lerpapj

246 G'T - GT/S

REPAIR AND WDRKSHOP MANUAL

F E fl. R A, A 11- So e R \I I 1 ro ASS 1ST It N 1. Ii.. TEe N U: A -" Plot 0 0 II;; III A

Copyright~ 19i6~ by Angelo Wallace. AU rights reserved. PrIn ted 1n the Uni.ted. Sta.tes 0 f AmEll" ice. No part of this publication may be reproduced, stored in ... retriev<'!,l system" or transmitted, in any form or by any tneans , electric ,mechanical, phot,ocopying, r~cording~ ar other~ise, without prior written permission .

. . '

ii

CONT.E.N'fS

P.age

C.opyri.ght Infotma Hon. lntroduc ti,on • Conversion Tables.

.it · tv v

PART I. ADDENDA SECTION

Variations from Vehicle Number 01118 to Vehicle

Number 02130 •

Varia ti on s from Veh i de Numb er 0213 2 On. Air Conditioning

Engine Crankc<),se Ven UhHon Tool9:

3

• 15

• 27

• 37

• 59

1P ART I I. • MA INTENANC E AND REP A I R INS IRU CTION5

Section I--General Data.

3

Section 2--Engine

9

Section 3--Lubricaticrn • Cooling .

Carburet ion (Fuel Feed) •

45

• 51

• 57

Section 4--Clut~h

Gear Box (Tr.a.nsmiss ion) • Rea:, Axle

• 69

• 76

• 85

Sec t Lon 5~-St eartng ,

.91

Sect ion 6-·-Front Suspel'ls ion.

· 99

Section 7-~Rea ... Suspens ton •

.109

Section 8--Brakes

.123 .136 .140

To r que Sp,ec.ifications--ChalSsis

Sec t i on 9-,-Elec trical Equipment.

.143

Section IO-Chassis .

.m (8"3

:i i1

INl''RODUCT ION

The followi:ng 11:; a copyright,edtranslation of the off:Lci.al s: ~E.F ~A. G,Ferrari Dina 246' Gl' ~ Instru.zioni, ''Iecniche repair mauual. Fluet! note

th~ two-part arrangemen.t. The. fit'"st 61 IHlI.ges are addenda. to the original repair msnuala,nd contain t,echnical da till and instruct.ions for later manufact ured Dino s • Ihus ~ if your caris 0 f a la 1:: et' numher (from No. 01118 on) you. will have to consult both the original manual (190 page.s) and the appropria te cross-referenced. Addenda sect:ion. pages.

Technical specifications ha'UB been kept mett:'ic~ as per the original lnanual , insofar as the metr Lc system is c::urrent,ly repla,cing the. present U • s. system. and that Ferrar.i mechanical parts are metric inmeasurE!l!l-ent, and ther::efore require"tite appro,priate metric tools. A Conversion 'Table is included in. page ;tv for any measuremen.t questions.

One valuable supplement to this manua.l is the Spare Farts Catalogue for the nino, ava1h.hle either from F'errari dealers or through F.A. F • Motorcars, inc.. in Atlanta ~ Ge.orgi-a.. The Ca talQgue will go a. long way in showing in clear detail the parts you have just extrac ted from the, car and will fur'thn aid in de~m.istifylng ehese mBLrvelous: machines, which have intrigued thh trandator 8':nce first seei.ng the 125 S, dr'±venby Franco Cortese in. competition at the C1rcui to di Caracal1a in 1947~. as a ten year old. andsinc.e ha.v:l.tlg rebuilt a .25.0 GT engine.

OneUna.l technical ncue , some me:chantc.al terms may change here and there in t.he manual. Pains have been tak.en to avoid this, but sOme may still be located. Flease forward a Dote if some misinformation results :;10 that I can inform all purchaser-s of this manual of aucb changes.

Finally. I would Li.ke to ded::!..ca t a this effort: to Em:o Ferrari and

the memory of Dino Ferrari ~ aU 1!Fena.risti, ii and to Mary. my ever-helpful wife and! Cater-itl.a and Vittp"[io~ our children.

August 18~ 1976

tv

CONVERSION TABLE

MULTIPLY

METR~ C STANDARD INTO U. S. STANElARD METRIC BY USE

Atmosphere (A'FM) Lbs. per. sq. in. (PSI) 14.70 Tire. Pres.sln,;,e

Centigrade (CO) Fahrenheit (Fe) tc x 9) + 32 Temperature

5

Cubi.c Centimeters (cc s) Cubic Inches (C .• I.) .06102 Displacement

Kilometers (Km..) Miles (Mi.) .6214 Dista.nc.e

Kilograms (Kg.) Pounds (Lba , ) 2.205 Weight

Kilometers per Hour (KPR) Miles per Hour (MPH) .6214 Speed

Kilogram Meters (KgM.) Pound Fe,at (Lb. Ft.) 7.2.33 Torque

Li ter (to.) Quarts (Qts.) 1. OS 7 Ll.quid Measure

l-leter Pressure (Olio) Lbs , per aq • in" (PSI) 1.42 Oil Pressure

Millimeters (mm.) Inches (In.). .03937 Dimend'one:

Kilogra.m,s/ sq. em. (Kg/ cm2) Lb s , pet' sq. in. (PSI) 14.22 Oil Pressure

v

leJll'8J1i

VETTURA

Varia t:1ona floom. vlhi ole nuaber O1ll8 to vehicle

mmber 02130 1

,Variations from Tehlcl.

: nWl1ber 02132 on 15

,En(1n. crankca Ie ven.ti.ht1on, J 7 I

Tools

t 59 t

Refer t·::,) e

VARIATIO~ FROH VEHICLE NITI.fBER 01118 to 'VEHICLE NUMBER 0.21.30

DESCRIPTlON

3

5

ENGINE

EUPTRICAL SySTEM:

" ..

.. Marelli s 125 B x 15 .~~rel1i BAE 200 A

•. ~,I'elli gzR 201 A

• Mar ell1 A,En 10) A

7

Distributor.. • ..

High tensi.on con '" •

Emeriency tini tio.n coil. Dinoplex elect.ronic url'i t.

• •
..
•
.. • •

.. ill

.. ..

59

FUBLS AND LUBRICANl'S

FI-ont and rear hydra.ulic brake cirelli h. • .. ATE tY}'le H f1.uid

FUEL SySTEM

Fuel system diagram

1. 'o/enttubes for ta nks J 2.. Filtal's to carbune tors tube, .3. Regulating filtsr, 4. Bendix punps , 5. Filtel'j 6 .. Fuel return tube.

60

Carbur~ tors.~

•

•

•

Refer to pale

68 CrankcBle ,asel and oil fu.'Iles ventilation diaeram

76 GEAR 3DX

DA TA .AND C HA.RAC rERIS'rI OS

FU. .49.. Crankcase ventilation system

l~ Crank:eas,e pr assure linti. tin, valve, 2. Calibra.ted intakes to t.he induction nw.rdJ'ol-ds, 3,. Cra.nk:e.ase ex,ha ust to pressure lim tiinc:valve tuba J 4~ 9 lowby-and. ventilation a.ssembZY, ,.. Breather to 5U.~' oil drain, tube, 6. Lower venUla t1, on t u'be , 7 ~ Thre e-wa y oil 11 li,er t 11 be" B '. Oil ii 11 91' ca, ..

•

.O~2>i-O .. 30 lIIIlIl. .. 0.,:;.5 nm.

.. splas h tY1'e

Axial fl'ee~play 'between mounted gears ana surfaces~

Haxi.t!II1..L'lI.Yl ea.r li:ni ts ~ • ~ .. • • ~

Lubr1eati;)n ai'geal" box asserniblies ~. ••

•

Ref·!;!r to. ,ale

78

Fig. 55

Gear-box. Rear Axle~ an.d Clutc.h Sectional View.

1. Gear Oox-diff'erenti.al oil fiiler plUi , 2. Gear ooxood.i.fferential oil drain ,lut, ). Enlihe oil drat.n ~lUIS J 4. Clutch housin.i oil drain p·1Ui, 5. Clu.tch

I return housil'l( cover J 6. Fer rule, 7.. Fe::rruJ.e, 8. Clutch-dri vElljlearinc: support case, 9. .Drive Ij:earinc, 10. Clu.tch bel1-housln~, 11. Intermediate housing,

12. Clutch cover, 13. Pressure ,late, 14. Engine flywheel, 15. Clutch shaft, 16. Flywheel to crankshaft fasteniIll bolts" 17. Clutch driven disc, 18. Semia::l"le !lallie, 19. Flana;e fastenint bolts, 20. leal"ifil SUppHll·t sid.e clovers,

• 21. B earlllJ preloadwu her, 21 •. RillE" ,ear pos i ti onill( wa s her J .. 23.~ Gea.r. box re<a!,' cover:, 24 .. Ferrule, 25. Ferrule, 26 •. Drive shaft,. 27. Output shaft,.

28_ Gear 'box ea ~UJ, 29. RPM counter unit J 3 O, D1.f f'erentia 1. 1"1 nctl:'!!hDr, .31 ~ Ri. ,·earpinionJ. )2. Rin:- ,ear to differential fa5tEtrd~ bo1t~, 33. Plat,e-t,y pe differential, 3.4~ Differentlal cove r ... 35 .. Plat,as, 36 .. Top COVel', 37. (}ear box cue lower cover, 36. Ball l:leari1lll., 35l.F.rrule,40. Roller bearinc, 41 .. 0:,.ceu'_ 42. Ouid.e body,4J .. 2nd 8.nd )rd lear~. mounted :ea.rinc, 44 .10 Spacer,

1.6. S]Ncer, 46. Space1r" 47. Crank:shaft, 48 .. Clutch 'biilll :rele.iUl!." .b"'~inIJ

49. Enc1ne oil cov&r, 50. Clutoh alilment ,in, 51. Gear box control Bhaft ..

STEERING

92

Collapsible 9teel'ing housing

See Table 30, Group 70. Pares Book for cars N6. 01118 on.

6

RJlI1I: to •

UmlGiiTS

BlAB SUSPIK,SI.CIf

113 VKIIL KOOln'IlfG VIAU'PftIGHTS

103

~ ... I

I

\

I 4

I

i

_~~_.imI Jgj_

p ~ 70. 11m suSlWsIm .... ftAJSVDSJ SlCflC.

REFER to p~e

7

116 Data and characteristic.s Front .

Type

Rear

Type

SHOCK AESORBERS (HYDRAULIC)

~ I

.Koni 82x1579 Sp2

.Kani 82x1603 Sp2

124

BRAKES

Da t.a and char-act.er Ls tics Front brakes (ATE)

Disc diameter

Dis: c th1c.kn e S:$

Cylinder. diameter

Number of cyl1nd'IHs for eachc,aliper. Brake pads.

Brake fluid.

