Alfa Romeo alfa 33 Workshop Manual
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Alfa Romeo alfa 33 Workshop Manual

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Table of Contents

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Summary of Contents for Alfa Romeo alfa 33

  • Page 2: Table Of Contents

    CONTENTS GENERAL VIEWS . . , ....OO-2 APPROXIMATE REFILL CAPACITIES. 00-24 Dimensions and weights... OO-2 ENGINE MAINTENANCE ...OO-24 MODEL VARIATION .

  • Page 3: General Views

    COMPLETE CAR G E N E R A L V I E W S DIMENSIONS AND WEIGHTS 1350 1500 Model 1200 identification number 905.00 905.02 905.04 905.05 905.06 - 905.07 Wheelbase ( i n ) 2 4 5 5 (96.651 1392 (54.8) Front Track...

  • Page 4: Model Variation

    COMPLETE CAR MODEL VARIATION (Except Switzerland, Sweden, Australia) 1500 1200 1350 1500 Model Body 5 -door saloon Drive Left Right Left Left Right Left Right 905.06 905.03 905.07 905.02 Identification No. 905.04 label 905 A 905 Al 905 A2 905 A2 label Type approval No.

  • Page 5: Identification Data

    COMPLETE CAR IDENTIFICATION DATA IDENTIFICATION LABELS 5 - Door Saloon 1200 - .I350 - 1500 (Except Switzerland, Sweden, Australia) Certification and identification label (Identification No. and Type approval No.) Intermediate bulkhead label-(Type approval No. and serial No.) Cylinder block label (Engine No.) Lubrication data label (see “Fluids and Lubricants”...

  • Page 6: Lifting Points And Towing

    COMPLETE CAR It consists of two sets of figures, ALFA ROMEO AUTO SPA namely: I II 305.00 00045 12 all engines having common gen- eral technical characteristics (Ex.: 305.02: 1350 engine with twin carburetor). assigned by production. LIFTING POINTS AND TOWING...

  • Page 7: Garage Jack And Safety Stands

    COMPLETE CAR GARAGE JACK AND SAFETY STANDS TOWING WARNING: Set ignition key to “GAR” and Closely follow Motor Vehicle Fiegu- When raising vehicle with garage do not withdraw it from switch; jack, be sure to support it with otherwise antitheft device could safety stands.

  • Page 8: Special Service Tools

    COMPLETE CAR SPECIAL SERVICE TOOLS Special service tools play a very on the manufacturer’ s expressly A.O.OOOO Special Service Tool important role in a vehicle’ s majnte- design, needed for overhauling, main- Tester tenance and repair of models are Reamer ensure accurate, reliable and quick listed and illustrated in this manual.

  • Page 9: Cleaning And Finishing Inspection

    COMPLETE CAR Heating system Doors and bonnets Engine controls Check proper working condition Check and make sure starter of levers controlling heater and stripping for tight fit and make c o n t r o l k n o b w o r k s f r e e l y , outlets for admission of air into sure they are not damaged, out without sticking;...

  • Page 10: Maintenance

    COMPLETE CAR MAINTENANCE Coupons will have to be stamped by side parts: bumpers, mouldings, the Service Organisation Agency to grills, headlight rims, letters and Maintenance operations consist in show that specified maintenance emblems making sure they are checking and restoring proper work- operations have been carried out.

  • Page 11: Maintenance Schedule

    COMPLETE. CAR MAINTENANCE SCHEDULE (Except Switzerland, Sweden, Australia) 0 0 - 1 1 M a y 1983...
  • Page 12 COMPLETE CAR (Except Switzerland, Sweden, Australia) 0 0 - 1 2 M a y 1 9 8 3...
  • Page 13 COMPLETE CAR MAINTENANCE SCHEDULE...
  • Page 14 COMPLETE CAR (Swiss version) 0 0 - 1 4 May 1983...
  • Page 15 COMPLETE CAR MAINTENANCE SCHEDULE 0 0 - 1 5 May 1983...
  • Page 17 COMPLETE CAR MAINTENANCE SCHEDULE (Australia version) M a y 1 9 8 3...

  • Page 19: Fluids And Lubricants Chart

    COMPLETE CAR FLUIDS AND LUBRICANTS CHART May 1983...

  • Page 20: Reccommended Fuel And Lubricants

    COMPLETE CAR RECOMMENDED FUEL AND -LUBRICANTS FUEL To ensure proper engine operation, use petrol with a 2 98 Octane Rating Rating.

  • Page 21: Fluids And Lubricants

    COMPLETE CAR FLUIDS AND LUBRICANTS 00-2 1 May 1983...
  • Page 22 COMPLETE CAR May 1983...

  • Page 24: Approximate Refill Capacities

    COMPLETE CAR APPROXIMATE REFILL CAPACITIES kg (lb) A P P R O X I M A T E A P A C I T I E S FUEL TANK 50 (11) FUEL RESERVE 6.5 (I ,431 COOLANT 7.3 (I ,611 With filter 3.6 (7.94) ENGINE OIL SUMP...
  • Page 25 COMPLETE CAR Bolt 3 Screw 2 Bolt Replacing timing belts with engine on car Interpose tool C.6.0168 between Mark on rear cover tapper bucket upper part and cam R E M O V A L 2 T - shaped reference mark minimum radius and, by means of wrench A.5.0193, operate until the Disconnect electric fan wiring,...
  • Page 26 COMPLETE CAR Check again engine timing. 4. Fit back camshaft support cov- alternator and water pump ers, spark control belt, electric plugs. Start engine and warm it up to normal running temperature, then remove again camshaft support cov- ers. Working on one cylinder head the time, proceed as follows: bring A milky oil indicates the pres- relevant camshaft in neutral position,...
  • Page 27 COMPLETE CAR 6. Fit oil filler cap back and start Refill radiator through relevant filler the engine letting it idle for about 2 according to following instructions: minutes. 7. Now check following items for any oil leaks: filter, pan, seal rings, mark expansion reservoir...

  • Page 28: Ignition And Fuel System

    COMPLETE CAR CHECKING CYLINDER o r b e t w e e n c y l i n d e r l i n e r s a n d COMPRESSION p i s t o n s . REPLACING AIR CLEANER When diagnostic poor engine perfor- CARTRIDGE mance because power is not up to...

  • Page 29: Checking Co

    COMPLETE CAR CHECKING CO% Spark plug thread: CHECKING THE DISTRIBUTOR CHECKING AND ADJUSTING IGNITION TIMING, Visual check IDLE-RPM AND COY.. Spark plugs 1. Remove distributor cap and rotor @ and check them for cracks or chips. 18.08 + 25.31 ft.lb) 2.

  • Page 30: Checking And Adjusting

    COMPLETE CAR CHECKING AND ADJUSTING Remove the small plastic IDLE-RPM AND CO% CAUTION: located on the engine rear cover. If during engine tune up there is no extra cooling fan available, keep checking indicator pump and the Preliminary inspection: water temperature gauge on dash- Clean or replace air cleaner.
  • Page 31 COMPLETE CAR 3. Start the workshop’ s gas ex- medium rpm, the vapors going up the Sweden, Australia) idling speed is oil filler go through the flame trap reached. located in the hose @ connecting (5) Act on mixture metering oil filler to air cleaner;...

  • Page 32: Trouble Diagnosis And

    COMPLETE CAR CARBURETOR CLEANING REPLACING FUEL FILTER as well as idle jets. JETS Loosen hose clamps and remove the Clean jets with compressed air If necessary, clean carburetor jets filter. Install a new filter paying (do not use any metal tool) and a n d b l o w - b y h o s e s a s f o l l o w s : special attention to the fuel flowing then fit them back onto carbure-...
  • Page 33 COMPLETE CAR Condition Probable cause Corrective action Spark is good: a. Check spark plug b. Check ignition timing Check fuel system d. Check cylinder compression Spark is not good: Low or no current in primary Check primary circuit for loose or Ignition system is out of order circuit disconnected terminals...
  • Page 35 COMPLETE CAR Condition Probable cause Corrective action High engine idling Stiff accelerator cable Check linkage Adjust Incorrect idle adjustment Check Malfunctioning throttle valve ENGINE POWER NOT UP TO NORMAL Previously mentioned Low compression Previously mentioned Ignition system out of order Incorrect ignition timing Adjust Dirty or worn spark plugs...
  • Page 36 COMPLETE CAR Condition Probable cause Corrective action Replace with petrol having specified Petrol used has low octane rating Other octane rating Dragging brakes Adjust Adjust or replace NOISY ENGINE (while driving) Use proper gear in driving Engine knocking Knocking due to carbon deposit Disassemble cylinder head and remove carbon deposit Knocking due to incorrect...
  • Page 37 COMPLETE CAR Probable cause Condition Corrective action A B N O R M A L C O M B U S T I O N (backfire, self-ignition, detonations) Incorrect ignition timing Incorrect ignition Adjust timing Replace with recommended type plugs Wrong type spark plugs Fuel system out of order Previously mentioned...
  • Page 38 COMPLETE CAR Condition Probable cause Corrective action EXCESSIVE FUEL CONSUMPTION Previously mentioned Engine power not up to Previously mentioned normal Idling too high Other Adjust idling Improper accelerator recovery Adjust Fuel leaks Repair or tighten fuel line unions Clogged air cleaner Replace cartridge Improperly adjusted carburetor Adjust...

  • Page 39: Checking Fuel And Exhaust System

    COMPLETE CAR AND BODY MAINTENANCE CHASSIS CLUTCH CHECKING FUEL AND EXHAUST CHECKING CLUTCH SYSTEM SYSTEM Check clutch pump @ and clutch sure control cylinder @ making there are not oil leaks. If required, tighten unions according to specified Check fuel and exhaust systems, torques or either overhaul or replace especially at connections, making faulty parts (Refer to: Group 12 -...

  • Page 40: Rear Axle And Rear Suspension

    COMPLETE CAR ADJUSTING WHEEL BEARING PRELOAD After replacement or disassembly of bearings, carry out adjustment oper- ating as follows. For wheel replacement refer bearing to Group 25. 1. Tighten wheel bearing lock-nut according to specified torque the same time turn hub 4 + 5 times 5.
  • Page 41 COMPLETE CAR FRONT SUSPENSION plane passing on the base of the nut HEIGHT connecting hub support to control arm, and the straight line tangent to Check front wheel alignment picking the hub support. up specified dimension which is Point 2: o b t a i n e d b y d r a w i n g t w o l i n e s axis of the bolt securing control arm parallel to floor plane respectively...

  • Page 42: Wheel Alignment

    COMPLETE CAR steering wheel and centre racks. Point 1: (1) Use suitable equipment and Axis of bolt @ securing front rod measure toe-out making sure it is to wheel support. within specified value. Point 2: Axis of bolt @ securing front rod Toe-out to body.

  • Page 43: Brake System

    COMPLETE CAR Camber angle Nut securing side rod ball joint onto vertical steering lever 2 8 . 9 2 + 3 5 . 4 3 Camber and caster angles cannot be adjusted. 4. Max steering angle BRAKE SYSTEM C H E C K I N G B R A K E F L U I D LEVEL 1 Joint’...

  • Page 45: Steering System

    COMPLETE CAR B O D Y (4) Maneuverability of control lever must result to be easy and smooth LOCKS AND HINGES running and when control lever is 1 . L u b r i c a t e h i n g e s a n d locks. engaged hooking tooth must be into Adjust lock striker plates.

  • Page 47: Chassis And Body Maintenance

    COMPLETE CAR CHASSIS AND BODY MAINTENANCE TECHNICAL DATA - INSPECTION AND ADJUSTMENT Axles and suspensions Vehicle static loading arrangement (1) (110 +55 =165) c = 490 (SOT; (110) Front wheel alignment mm (in) A =12 f7 (0.47 iO.28) Rear wheel alignment mm (in) Front wheel toe-out (2) (3) mm (in)
  • Page 50 ENGINE MAIN MECHANICAL UNIT REMOVAL DETAIL A (4.1 + 5 29.6 f 36.2) DETAIL 6 DETAIL C Drive unit central support Central supporr to body fixing bolt Rear support pin Rear support to body fixing screws Gearbox casing Engine unit Engine front support to crossmember fixing screw Engine front support Detail A...
  • Page 51 ENGINE MAIN MECHANICAL UNIT compartment - Electrlc w i r e s dlsconnectlons Engine Horn cables Ignition inductor cable Electric fan supply cable ignition distributor Windshield and rear window washers pump cables Cooling temperature transmitter cable Water temperature thermal contact cable Coil high voltage cable Oil pressure manual contact cable Tachometer and coil low voltage cables...
  • Page 52 ENGINE MAIN MECHANICAL UNIT E n g i n e c o m p a r t m e n t - Plplng r e l e a s e 1 Fuel pipe Clutch oil supply pipe Air bleeder into crankcase Sleeve for water delivery to radiator 7 Servobrake vacuum pipe...
  • Page 54 ENGINE MAIN MECHANICAL UNIT During engine removal from car, it is 6. With reference to the figure on after draining. necessary to remove engine and page 01-3 disconnect the following 9. Depending on what is to be gearbox - differential as single electric cables, preferably as indi- done, drain the oil from the oil sump unit.
  • Page 56 E N G I N E M A I N M E C H A N I C A L U N I T INSTALLATION Central support Bolt securing gearbox rear support support securing bolt 2 Central 7 Exhaust pipe 3 Rear support Engine cross member securing screw 4 Pin...
  • Page 57 ENGINE MAIN MECHANICAL UNIT 9 . C o m p l e t e t h e u n i t a s s e m b l e prescribed oil: Summer carrying out the disassembly opera- Potable water Engine oil tions in reverse order, with particular attention to the following steps.
  • Page 58 ENGINE MAIN MECHANICAL UNIT ENGINE DISASSEMBLY 1 9 8 3 M a y...
  • Page 60 ENGINE MAIN MECHANICAL UNIT (6.7 + 7.4 48.4 + 53.5) 5.8 f 7.2) Main bearings Compression rings Woodroff key Oil scraper ring Thrust half-ring Oil pump Oil pump gear Oil sump Bush Engine oil drain plug Seal ring Main bearing caps Rear cover Piston Oil plug...
  • Page 61 ENGINE MAIN MECHANICAL UNIT PRELIMINARIES Unscrew and remove screws @ f i x i n g u n i o n 0 t o b l o c k , t h e n remove the union. . R e m o v e d r i v e u n i t f r o m c a r according to procedures: Drive Unit Removal and Installation.
  • Page 62 ENGINE MAIN MECHANICAL UNIT (2) Unscrew right belt stretcher @ 9. Remove intake manifold (1) Unscrew nuts 0, remove en- securing nut and press on jockey pulley @ to overcome belts tension gine lifting bracket @ and mani- load; lock nut by fixing belt stretcher fold 0.
  • Page 63 ENGINE MAIN MECHANICAL UNIT (2) Suck oil from camshaft supports (2) Withdraw upward pump from 17. Lock flywheel by tool A.2.0378. tanks with a suitable syringe. block. 18. Unscrew screws 0 and @, ( 3 ) U n s c r e w s c r e w s @ and @ remove guard @and engine front securing cylinder heads to block;...

