Technical data

ManualsBrandsAlfa Romeo ManualsAutomotive33

@iSl

MANUAL SUPPLEMENT

models

ASSISTENZA TECNICA

Lj%-@j.

PA333500883300

May

1988

Summary of content (210 pages)

PAGE 1
models @iSl MANUAL SUPPLEMENT ASSISTENZA TECNICA Lj%-@j.
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Instructions for the insertion of the technical data in the binders When inserting the updating pages in the I_Alfa33) V O L U M E Ii binder, it is advisable to proceed as shown in the diagram below and to follow the order indicated. r CONTENTS INTRODUCTION LIST (Elue tard) I R43279000004X4 (with updating list) PA3279000BR4X4 (with updating list) PA327900000BRK) \ PA3279000000AC .:.
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FOREWORD This manuals is intended f o r models 331.e-m 33 1.5 4x4 33 1.3 33 1.3 s 33 1.5 TI 33 1.7 IE lt complements the manuals referring to ihe corresponding 33 1.7 + ( A l f a models indicated here below: PA32 7900000000 PA3279000004x4 PA3279OOOB R4x4 PA327900000B RK “WORKSHOP “WORKSHOP “WORKSHOP “WORKSHOP MANUAL MANUAL MANUAL MANUAL PA3279OOOOTDOO “WORKSHOP MANUAL m PA32 7900003300 “WORKSHOP MANUAL - models m Key to symbols: means that the corresponding Group in thti.
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QUICK REFERENCE INDEX [Alfa] 4 COMPLETE CAR ‘l=Gi-l ENGINÈ MAIN MECHANICAL UNIT ‘pLiil FUEL SYSTEM ‘G7i-j IGNITION, STARTING, CHARGING SYSTEM ‘pq ENGINE C O O L I N G S Y S T E M -IGRriLq CLUTCH GEARBOX MOTION TRANSMISSION ,, .. p-j .’::iI: [GR.l -pq (Alfa33) 4 DIFFERENTIAL AND DRIVE SHAFT ASSEMB LY FRONT SUSPENSION FRONT AND REAR BRAKES REAR SUS.PENSION GR. 25 BODY-SHEET METAL PANELS [Alfa] + ( :pLJi-j p3i-j ELECTRICAL SYSTEM ‘. .+5-l STEERING SYSTEM WHEELS AND TIRES I [GR.
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COMPLETE CAR CONTENTS GENERAL VIEWS . . . . . . . . . . , . . . . . . . . . . . 00-2 TROUBLE DIAGNOSIS SAND CORRECTION Dimensions and weights . . . . . . . . . . . . 00-3 ON IGNITION SYSTEM LE3.2 JETRONIC M:ODEL VARIATIONS . . . . . . . . . . . . . . . . . . 00-4 (1.7 IE with catalytic converter) . . . . . . . 00-21 ELECTRIC TROUBLESHOOTING IDENTIFICATION DATA . . . . . . . . . . . . . . . . (*) Identification label . . . . . . . . . . . . . . . . (*) PROCEDURE (1.7 IE with catalytic converter) . .
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GENERAL VIEW i l -I October 1988 00-2
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DIMENSIONS AND WEIGHTS 8 Mode1 33, *T 908.260 Identification number P Wheelbase Front (mm) Rear cp Front Sa Rear SP Overall length LU (mm) Overall width La fmm) Height funladen) H (mm) Min. steering radius (mm) Kerb weiaht (kg) Max. allowed gross weight (kg) Payload (kg) Max. allowed axle gross weight 3 3 1.5 a x a 33 1.7 * 33 1.7 IE 33 1.7 * 33 1.5 TO 908.060 908.061 A 908.080 908.100 908.110 908.1OlA 908.220 908.160 908.170 908.161A 908.140 908.180~ 908.120 908.
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MODEL VARIATION ENGINES WITH TWO CARBURETORS ENGINES WITH ONE CARBURETOR 33 1.3 33+ * Modal 5 door saloon Body I Drive - on certification label and Identtflcatwn NO. I L R 908.260 - L R R L L R L R 908.060 go8,061. / _ ( 908.080 1 _ 1 ;;;:““‘, 1 908.1’0 / 908.220 j - - on identification label Type approval NO. on identification label 905AB - on intermediate bulkhead label 905AOO Chasris No. - on intermediate bulkhead label Serial No Engme No. 33 1.5 axa 3 3 1 . 5 TI 33 1.
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MODEL VARIATION 5 DOOR STATION WAGON Drive - on certification label - on identification label Identification No. - on identification label Type approval No. .-8 L R 906.600 - T 908.600 905Al D 905Al F 905A2S 905A2U 905AlO 905A10 905A20 905A20 30587 from 0000001 30508 from 0000001 ! - on intermediate bulkhead label Chassis No. - l - on intermediate bulkhead label / Serial No 05379411 - I - on cylinder block label Engine No. Type and serial No.
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MODEL VARIATION Mode1 Body Drive Identification No. - on certification label - on identification label - on identification label Type approval No. -/on intermediate Ibulkhead label z! 908.650 908.660 - 905A30 905A3F 905A3G 905A4A 905A30 905A30 905A30 905A40 30558 from 0000001 VM82A from 0000001 Chassis No. -- -Ion intermediate jbulkhead label Serial No. l 65407756 - - on cylinder block label Engine No. Type and’sérial No.
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APPROXIMATE~ REFILL CAPACITIES L _ Mode1 Component FUEL TANK 6.5 FUEL RESERVE With filter (*) (1.43) - 6.5 (1.43) - 6.5 (1.43) - 6.5 (1.43) 4.57 (10.07) 5.25 (1.15) 3.6 (7.94) 4 (0.88) 3.6 (7.94) 4 (0.88) 3.6 (7.94) 4 (0.88) 3.15 (6.94) 3.5 (0.77) 3.15 (6.94) -’ 3.5 (0.77) 3.15 (6.94) 3.5 (0.77) 4.35 (9.59) 5 (1.10) 2.4 (5.29) 2.6 (0.57) 2.4 (5.29) 2.6 (0.57)’ 2.4 (5.29) 2.6 (0.57) 2.4 (5.29) 2.6 (0.57) - - - 0.9 (1.
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COMPLETE CAR CHASSIS AND BODY MAINTENANCE TECHNICAL DATA - INSPECTION AND ADJUSTMENT Axles and suspensions : -1 ;n CU tl 0 0 II d 67 k ô II m + a 0 Il -.
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I : -. 1 MODEL VARIATION ENGINES WITH lW0 CARBURETORS ENGINE WITH TURBO COMPRESSOR ENGINES WITH ELECTRONIC FUEL INJECTION I 33 1.7 * Mode1 I 33 1.7 IE 33 7.8 TO I I I 5 door saloon Body l L - on certihcatlon label and Identification NO. 33 1.7 * I I Ï l I I R I I I L I II go8,161A ( 908.170 ( ;;;;NX;;, ( _ 908.160 R Il I L II L R I R 908.150. / 905.180. / - on identificat!on label - on identification label 905A4 905A3D 905A3 l Type approval NO.
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COMPLETE CAR MAINTENANCE SCHEDULE The following schedule is valid for the Italian market only s I s 3 3 - X X X X X X X X X X X X X X - X X X X X X X - X X X X X X X X X X X X X X X X X X - X - X X X X - X - X X X - - X X - X X - X X X - X - x X - X - X X X - X X - X X - X May 1 9 8 8 X X X X X X X X X X X X X X X X X - X L- u: E ï .E P 6 2 00-6 X X - - P B 2 E
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2 2 ~g N. ~~ OPERATION A (1) - ~10 20 30 - - 8 si 19 Check terwon of and if necessary replace drive belts of: alternator.
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COMPLETE CAR MAINTENÀNCE S C H E D U L E Th,e following schedule is not valid for the Italian market and for countries where antipollution r&julatjons are in force - X X X - X X X X X X X X X X X X X X X a= X X - X X X X X X X X X - X X X - X X X - X - X X - X X X X - X X X X X X X X X X X X X X - - X X - X X - X X - .
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Km/1000 30 40 50 60 21 Replace camshaft drive belts 22 Check fuel system for leaks 23 Clean and check air filter element 24 Check tvghtness of air mtake system downstream from the air flow gauge (petrol Inlectlo” only) 25 X / Il I Il X X X X Replace fuel fllter (where necessary) I I I l I I I Replace air ftlter cartndge 26 I 4 X X Replace drive bett of alternator and air conditroner compresser (If fltted) I 8 X X 27 Clean carburetor lets and crankcase ventllatlon systembac
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COMPLETE CAR MAINTENA.NCE SCHEDULE The following schedule is valid only for those countries where antipollution regul,ations are in force E 32 9 X - X - X - - - X - - - X - - - - X X X X X X X X - X X X X X X X - X X X X X X - X X x X X X X X X X X X X X - X X - X X - X X X X X X X - X X X X X X X X X - X - X X, X X X X X X - X X X - 7 X X X X Lu X X X - B u % .
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COMPLETE CAR u w x Ix .u X - $ X - X x i‘F- f - _ --_ X X - X X - X - X - X - - X - - X - X X - X - X . X X X X - X X .
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No.
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COMPLETE CAR - MAINTENANCE SCHEDULE ,/ , The present periodical maintenance schedule, for all markets, is applicable to vehicles equipped with SERVICE BOOKLET having the new programmed maintenance. OPERATION ine oil and oil filter check ti Replace oil in gearbox - differential (and rear differential in X ( X 1 X 1 X 1 Check brake and clutch fluid levels 14 19 Check axial an’d radial play of supercharger rotor shaft and by-pass valve (only in diesel engine vehicles) 20 Check idle r.p.m.
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COMPLETE CAR OPERATION N.
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P NEW IDENTIFICATION LABEL /@@& - - A L F A L A N C I A INDUSTRIALE S . P . A . I I Ul2- '6 . 1 - Homologation code 2 - Body marking 3 - Engine type mumber 4 - Base type and vehicle version ‘<.._E HOTORE-ENGiNE VERSIONE-VERSION , L QI 1 - N’ PER RICAfl8I ti’ F O R SPARES 1 2 I * 3 - -,fl -,5 / 5 - Serial number with relation to finished units: necessary when ordering spare parts, for identification of production or assemply plant and as reference for introduction of modifications.
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MODEL VARIATIONS (According to E.E.C. markings adopted on new identification labels) I ENGINES WITH TWO CARBURETORS ENGINES WITH ONE CARBUTEROR 33+ * Mode1 3 3 Body St 2 0 4 Chassis serial No: - on service compartment front cross member, right side, horizontal plane Engine type and serial No. - on special rised block on engine block, Upper right part flywheel side Rim dimensions ; .’ on identification label - on Sérvice compartment front cross member, right side, horizantal plane.
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MO~DEL VARIATIONS (Accordinb to E.E.C. marking adopted on new identification label+ ENGINES WITH TWO CARBURETORS ENGINES WITH ELECTRONIC FUEL INJECTION 33 1.7 + 33 1.7 I!i 33 9.7 fi Mode1 ENGINES WITH ’ TURBO COMPRESSOR 331.8TO .. 5 DOOR SALOON Body I Drive I T l left leftlright leftlright lefilright -r .. - on identification label I I I 8 0 zî - on service compartment front cross member, right side, horizontal plane. vehicle type No. - Chassis serial No.
PAGE 26
COMPLETE CAR RECOMMENDED FUEL AND LUBRIC&NTS ,:,-- 00-l 1 FUEL For coke@ engine functioning the specification is for premium grade or unleaded petrol: RON 2 95. For models 33 1~7 + and ,33 specifikations must be used: 1.7 IE with electronic injection and catalytic convertor only unleaded petrol to the following ~ - Octane Number (Research method) R.O.N. 2 95 (for Switzerland, Sweden versions) - Octane Number (Research method) R.O.N. 2 91 (for Australia version) .
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APPROXIMATE REFILL CAPACITiES 83 ~~~ Mo&is 33, x 3 3 1.3 33 1.5 a x a 3 3 1.3 5 3 3 ‘1.7 + 3 3 1 . 5 TI 3 3 1.7 IE 331.BTO Measurement unit , Kg Liters Kg Liters FUEL TANK - 50 - 50 FUEL RESERVE - 63 Components 6,5 With filter- PI 386 4 4.57 5,25 Without filter (0) 3,15 3.
PAGE 28
COMPLETE CAR ENGINE MAINTE#NANCE ~ B e f o r e extracting the dipstick, dis- BASIC ‘MECHANICAL SYSTEM 1. RelFase clips which secure caver 1 to container. 2. Lift caver enough to remove cartridge without damaging sleeve 0. 3. Clean the cartridge thoroughly. by blowing’low pressure compressed air in the o&posite direction with respect to the normal air flow. 0 connect the minimum oil level sensor wiring from the stick.