.271 mm .• • 2.2 Illm. .48 Dm. .2

.T!EXSTAR 1431 foF type .ATE type H

~~~~~~--~. -~.-.-~----------- ~- ----~---~----------"""""

Rear brakes (AlE) Disc diameter

. Disc diameter Cylinders d i.amat er

Number of cylinders for eac.h caliper. Brake pad s ,

Brake fluid.

~

.277 mm. .20 mm • .38 mm. .2

.TEX!IAR V 1431 PF type .ATE type H

124

8

REFER p:age

133

--- n' ~ .. ~-. - -- .. ----- .. - .. -,." .. -.--.-.-~-----,.--.

to;' Emergency and parking bzake

In .. : ce rpcr at.ed . in the rear brake cal Iper s , hydr~ulic cylinders.

i

mechanically controlled by

Fig. 84 Hand b rake d La 11: r.am •

I. Cab Le ad jus tmant s tur-nbuckles.

Adj ustment

Pad lAfear 1$ autottJ.a.tic.dly c.cm.pensated for.

Stretched or loose cables can be adjusted. by tightening of turnbucklas 1.

165 DINOPLEX ELECTRONIC GROUP (Ma"telH AEC 103 A)

Gen.eral dataL

The engine not'maUy operates via the electronic ignit.ion systelp..

Only it."l!. the event of Lrr egul.ar running cfthe 01noplexun1t ~ the electronic igrlitiot'l. $y$t.~ can be by-pa$$ed.

To dQ this. move the snap-tn plug 1 into the se.a.t 2,a.nd the terminal 3hOOl the- normal coil 4 to t.he emergency coil 5. The terminals must only be moved eo t.he U Erne rg en cy 11 po si t ion wi. th th e ign it ion sw! 't e hed off.

Under these condiUon.s,1.~niUon is via bat tery , distributor ami ignition coil.

Und.er these condd r.tcns the RPM count ar is not operating.

Fig. 104 Nonn~l and emergency ignition system diagram.

1- 2 P lug to connee t 11 Emerge.tl.c y If igtion

I 3 Cable from con to distributor

4 No:t'1'e.a 1 co n

5 Emergency coil

,i;..

10

page

1. Eeadla:7l.:ps - :'lain cean ar,d .

din beam (iodine var.:-or bulbs) 2 .. Fr~nt :side and directi'onal

lights .

J. Fo£; lights (on request)

I 4. Directio!)' inaicator lights S: .. Cooling [<ins motel'S

6. Temperature sensitive switch for'

radia tor .rans

7. EeQting /ventilation .fan motor

8. Horn cOll1.!',re.s,s or rr.otor 9 .. Front trunk light

10. Satt,ery

,11. Electl'ic.al panel

12. Fuse box ( 6 fuses)

13. Terminal board foi' Sltli tChed current '14., Permanently live terminal board

: 15. Fuse bO¥. ,,6 fuses)

16. Alterna.tor re!1:ulator

11. Cha.rdng circuit :relay ~LuoCas 33231 . 18. Directior~l flasher unit

, 19. Radiator ceo ling fan relay ( Luea s J. 3213)

, 20., Horn relay

21. ~·~in beam, dip beal;" a~,J side lights rday- Lucas 33213

22. :C~ litr:c ~witch ... on r~;uest 2.3.j . ~';i.~,~er ~'J :,,::;1.:..er 3~i. tc.:·~

,: 24. Hipet' W<lsr.·er :;otOj'

25., Sto," li~t .wi tch

'26. nt:2a till.!;: fl'E):1ti1atiI'~ fan switch -7. Ci;;aretta li~htel'

8. I nstr'.L.wnt lit;:h't ~-:"~1e;).~tJt Rhe~stat for v~rylr.g wiper speed 1 ns tl' !l ~1-: . ,"!, liGh t~ .

31. E1 ect.r oni c r~v C ourrt er

32. H~iin baan warning light ,33. ,sT-eoc O;lleter

1.34. "Si.de light lolart'.i.ng light

!3.5. D.irection i.ndicator warning lights .3 6e Wiper and screen 'ioia;s,hel' lever~.

)7. Direction ind1cator lever

38. ~1ain beam, dip beam, and. headbmp'

I fl~sh lever

• 39. ReJ.ay swi.tch .for side, dip and main

beam lights 40.. Uornbu t ton

41. Revers e light swi tch

42.. Fuel level eauge t.ransmi t ter

, 43.. Engine compartment 11 ~ht

114.A~ ternator .

44,/1. Al tC!lt'na.tor terndna 1 boa rd

45 • El,eetrlc fuel pu.m.ps

46. Starter

47. Interior light

48. Oil tempera W1"e tl'BIlsmi t.ter

49. Water tEmperature transmitter SO., Spark plugs

51. Distributor

52. Emergency light switch

(only in vehicles requiring this)

53. Bnergency coil

54. ElectronIC ignition unit coil

5S. Dinopl ex electronic. ignition mit

56. Reverse lights

57. Luggage compartment light .

58. Rear direction indicator li.ghts 509. Rear position and. stop lights

60. License plate lights

61. Ignition sw'iteh and steering lock

62. Heating/ventilating fan warning light

63. Choke warning light

64. Choke warrdng light switch

65. Low 0 il pressure warning and t rans ~

mitter

66. Oil pressure guage

67. Interior v,entilation fan

68. Interior courtesy light

69. t. TI I. switch

70. Interior ven.tila t ion control swi tell

71. Cigarette lighter light (12 V-SWbulb)

72. Emergency lights control deflection switch (only in vehicles requiring it)

73. Power windows control motor CmmnItator (on request)

i4! • Power windows motor (on. request) 7'5. Power windowsd:rcui tfuses (on request)

76. Fog lights IS Amp., fuse.

REFER to

page I.NSTRU1>1F.l\TS ARID CONTR.OLS

r 173 ---T-:e-::~~~~:~'--' -- ... -----.,.-.--. - .. ---._- -~.- .. ,--.-~-~---.

j

I

! 1. Electric clock

2. 3. 4. S. 6.

8. 9. ~ ] 0 . ; IL ~ rz. ; l3.

• ,15.

J

~ : 16.

• ; 17, ~ : J iL

i19.

• : 20 + ; 2.1. :22. ,: 23.

· ::) ,~

~28"" ;2,9.

~JO •

• '.11.

32.

· 1.3 • 34.

;

.,! 3~ ..

I ,~ · )t'.

• - • of'

!J7. ~3f,

:, .~ ~j •

I' !"'I

~ -v I

7.

Left turn indicatol; (green light) Head.l ight 5 i ndi cat or (green light) Right turn indicator (green light) Spee:domet.er

LDW aU pressure in.dicator (red light) Electric oil pressure gauge

Oil tC'.mp~tature gauge

Odometer ze.ro cont ro l

TIa t er temperature gauge

Fuel re serve Lnd Lcat or (r ed H~h t) Fuel level indicator

u.

Ta e borne: t er M,pere gauge

DeiFo5ter with adjust~ble vanes CoIn air control lever

H.~ter tempwrature contro]

";v.3lJ:t air cont.ro.l, lever

,;Icve compa rt aent knob

Right ventilation contral

Radio Locat ion cover panel

Side 2ir inlet ...

Cleck Keeling knob

[~~trument lights rheD~tdt

Windshield wipers spped cnnrrol rheost~t Front hood opening lever

Brake pedal

:i ld~ <I.i r tnJ.e t -. Clutch ~edal Accelerator ?eda1

Right air v~ntiJatQr indicatnr iight (nT~nKe li~ht) }faio beam warn:!. n~ l1.'.;ht {h lu.€' U@ht)

Choke crmt n11 Lnd Lc tl.tOr t. J;'e~ 1 i gh t}

Ignition ~wi tcr.

Le It ai 1 yen t ~J a tpr R~,,'itC'.b ~ear shift lever

~ig~r~tte light~T

Asht rAy

Erner~ e~.L y ~'t'~t{e :'.,u'!d i~ Uw ko (",:rt~ t ro ·i.

I .::'i'!:h t !';" .. ;H:c;-

.... I .

.'. Z. S ic~., d i :_', ht'Jr], .~·1G I:.., "Ii i ,if];t~ .~ l,n" h l' ~.<r. t- re t lL'~v~r

1.3 " (l:j re c t inn j, n d "i. ;::.l t, T l.''('c r

4..... ~.,rj nds h 1 e.h:I!..·Esl.,~r (iml <':~' tH~" ,'('n t LuI 1. e'j~ r

~ ~. t-!1~I"t'L si,Gr.~l

: ~.

',"

#-- --'

Refer t,o pa;e 1J5

REFE.R eo page

13

--- ...... ----------~----~--.-- ~ ..

IGNl1'ION AND STEERING LOCK

Key position

O-Locked.

Steering locked and, key removable • The lights can be !'3witc:hedon actuat Ing switch 41 On the light switch lever 42 in the three positions. (Fig.l10~ p.12)

ll-Running position.

Ignit ion. elec t r i.c fuel pump and n,oT1'lIal running :services available.

III-Start

H.g. III Ignition and steering lock.

i 76/19·

14 a.f.t.G ,.e 181

VARIAno~s FROM VEHICLES No. 02132 ON

REFER to

DESCRIPTION

15

5

ENr.INE

Elec t r teal eq u Lpment Distri.butor

Igni tion cod I

.genc.y coil

inoplex electronic unit

Mar~lli S 125 Bx 15 Marelli BA! 200 A Marelli BZR 201 A ¥Krelli ARC 103 A

rear hyiraulic brake circuit

ATE type" fluid

En gine iden t Lf ica t ion number ..

I l , '~. r ;1 n ~1it:~ j ? S i I ) 11 f '~ 1.i .~ d r II ; .. [to r; r nr- ._~ t.! d r';'7J} 'n ~) llJi~ ~

.--.~-- ----

16

a.fer to page

IRGDlI C<l1LIlfG

53

L ivell io ,5!:, m. (LeYal)

Fig. 3,S,. iNGINB COOLING DIAGltAM

1. S.u"lnent.a.l eX)anBion t.a.nt I 2:. Ther.l!I.ostatic va.lve·~ ). TherlloeOUJilLe ~ 4. Hea"t exchanger ~ .5. Air relief val Vi!!! I 6. .11 ectrl 0 fans, 7. Water ua1n 'tal'~ 8. TberaQcont,a.et ~ 9'. Tank 'eA,., 10. Ov8I'floM tube.

Refer to ,·e

17

56

FUEL DELIVERY DU.GRA~r

Ta..nks V8,n.t tube, 2~ Pump to oarburet.ors tube, 3. FISPA. filteT'j 4~ CORa... NA pump, 5. Filter, 6~ Fuel return tube.

GENERAL DESCRIFTIONS

The engine :is s utPlied by a, CaRmL~ electric .fuel plliltP~

The pU.:E'lP is self-regulating and ~upplies the engine :under 0.3 Kg/cm2 of pressure ..

Pull:P operation be~i1.s uhen the iil:ni t Lon key is in posit!:m n~ 7ne rump1 s electrical circuit is protected by an 8 ampere .fuse.

60

•

18

R-efer to, ,age

68

---@

1. ':J11 ['.lIlieS condensat.or-, 2~ E.ngin.e bl.ock pres,sure Umi ting valve, 3. Oil drain tube from ccndensat er' to. su.;Iij}', ,IJ,. Oilsu.pply .filler caps,. 5 .. Intake :nanifolds unif::!l'm tubes"

GEAR BOX

76 CHARACT~ISTICS ANJ JATA

Synchronizers for first t;) fift,h gears. 9

Radial clearSince be,te,e'lJ'l. mounted beari ngs ~nd surfaces.,

?'!,axinmn wear lirn::1 ts" '" 0 ~

Axialcleara nee :::l,r 'I1:ounted gears. " Ha:dm.ulI liI ear li,f1'1.i ts. " • • Clearance bet~een gears control f:Jrk

interior of slidinji sleeve. '.

~'1llximum f"l'aar li:ni t. " • ~

Lubricati,:jh of gsa r-box gea:rin~.

iI Ii!} ..
• .. ii
~I • •
and
'.' .. ..
• .. .,
• '.' .. ENGINE/leAR 3)X DRIVE

~gine/ fi:ear box ratio ... Central gearing thrust Wei sher's ,

•

~ Spr:1l'1~ tine type .0.019 ~ 0.054, m!iIt,; .. 0 .. ,10 mm.

..,0.25.;;.. O.}O mJliI" ,,0035 !llI1l.

.0.10f0.20 mm. .0.30 n1.1l. ..splash t~·e

~ 30/.33 (0.90'9) .' R;:lller type'

Refer to pail:e

19

78

RATlOO WITH )0/33 REDTE'I'l3N DRIVE

ENGINE rpm RA.TIO:

Wheel rota tionirllth 17/65 final dri ve 2: ea rs

GEAR-BOX RATIOS

42: 13 38 ~ 17 34; 21 30: 25 26: 29 45: 15

j I .'

2 .• 3" 4" 5"

RM

'1

, 'I. I.~

. 2' r 4" 5'

,RM

3,.2307 2,2035 1.6190 1,:200 0,8955 3,000

3,5548 2,4238 1.7699 1.,3200 0,9850 3,300

1 "

13,.581 .~ 1 9,2755: 1

6,766 1

5,047 1

3,766 1

12.617 1

2& 3- , 4 h

5·, RJI..1I

Fi~ .. 55 ~ GSAR.~3OXt DIF'i-'EP.ENTIAL .AJ\.'D CLUTe H S"~TIONAL mA,aRAN

U. Clutch disc, 24 .. Flywh eel .. 48. ~11 reI.e1!I:!!Ie' be~dng,. .47 ~ Rn~1nl! crankshaft l' 9~. >1~ti.ng pinion, 26. ~r--bo:x input 5haI't, 27 ~ Gear-boJ{ out put s ha ft,. 18 ~ Se nd axl e f La ng e j 21., B aari ~ pre load wa s her,

)J~ Ji.ffere:1tial ass ernbly,. 35' • LiTlited-s lip differential pla.tes,

31~ Dit .t:erentia 1 p Irri JLJ., 28~. 3ear-ooCl( and differential as sembly case ..

20

REFER to page

g 1 ' Synchr oD.izIH:-r tog ~f 01." gear engagement

Fig. 56 First gear and synchronizer units.

1.Synchronher ring :a.Synchronr.aer drag spr:f.n:g$.·

3. Stop dowel. 4.lst gear 5.Thrust dowel 6.Retaining snap ring 7. Sliding sleeve hub 8. S Hding sleeve.

Ge.ar engagement synehronf.za tion is completed by the illu,stratea units in fig. 56. The. sU.din.g sleev€! 8 is internally toothed, designed to engage on the syncht'oni.dng "ting gear of moun.ted gear 4 on the: O),ltputshaft.

The gearing is now so 11 d 1 Y enga.g edon the slid :lng hub.

The spring syn.cht'ouizing dng 1 graduaUyequaHzee the ro·tadonrate dur Lag the movemen I: of the s 11 d! tug !S Le eve.

Actuated by the sleeve. syn.chronhiTilg dng I is dragged unti:!. one of its end9 is engaged in accel.er at f cn, a.s well t;mder dec.e:l.aration~ thus pushing agains.t thrust dowel 5 and producing a rotational effect which allows rapid sync.hronization. Two drag pIns (2), One futl.ctiDu.ing dud.ng ·acceleration and the other during dece lar.at.:ton ~ !'Ire a.ttached in order to increase the fric tion of the aynchront.a ing d ng a.gains t the s H ding S If;l eve.

The spring is comptessed betweenthrtlst dowell S and the tiitop dowal, 3 and de~ formed aginst the synchronizer ring.

'Thus ~ the synchronizing action • due to t.he pr easure of the ring., is l?rogr€!$$i~ vely increased by the radial pr~~$ure Df the spring.

Thesynchraniz1ng action ends when. the sliding sleeve and the drag gear rota 1: ion veloeHy L~ El.qual ~ the spring extend and the syncbromz er ring c Icsea,

Undet these conditions the final travel Df the !'llee:vewi11 occur with minimUIll effort, until it is coupled with tbe en~age~~nt teething fo the gear.

Hhen engagem.ent is eomp l e ted ~ the synchronizer ring releases wi thin the sliding , sleeve to aid in the securing of the engaged ~~ar.

Operational description

ERRATa Il1eorrect:

Fig. 56 bis. Stop ring a$sEmbly diagram.

Refer t3 ~Ie

21

85-6 CHARAC·TaRIS'Jl'IGS AL\ID .lliI..TA

Cyli.ndricaleou,Un&:: redueti.on ratio. CrO'Wo pinion aliinment~ .. • ~

• •• • 17/65

~ Spa: cer :s him eliPIi.nates this operation

@)

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~------------------~~~-----------

87

18. S erni axl.ea at tach~r..t fla:Lges) 20~ Bear Ing sUP;J·o:rt side c ::1ver,

3;). Ri hR: gear, 19. Fla nge a: t.t a e hment b 01 tS.t 21. Pre Lead beari ng shim,

:3 2. Ring gear' at tach~ent cal t s , 33~· Differential case, 34e Di fferentid c~ S€!. c~er, 35. Internal and external pl.stes j 52. Tapered roller bea~

r::bng ... S J ;.} • Satellite g-eaJ:"E, 51. $atell ~,. ... r7. e·"r·" <:ohaf·t··." r-'~.. P·l· · .... t.

(''',P''':<; • ... _ .... v" ·to· "" " '" . , ", :;l:l.~ ane.ary

..... ...". .• ,jI, """'''

22

a.tell to, ,.,i8

100

STEERING

Tele8!Oopic steerine wheel

mountilli unit. •

.,

See Table 29, Group fa in Part5 Diairam book fram oar ,number 0'2768

•

.,

FRONT SUSPEn3IJN

J\.S from. car num.ber 01118 (see p. 6)

109

REAR StJSPEl5ION

As from car nllIl'iber 01118 (see p. 6)

J!.25

As from oar ,nu.'TJIber OllIS (s ee p. 7 ~8)

116

SHOCK ABSORB ERS

As fr:)m vehicle number 01118 (s'ee p .. 1)

165

DINOPLEX ELECTRONl~ IQNITI J~l UNIT (l'f.;ar'e1l1 Am 10] A)

As fl' Om car n·.l1fiber 01118 ( 51 ee .,.. 8 )

DAS.HB QARD ccn."'TRJ1S ... ND SIGNALS

As from car number 01118 (see p •. 11-12)

--~~--------------------------------~-

Jl.76

IGNITION SWITCH w1TH A~~l-THEFT DZVICE

'As from car number 0111B (see p. 13)

------~--~--~----~~~~--------------------------

r~~~~~~ 1

r~·

1.::1:1 1

L._"" ...

,~

24

Refer to ,,8E'

173 EIJroTRIGA1 DUGRA..'1 DE3CRIPrI.ON

1. Headlamps '" Main beam and

dip beam (iodine vaFlor'o1.li.lbs) 2.. F,rant dde and dire cti onal

lights

3. FOil:: 11.li;hts (on req u.est)

4. Di recti on 1 ndi ea tor 1 ii:ht I!:i 5 .. Coollna; ram mot81'S

6. Tempe:raturesenalt1v8 switch for

radiator fa.ns

7 oil Heatine/ventliatiol'l fan moto:r 8. Horn com,ressor m.otor

9.. Front trunk: li.;:ht.

10. Battery

: 11. Electrical panel

. 12. Circuit fuses ( B valve box) 13. 8amp. fo. liif:hts fuse

14~ PermanentJ..y llye terminal board.

15.

16. Alt el'na tor re&ulato:r

17 ..

18. Dil'ecti anal flasher unit 19.. Had:! at or coo HIli fan re hy

(.Lucas n 213 )

20. Hor n relay

:21. :10\1 in b sam, dip beAm and s Ld e lights rei.ay ~ Lucas 33.213 22.. Fo~ lighbsWit,ch - on riY-illest 1 23 ~ ,~i ~1e r Tim G 1:::6.t' S"';":i. t.cr,

. .

24. Wip~r W;'sher ·.llOtQl'

25 ..Sto,Ua:ht .. itch

26.~ Heati~frentihti:n.-;; fan switch , 27 ~ Gi~aI'ette lighter

I ~ -

12e. ~ Ins.tr'J.'JIent li~ht ~n~1iE::mh.~

: :!S ~ Rhe ;;IS·tat for 'varyi~ \il~;peI' spsed 30~ I "l0tl'il'lJB.~d, lights

31 .• , Elect:r om c rWl e ounter 32 ~ }'fAin bea!"! "Warning light 33. S;~,::;'(I.c O'Tleter

3i. .. Side Ha:ht warn1~ ligh.t

35", J:i.:r ee ti on iOOi ca tor .... a rm na li.gh U .36.~ Wiper ani screen washer lever.

37", D.irecti on i 001 ca 11:; or lever

38. !"1i:1n beam, dip bB:IlJIl. and heaaltarnp flash lever

. 39. Relay switch for side, dip ami rro.ai.n

b~am lights .40 . .,. Horn button

41. Revers e li gh.t B'W it eh

1J2. Fuel level - g a ue:e t.ra ns mittel' 43. E:ngi nee ompartmulmt liii;:h t

hb !t4 ternatoI'

45.. F1iH~l pumps

46. Starier

47. Inter! or Uiht.

48. 'Oil tem..verature transmitter

49. Water t.&n!Psrat.ure ·t.ranlmitter 50~ Spark 1'1 Uil,

5'1... D1,ltrl bator

52 ... Emeriency li&::hts sv1 tch 53 ..Ehel,['~ency coil

54. E'let:tronic ignition unit eoil

55 ~ Di.noplex ele,ctro.nic iin! tlon unit 56~Reverse lia:hta

51. LU&,:.i'.iee compa.rtm.ent light

58. Rear directi on i:ndic.ator 111l:hts

59. Rear position and. ste, lights 60 • Lie ens e ,late liihts

61. I;:ni tlan swi.tch. a.nd steeri.:ng lock

62. Rea tlnt"ventila'ti ng fa n war nina: lia:ht 63.. Choke warnin&t 1i~ t

64~ Choke warninti light swi toh

65. Low oil pressure waI"ni~ and trana ...

wdt.tel'

1')6. Oil~1"es 5 ure goa ug e

67~ Interior ventilation fan 68. 1 uteri or c ourte sy light

69'.. ~l U H s'I<'litch

70. Interior ventilation control swi.tch

71. Cigar8itte lighter light ~ tch

72~ Emergency ligpts control defleotiOln 73.~ w..rer 'Wi.ndows control motor colil1t1l.utator 74~ Power 'Wind~s motor'

75~ Alternator protection fuse box (60 and 8 amp .• )

\

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... \ \ ....

-, v

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to \

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II

I Y

I,'

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\, -, \,

~--------~\~,---'.~\~\~,~--------------~\ ~

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-', -, ...

\ ........ "~~--4_ ~

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.... ,/ /.;=.~--- - ~~:~ ..... ::""

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fN\.~ .... ~ .. ··1

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25

AIR CONDITIONING

General descriptions. Clu.ra,eteriBtics and data

Fau.I t s diagnosh and related repa.1.I"s Controls opera ti.on and corapr easor s,tart ing Ma in t.enence •

Functioning (Part I)

Installation

Preliminary opera.tions for chacgdrig system (Part I.I) Partial system charging for: leak tea t ing .,

Full charging of the system (Part III)

Various operations (Part IV)

GENERAL DESCRIPTIONS

'27

.p. 27 27 28 29 29 29 31 :n. 33 34 35

The; syst: em h made up or a com.pressor driven from the engine via be.lt s through an elec:tromagne tic clutch; this is ac U va ted by the battery current via a dashboard switch.

The cooLi.ng liquid us~d (Freon 12) is circulated from the compnssot through a condenaatorJ a purifier-dessicator. an expansion valvet ihen returning to' the compres- 50r. Temperature variati.on and the volume of air sent through the. car are controlled by t harmos t at vend rhaos t a t swi.t che s IDeated on the air-concii tioning control pane L, The cooled air enters the car via directional Qutlets •

Fo r best operation of the .5)1S tern it is indispensable. above all.tha t no hUIllidity exi.st in the system.

CHARACTERISTICS AI."I"D DATA

tl

Type

I SYltem

Camp r es so r

'j Operating pressure i Fluid used

, Systemcapac:f.ty

I Fluid t'eplacemen t (to make up losses) j Comp ressor c,il

Lf t er-s

{- ~taxim.,u.III..' Compressor level

M.1nimum r~heck (fl uj d los sea)

he:i..gbt

mrn.

height

mm.

BORLET'Il ASP ERA 15~Hl FREON 12 1.1 AnnuI'I.llv

SUN ISO GRADE 4.30·44 40

27 Annu,a:lly

28

FAULTS DIAGNOSIS AND RELATED REFA.IRS