  • Page 65: Cylinder Heads

    ENGINE MAIN MECHANICAL UNIT 8. Acting on lever A.3.0324 com- press springs and withdraw valve stem totters using a screwdriver. 9. Sequentially remove upper caps, outer and inner springs, boots from intake valves, washers and lower cups. 10. Repeat removal procedure for each valve.

  • Page 67: Valve Seats

    ENGINE MAIN MECHAN1CA.L UNIT grinding, in order to ensure exact Engine Valve guide/seat perpendicularity as as proper valve working position. 38.875 + 38.9 Valve seat (1.5305 + 1.5315) outer VALVE SEATS 33.375 + 33.4 diameter Check valve seats for any scores, mm (in) cracks or burrs and make sure they are properly fitted in their respective...
  • Page 68 ENGINE MAIN MECHANICAL UNIT cup’ s nut intact and that the cup SPRINGS has retained its original punching Visually check the springs for cracks p o s i t i o n . and make sure they are not out-of- square if the evidenced flaws suggest CAUTION: it, check the technical data of the...
  • Page 70 ENGINE MAIN MECHANICAL UNIT MAIN micrometer. For relevant dimensions AND CONNECTING and tolerances see: Service Data and ROD BEARINGS Specifications - “Piston” chart. Thoroughly clean the main and connecting rod bearings and visually check them for scores as well as for any evidence of seizure.
  • Page 71 ENGINE MAIN MECHANICAL UNIT Dimensions relevant to each class are PISTON - CYLINDER Cylinder wall max. taper: shown in: Service Data and Speci- WALL FIT A - B = 0.02 mm (0.00079 in) “Cylinder block” chart. fications Cylinder wall max. out-of-round: X - Y = 0.02 mm (0.00079 in) (1) Reset the reamer by means of a When original parts are involved,...
  • Page 73 ENGINE MAIN MECHANICAL UNIT them with oil. Select bearings accord- Cylinder wall to piston play ing to the diameter of crankshaft Standard 0.03 + 0.05 mm journals. Oversize 0.03 + 0.06 mm (0.0012 + 0.0024 in) 2. Apply engine oil to piston pin, to the connecting rod small end, and to the piston pin supports.
  • Page 74 ENGINE MAIN MECHANICAL UNIT Fit seal ring in the main oil successive steps, according to speci- block having the gauge’ s indicating fied torque and sequence (from A gallery of the cylinder block rear finger touch the crankshaft parallel- to F). cover.
  • Page 76 ENGINE MAIN MECHANICAL UNIT 13. Fit crankshaft front pulleys. (1) Key the below mentioned parts Screws securing water pump according to the indicated sequence: 1 9 +24 Nam the belt guide washer @, the left head camshaft drive toothed pul- 13.7 + 17.4 ft.lb) ley 0, the spacer @, the right head camshaft drive toothed pul-...
  • Page 77 ENGINE MAIN MECHANICAL UNIT for torque spanner with 400 mm (15.748 in) lever arm (6.3 + 6.8 k&m 45.6 + 49.2 ft.lb) 16. Fit camshaft belts rear covers. 17. Fit belt tensioner assemblies on the cylinder block pins according to following sequence: sup-...
  • Page 78 ENGINE MAIN MECHANICAL UNIT P u m p b o d y t o s u p p o r t r e - Belt jockey pulley lock nut taining screws: (with cold engine) 37 f 46 (0.8 (3.8 4 4.7 5.8 + 7.2 ftblb) 27.5 + 34 ftalb) 19.
  • Page 80 ENGINE MAIN MECHANICAL UNIT (3) Key alternator and water pump 34. Assemble carburetor with spacer drive belt on relevant pulleys. and the interposed gaskets on intake Spark plugs: (4) Adjust belt tension according to manifold studs. 2 5 G34 N-m specified value t h e n l o c k...

  • Page 81: Engine Lubrication System

    ENGINE MAIN MECHANICAL UNIT ENGINE LUBRICATION SYSTEM 1 Bypass valve 4 Oil sump 2 Oil filter 5 Gear pump cartridge 6 Pressure relief 3 Camshaft bear- valve ing housing The engine is pressure lubricated by means of a gear pump. The pump is mounted on the rear cover of the engine and is actuated by a shaft which is driven by a gear fitted to the...
  • Page 82 ENGINE MAIN MECHANICAL UNIT sembly Engine Unit. 3. Tighten screws @ securing Engine Oil pressme Engine speed pump to engine rear cover then screws to pump support to the specified 117.7 f274.6 torque value. 1200 17.07 c-9.82) Screws securing pump to en- 1350 gine rear cover 411 .E + 568.7...
  • Page 84 -ENGINE MAIN MECHANICAL UNIT INSPECTION AND ADJUSTMENT CAMSHAFT SYSTEM U n i t : m m (in) 306.00 1200 305.02 1350 305.04 1500 L E F T S U P P O R T RIGHT SUPPORT C a m s h a f t 5 3 1 .
  • Page 85 ENGINE MAIN MECHANICAL UNIT CYLINDER BLOCK Unit: mm (in) Engine inspection data 1200 1 5 0 0 Class A 8 0 . 0 0 t 8 0 . 0 1 ( 3 . 1 4 9 6 +3.1500) 8 4 . 0 0 t 8 4 . 0 1 ( 3 . 3 0 7 1 - 3 . 3 0 7 5 ) 8 4 .
  • Page 86 ENGINE MAIN MECHANICAL UNIT PISTONS, COMPRESSION RINGS AND PINS Pistons Unit: mm (in) Engir Inspection data 1500 1200 1350 79.96 +79.97 (3.1480 + 3.1484) 83.96 f 83.97 (3.3055 + 3.3059) Class A (Blua) Class B (Pink) 79.97 f79.98 (3.1484+3.1488) 83.97 f 83.98 (3.3059 + 3.3063) Standard Class C (Green) 83.98 -83.99 (3.3063 + 3.3067)
  • Page 88 ENGINE MAIN MECHANICAL UNIT CONNECTING ROD AND CONNECTING ROD BEARINGS Connecting rod Unit: m m (in) Engine 1350 1500 1200 21.007 + 21.015 (0.8270 f 0.8274) Small end bush bore diameter “a” 52.696 + 53.708 (2.0746 + 2.1145) Big end bore diamater “b” Connecting rod bearings Unit: mm (in) Engine...
  • Page 89 ENGINE MAIN MECHANICAL UNIT FLYWHEEL Unit: mm (in) Engine Inspection data 1200 1350 1500 24.0 + 24.2 (0.9449 + 0.9528) Regriding dimensions (I) Parallelism of the driven plate contact face compared with flywheel-to-crankshaft support face (as read at 0.08 (0.0031) a 100 mm radius) Maximum out-of-flat of driven plate contact face 0.02 (0.0008,...
  • Page 91 ENGINE MAIN MECHANICAL UNIT Unit: mm (in) Engine Inspection data 1200 1350 1500 Max. misalignment between the centrelines of the two 0.25 (0.0098, pairs of crankpins and the journals centreline Max. out-of-square between thrust ring face and 0.03 (0.00121 main journals 16.065 + 16.080 (0.6325 + 0.6331) Rear crankshaft bush diameter “b”...
  • Page 92 ENGINE MAIN MECHANICAL UNIT CAMSHAFT SUPPORT, CAMSHAFT AND TAPPET BUCKET Camshaft support Unit: mm (in) Engine Inspection data 1500 1200 1350 35.015 + 35.040 (I 3786 + 1.3795) Front Bore of camshaft journal C e n t r a l bearing diameter “a”...

  • Page 93: Cylinder Head

    ENGINE MAIN MECHANICAL UNIT CYLINDER HEAD, VALVES AND SPRINGS Cylinder head Unit: mm (in) Engine Inspection data 1350 1500 1200 Valve guide seat diameter “d” 13.050 f 13.068 (0.5138- 0.5145) Standard Valve guide 0.0. “a” Spare Diameter of valve guide bore “b” 9.8 + 10 (0.3858 4 0.3937) Valve guide protrusion “e”...
  • Page 94 ENGINE MAIN MECHANICAL UNIT S p r i n g s Engine 1350 1200 25.25 (0.9941) Outer spring Length of valve spring with mm (in) valve open “a” 23.25 (0.9154) Inner spring 425.32 + 452.76 (43-4 + 46.2) (95.68 + 101.85) Outer spring Spring rating at N (kg) (lb)
  • Page 95 ENGINE MAIN MECHANICAL UNIT Unit: mm (in) Engine Inspection data 1200 1 3 5 0 1500 Standard 0.03 4 0.05 (0.0012 + 0.0020) Cylinder bore/piston play Oversize 0.03 + 0.06 (0.0012 + 0.0024) 0.035 + 0.067 0.035 + 0.067 -First compression (0.0014 + 0.0026) (0.0014 f 0.0026) 0.035 + 0.067...
  • Page 96 ENGINE MAIN MECHANICAL UNIT E n g i n e Inspection data 1 3 5 0 1 5 0 0 Standard 0.013 + 0.046 (0.0005 + 0.0018) 0.07 (0.0027) Valve stem-to guide play 0 . 0 3 0 + 0 . 0 6 3 ( 0 . 0 0 1 2 + 0 . 0 0 2 5 ) Standard 0 .
  • Page 98 ENGINE MAIN MECHAN1CA.L UNIT After having heated engine until intervention of radiator cooling electric fan, on cold engine, loosen, oil and tighten the six screw securing heat to base by following the order shown in figure In the event of in-car tightening of head nuts with the aid of the extension A.5.0198 to be applied as shown, the torque specifications are: 5 7 f 6 2 torque spanner having a 300 mm (I 1.84 in) lever arm...
  • Page 99 ENGINE MAIN MECHANICAL UNIT Condition cause Probable Corrective action Worn fit surfaces Adjust or replace and piston Poor oil quality User proper oil Dirty air cleaner Replace filter Too rich misture Adjust or replace carburettor Shortage of engine oil Faulty connecting rod Add or replace oil Check oil level on daily basis Poor engine oil quality...
  • Page 100 ENGINE MAIN MECHANICAL UNIT SPECIAL SE.RVICE TOOLS Refer to Tool number Tool nama A.2.0195 Base for cylinder head support 01-19 01-24 Yoke for cylinder head support A.2.0226 01-19 01-24 Tool for locking the flywheel Yoke to remove and refit valves 01-17 Puller of valve guides A.3.0311...

  • Page 102: Air Cleaner

    FUEL SYSTEM AIR CLEANER 6 Flame trap 1 C o v e r 7 Max. blow-by hose 2 Cartridge 8 Air cleaner body Cool air intake sleeve 9 Spring clip Hot air intake sleeve 5 Min. blow-by hose 1 0 N u t REMOVAL 5 .
  • Page 103 FUEL SYSTEM IDLE COMPENSATOR CHECKS AND 3. When thermometer shows speci- I N S P E C T I O N S ‘ - fied temperature, verify thermostat The idle compensator actually con- commands, i.e. closing of throttle sists of a thermostat 0 that checks valve thus fully closing the cool air HOT AIR INTAKE CLOSING the temperature of the engine intake...
  • Page 104 FUEL SYSTEM CARBURETORS W E B E R TWIN CARBURETOR (Except Switzerland, Sweden, Australia.) for 1200 model for 1350 model for 1500 model For 32 DIR 8IA/250 and 32 DIR i’ 7pR50 only 0 4 - 4 M a y 1 9 8 3...
  • Page 105 FUEL SYSTEM 72 Bush for sealed idling cap Carburetor cover including: 35 Safety washer 73 Adjustment screw cap 2 - S t u d 36 Spring for loosen lever 74 Idling mixture adjustment screw 37 Secondary 3 Starting throttle shaft securing nut 75 Sealed idling cap 4 Starting securing screw 38 Spring washer...
  • Page 106 FUEL SYSTEM (3) In case the verified dimension dimension is not (3) If within specified value,.loosen the nut remove cap and operate on travel and operate on control lever adjust- adjustment ment screw of throttle valve (see screw of economiser diaphragm (see following figure).
  • Page 108 FUEL SYSTEM WEBER TWIN CARBURETOR For Switzerland, Sweden, Australia. Carry out checks and ajustments following the procedures performed for the WEBER twin carburetors, previously de- scribed and referring to the tables provided in “Technical Data and Specifications ” relevant to check dimensions. WEBER TWIN CARBURETOR - EXPLODED VIEW (it will be provided in the next issue) 0 4 - 8...
  • Page 109 FUEL SYSTEM (it will be provided in the next issue) May 1983...
  • Page 111 FUEL SYSTEM Central Venturi securing screw 66 Sheath support 73 Air valve spring Sheath securing screw 67 Washer 74 Idling cut-off Air valve control iniermediate lever 68 Support securing screw 75 Air valve Air valve control 69 Bush return lever Air valve control tie rod Bush 70 Central Venturi...
  • Page 112 FUEL SYSTEM 3. Accelerator pump adjustment 2 . T h r o t t l e v a l v e o p e n i n g ( g a s To check and adjust accelerator Carburetor retaining nuts valve) with volet inserted.
  • Page 115 FUEL SYSTEM REMOVAL FUEL TANK FLOAT CHECK VALVE Remove float of fuel tank operating Remove check valve from supporting as follows: clip on fuel tank. WARNING: S u p p o r t t a n k b y m e a n s o f Before replacing any fuel line part, column lift and loosen screws secur- carefully follow below instructions:...