PAGE 29
COMPLETE CAR 1. U n s c r e w t u b e s @ and 0’ fit- E,ffect checking as follows: 2. Checking on circuit tightness tings and recover the gaskets. ProPerly’p!ug’fittings to prevent fuel outletl 1. Circuit pressure checking a. Disconnect fuel delivery tube @ downstream from the damper @ 2. Loosen clamp @ and remove filter @. ~ 3. Remou;nt the new filter in order that the arrow printed on filter body be positioned towards fuel delivery direct i o n . 4.
PAGE 30
COMPLETE CAR CHECKING OF EMMISSIONS CHECK A!D ADJUSTMENT OF IDLE, R.P.M. AND EXHAUST EMISSIONS Effect the following preliminary checks: a. Cleaning and replacement of air filter cartridge. b.lgnition system efficiency: spark 1 Acklerator table 2 Adjustment clip 3 Accelerator table sheath / plugs, tables, cap, frotary rotor (see G r o u p 0 5 - transistorised ignition without contacts). c. Ignition timing. ” d.
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COMPLETE CAR If notwithinspecifiedvalueorincaseof’ e n g i n e tune u p a f t e r e n g i n e ; overhauling or after having cleaned or replaced the carburetor, an adjustment involving mixture meteringscrew 1 a n d throjtle v a l v e s c r e w 3 i s C!il requised.
PAGE 32
COMPLETE CAR T O obtain better CO exhaust emission adjustment it is necessary to operate Check idle r.p.m. Check exhaust emission measuring the values cylinder by cylinder using special service tool C, 3.0054 connected as follows: The procedure is valid for 1.7 electronic injection engines with or without catalytic convertor. Procedure is applicable to 1.7 electronic i n j e c t i o n engines w i t h o u t 1. C o n n e c t t h e e n g i n e t o a r e v counter. 1 A.
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C O M P L E T E C A R 1. D i s c o n n e c t t h e ’ w i r i n g ,of t h e Lambda sensor. Check of ,e#hahst emissions T h e Nprocedure is valid for 1 . 7 elec- 2. Using the spanner A-5.021 2, unscrew the plug! 0 located at the inlet ,tronic injeckion engines with catalytic convertor. ” of the catalytic silencer box @ After adjustment of the idle r.p.m. following the’ above described procedure, pr@ed t o t h e c h e c k a n d adjustmentI (if necessary) of the exhaust emi.
PAGE 34
COMPLETE CAR 1. Put the vehicle on auto lift. 2. Working from en ine room, disconnect connectors Q 1 and @ of lambda probe and disengage wiring from clips. CHECK ANiD ADJUSTMENT T H E IDLE R.P.M. ‘For @m-l only OF Carry out the adjustment of the idle r.p.mi w i t h t h e e n g i n e w a r m e d up, the g~ears in neutral and all ancillary devices tut out, operating as follows. Unlock ‘the locknut and turn the a d j u s t i n g s c r e w 0 until the specified value 9 2 0 + 960 r.p.m. is encountered.
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COMPLETE CAR CHECK ON AIR SUPPLY SISTEM TIGHTNESS DOWNSTREAM FROM THE AIR FLOW SENSOR b. W arm engine up to normal running speed. c. Disconnect ignition. 0 a. D i s c o n n e c t p i p e 8 from dump v a l n v e 9 air source to the with a gauge connected. This procedure is for electronic injection 1.7 engines with catalytic convertor 0nly.i Makesurethatallpipefixingclampsare fully,tightened Start engine at idle r.p.m.
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COMPLETE CAR 1 Fuel vapour s&on pipe 2 3 4 D&ompression pipe for dump valve control Air delivery pipe ‘Fu!el tank 5 6 7 Fuel vapour exhaust pipe Compensation valve Fuel vapour separator a 9 10 Fiel vapour recovery pipe Dump valve Fuel vapour filter.
PAGE 37
DIAGNOSTIC AND CORRECTIVE INTERVENTIONS ~ ON LE3.2 JETRONIC INJECTION SYSTEM Procedures and diagrams for electronic injection 1.
PAGE 38
,’ COMPLETE CAR c :ii II October 1988 1 00-22 PA327900883301
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r ~ COMPLETE CAR THE ENGINE DOES NOT START During a start attempt, check the correct Ch& the:presmwxo’fxoltgge .plugs to Effect an electronic and functional test Check ignition system: integrity of ignition distributor, spark plugs and associated tables. Check the efficiençy 6f inrake, tiucts, filter ai/ fjow sensor. rhrottle body.
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COMPLETE CAR THE ENGINE STARTS WITH DIFFICULTY 1 May 1 9 8 8 00-24 PA333500883300
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COMPLETE CAR IRREGULAR IDLE RPM Check for correct air flow. throngh Check that on a suckins ducts don’t Effect electrical troubleshooting from ANObjlALIES IN ACCELERATION AND BURSTS IN RELEASING Checkicorrect fuel system pressure and ignition system efficiency (spark plugs, timing; etc.). P Checklthat no leaks do exist in air iritake ducts YES Check G60 ground efficiency. YES Check minimum & maximum opening No. 4 ‘of electrical troubleshooting.
PAGE 42
COMPLETE CAR EXCESSIYE’FUEL CONSUMPTION Check correqt functionality of the engine water tempqature sensor and relevant wiring by effpcting test No. 5 of electrical troublpshooting. YES Check valve clearance of engine timing. UNCORRECT DISCHARGE EMISSIONS Check functionality of Lambda probe by e f f e c t i n g electrical troubleshooting procedure. ~ Zonnect a CO-tester upstream, from :he catalyst disconnect Lambda probe md verify a CO value increase.
PAGE 43
COMPLETE CAR ~‘ELECTRICAL TROUBLESH00TlNG PROCEDURE for electronic injection 1.7 engines with catalytic convektor NOTE: TflI6 TROUBLESHOOTING MAINLY DEALS WITH THE ELECTRICAL/ELECiRONIC DIAGNOSIS OF SYSTEM AND SENSORS AND ACTUATORS ASSOCIATED TO IT. &ATTHE END OFTESTTHEANOMALY SHOULDREMAIN,‘lTWILLBENECESSARYTOCHECK biAI;N MECHANICAL DEVICES SUCH AS. VALVES, CYLINliERS, COUPLINGS TIGHTNESS OF AIR IINTAKE DUCTSi, ETC. .
PAGE 44
Lheck fuel system pressure - Connect a pressure gauge to fuel circuit - Try a prolonged starting and check p r e s s u r e presence between 2.8 bars and 3.2 bars. ?. NOTE: The pump must turn for a few seFonds even with the only key in the “MARCIA”’ running position. F NO NO Check G4 Fuse (15 Ohm) During a starting, check +12-V on fuel pump t e r m i n a l s . -i t-- c YES Check that negative terminal of pump is at ground. Check fuel filter and any possible duct /, throttlings.
PAGE 45
P COMPLETE CAR TEST’No. 2 - CHECKINGS ON GROUNDS (PIN 4 AND 5 OF CU) mi l Set hwltimeter to 200 Ohm FS. Check cohtinuitir between: - pin, 4 of CU’connector and G60 gr?und; - pin 5 of CU connecter and G60 grqund. Check also G60 grounds functionality. YES TEST: No. 3 - CHECK CONNECTION TO RPM SIGNAL (CU PIN 1) Set ~multimeter to 200 Ohm FS.
PAGE 46
COMPLETE CAR ,’ TEST Ntj. 4 - CHECK ON MIN. & MAX. OPENING THROTTLE SWITCH (CU PIN 15,AND 14) l Set molfimeter fo 200 Ohm F.S. Insert multimeter probes between CU connecter pin 15 and ground. NO Check setting and efficiency of minimum opening switch. Check the ~existance’of a resistance value lower than 10 Ohm. Press accelerator and check an infinite resietance value.
PAGE 47
,s r COMPLETE CAR ,- TEST No. 5 I CHECK ON ENGINE WATER TEMPERATURE SENSOR (CU PIN 8) l Set~multimeter to 20 KOhm F.S. . Disconnect electronic CU connecter. Check between pin 6 of CU connecpendipg on engine water temperature as pe,r curve. ,,’ 1 NO Check wiring continuity between: - electronic C,U connecter pin 6 and brown wire on S7 temperature sensor; - G60 ground and black wire on S7 sensor connection. I YES Replace S7 sensor TEST No.
PAGE 48
COMPLETE CAR 1’ 8, ; TEST No! 6 - INJECTOR SYSTEM CHECKING Check resistance between CU convector pin 3and terminal 87 of S12.a relay. Read from~8 to 5 Ohm. NO - NO Disconnect qecfors removmg relevant - Replace faulty injectors. connectors. Measure reslstance on termmal of every , single injecter. that Will result between I 14 and 18 Ohm. Checkon singleconnectorsof injectors NO that one of JWO pins be - Repairwiring fautt connected to terminal 87 of S12.a relay: and the other to pin 3 of CU connecter.
PAGE 49
I l l m - Set multimeter to 20 V F.S. ~Electronic -CU ëonmector discon; nected. c NO With ignition key on RUN position, check presence of + 12 V between connecter pin 2 and ground. J L Check wiring continuity between Check presence of + 12 V between terS12.b relay shoe terminal 85. and mina1 86 and S12.b relay shoe terminal groud G60. if necessary restore 7 87. wiring. Check integrity of fuse No. 2. With ignition key in RUN position check presence of + 12 V between S12.
PAGE 50
,i ‘,, COMPLETE ~ CAR ~ 1, TEST N{. 8 - CilECK ON LAMBDA PROBE (CU PIN 13) ,, l Conmct wiring side ‘connecter to CU. Set multimeter to 20 V F.S. With startect e n g i n e c h e c k t h e NC presence :of ,12 V o n p r e h e a t l n g r e s i s t a n c e termlnals of Lambda p r o b e . NO Check G4 (7.5 A) fuse integrity. NO - Disconriect resistance preheating B connecter of Lambda probe. - Set multimeter to 200 Ohm FS.
PAGE 51
r COMPLETE CAR INJECTION - IGhiITION W’IRISNG l3IAGRA.M for electronic injection 1.
PAGE 52
COMPLETE CAR ~DIAGNOSTIC AND CORRECTIVE INTERVENTIONS ON LE3.2 JETRONIC ~ INJECTION/IGNITION S’YSTEM Procedures and diagrams for electronic injection 1.
PAGE 53
COMPLETE CAR October 1988 00-3512 PA327900883301
PAGE 54
THE ,ENGINE’DOES NOT START * Check the presence of voltage to spark plugs YES .]I Effect troubleshooting procedure on injection PAd27900883301 00.
PAGE 55
‘T,HE EN~INE ~TART wtTti BIFFICULT? Effect troubleshooting procedures on Check air su$plyI system for leaks In tntake ducts or.c(ogged filter and fuel ~ WITH COLD ENGINE , ~8 Check functiona’lity of extra air valve. With cold engine, 2 mins. after ignition throttle extra ‘air valve pipe and verify that RPMs at minimum diminish noti- Replace extra’air valve. With hot engine, 3 mins. after ignition throttle extra air valve pipe and verify that RPMs at minimum diminish notiCeably.
PAGE 56
EXCESSIVE FUEL CONSUMPTION’ IRRkGULAR IDLE RPM lant temperature sensor and relative wirlng Check for correct air flow through throttle b o d y . Check that there are no leaks in the air intake duc+ and that the air filter is not clogged. procedures for injection system. YES YES 1 Ckeck electromtector trghtness. tien system and injection system.
PAGE 57
COMPLETE CAR TROUBLESHOOTING PROCEDURE ~ /’ FOR INJECTION SYSTEM ~ ~ for electronic injection 1.7 engines without catalytic converte; NOTE: THIS TROUBLESHOOTING MAINLY DEALS WITH THE ELECTRICALIELECTROikIC DIAGNOSIS OF TH~E SYSTEM AND SENSORS AND ACTUATORS ASSOCIATEb TO IT. ~ IF AT.~THE END OF. TESTS THE ANOMALY SHOULD REMAIN, IT WILL BE NECESSARY TO CHEF! MAIN MECHANICAL’ DEVICES SUCH AS VALVES, CYLINDERS, COUbLINGS, TIGHTNESS OF AIR INTAKE DUCTS, ETC. PA327900883301 00.
PAGE 58
>’ COMPLETE CAR TEST1 No.1 - CHECK OF FUEL PUMP CONTROL i- ‘, NO /Check NO During a starting, check + 12 V on fuel pump terminals. l fuel’ system pressure. . Connect a pressure gauge to fuel cir&t. Try~a prolonged starting and check pressure presence between 2.8 bars and 32 bars. NOTE: ~ The pu’mp,must turn for a few seconds even, wjth the key in the “MARCIA” running, position. ’ Check G4 Fuse (15 A) I YES YES . v Check fuel filter and any possible dUCt throttlings.
PAGE 59
COMPLETE CAR YEST No. 2, - CHECKING OF GROUNDS (PIN 4 AND 5, OF CU) Disconnect !Injection CU connecter. Restore wiring between: - pin 4 of CU connecter and G60 ground; -D - pin 5 of CU connecter and G60 ground: Check conti@ity petween: - pin 4 of CU c,onnector and ground; - pin 5 of CU connecter and ground. Check also G60 grounds functionally. TEST No. 3’ - CHECK CONNECTION TO RPM SIGNAL’(CU PIN 1) ~, Disconnect Iljection CU connecter.