,THE CClMPRESSOR DOES NOT FlJNCTION

~ossible causes

, Repairs

.ll. Ele.ctr-ical current not reaching the electromagnetic clutch 2. Stretched or deteriorated drive belts. '3. Faulty control switch or broken

cable 4. Faulty pre.ssure ga.uge switch with burned, or non-fane tionaing ccnt ac t s •

--------------~.~-----------~----------~~------~~

'1. Dirty or detEH"i.orated ring carbon. contacts.

I Z. Check tension or replace belts.

3 . Check and everi tu.ally replace .
4 . Check and e.ventualLly replace. THE COMPRESSOR FUNCTIONS BUT AIR IS NOT COOLED

I 1 • Empty or low FREON level in the g~nl'tem.

2. Purifier-dessieator clogged or 'humid.

3. Expansion va.lve faulty or. with clogged filter.

4. Therlliostat control at panel faulty or irregularly adjusted.

5. Pressure gauge eube cra~ked or slow in func t.Lcn Lng ,

,6. Loss of FREON ata pa r t Lcu.Lar conIllection .

. 7. Non-functioning evapo ra to r fans. '

Repa,irs

1. Partially refiU the system. and search for leaks (p. 33) (engine must be turned eff) •

:2. Rep lace.

3. Replac.e.

4. Check a:ndeventually replace.

5. Check and eventually replace.

~. Check with tester (engine off).

7. Examine rheostat for cause.

-...._-~=~------.,.,--~-----.- .. ----_. -_ .. _ _;_--

THE COOLING TEHPERA.TURE nOES NOT REACH IRE l"Ri::SCRUlED MINUM LEVEL

,

'1. Compressor: doe s not reach max imllm pre6sur~ due to wear or other causes. Z. Low FRE()N l.eve 1 in the system.

3. Haladj, us t eel expans Lon valve 0 r c 108- ged f t l.ee.r ,

4. Poor condensator cooling due tu parti~l obstruction ~f the Rir intake. S. Evaporat~r fans velocity slowed hy def~ctive rheostat.

6. Right ve.ntilatol" does not function when tr.e compressor oper at e.s ,

7. Hund.d i ty in the system.

Repa.irs

1. Check pressure, connecting compressor to high pressure manometer.

, 7.. Search and eliminate leaks; refill (p .. 31-3t.).

3. Replac E' ••

!~ 11 r.her:.k.

5. Ch~('l, t ha t the f sns' three speed 5 function effectively.

6. Lack of electrical curr~nt due to burned fuse or faulty motDr~ check and eventual.I v r e p Lace the mot or •

7. Check the purifier-dessicator view

., las ~, j I (egged, rarIa.t'.€; the purifier •

. _- ~"""' .... ~ .. ,."." _.- ., ..... - ",--,. ....... - - ... ....,......,. ... __ . __ ._-- -_._. _.,,_. --- - .. _ .. _-_._-- --'. __ .. _-,....--

29

OPERATION OF CONTROLS AND STAR1'ING THE COMPRESSOR

A.fter starting eng tne , rota.te therhe.ostat switch 48 clockwise to the Unt po~ sition in order to enga.ge the magnetic: c.lutc.ha.nd to start the compressor. The right hand ventilator i6 also now in operation.

-- Also rot.ate the commutator knob clockwise. At the fi-rst position the. ~vaparato'r fans will turn on. At the second and third ppsitions their speed will increase and also increase the spElled and volW'!le of th~ c.irculated a.ir.

To increase the amount: of cool air turn k1(loli 48c.lockwise.

NOTE

When the system T EO pressure reaches about 18 atm , ~ the pressure gauge cuts off the current and the compre~sor stops, when it will turn on again when t he pr eaaur e reaches about 14 atm.

In order to ventilate the interior 0·£ the car with the system off ~ allow the two ventilators to Dperate~ these are controlled by knob 48.

MAINTENANCE

!>:ormally the system will r~quire the: following periodic operations:

Complete replac.ernent of the FREON liquid annually. Annual check of the cornpre!'l$orTs oil level.

For t.hese cper a.t t.ons and for any malfunctions repairs we 6ugg~St that you contact a rer.resentatlve of tbe BORLETTI. VOXON. or FERRARI works, or any specialized Tepai r she p ,

rU~CIIONING (Part 1)

Bef ore Lns talU.ng t. he cornpr'es 50r on the engine. it i$ necessary to mount on

twa wooden supports, with the drive shaft ~oint~ng dawn, without touching any Burfac.es 90 that no pressure i s p l ace s en the shaft. Leave the comp reasor in this IJcsi t Lon for 30 minu.te 5. This operation is neces.sary $0 that the o i.L can lubricate perfectly the shaft Rasket before operating the ~ompressor.

The comp re as or is shipped front the teanuf actur'er ad aqua t e.Ly Iub r t cat.ed and filled with the quantity of nil required [Dr operation. If any unspecified oil is added ~t will contaminate the entire ~y$cem nnrl voiding the compressor and related u~its' guarantee.

OS F S UNIgO 0R.ADE 43044 on EXCLUS I.VELY

'n~e. compr es sc r 0 n, Lev e 1 L;, to be c hecked be"~ on: i.nst a.l l.a t ion while on the mounts: remove one of the ~:l de plug B, i.nser t<l rre tal i nd Lc a t o r tab and jnea sur e the quantity of fluid. Check that hoth pl~lgS aTe tighte~ed properly. ThE oil level in a new c(")m~T.e s se r is 40mm . After in i t La I use. the .! evel, must he kef. t a t 2: 7 +- 30 mm.

F.!,ECl'Ru;.tA/.~N[Tl C C1XTC H

The c 1 u t.c h ml1~ t be it. 5 t.al I ed on the CDIT,preS sot" bef or e ins tal1a tion on the ca.r .

The a pe r a tion. must be car r ted outtd en max lrrlJ,:m car e and the appropriate boo! t on the. sha f t must be t i[:,h t 1 y secured.

30

31

INSTALLATION

Do not use. water for any purpose while installing the system. or when its 'tubing is not tightly con.nected.

During d.Lschar gd ng t loading or tim.i.ng aoperat Icns , water can be poured over the con.densato"! to reduce excesS conden.sat.ion.

Do not. for any reason, remov,e the plastic caps at he joints of the flexible tubes or of the ecnn act Icns unt ilL ready for their ins t.el La t Lcn . This s Imp l e precaution e l.Imtnat es the possibility that humidity or impuriths will enter the system and do operational and madntenance damage.

Also use carE!. with the purifier-dessicator by not removing the caps until ready to connect them with other com.ponents.

If the unit is ld t open for a per Led of time. i tenn become saturated 'with humiditv and can radically influence its proper operaticrn. If the installation Is partially c(lmrleted~ ur must be left that way overnight or for several hours, dose every f l exfb l.e tube and €spec.ially the pur-if Ler connections.

Do not use any sealant material on the seat s of the f Lexdb l e vtubes connections. ~Je r ecomraend us 10ft a small quanti t y ('> f r DElpreSSor oil f or thi s purpose.

If the s ys t em is totally empty of FREON due to major Leaks, replace the puriU er , as it is pr obab Ly satur ed wit}) humf.d f t y ,

It is not n€cessary to completely drain a partially FREON filled system. If possible locate. and tepair the leak without any disman.t.ling. and add additional FR.EON (check to see that the gla~~ i.nd i ca t or v,dndoli!.T "c Lears" as noted in Part III onp.3~).

Do not subject t he comp r es so r belts to exces s Ive tension or stretching during as aemb Ly and removal ope r a t Lon s . Normal belt t ens i.on isrneasured at 6+ a mm. distance downward.

POLELIMINARY OPFRATTm~s rOR SYSTP1 r:HAWa:-fG (Par t II)

Necessary tools:

Hotor unit-di:scharKe pump.

Cha.'-gingun it far measur i ng and Load in~~ of FREON, w-i t h vi s :i.tle level marked 'Io!ith ccr respond tng .i[lcrement's to 1 t<r... of FR[("I:i~

:J Lst r ib u tor unl t , wIth :o;e,Tvic:('_ Ii ne s gauge s rand and con r.ro 15 for high and low pres sure .,.

The E;auges unit is made up of:

Discharge gauge w:l th 0 to -70ll mm .•. iJ .ae rcurv g r aduat i ons and a 0 to 10 K~!GmL rraduarions far low pr~ssur~.

A ~~uge gr aduat ("d !Yf")ITl [) to J~ K[" hn:"':. 0 r h j glL fJ'[e$~ure. ?ropane gas :!eak ind Ic a t o r {~jg. }}.

'I'he J n t ak e and de Ld.v ery .~C'r'! i c e v a.l VI~~' (" .md :) s I tua t.ed err! the compr essor ar e

,.-.f: the docb Le seat ty~lt' "fi1i.'2L~ ('.·1 He: ~?h~nt!" .... er UWv u r c [u11i' screwed in or comp Le t,ely llllS cr ewed ,

i~i I en val VE$ G and n a.re 1 ulI " 3(". H~I,.;I~C. Ln , po s j t i Of'. 3. 0( f ip,. 7.) t:he Lntake anil de l Lvs rv t ube s :::0' the sy s r en a r c r ul l .. cl o s etl , "'hile tubes 4 and 5 remain open (.5 er vi ce line s) betwe en the C('mpTCSflO r <::LaG th':'! va Ives A and B 0 f the high and J.o',,'; pres su r~- gaugp.~ of' o r cor. t 1',( 1, cb,~ l-I~': o r d j s c har fe c r ~ r a t ions. When the

va l ve s ~ and U are screwed out. they are in r.he Lr nc rnal functioning po s Lt Lon , T..;I, i l.e se ;;-vj c:n i iner, .'~ End <) .'! r e c 1 o~e -; . I s: vn l V€iS C arid D ar e no t cIo sed , in -2; , t her o ppos it_ e sea t, bo t::, (~C ~i ve ry .1 i.r:~' '" t;"CIT_;.l in open.

1 ~.f:' ir.tnk e va.hl[ is t.he 1. ,. r;,',er eJIle {i i; ~ ':) ~1id is C onnec ted with evapar<l.l;;or 52 r c tu rr: tll~.le [<~ (ft.;; I). ~d.~_h' r-:ll8 sr..'dlcl- dL·Hve'l~: val.ve on rI) is c.onnected i..'i t h the C ;"fi' (1'''.11 sate r r/I u!"l:)f!:::- cormec t l.Onilnrl its r e turn 1 inc. zo the upper

c.ornf'_C t .Li"1:.1 ·6f. ~1H:'"i [i CT S'~"

32

2 1 3

RECIPIENT!

FREON

(Freon gas con tai ner)

~ ~ I~: 1 Kg o

t-

il(

V)

e

Q ,.,

(Charg ·.r

In.E'ED ING AIR FROM 'fHE gy STEM

33

Bleed.ing of the SY9tem should be pre! erab ly done. with a vacuum. pump. If one. is not available • the system can be emptied usinga:. compressor; however maximum vacuum cannot be obtained,thus lowering the syste.nn1s eff1cle.ncy~ 'rhus, thee:ngine must; operate for a time in order to ae tuat.e the compressor.

CONNECTIONS

Remove the protective caps from the compressor intake and delivery valve stems and those of service lines 4 ~nd 5.

Connect the low pressure gauge flexi.ble tube to servic.e line 4 on the intake valve. Also c.onnect the high pressure gauge flexible line to the delivery valve.

mSCHARGING lHTH A VACUUM PUMP

Connect compressQr~ gauges and pump as in fig. 2. Position the valves as follows:

Valve A= open position Valve B~ open position Valve C~ p05ition 2 Valve D~ Position 1

Allow the pump to run for .5 minutes and then immerse the end of the air exit tube in a. cOn ca Lner 1 filled with compressoroi 1. Noah bubbles shou Id be noted. Any air bubbles will indicate leaks in the system. To eliminate Leaks , cheek aU tubing and connections of the complete system while charging with FREON.

DISCHARG INC THE CmfPRESSOR

Position the v~lve6 as follows; Valve A~ Closed position Valve B~ Open positiDn

Valve C~ Position 2, les6 1/2 turn Valve D~ PDsitiDn 3.

Turn completely to the right the air temperature regulator knob 48 and the air volume ccnt ro l knob 49.~'ith engine speed at 120~tJ(_)O rplli. Operation.ttrne t s for 1S mi nute s , and the vacuum value is at 281' of mercury (at 700 mm, of mercury),

Che ck. t hat the vacuum maat s specification!': and that after lOminuUs of discharging there are no air bubbles. Fo'!" tbi5 check, immerge the end of the air escape tube in cortainer 1 (fig. 2).

END Of D J SCEARCE OPERAT HlN

Before st opp i ng the C:Ottl[,re$$or ~ po ~i t.Lort th,e val '(nes a~ fallows:

Valve A~ ClosoEld pos LtLon V61ve B~ Clo~ed po~iticn

Valve C~ PD9~t1Dn ~, minus 1/2 turn Valv~ D~ Position 2, minus 1/2 turD.

Turn 0 r f ccmp ressor for 10 m i nut.es ; if the pr es sur e r ema Ln s ccns.tant , eher e are no leaks.

Link cormec cion F o[ the charge r to C enneeti on E. of distri butcr (r~ee fig. 2) after having placed the va]ve~ in the fDllowin~ rositions;

Valve A~ Closed position

Valve B~ Closed position

Valve G= Position 2

PH ~ .. V.E D~ 20$ :f" t ion 1.

34

Set en,gin.e speed at 120Q-1500rpm. Charging time is 1.5 to 20 minutes. Control knobs 48 and 49 tutrted fully to the right (fig. 1)

Open cha.rger ta.p F and loo~u:!n connection E: eo aHow a. small quantity of FREON to escape in order to bleed air from tne ty.bingt then close aga.in.

Op ~:nV a1 'lie ]. aad charge the system with 0.250 Kg • of FREON 12..

TESTING FOR LEAKS

Use propane pressure indica.to'" (fig. 3), attached w:1.tha. one meter long rubber tube. 'rh~ ~gine 1.$ turned off and all Eans or ventilators in the surrounding vicinity must he turned off. The car must: not be located where there is any moving af.r, o'therwhe any Leaking FREON gas will be blotJr! away and not noticed.

Move the indicator t.ube end over allc.onnec tiona and linkages ~ compreSS(lr valves J the rear pan of the clutch und.t to check the dr!,veshaft ga.sket sed. of the compressor-.

If there are any FREON le-aks the blue propane gas flame will turn green in color.

ATTENTION:

K,ee.p the tor-ell a.way from the face and! do not breathe in the gas; keep away from the carbureeors~ gas containers~ Dr painted parts. Locate the leaks. correct them and then proceed. to bleed the system.

FUlLL CHARGING OF THE SYST.EM (Par t It I)

FILLiNG THE CHARGER

About 1 Kg. of FREON h needid to fill the system. For this operation use the proper charger'.

Soli.cily f as ten on a high parmanen t stand the FREON container. Fnsten the ~harger in a lower position in order to

fill the char-ger , The charger should be set up as to be movab l e for use next to the car.

Connect the charger tubing td th the FREON container. turn. taps Hand F B.nd Le e the fluid flow into the charger until filled. If it will not fill to the prescribed mark ~ some internal gas pressure is creating a c.Olnlt er pre.$ sur e blocking the flot\'l 0 f FREON.

Eliminate this count€r-pressure by qui.ckly and sli'ghUy opening and closing several times tap G.

After fIlling the charger turn the taps Hand r off and disconnect the fREON cont.ainer tubing.

The charger t s now r eady for charging the :c;yst em.

Follow all the operations described in P~rt II by charging the sy~tem with all the FREON in the c.harger.

N01Lllally ~ .. hell 0.900 Kg. of 'FREON have been c.h.arged Ln t.o the system j t he view ~'lndow of the. rtJrifie~ ·,dll have cleared.

The last 100 grams are f I Lled in as reserve. The charge 1.5 ~om.Dl et e when, the high pres su.re. gauge registers 200- 250 1 b~! sq, incb (15i'i 8 Kg! c:mt.) and when air bubble s are no longer no ted in the purifier examf.na t I on wi.ndow,.

fi~. '], i?:-o['tme p.as pump leak tester.

35

On wat'rn days , a fa.n placed! 30 t.o 90 em. In front of the car and blowing on the ccndenaa tar will aid in cha.rging m.ore.rapidly, if a vaCutlfil pump is not. used.

D t S CONNECT! NG THE GAUGE S AFTER COMPLETING TRE 8Y STEM I S CHARGE.

PosUion the valves~s follows:

Valve A""- Closed pOsition Valve B'" Clo9-ed position Valve Co;;; Pc sf ti on 2 Valve Do: Position 2

lap F'" Closed

Elisconnect connection E. Disconnect sE!rvice 1 fnes l~ and .) from valves C and D. Replace valve controls C and D .safee.y covers. The system is nOW ready for operation.

VARIOUS OPERATIONS (Part IV)

TOTAL DISCHARGE OF FREON FROM THE SYSTEM (compressor turned or f) ;

Conne,e tth.e gauges without connecting the. FREON con ta.iner and position the

valves as follows ~

Valve A~ Closed positial1 Valve B~ Closed position Valve C~ Position 1 Valve D~ Position 1.

Slot.'fly open valve <1, the gas will escape from E wi.th traces of oil; recheck after the pressure has been discharged. If th~ high pressure does not decrease ~ ca ufully open valve B. maki.ng sure tha.t there is not: a sudden rush or oil.

CHECKING CONPRESS;OR OIL LEVEL WITH SYSTEM CHARGED

For this operation. the compressor i:lJnd the. engine must he turned off. Po-

sition. the compressor valves and! gauges as follows:

Valve A= Closed position Valve B~ Clcs~d position ~alve c~ Position 3 (~lo$ed) Valve D~ Position 3 (closed)

Afun," the above operations. connect valve A w1.th valve C and valveR with val~ ve D. Leave the FREON cDntainer tuhe disconnected from the gauges. Then po-

sition the valves as follows:

Valve A;;; Closed posi.t Lcn , minus 1/'2 turn Valve B~ Closed position. minus l!~ turn Valve C~ ~osition 3

Valve D~ Position 3

in order to eliminate tho PKEnN interna! preftsure. Open one of the ~cmpres~cr taps and with <I tub measure it§ I Lu Ld teve.l (See l'ar t I). If low. fill to prescribed l~vel.

Norma.lly. the oil level must be ch~cked ,,[ter "t€!placement of a ,1dec.ti:ve sea 1 or because of a leak. Any 0iJ shor tagET! can b enoted in the purif ier examimn:hm window.

?osition the valves as follows; Valve A~ CloAed po~irion Valve B; ~pen 90siLion Valve C~ Position 3

Valve D~ Position 3.

36

Allow the com.preSBO"t' to run f Q r iO to 1.S min u us + Ch!l!.ck its vac uum level by

in se.rt ing, the end. 0 f a t,ub e connec ted to the ga ug e in E in a con tainer f Hl,e.d with c.ompressor ,oil.

There should be no air bubbles noted. If so, there is a leak in the system. Check according to instructions fot' leak testing (Fa.rt 2).

DISCONNECTING IHE COMPRESSOR WITHOUT DISCHARGING THE, SYSTEM

Place valves C and D in position 3t unscrew t.he fastening bolts of the two valve groups on the compressor and remove it last from. its support.

31

FUEL EVAPORATIVE EMISSION CON1'R:OL SYSTEM,

GENERAL DESCRIPTIONS. ENG.INE •

Description.

Mechan1c,al checks and. adjustments. Spark plugmainte:nance. Carburetors maintenance.

C~n;huretors mixture control pt'ocedure Adjustment of the idle speed cam. Distributor microswitch • ENGINEELECTR:l:CAL SYSTEM •

General descriptions •

Ignition timing-

Distribu.tors contact R2, ad] ustment in relation, to Rl Dinaplex e Lect rcni.c unit.

AIR INJECTION SYSTEM

General maintenanc,e

Air pump.

Air pump filL ter rep Lacemarrt Diverter valve •

FUEL VAPORS EMISSION CONTROL Description '.

Maintenance •

Sealed air intake

EXHAUST SY STEN .

ELECTRICAL SYSTEM

37 38 38 38 38 38 40 42 42 44 44 44 4..5 46 46 48 49 50 50 50 50 51 53 55 56

.Page

n

. .

It

.,

't1

t1

'I'

GENERAL DESCRIPTIONS

ENGINE

CARBURETORS TECHNICAL DATA

, Carburetor type \"Teher 40 ,,' DCN,', F,' , 19l--

Choke diameUr 32 mm,

Main jet 1.2Smm.

Air correction jet 2.20 mm.

Idle jet: 0.55 mm.

Idle air je.t 1.20 mDI.

Can tral dH f uae r it • SO mID.

Pump jet 0.,50 mm,

I '

Pump cams 11 total

~,-- --- -

1.00 I!U!I. F/24

1.75 1IUlI. 52~O.25 n'Im. F 6/60

PlJIElP delivery valve Emulsion tube

Float. chamber valve Level (vertical float) Sta.rter jet Progression holes

No. 1 Ne,. 2 No, .3

O.so mm. 0.90 mm. 1. 301l'!ll1.

Engine air supply: specially provided for with a sealed air intake.

GTRER ADJUSTMENTS

Id le speed: Through a cam regula ted by the temperature of the eng,in~. timing Iubr Lca t:'cr ••

Operation:

- With oil t.emper'atur e at 2.0'" C +. the tappets must be aligned with the 20 sta1ll!p ed on the cam. Cold engine speed: 16.00 1: 2.00.

38

With eng1ne.wann ~ oil te:mper&t.ure at 80 e G. ~ t:he Cam. is ba.rely in con.tact wi.th the ta.ppets. Engine speed~ 1000 rpm '9 ± 50.·