  • Page 116: Exhaust System

    FUEL SYSTEM 2 . D o n o t t w i s t o r c r u s h b r e a t h e r surfaces. CAUTION: hoses after fitting; fasten them with bend twist pipes Carefully fit clamps back to line relevant clamps.
  • Page 117 FUEL SYSTEM MANIFOLDS AND 3. Remove central muffler as fol- MUFFLERS lows: Referring to the figure on page 0 4 - 1 6 , p r o c e e d w i t h r e m o v a l a s (1) Remove rear muffler (refer to follows: item 2 above).
  • Page 118 FUEL SYSTEM SERVICE DATA AND SPECIFICATIONS TECHNICAL DATA FUEL PUMP FUEL TANK Overall capacity Model Brand Imp. Gall 11 1200 1350 1500 part No. 305.00 305.02 305.04 Reserve Imp. Gall 1.43 510.355 Mechanical 531.354 S A V A R A 542.140 S A V A R A GENERAL SPECIFICATIONS...
  • Page 119 FUEL SYSTEM M a y 1983...
  • Page 120 FUEL SYSTEM 04-20 May 1983...
  • Page 121 FUEL SYSTEM INSPECTION AND ADJUSTMENT FUEL PUMP WARM - COLD AIR AUTOMATIC MIXER pump pressure Fuel Pump delivery Warm air inlet complete closing engine temperature warm 17.7 i29.4 KPa thermostat temperature (0.18 + 0.30 kg/cm2 ) (2.56 +4.27 psi) Cold air inlet complete closing at 5000 rpm engine temperature cold...
  • Page 122 FUEL SYSTEM 04-22 May 1983...
  • Page 123 FUEL SYSTEM...
  • Page 124 FUEL SYSTEM TIGHTENING TORQUES Unit ft-lb Item Carburerors retaining nuts TROUBLE DIAGNOSIS AND CORRECTIONS Probable cause Corrective action Condition Needle valve is dirty or its seat is Thoroughly clean petrol filter and Fuel leakage loose on thread needle valve; tighten seat firmly: if necessary, replace it with a new one (original parts) the float...
  • Page 125 FUEL SYSTEM Probable cause Corrective action Free valve movement so that it can Cold starting is difficult or Starting control valve, if any, is properly follow control cable impossible (continue) sticky Ignition and starting systems are out Overhaul ignition starting of order systems Checking operations to be performed...
  • Page 126 FUEL SYSTEM Probable muse Condition Corrective action Inadequate fuel level in float cham- Improper engine idling or Perform same checks and repairs as ber or defective starter, ignition or progression phases previously described overall engine operation as previously mentioned in connection with diffi- cult cold starting Adjustment of idling adjusting screws Carefully repeat all relevant adjust-...

  • Page 127: Special Service Tools

    FUEL SYSTEM SPECIAL SERVICE. TOOLS Refer to Tool name Tool number 04-6 Twin carburetor support (to be used with C.4.0101) Beaker for carburetor pump tests (to be used with C.4.0101) 04-27...
  • Page 128 IGNITION, STARTING, CHARGING SYSTEM CONTENTS BATTERY ......05-2 Test stand inspection ... . . 05-24 STARTER .

  • Page 129: Battery

    IGNITION, STARTING, CHARGING SYSTEM B A T T E R Y WARNING: Batteries left on the shelf or in cars Do not touch both the positive unused for long periods gradually and negative terminals of the lose their charge. Therefor they need battery at the same time with to be charged up again when they are your bare hands.
  • Page 130 IGNITION, STARTING, CHARGING SYSTEM If the needle stops in the red Also check alternator belt tension z o n e ( l o w c h a r g e ) b u t a t q u i t e than 12.4V, charge the battery and (see: Group 00 E n g i n e M a i n t e -...

  • Page 131: Starter

    IGNITION, STARTING, CHARGING SYSTEM General Specifications FLUID AND LUBRICANTS Application GREASE Battery terminals Std. no. 3671 - 69812 STARTER WIRING DIAGRAM A l l Battery A l . Al I. Starter Fuseholder box Front service junction Ignition switch 1983...
  • Page 132 IGNITION, STARTING, CHARGING SYSTEM BOSCH STARTER MOTOR Fork Dust co”er Rubber block Retaining ring Lamination Bush Rotor Commurator casing Brush holder Brush spring Snap ring 17 Pinion stop ring Excitation winding lug Drive housing Brush Yoke Bush Electromagnet M a y 1 9 8 3...
  • Page 133 SYSTEM IGNITION, STARTING, CHARGING STARTER MOTOR Trunnion 1 Washer Fork Bush Commutator casing Rotor Brush holder Starting clutch Brush spring Snap ring Brush 17 Pinion stop ring Yoke Drive housing Electromagnet Bush Plate Locator May 1983...
  • Page 135 IGNITION, STARTING, CHARGING SYSTEM 8. Unscrew the two screws securing the electromagnet @ to the drive housing @ and take out the electromagnet. 9. Remove the rubber block @ with the lamination. 10. Unscrew the bolt @ serving as clutch fork pivot. Brush holder positive 6 .
  • Page 136 IGNITION, STARTING, CHARGING SYSTEM Strip the rotor as for the Bosch 1 5 . U n s c r e w t h e i n d u c t o r w i n d - 4 . P u n c h o n t h e t r u n n i o n 6 f o r (see: Bosch Starter Motor, steps 12 securing screw on the the fork on the pinion housing 0.

  • Page 137: Checks And Inspections

    IGNITION, STARTING, CHARGING SYSTEM Rotor insulation test Remove the rotor electromagnet assemblage and take the rotor to Set the tester to c? x 1 scale. pieces as for the Bosch starter 2. Put one prod on the commu- motor (see: Bosch Starter Motor, tator and the other on the segment steps IZ., 13.
  • Page 138 IGNITION, STARTING, CHARGING SYSTEM prod brush 3 . E y e c h e c k t h e p i n i o n t e e t h . The tester should give no sign of holder plate and the other prod on a current flow.

  • Page 139: Reassembly

    IGNITION, STARTING, CHARGING SYSTEM stand to correspond with the crown Starter Motor, step 16). adjust the absorber current to the wheel and connect up to the electri- value in the under-load test. cal system. The torque should be that shown in CAUTION: the technical particulars.
  • Page 140 IGNITION, STARTING, CHARGING SYSTEM Starter Motor 533.051 533.052 536.611 BOSCH E95 - 0.9 kW EF 12V 0.8 kW 0001211215 1 2 v 11317 Over running torque (1.30 ? 0.261 (0.95 + 1.48) (in-lb) EM Switch on starter motor voltage 2.116 2.116 2.116 Pinion module...
  • Page 141 IGNITION, STARTING, CHARGING SYSTEM Probable cause Corrective action Condition Starter motor turns but starting Wrong assembly: pinion engages only Check concentricity and pinion-ring does not take place partially gear distance (continued) Impurities in the coupling: Clutch Clean and lubricate. If necessary does not slide on rotor shaft clean the coupling completely Pinion engages ring gear properly...
  • Page 143 IGNITION, STARTING, CHARGING SYSTEM BOSCH ALTERNATOR Distance piece Rotor Semipulleys Regulator side bearing Distance piece Diode - holder plate Stay bolt Regulator mounting Drive housing Brush holder-voltage regulator Control side bearing Brush spring Plate Brush Feather key May 1983...
  • Page 145 IGNITION, STARTING, CHARGING SYSTEM Pulley Feather key Brush holders Rotor Rectifier bridge guard Cooling fan Bearing-regulator side Stay bolt Excitation Tang Positive terminal Distance piece Voltage regulator support Drive housing Insulating washer Diode rectifier bridge Voltage regulator Bearing retaining plate-control side DISASSEMBLY Unscrew the two securing...
  • Page 146 I G N I T I O N T A R T I N G C H A R G I N G S Y S T E M 9. Extract the bearing 0 on the Hold the drive housing @ in a d r i v e h o u s i n g e n d o f t h e r o t o r v i c e a n d u n s c r e w t h e s t a y b o l t s s h a f t @ w i t h a n e x t r a c t o r ( s e e...
  • Page 147 IGNITION, STARTING, CHARGING SYSTEM 7. Remove the regulator mounting IO. Extract the rotor @ by tapping complete with stator and rectifier the end of the shaft with a plastic bridge (the diode plate) by tapping it hammer as shown in the illustration. on its edge with a plastic hammer.
  • Page 148 IGNITION, STARTING, CHARGING SYSTEM suitable press with plates and punch, Disconnect voltage regulator 5. Withdraw rotor @ h a m m e r i n g withdraw bearing on voltage regula- c o n n e c t o r s @ and @ of rectifier by means of a plastic hammer on tor support side from rotor shaft.
  • Page 149 IGNITION, STARTING, CHARGING SYSTEM (4) If there is no continuity in the windings, put in a new stator. 6. Brush wear inspection ( 1 ) T h e b r u s h e s i n t h e v o l t a g e regulator should not be chipped or dirty with carbon deposits;...
  • Page 150 IGNITION, STARTING, CHARGING SYSTEM Diode resistance in direct conduction Reverse the two prods The tester 7. Brush spring inspection R = 0 -lOa The brush springs should be stiff should show the prescribed re- enough to assure good brush contact sistance.
  • Page 151 IGNITION, STARTING, CHARGING SYSTEM TEST 3 . L e t t h e a l t e r n a t o r r o t a t e a t STAND INSPECTION 3,000 rpm for an hour with rheostat load to give a voltage of 13 + 14V.
  • Page 152 IGNITION, STARTING, CHARGING SYSTEM T R O U B L D I A G N O S I S Before starting alternator troubleshooting, the battery should be fully charged (see: Battery) Condition Probable cause Corrective action Tension the belt Alternator does not charge Slack belt Broken charging or earthing Check the circuit...
  • Page 154 IGNITION, STARTING, CHARGING SYSTEM arm and cap, The pulses are gener- heat maximum elimination and i n g DESCRIPTION ated by a magnetic pulse generator stable performances. The electronic ignition is an induc- Besides conducting or interdicting located into a variable air gap circuit. tive discharge transistorized system the output transistor, the electronic During rotation of distributor shaft,...
  • Page 155 IGNITION, STARTING, CHARGING SYSTEM CHECKS AND WARNING: ADJUSTMENTS Stroboscopic gun must always be ON CARS d i r e c t l y c o n n e c t e d w i t h b a t t e r y terminals.
  • Page 156 IGNITION, STARTING, CHARGING SYSTEM BOSCH DISTRIBUTOR Pulse generator securing screw Connector securing screw Rotor arm Connector Dust cover Spring securing screw Retaining ring Timer Distributor body Retaining ring Advance regulator Pulse generator (stator) Advance regulator Spring Retaining ring Spring securing screw Counterweight May 1983...
  • Page 157 IGNITION, STARTING, CHilRGING SYSTEM Insulating support Cap securing screw Spring Rotor arm securing screw Counterweight Rotor arm Distributor body Advance regulator securing screw Pulse generator securing screw Pulse generator (stator) Advance regulator May 1983...
  • Page 158 SYSTEM IGNITION, STARTING, CHARGING DISASSEMBLY In the following are prqvided the disassembly operations relevant to ignition distributors, limited to the part on which maintenance is carried out. BOSCH DISTRIBUTOR Clamp distributor on a vice fitted with protective jaws. 1. Remove cap 0 and withdraw f i r s t t h e r o t o r a r m @ with rev limiter and then the lubrication felt.
  • Page 159 IGNITION, STARTING, CHARGING S Y S T E M 1 Counterweights 4 Screws 2 Springs 3 Pulse generator support 2 Securing screws 1 Cap 5. Unscrew the four screws secur- 1 Retaining ring 2 Inductive winding ing advance regulator to lower base 2 .
  • Page 160 SERVICE DATA AND SPECIFICATIONS TECHNICAL DATA AND INSPECTldNS Ignition Distributor 542.168 542.161 Alfa Romeo B O S C H SM 802 AX I - 3 - 2 - 4 Firing order 1 1 0 0 ’1 0 %...
  • Page 161 IGNITION, STARTING, CHARGING SYSTEM AUTOMATIC AND PNEUMATIC ADVANCE CURVES 1700 1800 2500 3000 M a y 1 9 8 3...

  • Page 162: Ignition Coil

    IGNITION COIL 542.162 542.167 BOSCH BAE 207B Primary winding resistance 6700 + 9600 SPARK PLUGS 535.420 Alfa Romeo Class LODGE 25 HL FLUID AND LUBRICANTS Demmination Application Spark plug thread Standard 4500 - 18304 TIGHTENING TORQUES Unit 18.08 + 25.31 2.5 + 3.5...
  • Page 163 ENGINE COOLING SYSTEM COOLING SYSTEM ....07-2 ELECTRIC FAN CONTROL General description ... . . 07-2 THERMAL CONTACT .

  • Page 164: Cooling System

    ENGINE COOLING SYSTEM COOLING SYSTEM GENERAL DESCRIPTION Electric fan Thermostat Radiator Electric fan thermal contact Cooling drain plugs Centrifugal pump Header tank Cooling temperature transmitter Heater Cooling temperature warning light thermal contact Cooling temperature indicator Cooling temperature warning light Cooling water level sensor for check control Cooling water minimum level warning light (1500 Quadrifoglio model) M a y 1 9 8 3...

  • Page 166: Removal

    ENGINE COOLING SYSTEM INSTALLATION CHECKS AND pulley. For the timing and belt INSPECTIONS keying procedure refer to: Group 3. Refit front cover of camshaft water pump with The water pump cannot be over- belt, pulley, alternator, pump and relevant gasket to block and tighten hauled and in case of failure must: be alternator driving belt, in reverse securing screws to specified torque...

  • Page 168: Electric Fan Control Thermal Contact

    ENGINE COOLING SYSTEM L E A K T E S T compressed air through radiator 6. Test again radiator for leakages breather pipe until a pressure of as described above and then refinish 98.1 radiator with black synthetic enamel. Remove radiator from car (Refer 1 + 1 .I kg/cm2 ;...