PAGE 60
COMPLETE -CAR TEST No. 4 - CHECK ON MIN. 81 MAX. THROTTLE OPENING’SWITCH (CU PIN 15 AND 14) 1) -Fi Set multumeter to 200 Ohm FS. Key removed. CU ~Dlsconnect injection electronic CU j: : 1 Insert multimeter probes between CU connecter pin 15 and ground. Check the existante of a reslstance vajlue~lower than 10 Ohm. Piess accelerator and check an infinlItel resistance value. Insert multimeter probes between connecter pin 14 and ground. Check setting and efficiency of mini- q? I 1 YES 1 .
PAGE 61
COMPLETE CAR TEST No. 5 - CHECK OF ENGINE COOLANT TEMPERATURE SENSOR (CU PIN 8) Set multimeter to 20 KOhm FS. rerhoved! Key Ciisconnect injection electronic CU connecter. t :heck between pin 8 of CU connecter ind ground, a reststance’value depenling on engindcoolant temperature as Ier curve :heck wiring continuity between: .electronic CU connecter pin 8 and brown wire on S7 temperature sensor; -G60 ground and black wire on 57 sensor connection 25. I 1 i NO Westore w i r i n g .
PAGE 62
r COMPLETE CAR TEST No. 6 - CHECK OF ELECTROINJECTORS CIRCUIT Set multimeter to 200 Ohm F.S. Di,sco’nnect injection CU connecter. Check resistance between CU connec- Disconnect electroinjectors removing relevant connectors. Measure resistance on terminal of every single injecter, that Will result between 14 and 18 Ohm. Check on single connectors of injec. t o r s WIRING SIDE, that one of two pins is connected to terminal 87a of S12a relay and the other to pin 3 of CU connecter.
PAGE 63
COMPLETE CAR TEST No. 7 r ‘CHECK OF +12 V PIN 2 AiUD PIN 7 OF CU ,fLlfq Disconnect infeqtron CU conpector. With ‘igniiion key on RUN position, check presence of + 12 V between CU connectdr pin 2 and ground. NO + Check Integrity of fuse NO. 2. With ignition key in RUN position, check presence of +12 V between S12b main relay shoe terminal 30 and ground. NO With ignition key in RUN position, Check presence of + 12 V between termina1 88 and S12b relay shoe terminal 87.
PAGE 64
v COMPLETE CAR TROUBLESHOOTING PROCEDURi FOR IGNITION SYSTEM for electronic injection 1.7’engines without catalytic cbnverter NOTE: ~ THIS TROUBLESHOOilNG PROCEDURE MAINLY DEALS’WITH THE ELECTRICALIELECTRONIC DI:AGNOSIS OF THE SYSTEM AND SENSO’RS AND ACTUATORS ASSOCIATED TO IT. ~IF AT THE END OF TESTS THE ANOMALY SHOULD REMAIN, IT WI~LL BE NECESSARY TO ~CHECK MAIN MECHANICAL DEVICES SUCH AS VALVES, CYLINDERS, COUPLINGS, TIGHTNESS OF AIR INTAKE DUCTS, ETC. -.
PAGE 65
THE ENGhE DOES NOT START l . Check the presence of voltage to spark i’plugs (by attempting ignition). .. NO * Set multimeter to 20 V F.S. Key in RUN position. Check presence of + 12 V between ignition coi1 terminal 15 and ground. Check presence of + 12 V between ignition CU connecter pin 3 and ground. NO NO Check vehicle, system functionaiity (eg: c continuity between ignition coil terminal 15 and starting block; starting block supply and functionality).
PAGE 66
YES NO Restore wiring.- Check wiring continuity (after having clisconnected ignition CU (N20) connecter and ignition CU (Nl) connecter between: . ignition module conneètor pin 3 and ignition CU pin 1 - ignition CU connecter pin 13 and ignition module connecter pins 5 and 6 _ ignition module connecter pin 1 and white wire on ignition coi1 terminal 1. IYES Check ignition coi1 (A6) functionality verifying values listed hereunder: primary winding resistance: from 0.5 to 1.
PAGE 67
ADVANCE ‘VARIATION CHECK TEST No. i If any variation exists, but outslde the 1 Connect stroboscopic gun and check: - with cold englne advance higher than the piescribed value; - with bot engine, prescribed advance value. l Wlth engine’ running steady disconnect engine coolant temperature sensor conhemor (L24) and ,read advance value. Connect to ground the brown-white wjre of the sensor and check an advance variation with respect to that previously ~read.
PAGE 68
Discinnect minimum and m a x i m u m thrdttle opening switch connecter ahci read advance value. Short-ctrcuit pin 15 (white wire) with pin 16 (black wire) and check an advance variation with respect to thevalue previously read. Check wiring continuity between: . connecter pin 16 of minimum and ximum throttle opening switch S6 ground G60. . connecter pin 15 of minimum and ximum throttle opening switch S6 ignition CU N20 connecter pin 6. NO maand maand 1 YES ‘YES !.
PAGE 69
COMPLETE CAR ~INJk.CTl~hl - IGNITION WIRl,NGi DIAGRAM 1, for electronic injection 1.
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33+ * 331.3 ~~ 33cl s 33 1.5 axa 33 1.5 7-I 33 1.
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‘, ,’ 7, COMPLETE CAR _ SPECIAL SE#RVICE TOOLS Tool number Tool name Refer to page ,A.3.0156 Puller of pin from stub axle - 18 A.4.0146 Tool for suspension height check A.4.0149 Tool for suspension height check l ~ ; A.4.0150 88, A.4.0206 , Probe for suspension height check (to be used with A.4.0146 - A.4.0149 - Magnetic adapter for suspension height check (to be used with A.4.0146 - A.4.0149) - Magnetic adapter for suspension height check (to be used with A.4.0146 - A.4.0149) .
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~._....~ ‘, ,, * ENÛINE MAIN MECHANICAL UNIT ~DRIVE UNIT REMOVAL AND ~INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . OI-2 Removal (1.7 I.E. with catalytic converter); . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-2 ~ Installation (1.7 with catalytic converter) OI:7 Removal (1.7 I.E. without catalytic converter) . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-8 jnstallation (1.7 without catalytic con‘verter) . . . . . . . . . . . . . . . . . . . . . . . . . . .
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ENGINE MAIN MECHANICAL UNIT 11, , ,DRIVE U N I T REMOVAL A N D IINSTALLATION ,’ These procedures are for electronic injection ,A.7 engines REMO:$AL 1.7 LE. with ca’talytic converter During enghte,removal from car, it is necessary to remove engine and gearbox - differential’as single unit. Put the vehicle on ~the auto lift and engage ‘, first ,geas ~ WARNING: ~ Great tare dis required when dealing with a hot engine. ,, ~~1. Preliminary operations a.
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ENGINE MAIN MEC~HANlCAL, UNIT , .. LO,dTION OF DSIVE UNIT ENGINE MOUNTINGS As for ENGINE CO,MPARTMENT. LOCATION COMPONENTS Engine 1.7 Electronlc Injection ‘i 1 Coolant delivery hose .
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E N G I N E M A I N MECHANICAL UN’1-i ” 1.7 IE with catalytic converter Il Starter energizing table ?Starter supply bablbs 3 Odometrlc sensor table ‘4 Engine compartmeht wirlng 5Ground Gable wlring I~6’Power module on ianition distributor 7 Engine coolant temperature indicator table: 0 Englne coolant minimum level sensor table ~ 9 Col1 low.
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,, r ENGINE MAiN MECHANlCAL: UN!IT 41; aemoval of electrical tables For folhwing’removals, refer to figure at page’O#l-4. 12. Loosening nut of engine central support With reference to the following figure loosen bolt 0 fixlng central support 0 to the body without removing it. ~ c. Remove the discharge mainfolds @ lrecovering the gaskets and withdrawing from bottom the wirlng of lambda probe, previously disconnected. 15. Removal of reversing light table a.
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,; E N G I N E M A I N MECHANICAL UFflT’ 8’ “, VIEW OF UNDERPART OF VEHICLE - LOCATION OF ,COMPONENTS 1 Screws fixing cross member to body 2 Cross member to right strut connecting bolt ,3 Stabillzlng b a r ,4 Screws flxing engine front support to crossmember 5 Coolant drain plugs 6 Cross member to left strut connecting bolt 7 Cross member to body flxlng screws 8 Suspension left strut ,9 Exhaust manlfolds 10 Engine oil drain plug 11 Reverse light table 12 Muffler central silencer * 13 Exhaust manifold-cat
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~ r ENGINE MAIN MECHANICAL,,UNIT g. Unsciew and remove the two bolts 0:connectimng the front cross member t’o the left $rut @ . h. Swing the front cross member round as shown in the illustration to allok the drive unit to be taken out downwards. 1 Rear support of gearbox 2 Pin 3 Rear support securing screw 4 Bolt securing gearbox rear support 1 Boit 2 Central support i. Unscrew and remove the two screws fixiqg the drivce unit rear support 0 to tbe body. 1.
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ENGINE MAIN MECHANICAL IdIT 3. Reassembty of electrical tables Lower the auto lift and, with reference Nto figure on oage 01-4, reconnect elec~trical ‘cables’working in reverse order ,to that described under “Removal” ‘,step 11. ~~ ~ For fol!owing procedhes steps, refer Gto Figure 01-3. h. Remount hood. i. Remount the battery negative terminal. 1. Operating inside the passenger compartment refit the gear lever knob and rubber gaiters on the gear lever. REMOVAL ‘,4.
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ENGINE MAIN :MECHANICAL UNIT 11. Removal of electrical tables INSTALLATION 6. Completion of reassembly 1.7 IE without catalytic converter Operatè as described at step 11 page ‘01-5 with reference to Fig. page 01-4. 1. Preliminary operations 12. ~Loosening nut of engine central support Operate as described at step 1’ page 01-7. Operate as described at step 12 page 03-5. For’following procedure steps refer to Figure at page 01-6. 2. Reinstallation of reverse light table and of exhaust pipe.
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,,s ,’ l ENGINE MAIN MECHANICAL UNIT: ,‘~ ENGINE OIL GEARBOX-DIFFERENTIAL OIL Type: Type: AGIP Sint 2000 SAE loWl40 lb; Sintiax +A! lOWI40 SHELL Super Plus Motor Oil SAE 15w150 ~ AGIP Rotra MP SAE 8OW/90 IP Pontiax HD SAE 8OW190 SHELL Spirax HD SAE 8OW/90 Quantity: Oil quanrity for full refilling (lump, filter and duc&): 2,4 kg d. Bleed the clutch hydraulic system and top up said circuit (as per Alfa 33 Group 12). e.
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2 -2 2 8 0 !i Outer parts 1 Electroinjectors~ 2 Fuel supply manifold 3 Lifting brackets 4 Supply manifold 5 Fuel puise damper 6 Fuel pressure gauge 7 Intake manifolds 6 Supplementary air solenoid valve 9 Gasket 10 Coolant temperature sender (for indicator) 11 Gasket 12 Coolant temperature sender (for CU) 13 Dipstik 14 Single contact min.
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E N G I N E M’AIN M E C H A N I C A L U N I T Interna1 ‘ p a r t s J5+8’ ( 0 .
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ENGINE MAIN MECHANICAL ,$JNIT Interna1 parts 0T 1 2 3 4 5 6 7 8 9 10 11 12 $j33%00883300 Main bearings Woodroff key Thrust half-ring Oil pump gear Bush Seal ring R,ear caver Oil vapour separatar filler inlet Flywheel Washer Lock ring Pin ,Ol-11 13 14 15 16’ 17 16 19 20 21: 22 23 N.m (k9.
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4. Remoie spark plugs and ignition qlistributor. (1) Unscrew and remove spark plugs from cylinder heads. (2) Loosen distributor @ securing nut @ and withdraw distributor from rear caver. PRELIMINARY OPERi+TION,S 1. Remove #drive unit from car according t8 procedures: D r i v e U n i t Removql An4 Installation. 2. Remove Qearbox - differential unit and clutcq uni? from engine according t o ‘proc&d,ures: S e p a r a t i o n a n d Assemblv, of the’ Units (sec: “WORKSHOP MANUiL c-1’ ” - Group O-l ).
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“, ‘, ‘8, ~ ~ ENGINE MAIhI ‘MECHANICAL UNIf 9. P’ropeed as per (Alfa331 from step 11 to end, but for step 21 “Remove Cylinder Heads”, which should be modified as follows: (1) Unscrew the six screws @ which secure cylinder headsto, engine block. (2) Remove heads ‘along with camshaft Supports and the gaskets on engine bldck. 6. Flem&e sleeve and cooling system union.