Microsw:itc.h tappets in reurdedpos1.tion:

With t.hecam tappets uudet: mio.lmumac.celerat1on and near the 20 mark,. the microBwl.tch should have not as yet begun to open the ·circuit le.a.dill.g to the distributor. See page 39 fot' adj:ust.ment instructions.

ENGINE ELEGTRI CAL SYS IEM

Dl$tribntor with dual points Poin.ts advance

One Marel1! 50.1n.256.3 Dr S.125C 9.:11+· 7° (Before Top Dead Center)

Distributor set-up

Points retard

2 (l' +A 0 (After Top Dead Center) (of engine)

30 at 1 co of engine

39.0 "!.2·C!1 beyond 5.500 nIl t One UNUiAX 2HB 58-1

One MateUi RAE .200A and BZR 201A (Emergency)

M~rel1i ARC l03A

Siemens-Elet.ta type VAF-0447/A MardI! GCA li 19A

Corona, model 8240

Automa.ti G cen trifugal atdvanc:e Total adv$t!.ce

Distributor micro~w1t~h

Coills

High tension transistorized unit Air pump clutch ccrit rc 1 unit G~n~J,a.tor

:Fuel pump

AIR INJECTION SYSTEH

SAGINAtoJ air pump Air pu.mp belt:

Control valves Diverter valve Air pump c Iu t ch

G.M. No. 140.CS.23.7806.206 Gates Polyflex 7M ZOO

Two c, M. 5354987

G .M. 7029196

Baruf'fa:ldi EKM: 1

FlTEL VAPORS CONTROL SYSTEM

Seale~d fuel filler cap Controlled capacity t~nk8 Fuel vapors separator

Iht ee-'WalJ.y va Iv ~

Active carbon filter

HAT 124A 100 .. 104030.41 B. 1665- Two Ferr,ui

Ferrdi.ri

Borg w~.rne:r cux 2.219 or FIAT 100 GBC/1140/104806/4226204

SAVARA. 5126/50

EXHAUST SYSTEH

E.%ha.u~t sys:te"'l

E::.:.haust collector headers

ANSA t'Illlffler and 9pecial tubing

With exhaust gase9 pre-rel1e.f' tubes,

ENGINE

On the, can equipped with an exhaust ga.ses em:!Bsion control systemt sevel'.a1 m.o dit i ca f_ ions have been in t roduced ; 8p ee i:f1.c.ally :

-Idle :speed opera.tion, controlled by the. engine oU temperature.

-Microswitcht actuating on the the d.ual points distributors.

-Specia.l carburetors adjustment •

...:1Ei:xbaust collector head.ers tubes equipped wit.h gas analysis connections.

All these units ensure gas exhaust emissions of low levels * as long as these units are kept in correct adjustment and main t eaance.,

Mechanical checks andadjustment:a

Sp.a:tkplug maintenance

Champ ion tm 19V sp ark p lugs are used which ha Vel a ce'll tr a 1 l'eces sed elec erode and anaddi tiQflal surrounding circula.r electrode.

The electrode gap is set: by t.he manufacture.r (l.27t 0.4 lIIIlJ. .• ) and 1s not adjuatable.

When. the central electrode 1s worn or the porcela.in. is cracked or dark grey in appaa'rance, replace. the plug.

Every 5~OOO km.~ check plugsaccu:rately and replace if necessary.

During checking opera.tionst run en{!;1ne at idle speed in order to check for electrical discharges at the spark plug connections.

With the high tension Df.nep Lex unit the sparks produce an audible sound and. a luminous spazk ,

If peceSS3.ry. replace faulty c~ble connections. Every 10,000 Km. ~ replace plugs.

Carburetors maintenance

Periodic maintenanceh suggea t ed by the factory and it s authorized daaLer s . The ears have a apec La l.Ly desi.gned adjus traen t for exbauat gases emissi.on COnt ro Ls and t.his must not be altered under any c Lrcurasuance.s . The carburetors are BUPP lied with special screws fo"( the adj ustlllent of th~ mixture,. and must .Inly be ad] ust ed durin.g the peridic maintenance.

The mixture adj us tme.n t screws have, a friction tingand a spring which eon trol

Fig. 1 Champlonsp~['k plug UN 19V

Fig. 2 Carburetor Weiber40 DCNF 19 1 • Mixturea:djustrnen t SClrewg.

40

this free movement, and assure a slight mixture enr Lcbmen t in a. pt'ogrel1lsiv~ lo,osE!ning of the screws.

Mixture control operat Lons

Thes,e operations must be car'r i.ed out every i5, 000 Kill.

])0 not, under any circumsta.nces~altel' the adjustment of the mixture control ,6CI',eWS after these operations are eomp Let ed,

If the ail' and gas fi1tet's maintenance operations have been sc"tupolou.sly followed, the. carburetors should not need any additional maintenance in the peri,ods between mai,ntenalllce schedules.

Procedure: a CO gas analyzer, warmed 1:'0 the manufactarrar I s spe.cifi.c.ations ~ is used.

Fig. 3 CO analyze:r, Hartmann type.

Fig. 5 Synchronher tlni t for carbur euot-s , 1. Motometer unit, 2. Butterfly valves control shaft~ J. Valves adjustment screws, 4. Idle speed adjustment screw,

7. VRlv~g contrnl unit.

Fig. 4 Idle speed unit.

Fig. 6 GO gas check connect iCY!l5 •

41

RUn engine. lit id La speed, ehec king that all cy 1 indel's are func Uoning p 1'0- perlyand that there are no electrical d'ischarg,eB across the spark plug cap:8~. When ed.L and water temperaeUreS8l'e around 9O-C., rem,(ive the ail' int8Lke and check whether the idle speed cam is functioning freely.

W,it.h the engine speed at 1000 rpm' 8, equaliz,e the buttet'fly valve,s,openi,nga using a carbure.tor synchronizer tool.

When, the va 1 ves opening s have be en equal! z,ed , chec k w'het her the eng in,e idl e speed rpmta: remain at the 1000 l'pmtsminimwn with the idle speed cam in an inoperative position.

If the speed decreases, i:ncTellse :it byadju.sting butterfly valves adjust.ment screws 3.

Prepare the CO analyzer by connectingt)1:e analyzer dip-stick to the tubes!: the top of the exhaust collector connected to the body of the first carburetor (each carburetor body feef1s a cyH.o.der) '. A connection is ,attached to each colle.ctor for the insertion ef tbe analyzer d1p~8tick.

With the analyzer dip-stick -conn.ected, engine: speed-at least at 1000 rpm IS;. with ad.!' pump. fun,ctioning, engine oU and wate~, tem'Pera ture at 900C. ~ the CD analyzer ga,uge count should be between 1. U:-O. 2%.

If the mixture is too rich t lightly cl.ose the: mi::lture adjustment screws for each carburetor (ensurin.g each time t.hatthe analy~er indicator does not move) and. adjust tOo reach the prescribed CO values.

Rep,ea.t the eperatdoa for all six carburetors ~ disconnect the analyzer dipstick and reconnect the air intake.

Accelerate the engine to render inoperative the idle apeed control CBIIl and check for the la.st time the. engine idle speed. andtbe CO % count, which. must not vary for each cylinder.

The idle speed unitcontailils a bimetallic spring which mOves a circular diam'e ter cam, ~

With on tempera.ture below 60·,e., the high part of the cam surfac,e is in contact with a small tappet connected througb an arm with a butt.erfly valve control lever. Therefore, the butte.dly valves are. slightly open; il the engine. is 8tarted~ with ambient tempe.rature of 20Oc. ~ a few seconds after .starting it will a.uto:mat1.cal1y reach a minim'lllli of 1200 rpm t s ,

Idle speed unit di,agram.

1. Butterly va.lves control lever .•

2. Tappets ~ 3. Bimetallw .pr;j,~~ 46 ce.

'Fi.g. 8

l~ Idle speed control cam. 2 + Distributor microswitch.

42

As the oil tempe.ra.ture. 1ru:reaa,es and.t.he engine warms up, the ,camrot&te8 a.nd, af'ter a maximem of 1600 I'pmt8~ it becomes inoperative allo,wlng the ,engine to stabilize at an idle apeed of 1000 rpm t 8 (!Jlini:Jn.UDl) atIId wlth 011 t eDI.per a tur e at 800 C •

Adjustment of the idle speed cam.

Adj uBtment,witn cold engine. :

-With engine 011 te.m.peratut'e at 2(t'C. ~ check that the idle .8cce.le,raU.Qn tappet aligns to the nmnber .20 staraped. on. the top o,f the cam.

Remove the cam. ood rotate the internal bimetallic strip.

-Start the engine ,ilccelerate for 30 seconds at 2500rpm'fJ andth.en let it run at idle 9peed and check that it t'eii'lains at 1100~1200 rpm's for one minute.

Allow the engine to warm up by accelerating it several time8~

Afte'r about 10 m;inutEis, the maximum idle sp'eed W'ith the engIne, hot (oil tempet'ature at about s,<fC.), the, cam ,,!Hi be com,pletely rotated and the idle spe;e:d will be, WOO' rpm'8 with the cam disconn.ected.

Ad.j us,tment with warm engi,ne.;

-With engine 0.11 temperature at sosc, ~ the tappet must just: to.uch the cam and the eng ines peed abou Id be 1 000 rpm's,.

-Utbe a.bove c,onditions cannot beQbtained.~ it \11.11 be nec.essary to work

on the adj ua tment nu e 1 ( fig .4) t moving t'he t a ppe t. t.owB.rd III the cam to

obta.in a higher engine speed and away from it to obtain a lower one.

Du.ring the maintena.nceopera,tion t in. the di.sconnecting of the unit, check that there are no deposits, acc1il~ately cleani,ng and lubricating if necessary. In reattaching the unit, easure that with an engine oil temperature of 2(f'C~. the numbet' 20 marked On the cam is aligned with the tappet.

Proceed then to test the cold starting procedure a9 des,eri.bed ,earlier.

Attention; If.t wd. th a cold engine, the engine epeedi8 not:1,e.eably above 16000 rpm' s ~ check the microswi tch adju;stIl1ent to se'e if it has already opened the circuit, actuating the. advance ta.p'petofthe dhtri.butor. thus causing the .englne tim,ins; to be advanced ,and run at a fa,atel': ·8peed~

It is neceS.S8ry that, with tbe. idle acceleration engaged. the engine be retarded and, by movin.g the _,ccelerator level' (wi.tb t.he tappet of the idle speed aligned at the 20' mark)~ the micro8witch opens the circuit ( adls~ tinct click will be beard).

Distributor microawiteh.

The IltcroBWit.ch is mounted OD· the rear tap'pet ,cover. The movement of

th.e cut-out switch is controlled by

a 8i114:ll arm which carries a small whee.l in. contact with a 811811 .upport (adjuatablethroqb two nuts) f'ix: ••

on th.e ca.rDuret.orl butterfly valves con trol lever.

In the distributor there a.r. ioeate •

. two let. ,of coo.tactl!

1:1: ftCIraai .-dvu.oe pOiD.t. R.2: retard po:l.Du

-lU t'.~rd. by lL ;Q.e :1.11. ·.Uvaa9:

;'1Il. r.auQIl .t;q, ·U, ( , .. 43):.i

"I'» 9 _m-._ch ·14,"·...-t, ..

43

Fig 10 SpecIal tools.

L CO anaiyzer with h:cbans,e:r

2,. Ohmme fer

3 •. Carburetors s,ynchro~ ni:1l!:er

4. Goniometer B~ale

S. Exhaus t header tube.s connection cable.

R2 functionS unt.il a certain engine speed is reached and the microgwitch I!Ipells the circuit allowing lU fo fuuct:ion •

.Adjustment of the microswitch

Regular operation: durin.g engine operation at idle speed , the e.ngin.e should be reta.rded, with the micI'oswitch operating the R2 points; 8S soon as the accelerator leve,r is .oved Cl!om the pOBUionwith the tappet at the 20 qrk of the idle apeed (max.imUli height), the micrOBwit,ch mustope'n the circuit and allow pOints Rl to function.

Check: with engine. off ~ but bot t with idle speed. cam rotated so that its tappet is aligned to the 20 mark (with carburetors butterfly valvea sl1.ght1y open), mOve the udcl'oswitch. tab towards the body of the microswltch iUelf. You should not hear any click 60Und; which indicates the opening and 'the closing of the microBwitch.

Such 8. clic,k will be heard instead~ when the accelerator lever will be moved slightly from the .above-meo.tioned podtion~ aD when accelerating.

1'0 adju,st:, it will benec,es,sary to to e.ventaul1y work on the. nuts moun.ted on the carburetors lever in reference to' the am on wbi.ch rests t.he microswitch lever.

If, when cold ~ the engine 1d le 8p eed exc eeda 1600 rpm t s, check the lII.i.c T10-' switch a.djust.lQ.ent: the engine t:1mfngcould be advanced.

If the engine. while bein.g progressively accelerated during driving~. runs Ufievenly~ the microswitch is keeping the engine retarded too longt therefore it is necessary to adjust the. lever t.ravel 8S mention.ed above.

The m:1croswitcb needs no ma1.nte.nance, with only a periodic check ev.ry ls,oOO kms.of its cables and contacts to e.n!1lute that no current interruptions exist

and that the cables are well insulated.

If a cable must be disconn.ected, or if one of the cut-out switch ground cab~ le.a 18 missing or disconnected. the engine will ille at 1400rpm.ts rather tban at 1000 rpm's. To check whether the. microlllwit:,ch is functioning properly ~ directly ground the cable comi.ng from the di.stributol'. A decrease in eugin.e speed will be noted ~dDce 'the. distributor :r,etard points will be.aet1vated.

' ..

A.TTENTION; the ear should not be run with the m,iC"l"08witch contlnously ensagedas the retarded timing of U ~ on the engi,ne advance advance setting can cause faulty running at high rpmfs.

ENGINE ELECTRICAL SYS1"EM Dual contact p,oo.t:a 8,eries d'istl"ibutor.

Genera.l deecrlpt:l!Qu

'Tbe distributor fa of the dual contact points series type. the first seriest pt:i.n,cipal eent.act; point Rl ~ the second ser!.es;, contact points R2. 'The R2 points retard the distributor .5 0 30' (distributor rotation) in relation to pOints Rl. In order t.o adj ustthe R2 pednt s , use the adlj ustment screws and the holes in the distributor housing.

The igni.tion spark is generated by pa;1,nt!> Rl or R2 a.ccordingc,Q the poaf.t ion, of the liIicroawi ten.

The distributor needs no particular maintenance if the norma.l periodic checks Bad maintenance suggested in the Use an4Maintenance. booklet are carried out.

Engine igni Hon t'im.ing

Remove the right rear wheel and ~tone guard, so that th.e engine crankshaft

dam.pe.r and the COVer next to it are visible. I

Wi t.h the engine idling at 1000 rpm's, check with a sU'oboicopiC l:I.ght that the mark. on. the dam.per is aUg,ned with the -4, mark on the tab.

ROUte the distributor to al1.gn the two marks.

D.is tributor Ma l"elli S 125 C (50.10.256.3)

,A!J'o'lIHI.[ !:':(;I«C~ lEN TfW: Ols,TRlfjl,ltgli '1I,Io1l ANTltil'Q ~ I)I~tiil!iiVT'DI'!i:

~ Z<!£j~ ~:isa .~

DI~lR le~T[M! S,I'£~O (R P.t-I) ~I,iil ~I ~TR!e'llTORE, A~ l'

Fi.g. 11

Automat Lc advanc ill vari8i.t.ion

Ef\lG.!IIi£ CH.A£[s

GAAO lIM!ti PO SUi. Min'ilRE

10' ~~w~tV7f~~~ ·f';~~ ~·~i· "i1rilllll

t',.SLF- .. - , .. ,."':." '.,..... I

r~· {::"

~ _L~~_~,~~~/~~~~~~~=-~~~+-J~~-..&

-2' _-_ :~?~ .. '/ ~ jDD~ ~ooo SOOO ~5()lj ~ 'toil

€,N~I~[ AAM'

t,OD G1RI1t-!!IN,

-'10'

Fig. 12 Ignition advance diagram -Ignition advance full power carr fed out with normal points. ~ Igrlition advance during

the cycle carried out with retarded points.

Characteristics

Nonnal speed. ope.ra.t.ion: Rt 0.( Opening angle: 2.8 -.1 2 Co.

Closin,gaqle: 320 t 2.0..

Low speed operation (Rl connected to R2) with angles varying by 50 30 l (dist~ ribu tor aDg I.e) (d.egre.ed 0 f ret.a.rd o.f R2 ()'tHt i1) ~

• ..J: Opening angle: 220 30 t± 2.

Closing angle: 370 30 ,t 2.

llii Microswitch aot.uated by carburetors Rl- Principal cQ:R.tactl!l.

R21!1! Secondary contacts.

cont I'01 leve.r.

Dwell- 53.5% (IU) Dwell- 62.5% (1.2)

Timing I) f ecneact; pe fnts Rlin relation to R2:

Substitute the 'isr:r~butor rotor with the spec.i.a.l one marked with an index mark. Attach a Pl'ot8ct:or scale (gonicm.eter) on the distributor housing

(see .fig~ 13) and. connect: the ohmmeter between Rl and the distri.butor hoaa1.ng. Rotate the distrIhutor shaft until the meter indl.caue that Rl 1s openinS

the circuit and check the amount of degrees on. the scale.

Then. connect the ohmmeter between. R2 and the d 18 t rlbu t.ot' housing and f urthel' rotate the distributo1:' shaft until R2 opens the ·cJrcuU:.

The difference in degree.s read on the scale should be 50 30t •

If different readings are obtained. adjust the FHlative position of Ri--'R2 by loose.ning the bolts On the dht.:r:ibutor housing and proceed to repeat the operation~ This check must be carried out: wtthoq.t removing the distributo r from the engine. t taking cal' e to d iscouue.ct the contae ta ·of the elec. t 1"1.cal system and substituting the normal rotor with the special on.e.

'The rotation of" the distributor shaft can be. obtalnedby moving the car with a g ear engaged. ~

Fig .. 13

T1mipg of the d.1std.butor ~

4,6

Fig. U Nomal and emergency ignition diagram.

1- 2 Erne rg en c y 1 gn i t 1 On. cennec don s 3 Cable from coil to distributor 4 Normal coil

5 Em.erge:nc:y coil.

Dinopl~~ electronic u.n1.t

The engine normally 'OpeTat,es via the e Lect.ron Lc .if:,l:litiQn system.

On::')' in the event of i r.l"e.guhr runn Ing of the Dinoplex unf.t , the e l ec t ronf.c ignition systeffi can be by-passed.

For this purpose. move the sr .... lp-in p Iug 1 i nt.c t he seat 2. and thl'i! terminal 3 from the normal coil I! to the emer gancv coLL ~.

The tetLllina 15 mus t Dilly be moved to the 'I Er.lergency" posi t iortl,.,'i rh the igni ~ t: ion fOWl t.ched o f f e-

t~d~r the~~ conditions, ignition is via hattery. distributor and ignition C.O i 1. \,'hell the ern c ':"'r Qt"~Y ir-;n:i t ion is St>!l,t r.il(2.d or: the prm CNm t er is not ."To:·U.ng.

l~ 1; U. 11 v~d. t.age 19n1 t Lor.. : t :;'s c;;ngp-r,)us t.o tJHKh t he high vo 1 tage cab La

tf.!i~J.n<lls w'nile u.!~ F:'n'~)~e is runniup" \~.l '·!N'k on tt~e.('qtliprne.l1t should

h<? ,~aTd.ed out wH h l"Jw 19ni t Lon key removed,

:--~.' .. ' ((~)

Ir-~

1'2) ! I . i

. ....:;III~~I~ '. _ ----~~ --- J

~ .. In Ii

Y~t~ : ~

I I

r4'i I '-_ ....

., F""-+_--~--':i'~,9---:

.

).

I ~ ~~h-_,

• ;

H ,

f----I;o- ~T ... - ---I"

0)

T .'

C0LL E. [.~ ~E. H rl I ... ] f Uti tj.(lNJI!oi E. I.j r D l10fl MAL ( -==-- Mil II IrJ ~ I I(;t.ill' ~t.i Ito!! R I N 1.0 t, i, r uuT

n:lI.. U.AME.I'o TI IN F"Jlt~ 'J,,.,.#.l.It,,nl D'L"'lA~tN~1, - --- [!;tr~::'fhcr 11)1-1: glOH "",IRIj;(, _~,o.'Jr.

Yl~.~. 15 ]1.j ncpLex T,..1irinp, di;;,.gram.

1. trnergency c~11, 2. ~atterv. J. Hicr05l<:1 t.c h, 4. Hi,sfire pre'~~':on t 1 on m1 ern swi tc h untt

N. SS. 'inE'·('~C14nl1, 5. Elecl~Qn~~ iRnjtion, fi. Elcc~rDnic r.achomc t e r . 'I. ~1i1t'e.111. distd;; lJ t c r , A. ;) r "l r]I r 1 uf s , 9. ~D e c~· t r oud.c ;i f~n..L t i nn co i 1 ~are:l1 i

BAl: :~ r1() A I 1 r). ~'1i c r o s'.,:i t ch contcct-normally closeJ.

Fig. 16. Trunk location of car I s air pump electronic control unit.

47

1. Speed ad.1usbl1en.t.st::rew·.

The un.ft; is located in the baggage trunk.~ It con~rpls the electT'omagnetlc: clutch of the air pump to which it is coanecced , disengaging the pump fn)m the enginE! when the rpmts reach approx1mat~ly 4200.

The unit does not require any maintenance. If necesaerv, work can be car:tied out On the elec tromagneticc:1utch disengagement control via 'H~:rew 1. By rotat.ing screw 1 clockwia,e, the-clutch disengages at higher rpm 1 s ,

Do not turn the screw down t.co much 80 aa, to bring dis,engagement of the. clutch helow 4200 rpm 1 s , in order to stay within tb.,e ope,rating 11m! t8 and to avo:Ldpossible damage to the und.e ,

ATTENTION

Avoid having the clutch dise.ngaging above 4500 rpm ·8" since above 'these limits the pump could be dUiaged.