  • Page 169: Service Data And Specifications

    ENGINE COOLING SYSTEM SERVICE DATA AND SPECIFICATIONS ELECTRIC FAN I N S P E C T I O N A N D CAUTION: Electric fan intervention A D J U S T M E N T Produit harmful to the paint. Avoid temperature 88 - 92°C contact with painted parts.
  • Page 170 ENGINE -COOLING SYSTEM TIGHTENING TORQUES 33441 3.4 f 4.2 24.58 + 30.37 Water pump securing Screws 19 +24 1.9 + 2.4 13.74 + 17.35 TROUBLE DIAGNOSIS AND CORRECTIONS Corrective action Probable cause Condition Repair or replace Water leakage Repair Tighten or replace Replace gasket or thermostat Replace.
  • Page 172 CLUTCH DESCRIPTION al @, operated through a master moves thrust bearing (self centering) This is a hydraulic controlled, dry, c y l i n d e r 7 which transmits fluid and wins diaphragm spring action. singledisc clutch provided with a pressure increase to operating cylin- By means of gaskets performing on thrust bearing @ which is always...

  • Page 173: Clutch Pedal

    CLUTCH HYDRAULIC CONTROL UNIT CLUTCH PEDAL CHECKS AND INSPECTIONS DISASSEMBLY 1. Remove boot @, remove stop- Inspect pedal and pedal pad for REMOVAL per ring 0, then remove push rod deformation or damage. O p e r a t i n g f r o m t h e i n t e r i o r with fork 0, gaskets @ and 0, 2.
  • Page 174 Fluid Super HD corresponding to evidence of its integrity. Replace spring Alfa Romeo Part No. 3681.69905). damaged parts. If leakage occurs at der 0. 2 . R e m o v e b l e e d e r s c r e w p r o - joints due to loosening, retighten 2.
  • Page 176 CLUTCH 2. Check with a sliding gauge @ for even wear of both facings a n d whether clutch disc thickness is not near to specified limit. Replace disc if necessary. Wear limit for disc thickness mm (0.26 in) A.4.0144 A 1 Flywheel Clutch cover Cover fixing screws...

  • Page 178: Service Data And Specifications

    CLUTCH SERVICE DATA AND SPECIFICATIONS GENERAL SPECIFICATIONS FLUIDS AND LUBRICANTS 1 Thrust bearing 2 Bush Denomination Application Thrust bearing working seat @ GREASE Std. N . 367 I-69833134 Std. N . 367 I-69833134 Std. N. 3671-69841 GREASE ISECO Molykote Paste G End crankshaft bush @ Std.

  • Page 179: Trouble Diagnosis And Corrections

    CLUTCH TIGHTENING TORQUES Clutch caver to angine flywheel unit securing 10.8 + 17.4 screws Gearbox unit to engine resr caver securing 35.4 28.9 + 10.8 13.7 1.5 + 1.9 TROUBLE’ DIAGNOSIS AND CORRECTIONS Corrective action Probable cause Condition Some trouble symptoms may also be attributable to engine problems. First Clutch slip determine whether engine or clutch is causing the problem.
  • Page 181 CLUTCH Condition Probable cause Corrective action Repair or replace flywheel and/or Flywheel and/or pressure plate clutch caver Engine supports not efficient SPECIAL SERVICE TOOLS Refer to A.2.0378 Tool for locking the flywheel aligning A.4.0144 Clutch disc...
  • Page 182 GEARBOX CONTENTS 5 - SPEED MANUAL GEARBOX..13-2 13-25 Description ....13-5 13-25 Rear support . _ , .., ..SERVICE DATA AND 13-5 Rods and forks .

  • Page 183: Speed Manual Gearbox

    GEARBOX 13.74 + 17.36) 28.92 + 35.43) (1.9 + 2.4 13.74 + 17.36) Flexible bush Oit seal ring Gearbox casing Bushing Bushing Central support Flexible support Reverse gear switch Speedometer sensor Gasket Spring ring Plug Dowel D r a i n plug Rear caver Valve Gasket...
  • Page 184 G EARBOX S h a f t e , geara a n d differen~ial c a e i n g (22.5 + 25 162.70 + 180.771 (7 + a.7 50.61 + 62.91) 6 7 + 7 4 (6.8 f 7.5 49.17 + 54.23) 3rd speed driven gear Direct drive shaft...
  • Page 185 GEARBOX Roda and forks (2.5 - 2.7 18.07 + 19.52) (kg-m Lever Main selector rod Plug Guide pin R.G. fork Interlock plunger Bushing 1 sr-2nd speed rod Interlock plunger Detent hall 5th speed control fork Ist-2nd speed lever Spring pin...

  • Page 186: Description

    GEARBOX DESCRIPTION Installation of vehicle 3. After installing drive unit on vehicle fil1 up with prescribed oil In case of assembly of groups and ( A G I P F I R o t r a M P S A E 8OWQO The gearbox has five forward and installation on vehicle proceed as or IP Pontiax HD 8OWQO), oil should...

  • Page 187: Rods And Forks

    GEARBOX ASSEMBLY 3 . U n s c r e w s c r e w @ a n d r e m o v e 4. Remove pin @ inserted into plate @ securing oil bleeder valve flexible support @ and remove the Reassemble end flexible support to gearbox casing caver and remove flexible support itself from rear...
  • Page 188 GEARBOX 5. Remove main selector rod 2 S h o u l d removal of seal r i n g t a k e place while gearbox is fully assem- bled (on stand or vehicle), special tool A.3.0429 must be used. and recover selector 0, spring 8 3 and lever 0.
  • Page 189 GEARBOX ASSEMBLY 12. Remove 5th speed and reverse 14. Remove the following compo- gear rod @ together with 5th speed nents from the seats on the rear 1. Set the corresponding 1st.2nd c o n t r o l f o r k @ and sleeve 0. support of gearbox casing: and 3rd-4th speed control forks on The three detent halls @ from...
  • Page 190 GEARBOX together with relevant spring, then 5. Grease and assemble spring and tools A.3.0304 and A.3.0309. Grease M o u n t lock ring of 5th speed and a n d insert relevant bal1 into radial reverse gear rod on the end of the rod itself, on the differential side.

  • Page 191: Shafts And Gears

    GEARBOX R.G. switch to gearbox casing 2 8 . 9 2 + 3 5 . 4 3 ft-lb) TESTING Check working condition of spring- plunger-rod assembly making sure that speed selection is smooth and that speeds do not jump out of their position and become disengaged.
  • Page 192 GEARBOX If friction between the pinion and the inner race of the rear taper roller bearing hinders withdrawal of the 3 Pinion shaft front bearing Adjusting washer 7 . R e m o v e t h e pinion 0, w i t h Synchronizing units relevant taper roller bearing @ and adjusting washer 0,...
  • Page 193 GEARBOX d cl lo --- - R.G. shaft retaining screw 1 Lock ring 2 Thrust bearing support 1 Pin retaining 3 Joint spring ring 4 Spring ring Remove the direct drive shaft oil gearbox casing. Having removed the direct drive shaft, if necessaryL remove the direct drive shaft bush with the help of tool A.3.0291.
  • Page 194 GEARBOX tool A.3.0296 2. Loosen the screw securing the gearbox-differential casing and then primat-y shaft to its rear bearing and fit the A-3.0492 end piece. remove the oil deflector. Carefully tighten the screws securing Using tool A.3.0495 remove the 5th speed driving gear 0. differential casing to avoid damaging the casing’s threads.
  • Page 195 GEARBOX Keeping tool A.3.0296 in place, Gears and splines ASSEMBLY remove pinion shaft with all the part? Check that teeth contact pattern that are fitted on it; now totally Primary shaft of primary shaft and bevel pinion remove tool A.3.0490. gears extends to the entire working First fit on the primary shaft the 13.
  • Page 196 GEARBOX 3 . I f p r e v i o u s l y disassembled f o r 6. With the help of suitable plyers gearbox casing, using the same tools overhaul purposes, reassemble syn- fit the lock ring in its seat on tha u s e d during d i s a s s e m b l y ( T o o l chronizing units (refer to: Synchro- primary shaft’s rear bearing support.
  • Page 197 GEARBOX In case of friction between the bearing’s inner race and the pinion, parts belonging to the different use tools A.3.0300, A.3.0301 for synchronizing units. easier fitting. 6. Fit the bushing and the hub of the 5th speed driven gear and then tighten by hand the pinion gear train E n g a g e t w o g e a r s a n d t h e n tighten the nut according to specified...
  • Page 198 GEARBOX A.2.0274 Screws securing tool C.6.0162 A.4.0142 to gearbox-differential casing: (4 + 4.9 kgmm 28.92 + 35.43 f-t-lb) Front taper roller bearing inner race Turn dummy pinion a few times 11. Determine as follows the “S” in both directions to allow bearings thickness of the shim that is to be f i t t e d b e h i n d t h e pinion h e a d : 6 .
  • Page 199 GEARBOX roller bearings pre-loading: various parts do not rotate. How to determine pre-load of 6. Fit the shim selected as per pinion &aft taper roller S = 9.60 - G - 0.10 above computation; now fit the bearings bearing inner race, all the parts whereas 0.10 is a play-correcting making up the 5th speed driven gear CAUTION:...

  • Page 200: Differential Carriers

    GEARBOX gear train. a. For original bearings being used again 4 + 7 N-dm (0.40 + 0.70 kg-dm 0.289 + 0.506 ft.lb) b. For replacement bearings 1 3 + 1 6 N-dm 0.939 + 1.157 ft.lb) Fit bushing on primary shaft making sure that holes for sub- sequent pin fitting are aligned;...
  • Page 201 GEARBOX Using tool A.3.0299, remove the DISASSEMBLY differential carrier taper roller bear- ing outer race. IMPORTANT: The following procedure refers to the right hand differential carrier. Difference between left differential support and right one is only con- stituted by absence of phonic wheel i n t h e l e f t d i f f e r e n t i a l s u p p o r t 1.
  • Page 202 GEARBOX ential carrier, proceed as follows: Following the same procedure, disas- Apply gearbox oil to the oil seal semble the left hand differential ring outer surface and fit it into its carrier. seat on the differential carrier using In case of malfunction of speed tool A.3.0430.

  • Page 203: Crown Gear And Pinion

    GEARBOX scribed in paragraph “Differential Following fhe same procedure, reas- 3 . W i t h t o o l A . 3 . 0 2 8 7 r e m o v e Casing - Assembly”, fit crown gear semble the left hand differential inner races of taper roller bearings to differential casing.

  • Page 205: Gearbox- Differential Casing

    GEARBOX lash and if now within specified CAUTION:. values, repeat above adjusting opera- tions. avoid confusion in computations. When refitting previously disas- sembled parts (carriers, differential 5. Compute, as shown below, the casing, bearings and crown gear), it is essential that also same A and B average value “Hm”...

  • Page 206: Disassembly

    GEARBOX S h a f t s a n d G e a r s A s s e m b l y ) . then fit thrust bearing on direct drive CHECKS AND INSPECTIONS Fit differential casing (Refer to: shaft (Refer to: Group 12).

  • Page 207: Service Data And Specifications

    GEARBOX SERVICE DATA AND SPECIFICATIONS TECHNICAL DATA Differential ratio Gearbox Gearbox Speed selector Speed ratio lever positions Gearbox- Speed Gearbox- Speed differential differential at 1000 r.p.m. differential at 1000 r.p.m. overall ratio Km/h (mi/h) overall ratio Km/h (mi/h) 1 : 3.750 1 : 14,580 7.08 (4.39) 1 : 13.293...
  • Page 208 GEARBOX Application Name “0. Outer races of differential casing and pinion GREASE taper roller bearings Std. No. 3671 69833 Mating surfaces of: See item 5 shaft Outer surface of: GREASE AGIP: Fl Grease 15 selector lever connection Std. No. 3671-69811 Speed selector lever guide Fill-up of gearbox-differential casing 2,300 kg...

  • Page 209: Inspection And Adjustment

    GEARBOX Application Name Screws securing forks to speed selector CEMENT Omnifit 150 H rods Std. No. 352400023 SURFACE N.B. For surface cleaning use: Omnifit FIXING AGENT CEMENT Inner surface of bore for oil plug on gearbox casing Std. No. 3522-00015 INSPECTION AND ADJUSTMENT RODS AND FORI<S REAR SUPPORT...
  • Page 210 GEARBOX PINION Thickness ‘ 3” of shims B for pre-loading of differential 1. Thickness ‘ 3” of shims for setting of pinion height casing taper roller bearings = value engroved ou pinion and flange of L.H. differential carrier 0.20 = corrective value for bearing preloading Thickness Part No.

  • Page 211: Tightening Torques

    GEARBOX Thickness “S” of shims for pre-loading of pinion Pinion to crown gear backlash taper roller bearings = 9.60 - G - 0.10 9.60 = sample washer thickness Backlash 0 . 0 5 + 0.10 0.10 = corrective value Part No. Thickness mm (in) 4.10 (0.164)
  • Page 213 Probable cause Corrective action Trouble Noisy both during acceleration Differential gears are worn or Replace gears and deceleration (drive shaft damaged assy already checked) Check and replace, if necessary Excess play of hypoid gears Crown gear securing screws are Tighten loose Bevel pinion shim is worn or Replace shim...
  • Page 214 GEARBOX Trouble Probable cause Corrective action Bushing on outer speed selector Speed selection is poor lever is worn Plungers are worn or damaged Springs can no longer be used due to fatigue or because they are broken Rod millings are ‘ worn or deformed Selector fork and/or levers are worn or damaged Sleeve and gear front toothing are...
  • Page 215 GEARBOX Refer to Tool number Tool name Support of dial gauge to read pinion 13-18 spacer thickness (to be used with A.2.0234) A.2.0243 Tool for locking pinion 13-24 A.2.0274 Adapter of sheave for checking 13-16 pinion bearing pm-load 13-18 A.2.0300 Tool for locking mainshaft (to be 13-12 used with A.3.0300)
  • Page 216 GEARBOX Refer to Tool name Tool number Plate for whith drawal of differential spindle Puller / driver of rear pinion bearing cup and puller of pinion shaft and mainshaft 13-15 A . 3 0 2 9 7 Puller I driver of front pinion bearing cup (use with A.3.0296) 13-15 Puller of speedometer pinion and...
  • Page 218 GEARBOX Refer to Tool name Tool number Driver of output shaft seal 13-21 A.3.0430 Puller of drive spindle seal (with unit A.3.0452 assembled) Driver of drive spindle seal A.3.0453 13-73 Puller of 4th - speed gear from mainshaft (to be used with A.3.0296 and A.3.0492) 13-14 Puller / driver of rear mainshaft...
  • Page 220 GEARBOX Refer to Tool name Tool number 13-16 Sheave for checking differential bearing 13-17 pm-load (to be used with A.2.0274 and 13-18 13-17 Reference gauge for pinion setting (to be used with A.4.0136) Tool for checking pinion setting (to be 13-17 used with A.4.0136) 1 3 - 3 9...

