litre models Lubricate the distributor centrifugal advance mechanism on 1.3 litre models

18

Routine maintenance

—_ SS

Automatic transmission (Chapter 7)

Braking system (Chapter 9)

Drain the transmission fluid, clean the oil strainer and refill with fresh fluid Check the operation of the parking pawl

Renew the flexible rubber hoses and the rubber calipers, wheel cylinders and master cylinder Renew the air filter in the servo unit

seals

in the

Braking system (Chapter 9) Renew the brake fluid

Every 48 000 miles (80 000 km) or 4 years — whichever occurs first

— Every 36 000 miles (60 000 km) or 36 months — whichever occurs

In addition to the items listed in the annual service, carry out the following:

first

TM

In addition

following:

to

tT the

aaa

items

ais,

in the

annual

as

service,

= ace

carry

out

the

Engine

(Chapter

gine 1

7

ee

on

1.6 litre engines

Fault diagnosis Introduction

Electrical faults

The vehicle owner who does his according to the recommended schedules section of the manual very often. Modern that, provided those items subject to inspected or renewed at the specified

or her own maintenance should not have to use this component reliability is such wear or deterioration are intervals, sudden failure is

comparatively rare. Faults do not usually just happen as a result of sudden failure, but develop over a period of time. Major mechanical failures in particular are usually preceded by characteristic symptoms over hundreds or even thousands of miles. Those components which

do occasionally fail without warning are often small and easily carried in the vehicle. With any fault finding, the first step is to decide where to begin investigations. Sometimes this is obvious, but on other occasions a little detective

work

will be necessary.

The owner

who

makes

half a

dozen haphazard adjustments or replacements may be successful in curing a fault (or its symptoms), but he will be none the wiser if the fault recurs and he may well have spent more time and money than was necessary. A calm and logical approach will be found to be more satisfactory in the long run. Always take into account any warning signs or abnormalities that may have been noticed in the period preceding the fault — power loss, high or low gauge readings, unusual noises or smells, etc — and remember that failure of components such as fuses or spark plugs may only be pointers to some underlying fault. The pages which follow here are intended to help in cases of failure to start or breakdown on the road. There is also a Fault Diagnosis Section at the end of each Chapter which should be consulted if the preliminary checks prove unfruitful. Whatever the fault, certain basic principles apply. These

are as follows:

Electrical faults can be more puzzling than straightforward mechanical failures, but they are no less susceptible to logical analysis if the basic principles of operation are understood. Vehicle electrical wiring exists in extremely unfavourable conditions — heat, vibration and

chemical attack — and the first things to look for are loose or corroded connections and broken or chafed wires, especially where the wires pass through holes in, the bodywork or are subject to vibration. All metal-bodied vehicles in current production have one pole of the battery ‘earthed’, ie connected to the vehicle bodywork, and in nearly all modern vehicles it is the negative (—) terminal. The various electrical components — motors, bulb holders etc — are also connected to earth, either by means of a lead or directly by their mountings. Electric current flows through the component and then back to the battery via the bodywork. If the component mounting is loose or corroded, or if a good path back to the battery is not available, the circuit will be incomplete and malfunction will result. The engine and/or gearbox are also earthed by means of flexible metal straps to the body or subframe; if these straps are loose or missing, starter motor, generator and ignition trouble may result. Assuming the earth return to be satisfactory, electrical faults will be due either to component

malfunction

or to defects

in the current

supply. Individual components are dealt with in Chapter 10. If supply wires are broken or cracked internally this results in an open-circuit, and the easiest way to check for this is to bypass the suspect wire temporarily with a length of wire having a crocodile clip or suitable connector at each end. Alternatively, a 12V test lamp can be used to verify the presence of supply voltage at various points along the wire and the break can be thus isolated.

Verify the fault. This is simply a matter of being sure that you know what the symptoms are before starting work. This is particularly important if you are investigating a fault for someone else who may not have described it very accurately. Don’t overlook the obvious. For example, if the vehicle won't start, is there petrol in the tank? (Don’t take anyone else’s word on this particular point, and don’t trust the fuel gauge either!) If an electrical fault is indicated, look for loose or broken wires before digging out the

test gear. Cure the disease, not the symptom. Substituting a flat battery with a fully charged one will get you off the hard shoulder, but if the underlying cause is not attended to, the new battery will go the same way. Similarly, changing oil-fouled spark plugs for a new set will get you moving again, but remember that the reason for the fouling (if it wasn't simply an incorrect grade of plug) will have to be established

and corrected.

Don’t take anything for granted. Particularly, don’t forget that a ‘new’ component may itself be defective (especially if it’s been rattling round in the boot for months), and don’t leave components out of a fault diagnosis sequence just because they are new or recently fitted. When you do finally diagnose a difficult fault, you'll probably realise that all the evidence was there from the start.

A simple test lamp is useful for checking electrical faults

Fault diagnosis 20 e a e i If a bare portion of a live wire touches the bodywork or other earthed metal part, the electricity will take the low-resistance path thus formed back to the battery: this is known as a short-circuit. Hopefully a short-circuit will blow a fuse, but otherwise it may cause

burning of the insulation (and possibly further short-circuits) or even a fire. This is why it is inadvisable with silver foil or wire.

to bypass persistently blowing fuses

Spares and tool kit Most vehicles are supplied only with sufficient tools for wheel changing; the Maintenance and minor repair tool kit detailed in Too/s and working facilities, with the addition of a hammer, is probably sufficient for those repairs that most motorists would consider attempting at the roadside. In addition a few items which can be fitted without too much trouble in the event of a breakdown should be carried. Experience and available space will modify the list below, but the following may save having to call on professional assistance: Spark plugs, clean and correctly gapped HT lead and plug cap — long enough to reach from the distributor Distributor rotor Drivebelt(s)

— emergency

type may

the plug furthest

suffice

Spare fuses

Sealed can of hydraulic fluid Emergency windscreen Worm drive clips Tube

of filler paste

If spare fuel is carried, a can designed for the purpose should be used to minimise risks of leakage and collision damage. A first aid kit and a warning triangle, whilst not at present compulsory in the UK, are obviously sensible items to carry in addition to the above. When touring abroad it may be advisable to carry additional spares which, even if you cannot fit them yourself, could save having to wait while parts are obtained. The items below may be worth considering: Clutch and throttle cables Cylinder head gasket Alternator brushes Tyre valve core

One of the motoring organisations will availability of fuel etc in foreign countries.

Tin of radiator sealer and hose bandage Exhaust bandage Roll of insulating tape Length of soft iron wire Length of electrical flex Torch or inspection lamp (can double as test lamp) Battery jump leads Tow-rope /gnition waterproofing aerosol Litre of engine oil

able

to advise

on

Engine will not start

Engine fails to turn when

Set of principal light bulbs

be

starter operated

Flat battery (recharge, use jump leads, or push start) Battery terminals loose or corroded Battery earth to body defective Engine earth strap loose or broken Starter motor (or solenoid) wiring loose or broken Automatic transmission selector in wrong position, switch faulty

Ignition/starter switch faulty Major mechanical failure (seizure) Starter or solenoid internal fault (see Chapter

Carrying a few spares may save you a long walk!