... 1

OC!)

1,tllm.

Fig. l.8 Ail' pt.i:itllp C lu re h 'wir:i:ng d :L.agr am •

L. Air p'lII!lrp fuse" 2. Dinoplu1 3. Con~rol unit, 4. RelaY'~

.5 • MarelH. di stri bu t.or • 6. Air pump clutd} solenoid ~

AIR INJECTION SYSTEM

Fig. 19 General layout •

. L Air pump.

Z. D~verter valve.

:3. NQtl-retu;rn valve. 4- ~ lnj eat·on .

The sys t em cons'i.st s of an air pump (comp l.at e with supports a.nd at.tachmenu) t anelectromagnet:tc clutch, 1.nj ec t or s (one for each cylinder) t an air exhaust va]_ve~ two control valves, air GollectQ['s, and tubing for the connecting of the var Lcus compoll.e.nU.

Genera.l maintenance

Every 5000 Km , check the condition and tension cf the alte,rnator belt as; explained on p. 49 (COOLING chapter).

The belt transmits motion to the alternator which then transmits it to the air pump.

Eve.ry l O ~ oem Km, check for leaks bettJeen the connec t Lons and the ve lves •

Pig. 20 El~ctromag~etic clutch.

Fig. 2] Tnj er:tors.

Fig. 2.2 Clutch d.i,agram •.

49

1 t

'---.---~--+-1. , .

If exn,a:us t e~plot1ons Bre nc ted ~checkthe depression tube connec ted to the exhaust val vii! elindna t.ing any occlusion.

The control valve ac·td to impede the flow of exhaust gas fromreturnin.g eo the pump.

Every I 5,000 Km. chec s t.ne clutch d i.sengagemen t a.c e Len ,

Accelerating to 4200 rpmTst check that during the period of acceleration th~ dutch rena ins ar sa-gad> this Lnd Lca US rhar the a.ir pump h functioning (to check this, it ir suffi·cient t.o re.move one of the rubber tubes which de 1 "",ve 1· a~"( to the inJeclu1:~ fnm~ the d iver rer valve and check to see whether pl~~"suri aed a.ir is coming out of the tube).

Over 4200 rpm's the clutch must he disengaged, that is, the air pump should nat be delivering air.

Clutch clearance: between 0.6 + 0.8 1I'I!m.. If greater. remove the magn.etic pa.rt of the clntch using the proper tool; remove the clutch shaft spacer and replace. it with a. thinner one , thus reducin.g the c l.eaeance .

Air pump

The air pump (fig. 23) comp'resses fresh air ac ross the injectors and the ~e1ated t ub1ug in the exhaus t system. This air inj ec t ion .ign1 us the uncombustible part~clis Df the exhaust. reducing the HC and CO level$.

Fig'. 23 Air pump unit with clutch and generator.

1 .• Air pump.

2. Electromagnetic dutch. 3 .. Generator .

. j>

50

:-'ig, ~ 4 Rencval; of fan unit ..

Air Fi1 ter.,

Fig. 2£./ r Fan uni t assembly d1agulll,

Th@ design of the channeling of a.lr towOl'rds the pump fan (fig. 2.4) also allows for the fl1tering o~ incoming air. The direction of the fan·s rotaticrn centrifugal force forces impuritie,s to (;.,ollec.t on the walls of the fan. In order to clean itt It is necessa.ry to remcve the fan unit from the pump. This: cper-at Lcn can he ·c.ar--ried out af ter removing the pump c Iut ch unit and genera t oz Erom the e:ngine.

~arning;

I.n r.ea~sembling the fan unit afte!.rcl.ean:lng,) follow these directions:

1) The f an ~ s Lnt e rna.l oosi tinning must be ·,.Ie11 sea t ed in the exis ting cent ar Lng ncd.nt located at the cen.terin.g pin (f ii3. 24 i 1) .

. ;:) Be sure that no i.mpurities enter the pump thr ough the fan slots.

Diverter va Ive (Fig. 25)

The exhaus t valve. t"'H~ ,1 ac tuat ed by a. t apfd dec r ease Ln pressure in the collec:tor. imped.es the 'i; rave l of air to the injec tors. preventing any explosions in the exhaust system du r inf; the period when d r1 che r IRis cuce is required • The exhaust valve also LjOYfH:!S <l safety valve which a.l.Lovs the air ft"om the pump

to be bypasaed i_f ':.h~ c Im.ch does: not dj_t'len~al'.e ;'It hl.?,h rpm IS.

G.NSOLINE VAPORS r."~T5S.IDN C(lNTROL SYSTE:1

De sc.r Ipt ion

In order to control ?asolin~ vapors evapOratin~ from the gas tankst they have been t_hanneled t h rough .a f.?ste.m of tubE'_~ to an Bc.tive.carhon filte't" in the enf_!:i.ne c.[)m~art:ment. wjlel~·e thcy are absorbed.

Durinr. the eng:; ne opera t • ems j a flow' of fd.U"rr, .1.:i.r l"er,enera tes the carbcn component 50 that it ext re • c t s the gasoline vapors and channel s them into, the in.take col1f'cto['s.

The gE'IH~rl'll Lavcu (: f:<:, f n d .":..'H ~d in fig. ?l,.

Fig. 25 Diverter valve in open position.

1. Exit tubes. 2.. Intake, 3. Air exhuast~ 4. Membrane,S. Low pressure tube.

Th~ :gyste.ttl Ls e$sential1;' made. up of the following componenr.s r

- A perfect seal ?;a~~ t an k cap.

- Limited capacity ~as tanks (62 liters).

- Outlet tub ; ng wi th vapor se.parator.

Three-way va Jive w!1ich rrovides;

that the tanks aT@ a1·...,..3.y5 under light pressure ~ allowing of :incomin~ air to continuously equallz~ the pressure and prev€Qt lew pressure CQficit t ions; the :::lit"linaUon of e.xtremely high pressures through a safety valve.

- An air intake wi.th an air tight seal valve.

ADDENDA to: AI R INJECTION SYSTEM~-Ge,neraJ maintenance (page 43~9) .

Every 30,000 KIn. discOIll1e,ctthe overflow collectors t loosening the inj ect er s connecting bolts. remove the inHctor$ and proceed to accurately chan them~ eventuaU.y re,phctng the injectors if necessary.

5:2

Fig .. 26. Fuel vapors emission control W1it diagram.

) ..

1. Gas. 1"iller cap, 2. Ca.l"'ouretor butterfly valve, fuel return line .• Exhaust hot air intake tube, 4. r-".ax:!mu f'ltel level, ;; ~ Fuel feedpwnp, 6. Three-way control vave,. 7. Liquid vapor separator, 8 .. Fuel return tube, 9. Acti.va.ted carbon flUe!'.

Fig.2_7 • ~U€l van:l'rs separator.

1. Vapors exhaust, 2.Vapors intake.

t (6')

Fig. 28. Activated carbon filtel'~

~" Activated carbon,;

2. R.egeneratin&: air filter, ).0 Synthetic filter, 4. H (lit rBi~erllliJ·rating air intake"

5. Fuel vapors intake J

6. TQ ruel feed intake tube.

JJ.RINl'AKE

The air intake unit betlleEin the filter carnidie container am the air intake contains a valv'e contrg.lled. b1 e!liine oil ,rea sure ..

Wi th the eneine runni lli, 0:11 ~rei5 :sure keeps the val v,e o,en Jermi t t i"i air to enter the carburetors, and when the eni1m'! is turned oft J' the-valve closes, due to the falliOi off of the 011 pressure., thW!! not allawini cas vapo,r's to escape. At the moment of startl,lii the eneineJ' the lower pressure caused by the starter a,cti o n opens a small valve lit 1 thi nthe larger val'lte so as t,o provide suff:L,cient air fit!r the st arti ne or the engine •

53

Attent10nl

If duri Fli the rwmi:na: of the fll'1iinl, the oil ,re s sure, should suddend~ fall, this may be du to an oU leak in the air intake valva.

Tne fll'Iii ne w111 than is utr ar il not1cea hI. decrease of efficiency in that the val~e will close not parmi ttinl a flow of air into the e1liine.

Quickly sto, the cal', clr:)fH9 ·off the eniine to air intak!e oil de 11 very tube, check the oil level for ii lower readilli, ",rd take your car in to the Ferrar:1 dealer and have the fault remed1ed~

I I I

ct

F.ig.. 29. .Air inta k e.

1. Air filter co ntd ner ~ 2. Juid e t. ube , 3. E::i<tar nal valve in closed pos i ti on, 4. Internal valv·e in open pos.i Uem, 5 ~ Internal valv',e, 6,~ Carburetors air bOJl:j! 7. Valve contrJl piston, 8~ Oil delivery tube.

54

Position l.

F:t:"Q!Il tank to act::il:vat.ed a8,rbon f11ter:~

Posi.tlon 2

Arnblent til i.r to tank.

Position :3

Fuelii:a se s tram taM: to ou.ts ide (eJCc811sive tank pressure),.

A~From. tank; B-Toacti vat.ed carbon iil tel', C-Air int~ke .for tank,; p ... Security (pressure relief valve) ..

55

EIHA.UST SISTEH

The exbaust system has been defligned to meet exhaust em:i.ssioruscontrol limits.

Make sure t.hat th.e exhaust now is properly controlled in order to avoid dS!Iliai\:e; due to e.xcessi va heat.

The ex-haust conn.ections mus't be pert ectly s soured.

[ ® ® ]
I
'II -.,J

II ' -

,It.. ,

: I

_ .. : i1 'I i

...

n "

..

Fig~ 32. Electrica 1 1;!liring diagram ...

1. Sealed beam li"hts-'_1 •• Dd. dip beau

2 .. Front side and directional

lights .

31' FO;5i: lights (on requ.est)

4. Directi en indieator li~hts 5.. Cooling fans mot 6l"S

6. Temperature sensitive switch f.or·

radiator rans

7. Heating ;\r,entilation fan motor

8. iIarn compress;)r ~otor 9.. Fro'nt trunk light

10. Battery

11. Electrio~l p~nel

12. Circuit rusee ( 8 valva box) 13·~ 8.amp. !'o~ lights ruse

ll+. Fer.nanenu..., Ii ve terminal. board 1$ .. Brake effi ci aney li i ht rel.y

(SIPEA. T 5210)

l6. Alternator regulator

17 .. Pow.er¥lindO'lls control oircuit 'relay (Lucas J.321J)

18. Direetion:;l.l flasher' unit 19 II Radi.a t:)r coo ling fan l'e lay

(Lucas 33213) .

20. Horn relay

21.. :·iain beam, dip bEla];. anJ dde

lights relay ~ Lucas 33213

:22. rCil ligtt switch - on rC'.;:_ ':1e1.,;-t 2')« ~~i!Jer ~~~ :'~ler s'~i t.cl;

24. Wirer 'W:.sher .nct or

25.. Stop 11.:ht .wi tc h

26. He a ti~, IT ~lClti bti~ fan ;switch

27~ 28. 2~. 30.

Ci;;aret v~ li!:hhr

I ,.""t ·,'..,e-~t· 1~ ,.1,": ~'1'. ,,,.+ _,.I.

~'.!KiI u .,1,.. · ... Ci.L.a.I". ... ~ G'iu"1I.J "-'1j"I; ~

Rh~Qstat for varyir-.g wiper In::.tl' It.,'lY~_',~., liGht.'],

Electr:Jni c rev C cunt.er-

I'!ain. bear: l'U.lrr:c.ng light

speed

32~ 33. S~~G~ o-ne t ~l' 34.. Side light 'Warr..dng light

3.5. Direction indicator Vl8rning lights 36~ Wiper aoo screen washer 1,ever·.

37. Direction indicator lev~r

38. l1ain beam, dip be<lJi'. and head il:.ar:LJ'I .fla;sh l€ver

J9~ F.elay sr,.;i tCll for 5ide, dip and Jll;;.Iin

bsam li[hts 40 .. Horn button

,41. Revers e light sw itch

42. ii'uei l~vel eau&e tl'<lIp.sf:'l.itte!" 43 .. Eng-ine ccmpart.nent, light

h!~. Al i-erna t or

45.. Fuel pUJ7lpS ( electrical)

46. 47. .48(0 49 to 50. 51. 52 .. 5). 54. 55. 56. 57. 58~ 59~ 6o~ 61 ..

Starter lnter10r light

Oil te~rl;·.erature tral".sm1tter Water temperature transmitter Spark plugs,

Distributor

Emergency lii;;hts Slil.1. teh Emerjlency coil

!lectronic ignition unit e·:)il Dinoplro:: electronic ie-nition uni t Reverse lights

luggage ecmpar tment, light

R®ar direction indioator lights Rear position and stop light.':! Li 06 ns e plat a li;:J.it.s:

h~ni ti on swi t eM Istee:ri:me lock irw:ieator control :3li1itch .Brake rail ureinlii,cator liil:ht Hand brake eniioi911ent ll&ht

rr II ;T "switch

L~ oil pressure "Warm>\;; a.nd. trans- . mitt.el'

669 Oil Fress,ure Gauge

67'. Ir.terior ventilation fan 68. Interior courtesy light

69. II n n .switch

70 .. E rake fluid pre,8sure control uni.t

71. Cigurett e lit;;hte.r light ~tch

72.. E.'?lergency llgh ts c antrol defIectiOBl 73. PO"'der windO\~s control motor cot'fl;'1t'utato!r 7 4. rO'~el' wind,O";.IS moto.r

75. Alternator :protection fuse box (60 and 8a;;np.)

1i:n1ti:Jn key indicdor

1'1 Ii" ii

76. 77. 7S. Distributor p'oin.trs o,en1rli retard

m1croswitch

19. Air pWllp electrol'lilaenet1e clut,ch control

80. Electro,1Tli1in.et1c ol11to.b ele'ctronic block

BL Relay far 80 (LUCAS 33232)

82. Gear'-box engaged switl:! h (car net :1.n Motion)

8J.~ Driver's Beat belt switch (on when belt not in u.se)

BIJ. Pa,ee,enger's seat Pitch. (off when !I.at is occupied)

85. Passenger's seat belt switch ( on when belt not in use,

86. 5,eatbelts not in use ... -I!!ound indic ....

tor

f7. Seat belts not inu~(I~-indicl.tor liglit A B. Dashboard inst.rument light s

e.9. Seat beltecontrol circuit relay (SIPEIL T 5220)

90. Electronic anti .... oscillating unit

(mer 0 wi t,ch 78).. .

retch

59

REPAIR AND MAINTENANCE TOOLS

Design Number

ENGINE

AV • 617 A,V • 50,8 A - 60;,17

: 361 . AS ·4426 . 312·As·_' 5 514 . ! 312.AS· ~513 J l722-AS-5B97

! 706·AS· 9560 \ I 706AS-9500 A j

AV. ;':2j

152·CS· 7148 152.AS-J 149

I

I AV. 468

13 r 61-AS. -4 '.36 AV, 240

I A, 90355

~ 706·AS·9562 A, 60077

A 50213 A. 90]C7

A, 60346 612·AS· 7084

, 622·AS·5422' , 622-AS·5960 'I AV. 466

A_ 96213

Ro tat ing engine mount .•

Val ve S pr ing s removal and as,semb 1 y tool. Wooden bench for cylinder heads valve work.

Piston/rings to cylinder sleeves inse,rtiontool (piston .~ 92.5 mDl.) • Valve guides el!r.traction tool •

Valve guides moun Ung tool.

Engine - timing protractor/goniometer with gr aduat ed disc 312-AS-7006. Valve adjustment. shim discs 'removal tooltw1th camshafts in place.

Connee ting rods bolts socket (used w'1 th torque wrenc,h).

Tool gauge for measu.ring adjustment shim dd.sc.s thi.ck:ness. Zero-setting gauge teol to measure adjustment shim discs thi.c.kness.

15mm" socket for cylinder he.ads nuts (u.se. with torque wrench).

Man.drel fot' checklng camshafU, mounting. Main support bearings lap grinder •

. Engine valve guides bores p Lanar (amm.).

, Ring for oil retainer assembly on rear Bide of c'tankshaf c , Connec t Ing rod retaining tool during wrist pin bushing reamin,g.

Connecting rod bushingremova:l and reassembly punch.

, Expanding reamer (2Omm. 0 ) for connee tingrod bushing hole.

Piston wrist pin removal and reasaemb ly punch , _

Piston wrist pin retaining ring assembly tool (piston 0 92.5 mm.).

, Cam!:lhafts drag pins extraction tool.

Camshafts drag pius as.semblytool. Cam~haft6 timing tool.

Combustion chamber depth-t.o cylinder heads plane gauge.

USAGART27BL Spark plug socket t.oo l ,

lS2"CS-1431 Val vee guides se at s checking tool withs topper (37.015 mm.·~ ) •

AV 476 Boeke t for f ast.en ing HeLSET damper (use with t or que wrench).

j

lA, %13,1

l. A_40206/130l A_40207/813

A 94058 A. 94041 062-AS-8878

AS -'9798

--------

Ring gauge (92.. 5mm. ~ )fo'r zero-setting measurement of cylinde.r sleeves.

PercusSion extractor to be used with tool A.40207/813. CI'ankshaft-clut'ch guide bearing extraction tool-abo f.or removal of rear support of timing shaft drive.

Mandrel for count er s inkfng of valve seats in cylinder heads. Engine valve gu.ide holes stem brace (8 mm. ,~n.

Ca'['bul!:.'etor~ butterfly valves 5ynchronhation tool (at 1500-20,00 rpm).

Top Dead Center {r.M.S.) checkioR tool.

706·AS··6581 Input shaft fasf.cliip.g un.it for a.ssembly of individual cenponenea. 706.AS .. 66B4 'Bearingmounting tool.

706.AS.6683 Rearing ca.ge mounti.ng tool.

706.AS.668.5 Baar Ing tool.

175.A;S.5568 'F.a.st.ening tool for s.elf.-locking ferrule of inpntsha.ft rear ~ bearin.g •

. Gear drive ferrule fastening tool.

Input shaft ferrule tool.

'Bearing mounting tube.

Bearing mounting tube. Bearing mounting tube.

t"e.verfork.s to gear shift control al1gnmerl:'t tool. Outpntshaf t hnule tube.

Oil drain plug tool (socket sig;e 12 DIm .• ) from car chassis No. 0'2132. {To chassis number 0'2130. tool AV 477)

A. 96306

A 60544 A. 61001112 3S .. 0.218,6j 35.021158 35021863 35.022042

...

I 706~SA6663 706-ASy5665 . 706-AS·6666 7'O&ASA6667 7 06~AS-6668 ~06·AS· 17MJ 7 06·AS~ 7238

706·AS· 7 45 8 706·.AS·6705 7 06·AS·6 679 706·AS·66S0 7 06·A.5.·6 578 706.AS·9561

I 706·AS·6527 AV.477

Graduated r,e:ference dhc for ,controlling timing in mounted engine.

I ere u ~be 8m tool for it,ff-iugl' e,!lgitl.e •

Rotating en.gice mounts fa,stening frame members.

'Cylinder he8l!i,s valve seats re.Burfa,cing cQuntenink (45-). 276countersin:k fot' reduction of upper part 0'£ intake valve I),eat size.

I I ~~Ocountersink fot' reduct ion of low,er part -.of ,V'aive seats.

I 27·counte.rsink for reduction of lower part of exhauet valvesea.t si..:·e.

CLUTCH

'Roller cages insertion tool.

Oil seal ring ins,ertion tool • Bearing insertion. tool. Beuing insertion tool.,

Roller bearing raees mounting tool. Clutch shaft I.:Q01

Clutch ~haft extr~ctor.

GF.AR BOX

175.AS.5067 Pr e Ioad meaSUl"emen,t pulley.

706.AS.6704 Pulley ext€!nsion.

165.AS.5763 Spacer for mounting of differential for preload: measurement.

,36S.CS.5341/A Tool for determining thickness of preload washer.

365 ·CS·5 341/b S.&mp Ie con e •

I 355 ·AS-:5839 I Sid e covers 0 il rin gs rno un tin g tool.

365.AS-5764 Tool for mounting bearings, to d if ferenti.a:l case hubs.

7Dt3-AS· 7237 706~AS·7396 505·AS· 7 394

AV.485 705·AS·90 rs

DIFFERENTIAL

STEERING

Steering wheel housing hub extractor.

Nut for removal of steering c.olumn from suspension upright. EX.tractor fQ'T removal of suspension upright ball joints shafts.

Tool for tightening hub to stening wheel se.1f-loddng ferrule.

Steering wlieel hub €;xtractor (fro'm chassis No. 01118).

61

~-----~--~-- SUSPEJ)lSIONS'~--~~---~~-~~--~--~~~-

125434054/55 125.,84054

706-A.5·956 5/ A , 7 06·AS~9 009 / P , 506·AS·] 394 706-AS-9566 A.74UO

Front. and rear whe,d. mounting hub extractor. Extractor bolts.

Shafts for posit.ioning of car static weight without ]nOUQ.ted shock absorbers.

Uprights ball joints shafts extractor.

Shock ahsorber $pring removal and a.ssembly tool.

10'01 f'or$e~tlring of uut s : on front uprights and rear wheel suppor t shafts.

706-AS·9002 706-AS-9006

FOR CARS WITH CHASSIS NO., m n s ON

Rea'r whe e1 suppo rt s ha £: t ex t r acto r .'

Extra.ctor for removal of "ear wheel hub from. shaft.

lerl'ari

VETTURA

~p.,[', '"ton. Pal2:.e
1 3
2 9
3 45
51
57
69
76
as
5 91
6 99
7 109
117
8 123
136 ! I
140
9 143
10 1.Il!! GENE'RAL DATA

ENGINE

LUBRiCATION

COOLING GAR.BURATION(FUEL FEED)

CLUTCH

GEARBOX (TRANSMISSION) REAR AXLE

STEERING

FRONT SUSPENS ION

~ :

REAR SUSPENSION

I SHOCK ABSORBERS

BRAKES

WHEELS AND TIRES TORQUE SPECIFICATIONS

Et E eTRI CAL EQU I.PMENT

CHASSIS

SECTICti 1

G ElNFJitAL DATA

PAGE ;;

6

'7

8

PRINCIPAL DATA PEflFORKJ\NCE CAPACITIES

IDENTIFI CAT I ON DATA

R.EPLACEMENT PARTS

8. 8

KEYS DATA

4

.. • til

....

·t· -..

...•.. ;V

~ ...

" f

\.

. '.

')

" \'

'V·.···

,.

',.

GEN,B}tAL DATA

PRINCIPAL DATA

IDBm'IFICATION DATA

Chasis type Eng1,n.e type,

E:NGINH:

2460T 135 CiS

tra.nSver se position 6 V 65° 92.5 run.

60 m:m. 2418 em3 9t1 195 76Cio 7800 23 kg.

5500 26.7

Number 01' cylinders Bore

Stroke

Pi at on D lspla cemeli t Com;pl"essi on ra. t i 0 Maximum b. h .p • Equivalent r .p.m" Maximum r.p.m. Maxi'rm:un.t OTQ_ ue Equiva.lent r.p.m.

Taxable her sepower (1 taly )

CUJTCH

Singl~ plat€lt dry

GEAR BOX

5 forward and 1 rever se gear Synchroni zers on a.ll forward gears

Opera ti on by cent r,a, 1 flo or Ie ver moun ted. in tunne 1 •

Oscillating semi-axles Cylindri cal reduct ion coupling .. itt! heUcoida.l gear

Red u cti on ra. t to, 161 S8

STEERING

Ra.ck and pi.nion.

Steering sh.aft with center section mounted w.ith two. oal'danic joints.

14inimum steering dlameter 11.40 m.

equ.al to 3.1/4 stearing

wheel turns

5

FRONT SUSPENSl.ON

Independently sprung wheels.