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~ ,’ ENG!NE M A I N MECiiANICAL UNIT’ ; l 8’ ‘, CHECKS AND INSPECTIONS ,l These procedures are for electronic injection 1.7 engines with CatalYtiC CO~ve~or CnlY cup is free, of any trace of sizing, CYLINDER HEADS etching, or unusual wear. WARNING~ AND VALVES ,Procedures-described for (Alfa] 2. Check fhat the cups Upper plane are stik ,valid( except for what folAs per (A-33) except on which cams work is free of unusual ‘lows. ~ wear. ,For technfcal data of 1.
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8’ ~ ‘, ENGINE MAIN MECHANICAL U~NIT (2) Set the camshaft in rest position (no ca” engaged; valves closed). (3) F,it the~cylinder heads with crankshaft sipport on the cylinder ,block, and ~ifis&the appropriat’e gasket. Proceed as ‘per (Alfa] f r o m Step;(t). l Step 18. ‘Installé timing belts. (1) Fit~ camshaft drive pulleys and tighttin ‘he’ retaining screw to specified torque being caeeful, at the same time, to stbp~ ptlley rotation by tieans of toothecj spanner A.5.0195.
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ENGINE MAIN MECHANICAL UNIT, ;’ ” ~ : Tightening torque : . Water temperature sender (for temperature gauge) + 41 N.m y:4 + 4.2 Kg.m) . Water temperature sender (for injection CU). Max torque 1 5 N . m (1.5 Kg.m) ! (13) Loosen the nut of right-hand belt straighten~er,, then tighten it to the prescribed torque, CAUTIOk ~ ,’ Dr$ing ~this operation, do not press the belt’straightener to prevent alter‘i’ ing the ~load, envisaged for belt straightener ~itself.
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~ 27. Fitloil filter by manually tightening it and insert dipstick. ENGINE MAIN MECHANICAL UNiT (4) Adjust belt tension according to specified value and then lock bolts 30. ,Retiount injectors on intake manifolds, replacing relevant O-rings, and fix lfuel manifold. , 28. Bi means of a suitable box span‘ner fit Fpark plugs tightening them ac‘cording t9 specified torque. Load: 8 Kg Arrow: 15 mm - power module on distributbr - engine water temperature sensor - injectors.
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1700 305.58 1500 1350 1200f Features Otto 4 stroke Cycle L 305.58 A 4 horizontally opposad Numbers of cylinders and arrangement Right head Laft head Cylinder identification Bore - Stroke Displacement mm cm3 80x 59 1186 80 x 672 1351 80 x 67.2 1351 84 x 67,2 1490 87x72 1712 87x72 1712 Combustion chamber volume cm3 37 42,2 39.7 44 49.5 49,5 Compression ratio 9 Max Power DIN kW (HP) Specific N.m (Kg.
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ENGINE <--,;, M A I N MECHANICAL UNIT ~’ INSPEOTIdN AND ADJUSTMENT CAMSHAFT SYSTEM Unit: mm (in) .-. Double carburetor engines Single carburetor engines LEFT SUPPORT 1350 305.86 1200 * 3g5.85 546.232 545.766 Camshaft 1500 305.88 1350 305.87 Inta ke 035 + 0,40 Exhaust 0.45 + 0.
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m n For countries where antipollution regulations are in force (0) Crankshafl rotation ACW seen from flywheel side. (*) Not marketed in all countries.
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ENGINE MAIN MECHANICAL QNI,T ~ CYliItjDkR BLOCK Unit: mm (0) Area for dimension check Engines Inspection data Glass A i ,, Class B Class C ‘,S Glass D C$n,der ;bore “a” Glass E 1 s t Oversize ‘1 2nd 3rd 1700 305.50-305.58 1200*-1350 305.85186187 1500 305.8% 80,00+80,01 80.01 +60.02 60.02 t80,03 80.03 C80.04 80,04+80,05 84,00 f 84.01 84.01 + 84.02 84,02 + 84,03 84.03 G84.04 84,04 t 84,05 80,20 + 80.
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Unit: mm (in) ENGINES ‘L 1200-1350 305.85 (1) 305.86 (2-3) 305.87 (2-3) Inspection data C!as$ A (Blue) Glass C (Green) Standard Class D (Yellow) Class E (White) 1 s t 2nd 3rd 8 4 , 1 5 4 + 84,170 8 4 , 3 5 4 f 84,370 8 4 , 5 5 4 + 84,570 8 7 , 1 5 0 + 87,170 87,350 + 87,370 87,550 + 87,570 1,525 ~+ 1,545 Second compression ring groove height “d” 1,775 ; 1,795 Pin-Seat bore “b” A For countries vvhere antipollution regulations are in force 2 c.2 0 80i154 + 80,170 80,354 + 80,370 80,554 t-80.
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Unit: mm (in) I Inspection data Ring thickness “b” Engines 1200 * 305.85 1350 305.86 - 305.87 1500 305.88 1700 305.50-305-305.58 First compression ring 1,478 ~1,490 1,478 + 1,490 Second compression ring 1,728 + 1,740 1,728 + 1,740 Oil scraper ring 3,978 f 3,990 I I 2,978 + 2,990 First compression ring 0,30 + 0.45 + 0.30 045 (2) 0,30 + 0,50 (3) 0,30 + 0.50 Second compression ring, 0,30 + 0,45 0,30 + 0,45 (2) 0.30 + 0,50 (3) 0,30 f 0,50 Oil scraper ring 0,25t 0,40 0,25 0.
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8, m,‘, ~ ( i, ,’ ‘i fi ,., l ,l ~ ‘ENGINE MAIN MECHANICAL UNIT ~ ~ ~ Unit: mm (in) ‘1 8’ 1, ~ hpac?ion d a t a ,’ I Engines 1200 * 305.85 1350 305.86 - 305.87 o,oo$ + 0,12 P i n - p i s t o n slack ” ‘1 1988 1700 305.50 - 305.58 20,996’+ 21,000 P i n diarndter “a” Mai 1500 305.
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ENGINE M A I N MECHANICAL~, UNI-r COh$ECTlNG ROD AND CONNECTING ROD ‘BEARINGS ‘i, Connecting rod (1) Unit: mm (in) Engines Inspection data ., 1200* 305.85 1350 305.86/87 1500 305.88 Small end bush bore diameter “a” 21,007+21;015 ~ F$end bore diametar “b” 52,696 + ,53.708 1700 305.
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18 ~ ENGINE MAIN’ MECHANICAL ,‘,’ ‘8 UNIT l FLYWHEEL ” Unit: m (in) Engine 1’ Inspection’dete 1200 * 305.85 1350 305.86/87 a 500 305.88 1700 305.50/58 ,” ~ 24,0 + 2 4 . 2 8, G 0.2 ~ Parall,elism bof the’driven plete.contact face compared with flywheel-to-cranksheft support face (as read et ,’ > 2 0 . 9 5 OS@ ‘a 108 mm (3.94 in) radius) 0.02 Maximum outof-flat of driven plate contact face ~ 2.
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~ ~ ?’ ENGINE MAIN MECvANICALs UNI$ CRA$lKSHAFT, THRUST RINGS AND MAIN BEARINGS ~ Cranlishaft Out of. round X - Y Taper 1 Flywheel locating dowel 2 Gear tooth beginning line A - B Unit: mm (in) Eng/ne Inspection date 1200 * 305.85 1’350 305.
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‘, : ENGINE MAIN MECHAhlICAL U’NiT 8. Unit: mm (in) ~ E n g i n e l Inspection data 1200 * 3 0 5 . 8 5 1 3 5 0 ‘305.86187 Max. miialignment betwaen tha centrelines of the MO pairs of crankpins and the journals centreline 1500 305.88 1700 305.50/58 0.03 ,l, ” Rear crankshaft bush diameter “b” 16,065 + 16,080 Fitmant~ of raar crankshaft gear “CL” (distri,butor/oil pump drive) 22O f 260’ il j.
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” ” ENGINE MAIN MECHA~WCA~ LJNIT CAMSHAFT SUPPORT, CAMSHAFT AND TAPPET BUCKET ,’ Camshaft support and tappet bucket -b--l- ,’ ~ l Unit: mm (in) i E n g i n e 1200 * 305.85 Bore of cbmshaft journal bearing di&-&f “‘a*’ Seat tappet bucket d i a m e t e r “ b ” Tappit bucket diameter “c” (“1 1350 305.86187 1500 305.88 1700 305.
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Rear Central Front I I .n (0 ” U n i t : Inspection data Cam height 1200 * 305.85 ’ 1350 305.86 1350 305.87 I (“) 1500 305;88 1700 305.50 1700 305.58 1700 305.58 A Intake 8,50 10,2 9,80 9,50 Exhaust 8.50 95 w 8,45 Front “a” Camshaft journal diameter Engine with electronic ignition Double carburetor engines Single carburetor engines L m m 34,940 f 34,962 Central “b” 46,440 + 46,456 47.
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Cylinder head Unit: mm (in1 - Engine Inspehon data 1200* 1350 305.85 365.86 1350 305.87 1500 305.88 13,000 + 13,018 Valve guide seat diameter “d” 13,050 + 13,068 Standard l Valve guide O.D. “a” l Spare 13,064 + 13,082 Diameter of valve guide bore “b” 8,013 + 8,031 Diameter of saating for valve Stern sealing cap. “f”~ 10,85 + 10.95 9,3 + 9,5 Valve guide protrusion “8” Min. cylinder head thickness after resurfacing “c” (1) Max. error of parallelism betweenhe,ao surfaces Max.
PAGE 105
l-b-4 Unit: mm (in) Engine Inspection data 1350 305.86 1200 * 305.85 1350 305.87 Intake 7,985 + 8,000 Exhaust 7,968 + 7,983 1500 305.88 Valve stem diameter “a” Intake 39,70 + 39,90 38,00 + 38.20 Valve head diameter “b” Exhaust (“1 Net marketed in ail countries 33,00 + 33,20 1700 305.50 - 305.
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ENGINE’ MAIN MEi2HANICAL U~lilIT VALVE SEAT RECUTTING DIMENSIONS file~aft~r, max recutting Unit: mm (in) Engine Inspection data Referr&e diameter “OR ” ,’ ~ 1200 * 305.85 1350 305.86 1500 305.88 Intaké 37,3 39.0 Exhaust 31;9 31,9 2.9 23 Fut liinit of ;Valve seat top surface “a” ,’ Fut limii of’valve seat mating surface “b” 1350 305.87 Intaka 1,07 Exhaust 1,26+1,56 Valve seat top surface limit angle “a” +1,37 1.07 + 1.
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,,, ,! ;, ENGINE MAIN MECHANICAL UNil? I FiTMEbT’P&AYS OR INTERFERENCE FITS Unit: mm (in) ~ Engine ‘1 ;, ;’ inspection data 1200-1350-1500 305.85 - 305.86 - 306.88 305.87 '1 Standard 0,03 + 0,05 Oversize 0,03 + 0,06 0,03 f 0,05 (1) 0,04 + 0,06 (2) 0.03 +0,06-(l) 0.04 + 0,066 (2) Cylin@ borelpikn play First compression ring Ringlgroove end float 'i ~ 0 , 0 3 5 1 7 0 0 305.
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i> ,!, ENGINE MAIN MECHAN~CAL ?N~T HEAjING TliMPERATURES As per (Alfa2 . ~ ;, GEN’ERAL SPECIFICATIONS FL,~IbS;~AND LUBRICANTS Unit: I (Imp. Gal) Application aty (litres) Denomination Type AGIP SINT 2000 lOW40 Engir!e oil sump at max level 3.5 Std. No. 3631 - 69352 Filter~ an? interyal piping Peri$lical change with filter replacement (“) 0.6 IP SINTIAX iOW40 OIL 4 Std. No. 3631 -‘69353 .
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~ ~ E N G I N E M A I N MECHANICAL UNIT ~ ~~ssE~~~c~ DATA AND 8, ‘1 SP EC IFIC A T I O N S F o r d i e s e l engines only ” ’ ~T+iNICA;L DATA As for 33l.ETO exc&t for those features listed below: ENGIN$ Dka Features VM82A Engine t~ype 4 - Stroka Diesel (Precombustion chamber OMET) 3 in line Number,of cylinders and arrangement Cylinded identification Runningidirection Bore - Stroke mm lin) Displace~ment cm3 (cu. i n ) Combustion chamber volume cm3 (CU. in) ~ 892 x 89.2 (3.62 x 3.