10)

or inhibitor

Fault diagnosis

21

Fouled or incorrectly gapped spark plugs regap) Other ignition system fault (see Chapter 4)

(remove,

clean

and

Other fuel system fault (see Chapter 3)

Poor compression (see Chapter 1) Major mechanical failure (eg camshaft drive)

NEGATIVE

Engine fires but will not run

18 in. MIN

Air leaks at carburettor or inlet manifold Fuel starvation (see Chapter 3)

Other ignition fault (see Chapter 4)

DISCHARGED BATTERY

Engine cuts out and will not restart

BOOSTER BATTERY

Engine cuts out suddenly — ignition fault Loose or disconnected

Wet

LT wires

HT leads or distributor cap (after traversing water splash)

Coil or condenser failure (check for spark)

Other ignition fault (see Chapter 4)

Engine misfires before cutting out — fuel fault Fuel

Jump start lead connections for negative earth — connect leads in order shown

tank empty

Fuel pump defective or filter blocked (check for delivery) Fuel tank filler vent blocked (suction will be evident on releasing cap) Carburettor needle valve sticking Other fuel system fault (see Chapter 3)

Engine cuts out — other causes Serious overheating Major mechanical failure (eg camshaft drive)

Engine

overheats

Ignition (no-charge) warning light illuminated Slack or broken drivebelt — retension or renew

(Chapter

10)

Ignition warning light not illuminated Coolant loss due to internal or external leakage (see Chapter 2) Thermostat defective Low oil level Brakes binding Radiator clogged externally or internally Electric cooling fan not operating correctly Engine waterways clogged Ignition timing incorrect or automatic

advance

malfunctioning

Mixture too weak Crank engine and check for spark. Note use of insulated tool to hold plug lead

Note: Do not add cold water to an overheated engine or damage may result

Starter motor turns engine slowly Partially

discharged

battery

(recharge,

use

jump

leads, or push Low engine oil pressure

start) Battery terminals loose or corroded Battery earth to body defective

Gauge reads low or warning light illuminated with engine running

Engine earth strap loose Starter motor Starter motor

(or solenoid) wiring loose internal fault (see Chapter

Oil level low or incorrect grade

10)

Starter motor spins without turning engine Flat battery Starter motor pinion sticking on sleeve Flywheel gear teeth damaged or worn Starter motor mounting bolts loose

Engine turns normally but fails to start Damp or dirty HT leads and distributor cap (crank engine check for spark) No fuel in tank (check for delivery at carburettor)

and

Defective gauge or sender unit Wire to sender unit earthed Engine overheating Oil filter clogged or bypass valve defective Oil pressure relief valve’ defective Oil pick-up strainer clogged Oil pump worn or mountings loose Worn main or big-end bearings Note: Low oi/ pressure in a high-mileage engine at tickover is not necessarily a cause for concern. Sudden pressure Joss at speed is far more significant. In any event, check the gauge or warning light sender before condemning the engine.

22

Fault diagnosis

i

SS

OE

Tapping or rattling Engine noises

Pre-ignition (pinking) on acceleration Incorrect grade of fuel

Incorrect valve clearances Worn valve gear Worn timing chain or belt Broken piston ring (ticking noise)

Ignition timing incorrect Distributor

faulty or worn

Worn or maladjusted carburettor Excessive carbon build-up in engine

Knocking

Worn

Whistling or wheezing noises Leaking vacuum hose Leaking carburettor or manifold gasket Blowing head gasket

or

thumping

Unintentional mechanical contact (eg fan blades) Peripheral component fault (alternator, water pump etc) big-end

bearings

(regular

heavy

knocking,

perhaps

less

under load) Worn main bearings (rumbling and knocking, perhaps worsening under load) Piston slap (most noticeable when cold)

Chapter 1 Engine Contents

Part A: 1.3 litre engine ANCHIALVECOMPONEMtS:

= GETITELIMNG carcszateserevesssxaterssncodesmavonosdoate aesunseseees 40

Ancillary components — removal 9 Camshafe anGgitappetsS. == EXAMINATION sccrscncrssocsvecsserocesssoessscvesiorsneccesuts 25 Can shahtrandita pers a RETO josccctec ven terse cceeec teres nerpei cid stietags teas 35 CaashartwahatapPelS.—

TE MOVEL .csscsae. ceccivanxsxcaccvacaacgexsersavenestccvcatwesews

16

Crankcase ventilation SysteM — CESCTIPTION ........:cceecesseeeteeeeeeseneeees Crankshaft and main bearings — examination and renovation....... Crankshaft and main bearings — refitting ............. : Crankshaft and main bearings — reMOVA ......ccccsescsessessseseessecseseneeees Cylinder block and crankcase — examination and renovation ......... Cylinder head — decarbonising, valve grinding and renovation. ..... Goudie te) TAVe@) = TCP ENMU Get Fa 380 peneeeeet on cencncon denocenbabnccoronieoenoconbucRorROReEGD Cylinder head — reassembly and refitting Cylinder head = remOVallic..c..0::..cctecches=--s-ssanersnevzvans= ie Engine — adjustments after major OVErhaUl ..........cceeceeeeteeeteetetereees Engine — attachment to GearbDOxX .......cccsccessnsercscssesnessscenerneressseanseeeees Engine — separation from Gearbox ......csceeseeeeneeeteeneeserereens Engine and gearbox assembly — refitting .......ccccceeeeteeeesens Engine and gearbox assembly — removal Engine dismantling — Qemeral .........eccececeseeeneeeerseseeseesssresisesenesseaees Engine mountings — removal and refitting ..... eee sereseeeseseees Engine reassembly — Gemerral ............serceccssecsneeseesens Engine tie-rod — removal and refitting Examination and renovation — general Gearbox adaptor plate — examination and renovation Gearbox adaptor plate — refitting .........:ccccccesesesceereesseenenseeseessnssesaseees Gearbox adaptor plate — removal ......:ccsccscscesessesseseneeseeeeasereneenssssnnssones Gemeral CSSCIID LOM srevetev ree: cenenenesereacsereoey fecesarsisavarsstrcequcseerraenrarcnencs"srenras Maintenance and inspection Major operations possible with the engine in the Caf .......:.eee Major operations requiring ENGINE FEMOVA] .....cscserseeesecerereereeereetees Methods of engine removal

19 22

Oil PUMP

— EXAMINATION 0... ces ececeeceeseetecectestenteestestensseerestensenestesseneeneey

Oil pump Oil pump

— refitting — removal

Pistons and connecting rods — examination and renovation .......... Pistons and connecting rods — refitting .....ecseeesrseseeeerseseetsestsenens e setersrseetsceseenens Pistons and CONNECTING FOdS — FEMOVAL oo. secr

SUMP — Fefitting «2... secccecsesesectecereetesessenesseeessseenseseenesisterneneetenentenenss SUMP — FEMOVAL nes eesecsesecseseeseesesteneenesesseessesseeneereeneneeneanenscesenseneces Timing cover, chain and gears Timing cover, chain and gears Timing cover, chain and gears Valve clearanceS — ACjUSTMENL

OES} 28 ila 39 AKG) 43

65

Crankshaft and main bearings — examination and renovation ....... Crankshaft and main bearings — refitting .........ccsscsscesseseesseeesneeesees Crankshaft and main bearingS — reMOVAl .......ccsssesensseeersesseesessees

68 77 64

Cylinder block and crankcase

67

— examination

and renovation........

Cylinder head — decarbonising, valve grinding and renovation ..... Cylinder head) —GishmaMntlinG we rcccsesevserestateareasceseeeeestneecseevansactysscpaerercoas Cylinder headi— reaSSemDly cecrssceesseevunceassecerersrss-ecsrres sweduasrscncocuanmaras (Cyalimekere nieve = TEMMRAIING) coscepenancnceceanonnece conencocSseuoncooseccaceaaRan Cylinder head removal — ENGiNE IN CAF... ceeeeeeeeseeseeeees Cylinder head removal — engine on bench Engine — adjustments after Major OVErhaUl .........ccccecceeseeseeeeeeeteesens Engine — attachment to manual gearbox or automatic CHANISTMISSO Mrocccceceesesrsateucuaneteccnceieestatien comet: eastartretmen secatentcemroccectsanipencees Engine — refitting with manual gearbox or automatic LATISIMUISSIOM scssccscvvnaasseccncenecears sesasosace’ncacdutcve vecavshascvacde: canoer meeeneeRe, Mares Engine — removal with automatic tranSMISSION ........:ceeeeeeee

74

Engine — removal with Manual GearbOX ......ccccceseesesersesenseseeeseeeeenees Engine — separation from manual gearbox or automatic BAM SMMISS|OMlpecwrssereeseecemeersoedese trae

50

Engine

90

88 89 51

mountings — removal

and refitting

Engine. reassembly — Gerenall .........cc.ssscsdessssesreeccrvsetevcorerecesebedtereetseeesse

36 14 1 2 3 4 5

24 33 de,

- O/ S213

Part B: 1.6 litre engine ke and renovation ......:e

Crankease! ventilationssyStetn — CeESChIP tO Mscecesiecetacncernsescesccetrers:

Engine dismantling — general

5 CAS — examination 38 — refitting weer (|2 — reMOVAl wcrc etieey 44 ee reereeseteeteseteeeeteet eter cccee .....

Ancillary components — refitting Ancillary components — removal Camshaft and tappets — examination

Camshatteandl tappetsi sre titi G|emcemnern cements se eeecntser tna cateaerascee re 83 Camshaft and) tap pets: — ne nnOVall evescesntesseccetee cee meeeeee eee eae 58

Examination and Gearbox adaptor Gearbox adaptor Gealboxsadaptor

renovation — General .........seceeeeseeseesenes plate — examination and renovation plate — refitting .........cccscsseceeeseereenees late — =TeMlOValircsrerecectectecenceneeesete cera: eaveensepeeneeee sete

(Cyan VET CLEC OAKOL A).cococnecerorence: noonoqococeC base gana fogponanaccisonoxencprorocasenr0q76593000 ViaIntenanc GuaMmCiSMECtUOMrresctrwe vasstcncensenecmerareteesmarennat Major operations possible with the engine in the car Major operations requiring ENGiNe rEMOVA ..... eres MethodsonrenGim@unelm OVal icrccccsccetsncscecescnantreaseeuee-cee coshaeceneemeeener arts Oil pump and housing — examination and renovation Oil pump and housing — refitting Oil pump and housing — removal Pistons and connecting

rods — examination

and renovation

Pistons and Connecting rods — refitting .............cscssserseresssesssesesnseens

78

Pistons and connecting

63

rodS — reMOVal .........scssesessevecessceeserscenseere

inne) ERTL |axe once esenoscodnogsa. 539 cncodebubo psosepeeCOCORC SWUinmfey = GEMMONIEL) ceonrercntocessse centcenonerenonosnooeccotooseos9a0-0 258 Tappet clearances — checking and adjustment

oc ac su

teil (240) (HS)

Timing belt — refitting and AdjUStMENE ......cceeeeeeee estes teesesestetetees

85

Timing belt — reMOVAl oc cccsesecccecsssssseseeessnensnesenesnsesessssssesorsssseasanssees 55 Timing belt, sprockets and tensioner — examination and snmeneettemna stents 73 FEMONVATIOMisiciervssteaserceccancersecssorucaaeescventucsecsmssabescscussnanmisnar

Part C: Fault diagnosis 72

Fault CiaGnOSiS — ENGINE .....ccccccseeceseseeeeesneteneenesssesssssesesestenenenesesereeeees

oil

24

Chapter

1 Engine

Specifications

Part A: 1.3 litre engine General Four-cylinder

in-line, overhead

2.780 in (70.61 GAD GCL: eee heceutecscinesunntraeaternarsevecedecepweese wyrcvaceieveite eteomancoases emeT eee a UHI GSORGGL; cases crertcseeseetonetes ements pret ta seen ke oc Goce ak ee var CITT e

valve

mm)

3.200 in (81.28 mm) 1275 1eo(7 7-8 cunin)

1—3-4-2

(No 1 cylinder at crankshaft pulley end)

Crankshaft Main ounmalmctamletelann sass torcnree cic a tteonrstcenenaunnttesstty tere autaehaerate. NEN elONSETANS) UUAUMNTNS), CLES IRIGEE ec rennenenonsccoconencereceon: -conceceenooorot Ac dororerocr Main journal minimum regrind diameter ......cccccccsccscseeseseesssessessesesssecsseeees PNM GONG) OUNA MEN CHEN AAKERTEN? cococesonantoceteceteca soasocdectpoanbesomts saeccchoece ceenereeneeerceneorees Cramkpinmnun ima nclealanCerca tac cesses ne once eer eeeeee en CHET VONIN [MUMMY (ELS AKTVC] CHAM AKEREN os cscocceeecnccons 6eeannrermnooncoptennsneetanicecnenocee

CrankshattwencilOaithceqnsmar ccc

Connecting

eAs ati

oe ten tene

ee

2.0012

to 2.0017

in (50.83

0.0003 to 0.0030 1.9811

in (50.32

1.7497 0.0015

to 1.7504 to 0.0032

1.7297

0.002

in (43.93

to 0.003

to 50.84

mm)

in (0.008 to 0.076 mm) mm)

in (44.44 to 44.46 mm) in (0.0381 to 0.0813 mm) mm)

in (0.051

to 0.076 mm)

rods

ERGTNEDE TWEE Ire GtheS etieeererecuse ceeereeee ee eee oe ee pe

5.750 in (146.05 mm)

Pistons Skirt clearance in cylinder: GUKayolscecAlcnacrna cecer rer ernie eset enceern Cred Pore ECE eR eee eee BOttO Mirren ee Se Ee Oversizesavallable vere ata aen JAUa & Se ee Ree Tee.

0.0029 0.0009

0.020

to 0.0045 to 0.0025

in (0.51

in (0.074 to 0.114 in (0.023 to 0.064

mm) mm)

mm)

Piston rings Clearance mmGroOves (COMmneSSlOMuniiGS masta eee ae eee meee Fitted end gap: MOPECOMpneSSlOllaeeccate

Gudgeon

cena

conn cnn tiene

merece

ene:

ee

eee

0.0015 to 0.0035 0.010 0.008 0.015

to 0.017 to 0.013 to 0.041

in (0.038 to 0.089 mm)

in (0.25 to 0.43 mm) in (0.20 to 0.33 mm) in (0.38 to 1.04 mm)

pins

ONINNEM Pcie

cn nena

ero

een

ee

0.8123

to 0.8125

in (20.63 to 20.64

mm)

Hand push fit at 68°F (20°C) 0.0008 to 0.0015 in (0.02 to 0.04 mm)

Camshaft Journal

diameter:

1.6655

‘Ele Ue hOhee

eee

te

te

een

ee

oe

ee

en

to 1.6660 in (42.304 to 42.316 mm) 1.62275 to (.62325 in (41.218 to 41.231 mm) 1.37275 to 1.3735 in (34.868 to 34.887 mm) 0.001 to 0.00225 in (0.025 to 0.057 mm) ee

en

0.003 to 0.007 in (0.076 to 0.178 0.318 in (8.08 mm) 0.812 in (20.62 mm)

mm)

45° Ural tee dade batse ssdetevachre reonsvaytearcanen ease iicicstearid cco

1.307

to 1.312

in (33.20 to 33.32

1.1515 to 1.1565

mm)

in (29.25 to 29.38 mm)

0.2793 to 0.2798 in (7.094 to 7.107 mm) 0.2788 to 0.2793 in (7.082 to 7.094 mm) IpetUtserene atereaversiisrtivn ccctenacteeeseva

hee

ee

a,

0.0015 to 0.0025 in (0.038 to 0.064 mm) 0.002 to 0.003 in (0.051 to 0.076 mm)

Length

1.687

Valve springs: Pie Ome ILGU ieaceareetaeatetscrstreses, tector teraeate ee Valve timing (at valve clearance of 0.021 in/O0.53 mm): [MET iODen Staemmenmmeere hc, ar een tet UAVER (CHOSELS ccccxcacotcc et tos Dee eee ee

ee ee EE

eee ie,

in (42.85 mm)

0.470 to 0.471 in (11.94 to 11.96 mm) 0.2813 to 0.2818 in (7.145 to 7.158 mm) 0.540 in (13.72 mm)

1.95 in (49.53 mm)

ke

ZO? BIDE 52° ABDC 56°, BBDC 17° ATDC 0.014 in (0.36 mm)

Chapter 1 Engine ee enn

Lubrication

system

Oil pump: “UR[IER sas acisenesncs aches setae cea

Re Counc Be cre

Olitemiotorieid flo ati acre eee one ety cee Ne ee InTkelemmentorr tatenilOVeht -ccomescsc pee ecciouneoa caceme teratoma crep-cee aterm tte tee OMe

TahOLO l=tO-NOcWae eajalce peren een ne nee

ROt@im@l Obemcl CalamCees System

25

sera nce

0.010

weer te eyastanctsrar ees erseheareees

pressure:

NeAURING sett ases ca cancectstcmceeRinntaath ccs c.ckGe Stes artagdu dette Sar. ctyocatacancvttert (WLMfe eae tetate hee RN rane, kt ete Senn en Watningnlighty Switchroperating pressures.

make

aks rte

Bi-rotor

0.005 in (0.127 mm) 0.005 in (0.127 mm)

oe eee,

Pressure relief Valve Operating PrESSUTE. .......cccccccccsosscscseerserseseeceecessusnsnsesnes te ycreceeueoee Pressuremrelictavalve spning) tree lemgth macs ccc eerste

in (0.254 mm)

0.006 in (0.152 mm)

15 Ibf/in? (1.0 bar) 60 Ibf/in? (4.1 bar) 6 to 10 Ibf/in? (0.4 to 0.7 bar) 60 Ibf/in? (4.1 bar) 2.86 in (72.64 mm)

Ibf ft

Nm

Camshatimlocatinguplatesboltamemseentes cote e ik tenes eee eee, Cammsiane eval imp tauite onc vesereene esens eee seers ha Wee tees cckctowe eee, Connectinagrod big-endiicammUtsrske.tes. eet een ink eee Canicshrahty PUlle vsDOl tates ease ae ae et ee Seen ee OE A Me eaten. GA IR) Se.