Upper and lower transverse w1sh.bc:me suspension anns, coil springs, telescopte hydraulic dampers and a transverse anti-roll bar.

REAR SUS PENS ION

Independently sprung whe,els.

Upper and lower transverse wishbone sug,pens ion arms ~ coli springs. telescopic. hydraulic dampers and a transverse anti-roll bar.

BRAKES

Disc type on all four wheels with independent front and rear circtli ra, Bonaldi Master Vac vacuum brake servo. Braking regulator located on rear circuit. Mechanical hand brake unit positioned on rear brakes.

WHEELS AND TIRES

Light alloy wheels Radial type l1ICHELIN tires

14 x 6~

205/70 VR l4 X (tubele,ss)

ELECTRICAL SYSTEM.

Current Ba.ttery

Al t.erna t 0"('

12 volt Ah 60 F 4207930

Starter motor ~1areH i MT42E

Dual cont~ct6 distributor S 125 AX 150

GO! 1 MereUi BZR 205 A-12V-8F

DINOPI,EX electronic unit Ma;teUi AEr>101-])A (capacitive discharge type)

l.]Er~HTS

Gar in driving condition (filLed with fuels. 0 Ll.s , t.'a t er , spar e wheel, tools

and accaasor Le s) 1080 Kg.

-rear axle

maximum alloT,.labhweight 800 Kg. -front axle

maximum allm.,rable weight 800 l\g.

:fumbe r 0 f sea.t s 2.

6

110:1 IIlWQ. S poeads on open road, wi th two pal sene ers , it 000 road. corxl:l ti OrIS and enaine fully run-im

in first gear. • .Kmjb 66.5 in second gear... • III 96.5

in th:1rd g eEiI.r • .. ., ~ 1) 4.

in fourth ji:€!ar.. • 1:1 Hll in fifth irear. • • n 235 1nreVeI'S8 gear.. • II 75

MD:1Im.lJQ .steepneelsQf e:1ope tha.t,· ean be Cll.r.1,lolith road ln good condi~ ti on. am engine :fully run .. ! nI

in ru.t "ear. • • • .161

in second iear~ • • • .35%

in 'third ,ear. • ., • ..2;%

in fourthiil:·e'ar~ • ., ~ .. 187.

in fifth ge~.r.~ • .~ ~ • 9%

1 seconds 27 :2;10 second:;!

Stand'itli Inile - f1 nal s peed 2 6B /10: s econdsat 19akm/h

Fly1 ngnd 1e"0'or1' es;pooo.ing v fll oct ty ! 325 km/h

J

o ... ...

~ 14.25

1

Fig. 3. Side view of as semb l.ed engine and compcnan t s •

ClI.PACITIES

"I~t-em-",,-s~t-o""""b~e--::'fi"!'·l=-:l~e-. d':""' ---~ Quan,t~ ty Fuel and srr types,

~--~~~~--------~

it. K£!.

11

Super premium, 9all 00 octane

70 12 - 14

rr

II

'Fuel tanks

with a, reserve or Radiato!, eng.ine and cooling

Antifree:ii!:€ mix,ture (2) SHELL oil (4)

,SHELL SPlRAX HD 90 or 'EP 80 oil

SHELL DONAX-SAE 70/R3

17 7 4

it

n

II

system

Eng,i,ne and f 11 tel: (l) Gear box and differential

0.270 0.252 0.180

0.300 0.280 0.2:00

Front braktng cit"cui t Re.ar braking ci rcui t ,Steeri.ng gear

"Front hydraulic shock ab sc rber s (each unit)

:Real' hydraulic shock absorhers (each unit)

'Windshield washer be t t Le

'SHELL SPIRAX EP 90 oil i

0.190

O';t171

SHELL DOMAX Al

0.234 1

0.260 1

W'ate:t' and cleaner mixture

'i) The total capacity of the engine, filter an.d tubing is 8 liters. The quantity indicated above. is that whi,ch must he replaced w-hen the oil and .filter is . changed, aE! -indicated on page ,43.

'2) For exter_nal eemner aeur es below 0 C. add SHELL ANTIFREEZE in the follow:hu~; quantities: f_-l O. C. =It. :3:75;1 -=-i 581 c. -1 t. ii,. i-d. ~20a c. ::It. 5 ~7 ; r~30Cl' C. "11::..6. 4 ~ 'J

! 3) For effective windshield cleaning one container of glass cleaner is recommen~ ,ded in summer and two in winter •

. 4) F'or tempet:.aturea to -i5 0 C. use oil SHELL SUPER MOTOR OU 100 For temperatures he-loW -15 (I C. use SHELL X lOO-lOW30.

7

./

~

A. Chassis ldentifir3ri.~ numbe r

1, Pos i t1.oo. of gen~t',l1 data C. Eng! ne number. ~'l'Ut>.

SrA~[ PARTS

Spare parts orders mu ..• '~ b t; ~;t1nplied with the f 011 f".-Ilnr' III forma t ion ~ - vehicle model (conn.r,'. L :1~. !"-ame desJ. ~na tiCJlll

-- chassis type and n·l:I';· ,.:

- engdne type and nl.,··' ',"

- spare part nWL'lbe.r, ( L.ll'en -om spare pa.r t s c.' t·p, - Cf~" .

VEHICLE KEYS

Each vehicle is supp 1: ," -, '~ :-:. two ~.;e L~' C) ~ kE':; S C) f 1:\0.'0 key:;;; each} for: - Ignition swi teh t f; reo·' •. H' motor and Va r Lous b igr:~c Lj-

- - Soar arid trunk Leek s .

Each key Ls stamped J;;n c h <"!" tde~ t Hi ca Han numbe r ,

SBC'rION 2:

f'ase

PRINCIPAL, DA:TA

n

IRREG1.l'LARITIES AND RmiEIDn:S

13

RE,MOVA1 ANDREINS,tALLATION

1.9

PISTONS AND OONNECTING 23-

RODS

CRAJ!.rKSRAFI - MAIN :2 7

BEARINGS

CYLINDER HEADS ~ VALVES - 31

VALVE GUIDES - :SPRIHGS

'I'::HUNG· 35

REASSOO1Y AFTER 4·0

ENGINE RECONDITIONING

ENtUNl'; STAND AND ROAD 42

TESTING

F :E.NAL en E:CKING AND 'TUNING-UP

43

TORQUE SPECIFICATIONS

43

1,0

ENGINE

•

11

.• page U
,., B
~ •. '.
n 19
., .
II 19 . ,.

Coni~al piston ~kirt section Retainilng

Oil scrape!:

Slotted 011 ~craper type with j,ntetnal spring

Chain

Integral within cylinder h~ada Mounted atop cylinder hea01~

135 CS 6

92.S 60 2418

9:1

iSIS

760'0

7800

.23

5500

.26.1

4,

Thin wall eype w1.tb anl::.l~ft"ietion lay~~

2: o~ ·the rear ~upl?orlt:

Clockwl,se

Thin waUtype wi,th a.ntifriction layer

Fre.e~floating type td thin the conn.ec U ng 1:',0 d 1"; .<;I.S e and thepl~ton

ENGINE

l'ype. •. .•

Number of cylinden, if of 65°.

Cy 1 ind et' dlam:etet 1p i se.,on tra.vel. ';lotal capacity.,

,Oornpr,ess ion rat ie.

Na.x1mWlil horsepower " a, a.. E. net:)

I Corre.sponding rpm's .,

Ma.;.;::imum ·rpml s· ..

Ma:xtlJtiUTD. tor-que.

e orr e:spon.d.ins rpm' R.·

:f{ated :fhcal honepow@.:r (lcaj,y).

. ,

,,1tIIIl .. .IIlml! .¢'IiI!~

.'

.Kg.

.cV'

CMNK8RAFT

Number' of main bear-lI..ng ~uppm; ~s M1iI1n bea:rings .

Support rings

C r lin ksha f t 1:'0 tat io'n

CONNE.crING RODS

PISTONS

Type

Fl,il'lg for first groove Ring for second p;roO'vc: lRing for third grO,;'lve

l?in. boss I Fin

C';)r'lt};oi '·''l'.lver

I C::mt5haft.s and ] obes

--, I

I Firing iOde'I

Ini.t.:ta 1 t imi ng .~dv ~~Ct'l Cen t rifuga.l But'O!lla tic :1d vance ,( on eng ine)

I Distributoz points gap Spa.rk plugs

Elle!cuode g2\p

Di,amneter andthnad

I Fuel pt.mlpS

Fuel pump.sc ontrol C8Ll·b~l!:'letor.s

.Ail' filter

C1!:'ankcas e vi!nti lati'Ol'I.sya,t:em

WiRICATION

I

iPumP Filter

Pre s Sur e 11m! Ung v.ahe OUpre,aure

o 11 coolin,El

Type

! ST AR.n.NG

Type Eng.agemen t Control

2 el,Qctl'i.c (Ben.dix) Via ignition key

:3 dClal:~·thrlo'a't Nilber type 40 'DeNF I "I

Sing le cBrUidge type

Witb 11ll:l1Ung valve in. air intake.

Geat: .fype Cartd,dge type Adjustabl,e type tr. J-.'- "6" ;;,w',"'," I, c--1..

'iJ ~ . ,.;J .. ~.' c~mJ ~

vi a heat ,excbanger

Elec U' oni e t wi til. bat tery J .d.lstributor~, Dinoplex unit ~,con (high tension type.).

iBIDerge.ncy 1.gl'lie1on iUt'l.c,tion:lng betlii',e.en dlst~lbutor end n,~n'~ malc::oil.

1 - , - 2 - 5 - 3 - 6 6'" OD. the eng be

30'·

'0,.3:2 - 0.38 mM" Cham.p 1'0'11 III 60 Y 1().4...L O.S m '

- . .. . - _.' "~ .•

14x 1.25 M~.

Wit h de,e t1'i<: mO eo r Eleetromagneti.c

Vi.a key

DUGNOo,SING ENGINE MALFUN'CTIONS AND RELATED REMEDIES

THE ENGINE WILt NOT STARt

Remedies:

2)' Be ttery te 1"11110815 c'o,noded or' odama,g:ed

I 3)Fau.lty ,sta1rte1" motor

, 4 ) D ef ecti v,e start el' c ommu t a tor ew! t ell 5):t"aulty coil

6) Co !lto dis t l"1 bu t,Ci't' , dis tri1buto r to spark plug~ w1resstretched~,· b1"ok-en

I 7)Doisuibutor C8LP cts!cked.

,8 ) Damp' ot' c a rbol1 i z ed dis tr ibutot" cap and eableeDnTh€!ctions

9)])1rty t ox1,d.ized. or e:xeessiv,e1y I'!;apped diatdbutot" point,s

lO)Worn or cat'bon:iZ'fld distributor

: roto,r

11 )Cent,ral d.iatribu't,or c.arbon ti.p loose ,Q'r deformed pressure F-p'~ing U) Shot't-e,ircu1 te,d cOfidelilsaC,or er insuffie::l.lently insula ted,

13)Burned distributor fuse l4)'Dil."ty or ex,e,easively gap'ped. spark plugs

15) Flooded earbur,etor dtlP. to altered. float l'evel O't: imput'ity bet- . ween adj us'tment screw dtHl seat:: l6lMon-functioning fuel pumps

17).Doirt o,r water in fuel l1n'!;!s or in I 'carburetors

I 1) Check and re,cha:rge, 'battery as indica~ ted on 1'. L45.,

2) Clean,. exa.mine and ti.gh.ten 'conne'etion,g at battery terminals

3)Exami.ne on 'test bench

4) Replace

5) Ex,amin,e,t replae,e if nec.essa;ry

6)Examinij:;; readjust connections and -rep;ltu:,e, faul'ty cabl,es

7) !tep Lace cap

I ,8)D1'Y and clean c.ap and cable connections

9)Clean ,and readj'ust gap

12) Chee It c and anea eor on t,e s t bencn I' I"eplau::e if def eeHve

13)Repla.c.ea.nd locate cause 14)Clean and reset gap

15)Cbeck and adjust if' necessary

16 ) Ch.eck f US€! S 't con-nee '!::ions t f i1 t et' s and f 1Il,e1 level Ln tanks

I 17l:Remove and tnoro.ugbly dean the ca~buI retor's; if .fs1iJl tcontin,ue,B;, have t.he fu·el tan:!ks<llnd. lines cleaned and flu,shed 18)oSwitch over to emergency 19niticn

I sy.stem and bav~ un,i t replace.d as soon .as lpossible (tac.hometer will Dot function

. in, this mode.)

14

THE ENGINE S'IOP!a,

1) Engine 1.dle a:pe.e.d sett.ing too low

:2,) Idle sp eect set t iogeitbe,Y too lean 01' tootich

:3 )'Fio'od ed c~r1bul' e t 01,;

, ,4) D1 rt crw,al!er in fuel 1 inesor in carbu~etors

, f'ue}

5) Corroded ,or damaged ·ba.tt:ery teminals

6) Co ilta dis t riibu t,C) r ~ d i., I: l' i bu tor to ,spark plugs wires ::'OO~Q

7) !Dirty , wet, i'!!l;BufUd.ently o-rexces.s1.vely gapped spa1::'ko.J.ugs

8) larty, oxid:1,:zed orw,orn d1,5tdbu~ 1:: or eO'rlt,ace:s

, 9) Worn dis tributor t'otQlf surfac·e, HI) Inexac t 18:01 t1 on timing advance 11) Defective - c,on QTc)c'nJn,n,~ers 12)I1efect iv-e valve operaU,ofJ, due to

, fa:uUy valve ':s,e,ats 'or de;~cche , valve settings

t3)Overheated engine

'EHE ENanE LAJCKS POWER

Remedies,:

1 )Incl'ea,se carburetor butterfly va1v~ .op en btgs 11gh tl Y and adJi ustmlx eure setting (p. 64)'

2)Ajuet mbture setting (p. 64)

3) 'I'Ul'nto 1nstructf.o,ns under hea,ding

. !I CAR1BURE'E10R:'~'

4)&emove and thoroughly clean the '~arib''''ll:',e.to'1f's ;H fault continues ~ have the fuel t,a.nks and ,Unesc1 ea ned and n ushed 5)Clean·l, examine and tighten battery terrm1na l~· eonnec t i!O'nB

6)E;x:amine a:nd ti~hten connections

9) Replac.e rotor

~ O).Adjust enginel dhtdbutar 'timing

11) Examine and t ep lace if nae e s sa.ry

12) Adjus t valve d'e ar'an e es a:ndcheck each e;,ylinder'l s com.pressi.oIll

1-

,

1l)Check radiator water le¥~l, water PUmD and thel'm~s,Ut ope.ratiorn; water losses due to leak.s and c.ooling vent(; 14) SwUc~ ov,uto ~rgeney ignition and hav eu:rd t rep l,aeed as' soon. as po ssible ..

I

2: )Ae:,e:.el,era.t.ot' ped.a 1. does not tl.",aJvel it: s full h:n,ght

3) Elehc.tive dis tributor aut.omatic .pdva,nce:

4) Insu'fflcJ"ent clearance at t:.he dbtribut:or poin.ts opem,ing

5) tneoerecc d1.strlbut'or U:md:ng

6) lfiBU f fie! En t ()ompl'!E! ssion

i) Dirty ~ wet .~pBrk plugs orexcesI s~~rp 'electrode gap

l;'Che.ck and carry out timing operations (p. 42)

2) Tr ae e cause 0 fb Le ckag e and t',emove

3)Readjust ReGarding 1::0 instructi.ons given in the a.pp ropr!.ate chap tel:' 4)Adju:St the points opentng gap

~) Che.ck timing (p. 41)

6) Check valv'!'i!:s5eating and cylinders e mnp res 5 i en

7)C1ean plugs oindreset to exact electrode gap (po 167)

·.,

l1)Fuel mixture t,oo lm'1 ot' tee t'icb 1 Z) One carbu,retor' no t ope.ning e om-' letdy

13)Weak y,alve spt'ings due to defol'm.ati,on

14) Insu:ff1cien.t fu.el deUvery due to. defective fue11il,umps or c10gsed filters

l:5)E'lI:cessiV'ely loose timing cn~1n tension

16);t!:Seizi'Dg" of en,l!!;ine int,ernal

units; as: connecting rod or main bearing,G - p i.s ton,6 ~ c<a!J1'I.s,na f ts, I' stic:ki:ng of a vaiv'li! in l,ts ,gu'ide, etc. 1 nDefect;ive Dinoploex unit:

1:5

9)F'uel octane rating too low 10)Worn cIWshaft lobeC!!!)

8)lteplai:e spuk plugs,t use T'ecommended type

I '. ._

'9) U g,e recommend ed fuel

10) Check out, lobe (8)1 t replace cmII!!ihaft if ne,c,essal'Y

InCheck out earbureto'Tsjet farttings (p.6.0 ') 12)C'heck out COD,trots

l:nGhe,ck as per table O'~ psg,e,,3A ~ if necessary, replace spri'nga

14)Check o,utt cl,ea.nmd replace defeeU,ve

uni ts if nec:,eas;ary'

.15) Check. 0 u t cha in 'tens :loner; if neces sary ~ rep lace chain

16)Chec.k eue , repl.a.c.e def,ective unit (a),

17)Repla,ce uni.t.

'THE. ENGINE MISSES .AT HIGH SPEEDS

Possible causes:

, 1) Insuffice(l:t fuel delivery

2: ) C 10 gg,e d d1e11 V'E!l'y a 11' r i 11:: ell;' 3) Partially clog,Bed fuel li'nes and cBl:'buretot"s fil·ter,s 4)Dirty or wet spark plugsj or

I mdadj ustedl ga.p!3 or Up!\!

II 5) [Ie ~ ec.ti ve or imp rap et":I.y sea ted spark plug ca.usine!: pre~:ign1tion

I 6)lgnition timi'n,g setU.llg higher tha'n : pres.cribed .setting for high Tpm~ S

7) Distri,bu.to·r cut-out 9:wi tch springs w,e ak 01' de f o'rmed

. ,6) Valve SpT in;g (s) ddomed or inI sufficiently loaded

1 9)Valv,e (5,) travel impeded itl the 1 guide (5) !'Jr' valve n~ t c.~.OSifig

completely

Un Flooding of oaeor more carburecer

ll)Waterin fud

12) Def,ective Dine'plex unit

..~

Remedies ,;

l)Clogged filters in the elec.tric pumP,G,. excessively warm. fuel, fuel tanksc.apaci ty nearing reserve level

.2] (;1 ean t 1:1 1 ow dry 0 r r,e,!? is e e if neeeasa t'y 3)Gleati. ngudtor and ,carburetors filters

4) Glean and adjust tips and gaps"I'eplace if worn exc:e~,dvely

.5 )Che,c k caridi U,cm and type C! f p lug

6)Check with strobo6cop,e at 6000 rpm ta,

7)Check and replace if necessa.ry

8)Che~k and replace springs

9')Check~ if nec1essary replace valve and guide

10) C he c k and elLe an no a t need Ie valve and t ep l,ac;:.e t.r 'wo rn

ll)Tho1':oughly c.1e,an the fuel !!i:y,~tem 12) Rep,lace.

'16

ENGINE RUNS IRREGULARLY

J.

61'De.f'e,e:tive fuel 'P:ickup pump,s

l)Dirty or wet spark p,lugst or ,excessive gap

,2) I,n,exact 1,gnitioR t,imi n,g

3) Maladj listed idle ,speed mixture 4.) 'Ca.rbu,retors buttedl}'" v,alves

I syndu::onizaU,on 5)Defec;tive fuel pumps

i) 'In egulol' cylinder s(:'ompr essi'on 8)t'Sehedl! ,01;' burnt engine va.lves 9'U,rregulu v,DIve el'earanee,s

lO),C .... :r'buretor f10,od:i'ng due to dirt between. needl,e and seat

11 )Altered eal"Du:retcn" flc'at levels 12)Ait' leaks between, ait' intakes

I ,and cyl ind.er- head is and be tween exhausttub,e;s i1lnd heads

1:3) ExcEls,s,ive play intbe earblu·,e~ tors control l,ever shafts

14) Non-functioning aut,omatic advance 15,)l!listl'ibuf:or cut-out switch tal"~ nis,bed or wi eh inuae it e lea.ranc'e· 16}Defective 'Din,op.l,€!X unit

Reed 1e s :

1) Check ~ cle,an and. lr,es e't ,gap

I 2)Cbec\c: dbfibutol'adV's'nc.,e 3)'Adjust

4)Check

5)Check fuel lines cDoneetionsand

1 filteI's cleanliness

6)Check 'tr~vell' blockages in jets an.d cend it1cn ofmem.b nne s

7) Che ok wi. th e ompTes,sion gauge ,IH'Check !l:l'ld replace valves 9')'Allju,st (p .•. 1'8)

lO)Clean carburetor bowls a:nd filters

] 1:) Check le'Veh (p , 6,~)

12)C.beck intake rubber seal rings and exhaust f lange,s, tightness

.13) Check end t:eplacethe faultYlmi es

1lI,}Check on test bench 15)Cheek~ cl,e.lln and adjust

m6) !Replaee '.

I'

NOISY VALVES AND TAPPETS

I )1 Exc,es.si'lle elearan!ce between cam.ahaf t lobe and valve ,a.d.j ustment t.ab 2)Wo'r~ or deter1or,B'ted camshaft lobe or spacet' ta!b

.3)Broken 'valve return spring(s) 14)'~ce,ssie clearance between tappet th imb Le and gu:fd1e hole

I S)V'alve stem(s} 'Rot 1:.ifavding fr,~dy in ,the guide (8)

6)'Wicnm ,or loose tim.ing, eRa,in

Remedies:

1 )Adjust by subst1 tuting eabs

Z) Ghe,c:k and substitute ,c8t1i.sha.f,t and tabs

3)R.eplace 'b'r,oken sprins:(s) ,4) Ghe.c'k , (p. 36)<

5,) Check (p.. 32)

6) Cbeckc:hain t end OI'H~l' effie iane Y' i. ch.eck chain weaT.

u

NOISY CQNNECTING ROD:SBEARING SURFACES

1) D'isas s mb I.e engine, c'he ck b eating and, j oUTnals wear, eventua.lly substituting

the bea.Tings and resuI'faelng the Il::rankShaft: 2) Chect aut a 11 pump and deli very and return tulbi:ng

3) Subse1 tute .

,4') Check oil p'ressure re,gu1.ato1' valv,e and filt,era

5)Exc:e.ssive, clearance between piston 5)Disassemble engine, eheek pin and bushing.

WI:' is e pin sand C:Omlec t i ng 1'0 dB busb ing I wear,. I"epi.ace worn un1 ts •

1) E·x,c:es,slve clearance be'tween connecting 'rods bearing and crankshaft journals

2) I:n.auffi den t oil de Ii,very

.3)Use of non-p'rescd.b,ed oU 4)Low 0,11 pressure

Remedies:

ENGINE VIBRA:TES

...

I~

Possible C4uses~

1) Defee tive igni.tion or excesd've timing advance

2 )oDefe(!tive carbur'eUotl

3) [l,efe,C:fivE! carburetor synchr,oniz,aUon 4)Excessive clearance between main bea,rings and c:r,anksooft j,ournale

5) C cnnee t ing rod a and phi tons Qlf une,qual weight

6) Illcor1',ect camshaft II ebas and tappet shim. tabs clearance

7 ) UtlI.eq ua 1 e 1'1 inder COlwpr 0': s siC' n

,8 )Worn or s e'1 z ed e18 6 tic engine support mounts

9)Unbalanced engine fl}o'Whe:d - clutch a,s,sembl y group

]O)Non-funet,!,cnlng cyUnd3r C~,)

l)Check OU.t and overhaul 'the ignition ,system b. 40~2) ..

2)oCheck out and adjlus.t

3) See specific chapU:r instructions (p. 64 )

4) 'Cohee k diameter of main j olll,rna1 s

6).Adjust

7) l',est.. cylinder com.press'ien a.) RepoU,c e support s

, .

EXCESSIVE OIL PRESSURE

10) Id.entify cylinder (61) and, check liipstk I i"lugs abd. cables

Possible causes:

Re_med,ies :,

1) Non-spe,clUed oil~ ou. weight too 1) Subst:1tutewitb. prescribe.d oil

high

2) O'il pr'essure regul.ation. valve ob.. 2:) C:heck and repkace f'aul t,Y units. Read.tus,t

eructed ,0 r wi t h aU e:red s e tt iug to p'l es cd bad seC. t ing,s

3) Glogg,ed oil ,cit:cu1 t lines 3) Cl'ean and .flush oil lines 1 I'eplace f:U ten ..

' __ ~ __ ._. __ .• _. __ ~n-. __ . . ._ ..• __ . '_~"_'_'. ' __ .~_'__ """,~ ~~ ~~_......-I

LOW OIL PRESSURE

I Poss,ible causes;

1) Exc,e:ssive oil temper~ ture

2) Iuapprop'r1atlll oil type. for conditions,

3) Excessive 'ciear.allce bet;;.,Teen, main

and ccna ecHng TO d j ournClh, I be~ring is 4) ID,e:f ec t!ve I jammed 0 n f)TE':S sure re g:u;" lating v,a.lve

Remedies:

1)0 Do nee over-rev lengine (p. 47 )

2) SubstitUte with s,p,ecified 011 (1'. 49' ),

3) IDhassemble t cheek crankshaft j ournah,; t'e S1Il rof ae e. j onrna 1s and rep lace. bea,I' i:ng Ii

.. ~) Check cut,

S. C10KleCL oil. PW9 ttl.tar.

6., 'ault:y' oil ,JIJ"e'SIUl'II 1EId:lcator .• "I,. Low Ium, 011 level.

B. Incorrect ,lck-u_' ,ump Jic'sit1,ell1in&. 911 .A1r leak in the all' :intak e s78tellL.

s. Remove amp' cover and clean filter.

I 6. Cheek out Old eventuall;y replace'. 7. Check out ·and. r erill, to level.

S. VerifY posi-tloml1i ...

9 .• Cheet out and eventually replace.

1i9

RiMQVAL ,ANDINS:T.ALLATIQN OF ENGINE FROM CAR