PAGE 110
r ~ ‘1’ ENGINE MAIN MECHANICAL UNIT ‘CRiXKS AND ADJUSTMENTS ~ ,’ TIMING DATA (1) 129.958 Alfa Romeo Part No. Camshadt Normal;valve clearance “a” 8, ~ ‘1 ~ Intake 0.30 (0.012) Exhaust 0.30 (0.012) ~ 7.20 (0.283) Intake Normal cam lift 7.64 (0.301) Exhaust I I (1) AIl values refer to cold engine TI~II~~~: DIAGRAM (ANGULAR VALUES) (11 (crarjkshpjt clockwise rotation, viewed from front side) ” T.D.C. “ Opens (B.T.D.C.) I n t a k e 88 Intake ‘1 1: 1 ~ 460,? ‘
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~ E N G I N E M A I N MECHAiUICAL UNIT~’ ~ r CYLINDER LINERS, COMPRESSION RINGS, GUDGEON PINS AN,D F!ISTONS Cylinder liners Unit: mm (in) ‘8 Engine ,m 1800 Inspectiqn data ” ,, 1, VM 82A 1’ 92.000 to 92.010 Grade A Liner bore “a” i (3.6220 to 3.6224) I 0.11 to 0.23 (0.0043 to-0.0091) Recess of cylinder liner outer rim from engins block (1) “c” L i n e r stand;out “b” from engins b l o c k (1) 6.00 to 0.0,~ (0 t o 0 . 0 0 2 4 ) M a x lbv& oya)ity and taper fat wear limit) 0 . 0 1 0 (6.
PAGE 112
!, r ENGINE MAIN M&HANICAL IJNIT ~ ,, Compression rings 0 -. 7 --. WL a Unit: mm (in) Engine 1 8 0 0 Inspection data VM 82A Ring thickness “a” l 81, ~ 1 st compression ring 2.075 to 2.095 (0.0817 to 0.0825) 2nd compression ring 1.978 to 1 .s90 (0.0779 to 0.0783) Oil scraper ring Ring gap (‘1 ) “b” ;’ 3.978 to 3.990 (0.1566 to 0.1571) 1 st compression ring 0.40 to O.b5 (0.0157 to 0.0256) 2nd compression ring 0.25 to 0.45 (0.0098 to 0.0177) Oil scraper ring 0.25 to 0.58 (0.0098 to 0.
PAGE 113
88, ENGINE MAIN MECHANICAL UNIj- ; i Pistons~ (with insert) b c d Unit: mm (in) ,Engine 1800 Inspection data ~ VM 82A ~ m,91.965 to 91.9P5 (3.6206 to 3:623 1) Grade A Pistbnidiameter:(l) (‘a” 1st coypqession ring groove height “b” 21175 to 2.205 (0.0856 to 0.0868) ~ 2nd cdmpression ring groove height “c” 2.060 to 2.080 (0.0811 to 0.0819) Oil scr:aper ring groove height “d” 4.020 to 4.040 (0.1583 to 0.1591) :, ,” 30,002 + 30,007 Gudgeon pin bore dia.
PAGE 114
8’ ,’ Y :, ENGINE MAIN M~ECHANICAL $lT~ CRAfiKkHAFT, CYLINDER BLOCK AND MAIN BEARINGS; CQl)lNECTING PODS, BIG END BEAFING AND FLYWHEEL ICrat)@shaft I., d3 62 dl Ovality X-Y Taper D-E Unit: mm (in) Engine Inspection data 1800 I 62,995 f 63,010 63,005 + 63,020 69,985 + 70,000 53,940 953,955 Standard Crankpin diameter “6” ;. Undersize ~ 1st’ 53.670 + 53,690 2nd 53,420 + 53.440 Fear main journal length “C” ~ 27,975 G-28.
PAGE 115
‘i, ‘, ,, l ENGIR;E M A I N MECHANICA’L UN’IT’ ~ Cylinder: block hd main bearings ” ,’ Unit: mm (in) I ~ Inspection data ~ Front bearing housing bore dia. “A” in engine block ~ :67.‘025 d 63.060 to 63,110 (2.4826 to 2.4846) ‘8 S Front bearing inner dia. “8” in engine block t a Undersize n d a r 1st 2 n 62.810 to 62.860 (2.4728 to 2.4748) 62.‘560 to 62.610 (2.4630 to 2.4650) d Intermediate bearing housing bore dia. “C” in bearing split rings (1) I 66.670 to 66.687 (2.6248 to 2.
PAGE 116
‘1 Y E N G I N E MAlN~MECHANICAL~UhjIT ‘Connecting rods and big end bearings Unit: mm (in) Engine 8’ Inspection data 1800 V M 8 2 A Connecting rod small end bearing bore “a” 30.030 to 30.045 (1.1823 to 1.1829) Connec$ing rod small end bearing outside diameter “b” 34.089 to 34.129 (1.3421 to 1.3437) Bush housing inner dia. “c” in small end 34.000 to 34.025 (1.3386 to 1.3397) Big end inner dia. “d” (1) 57.563 to 57.582 (2.2663 to 2.
PAGE 117
1, ,: 1 ~ ENGINE MAIN~ b/iiCHANICAL U~NIT ~ 1’ FITl$NT PLAYS AND INTERFERENCE FITS ~ Unit: mm (in) ,, l Engine 1800 Inspection data VM 82A 0.625 to 0.045 [(0.984 to 1.772).10”] New Cylind’er liner/piston clearance l Wear limit ‘i 1~ 0.5 (19.68.1 03) 1 st compression ring ~ Ringlg’roove. end ‘float 0.080 to 0.130 [(3.149 to 5.118):10-3] 2nd compression ring 0.070 to 0.102 [(2.756 to 4.016,.10-3] Oil scraper ring 0.030 to 0.062 [(1.181 to 2A41j.
PAGE 118
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 04-2 ( General description . . . . . . . . . . . . . . . . . 04-2 . Injection system Jetronic LE 3.2 . . . . . . 04-2 lAccelerator throttle switch calibration . 04-20 Fuel’ pressure checking and fuel tightness . . . . . . . . . . . . . . . . . . . . . . . . , . . . .(a) Ignition system . . . . . . . . . . . . . . . . . . . . 04-2 Adjustment for accelerator control table (a) , . Air, fuel, fuel vapour system chart . . . . .
PAGE 119
D E S C R I P T I O N ‘~ .~ For electronic injection 1.7 engines’ ~ GENERAL DESCRIPTION . The JETRCNIC LE 3.2 electronic system consists an inductive discharge transistorized injection system equipbed with a control unit (CU). The ignition, how,ever is ensured by an electronic ignition system equipped with an electronic power module. The data necessary for controlling the system is colfecfed by means of sensors that transform the data into electrical signais.‘This data concerns: battery voltage l .
PAGE 120
FUEL SYSTEM AIR, FUEL, FUEL VAPOU’R SYSTENl CHART ,,” ‘1 1 -- PA32~9qO883301 October 1988
PAGE 121
,:t 8’~! ~ INJECTION SYSTEM WIRING DIAGR’AM I ------.-..
PAGE 122
~ MA/N, COiMPQNENTS FUEL PUMP The pump is of the rotating type with cells Sand rollers, driven by an electric moto; which remains immersed in the fuel under pressure downstream the pumping ,unit.
PAGE 123
i FUEL SYStEM 8’ a full load contact. In this way a signal is sent to the electronic CU when the ‘en’gine is running under conditions of ‘full load and the CU is able to alter the air-petrol ratio according to the requirements of th,ese engine conditions. When the aceelerator is released the fuel supply is tut off by means of the minimum throttle opening switch. When the accelerator throttle valve closes and the engine r.p.m. (s higher than 1600 r.p.m., the fuel’supply is tut off until the engine r.p.m.
PAGE 124
The iollowing components are fore seen ~on~ly on models with catalytic converter. FiLtiEl+INLET F O U,F$EADED PETROL R Thé filIer inlet of the fuel tank is fitted with ~a special device which prevents ‘filling with petrols other than those whlich are unleaded. O’nly lthe~ delivery nozzles of unleaded petrol pumps are able to pass through the ne& of the filler inlet, thus opening ~the valve and filling the tank.
PAGE 125
l l ,; 1’ il ~ 1 Fuel vapour intake tube 2 Vacuum pressure tube for dump valve control 3 External air delivery tube 4 Fuel tank 5 Fuel vapour breather; hose ~6 Compensation valve 7 Fuel :iapour separator 8 Fuel ‘vapour recovery tube 9, Dum&+e , 10 Fuel !vapour filter ~ IMPORTj’ihjT GENERAL DATA ,’ Never istart the engine when ‘the battery latiles are not properly connected. TO star-t the engine, never use a rapid baftery charger.
PAGE 126
71 FUEL SYSTEM 1 2 3 4 5 Air filter Air flow sensor Corrugated sleeve Throttle body Air inletloutlet hose from supplementary solenoid valve 6 Metal fitting 7 Oil vapour exhaust hose 8 Vacuum pressure intake tube 9 Fuel vapour circulation pipe 10 Fuel vapour fllter 11 Air manifold 12 Extra air solenoid valve 13 By-pass tube to set idle rpm 14 Air intake sleeve (‘) only for vehicles with catalytic converter
PAGE 127
, FUEL SYSTEM ,, AIR FLOW SENSOR AIR FILTER The body of fhe air flow sensor incorporates the blectronic control unit for the pilotiqg of the fue! injection syStern. REM,OVAL 1. Disconnect the multipolar connector @ from the body of the sensor 0. 2. Loosen the clips securing the ducts 0 and 0 and detach them from the air flow sensor. 3. Unscrew the three screws shown in the fi ure and remove the air flow sens o8 r 2 . 4.
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r FUEL SYSTEM SUPPLEMENTARY AIR SOLENOID VALVE 4. Remove plastic caver @ . 6Unscrew the two ftgure-shown;bolts fixing starter 0 and remove it. CH~ECK AND ISPECTIONS 1; Check solenoid valve opening a. Make sure that the engine is cold, then start and throttle several times outlet tube 0 of solenoid valve @ b: Check that engine rpm falls and continues ito fait with the passage of time (at rooin temperature of 20°C no fall in r.,p.m. Will be noticed after 3 minutes).
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FUEL SYSTEM 6. Disconnect depression tube 0. 7. Unscrew four fixing screws and remove throttte body @ and gasket f r o m supply~,manifold @ . REMOVAL Proceed to assembly operating in reverse order in respect to removal, following these instructions: . Fit a new gasket between throttle body and intake manifold. . Effect ‘calibration and setting (see: Calibrations and Settings). The two upper screws fix braket @ aswell.
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II FUEL SYSTEM 3. Remove lock ring 0 and disconnect’sheath @ from bracket a 4. Disconnect wiring @. 5. Dfsconnect tube @ from throttle body. 6. Ldosen clam s and disconnect tubes @ and 63 from manifold 0. 7. Disconnect tubes 63 C$d @ from manifold and tube @ from throttleibody; (only for models with catalytic converter). 6. Unscrew fixing c9 and separate servobracket depression tube from manifold. 9. ‘Loosen clamp and disconnect sleeve @ ‘from throttle body 0. PAd279E0883301 10.
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A s!0 12 3 4 5 E Pressure l e c t r o i ngauge jectors Fuel filter Fuel supply tube Tube support spring 6 7 8 9 10 Ground table Fuel tank fixing st!ap Fuel level gauge assy Level gauge fixing screw Tank (‘) only for models with catalytic converter 11 12 13 14 15 Filler pipe Fuel pump Excess fuel recovery pipe Pulsation damper Fuel supply hose . .
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- FUEL SYSTEM - DAMPER FUEL PilMP REPLACEMENT REPLACEMENT 2. Disconnect electroinjectors connectors one,by one; each time detect CO percentage at exhaust and check that value remains constant at all checks. 1. Loosen clamps and disconnect fuel inlet and outlet tube 0 and @ from damper. 3. If this is not the case, locate the faulty electroinjectr and replace it. (seei Replacement). 1; put ‘the vehicle on auto lift and disconnect battery negative terminai.
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FUEL PRESSURE G A U G E 4. Effect assembly operating in reverse order in respect to removal. REPLACEMENT WARNING: Operate carefully: fuel system coud be pressurized. 1 Fuel supply ihose 2 Electroinjectors supply wiring ‘4. Remove e,lectroinjectors 0 com:plete with b-ring @ ‘ancl gasket @ 1. Unscrew the two connecting fittings oEue supply hose @ to regulator ’ 2. Disconnect tube 0 from regulator. 3. Connect tube @, unscrew f lg$: shown nut, and remove regulator -. .
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r, FUEL SYSTEM FUEL VAPOUR EMISSION CHECK SVSTEM For electronic injection 1.
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FUEL SYSTEM FUEL, VAPOUR SEPARATOR 2. Disconnect’ valve @ from fuel recovery tube circuit. REMOVAL AND ASSEMBLY 1. Move, away left side covering of trunk. : 2. Loosén Aamps and disconnect tubes 0~ and @ from separator. ~ i 3. Unscrew t h e t w o s e c u r i n g n u t s indicated in the fig,ure and remove the s e p a r a t o r ~@ 1 Retainer valve 3. Ceck that valve works properly that is, that otherwise, replace valve it allows the passage of air only in the direction shown by the arrow.
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i, FU:EL S Y S T E M 1 2 3 4 External air Fuel vapour Fuel vapour Fuel vapour tube intake tube Inlqt tube fllter 3. For assembly, operate in reverse order in respect to removal. CALIBRATIONS AND ADJUSTM~ENTS For electronic injection’ 1.7 engines only CA;LIBRATIOW T,HROTTLE BODY (Fviow) 1,. Loosem clamp and disconnect sleev,e ~0 fiom throttle body -0 . 2. Disconnect depression tube under ,tprbttle’body @ and suitably plug thq relevant fitting. 3. Loosen switch @ fixing screws on throttle body. 4.