8 65 30 105

11 88 41 142

ENV [UCLA

ean

55

US

BUC DlatectOummali Oe animG. Cal Meeectts-cee amet teem tee Seca en eee cer ores rears tte ceeeeretie acer EFOMt ML atectorey linden Ok ccm GSAT DON eAGa PLOls PlaceuDOltS rccarasessvcscarcxeccx: caseuncscoceserecetvaeera sesssaseevduoeeiseeanns ee) a ee re he MAENURY. (SERENE) eeYar1BY) Nea oS See eR QU iTASTE UTHER STE TSS Esc aa he eee MR aya RUE ees een etree ON ACUCor amet MCh DOES tearteenes eecascoecst (ors sock carsrservecaxcssren

5 16 18 65 18 8

7 22 24

settings

Torque wrench

GUN Sieeceanacee ers eee

CHPMLeSStnemrenet

mec

ee ay canes Seceestawe ve ease

oe

ceresocsent tees eee dees Walve-Gap: (Ut vcscntucat

ees Wa Avot OLS eperece mecree Renter seucanceatorm Ware ntrtoct oe Me ane een OSS ee ROCKEEIOOV ET OO IES caceerre care eect ws vceac ces caves tevecvareigvresbontes terreeoeetaae ees aoanereee ee, ROCKEt Shalt PCGSStal MUESissscac-nnes-car-cusrenrissccace toome SyURUTHDAC Be BEIM ULC) cattencaaeaenc eee ester sa nearer mca Ae Cece A RE SUMP ME CALM DONS inca cceounsastn ass: oncvtren tev cerseze cane cavvasucerucoebesth tescenoweeceucmecbensn see Timing cover to front plate: SEER) NEES ieee leds ae cence cas ar ea ac etchant ie tee see es eS

SETI X01|SeRane Reo ea RRR Rope See hey te er ere entree Oh th

See Li

88

16 3 24 28 8

24 11 61 22 4 33 38 ili

5

i

45

ir eee Pract

12

16

VacGutlin nose DaniOMMlOM NOME: sccvner sai cvcasacdsorseunsseaetecaccteanesaceeceensccesease secs Left-hand engine mounting bracket to DOY ...... eee eeeeeeeeeteeeeteeeeeeeeeeee Left-hand engine mounting-to-bracket retaining bolts ...... cece

Si 18 18

50 24 24

Left-hand engine mounting through-bolt ......... cece eseeseeseeeeseesseeesereeeees

34

46

Fer MAnG enciae MOUNT) OO SANION nsasescnscvaceuceecanacarthoctesscoseeoutussecseateo Right-hand engine mounting support Strap DOItS oo... cece sseeeseeeneens Right-hand engine mounting bracket-to-engine side bolts .......... cee Right-hand engine mounting bracket top and bottom bolts .............04 Right-hand engine mounting through-bolt .........ceceeeseeesseeseteessssestesseens BET NO GAGS EG)iS cores veer snus a an nate evan ave ekewnerne snare hacaui anh son awnaeacame soeesaése

30 18 18 30 34 34

41 24 24 41 46 46

Ne OC ONCOMING MAC Oye caearatea mans secaerces cass uedensumsbiartecomaoidavyr nevucpudrnrinianrnbae cr FIG =hO Cs LOMCKOSSIICM DE lectasrttiaeehar ere -cseeeou saves onus ceacads doch:nceysaceetbeessrauza santas

67 34

oil 46

Part B: 1.6 litre engine

General BS) ecroxscetsonact eee re vaceee Ccece PEPE PEDO ty PR °c TERA BBN es eee ce ces weak oe sale eevaeret te PR ETO Groce eterna a eniscn cores SOE

>

cE PLY Cee ESCO REE aC GEE Pc

RE

se ae Coe tae Aude ot hate toe ok Me Ms GH ts Pie Meee ee ae ewan

Gaal yep eeeeen arraeen care eeastner varvvacvenesearsne sm aralar cca mirytttha Ranga ater Pads ates neath COE Co EE Ee Eline) la t215 cocecocecocnca a borer ceoeoeeeecennanr no aeO cen cua IO- O20: SAO

Four-cylinder in-line, overhead camshaft 3.000 3.443

in (76.20 mm) in (87.38 mm)

1598 cc (97.5 cu in) 1—3-4-2 (No 1 cylinder at crankshaft pulley end)

Crankshaft Narcan ennts eteviereescurssecsssseetescartearneteryraturnratiresnrvearecseacarnrer

Main OUnma leita

Main bearing running ClEArANCE .....cccceeeeeteeterenersetersenseersenssssisesesersessesees essesesses sssessessere: Main journal minimum regrind diameter occ esses esesesessesssssererssssseeerssrssereees Crankpin jourmal GiaMeter .....ccccccceetteeters Crankpin

ClEAPANCE .....ccccccceee tees

rUNNING

Crankpin MinimUM Gr tla

ee

Connecting

es eeeeseststeesssssteresessseeensserenets

reese esr regrind CiaMeter occ

ee

ee

le, Patria eeaveasricaccat coy tee ntameNicemrssactes aids naam:

rods

Length between CEMtreS ....csccecsecseessernesreeneresessessessesssnnsssesseesesseensesensieeteeneety

Pistons Skirt clearance in cylinder: iUIfs\o}ereseencco Bottom (OW ETFS CAVEMENEY ccrceancstec ce: or eae echo ncoonncnnseece =. cotlepcecdoan! ogbuueer@qpocrocreeenaaeeee

to 2.2520

2.2515

in (57.19 to 57.20

mm)

0.002 to 0.0035 in (0.05 to 0.09 mm) 2.2115 in (56.17 mm) 1.8759 to 1.8765 in (47.65 to 47.66 mm) in (0.04 to 0.08 mm)

0.0015

to 0.003

1.8359

in (46.63 mm)

0.004 to 0.007

in (0.10 to 0.18 mm)

. 5.830 in (148.08 mm)

. 0.0028 to 0.0044 in (0.07 to 0.11 mm) 0.001 to 0.002 in (0.03 to 0.05 mm) 0.020 in (0.51 mm)

26 oS

ee

Piston

Chapter

rings

ncaa eats earners eareatnde Clearane- i) GLOOVES seeccra was ceececesertermesttereedeacraeenere Fitted gap:

n cece suiteS516 allercesecroenecerecrece secstn boner etaresee-ccsreceroreveccnanasecencoaaoucuanncacsio (Clotnrny o abonooodebbdemsonueueanohaccce senseenootdeccedverecn eIKS! cepsseecaereorerncencooccncoosoacc (@)lltererahartel Mt

Gudgeon

pins OiStOmanne

Clearance:

eases stanzas ee

eee

Diam ete cee occ rc nce

0.0015 to 0.0035 in (0.04 to 0.09 mm) 0.012 to 0.022 in (0.30 to 0.56 mm) 0.015 to 0.045 in (0.38 to 1.14 mm)

0.8123 to 0.8125 in (20.63 to 20.64 mm)

RE

eae ee

mceeeree stesrececancestirac seed carsate ccnp amenerereeee

crate

1 Engine ne ee

Interference fit im CONMECTING TOC ........ceccscsvessrsscsessenssnensscacseseenscenconsensveeses