l;"P lace S'U.ppon s a:t rear of the Vii~'h i,'ele .' 2-Remove engine and tI'unk lids. 3-Disconnect, battery ground cable. 4-Remove eng1ne~trunk parti,tion paOJel. S-Remove rear wheels,.

6~iemove right fender stone guards. 7··0pen ene;ine ~ radiator water taps ...

,B~'Rem,'l've ,cylinder heads, to radiator wat'er tubing together w:1th the two sl,eeves. 9-R,emove the ,a'U~i11ary fu,ell!ank cap and the air filter unitt, removing, thB blowby tubes from the carburetor box.

1 O~ Remov'e the ,two rubber sleeves ~nd 'the top, part 0 f the blower. 11~Diseonnectthe auxiliarywaur tank and it.s transverse chassis ,Bupport.

12 -Dbconnec,t the mu.ffler mount.1o.g, flanges aft,erl'iaving fInt dhcounect,e,d, the expa.n,Bion unit.

13-Disconnect the heat excna.nf!l,er waU!r tubes. l4-Remove the all filt:erls,uppo,rt. unit.

15~RemoV'e the heat excr. '_q~er and the 011 f iller I dr.ain tubes. 16~Remove 'the cylinder heads ~ heat exchanger wat,er e';abe. 17-Dbc'Qnnect the oil filler t.ube :h'om the. engine.

18~Remo\fe the dist'r1buto1" cap J d::'sconne,cting the high and low t,e:nsi'on ,cables. 19-Disc'oml"ect the wa:ter ~ oil aDd starter 'motor cables at the engine connection.s. :2.0~Di8c,o·'Mect the engine g'round, cable and the reverse gear el'e.etrical uable. 2.1-D19 conn €i.e t vacuum br ake b OO.s t er in t.ake t eb e •

22-Remove the gear shit t c,ontrcl connec tion.

23-Disconnec:t, the. engine/ chusi,5, a,c:c:eier8tor pedal support. 24.-Elisconnect the carburetor. ro.a.in. and,retU:I!'fl gas lines.

25-IDi~:H.:,onnect the clutch contr.o'ls from the shaft by sliding the eovez from the, supp,ort located. at the gear=box.

26~Disconnect the :semi-axles and differential flanges. 27-Re!llO'v.e. 't'he four engj.ne to chassis f.ast,en1ng bol U •

28,"'Sup'port the engine \o'i. th tccl, A. 60.5,44 01' with 'two met,d cableshoi.sts 'i 29~bis'E! engine slightly and dbc:,onnec:t t.he 'two re,ar engine liI.upp,ot't mounts. 30-Raise eng,ine with the clutch side le,wered and l'e!I1!ove - it diagonally to' the, lo:n:g1tudinal axi,s of the car.

NOTE

For many units; as the heat ex c:hange.r , the 'rear exhaust header , and the real' engine s.uppo:rts mcunt.e , ,,,,,,~ suggest that they be removed from the engIne in order to, f,acilita te r'enlt:l'val and reinstalla Hon"

~A:f tel' hSlving removed thE!. ane ir'e engin.e un! t from thecal' t and h~vili'!.tl, discODnect,ed the ~lutch bell housing, the dut,c:h, the flywheel and the intermediate housing as described on p •. 74, prncead to disconn.ect the ,engine from the gear bo-x.,

-connect the two side mounting arms of rot,ating engine stand AV 617 to, the engin'e bl.ock.

-R,emov,e the in take ma.nif old nut,s at the c!',anK'c.ase and d1sconnec t 'them cam,lete.l.y at. the cartmr etor 13, a S a uni t '.

'~D'iscOfUlJec.t 19u1.Uon. d:t~trf.ibut..o'r from the engine.

-Remove spa.l'kplugs; also disaonnect~the small camshaft cove'rs at the end of the cylind.et"head.8 •

~R.(!U1ove the two 'c,wnshaft c.oVie,'rs,.

~Loosen the f'our Dolts thatfas,ten the timing gears 1:;,0 the camshafts.

-Turn the engi~e: cr_kshaft 'cloc.kwiae u~tU 'the hent t'~n::~d!onal vih'rat.ion damper not!~h i6 aligned to the diBtrlbu:t:,o'r ease ,notch,. ,At ~he same time ~ make su~e

that the aligmuent marks on the four caJIshafu are d1e;,ned with the marks on the

ea ps of the. front carmshaf 1:; ,suppor t.s • If not ,aligned, tum eng ine over ()nea.dd:l. donal

r,ev,ol 111: LO'n. .

-WARNING

Do not turn' engine C"\1e~ until the camshaft,s have been, removed from the, cy.linder head,a.

-Reaeve the £ourt1m1~ geanbol tal l'oo8,ened earlier * wi tb I' too,152,2 .. -AS-S,42.:2.

ex U ae t the c'enter ing and drag p 1ns .'

R.e1!l.QV'e the g,eara from the boo.:: ~ -

~RemQV'e al;,lthe ·camshaftsuppot't caps fI'iom t:hecyl1n.del" haada,

~LoQ~en Urn. wat,er retum. pip,e from the engine beads ~ together w1ththetherm.o~ aut aM wa t at' In take tu.b e at tbewat'l1'l r Plilmp'.

~Withtool AV-498 loosenaH cylinder heads .fa.liitening bolts and 'remove heads from the ,eo:gll!le ]block.

- Discanne,c t t he to IS foul .. tamper ~ .

-DisC:OntHi!!Ct the :t!fmflll case from the block, t,ogetnerwHh the oi1 andwatel' pmtl.p.

~Remove theenginEl. ipteme.diat,E'; housing tog,e.ther with the cranks.bAft oil seaIf alBa remove tne .oil pressure sending unit.

~'Iurn the eng.iWJ::e block over ~ removing the c,onn'El,ct.!ng rod' caps ana slide the conne!C~ tin,g rod,~p1.ston un.1tthrQugh the lower pan of the cylind.er sleeves.

-Remove UI!e malnbe.aring support caps and remove the cra.nkshaft.

~Remave the t.wotilling ~ed'l.u:t1on gears BUppC,ns together with t.hel!iming chain 'contro 1 p iniofis •

~To remove 'the shou.lder SUppglt~ ball bear1ngs(if neces.sa.ry), .le,osen thehuU on the small shafts an.dpush the~e out: fr,~rn. theo.e.arip,gs. Remove the two' external ,elastic rings and slide OU.t the bearings.

An ,expan.siOlD: e~trHctol' or tools A 4(}206/80[ (:.. and. 40207/813 ,can be used to re-

move tho sa tI,e ar bg8 pres s ... fi t t edin the eng i.ne b look.

~R:emov,e the valve control tappets keeping them togethe1r wid. their respective, clearance adjustment. sbims; with t,oQl AV.508 !',e:IDorve the valve springs a~d! the oil ~et.aifJ.ins; rings and the i.nu.ke and exhaust valve.~.

ENGINE RliOCK.

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21

CHARACTERISTICS

GENERAL CLEANING

CYl.INDER. SLEE,VES CONIR:Ol. CYl.nmER SLEEVES B'ORING RESURFACING CYLUm:ER SLEEVES

CHECKING, RESURFACING OF ENGiNE BLOCK!CLYNDEll READS SURFACES CHECK OF MAIN BEARING SUrpORTS ALIGNMENT

Char,a'ctet'ist ice

page. 21 21 21 22

22 22 22

I'!

'The cylinder,s are Oof a special alloy; cast togethel: with tbe engine block. The c:y11nd"e.r sleeves are bored. out of' the same block casting" 'Fhe ,eng.ine black a.1so c:ontaililsf'our Sill~;pot'tsea:ts f'or the mailll, bearings. On the rear s.u·p'POl'ts are m@unte.d thrust bearings for the crankshaft"

The engine 011 pan al.sc :serves as the gear box case cover.

General cleaning

tmmer,se the block fot; 20 minut,es in a tub ,e,onta1ning a water aod Goda solution Olf BO~ 850 C. With a pr€!ssut',e hose spray the block with the. soluti,o,n to eli~ III in at,e, any deposHs in t:I'lIe lubrication chafine.ls of the block.

Dry' out with compressed ah:- the block, parti.cula,:rly the luoricati.on channels,

Examine the slLeeve 6ud:1,ees and' carry out" the dime'ns1onal m,eas,urentents as lndlcat ed in f1 gur,e 7.

Maximum tolerated wear :r.!'I. 0, OS + 0,.08 mm. ever the nominal d1.2metel'measu1"emen't. If wear or dei,erma Hon i.9 wi thin the 0.,05 mm. limit ~ fine hone the ib:ylinder sleeve surfaces with an emer~l cloth IIlouneled on a,grinder befot',e. insertion of the. pist.ons.

Warning

If wear and out-of-'I"oundnei\l~ is fou-nd and the sleeve must be resurfaced" follo,w these directions:

If the ~mi;H,.:!;nt of mater! I'll is ,sma.il Uess 'tha.n 0.15 mm.) ~ it is, suif;li;,ieDt to

_ only hone. the sleeves ~ if' it /i;ixceeds the 0,,15 mm. limitf rebcripgh necessa.ry.

- I

Fig. 7 Measurement d.:l.::l.,gl:atlt for cylinder sleeves.

Cylinder dee.'Ves diameter.

fIj'Of!i1IN A LN'omlnal

Cia~I' A

'I'

92,.500 + 92,530 92,500$ 92,5,15, 9.2.!B 5 + 92.530 I

..

e

i,

1 • M I g;g iOr ill i,Qu'Ovel'sizS' _

Ci~:n' AI II

~,leOo -:- 92. 130 9-2',700 -:- 92,715 92}15 + 92,730

c

2' Mall.gio,r.u iOfu'Ovel' s.:1.. ~

Cil!lIl' A ••

92,9(0+ 92,930 92,00) + '92.915, 92,:91[,5 'oii- 92.93(l

c

"

3' Mag,!! ~o ~ n i;o ~ .Ovet iEJ :1z:t. " . 93.100 -+ 93, llO

elllie' A "931Joo ... 93, US

•. c .. 9;!1,1]5 + 93,1,30

22

J.tememb er that m.s.x:lm:umrebc!l:ring m!us t no t exe eed 0.6 mm.

The resu:d,aclng of the sleeves IllUstbe pedo,rme.deomatch the d1ametel'o,f the replac.e1Ilent pb't;on& (IG. 2 ... 0.4 +0.6 tmn.) and the c:()'rt'e~pond:.i;ng clearence bet-

ween, the pa.r t8, • .

Wa1!:'niD!pwben choosing pistons make sure that. they are matched with and. to the couesPQndin;g cylinder slee'Ve s,b,e.

Measure the sle,eves in order to ,establish th,e exact diam,eter to' which they mUB t be b or,ed •

A:it,er ha.ving mounted the block to the propet' inclined surface and. secured to the sliJ.ppocrt sut'fa,ce of the reamer, inseUe.he mand.rel of the reamer " with a centering device, into the sleeve.

Ex.ecut,e an eiX8C t een t,E\!.r 1ng 0 :IE the mand r,El lin relation to the sleeve and secure the support surface of thierearner.

Remo:ve the. c.ap of' the ,ee!ltering d.eviceand regula:t.e the projl e.c:ti'on af the c'ool

1::0 the des! nd di~eter. - - -

Ha,ving set the 'projectLo,n, begin boring leaving 0.04 + 0' •. 05 mrn. 'o,f !:!udace to be f'inely ground out in. the nJext operation.

Resurf.acing (gdnd.il:ng) of cylinder sleeves

Mount and sec:u:ite the blo':!k to the surface of the griooer ~

Using a seriles of medium grade grinding blocks, then. a. :sE!ri.e,s o·f fine gI:acde, proceed to grind ..

III 'order to ,~btai:n the desired suda,ee 1'loughne:ss (35"" 38 m.icJrQin.ch.es) ga over the 61 eeve wi tit a grind In.g do it; h at tachedto thegr.inder.

Repeat the above opera U onsen all t,he ,,:ylind.eJt.~.

After extended us,e o.f the engine or after use in c.ondHi.ons ,pi ,extrem.e engine oveI:heaf i ng t it is ad V':l..~a b 1 e t,e c. heck eue the sa s~l' faces. U :sling oS fis t rul er c,oatoo with Lamp bla,ck or slmilar substOl:nc~t sprea.dehe material over the slrr.faces .

In order to 'I'·e,surface the a~,e,as~. it is 'n.ecessa:ry ee 1,",morveal1 cylindler n!e.ad

stu.d~ •

The resurfacing operae.on r,~ust be ca;rr1ed out with tn.e prope~gr,indins/planiog ma,e:h:n:rne in sueh a way astQremove a. minillllu.m quantU::y of m.etaJL (maximum to be re1PDved- 0.2: t 0.3 m1fi.)

Check of main be.adns. supports al igf.llme:nt

For this opera HOOt tool 361 ~A.s~4 736 and lap g,rinder A\7-2:40 n'l! used.

u

r:

"

PISTONS - commercE'ING Rrms

23

CLEANING

PIStON/eYLI N)ER SLEEVE AND PISTON WRISTP]N CLEARANC.E CONTROl. P lSTON {WRIS 'T PIN REI AINING RING

PIS10N WEIGHT CONTROL

PISTON RINGS

CONNECTING ROD BEAIINGS CONNECT ING ROD BUSH INGS

'Remove any incrustations from p:i s ton, domes and riog, g~oo'VePii uS!lilg at cUl:'ved

scraper. Abo remove any impurities from luibrica~

t ion passages and froln the lntet:nal surfaces, of the: 11

pi s t ena and connecting 1''0 ds .' When clean iagh flni-

sbed, make sure. t:ha t: the uni.ts areruot cracked or 2,', ,.

damaged ~ ~equi1'1ng l'eplaceme,nt:, of tnolile units.

Cleaning

P 1 S 1::60./ cy 11 nder sl'e,e,veand piston wrist p I.n c Lear ance con tIC"O 1

p,age 2:11, u 23 u 24 II 24 II 24

II

Piston! c:ylind,ey sleeve clenance con,trol is

,l\l.'chiev,ed !by matching the bore aize to the !I'!I'

Cot' l"e e t p i.s ton siz'e. l'hese s1z:,es fIlUs t be accur~tely matched.

NOTE: if the car Msbeen run for 5©i60~OOO km. at engine rebuf Ld , it is advisable to replace-the pi:st,ons.

Repalcemeo,t pht.ons: are su.pplied in,Qversi:z:es of 0.2 - 0'.4 - 0.6 lmU.

Fig ... 9l?dndpa.1 piston B'nd wrist, pin dan.

Piston datlJ

~ 92.330 ,. 9.2,330

,,' 92.346

92,360 92,345 t '92,360

NOMlIIIN,A L' CII,"', A

C

Urst

l' l'i'Iu;i'!!irU'oil,eQV:e,t'1I!l.1ze

CII,U; ,/l.

C

IfJ 92.530 7 " 92,030

,. 9~.545 +

9.2,'500 92,54& 92,560

___ I

PiS. 8 P is tonI eennec Ung: rod u,nit

1. NU!'Il,lber indicating wristpin/pi.st()u boss assembly matching sbest 2. Lette.r indicating phton class siz.,et 3. Numher indl.'cat:ing pist.on oversi:I!l.E! t 4. Jt,amped lllullb,er indicaUn~. proper cylinder / connec ting roo match.

aol!:CDnG.

2' M 1~1I io UI ~ 10 n'~'OVe,r8i z e CI"I~ A.

C

~ 92,730 -r" 92.730

" 92./45,

92.7fiO 92./415 92.7fJJ.

~~----"l:l::l'!:'7"t';::~,:,lr, ~~~~-~~~~~ 3' M~~lIiDt;iiZ'ionl-nird

e !.IUli A oversiz e

c

q. '9~,930 "92.930 .;"92,945

92,900 92i945 92.9(~),

Pistons are matched in three cate;gol'iesl each with ,a, nominal base diameter and wi th fwo add.it1cnal eaee;g:od,es of wrist pin, d1atneter,

The. letter and the numbierifid1caUng the p1st~tn ,dan and the wris,t pin!pfston boss size are stamp,ed, on the base o.f f.he. connectin.g rod and on th,e internal' ~:imof tMpi.st'o·n (fig ~ 8,).

:W:r bt p in I piston boss IC lea1!: ance is I~J. 002 .... 0,. OOBIMil.

On€lm,ethod 0'£ ,ebecklng out the wd:stpin/p.iston fit is to insert the pnseb.cud wrist. pin, highly luDriJca.ted with Cles.'D, engi,ne 01,1 i.nt.o the pi.ston bos.s.l[,f the fit i.e c,O[l'ec t ~ ·the wrist p1n will fit in by hand pres.sure.

'U is ,Si,dvhable to replace tbese every tbethat ·the p,htO'n./wrht pin: assembly is dismantled.

Before reassemblYt make~ure that the new 'rings t exterDal diam,eur is 23.5 mm

ct O. 2mm .• ) meaSUT ed. on it I!!Ip,e.rpeDd ieular &Xis in it s . C u;!; edges and

that this d1stal'l;ceis 10, mm~+t. Use b~ol 63:Z-AS- 7084 fQt' inse.rtiQn of the rings into the piston bQ.s~ •

P ,is t on/'Cylindet: clea;rance

Cle.a.rance is mea.sured. in rela.t:.ionship t.o the normal axis of the wrist pin and Z:S mm. above the: base of the cylinder.; ,clea:ralnce should be O.li 60 :-- 0.180 for all pi.ston cl.aa.,ses.

Bet orepistciD. reassEm.hly hegins!.llake sure that all six piuons are of equal, w,e1gnt; ~ltuWI'J: to,lera.nee .. :t2 ,gnms.

Piston rings

Ri ng Ii ,~ gr coves c lea 1:.' ance

T:he e 1 ea. t' ance 1s checked by a ss emil Ilngthe C01:"rect rfng to the pis ten g I'IQOVe and using a pro~ 'per thickness gause.

NOTE ~ it is D eces suy f or p'rop er fune t ion i ng and long eng i ne life to a.dhere d,o!lie 1 y 1::.0 the 1 iig ted ,~s,sembly c lLearances.. .(Axi.d clearance: '0 f pbton rings an dt hei t' reJ.a ti VEl groove.s)

Fig. 10 Riu,gs. - piston grooves data.

Slatted oil 9craper rinlO!:: seatina

o. OZS +- 0 •. 057

u

F1,g. 11 Checking plat,on ring cl,(!,arance

Piston ring clear'ance

data

Ring type

1 Comp U' ss 10n ring

A ::C lear ance,""IDm.., " 0.30 .. 0,.,45

2. Oil sc:rap~r ring

3 au sera,per ring

0.25+ 0.401

The clearatu:::e must be checked 'pri(lr to mounting them on, the pistons and it. mU!llt be m,easured af tel' in s er:t: ion 0 f the ring is 'the cylinder (fig .. 11) and they must c.onf 0 t'1'!l to e he tabl,e, mea i=!uremen t 5 above,

In case of insufficent clearance, gri'nd the ring ends with an appropriate grinding 'tool. A.lt,er' mounting t!u::m en the pil!!e.ons ~ ur,ange the ring end gP'~~ 12:(1- from each -orher ,

25

Fig '. 12 Con.nee e ins rod", and connect in8; r'o,d rEI beat' ins; s dB. ta •

r IN OIRIMA,L I

I lB,y tlnd era he d iame tel' 1,n. em. 01.1271' 0,.25' I 11l,,508 0,762 11,,0'16

1.7"~2 1.718

NOrr'E: Durin.g any dismanU,ing orn.buildin.g of an engill€! ~ the rings must be rep,laced. NOm: the cleara.m:.e A (Ug. L 1) must be held cons cant fot' aU cylinder sl,eeves ov,er sizes. Rings are av,dlB.ble in overs.'ize.s. of 0,.2 + () .4 - 0.6.

c.onnecting rods hei:!-t:'in~1'3

The Hth1:n .... walrl t.ype bearings mU:9,t not be filed 'or smoothed, ana, tneit'9)urf • sees must be pr'otected~u: ~11 times 'pr.i()'t to ass'l!!mbly. If de,ep s,era'tches or wear are noticed1t they must be rep Iaced, After .~scertaining the ecnd i tion of the beadns.s, cheek cu:t the bea~in~.51 c'l."onksbaft j ouroals clearances,t using the ,ot'ppropriate microme.ter and thickness gau;_,e.s, .•

If theob tained cle,arar:r.,. is within ,a,s,s,embly 11.mi.ts of 0.056 +- O. ()99, or under the 0.12 ntm. journal wear Ji.imits ~ r,eplac,ement of same siz,e bearings is allowable. w:Lth~ out haVing, the crankshaft j ou.rnals ID:lcbined.

If the clear,lI1!fiCe limits have been exc,eeded t substitute with uud,er,sized diameter bearing,s and resurface th.e cranksh.aft journals as ind1,i;,ated on p. 111 and according, to the specified limits.

26

Connecting rodsbusb1.ng8

The piston wrist, pin. bushingis TRIONE a.re suppli,edwUn asl1ghtly cfVl!!r8,ize.di Dllt- V

side diamete.l" I( 0.4 mm ,.) measurementf 0 r a s e_c ure pres s fit in the CODtlee t1ng re,d.

The, bUlning must be orient.ed. 1nthe connecting rod hole so that the 'bushing 1ubr.i'cati.onbole :L.s at ·4.s° in relat1:on. to the u,pp,er connect.1ng rod lu.prl.cat;.i.ofl. hole

arul nOlt ax:tal,lyal1gned with the coanecUng rod. bearill2js alignment indentations

«:fig. 12).

The bushins i~.terna:l diameter is best checked out aft,erits assembly entne COn~ nee-Ung. rod.~ uai.ng a reamer ort:oo,lA 6(11077 and expandtng reamer A 90;3.07, to the diameit,e:r corresponding to the ind1v1.dual classes 'of wrist P~:DS f20_.0]2 ~ 20.018

La.s t ly.~ check the para.l1eU sm between the connee ting rod journal and thewri s t

pbl. Bx:el'l" ('['oLersIu!e- 0.0.2: mIll. measured at the two wrist pin ends).

NOTE ~.W1th every e,ngin!l!o disassembl, and espada.Hy wh~ replacing. the wri.sc pin bushings ~. it hnre,ces san" t·Q(;: heck the par a UeH.sm between tne two axes.

,~

u

27

r:

CRECKIH'G AND, REStmF AGING OF MAIN AND CONNECTIN'G ROD J'OTJRNJ!.LS MAIN BEARINGS

CRE,C1{ING CRANKSHAFT B.t\LANCE

'CBRCKING MAIN AND CONNECTING ROD JOURNALS ALIGNMENT CHECKING >CltANK:SHAF'I' SUPPORTS CLEARANCE

ENGINE FLYWHEEL W'I'I'H RING ,GEAR

CLEANING OIL LUBRICATION PASSAGE'S

CHECKING CRANKSHAFTFR.ICTION' BEARING

'paSi.:! 21

n 28

28 2,6

29

29 2'9 29

II

Che,cking an.d resur£a,cin.g ,0'£ main and ,conne,cttng rod jou,l'nall!ii

The. crankshaft must not be sccred , 1''Magnaflux!! it, t'CI examia,e" and replace if cracks a,re dliseover,e,d,. Light seizure marks on the jou~nals may be polished out by lUsin,g th.:! :fines t ,g r ad,e, M carbcrund lim n ;8 tiona +

f Und,ershed by rom.

II M'O RI!\IIAL '

I O,Hi7 ,0,,254 0,10,1

U:.li4' 12.116,6

',:ii,,",4 U .,.,40 U;7112 ',~."il

~1.Ol "

NII;i'RMAL

Undersized by min.

0,,712

, - 4l, ;,1. 43,:U·5, .. 3,,'1 1 ;

"l,Iii,H U.UI;j, 4,:1.12.11

I

Fig. 13 'Principal data fO'l" ma.in ~ connect,ir.,g, rod j ourna.ls and support (thrust) rings,.

Main bearings thickness dat,a

When s'coring oft,he journals 1,8 deep; O'I' when. the out~of~roundnes!!ii exc'eed,9

o. as mm.mea,9ut'ed, with a ra.icrome,ter t the

, OVen,ize by 111m. j oumab mU.st, 'be. resurfa~ed. This ope ...

NQ'.MA'!.J,!.I--~"","""~--r""'~-'Ir"'"""""---r""'~"""" ration must be can;ied out: in vi,ew of the ~"""_---Ir--0_ •• _I~l'+ ... 'O~,:I_!_ ... _: ...... a'! ... I_O~' ~I .... _Q,_·' ... 'I; ... - _..,1,..;' ,_II' ... ' I ... ~'.......j a.9se.mbly ,clearances and the bearing o"ver-

1.1',1: I' 2','0,7,' size needed,. Resurfacing ofche lIl4!in and

, ,u,. 11,Ul I,UI ,e'on:nec,ti'n,g rod -journals mus:t;, be done ,BO