  • Page 222: Trouble Diagnosis And

    DIFFERENTIAL AND DRIVE SHAFT ASSEMBLY CONTENTS Installation ....17-5 DIFFERENTIAL ....17-2 SERVICE DATA AND Crown gear and pinion .

  • Page 223: Differential

    DIFFERENTIAL AND DRIVE SHAFT ASSEMBLY DIFFERENTIAL DIFFERENTIAL CROWN GEAR CASING AND PINION For crown gear and pinion over- p r o c e d u r e r e f e r t o : G r o u p 1 3 hauling procedure refer to: Group 13 Gearbox - Crown...

  • Page 225: Checks And Inspections

    DIFFERENTIAL AND DRIVE SHAFT ASSEMBLY ASSEMBLY Reassemble joints being careful to fit parts back into their original posi- tion, as marked at time of disas- sembly, and following the procedure hereafter described. OUTER JOINT (A) 1. Thoroughly coat with grease (Molykote VN 2461 C or Optimol Olistamoly 2 L N 584) the cage, the 4 Inner cover...

  • Page 226: Installation

    DIFFERENTIAL AND DRIVE SHAFT ASSEMBLY way along the splines; to this effect 7. Fit lock ring following disas- Fit washers on shaft, wheel side, splines should be covered with tape. sembly procedure in reverse se- according to numbering marked at 2.

  • Page 227: Trouble Diagnosis And Corrections

    DIFFERENTIAL AND DRIVE SHAFT ASSEMBLY SERVICE DATA AND SPECIFICATIONS GENERAL SPECIF~ICATIONS FLUIDS AND LUBRICANTS Application Denomination Drive shaft assembly constant-speed GREASE Molykote VN 2461 C or Optimal Olistamoly 2 LN 584 joints (for each joint) (2.82 oz) Std. No. 3671-69843 Split grease quantity between the two sides of each joint;s crown of steel balls TIGHTENING TORQUES...
  • Page 228 F R O N T S U S P E N S I O N CONTENTS SERVICE DATA AND DESCRIPTION ....21-2 SPECIFICATIONS .

  • Page 229: Description

    FRONT SUSPENSION D E S C R I P T I O N Coil spring Bearing Steering lever Hub nut Strut Wheel hub Wheel screw Shaft Brake disc Semi-trailing link Dust cover Transverse link Ball joint Hub support 2 1 - 2 May 1983...

  • Page 232: Assembly

    FRONT SUSPENSION 5 . W i t h d r a w b e a r i n g f r o m h u b support by means of press puller A.3.0302 and two plates. Reclamp hub in vice and using a suitable tool withdraw bearing inner race.

  • Page 233: Installation

    FRONT SUSPENSION INSTALLATION (2) Connect shaft to differential Nut securing semi-trailing link drive shaft by locking the six secur- b a l l j o i n t t o h u b s u p p o r t ing screws to the designed torque.
  • Page 234 FRONT SUSPENSION REMOVAL Hold strut properly, then loosen A.2.0251 and unscrew the four screws Place lift, block rear securing strut bracket to hub sup- wheels, jack up front of vehicle, then port. support it by stands placed in adja- cent position to jacking points (refer to: Group 00 - Lifting Points and Towing).

  • Page 235: Transverse And Semi-Trailing Link

    FRONT SUSPENSION Refit remaining parts of strut .as- Remove wheel from the opera- CHECKS AND INSPECTIONS sembly complying with sequence tive side. Clean all the components. 3. Loosen and remove shaft secur- shown on figure. ing nut (wheel side). 4. Detach constant-speed joint Check self-lubricating bushes embod- from differential drive shaft by...

  • Page 236: Service Data And Specifications

    FRONT SUSPENSION CHECKS AND INSPECTIONS Screw securing semi-trailing Clean all the components CAUTION: link ball joint pin to wheel ease joints installation, lubricate support Visually check semi-trailing links outer surface with the fluid pre- and front transverse links for blows, scribed for rubber parts fitting to deformations, oxidation, cracks.

  • Page 237: General Specifications

    DATA OF SHOCK ABSORBERS SETTING LEFT RIGHT SHOCK ABSORBER 542.352 542.353 Alfa Romeo Part Number 1 0 7 . 9 + 1 8 6 . 4 (11 + 19) (24.25+ 4 1 . 8 9 ) Compression Low speed Expansion Compression...
  • Page 239 FRONT SUSPENSION Trouble Probable cause Corrective action Check and replace if required Steering wheel shocks, Excessive play in steering linkage vibrations or shimmying Tighten Loose screws securing steering (cont.) Tighten or replace Unserviceable shock absorber or loose securing points Drifting becomes evident when vehicle is running on a flat surface with hands Vehicle drifts or wanders off steering wheel.
  • Page 240 FRONT SUSPENSION Probable cause Corrective action Trouble Adjust Improper tire air pressure Stiff steering wheel Excessively worn tire Replace Pinion-rack mating incorrectly Adjust adjusted After these preliminary operations, if trouble persists, check and operate as follows. Jack up front of vehicle and support on safety stands. Separate strut knuckled arm from track rod and move steering wheel.
  • Page 241 FRONT SUSPENSION Refer to Tool number Tool name Puller/driver of cup of front hub 21-5 bearings 21-5 Driver of seal and bearing of front hubs (to be used with A.3.0415) 21-5 Base of withdrawal fitment (to be used with driver A.3.0330) 21-5 Wrench for bearing front hub nuts A.5.0239...

  • Page 242: Refer To Group 00 - Chassis And Body Maintenance

    F R O N T A N D R E A R B R A K E S CONTENTS DESCRIPTION ....22-2 Control lever .

  • Page 244: Service Brake

    FRONT AND REAR BRAKES SERVICE BRAKE the pedal all the way down; now BRAKE CAUTION: tighten the bleeders. During bleeding operation always SYSTEM BLEEDING keep the level of fluid in reservoir It is up to the operator whether to above the “Ml N” level. carry out the operation by operating Bleed brakes following the procedure at the same time or separately on the...

  • Page 245: Pedal Assembly

    FRONT AND REAR BRAKES P E D A L A S S E M B L Y (kg-m 1 Retainer 13 Brake pedal 2 Washer Spacer 14 Bull ring 3 G a s k e t Accelerator pedal 15 Spring 4 Pedal assy bracket Bolt 16 Spacer...
  • Page 246 FRONT AND REAR BRAKES CHECKS AND INSPECTION 4 . L u b r i c a t e e n d o f a c c e l e r a t o r cable before connecting it to pedal. 1.

  • Page 247: Brake Master Cylinder

    FRONT AND REAR BRAKES BRAKE MASTER CYLINDER 2 2 - 6...

  • Page 249: Hydraulic System Piping

    FRONT AND REAR BRAKES Tighten to the prescribed torque syringe in order to suck the 3 . L o o s e n a n d r e m o v e b o l t @ l i q u i d o f b r a k e c l u t c h t a n k . two new nuts securing brake connecting the Panhard rod @ to piping is removed, remember...

  • Page 251: Vacuum System

    FRONT AND REAR BRAKES INSTALLATION so that the crawfoot in the above 2. Remove non-return valve (iJ figure points towards the intake after having relevant On bank, reconnect master cyl- manifold _ clips 0, inder to servobrake tightening secur- ing nuts to the prescribed torque (see: Brake Master Cylinder - Instal- lation).
  • Page 252 FRONT AND REAR BRAKES Pad replacement 5. Remove both pads, each with 11. Restore proper brake fluid level relevant dowel pin 0, and then in reservoir (ATE “S” or AGIP Fl Lift car’ s front end positioning it remove from pads, pins Brake Fluid Super ED or IP Auto on safety stands (Refer to: Group 00...
  • Page 253 FRONT AND REAR BRAKES 2 . L u b r i c a t e b o o t i n n e r s u r f a c e CHECKS AND INSPECTIONS with the above mentioned grease, Thoroughly wash all parts in alcohol and fit it into its seat.
  • Page 255 FRONT AND REAR BRAKES Pad replacement Empty brake fluid reservoir with CAUTION: a syringe. Lift car’ s front end positioning it When pads are off, do not push brake 2. Disconnect brake fluid hose. on safety stands (Refer to: Group 00 pedal in order to avoid piston from 3 .

  • Page 256: Rear Drum Brake

    FRONT AND REAR BRAKES assembly of floating caliper, operat- Proceed and complete the as- ing as follows. sembly fitting the pads and securing Apply coating pre- them by means of relevant dowel scribed brake grease to cylinder, pins (Refer to: Pad Replacement). piston and seal ring;...

  • Page 257: Parking Brake

    FRONT AND REAR BRAKES c. On installed drum, adjust dis- JAW REPLACEMENT 6. Disassemble, (if required) the t a n c e b e t w e e n j a w - d r u m b y operating as adjustement device, repeatedly operating on brake Removal...

  • Page 259: Control Cables

    FRONT AND REAR BRAKES REINSTALLATION placed between support and body. adjusting fork @ , withdraw pin T o r e i n s t a l l c o n t r o l l e v e r w i t h support, reverse the order of removal this one from the lever.

  • Page 261: Inspection And Adjustment

    FRONT AND REAR BRAKES Application Denomination Brake pedal hub (inner GI) GREASE Clutch pedal (inner 0 ) Std. 3671-69810 to master cylinder control clevis Spring adjustment square bush for brake pressure regulator Spring seat fork on brake pressure regulator Parking brake cable sliding surfaces GREASE Knuckle of parking brake cables on rear Std.

  • Page 262: Tightening Torques

    FRONT AND REAR BRAKES BRAKE PRESSURE HANDBRAKE LEVER ADJUSTMENT REGULATOR VALVE Number of free notches Adjustment. on the sector gear before wheels locking 1 G-3 plied to hook of fixture A.4.0148 TIGHTENING TORQUES Unit Item Unions of brake hydraulic system pipes 5 .

  • Page 263: Trouble Diagnosis And Corrections

    FRONT AND REAR BRAKES TROUBLE DIAGNOSIS AND C.ORRECTIONS The following are the indispensable presuppositions for any trouble diagnosis of braking system verification of: Condition Probable cause Corrective action Excessive pedal travel Leakage in brake master cylinder Overhaul brake master cylinder Leakage in clutch master cylinder Overhaul clutch master cylinder Faulty no-return valve of vacuum...
  • Page 266 FRONT AND REAR BRAKES Corrective action Condition Probable cause Out-of-rround or off-center drum Pedal pulsates On disc brakes, lateral runout of brake rotor is excessive ions, repair or replace disc Excessive variation in thickness of neter. Replace disc as required brake rotor surfaces Rear lock (Under light brake Faulty brake pressure regulator...

  • Page 267: Special Service Tools

    FRONT AND REAR BRAKES Probable cause Corrective action Condition When parking brake control Control lever release pushbutton Disassemble lever, and release or re- lever is released, the car re- does nor spring back place if mains braked (continued) The brake ON indicator does Wires disconnected Restore connection not illuminate...
  • Page 268 STEERING SYSTEM CONTENTS Removal ..... 23-7 STEERING SYSTEM ....23-2 Disassembly _ .

  • Page 269: Steering System

    STEERING SYSTEM STEERING SYSTE.M 3 9 4 4 8 28.92 + 35.43) Track rods Steering rack Universal joints Lower column (4 + 4.9 ft.lb) Upper column 28.32 + 35.43) GENERAL DESCRIPTION is positioned so as to collapse under they reduce the variation of wheel Steering i s b y r a c k a n d p i n i o n .

  • Page 270: Steering Lock-Ignition Switch

    STEERING SYSTEM if necessary. the whole column. 9 . R e m o v e 2. Check against presence of dam- ages or absence of lubrication in universal joints. Replace lower col- DISASSEMBLY umn if necessary. 1. Unscrew bolt securing universal Verify integrity of upper column j o i n t t o u p p e r c o l u m n s e c t i o n .

  • Page 271: Steering Link Rods

    STEERING SYSTEM CHECKS AND INSPECTIONS ing lock - ignition switch. 3. Remove the broken head screw Verify good conditions of cables securing steering lock to column and connectors. support. 2. Check proper operation of the R e m o v e s t e e r i n g - lock unit whole assembly by verifying all w i t h d r a w i n g i t f r o m i t s s e a t i n positions are...

  • Page 272: Checks And Inspections

    STEERING SYSTEM CHECKS AND During tightening of bolts, make sure Loosen fixing nut 0, unscrew INSPECTIONS that on the static load position, ball joint @ and remove it from upper plane of ball pin is parallel to rod 0. gasket face. Check against damage or wear in the steering rods ball joints, .and verify that pivot free from crawling...

  • Page 273: Steering Box

    STEERING SYSTEM STEERING BOX upper Pinion Bush Adjusting screw IO Bearing support Spring Lock ring Right cap Plunger Lock ring Seal ring Lower cap Studs Rack Bush Sleeve Rack box Clamp Left cap steering box by estracting it from the REMOVAL steering rod slit on the left side and remove rubber supports @.

  • Page 274: Disassembly

    STEERING SYSTEM D I S A S S E M B L Y Remove the cover @ from rack 9. Remove pinion from rack box b o x 0, s c r e w a n d e x t r a c t together with the bearings, by means 1.
  • Page 276 STEERING SYSTEM to point 3) and introduce it into the guide tube after rotating pinion, in order to realite, when assembly is ready, reciprocate positioning be- tween rack and pinion verified by dimension “A” with pinion oriented cutout downwards (obtain with angle u = 90”f 26”).
  • Page 277 STEERING SYSTEM rotated with respect to each other, with reference to the boot body junction line. 12. Center steering stroke by ob- taining dimension “A” as per figure indicated at step 5. I N S T A L L A T I O N Mount steering box assembly on vehicle by tightening securing screws at the prescribed torque 39 + 48 N.m...