Hand push fit at 68°F (20°C)

0.0008 to 0.0015 in (0.02 to 0.04 mm)

Camshaft Journal

diameter:

pore ae 00 nm Deere = enti G0a sa Eee eee cercoceE Caro aero ORR ae CRT aaa Map eT Cdl FSi ee al se Ue eet 2 RR ota enter rere Runming Clearance i DEAriNGS ...........c.c.sssscssesscesesesesescstsesteresenenenooseonsesesenes FETC Galitnere ere ccseers acer cons aie rsceniace asus snamiaeuaee cae rate emsreatinn Ecaae Tartare Valve

lift:

Wal titer eects ree a es wc eee | Se eae askvatracnnsBcvaceneaiaes avdeaeiniraiee eM STetet cere ws steccae ot ara tases aerate Cet ceot nu sarstntnctcis cat axa enonmeelins cas oansterameets EX

1.9355 to 1.9365 in (49.16 to 49.19 mm) 1.9668 to 1.9678 in (49.96 to 49.98 mm) 1.998 to 1.999 in (50.75 to 50.77 mm)

0.001

to 0.0023 in (0.025 to 0.058 mm)

0.002

to 0.007

in (0.05 to 0.18 mm)

0.342 to 0.344 in (8.69 to 8.74 mm) 0.338 to 0.340 in (8.58 to 8.64 mm)

Tappets ANGLES TIM STi seveeeense eee cacoee se ere cas soar ee arbres reasmnscebcrscerassceaancdrevessveeyintevtnsecendee (CURBSEx Coleman ocaeererere eccoce ee oro peer are cacobecocnrcnek pncdbiae GcbaotsrenGcencocteapaehGancoo7au Adjustment shim number:

aan

ei

eh

oe OE

OS eR eae Se ee Cie eerie eae

CE

Oe seas

Ee Me sc ita aad bao ees ds Sree ea, cea

oe I aS cD conte eMC cores Pra eE

0.097

a one ah nen

ENA Ee YR NR

cc Solis SOR Lab

ee ee tte: ee

oo

SUEY sia PR, Bice i tone auranp iin 5” oat eae ay eee EERE Te ecere ene enor scGcrs DE et ne Re ath Re Re Me Re ree Mente eaba sce tate acon seek atten ened

5 ae pa eyRn

Tee Naty WE ory eR eee Prt

Le eyeCr

e ce

eee

EE

in (2.46 mm)

0.099 in (2.51 mm) 0.101 in (2.57 mm)

ee ee ctr ee, te nO Sn eae ga eee net OE

babes Cao EER APE eine Sr BRE reer Geen erect coe OT ace ete me Se rca an Osada eae sean ed mene rcuaa cee an eres een tees nc OE ee ara ae OF ee ror cr omens ee, Pree KD eee ae et a Reiger rel Sed MOOR LILLE LE, Om Me RCE gai SMa Gearon COE eeNeos sD geese re Reece rates cM eee celeons ew ew de Hadas vad ce eneecaca ees eta ees CU eee ee ne pea rete ci oc ie ac ay os ont Meade Aaeh wartahthuaartite arena i ee ea Ney eR cece eerste cee TN ee Sr ee ede NN ae ny PEER Se 0 neta ca pas PR RR i cE SE eT ce fprenotes ee eee herepee Re PCAC crerttr ccaet HS een eee mit

DE

Selective shims 1.1865 in (30.14 mm) Corresponding thickness

0.103 in (2.62 mm) 0.105 in (2.67 mm) 0.107 in (2.72 mm) 0.109 in (2.77 mm) 0.111 in (2.82 mm) 0.113 in (2.87 mm) 0.115 in (2.92 mm) 0.117 in (2.97 mm) 0.119 in (3.02 mm)

0.121

in (3.07 mm)

0.123 0.125

in (3.12 mm) in (3.18 mm)

0.127 in (3.23 mm)

Valves Seatwave

seseecone ves vavnutenes seco tacwtennacceearsnen ery Giecacuaey saussianncuanestessaneectuceanatanassts

45.25°

Head diameter:

Ne CMs cess ciscece saeco cetera con nce APTS Tee one Eee er oe os [oa AVETLC) epee eae Monee meen emt a Ponte cos oe a ess ast ouWasiolbdi daw ovaitetiteaeyeoatd

Stem diameter (standard):

:

ee Ee Nal tibccs suctitedesinaaunede ona cect dary ove RTO MRT EEX UNS MR secs ecco csv spreesu seu coca so reo ae STSMMea

1.500 in (38.1 mm) 1.218 in (30.9 mm)

CN eee

ees

vaccrsusvoce reset RSNORE: er nemee Cet. nak cauccnst eee amie tet (OVETSIZE) rosscesesevsons

SiteimatOsQuice: ClEAFAMCE caccvueesccasccrcaapourctecaterassusearteeeeatey oars tsek everett crtannet Valvesspringptree: lent: Amiiinctce stds Mericsdscdietsctvs eetvssssavecut coved aa Valve timing (at tappet clearance of 0.021 in/O.53 mm): NMC OD ONS. svecesecesscosrcncceant sued eccactuass oan cau irantssrees oresteventse tae aera eee aeSreeaeet IQlOERCIOSO Sian, sires du cctee cette tes oe Oh aie take eevee eee eee aa ei EXMQUSTIOD EDS scsavscte cs covvczstaemeene teen ee tae, ea ie teh REE eh cee tee oe EXitaliSts ClOSGS ice vce. ssssdssvaiavici ee oars em ea genaaec saevecestuncnnn Tappet clearances (cold):

0.3115 0.3109

to 0.3120 to 0.3114

in (7.91 to 7.92 mm) in (7.90 to 7.91 mm)

0.3331

to 0.3336

in (8.46 to 8.47

mm)

0.0015 in (0.038 mm) 1.810 in (45.97 mm) iso 59° LZ 19°

dei bke ABDC [shah DXC: ATDC

PA:

0.014 to 0.015 in (0.36 to 0.38 mm)

asoacnucnspiuceynct Rees ta Me ENMUSprites teed arecsivettssvasshivrteeta

0.017 to 0.018 in (0.43 to 0.46 mm)

Pfautlie seston cise ntovtn oxonncveho NAGE eee st eoaNT se Re

AdjustzonlVyaitaless: than s...:..c0Actie) ater Meee

SIT re eA

eee

ee

at ei

Valve sequence (from front of head): Wn Ceara ee tn ce vite rss nse Sat alzymetbtowsssauidlsits coat sua selec lon Ra aTC CR eens’ e mote EXNGN tetra e rsemr crease aynceetwascesyeaasace onc shiswescas coseiac duane ices Mveee ete Setraact REE es

0.012 in (0.30 mm) ES

Ont

1,4,,5,8

Timing belt Tensioning TTL Ud OG MeeeentCnme tn cesocciets sate tiutoaeseaeenotn Ser wee

ene

aera

Torque

wrench

engaged

Tension:

NG@welDelituateassteccre

terete: ssc cotecraticctours ter heriaet eee terete eee

Used! De ltrataecnve crac emer

ermesta eurincecavtersenecterdeere comer ete tametermes

10 Ibf ft (14 Nm)

15 Ibf ft (20 Nm)

with hole in tensioner bracket

i

;

en

Cylinder

Chapter 1 Engine

27

head

Height:

Vie SEEN REN CarEC OTe e coos HELO ea COO SOLE cer Sobre Ee EE oe Minimum Seas negiess gccy ag Has Wonca a sggabcn tyes cnsan tas yov ergy onc véepvsnsnaysseasso Maximum clearance under Straight-edge across SUIFACE voeeeecccccseecesesesees

Lubrication

3.312 to 3.322 in (84.12 to 84.38 mm) 3.302 in (83.87 mm) 0.002

in (0.05 mm)

system

Oil pump: EY Fe este ee

ate

ets

Oe

ase oh hace

iets

naahcaae

ee

Bi-rotor

CANE TORO GON OME Mette cared hac ucesinin ae inu Oe Ao. OURSHMOLOISG-DOdY (ClOSlANGE ecntcasaariieyosmanuistacsicactche4 ROME OWO WCIGAFAlee

Seq %

SS

Heater mat.