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_ I ,” FUEL SYSTEM ~,6. If you do& detect specified values, ~proceed to setting. ~a. Break seal 0 and act on adjusting screw 0~ u?til speciofied flow value is obtained. 3. Rotate throttle 60° f 4’ and check full load contact closed, detecting following resistances on male connectors, with tester. - With accelerator throttle open by an angle of a3 60” f 4O between terminals 3 and 13 one must detect a resistance’of 0 approximately. 4.
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r FUEL SYSTEM ~ ELECTRICALIELECTRONKI COMPCUVENTS’ For electronic injection 1.7 engines’ only ELECTRONIC CONTROL UNIT 2. Unscrew four fixing screws shown in figure (one of which is under seal cap). CHECK OF FUNCTIONING 4. Remount CU operating in reverse order ‘in respect to removal, then apply a new seal cap (in screw Seat). If CU has bee~n replaced, proceed to check and if necessary, to effect setting of CU percen’tage at exhaust (see: Calibration and Setting). 1.
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1 2 3 4 5 Gaskets Front manifolds Nut Plug for CO% sampling upstream catalytic muffler Support ring 6 7 8 9 Catalytic muffler Gasket Lambda probe Buffer 10 11 12 13 Rear muffler Clamp fixing bolt Clamp Nuts fixing manifold to heads
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FUEL SYSTEM lp;RkCAUTIONS TO ADOPT FOR CATALYTIC MUFFLER EQUllPPED VEHICLES . Use only lead free petrol. . Avoid petrbl level in tank from becoming very low. . Dhn’t start engine with a disconnected spark plug. . . Dlon’t overload excessively the engine for long periods of time. Be careful whep towing uphill for long periods. DP not switch ignition off while vehicle is moving. Ignition is to be switched off with vehicle stopped. .
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(3) Unscrew nuts @ securing catalytic muffler @ and exhaust manifold ‘I@. ~ (4) Free! cetalytic muffler @ support SUPPORT RINGS ” Verify integrity of support rings and replace them if necessary. brackets! f r o m lock r i n g s @ a n d r e m o v e it.~ 4. Remove manifolds @ as follows: (1) Disconnect manifold @ from catalytic muffler unscrewing nuts 0. (2)’ Loqsen n u t s @ s e c u r i n g manifold fl8nges to cylinder heads and then remove rear element @ and gasket ‘0.
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r FUEL SYSTEM ~ ~TROUBLESHO’OTING FOR CATALYTIC MUFFLER ~ ~MARNING: :High’temperature of çatalytic muffler could damage,alumina monolith an! consequently weaken the conversion efficiency. ~It~co$d also damage the container and cause fire.
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i- ----~ ~ ,’ FUEL SYSTEM l ~ SERVICE -DATA AND ~SPECIFICATIONS For electronic injection 1.7 engines o$ym TEC,HNICAL DATA Litres 50 Overall,capa& 65 Rèserve CHECKQ AND TIMINGS Acceleratdr throttle switch calibration 2. Idle rpm terminal’ (corresponding to position A: closed,throttle) 3.
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FUEL S Y S T E M ” Abcelerator c o n t r o l Clearance between throttle control and accelerator table pawl (w;th accelerator pedal at rest) tq’ -1 . ! I 01 = 1 + 2mm Cllearance between throttle control and stroke end (with accelerator pedal fully pressed) ~~ i - G2=1+2mm Idle rpm; emissi.on at exhaust rpm 950 +‘O” -50 - total, upstream catalytic muffler with lambda probe disconnected 56 i n v o l . 4 0,8 f 0,2 - total, at exhaust pipe outlet % in vol.
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I l Position & !i 1st Carb. central I I RH 2nd Carb. -RH LH Diffuser 0 mm 23 Centering device 0 MM 3.5 4.5 12189.01 3,5 Main jet 0 . 122 130 118 125 Main air jet corrector 0 . 180 170 180 190 F 6 8 F67 Diffuser Idling jet 0 Idling air corrector 0 Progression holes 0 Needle valve 0 . l . ~~ I 175 24 II 120- 100 100 - 100 I 9164.01 ~46 50 l .28 LH 28 F67 48m 115 120-120 120 1 195 100 - 140- 140 100- 120 - 130 140 - 140 140- 150 .
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2; % Displacement 1500 Type 305.88 .ENGINE ALFA ROMEO Part No. 580.778 - 580.777 M.odel Twin DellortoDRLA40FD - DRLA40FS CARBURETOR Position 305.50 580.776 - 580.775 Twin Weber ’ 40lDF81 _ 40lDF80 LH 546.860 - 546.861 546.858 - 546.859 Twin Dellorto ~DRLA40FD _ DRLA40FS Twin Weber 40lDF69 - 40lDF68 LH RH LH RH LH RH 0 mm 30 30 32 32 Centering device 0 mm 12189.01 3.5 - - Main jet 0 . 135 140 142 140 Main air jet corrector 0 . 205 200' 180 190 9164.
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,l ‘, FUEL SYSTEM SPECIAL SERVICE TObLS [ Identif(cation Number ~ Key for plug of exhaust gas sampling fitting of Lambda probe &2:0051 Fitting for exhaust gas sampling of Lambda probe October lg88 ’ Denomination 4.5.0212, C.2:.0056# ‘, For electronic injection 1.7 engines only 8’ Buffer for air flow checking to be used with C.2.00% 04-19 04-26 Fitting to be used-with C.2.0056 04-l 9 04-26 04.
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,i ~ ~ Y IGNITION, STARTING, CHARGINGN SYSTEM C O N T E N T S IGNITION ......................... 05-2 Checks and inspections . . . .,. . . . . . (*) Reassembly . . . . . . . . . . . . . . . . . . . (*) ~Fuel: injection-ignition ~diring ,diagram ................. (*) Test stand, inspection . . . . . . . . . . . . (*) ~Technica,l data and specifications . . 05-2 Serviae ,data and specifications . . . . 05-I 0 D~istributor and ignition Trouble diagnosis and corrections . ,.
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i Technical data and inspections 1200* - 1350 305.85 - 305.86 Engine 581.293 Alfa Romeo Type Interna1 resistance of distributor rotor arm Air~pP 581.363 1700 Electr. injection 1700 Electr. injection 305.58 305.58 A 581.291 548.604 Bosch Bosch Bosch Bosch Bosch 0.237.601.021 0.273.601 ,017 8.237.540.173 0.237.601.014 l-3-2-4 R 1100+10% n 1000 mm (in) (A) For countries where antipollution regulations are in force.~ Not marketed in all countries. 581.292 1700 305.50 0.237.
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;i IGNITION, STARTING, CHARGING ~SYSTEM DISTRIBUTOR ADVANCE CURVES ENGINES 1200 - 305.85 1350 - 305.86 Automatic ,advance curve 250 tis id 500 1000 1500: ~ ‘2&00 ‘, 2500 3000 Distibqtor r . p . m .
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IGNITION, STARTING, CHARGING SYSTEM ~ DISTRIBUTDR ADVANCE CURVES ~; ENGINES 1350 - 395.87 1350 - 305.88 1 A u t o m a t i c adtiance c u r v e 1000 1500 Distibutor r.p.m. 2qop 2509, 3000 509 600 Vacuum pressure corrector curve Y~0 .~ 100 20,o 300 4 0 0 Vacuum pressure m.
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‘8 r IGNITION, STARTING, CHARGING SYSiEM DISTRIBUTOR ADVANCE CURVES ENGINE ’ : 1700 - 305.50 Automatic advance curve Distibutor r.p.m. 0 Vacuum :Pressure corrector curve $00 t i i i i i i i i ,i i in-i i I i l i i ‘i i i i ,i 34 4 i i/iÏ i i i k 5;c , ‘0 I I I I I I I 1 I I 100 400 200 30,o Vacuum pressure m.
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” IGNITION, STARTING, CHARGING SiSTEq DiSTRIBUTOR ADVANCE CURVES ENGIilE 1700 - 305.58 P n e u m a t i c advance curve I a3ueApe .4o~nq!.
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r IGNITI~N, !N S T A R T I N G. CMARGING ~SYSTEM D I S T R I B U T O R ADVANCE +M~ES /: , ’ ENGINE ” Ii ‘,’ 1700.305.58 :, FOR COUNTRIES WHERE ANTIPOLLUTION REGUiATION ARE IN FORCE ,’ Automatic adyance cude Qistributor _. ;. ‘r;p.m.:. ‘; 1 ;, _ Vacym pressure corrqctor c,urve.
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IGNITION, STARTING, CHARGING SYdTE’h 5. Disconnect the v,acuum advance ho- ~ se from distributor; with the stroboscopie gun cgeck that at idling rpm: CHECKING hND ADbUSTING BHE’lGN,lqlO~N ‘TIM’ING 8. Using the $roboscopic gub, check also that at engine rpm of 950 + 100 _ 5. r4.m.
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‘, , ,' f 4GNITION, STARTING, CHARGING: SYSTEM IGNITION COIL (BREAKERLESS IGNITION) Electriqal data and checks 1200-305.85 1350-305.86/87 1500-305.88 ENGINE ~ Alfa’Romao Class 1700-305.50 1700-305.58~ 547.811 1700-305.58 542.162 8’ B O S C 0.221 .122.323 Tvw H BOSCH 0.221.600.002 ,” Primary winding voltage V 12 Primlry winding resistance Rl (20%) B 0.7 thru 1 PrimBry winding resistance R2 (ZOOC) B 6700 thru 9600 (a) Fbr !countries where antipollution regulations are in force.
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1200-305.85 1500-305.88 Voltege V -~_ l7!0-305.58i~ 1~~5OZjO~@Y87 1700-305.50 1700-305.58 1800-VM’$2A 533.051 533.052 536.611 547.199 195.27.05.030.00 BOSCH EF 12 V - 0.8 kW 00012 11215 DUCELLIER .6246/C MARELLI E95 - 0.9 kW 12v BOSCH EF(R) 12 V - 0.85 kW 0001208 266 BOSCH EV-12V-2.
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8’ * IGNITIObJ, STARTING, CHARGING:S;YSTEM ~ CHARG,ING SE~RVICE DATA AND SPECIFICATIONS ENGINE ,’ I I Alfa Rom00 Pan No. 1200-305.85 1350-305.86/7 1500-305.88 1700-305.50 1700-305.58~1, 1700-305.58 I 1800-VM82A 1 547.949 ~ 549.399 547.565 Albrnator BOSCH 0.120.489.480 TYPE I - I I BOSCH ~ Kl (R)14V-23/65A 0.120.488.118/119 K1-14V-23/65A I Nomi’nal Voltage V - 14 - Volt& range ,” V - - - 55 65 65 ~Max current output A Output st.
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CONTE’NTS ~ CCOLING SYSTEM . . . . . . . . . W&TER PUMP . . . . . . . . . . ,1, THERMOSTAT . . . . . . . . , . . . . ~Removal and reassembly ~ ~ Checks and inspections . RADf ATOR . . . . . . . . . . . . . . . . COOmLANT TEMPERATURE . . ...... (*) . . ...... (*) HEADERTANK PRl%SURIZED PLUG . . . . .‘. 0(*) SERVICE DATA AND . . ...... 0 7 - 2 . . . . . . . . 07-2 SPECIFICATIONS . . . . . . . . . . . . . ........ 0 7 - 3 Technical data . . . . . . . . . . . . . . . . . . . . (*) . . . . . . . . 07-2 . .
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‘8,’ ‘1 ~ ,‘, ENGINE,COOLINh S Y S T E M ’ ~ 1: TI~ERM’OSTAT ~ I CHECKS A?D REMOVAL &ND It$JSTALLAT:lON I’NSPECTIONS 1: Drain coolant of cooling system into alsuitable container. Using suitable tools, check that initial thermostat opening occurs at a fluld temperature of: 64 thru 66% Otherwise replace thermostat. 0 21 Disconnect hose 1 from thermostat,0x 31, Unscrew screwIfixing thermostat to engine block. ~ 4’ DisGnnect tubes @ , ‘0 , @’ , and 5 from ithermostat, then reme ve ‘it. 5.
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,, ~ ‘, r ENGINE COOLING SYS’TEM ~ SERVICE DATA AND SPECiFICATIQNS GENBRALDATA Min. external As per ;(Alfa] except for: Avoid contact with painted parts. I 5.1 F r e s h water (Imp. gall.) (1.12) 3.65 4.7 (1.03) (0.80) TIGfifENING TORQUES Unit of measurement Il, Elec$ic {ah control thermal contact on radiator i Cqoling iemperpture transmitter on feed ~ mar(ifold Wat+ pump securing screws CoolBnt level sensor for injection CU (max. torque) 1 3 thru 3.5 29 thru 34 ;, 33 thru 41 3.4 thru 4.