  • Page 278: Inspections And Adjustments

    STEERING SYSTEM INSPECTIONS AND ADJUSTMENTS 3 . L i g h t Dimension “A’ for rack rod centering in the steering steering wheel structure tube mm (in) O f 6 (0+0.23) 125 (4.921) mm (in) 2. u cutout positioning angle on rack pinion (rack Thickness of rack guide pad.

  • Page 279: Trouble Diagnosis And Corrections

    STEERING SYSTEM TROUBLE DIAGNOSIS AND CORRECTIONS Probable cause Corrective action Condition Tighten screws Loose steering box screws Excessive steering wheel backlash Replace defective components Damaged steering rods or universal joints Replace bearings Worn column bearings Column noise in drive Tighten screws Loose steering box screws Drive noise Replace defective parts...
  • Page 280 CONTENTS DESCRIPTION ....SERVICE DATA AND 25-2 25-8 REAR HUB ..... . SPECIFICATIONS .
  • Page 281 REAR SUSPENSION DESCRIPTION 1 Shock absorber 5 Front tension rod 6 Rigid axle Spring 3 Rear tension rod Wheel hub The transversal connection is carried The rear suspension is a rigid axle Between axle and body near the one. The axle longitudinal anchorage o u t b y m e a n s o f a t e n s i o n r o d w h e e l h u b s a r e i n t e r p o s e d t h e i s c a r r i e d o u t b y m e a n s o f t w o...
  • Page 282 REAR SUSPENSION REAR HUB Grease seal ring Washer Hub cover Drum bearing Outer REMOVAL Block front wheels with CAUTION: suitable system, then lift rear part of Do not drop bearing. car and position it on support stands (see: Group 00 - Lifting Points and Towing).
  • Page 283 REAR SUSPENSION CHECKS AND 2. By using taker-in A.3.0329, hub inner bearing assemble outer ring of inner bearing with 9 specified grease and insert on hub, inserting at wholly in its into its seat. seal ring with Lubricate seat. specified grease and insert it into its seat on hub by using tool A-3.0459.
  • Page 284 REAR SUSPENSION REAR SUSPENSION (3.4 + 3.9 24.58 + 28.2) (7 + 8.7 (kg-m 50.63 + 62.93) 24.58 + 28.2) 13 Front tie rod Coil spring Upper cup 14 Brake adjuster Shook absorber anchor fork Rubber bumpers 15 Panhard bar Lower cup 16 Pin Stud plate...
  • Page 285 REAR SUSPENSION 6. From luggage compartment re- b. Insert springs coaxially to the lease and remove lock nut and nut of shock absorbers and make sure upper shock absorber fastener, the caps and upper spring support remove cap and anti-shock rubber gaskets are properly assembled bumper.
  • Page 286 REAR SUSPENSION Flexible hose connections 9 . 8 t 1 4 . 7 N - m 7.23 + 10.85 ft.lb) REMOVAL Remove co.il springs with the same A d j u s t p a r k i n g b r a k e l e v e r procedure followed for removal of stroke (see: Group 00 - Mainte- shock absorbers;...
  • Page 288 REAR SUSPENSION NOTE FOR CAR OVERLOADED ON REAR AXLE Should high overloads be applied to the rear axle, like in the case of gas installation. the series rear springs can be replaced on sedan versions with springs having part number 705.507, in case of overload of about 980 N (100 kg)(220.46 lb) with respect to static load, they allow a “rear position”...

  • Page 289: Trouble Diagnosis And Corrections

    REAR SUSPENSION DATA FOR SHOCK ABSORBER CALIBRATION 542.147 Compression 5 9 f 1 4 7 (6+ 1 5 ) (13.23G33.07) Low speed Extension Compression 2 7 5 f 4 1 2 (28+42) (61.73G92.59) High speed Extension 638 f 834 at 20 NOTE: Values to be measured with shock absorbers TIGHTENING TORQUES kg-m...
  • Page 290 REAR SUSPENSION Condition Probable cause Corrective action Instability in driving. Loose wheel screws Tighten to specified torque This trouble is also related to Shock absorber malfunction Repair or replace front suspensions. For trouble diagnoses also refer to Incorrect steering geometry Yielded coil springs Group 21 Yielded coil spring...

  • Page 291: Wheels And Tires

    WHEELS AND TIRES CONTENTS CHECKING TIRE CONDITIONS ..CHECKING WHEEL CONDITIONS . . . 28-4 28-2 Checking tire ....Wheel balance ....28-4 28-2 SERVICE DATA AND...

  • Page 292: Checking Tire Conditions

    WHEELS AND TIRES CHECKING TIRE CONDITIONS CHECKING TIRE Abnormal tire wear 1. Check tread thickness. If below Correct abnormal tire wear according to below chart. min. allowed limit (1 mm; 0,04 in.) replace tires. Corrective action Trouble Probable cause If tires are provided with “tread wear indicator”, when marks appear, re- place tires.

  • Page 293: Tire Rotation

    WHEELS AND TIRES TIRE ROTATION Operation to be carried out every 5,000 km (3,107 miles). Tires tend to wear unevenly and become unbalanced after a certain running distance. Uneven tire wear i n p r o b l e m s t h a t , often results however, one tends to tink as being...

  • Page 294: Wheel Screw

    WHEELS AND TIRES WHEEL SCREW Be careful not to smear threaded portion of screw not relevant seat CAUTION: Two types of wheel screws are used: one is designed for use with steel wheels and the other for use with l i g h t a l l o y w h e e l s . D o n o t m i x different type wheel screws.

  • Page 295: Service Data And Specifications

    WHEELS AND TIRES BALANCE WEIGHTS Be sure to place correct balance POSITIONING weights on inner edge of rim. D o n o t p u r e m o r e t h a n t w o weights on each side. Two types of balance weights are used: one is designed for use with steel wheels and the other...

  • Page 296: Technical Data

    WHEELS AND TIRES T E C H N I C A L D A T A 2 8 - 6 May 1983...
  • Page 297 ELECTRICAL SYSTEM CONTENTS HOW TO READ THE WIRING Windscreen wash/wiper ..40-28 DIAGRAM ..... . 40-2 Windscreen wiper .

  • Page 299: Wiring Diagram

    ELECTRICAL SYSTEM Orange The example shows continuity be- Orange - black tween terminals 2 and 3 with the Orange -white control set to position 1. Grey Grey - yellow Grey - black Grey - red Grey - green The chain line, on wiring diagram, Yellow delimits those areas containing the Yellow-white...

  • Page 300: Power Supply Routing

    ELECTRICAL SYSTEM POWER SUPPLY ROUTING SCHEMATIC/POWER SUPPLY ROUTING r - - - - May 1983...

  • Page 301: Fuses

    ELECTRICAL SYSiEM FUSES CHECK LOCATION CAUTION: In case a fuse blows, before replacing it, make sure that the support board and is lo&d on left cause of failure has been re- side of the intermediate bulkhead, in moved. the engine compartment. Use fuse having the prescribed amperage, only.

  • Page 302: Ignition Switch

    ELECTRICAL SYSTEM Modal 1200 1360 1500 a.* 1500 Protected Service Ampere 905.00 905.02 905.04 905.06 305.03 905.05 905.07 Cut-off solenoid valve - Reverse switch Trip Computer - Check Control Side lights left front and right rear-R. H.number plate light Clock Check Control Cigar lighter Side lights right front and left rear-i.

  • Page 303: Electromechanic And Electronic Devices

    ELECTRICAL SYSTEM ELECTROMECHANIC AND ELECTRONIC DEVICES RELAYS AND TIMER CHECK support board, located on left side of LOCATION intermediate bulkhead. For location, The relays and the timer, must be of The relays and the roof lamp timer refer to “Electric Component Loca- the type indicated in the specific are inserted into the special socket tion”.
  • Page 304 ELECTRICAL SYSTEM “Relays and Timer” Table Symbols External view Position Passenger compartment roof lamp timer Horns relay Heated rear window relay Headlight wiper relay Front power windows relay M a y 1 9 8 3...
  • Page 305 ELECTRICAL SYSTEM Symbols External view Component Windscreen wiper electronic Electronic device for headlights and flashing changeover Hazard and direction lights intermittence 1 9 8 3 M a y...

  • Page 306: Lighting System

    ELECTRICAL SYSTEM LIGHTING SYSTEM LAMPS CAUTION: Before starting operations on lighting system, make sure that the ignition Lamp characteristic data, type and switch is to the “ST” position and e l e c t r i c p o w e r a r e l i s t e d i n the the battery ground cable is discon- following table.

  • Page 307: Combination Switch Assembly

    ELECTRICAL SYSTEM COMBINATION SWITCH ASSEMBLY VIEW FROM M Left lever Connector Turning stalk Connector Connector Connector Right lever 4 0 - l 1 May 1983...
  • Page 308 ELECTRICAL SYSTEM of combination switch controls and T h e table shows the the concerned services. Service enabled Control rotation Stalk Movement parallel the 0 and 1 positions) Left lever to steering wheel axis tion in position 2 ) parallel Movement to steering wheel plane Position...

  • Page 309: Outside Lighting

    ELECTRICAL SYSTEM OUTSIDE LIGHTING OUTSIDE LIGHTING - FRONT SIDE...
  • Page 310 ELECTRICAL SYSTEM OUTSIDE LIGHTING - REAR SIDE ( f o r t h e 1 2 0 0 - 1 3 5 0 - 1 5 0 0 m o d e l s ) I’ 40-l 4 May 1983...

  • Page 312: Headlight Switch

    ELECTRICAL SYSTEM HEADLIGHT SWITCH When in the O F F position = ma Location When in the ON position = 0 fi Low beam/full beam light change- The switch is mounted on gearbox o v e r is executed via left lever of (see: Group 13).

  • Page 313: Front Combination Lamps

    ELECTRICAL SYSTEM FRONT COMBINATION LAMPS 7 L a m p 1 Front combination lamp 8 Lampholder 2 Halogen lamp 9 Lamp 3 Securing spring 4 Supply connector Headlight wiper clamp 5 C o v e r 6 Lamp holder R E M O V A L A N D INSTALLATION With reference to the exploded view proceed as follows.

  • Page 314: Lamp Replacement

    ELECTRICAL SYSTEM For installation, reverse order of Operating from fender inside, (3) For installation of transparent compress the two springs securing cover, reverse order of removal. transparent cover of side direction i n d i c a t o r @ to fender @, t h e n LAMP REPLACEMENT CAUTION: remove it.

  • Page 315: Rear Combination Lamps

    ELECTRICAL SYSTEM = distance of headlight centre centre must be equal to distance E from ground between headlight center. = height of luminous beam The dimensions indicated in the = IO m (32,8 ft) diagram comply with provisions in force in Italy. For other countries, Orientation is correct when the comply with national provisions.

  • Page 316: Inside Lighting

    ELECTRICAL SYSTEM Open back door and lift rear Press bulb of lamp and rotate it in order to remove. trim. Press on lampholder side 0, Replace lamp and refit lamp- pull; then remove it. holder. For identification of lamp loca- tion, refer to diagram of the follow- ing figure.
  • Page 317 ELECTRICAL SYSTEM A l B a t t e r y G30 Power window and door lock connector Passenger compartment roof lamp Roof lamp switch on passenger compartment pillar ROOF LAMP Lamp replacement By means of proper tool, remove transparent cover, pressure For lamp installation, reverse Withdraw and replace the lamp..

  • Page 319: Cluster

    ELECTRICAL SYSTEM securing LIGHTING AND WARNING c l u s t e r @ to support CAUTION: LAMPS REPLACEMENT bracket @. Before starting operations, make sure Remove the pressure inserted “ST” that the ignition key is to the Remove cluster (see: Removal cover 0, disconnect harness 0, position and ground cable is discon- and Installation).
  • Page 325 ELECTRICAL SYSTEM FUEL LEVEL TRANSMITTER Connect a lamp indicator to pins of float plug, as per figure. Removal and installation Check device proper function- ing by verifying the following. For removal and installation see: Groupe 04 - Supply System. Float lifted: lamp indicator off CLUTCH AND BRAKE OIL Float lowered:...

  • Page 326: Windscreen Wash/Wiper And Headlight Wash/Wiper

    ELECTRICAL SYSTEM WINDSCREEN WASH/WIPER AND HEADLIGHT WASH /WIPER W I N D S C R E E N W A S H / W I P E R A l B a t t e r y Windscreen washer and/or headlight wash/wiper pump control switch G85 Front service N7 Trip Computer...

  • Page 327: Windscreen Wiper

    ELECTRICAL SYSTEM WINDSCREEN WIPER Brush Bush Bush Motor Cowl top cover Spacer Motor cover Linkage Unscrew the three screws secur- 5 S p a c e r Remove cowl top cover 0 ing motor 0 to linkage @ and REMOVAL AND (see: Group 75 - Cowl top cover).
  • Page 328 ELECTRICAL SYSTEM TROUBLE DIAGNOSIS AND CORRECTIONS Corrective action Condition Probable cause Replace fuse Burnt fuse Windshield wiper does not operate Restore connection Loose connection or open circuit Improper switch contact Verify combination switch; (right light); replace, if necessary Foreign material interrupts link Take off foreigti’...
  • Page 329 ELECTRICAL SYSTEM Corrective action Probable cause Condition Replace switch Intermittent speed is erratic Faulty wiper switch Faulty wiring Verify wiring Replace motor . Faulty wiper motor Replace intermittence Faulty intermittence M a y 1983...

  • Page 330: Headlight Wash/Wiper

    ELECTRICAL SYSTEM HEADLIGHT WASH/WIPER 1500 Quadrlfogllo m o d e l I 1 1 ’ 1 r May 7983 4 0 - 3 2...