1 2Demister duct

Chapter 12 Bodywork 224 a ee

ee

ee

eee

38 Heater — dismantling and reassembly cc a ee 1 With the heater removed from the car, remove the drain hose then release the retaining spring clips and remove the heater upper support pins and carrier strap. 2 Remove the side vent elbows. 3 Remove the Rokut rivets securing the heater control panel, remove the flap link rod from the trunnion then move the control levers and panel to one side. 4 Undo the screws securing the matrix pipe bracket, pipe support clip and matrix flange. Lift out the matrix and pipes. Undo the retaining

screws and remove the pipes and gasket from the matrix. 5 Undo the eight screws and two clips securing the heater motor terminal cover. Lift off the cover and disconnect the motor wiring harness plugs. Remove the harness clips.

ee

Undo the two screws and washers securing the demist flaps. 6 Drill out the pop rivet adjacent to the heater lower mounting. 7 Remove the sealing tape from inside the heater control panel aperture. Release the spring retaining clips and separate the two halves of 8 the heater body. Withdraw the resistor unit and place the wiring harness to one side. Remove the two plastic hinge bushes from the flaps.

9

Using a flat screwdriver inserted between the heater body and the

rear of the blower motor casing, carefully ease out the motor. 10 With the heater dismantled, inspect the matrix for signs of leaks and, if any are apparent, renew the matrix. If the matrix appears serviceable, brush off any accumulation of dirt or debris from the fins and then reverse flush the core. Inspect the remaining heater components for any signs of damage or distortion and renew as necessary. 11 Reassembly is the reverse sequence to dismantling, but adjust the

heater flap linkage, as described in Section 36, on completion.

Conversion factors an na Length (distance) Inches (in) Feet (ft)

X X

25.4 0.305

Miles

X

1.609

= Millimetres (mm) = Metres (m)

X 0.0394 X25

= Kilometres (km)

= Inches (in) = Feet (ft)

M0

O62 1) = Miles

Volume (capacity)

Cubic inches (cu in; in*)

X 16.387

Imperial pints (Imp pt) Imperial quarts (Imp qt) Imperial quarts (Imp qt) US quarts (US qt) Imperial gallons (Imp gal) Imperial gallons (Imp gal) US gallons (US gal)

X De X X X X X

0.568 = Litres (I) Sie—sItress (|) 1.201 = US quarts (US qt) 0.946 = Litres (I) 4.546 = Litres (I) 1.201 = US gallons (US gal) 3.785 = Litres (I)

X

0.061

x Xx X X Xx X X

= Cubic inches (cu in; in’)

1.76 0.88 0.833 1.057 0.22 0.833 0.264

= = = = = = =

X X

28.35 0.454

= Grams (g) = Kilograms (kg)

X X

0.035 2.205

= Ounces (oz) = Pounds (Ib)

X X X

0.278 4.448 0.1.

= Newtons (N) = Newtons (N) = Kilograms-force (kgf; kg)

Xx X x

3.6 0.225 9.81

= Ounces-force (ozf; oz) = Pounds-force (Ibf; Ib) = Newtons (N)

X

0.070

= Kilograms-force per square

X

14.223

= Pounds-force

= Cubic centimetres (cc; cm’)

Imperial pints (Imp pt) Imperial quarts (Imp qt) Imperial quarts (Imp qt) US quarts (US qt) Imperial gallons (Imp gal) Imperial gallons (Imp gal) US gallons (US gal)

Mass (weight) Ounces Pounds

(oz) (lb)

Force Ounces-force (ozf; oz) Pounds-force (Ibf; Ib) Newtons (N)

Pressure Pounds-force

per square inch

(psi; Ibf/in?; |Ib/in?) Pounds-force

centimetre (kgf/cm?; kg/cm?)

per square

(psi; Ibf/in?; |b/in?) Pounds-force

inch

X

0.068

= Atmospheres

(atm)

X

14.696

= Pounds-force

per square inch

(psi; Ibf/in?; Ib/in?)

per square

inch

X

0.069

= Bars

(psi; Ibf/in?; |b/in?) per square

Pounds-force

per square inch

(psi; Ibf/in?; Ib/in?)

inch

X

6.895

= Kilopascals (kPa)

x

14.5

= Pounds-force

per square

X

0.145

= Pounds-force

per square inch

(psi; Ibf/in?; Ib/in?)

inch

(psi; Ibf/in?; |b/in?)

(psi; Ibf/in?; Ib/in?) Kilopascals (kPa)

X

0.01

= Kilograms-force

per square

x

98.1

= Kilopascals (kPa)

centimetre (kgf/cm?; kg/cm?)

Torque (moment of force) X

0.868

0.113

= Kilograms-force centimetre (kgf cm; kg cm) = Newton metres (Nm)

Xx

8.85

X

0.083

= Pounds-force feet (Ibf ft; Ib ft)

Xx

2

X

0.138

= Kilograms-force (kgf m; kg m)

metres

X

7.233

(Nm)

x

0.738

= Pounds-force

metres

X

9.804

= Newton

X

0.0013.

Pounds-force (Ibf in; Ib in)

inches

X

1.152

Pounds-force (Ibf in; Ib in) Pounds-force

inches

X

inches

Pounds-force

feet (ibf ft; Ib ft)

Pounds-force

feet (Ibf ft; Ib ft)

= Pounds-force inches (Ibf in; Ib in) = Pounds-force inches (Ibf in; Ib in) = Pounds-force inches

(Ibf in; Ib in)

(Ibf in; Ib in)

Newton

metres

(Nm)

X

1.356

= Newton

X

0.102

= Kilograms-force

metres

= Pounds-force feet (Ibf ft; Ib ft) feet (Ibf ft: Ib ft)

metres (Nm)

(kgf m; kg m)

Power Horsepower

(hp)

X

745.7

= Watts

X

1.609

= Kilometres per hour (km/hr; kph) X

X X

0.354 0.425

= Kilometres = Kilometres

(W)

= Horsepower

|

Velocity (speed) Miles per hour (miles/hr; mph)

0.621

.

Miles per gallon, Imperial (mpg) Miles per gallon, US (mpg)

Temperature

Fahrenheit

*/t is common

,

= Miles per hour (miles/hr; mph)

Fuel consumption*

Degrees

(hp)

=

(°C x 1.8) + 32

per litre (km/|) per litre (km/I)

eZ. 825 x 2.352

= Miles per gallon, Imperial (mpg) = Miles per gallon, US (mpg)

Degrees Celsius (Degrees Centigrade; °C)

practice to convert from miles per gallon (mpg) to litres/100 kilometres (I/100km),

where mpg (Imperial) x 1/100 km = 282 and mpg (US) x 1/100 km = 235

= (°F - 32) x 0.56

Index A

radiator grille — 207

About this manual — 2 Accelerator cable removal and refitting 1.3 litre engine — 82 1.6 litre engine — 82 Accelerator pedal removal and refitting — 83 Acknowledgements — 2 Air cleaner and element removal and refitting 1.3 litre engine — 78 1.6 litre engine — 79 Alternator brushes removal, inspection and refitting — 169 fault tracing and rectification — 168 removal and refitting — 168 Antifreeze mixture — 72 Automatic transmission — 141 et seq Automatic transmission description — 142 fault diagnosis — 144 final drive gear oil level checking — 143 fluid draining and refitting — 143 level checking — 142 kickdown cable adjustment — 143 maintenance

rear windows repair

,

— 210

major damage — 206 minor damage — 205 seat belts — 217 seats — 217 sunroof — 218 torque wrench settings — 204 windscreen — 210 Bodywork repair sequence (colour) — 214, 215 Bonnet lock adjustment — 206 lock and release cable removal and refitting — 207 release cable and lever removal and refitting — 210 removal, refitting and adjustment — 206 Boot lid removal and refitting — 208 lock removal and refitting — 208 lock solenoid removal and refitting — 183 private lock removal and refitting — 209 release cable and lever removal and refitting — 210 Braking system — 152 et seq

and inspection — 142

removal and refitting — 143 selector cable adjustment — 144 removal and refitting — 144 selector lever assembly removal and refitting — 144 specifications — 141 starter inhibitor/reversing lamp switch removal and refitting — 144 torque wrench settings — 141