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GEARBOX C O N T E N T S 5 - ~PEED ~AN~AL GEARBOX . . . . . . . . . . . . . . (*) GEARB’OX &TER LiNKAGE . . . . . . . . . . . . . . . . . .i 3-2 SERVICE DATA AND SPEÇI
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‘8 ,’ GEARBOX ~ ‘, s 1, ~ ,’ GEARBOX OUTER’ LImNKAGE As per (Alfa) Volumes I and II except for the following procedures. REAR; WHEEL; DRI’VE SC LEGTOR Reqove lever and if necessary the silentblock @ from lever support. If necessary remove the silentblock @ from the bar. 1 2 3 4 5 6 7 Inspectio& and checks Check that the silentblocks situated on linkage articulated joints are in good condition; replace them if necessary.
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Models Characteristics Gear Overall ratio 1st 1st 3rd Gearbox ratio Speed at 1000 r.p.m Speed at 000 r.p.m OW?dl ratio 8,010 1:12,921 .1:3,143 ratio 1:11,629 .R.G. Speed at 1000 r.p.rr Overall ratio Speed 9,081 1: 12,220 8,641 14,571 at 1000 r.p.
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TECHNiC% DATA Features Crown gekr ancI pinion ratio Speed seiector lever position Gearbox ratio 9. 17 (1) Gearbox differefitial >verall ratio kpeed at 1,000 r.p.m. Kmlh Gearbox differential jverall ratic lS' 1 : 3,143 1 : 12,921 6.010 1 : 11,629 2nd 1 : 1,864 1 : 7,663 13,506 1 : 6,897 3rd 1 11,323 1 : 5,439 19,029 1 : 4,895 41h 1 : 1,027 1 : 4,222 24,514 1 : 3,800 5th 1 : 0,854 1 : 3,551 29,479 1 : 3,160 R.G. 1 : 3,091 1 : 12,707 6,145 1 : 11,437 Speed at r.p.m.
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After modification - ,APPno. Application Inner surface of: - Seal ‘ring of main selector rod - $eal iring of primary shaft - SeaI, ring of differential shaft - ~Seal !lip and work seat on shaft Outer surface of: - Seal ~rings Outer races of differential casing and pinion taper roller bearings MatingI surfaces of: -, Ring nut securing bearing to differential sha Type GREASE OIL GREASE’ OIL 13-6 Name Q.W ISECO Molykote, BR2 Std. No. 3671-69841 See item 5 AGIP: Fl Grease 33 FD Std. No.
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F R O N T SUSPENSlbJ DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . (*) FRONT WHEEL HUE FRONT SUSPENSION . . . . . . . . . . . . . . . . (*) . . . . . . . . . . . . . . . . (7 SERVICE DATA AND Sf%CIFICATIONS . . . . ,.,......,........ 21-2 . . . . . . . . . . . . . . . . . . . . 21-2 ~Technical data General specificatipns . . . . . . . . . . . I n s p e c t i o n a n d adjustment . . . . . . . (*) ........ . . . . . . 0 Tightenin,g torques TROUBLE DIAGNOSIS AND CORRECTIONS . . . .‘. .
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~ ‘! ‘8 ,m ‘,; I ,,, 8’ ,, ,, F R O N T SUSPENSl’ON 8’ ~ i 1, ’ SERVICE DATA AND SPECIFfcATIOMS TEC~NI& DATA +IL ~SPRI$lG, SHOCK ABS&BER AND ANTI-ROLL BAR I Coi1 spring’ ~ ~ T Wire diameter mm (in) Coi1 diameter mm (in) Free length mm (in) 13.6 (0.53) 13.2 (0.520) 160 (6.299) N/mm (kg/mm) (Ib/in) t Stiffness 133018 131883 ‘$ Alfa Romeo Part No. 310 (12.205) 333 (13.11) 21.6 (2.2) (123.2) 24.5 (2.
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) SI ‘, ~ I, * ,s i R E A R SUSPENSl’ON ” ~ INSPE’CTION A N D A D J U S T M E N T DAT+ OF SMOCK ABSORBER SETTING 33 ‘, ~HOK A B S O R B E R 33 1.3 5 33 33 1.7 IE 33,1.7 B A 33 1.7 IE a RH LH L o ‘, LH’ RH 581045 RH LH 8OGE 581044 BOGE 549122 549123 581046 581047 Compression N (kg) 150? 30 (15 * 3‘;) 157+40(16+4) 250 + 50 (25,5 + 5) Expansion N (kg) 330’6; (33 ’ 622;) ’ 392 + 40 (40 k 4) 4902~~’ (49 t 9+~‘{‘) Compression N (kg) 460 + 60 (46.9 i. 6.
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CONTENTS DESC~RIPTION . . . . . . . . . . . . . . . . . . . (*) Control lever . . . . . . .’ . . . . . . . . . . . (*) SER~V~ICE BRAKES . . . . . . . . . . . . . . . . (*) Control’ tables . . . . . ., . . . . . . . . . , . (*) Brake system bleeding . . . . . . . . . . . (*) SERVICE DATA AND Pedal assembly. . . . . . . . . . . . . . . . . (*) SPECIFICATIONS.. . . . .‘. . . . . . :. . . . 22-2 Brake:master cylinder . . . . . . . . . . . (*) Technical data . . . . . . . . . . . . . . . . .
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1, 1, S E R V I C E DATA AND SPECI~FCATIO’NS TECHNICAL D A T A FRON% B’RAKES Caliperi, brake pads and discs 3 3 1.1 a x a 33%7IE, 3 331.ETP 3 1.3 s 3 3 1.55 7-I A 3 3 1.7 + 3 3 1.7 + A Features I Calipers .‘.’ A.TE Part No. 547168/9 547808/9 .DBA Part No> 54717819 - ATE Part No. Tvpe I ~ Tvpe ‘DBA 8, Brake P a r t N o .
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,’ ,! r FRONT AND REAR BRAKES ~ l SERVOBRAKE REAR ‘BRAKES Unit: mm (in) ~ 9” Drum nominal diameter : 130.695 Part N O. Dri~i nominal interna! diameter 8” 228,6 + 0.2 131245 -0,l 203.2 +o,2 5 5 Eraka lining thicknass Part N-o. 546.657 BENDITALIA Type: BENDITALIA or ATE 7 in Diameterof working cylinder BRAKE PRESSU#RE PROPORTIONING VALVE, BR’AAKE :MASTER CYLINDER Typz$: ~ RE;1 BENDITALIA ~ Part “;5*“98 20:64 mm (0.812 in) Diameter 32 mm (16 +16) 1.26 in (0.63 + 0.63j Part No. 548.
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1:, F R O N T A N D R6AR:BR,AKES’ ~ Unit: mm (in) 8; REAR ~BRAKES Drum nominal diameter As per r-33) except: 229.1 (9,021 204 (8.03) 229.6 (9.04) 204.5 (8.05) Roundness error < 0.03 (0.00118)
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CONTENTS (*) (*) (*) (*) (*) (*) ~Brâke pressure proportioning valve . . (*) Servobrake . . . . . . . . . . . . . . . . . . . . . . . . (*) Vacuum system . . . . . . . . . . . . . . . . . . . . (*) Front disc brake . . . . . . . . . . . . . . . . . . . (*) Rear drum brake . . . . . . . . . . . . . . . . . . . (*) PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . (*) ~ DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . SERVICE BRAKES . . . . . . . . . . . . . . . . . . . .
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F R ON T BRAKES Calipers, brake pads and discs Mode1 Features Callpers Type ~~Type ATE part. No. 5471 SS/9 DBA part. No. 54717819 ATE part. No. 795357 DBA part. No. 795356 54780819 54717819 720402 795357 795356 Brake LIGHT BLUE (FRENDO) Colours Paci nominal thickness “Y BLACK (FERODO) mm (in) External diameter mm (in) Nominal thickness “c” mm (in) 16,5 15 135 239 ~Discs C 54716819 12.7-O.’ (O.5-o.
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SERVOBRAKE R+ BRAKES Unit: mm (lb) i ;Drum nominal diameter: TYPE: ATE ;Or ‘BENDITALIA 9” t 7 in Diameter o[ working cylinder Pifi No., Dr$ml nqminal :internal diameter 131.245 228.8+0,2 203.2;;; (9+7.9 ,, 10=3) 5 (0.197) ~Brake litjing thickness C 130.895 -3 !3$ : $3) 5 (0.197) BRAKE PRESSURE PROPORTIONING VALVE (7) ~+y for 4x4 versions Bi+KE MASTER CYLINDER Type~ ‘, Diameter Strole ,, ,, ‘i i’ Ty$: Dikmeter Stioke Part No. 544.498 0.
PAGE 177
DESCftIPTION . . . . , . . . . . . . . . . , . . . FIE&R) H~UB . . . . . . . . . . . . . . . . . . . . . . REAR SUSPENSION . . . . . . . . . . . . . . . (“1 (*) (*) $EF$ICE DATA AND SPEkiF ICATIONS. . . . . . . . . . . . . . . . . Tfzhn’ical data . . . . . . . . . . . . . . . . . ,i 25-2 25-2 General1 specifications . . . . . . . . . . . Inspection and adjustment , . . . . . . . Tighten~ing tbrques . . ., . . . . . . . . . . . T R O U BL E DIAGNOS~S ANO CORRECTIONS,. . . . . . :,.‘. . . . . . .,. . .
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REAR SUSPENSION ~ ‘-.. ~SE#RVICE DATA AND’ SPECIFICATION ~ TECHf4ICAL D A T A COIL SifRING AND SHOCK ABSORBER Versions 33+ * 3 3 1.7 * 33 1 . 3 3 3 q.3 s 33 1.5 TI 3 3 1.7 + A 331.s-rcl 3 3 1.5 a x a ’ 33 1.7 IE 33 1.7 IE, A Festures ,: Alfa Romeo Part No. 130938 131805 11,5?0,1 11,2&0,05 131990 ‘, , Coi1 Springs Wire diameter mm Coi1 diamete’r mm Free length mm ~ 11,8*0,1 111 .310’ 302 313 21,3 (217) 23,l (2.
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CONTENTS ,DE$~Rl~PTI6N . . . . . . . . . . . . . . . . . . . . . . . .(*) ‘8 ,REAR H U B ‘........................... (*) RE@ SUSPENSION ~ Generabspecifications . . . . . . . . . . . . . . (*) Inspection and adjustment . . . . . . . . . . 2 5 - 3 . . . . . . . . . . . . . . . . . . (*) SERVIC:E DATA AND SP~($lFICATIONS . . . . . . . . . . . . . . . . . . . . . 25-2 ~ ?&hnical: data TROUBLE DIAGNOSIS AND CORRECTIONS . . . . . . . . . . . . . . . . . . . SPECIAL SERVICE TOOLS . . . . . . . . 1J , .
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~ ;,~SERVICE DATA ANDY SPECIFICATIONS ,l, 1 ~‘TECH$CAL DATA j COIL %=RING, f%lOCK ABSORBER AND ANTI-ROLL BAR Coil’Sprine Coi1 diameter mm (in) Free length mm (in) 111 ,(4.37) I ~. ~ B Type Shock abiodber, O G S&ICA E I! HYDRAULIC I 11’ (2) (0.433) 12 (1) (0.472) Piston rod diameter mm (in) ~ ~ 180 (1) (7.086) Stroke ,-- _, 23,s !(2,?) ( 1 3 4 . 4 ) StiffnessNlmm (kglmm) (loin) l 323 (12.72) 302 (11.89) 313 (12.32) mm (in) 144 (a), (5.
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Iil%~ti~kï?ikib ADJUSTMENT DATA OF SHOCK ABSORBER SElTlNG n + 3s 4.7 k3 BOGE SPICA BOGE 549137 5491230 549142 549134 581052 (kg) 216+40 (22+4) 11716 f40 (12 54) 180540 (18,4&4) 117,8+40 (12+4) 1 OOf (10,2f4) 220+46 (22,4+4) N (kg) 196f40 (20f4) 117,6+40 (1254) 200f40 (20,4&4) 157f40 (16+4) 90f40 (9,2&4) 2OOz!z40 (20,4+4) Compression N W 520+40 (53+4) 461 M9 (47t5) 52Or140 (53-14) 451+50 (46+5)~ 400f50 (40,7&5) Extension N (kg) 760+40 (77.
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C O N T E N T S ,m ,’ ~CHkCKIN’G TIRE CONDITIONS . :. . . ‘TIR~E~ REPLACEMENT . . . . , . . . . . . . , CHECKI~NG’WHEELCONDITIONS , ‘SEti\iIqE ‘DATA AND ‘SPklFIICATIONS.. . . . , . . . . , . , . . , ,’ (“) (*) . . (*) Genera~l specifications . . . . . . . .‘. . . ‘Inspec$ion and adjustment . . . . . . . . Tightening torques . ; . . . . . . . . . . . Technkal data . . . . . ~. . . . . . . . . . . . (*) (“) (“) 282 .