  • Page 331: Headlight Wiper

    ELECTRICAL SYSTEM HEADLIGHT WIPER 1500 Quadrlfogllo m o d a l Motor Bracket B Wiper arm Headlight wpsher hose 9 .Headlight washer hose 4 . Grille 10 Bracket Wiper arm 1 1 M o t o r Unscrew the six screws secur- motors bracket @ and @ ! then remove REMOVAL AND...
  • Page 335 ELECTRICAL SYSTEM SPECIAL SERVICE TOOLS Refer to Tool number A.3.0602 Wiper arm puller May 1983...
  • Page 337 ELECTRICAL SYSTEM HORNS HORN CONTROL Location PUSHBUTTON The horns are mounted inside engine Location compartment on support brackets located under front combination The pushbutton is located at centre lamps. of steering wheel (see: Group 23 - Removal and installation Steering Wheel and Column). Operating from engine com- Check h a r n e s s 0.

  • Page 339: Power Window

    ELECTRICAL SYSTEM Dry end of ruling pen to remove By means of a hot air jet, heat silver compounds. t h e r e p a i r e d a r e a f o r a b o u t 2 0 Once the repair has been carried k e e p i n g t h e o r i f i c e o f minutes,...

  • Page 341: Power Windows And Door Locks

    ELECTRICAL SYSTEM POWER WINDOWS AND DOOR LOCKS 1500 r e-- 40-4 1 M a y 1 9 8 3...

  • Page 342: Door Lock Control Unit

    ELECTRICAL SYSTEM DOOR LOCK CONTROL UNIT LOCATION The door lock control unit is located inside passenger compartment, in the gear lever console, behind Check Control and Trip Computer. REMOVAL AND INSTALLATION vant harness. Remove control unit @ by unscrewing the screw securing it to Trip Computer 0.

  • Page 344: Check Control And Trip Computer

    ELECTRICAL SYSTEM used to set in evidence the enabled For instrument installation, re- LOCATION function in order to allow user an verse order of removal. easy identification. Check Control and Trip Computer When reading a red led diode is are inserted into a special instrument holder integrated into gear lever console, in centre position, under dashboard.

  • Page 345: Electric Component Location

    ELECTRICAL SYSTEM ELECTRIC COMPONENT LOCATION ENGINE COMPARTMENT Front power windows relay Passenger compartment roof lamp timer Horns relay Electronic device for headlights and flashing changeover Heated rear window relay Headlight wiper relay Windscreen wiper electronic intermittence PASSENGER COMPARTMENT Hazard and direction lights intermittence...

  • Page 346: Harness Layout

    ELECTRICAL SYSTEM HARNESS LAYOUT GENERAL HARNESS 1 Engine comparment harness Front part and dashboard harness 3 Roof lamp harness 4 Luggage room harness 5 Passenger compartment harness ENGINE COMPARTMENT Alternator with built-in electronic regulator Thermostatic switch for engine coolant max. temperature warning lamp A8 Ignition coil Thermostatic switch for engine cooling electric fan Al 1 Starter...
  • Page 347 ELECTRICAL SYSTEM PASSENGER COMPARTMENT AND LUGGAGE ROOM (L.H. DRIVE) May 1983...

  • Page 348: Dashboard ( Lh)

    ELECTRICAL SYSTEM DASHBOARD (L.H. DRIVE) Air ventilation controls lighting lamp 82 Windscreen wiper control switch G5 Connector Control switch for headlight, flashing, low beam and full beam G6 Cluster B connector G7 Cluster R connector Direction lights indicator switch G86 Passenger compartment roof lamp connector Heated rear window control switch H3 Stop light switch H13 Choke switch...

  • Page 349: Switzerland-Australia Model Variation

    ELECTRICAL SYSTEM SWITZERLAND-AUSTRALIA MODEL VARIATION -HAND BRAKE SWITCH (For vehicles 1350 - 1500 and 1500 Quadrifoglio models for SWITZERLAND and AUSTRALIA) and HAND BRAKE SWITCH (For 1500 Quadrifoglio vehicles, A USTRA LIA models) r - 1 A l B a t t e r y G7 Cluster R connector G30 Power window and door lock connector HI Hand brake switch...

  • Page 350: Circuit Diagram

    ELECTRICAL SYSTEM CIRCUIT DIAGRAM H3 Stop light switch Roof lamp switch on passenger compartment pillar HI 3 Choke switch A l Batter/ H17 Brake fluid min. level control switch Alternator with built-in electronic regulator H27 Contact switch, on rear door, for heated rear window A5 Ignition distributor Heated rear window relay A8 Ignition coil...
  • Page 353 ELECTRICAL SYSTEM H2 Reverse light switch H3 Stop light switch Roof lamp switch on passenger compartment pillar HI 3 Choke switch A l B a t t e r y Alternator with built-in electronic regulator H27 Contact switch, on rear door, for heated rear window A5 ignition distributor Heated rear window relay A8 Ignition coil...
  • Page 354 B O D Y - S H E E T M E T A L P A N E L S CONTENTS GENERAL INFORMATION., ..49-2 Symbology .....49-21 Identification codes .

  • Page 355: General Information

    BODY -SHEET METAL PANELS GENERAL INFORMAi-ION IDENTIFICATION DATA Identification and Identification and Chanis No. certification label certification label Identification and-certification label Chassis no. (according to CEE/ISO standard specifications) See Group 00 - Identification Data See Group 00 - Identification Data 4 9 - 2 May 1983...

  • Page 356: Lifting Points

    B O D Y - S H E E T M E T A L P A N E L S LIFTING POINTS Front towing eye and jack seat Rear towing eye Front axle and suspension Jack and safety stands WARNING: M - H =4+1 Toe-out...

  • Page 360: Body Construction

    BODY -SHEET METAL PANELS BODY CONSTRUCTION BODY CONSTRIJCTION 4 9 - 7 M a y 1 9 8 3...

  • Page 362: Body Sealing

    BODY -SHEET METAL PANELS BODY SEALING DESCRIPTION The following figures, show the body areas which are possible sealing faults. sealed by Manufacturer. The scalings applied to these areas, must be smooth and free from scratches or gaps. 8531 IE Take care not to apply too much sealing and not to Alternative: part.

  • Page 364: Body Alignment

    BODY -SHEET METAL PANELS View from L View from I Detail BODY ALIGNMENT MEASUREMENT OPERATIONS Method of measurement operation When a measuring tape is used, verify there is no When a tram tracking gauge is used, adjust pointers elongation, twisting or bending. (A) and (B) to equal lenghts as shown in the follow- ing figure.

  • Page 365: Measurement Points

    BODY - SHEET METAL PANELS MEASUREMENT POINTS M a y 1 9 8 3...
  • Page 366 BODY -SHEET METAL PANELS...

  • Page 368: Cautions During Replacement Operations

    BODY-SHEET METAL PANELS Outer parts protection When removing external parts (hood, back door, Arm different moldings, finishings) it is necessary to protect body length surfaces with clothes, protection tape or other materials, in order not to damage or scratch vehicle body.
  • Page 369 BODY -SHEET METAL PANELS Operate such as sheet forms a tight angle with electrodes. welding streng.ht insufficient. (3) Welding of three or more overlapped sheets. In the areas where three or more sheets are overlapped, spot welding must be repeated. INCORRECT INCORRECT CORRECT...

  • Page 371: Mig Welding

    BODY - SHEET METAL PANELS MIG welding Conditions of panel to be welded. CORRECT By means of belt sander or wire brush, remove any foreign matter from surface. It must form an opening of Paint films, rust or oils present on sheet surface, causes about 3 mm dia., when stressing decrease of welding strength, thus generating blow holes.

  • Page 373: Replacement Operations

    BODY - SHEET METAL PANELS REPLACEMENT OPERATIONS HOW TO READ THIS CHAPTER The formulation of the present part of the manual is uniform for all the replacement operations. For its struc- ture, refer to the following example. WHEN REMINDER In detail: The parts Tepresented by chain line, set in evidence the SUPPORT REMOVED”...

  • Page 374: Symbology

    SYMBOLOGY BODY -. SHEET METAL PANELS Spot welder CUTTING AND WELDING/BRAZING OPERATIONS The symbology used for the cutting and welding/brazing operations is shown in the following figures. MIG plug weld n n n n Cutting performed by means MIG seam weld/point weld Spot welding Spot welding of two overlapped sheets l l l l...

  • Page 375: Removal And Installation Procedures

    BODY -SHEET METAL PANELS Welding - brazing (3) Cut-off damaged parts. Sealing Air saw Air chisel REMOVAL AND INSTALLATION PROCEDURES (4) If welding spots are not visible, remove paint by means of rotary wire brush. Tools required: COMPONENT REMOVAL Rotary wire brush (1) Make sure that all the damaged parts have been detected, by measuring the installation main dimensions.
  • Page 376 BODY -SHEET METAL PANELS Caution during operation Punch deeply in the center of each, welding spot. A below 8 mr non-centered punch does not allow complete cut of nugget. Besides, a shallow marked hole location does not allow a reliable drive of drill. As a rule, punching must be executed from sides of the components that are to be removed.
  • Page 377 BODY -SHEET METAL PANELS Carefully remove iron powder from the surfaces which have been grinded and from surrounding areas. Presence of iron powder, causes decrease of welding efficacy and can also generate corrosion, (4) Apply primer to edges of new components and of body panels which are to be welded.
  • Page 378 BODY - SHEET METAL PANELS PREPARATION FOR NEW COMPONENT Cautions during operation: INSTALLATION Remove paint from both sides of components that are to be welded, such as the surfaces to be spot (1) If a partial replacement is to be carried out, it is welded, spot welding rims and edges of surfaces to be necessary to maintain an overlapping tolerance of about butt welded.
  • Page 379 BODY - SHEET METAL PANELS (3) Grind MIG welding by means of a sander machine. Cautions during operation: Position components as per figures provided in “Body Tools required: Into body compartments, install the Alignment”. Air sander . movable parts (i.e. windscreen, doors, hood, back- door) in order to carry out check of clearances, grades and parallelism.
  • Page 380 BODY -SHEET METAL PANELS (7) For under body protection, apply a coat having 4 mm (0.16 in) thickness: Antidrum: part. No. 3523 + 00001 Alternatives: 3M Body Plast 8874 E Body Schutz 8864 E (5) Apply anti-corrosion agent to the welded compo- nents.
  • Page 381 BODY -SHEET METAL PANELS May 1983...

  • Page 382: Radiator Core Support

    BODY - SHEET METAL PANELS RADIATOR CORE SUPPORT Parts to be welded c. Radiator core support and hoodledge panel upper Radiator core support and engine support lower cross support Radiator core and engine support lower cross member member b. Radiator core support and hoodledge panel upper Radiator core support and hoodledge panel REMINDER WHEN INSTALLING REMINDER WHEN REMOVING...
  • Page 383 BODY - SHEET METAL PANELS Install parts temporarily Check and adjust clearances, grades and parallelisms. May 1983...

  • Page 384: Hoodledge Panel With Radiator Core Support Removed (Partial Replacement)

    BODY - SHEET METAL PANELS HOODLEDGE PANEL WITH RADIATOR CORE SUPPORT REMOVED Carry out replacement after Radiator Core Support has been removed. Parts to be welded h. Upper hoodledge assembly and engine upper cross member a. Upper hoodledge assembly and lower hoodledge Hoodledge assembly and engine upper cross member b.
  • Page 385 BODY -SHEET METAL PANELS E R W H A L L I N G M I N D E N I N S T Install together radiator core support and hoodledge When are removed welding spots of the three over- panel;...
  • Page 386 BODY -SHEET METAL PANELS HOODLEDGE PANEL WITH RADIATOR CORE SUPPORT REMOVED (Partial Replacement) been removed. Carry out partial replacement after Radiator Core Support has Service joints Parts to be welded a. Upper part hoodledge and lower part hoodlege REMINDER WHEN INSTALLING REMINDER WHEN REMOVING Precaution when cutting the spare half hoodledge panel By means of air saw, cut according to lines A and B.
  • Page 387 BODY -SHEET METAL PANELS Dimension check and fender temporaneuous installation Install together radiator core support, half hoodledge panel and body. Check alignment dimensions referring to drawings provided in “ Body Alignment” . May 1983...
  • Page 388 BODY -SHEET METAL PANELS FRONT SIDE MEMBER WITH HOODLEDGE PANEL REMOVED Carry out replacement after Hoodledge Panel has been removed. Service ioints Parts to be welded Plate and replaced side member Plate and present side member REMINDER WHEN REMOVING REMINDER WHEN INSTALLING By means of air saw, cut according to line A in figure, Precaution when cutting spare side member.

  • Page 390: Central Pillar

    BODY -SHEET METAL PANELS CENTRAL PILLAR Service joints SECTION A-A Parts to be welded Outer pillar and inner pillar Pillar and pillar inner reinforcement Outer pillar and inner pillar Inner pillar and roof panel side member -Remove paint in correspondence with the four REMLNDER WHEN REMOVING welding spots of pillar reinforcement lower part at Unscrew the two screws securing rib to roof panel...
  • Page 391 BODY - SHEET METAL PANELS By means of clamps, temporarily secure central pillar. REMINDER WHEN INSTALLING Check component alignment. Precaution when cutting spare pillar After continuous welding of central pillar, carry out Cut spare pillar aligned with the upper and lower part tinning.

  • Page 392: Outer Side Member

    BODY -SHEET METAL PANELS OUTER SIDE MEMBER Service joints Parts to be welded c. Outer side member and closing inner central pillar a. Outer side member, front side member and inner Outer side member and inner wheelarch front pillar Outer side member and outer wheelarch Outer side member, diaphragm and central floor side Outer side member and central pillar reinforcement member...

  • Page 393: Outer Side Member (Partial Replacement)

    BODY-SHEET METAL PANELS REMINDER WHEN INSTALLING The continuous welding areas of outer side member Precaution during cutting of outer side member to central, front and rear pillar, must be tinned. Cut outer side member aligned with non-replaced panel part tolerance Welding indications Apply anti-corrosion agent to boxed part inside.
  • Page 395 BODY -SHEET METAL PANELS REMINDER WHEN INSTALLING Precaution when cutting outer side member Cut outer side member aligned with non-replaced panels The continuous welding areas of outer side member to central, front and rear pillar, must be tinned. Apply anti-corrosion agent to boxed part inside. Welding indication Use MIG welding method to weld the three over- lapped sheets along the whole perimeter from both...