B

Braking system description — 153 fault diagnosis — 165 footbrake pedal removal and refitting — front brake caliper removal, overhaul and front brake disc removal and refitting — front disc pads inspection and renewal

handbrake cable

163

refitting — 154

155 — 153

adjustment — 161

Battery

charging — 168 ee removal and refitting — 168

Bleeding the brakes — 160

Bodywork — 204 et seq

Bodywork bonnet — 206, 207 boot lid — 208, 209, 210 bumpers — 218 centre console — 220 description — 204 doors — 182, 206, 210, 211, 212, 213, 216 facia panel — 220 front body panel — 208 front wing — 208 heater — 220, 224 maintenance

bodywork and underframe — 204 hinges and locks — 206 upholstery and carpets — 205

handbrake cable (front) removal and refitting — 162 handbrake cable (intermediate)

removal and refitting — 163

handbrake cable (rear) removal and refitting — 163 handbrake lever and switch removal and refitting — 163 hydraulic pipes and hoses removal and refitting — 159 hydraulic system

bleeding — 160 maintenance and inspection — 153 master cylinder overhaul — 158 removal and refitting — 158 rear brake backplate

removal and refitting — 158 rear brake shoes

inspection and renewal — 155

Index >

SS

rear wheel

EE

EEE

ee

cylinder

overhaul — 157 removal and refitting — 157 specifications — 152 stop-light switch removal and adjustment — 163 torque wrench settings — 152 twin GP valve description and testing — 159 removal and refitting — 159 vacuum servo unit description — 163

removal and refitting — 164 servicing — 164 Bulb renewal front direction indicator — 176 headlamps — 175 heater control illumination — 177 instrument panel illumination and warning lamps — 177 interior courtesy lamp — 176 number plate lamp — 176 rear lamp cluster — 176 selector lever illumination (automatic transmission) — 178 switch illumination — 177

Bumpers removal

221

— EE

and refitting — 218

fault diagnosis — 76 filling — 72 flushing — 72 maintenance and inspection — 71 radiator — 73 specifications — 69 thermostat — 73 torque wrench settings — 69 water pump 1.3 litre pump — 73 1.6 litre engine — 74 Crankcase examination and renovation 1.3 litre engine — 35 1.6 litre engine — 35, 56 Crankcase ventilation system 1.3 litre engine — 34 1.6 litre engine — 56 Crankshaft (1.3 litre engine) examination

and renovation

— 35

refitting — 38 removal — 34 Crankshaft (1.6 litre engine) examination

and renovation

— 35, 36

refitting — 59 removal — 55 Cylinder block examination

and renovation

1.3 litre engine — 35 1.6 litre engine — 35, 36

Cc

Cylinder head (1.3 litre engine) decarbonising, valve grinding and renovation — 36

Camshaft

(1.3 litre engine)

examination and renovation — 36 refitting — 39 removal — 33

Camshaft (1.6 litre engine) examination and renovation — 57 refitting — 62

Capacities, general — 5

dismantling — 32 reassembly and refitting — 41 removal — 31

Cylinder head (1.6 litre engine) decarbonising, valve grinding and renovation — 57 dismantling — 54 reassembly — 62 refitting — 64

Carburettor (SU)

removal

adjustments — 84 description and operation — 83 dismantling, overhaul and reassembly — 87 removal and refitting — 84 specifications — 77 Clutch — 105 et seq

Clutch assembly inspection — removal and cable removal and description — 105 fault diagnosis — pedal

109 refitting — 108

D Decarbonising 1.3 litre engine — 1.6 litre engine — Dimensions, general Direction indicator —

36 57 — 5 172

Distributor (1.3 litre engine) refitting — 107 111

removal and refitting — 108 release bearing: removal, inspection and refitting 4-speed gearbox — 110 5-speed gearbox — 110 specifications — 105 torque wrench settings — 105 Coil, ignition description and testing 1.3 litre engine — 100 1.6 litre engine — 103 Connecting rods (1.3 litre engine) examination and renovation — 36 refitting — 39 removal — 33

Connecting rods (1.6 litre engine) examination and renovation — 36, 56 removal — 55 Conversion factors — 225 Coolant temperature thermistor removal and refitting — 76 Cooling fan assembly removal and refitting — 75 thermostatic switch testing, removal and refitting — 75 Cooling system — 69 et seq

Cooling system antifreeze mixture — 72 coolant temperature thermistor — 76 cooling fan — 75 description — 70

draining — 71 drivebelt — 75

engine in car — 50 engine on bench — 52

dismantling and reassembly — 96 removal and refitting — 96

Distributor (1.6 litre engine) cap and rotor arm

removal and refitting — 103 Door central locking description — 182 solenoid: removal and refitting — 182 front glass and regulator: removal and refitting — 212 inner trim panel: renewal and refitting — 210 lock: removal, refitting and adjustment — 211 mirror: removal and refitting — 213 private lock: removal and refitting — 212 removal and refitting — 211 rattles tracing and rectification — 206

rear glass and regulator: removal and refitting — 216 inner trim panel: removal and refitting — 213 lock: removal, refitting and adjustment — 216 removal and refitting — 213 Drivebelt renewal and adjustment — 75 Driveshafts — 146 et seq

Driveshafts description — 146 fault diagnosis — 151 inner constant velocity joint removal, inspection and refitting — 149 maintenance and inspection — 146 outer constant velocity joint removal, inspection and refitting — 150 removal and refitting — 147 specifications — 146 torque wrench settings — 146

ee

a

228

Index ED,

E

refitting with transmission — 67 removal methods

— 45 with automatic transmission — 49 with manual gearbox — 45

Electrical system — 166 et seq Electrical system accessory wiring — 183 alternator — 168, 169 battery — 168 boot lock — 183 central door locking system — 182 clock — 175 description — 167 direction indicator and hazard flasher system — 172 facia switches — 173 fault diagnosis — 19, 184 fuses, relays and control

units —

radio, radio/cassette player — 181 specifications — 166 speedometer cable — 181 starter motor — 170 steering column switches — 172 torque wrench settings — 167 windows, electrically-operated — 181, windscreen washer — 181 windscreen wiper — 179 wiper blades and arms — 178

182

to 239

Engine — 23 et seq

Engine (1.3 litre) adjustments after overhaul — 42 ancillary components — 31, 42 attachment to gearbox — 42 camshaft and tappets — 33, 36, 38 crankcase ventilation system — 32 crankshaft and main bearings — 34, 35, 38 cylinder block and crankcase — 35 cylinder head — 31, 32, 36, 40 description — 27 dismantling — 30 examination and renovation — 35 fault diagnosis — 20, 68 gearbox adaptor plate — 33, 36, 40 maintenance and inspection — 27 mountings — 37 oil pump — 33, 35, 38 operations possible with engine in car — 30 operations requiring engine removal — 30 pistons and connecting rods — 33, 36, 38 reassembly — 38 refitting with gearbox — 42 removal methods — 30 with gearbox — 30 separation from gearbox — 30 specifications — 24 sump — 33, 40 tie-rod — 38 timing cover, chain and gears — 32, 36, 40 torque wrench settings — 25 valves — 36, 42

Engine (1.6 litre) adjustments after overhaul — 67 ancillary components — 50, 67 attachment to transmission — 67 camshaft — 57, 62 crankcase ventilation system — 56 crankshaft and main bearings — 35, 55, 56, 59 cylinder block and crankcase — 35, 56 cylinder head — 50, 52, 54, 57, 62, 64

description — 42 dismantling — 30, 49 examination and renovation — 56 fault diagnosis — 20, 68 gearbox adaptor plate — 36, 54, 56, 60 maintenance

— 49

sump — 54, 60 tappets — 57, 62, 66

timing belt — 50, 57, 65 torque wrench settings — 27 Exhaust system checking, removal and refitting — 91