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” SERVICE DATA Ai’iD 8’ TsEC~llNICAL D A T A n - a P a P a P 7 a 0.
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* ~ WHEELS: AND TXRES, ‘8 1’ i CONTENTS CHECKjNG TIRE CONDiTIONS . . . . . . . . (*) TIF& REPLACEMENT . . . . . . . . . . . . . . . . . (*) 8’ General specificaticns . . . . . . . . . . . . . . Inspection and adjustment . . . . . . . . . . Tightening torques . . . . . . . . . . . . . . . . . Technical data . . . . . . . . . . . . . . . . . . . . . (*) (*) (*) 28-2 CHECKING WHEEL CONDITIONS . . . . . . (*) 1; I.. # ,’ ; SEi3kE DATA AND SPECIPICATIONS . . . . . . . . . . . . . . . . . . . . .
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TYRES of RIM measurement 165/70 RI 376s 165170 RI 379T 5 1/2 J x 13” 175i70 R_l3 82T 5 1/2 J x 13” 185/60 R14 82H 5 1/2 J x 14” A P 1.8 1.8 A ç % - - Balance (max. allowed residual balance) 9 2!I Balance weights Cl 10 i 40 (at 10 g-intervals) 63 _ Snow chains Chain “S” max. dimensions (for tyres 165/70 R13) Kg/cm2 - - ,-------_\ 2.0 1.8 1.8 - 2.0 8 .~~ mm 16 [(A) With eiectronic injection engine for countries where antipollution regulations are in-force.
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,’ ~ r ELECTRICAL SYSTEM ‘~ ~‘, ‘,’ ~ ‘, ~ All information contained in this group is applicable fo 1.7 electronic injection engiries with cata!ytic convertdr only ‘; ‘8 CONyiENTS ~ ‘HOWVTO’READ THE WIRING DIAGRAM (*) Cl&ter . . . . . . . . . . . . . . ...’ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-9 FUEL~ DI~STRI~BUTION . . . . . . . . . . . . . . . . 40-2 Carburettor power supply and rpm puiser (wiring diagram) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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~ l E L E C T R I C A L 8, S Y S T E M ~ i ‘, POWER SUPPL.Y ‘R0~UTI.W ~ 8,’ For 1.7 electronic injection engine.
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LOCA~TION CAUTION: The fusebox is an integral part of the a. terminal board support and is located on left ~side, of the intermediate bulkheadl in the engine compartment. Furthler,mdre t h e r e a r e t w o f u s e s relating to Injection wiring in rightfront SERVICES PROTECTED IhY FUSES Should a fuse blow, before replbcing it, make sure that the cause of failure has been removed. b. Use fuses with the specified ‘. amperage only. Never use fuses with an amperage greater than that specified.
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Models Protected Service Ampere 33 Reverse switch - H,azard light switch lighting 8 ALFA ROMEO Control ~’ Sida light left front and right rear - RH. ~~~number plate light Drawer light ( 1.7 IE 3 3 1.7 + Injection X X - - X X x X 8 ALFA ROMEO Control (Side light left front x and’ right rear - RH. number plate light) Cigar lighter X X X X Side light: right front and left rear - L.H. I number plate light ALFA ROMEO Control (Side light! right ~ , front and left rear - L.H.
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r ,. ELECTRICAL S Y S T E M ~~ ELECTROMEC~HANICAL AN~D ELECTRO’NIC DEVICES Only for 1.7 electronic injection engine with catalytic convertor RECAYS, ~ELECTRONIC AND INTERMITTENCE DEVICES ~LOC&T(,ON ., To &ate komponents, see following figures and the two tables “remote control switches and electronic devices and intermittences”.
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Position (See fig. pag. 40-5) Symbols External view 43 30 86 87 85 8 2 7 3 ,Horns! relay ~ l il Heated \eer window relay ~ 3 1 0 4 86 87 85 2 ‘, 5 30 6 86 87 85 ~ %b 87 ‘: Front f*glamp relay ,, 1 117 8, l i.
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“R@&s and Timer” (Ta’ble corhnued) Main &je?ion arelay -Position i :(Sec f i g . , ,pag. 40-5) !Symb& ,External ;view Component S12b i -10 , S12a ‘Yntetyi~tences :and ,electronic devices” Table ” Bymbols ;External r i e w :Com.ponent ” .Position ,(See fig. ;pag. 40~5) 8: ~ ‘1 1 ,l ~ 1, ,” ..i Windscree~‘.wiper .electronic ,inter,mittence ;N14 Electronic ,device for ~headlights ,and Nflashing changeover ,
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1 ,:’ ~ . E L E C T R I C A L LIGHTING S Y S T E M ~~ SYkTEM, For 1.
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i, i r i’ ELECTRICAL S Y S T E M ~ !’ PAN~E’L~ I N S T R U M E N T S, SENSORS~ AND TENDERS For 1.7 electronic injection engine. with catalytic convertor only CL+TE,R Front ;view Rear view 8 9 Tachometer - odometer Fuel level gauge Fuel reserve warning lamp Max coolant temperature warning lamp Coolant temperature gauge Rev.
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Cl C2 c4 C6 Dl D2 D3, D4 D5 Electronic rev. counter Electronic tachometer Fuel. Ievef gauge. Coolant temperature- gauge Alternator- charge: warning: lamp Direction, light warning. lamp. Side light warning: lamp Full- beam warning: lamp Brake fluid level warning lamp: D7 Hand brake warning lamp DE Fuel reserve warning lamp D1~1 Engine oil min.; pressure warning lamp D13, Engine coolanti max. temperature warning l a m p F12 Cluster lighting, lamg G5, Connecter ,N G3 Cluster B.
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~ ,’ kIN-$lT~ LOCATION For,lo$a\ion of pin-ou& of connectors 1, 2 and 3, refer to the followifx$ figures and tables.
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(wiring diagram) 1’1~ FUEL ~s;UPPLY AND REV. COUNTER PULSE ~GENERATOR ,s ;i r _ - - - - - - -y - ‘1, -1 I f- m S’LSS i May 1988 ‘,’ ,’ : 0u 1’ ~ 1, , 1 I IL--i .--. < SCSE’OS -L1 1 lilsn ION 0Fi l Fr.
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ELECTRIh SYSTEM ‘:’ ,;’ ‘8 EN&N,E SPOOLING, LUBRICATI.ON; BRAKE P A D WEA~R s’~NS~R,,~ BRAKE-CLUTCH (wiring diagranî) FLljlti MIN. LEVEL SENSOR For 1.
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7 - - - - - 1’ ~ - Mày 1988 PA333500883300
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ELECTRIFAL SYSTEM WINPSCREEN WASHER 1 2 3 4 5 6 7 8 9 10 11 12 13 PA333tjOO883300 Tank Liquid level sensor Windscreen washer pump G a s k e t Pump wiring Delivery tube fo sprayers Plug Pump covering Flller i&t Gaskel Lower fixing screw Upper fixing screw Grave1 guard pf right front wheel May 1 9 8 8
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P ‘8, 1 ‘REMOVAL AND INSTALLATION ‘i indicator ~ ~3 . OpeLating,;from, e n g i n e compart,’ ment, rerhqve press~fit filler inletfitting ‘~ ~, ;, 4. Unscr;ew~Uppe,r fixing screw 0. #i, 5. !Opei.a$ng froml under wheel arch, ,, unscrew~ +rew 0 a n d l o w e r t a n k 0. ~: ,6. Discomnect level sensor @ wir;~ ing )and ki~ring ‘@ from pump ‘0. ,;“7. Disc@nekt tube cc> f r o m p u m p , 8, remove ta& and drain liquid. 1 ‘ 8 .
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E L E C T R I C A L SYSTEM~’ ~~ A : STARTING - CHARGING A l A2 A3’ A4~ A5: A59 A5b A6’ A 7 A8’ Asa A8b A9’ A10 Al 1 Al2 Al3 Al4 Bàttery Alternator Alternator with integral electronic voltage regulator Voltage regulator Ignition distributor Ighition distributor A Ign’ition distributor B Pu’lse generator Rotor Ignition coil Ignition coil A ‘Ignition coil B Coi1 resistor 2-way connecter for coi1 Starter motor Spark plugs Pre-heating glow plugs Alternator table terminal board B: MANUAL ELECTRIC CONTROLS
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” E:~ 88 EX’TERNAL LIGHTS fcontinued) : Front side light Front direction indicator and side ligh’t Frdnt side marker light ;: Loy beam light E5 Low bea,m light with incorporated side light E 6 Ful~l beam light ,’ E7 $0~ and full’beam light : E8 Side repaater ” E9 E l 0 ,Fog light Rear d’irection indicator ~', Eil El2 Rear side marker light El3 ‘Rear parking light E l 4 ‘Re~ars~in~g’light 8” E l 5 Sto,p liglit ,’ El6 Rear fbg lamp E l 7 Numberplate l i g h t El8 Stop and rear side light El 9 Rear right
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,;‘, G: ~FUSEBOX - C O N N E C T O R S - GROUNDS (continuedj G63, Rear ground G63a Rear right ground G63b Rea’r left ground G 6 4 ~ Connecter for Trip Computer - clock G 6 5 ~Coa:xial table G66 Motronic wiring ground G 6 7 Moyinic connecter G68 Con,nector A with board wiring G69 Connector#B with board wiring ,G79 Connecter C with board wiring G71 Con;necter for warning lamp on instruments ‘G72 Cormector for Seat back adjustment wiring G73 ~Connecter for rear services G73a Con’nector for right reer servic
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H: 146 147 SW~ITCHES fcontinued) Hi 7 Brake fluid minimum level check switch H i 8 Fast-idle switch in gearbox Low fuel pressure switch HI9 Ine~rtia’switch HZ0 Clutch, pedal fast idle switch HZ1 Igniition microswitch HZ2 Engine compartment lamp switch HZ3 Luggage’compartment lamp switch HZ4 Glovebox light switch HZ5 H i 6 Cohtact switfh on rear door for rear window wiper HZ7 Coptact switch on rear door for heated rear window HZ8 Cadbudettor contact/switch HZ9 Switch, for rear drive engagement warning lam
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S12a Fuel pump Motronic relay S12b Motron’ic relay with’diode SI~C Timingjvariator devi,ce Motronic relay S12d Auxflia’ry Motronlc relay s13 Timfng’sensor SI4 ~Rev sensor S15 i ThhQ variator devlce Si6 Altitude compensation device ‘CEM control unit SI7 S17a ‘CEM control unit whlte connecter S17b CEM control unit black connecter S16 Throttle angle sensor Hall sensor SI9 l ,Deton lsensor ~ 520 Throttle actuatoi 521 s22 ; Electroinjector terminal S23 ~Electroinjector resistor S24 ~Electroinjector terminal boar
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r ,l BODY-SHEET METAL PANE,LS ~ 49-2 BODY CO~NSTRUCTION . . . . . . . . . . . (“1 ............ (*) BODY SEALIING . . . . :. . . . . . . . . . . . (“1 L’ifting points . . . . . . . . . . . . . . . . . (“1 BODY ALIGNMENT . . . . . . . . . . . . . . (“1 ,Wheel ,alignment . . . . . . . . . . . . . . . 49-2 CAUTIONS FOR THE OPERATORS . . (“1 (“1 REPLAmCEMENT OPERATIONS . . . . . . (“1 GEI$ER~AL INFORMATION . . . . . . . . . ‘Identification codes BO& COMPONENT PARTS . . . . . . . .
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,, G E N E R A L INFO-R-MATION ” l WHEEL ALIGNMENT CAUT& The techmcians assigned to the repair and replacement operations of sheet panels,‘shall always take into account, content of the remaining part of the “Workshop Manual” in order always to maintain original quality and functioning conditions of car as a whole. As, restoratio’n of car correct alignment is of particular importan’ce, ~fn the~following part are provided the data relevant’to geometr,y of both front andmrear suspensions.
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_. ‘, Y BODY-SHEET MET& PAhELS CONTENTS ~, ~ GEjrl+AL INFORMATION ,, ~Identification codes . . . . . . . . . . . . . 49-2 . . . . . . . . . . . . . . . . (*) ~L(fting points . . . . . . . . . . . . . . . . . . . . . .(*) ~ ‘Wheel alignment . . . . . . . . . . . . . . . . . . . 49-2 ‘, , -_ B?D;~ CPMPONENT PARTS . . . . . . . . . . . (*) BODY ~ CONSTRUGTION . . . . . . . . . . . . . . (*) BODY ‘SEALiNG .......... BODY ALIGNMENT ....... . . . . . . . . . . . (*) . . . . . . . . . . .
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$,, m!, ! : GENERAL ‘INFORMATION WHEEL ALIGNMENT :i, ‘8 CAUTION:, “,’1 ;j In orde,r ~toi maintain ‘the original quality and functioning of the vehicle as a whole. technicians must;always keeb in mind and refer to the other parts of rthe Workshop Manual”. However. as correct alignment of the vehicle is of particular importance, the data relating to the geometry of both front and rear suspensions is given below. For any further information refer to the specific groups.