  • Page 396: Rear Fender

    BODY --SHEET METAL PANELS REAR FENDER Service joints Parts to be welded Fender and outer wheelarch Fender and drip Fender and inner wheelarch Fender and upper rear panel Fender and inner fender reinforcement Fender and upper rear panel Fender and outer wheelarch REMINDER WHEN REMOVING Take care not to cut frame of rear fender.
  • Page 397 -- SHEET METAL PANELS BODY The fender area of continuous welding to roof Fender temporaneous installation panel side member, must be tinned. By means of clamps, temporarily secure rear fender. Sealer application Apply sealer to wheelarch outer side. Temporarily secure the adjacent components: door and backdoor.

  • Page 398: Drip With Rear Fender Removed

    BODY -SHEET METAL PANELS DRIP WITH REAR FENDER REMOVED Carry out replacement after Rear Fender has been removed. Service joints Parts to be welded Drip and rear fender inner frame Drip and rear panel, REMINDER WHEN INSTALLING REMINDER WHEN REMOVING By means of air saw cut according to lines A and B Caution when cutting spare drip shown in figure.

  • Page 399: Lower Rear Panel

    BODY-SHEET METAL PANELS LOWER REAR PANEL Service joints Parts to be welded Cross member and rear panel Cross member and floor Cross member and side member REMINDER WHEN REMOVING By means of a saw, cut areas A and B taking care not Punch junction points of lower rear panel to rear floor of spare wheel area.

  • Page 400: Upper Rear Panel

    BODY - SHEET METAL PANELS UPPER REAR PANEL Service joints Parts to be welded Rear panel and drip Rear panel and outer fender Rear panel and outer fender Rear panel and floor REMINDER WHEN REMOVING REMINDER WHEN INSTALLING means of air saw, cut according to line A. By means of clamps, temporarily secure the upper rear panel.
  • Page 401 BODY - SHEET METAL PANELS Temporarily secure backdoor and check clearances, Precaution during welding grades and parallellisms. For the spot welding, make use of a brass wire. Check correct positioning and alignment of bumper to rear panel. May 1983...

  • Page 402: Rear Part Of Rear Floor With Rear Fender And Rear Panel Removed

    BODY -SHEET METAL PANELS REAR PART OF REAR FLOOR WITH REAR FENDER AND REAR PANEL REMOVED Carry out replacement after .Rear Fender and both Lower and Upper Rear Panel have been removed. Service joints Parts to be welded Rear floor, rear side member and inner rear wheelarch Rear floor and rear side member Rear floor and rear seat cross member Rear floor and rear side member...
  • Page 403 BODY - SHEET METAL PANELS REMINDER WHEN INSTALLING Secure rear floor temporarily and carry out marking along side member and cross member from floor underside. This easy drilling operation of the MIG welded spots. In order to obtain the best welding result, make use of spot welder as far as possible.
  • Page 405 BODY - SHEET METAL PANELS REMINDER WHEN 4NSTALLING After temporaneous securing of side member to rear floor, carefully check dimensions provided in “Body Alignment”. May 1983...
  • Page 407 BODY -SHEET METAL PANELS REMINDER WHEN INSTALLING Before carrying out welding, apply the adhesive to Apply sealant to the areas indicated in “Body joints between roof and central rib. Sealing”. Carry out tinning in the areas between roof and rear fender, which are continuous welded.
  • Page 408 DOORS CONTENTS FRONT DOOR .., .., _ .., M 55-2 Internal finishing panels ..55-7 Door assembly .., _ .., ..55-3 Fixed glasses .

  • Page 409: Front Door

    DOORS FRONT DOOR 3 5 21 ( 1 . 3 6 + 2 . 2 9 . 8 3 + 1 5 . 9 ) Door Tie rod Door lock device Hinge Lock block clamp plate Lock block 18 Panel lower clamps Handle Seal Molding and weatherstrip...

  • Page 410: Door Assembly

    DOORS DOOR ASSEMBLY screws, then remove it. 3. Unscrew the five nuts securing 2. Remove ornament covering the window regulator @ to door, then REMOVAL AND door securing screws, then remove remove it. INSTALLATION window regulator handle @ . 3. Remove plastic rivets securing With reference to exploded view panel @ to door.

  • Page 411: Door Locks And Handles

    DOORS DOOR LOCKS AND HANDLES REMOVAL AND INSTALLATION Remove panel move sealing trim @I screen @ . completely in 2. Lift glass @J order to avoid damage. 3. Remove plastic fasteners secur- ing levers to door. DOOR MIRROR 6. Withdraw clamp plate of lock REMOVAL AND block @ by means of proper tool INSTALLATION...

  • Page 412: Moldings And Seals

    2. Remove molding 8 . CAUTION: 3. Remove panel trim with weatherstrip @ . rod and door lock device. Remove door mirror 0 . 5. Remove molding 7 . 6. Remove glass 0 and glass velvet with trim 8. Reposition moldings and seals by reversing order 05 removal.

  • Page 413: Rear Door

    DOORS REAR DOOR Door Hinge Spacer Window regulator device Ooor lock device Hinge Rubbers Panel lower clamp Seal Handle Fixed glass Sealing screen Upper trim and weatherstrip Fixed glass guide Door lock control Window regulator handle Molding Arm rest Glass velvet seal with trim Panel Glass Door lock electric device (1500 Duadrifoglio model)

  • Page 414: Door Assembly

    DOORS WINDOW REGULATOR DOOR ASSEMBLY 2. Remove ornament covering the door securing screw, then remove DEVICES AND REMOVAL AND window regulator handle @I _ INSTALLATION 3. Remove plastic rivets securing GLASSES panel @ to door. Remove panel With reference to exploded view by bending it.

  • Page 415: Door Locks And Handles

    DOORS DOOR LOCKS 6 . O n l y f o r 1 5 0 0 Q u a d r i f o g l i o model AND HANDLES Release connecting rod between lock @ and door lock electric REMOVAL AND device @ _ To remove it, if neces- INSTALLATION...

  • Page 416: Service Data And Specifications. M

    DOORS Reposition molclings and seal by reversing order of removal. CAUTION: 7. With reference to the following Apply proper grease to hinges and figure, take care to secure glass velvet door lock device. on clamp @ of glass guide @ seal located inside the door.
  • Page 419 HOODS HOOD POSITION rod is positioned in the center of hood lock slit by operating on ADJUSTMENT the two screws Then, temporarily tighten the lock. Loosen the four screws securing hinges to hood and move hood forward, backward and side to side until correct position is obtained.
  • Page 420 HOODS 6 . I f n e c e s s a r y , a d j u s t s h e a t h O p e r a t i n g f r o m e n g i n e com- oil letting it slide into sheath.
  • Page 422 HOODS REPLACEMENT OF BACKDOOR OPENING 2. Operating from vehicle inside, withdraw cable and sheath from CONTROL CABLE Insert new cable with sheath and screw of bracket @ sheath securing. 1. Cut cable @) in proximity to secure i t t o backdoor o p e n i n g control lever.

  • Page 424: Roof Trim

    INTERNAL TRIMMING TRIM ROOF TRIM Roof Taps Sun screen Sun screen Passenger handle Passender handle Roof lamp Passenger handle Inside mirror support Roof lamp Inside mirror REMOVAL AND screws securing mirror support @ INSTALLATION to roof nanel and remove it. 5 .

  • Page 425: Floor Trim

    INTERNAL TRIMMING FLOOR TRIM...
  • Page 426 INTERNAL TRIMMING R e m o v e s e a l s o f f r o n t d o o r REMOVAL AND material trim @ . INSTALLATION compartments in the part where they 7. install floor trim by reversing cover floor trim and remove the order of removal.
  • Page 427 INTERNAL TRIMMING -Install safety belt and pillar trim by reversing order of removal. All the anchor safety belt screws, must be tightened to the prescribed torque. Safety belt anchor screws 27 + 43 kg-m 20.25 + 31.8 ft-lb) CAUTION: If the vehicle is collided or over- turned, t h e e n t i r e b e l t replace...
  • Page 428 INTERNAL TRIMMING REAR PILLAR TRIM 1 Back door seal 3 Plastic cap Rear pillar trim 4 Door opening seal REMOVAL AND INSTALLATION 1. Remove door o p e n i n g s e a l Detach plastic Install trim by reversing order of in the where it covers remove pillar trim 0.
  • Page 430 INTERNAL TRIMMING ( 3 ) R e m o v e p l a s t i c t r i m s @ REMOVAL AND a n d @ . INSTALLATION (4) Unscrew the four screws secur- ing to seat @ the seat back adjust- Take care not to stain seat and seat m e n t d e v i c e @J a n d h i n g e 0;...

  • Page 431: Rear Seats

    INTERNAL TRIMMING 7. Install seat on car by reversing order of removal and tightening Securing screws of seat back adjustment device and of hinge screws securing seat guides to floor, 17 + 29 N-m to the prescribed torque. (1.8 + 3 kg-m Screws securing seat guides to If necessary, remove headrest by floor...

  • Page 432: Rear Console

    INTERNAL TRIMMING REMOVAL AND 4 . U n s c r e w n u t s e c u r i n g s e a t INSTALLATION back @ to body @ and remove it. Take care not to stain seat and seat back upholstery.
  • Page 434 INTERNAL TRIMMING 6 6 - 1 2 M a y 1 9 8 3...
  • Page 435 TRIMMING INTERNAL REMOVAL AND INSTALLATION ing heater control assembly @ to console 0. Remove the four screws securing console @ to dahsboard. CAUTION: Disconnect battery ground cable. com- removing Before ponents fitted with harness, make sure that relevant con- nections have been discon- nected.
  • Page 436 INTERNAL TRIMMING DASHBOARD May 1983...
  • Page 437 INTERNAL TRIMMING By means of proper tool, remove REMOVAL AND ornaments @ and @ . INSTALLATION By means of proper tool, remove finisher @ of duct @ and unscrew t h e t w o s c r e w s s e c u r i n g d a s h - board @ to body.
  • Page 439 INTERNAL TRIMMING SERVICE DATA AND SPECIFICATIONS TIGHTENING TORQUE Unit kg-m Item CENTRAL PILLAR TRIM AND SAFETY BELTS 2 . 8 + 4 . 4 2 0 . 2 5 + 3 1 . 8 Safety belt anchor screws 27 + 43 FRONT SEATS Screws securing guides to seat 17 + 20...
  • Page 440 EXTERNAL TRIMMING CONTENTS G LASSES ..... . . FRONT BUMPER ....75-7 75-2 REAR BUMPER .

  • Page 441: Front Bumper

    EXTERNAL TRIMMING FRONT BUMPER. 4 Fog light fog light 2 Bracket 3 Bracket REMOVAL AND INSTALLATION With reference to exploded view above proceed as follows: 3. Unscrew the four screws secur- disconnect fog present, ing brackets @ and @ to sills. light @ and @ harness.

  • Page 442: Rear Bumper

    EXTERNAL TRIMMING REAR BUMPER 1 Bumper 4 Bracket 2 Bracket 6 N u t s 3 Bracket 6 Bracket REMOVAL AND INSTALLATION W ith reference to exploded view above proceed as follows: 1. Lift luggage room upholstery and rear trim. 2.

  • Page 444: Grille

    EXTERNAL TRIMMING GRILLE 3 H o o d 1 Badge 4 Screw G r i l l e 4. Install grille by reversing order REMOVAL AND of removal. INSTALLATION With reference to exploded view above proceed as follows: CAUTION: 1. Open hood completely removing Be careful not to exert excessive it from stay.

  • Page 445: Cowl Top Cover

    EXTERNAL TRIMMING COWL TOP COVER 5 Windscreen washer pipings 1 cowl top cover 6 Windscreen wiper arms 3 Plastic nut screw 7 Sprayers 4 Seal rubber 4. Unscrew the two screws, pro- With reference to exploded view tected by a cover, securing cowl top above proceed as follows: cover @ to body;...
  • Page 447 EXTERNAL TRIMMING REMOVAL With reference to exploded view p i l l a r t r i m 0, then remove it. remove, by means of proper tool above proceed as follows: 5. Operating as per the following ornament 0. 3.

  • Page 448: Windscreen

    EXTERNAL TRIMMING Rest windscreen on lower side of properly centered with weather- strip @ mounted on lower side, only. 3. Slowly pull first cord starting from upper rim and follow position- ing of weatherstrip rim by slightly tapping, with the hand, on wind- screen from outside.
  • Page 449 EXTERNAL TRIMMING REMOVAL of every 10 cm (4 in), starting from under rear window. 2. Disconnect electric cables of With reference to exploded view between back door @ sheet and heated rear window. above proceed as follows: rear window weatherstrip seal 0. 3.
  • Page 450 AIR VENTILATION CONTENTS WIRING DIAGRAM ....80-2 Heater fan switch ... _ _ . 80-5 AIR VENTILATION UNIT a. .,. . . , . . . 80-3 TROUBLE DIAGNOSIS AND Removal and installation .
  • Page 451 HEATER WIRING DIAGRAM-~ I I,i,i 1 I M I A l Battery El Ignition switch Control for headlight, flashing, low beam and full beam Air ventilation control lamp Air ventilation heater fan Air ventilation heater fan control (IV - Low speed) 8 0 - 2 May 1983...
  • Page 452 HEATER AIR VENTILATION UNIT Air ventilation unit shell covers Heater fan Door Air ventilation unit controls Door Air ventilation unit shell covers Heater core Door Outer air duct frame Outer air duct Incoming air intake nozzle Air ventilation unit Engine compartment cross member Liquid delivery pipings May 1983...
  • Page 453 HEATER REMOVAL AND 5. Loosen metal clamps securing Remove or cut seals. pipings @ to air ventilation unit; INSTALLATION ( 3 ) S e p a r a t e t h e t w o s h e l l c o v - then remove pipings.
  • Page 454 HEATER HEATER FAN SWITCH LOCATION CAUTION: The switch is located in the lower ornament of central console (see: nection, it is necessary to top up Group 66 - Consoles). header tank of engine cooling CHECK system. Lubricate air ventilation unit Check switch proper functioning by control cables by means of verifying that continuity between...

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