172

fusible link — 172 headlamps — 175, 176, 178, 181 horn — 181 ignition switch/steering column lock — 172 instrumentation — 173 instrument panel and instruments — 173, 174 lamps bulbs — 175, 176, 177, 178 maintenance and inspection — 168 precautions — 167

wiring diagrams — 231

separation from transmission specifications — 25

and inspection — 45

mountings — 58 oil pump and housing — 54, 56, 60 operations possible with engine in car — 45 operations requiring engine removal — 45 pistons and connecting rods — 36, 55, 56, 60 reassembly — 59

F

Fault diagnosis automatic transmission — 144 braking system — 165 clutch — 111 cooling system — 76 driveshafts — 151 electrical system — 19, 184 engine — 20, 68 fuel system — 93 gearbox — 140 ignition system electronic — 100, 101 programmed electronic — 104 steering — 203 suspension — 203 Facia panel removal and refitting — 220 Fuel and exhaust systems — 77 et seq Fuel gauge sender unit removal and refitting — 82 Fuel pump removal, testing and refitting — 81 Fuel system accelerator cable — 82 accelerator pedal — 83 air cleaner and element 1.3 litre engine — 78 1.6 litre engine — 79 carburettor (SU) — 83, 84, 87 description — 78 fault diagnosis — 93 fuel gauge sender unit — 82 fuel pump — 81 fuel tank — 81 maintenance and inspection — 78 specifications — 77

torque wrench settings — 78 Fuel tank removal, servicing and refitting — 81 Fuses — 172 Fusible link — 172

G Gearbox — 112 et seq

Gearbox

(all models)

description — 113 fault diagnosis — 140 gear lever

adjustment — 139 gear lever and linkage removal and refitting — 139 maintenance and inspection — 113 overhaul — 118 removal and refitting — 113 specifications — 112 torque wrench settings — 113

Gearbox (five-speed) differential unit inspection — 126, 133 gear carrier housing overhaul — 131 mainshaft dismantling and reassembly — 132 mainshaft, pinion shaft and differential reassembly — 133 removal — 131 pinion shaft bearings renewal — 123, 132 reassembling the housings — 136 separating the housings — 128

Index

229

SR

Gearbox (four-speed) differential unit inspection

— 126

gear carrier housing overhaul — 123 main casing overhaul — 123 mainshaft dismantling and reassembly — 124 mainshaft, pinion shaft and differential reassembly — 126 removal — 121 pinion shaft bearings renewal — 123 reassembling the housings — 128 separating the housings — 119 synchroniser units inspection — 125 Gearbox adaptor plate (1.3 litre engine) examination and renovation — 26 refitting — 40 removal — 33

L Lubricants and fluids, recommended Lubrication chart — 11

— 11

M Main bearings (1.3 litre model) examination and renovation — 35 refitting — 38 removal — 34 Main bearings (1.6 litre engine) examination and renovation — 35, 56 refitting — 59 removal — 55 Maintenance, routine — 13 Manifolds, inlet and exhaust removal and refitting 1.3 litre engine — 89 1.6 litre engine — 90

Gearbox adaptor plate (1.6 litre engine) examination and renovation — 36, 56 refitting — 61 removal — 54

O Oil pump (1.3 litre engine) examination — 35 refitting — 39 removal — 33 Oil pump and housing (1.6 litre engine)

H

examination and renovation — 56 refitting — 61 removal — 54

Hazard flasher system — 172 Headlamps aim adjustment — 178 bulb renewal — 175 lens assembly

removal and refitting — 176 washer jet

removal and refitting — 181 Heater adjustments — 220 dismantling and reassembly — 224 removal and refitting — 220 Horn removal and refitting — 181 Hub bearings removal and refitting front — 190 rear — 194

P

Pistons (1.3 litre engine) examination and renovation — 36 refitting — 39 removal — 33

Pistons (1.6 litre engine) examination and renovation — 36, 56 refitting — 60 removal — 55

R Radiator removal,

Ignition system — 94 et seq Ignition system (1.3 litre engine) amplifier — 100 coil — 100 description — 95 distributor — 96 fault diagnosis — 100, 101 maintenance and inspection — 95 spark plugs and HT leads — 99, 100 specifications — 94 timing — 98 torque wrench settings — 94

Ignition system (1.6 litre engine) coil — 103 coolant thermistor — 103 crankshaft sensor — 103 description — 102 distributor cap and rotor arm — 103 electronic control unit — 103 fault diagnosis — 104 knock sensor — 103 maintenance and inspection — 103 spark plugs and HT leads — 99, 100

specifications — 95 torque wrench settings — 95 Instrument panel and instruments dismantling and reassembly — 174

removal and refitting — 173

J Jacking — 10

inspection, cleaning and refitting — 72

Radiator grille removal and refitting — 207 Radio, radio/cassette player removal and refitting — 181 Relays and control units — 172 Repair procedures, general — 9 Roadwheels general — 202 size — 186 torque wrench setting — 186 Routine maintenance — 13

S Safety — 12

Seat belts removal and refitting — 217 Seats removal and refitting — 217 Spare parts buying — 6 to carry in car — 20 Spark plug conditions (colour chart) — 99 Spark plugs and HT leads — 100 Speedometer cable removal and refitting — 181 Starter motor overhaul — 170 removal and refitting — 170 testing in car — 170 Steering column assembly removal, overhaul and refitting — 197 column intermediate shaft removal and refitting — 199

230

Index

SS

column lock/ignition switch removal and refitting — 199 description — 186 fault diagnosis — 203 front wheel alignment and steering angles — 201 maintenance

and inspection —

189

rack and pinion gear dismantling and reassembly — 201 removal and refitting — 200 rack rubber gaiter removal and refitting — 199 specifications — 186 tie-rod outer balljoint removal and refitting — 199 torque wrench settings — 186 wheel removal and refitting — 197 Sump (1.3 litre engine) refitting — 40 removal — 33 Sump (1.6 litre engine) refitting — 61 removal — 54 Sunroof removal and refitting — 218 Suspension anti-roll bar

removal and refitting — description — 186 fault diagnosis — 203 front hub bearings removal and refitting — front lower suspension arm removal and refitting — front lower suspension arm removal and refitting — front suspension

194

190 193 balljoint 194

Tools general — 7 to carry in car — 20 Towing — 10 Tyres general — 202 pressures — 186 size — 186

Vv Valves (1.3 litre engine) clearances adjustment — 42 grinding — 36 Valves (1.6 litre engine) grinding — 57 Vehicle identification

numbers

— 6

strut

dismantling and reassembly — 192 removal and refitting — 191 front swivel hub assembly removal and refitting — 189 rear axle removal and refitting — 197 rear hub assembly removal and refitting — 194 rear hub bearings removal and refitting — 194 rear stub axle

removal and refitting — 195 rear Suspension strut dismanting and reassembly — 196 removal and refitting — 196 specifications — 185

torque wrench

Tappets (1.6 litre engine) clearances checking and adjustment — 66 examination and renovation — 57 refitting — 62 Thermostat removal, testing and refitting — 73 Timing belt (1.6 litre engine) removal — 50 Timing belt, sprockets and tensioner (1.6 litre engine) examination and renovation — 57 refitting and adjustment — 65 Timing cover, chain and gears (1.3 litre engine) examination — 36 refitting — 40 removal — 32 Timing, ignition (1.3 litre engine) adjustment — 98

settings — 186

Suspension and steering — 185 et seq Switches facia — 173 ignition/steering column lock — 172 steering column — 172

T Tappets (1.3 litre engine) examination — 36 refitting — 39 removal — 33

Ww Water pump removal and refitting 1.3 litre engine — 73 1.6 litre engine — 74

Weights, general — 5 Wheels see Roadwheels Window lift motor removal and refitting — 181 ‘one-touch’ control unit removal and refitting — 182 Windows, electrically-operated — 181 Windows, rear removal and refitting — 210 Windscreen removal and refitting — 210 Windscreen wiper linkage removal and refitting — 179 motor removal and refitting — 179 primary link removal and refitting — 179 Windscreen washer reservoir and pump removal and refitting — 181 Wiper blades and arms removal and refitting — 178 Wiring diagrams — 231 to 239 Working facilities — 8

231

Symbols used in the wiring diagrams

Colour code

Component earthed by a lead Component earthed through its mounting If fitted Printed circuit Line connector aNAaRWN— Sealed joint

Purple

Black

Red Slate Blue

Green Pink Light green

White