~~~~.._ ...... ~ ....... _~&.... __ ._.. ..... _...,~ ...... _ .......... aa,t;o arrive ,at the c;crJ:'re6pond.ing diameter values- Hated in the tables , aod ac.,c:,o,rd1ng tot:he, radiuB of the }Qurnals as shown in fig. 13,.

Replace thea,eif sceree, ~eizure, or exc.essiv'e. weaT marks are no'ted. Bearings cs:nnotb e r8stor,edr: 0' od.ginal ISP eel fica tio:n s e 1: mo dl fied •

If, a.fter ,e,xaminaU,Ot\ ~ the beadngscan be j udged as reusable" verify the exis"" ,tinS bear:f:n,glfnd1vidual c.ranks,]18.ft jlo'ut'oal clearance by t.he follo:wing method: ~As8emble the mdn bearings to their journals and the1'r ca.ps.

-T'Orque tight.e.n all cap nutato 11 Kg.

-With ,a prop,erly adjusted (zero adjlua,tment set.ti.ng) gauge , verify thg. bearings

d iaruet er .,

~With a vtl-icrometer v,erify tne. cra~kshaft journals diameter.

-'Compare the d,fff ere.fice between the sut'fa,e:,e values of each j ourn.aland its reb ti VI! bear ing.

Normal ass,e1nbly elesranc,e between the main bearings <l,nd th'e crankshaft j,oln:onals is 0.. 04m TO. 090 mm..; 1. ~ tbe cleuan,ce exceeds 0.1 S mm. , substitute wi tht.he proper unders.1,z,e d1~ter bea.rlngs (see chart), having previously verified the ,journal!. surf8c,es.

After verify 108. all j Durna Is /bearing s c:~ Ie 81" ane e samd any nee€! SiS a :r:y sub s t1 tu t10ns ~ attach the beari:ng caps ana torque the nuts to' 1] Kg.

Fr,ee l',otation of the crankshaft indica res a proper Ht and perfect assembly and ,ex;ac t pairing of the _1, Qum,a.ls with their l'E:spec ti'Ve bearings.

,U

After: resurf~cing, of the cran.kshaft j curnaf s it is adVisable to verify the balance dynamically at .1S00rpm I' S ,add.tng,l:o the connecting rod j au.mala, thepr,o'per count,erwe1ght 'ring.s '.

Md the flywheel atl.d t:'ae 'tordoa.nl damper to the cra:nkshaft and repee t the baJ!.ancing opera tiofi,.

Checking JnI:I,in and conne.ctb!.g eod j ournah alignm-ent

MCloUn.t the cranksbaft. by s\!pporting it. at i,ts two ends by two p,a.rallel ba.ts, and veri.:lfy wi th a gauge ~

~·The main. j ournah, alignment;, maximWll allaweible toler'ancE!: is 0.02 mm. (as r,ead On the dbl gause).

~Connecting r,od journals ,.alignment:; maximum aU(lw:able t"olerance a,s com.pared to to the main bearing journals i:s:! 0 .25 mm.

-Ma,i,n and connecting rod j Du,rnals out~of'-roun.dness: m.aximlUm aJJLowable tolerance after resurfacing is O. 005, lIUII.

~Ma1n and eenneet ing rod journals taper ~ maximum allowa.b l,e 'to}.2~ance after resul;"fa.cing is '0.005 ml!1..

I

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29

J.

~Cl'ankshaft sxi.sl flywheel s.uppotrt surface.s perpe.nd,ic.u1a::rity:: a gauge :ind:tcetor fastened a~pl'oximately 35 •.• from t:he. crankshaft QX1.slll:U.~t not indicate an.y va.r:1&t ions over O. 02.5 mm.. won.en tb!e C l' a.nkshaft h ret ated •

Verify the c1taDklhaff supports (thrust bea.rings) clearance between the rear 9UPPOEts b,alf-rmgs and the crankshdt surfaces.

Attach a gauge with & magnetic ba6e to ·the engine block and inlilert a screwdriver at each .end between the crankshaft and the block.

Move the crankshaft sideway.s and ve~ify that the mo,vem.ent h w1thinthe values c,f -0.0.5,0+ O.240mm. on the d:tal gaugefa.ce.

Iftne movement exceeds 0.35 mrn.. l(max.1m.um allowabletoleracnce)l:t Eepla,e:eth.e thrust bearings half-rings with 0<. :1[27 mm. over.sized enee, ava.iiable as 't,eplaceDl.en.u and hav-I.ng a thiekn.esB of 2.437;' 2.487 mm.

In the oI'llGisemblYQf the h8U-'r1ngs.~ l;·emember that the grooved ddeof the rings must face towards the cranksna:ft support.

Vedfy the condition of th~ riDg ge$t'; ·repla.ce ent:ireu)):!it if gea:rt,eeth are d.amaged.

The flywheel start,er motor shaft and clutch. con.tact surfaces mrust be 'ocnly lightly worn aDd should not show scratch marks.

To veri.t'y that these ,e;:ontact snrfac,es are aosoJLu.tely aligned on the 'rotation axis, placeth:e flywheel on the engine crankshaft, pLace bothOTl fwo fi'8t'3ll1el SUppO!its and. with a dial gauge verify that the surfaces of ehe. clutch disc and cover don.ot r,ot;a,t;e more than {).1 mIn. out~of~centeI':.

For an aeeuea te clean:ing opera tion.of theBe passages it is ne.ceSS8l'Y' th~.t all fill and drai:o plugs be removed.

Acc:ura.tely washt.he intern.a1 p.assagea with ga.soline and blow dry with ,compressed air.

L.a.st.ly, pres:!;! in the new unthread,ed :Sit,oppers andst!cur,e into pla.cewith a punch,

An inte~oHlly lubricatedt sea.ledroller boe,O}rlng is located at the rear end of the crankshaft.

l!1henevel' noise 01' wear is noticed in the ro'ta tiD" of the oea.rinj!; ~ U. lsnecee~ sary to replace it by removing it with an. extractor A 402.06!80m and tool

A 402.011613 ~ making i.t oec.e.SS!i!:ry to remove the engine flywheel sin.ce it hold.s the b ear:Lng in place.

J

I •

, )

CYLINDER HEADS

31

REMOVAL, AND REKOUNTING DISAS,SEMBLY AND ASSEMBL,Y CLEANING

CHECKING AND RESUR'FM!ING SUPPlO!tT SUR.FACES 'CHEC.KING HYDRAULIC OPERATIONS

CHECKING VALVE 'SEArs

CHECKING AND'RESURFACING VALVES TESTING VALVE ACTION

VALVE, GlJIDES

VALVE, SPRI l'G;S

pa,s:e 31
1M' 31
I" 12
II 32
II 32
II 32
II 33
IT 34
~I' 34
u 34 Whil e i.t is l;',eiatively easy to loosen t remove and remount the resr ,eyl;l.nder head with. the engine still mounted to the car t the loosening of the front one presents, diffkul ty I t'RUS it is necessary eo remo,ve the complet;,e engine un;!L"t hom the car. FCl'r 'this operaH,c'(!l. refer to the steps listed on pSBe '19. T,e nl,stta,ch the ,cylinder heads to the engine bl,ock f,o,llow the ope,l"a tions described! for tbe loa,s,ening and removal in r,eve.rse, aM Qbset'v,e the fellowing steps:: ~Always repla'ce the old cylinder bead ga.skeu with n,ew, iceeping them. clean ami free of gre.sse •.

Alsot21ways repla,ce v:'l.lve cOover ga~kets.

~Ti,ght;~,n the cyHnder no.ads to block stud nuts in the crder 111ustra.t.;ed in, fig •. 14 in ,two steps:

1st s.t.ep, 'torqu.e downt'o 4 Kg. 2nd st.ep ttorque.downto 8, Kg.

Dissssebly andrea.ssembly

Pla,ce cylinder bead on IiIUPP(,l't l (A. 6033-7) .' Ad:,ju.st tool 2 (AV50~mnm)es, ~hown in fig. 15 and compr,e~B the valve sp'fings and loos,euche retailling V'alv,e cone hal.ves , Remove the, springs with theit respective eaps , 'making sure that after ,examining th.em they arer,epla.';ad ba,c~ with their r,espective sean,. Slide out:

.~

P""" 10 e 1 :3 S. 11

0.. .... ·- ... 0 0,.- -..0' Q. ... - ... ...0'

I v , \(- .,~\

I 6 }I 5 I, 4 I

\ I \ !.... l

0' .... _1) &- ... 6 O .... ~4)

12 6\ 4 2 7 9

~ ~B

!

,

13 r ' I c

Fig. 14 Head bolts tightening sequence. Fig. 15 Cylinder heads v'a,lve removal with toe,l AV5Q8 (DINO) •

! .. Re,sting surface, 2:. Va,lvE! re.moving tool.

valve:!'!! from the. bQ'tt'QIIl of the cy.l:f.nder bea,d.

Rea.8embly 0'£ 'the 'hud is ac.e,ompl1shed. by retr,ac1n8 the disassembly operations t8 f'eveTI,e.,

lemove cat:bon deposits from all eombu,sU.on ,chamber,s. Do the same for the exhau9t tubes, cheek and clean in:take tube,a and eamsbaf,t; lubrica.tionpal'Js8ges,.

We advise cleaning the combustion cb_bers by immersing the head in. ,s liquid eiean:LIII_s,olut1:0rJi, as !'MACdU[S ?5.iu .for ~O to 1.5 hcurs aft'er h~V'ing completely d.1sman-

t'led the cyU:nder heads. -

'Rinse out with ,com,p't"es,se,d water, blow dry w:ith compl:essed ,a11' and reaBsembie all units, after lubrIcating theJll.

Slide the cyliud'er b~ads on a flat ma,eh:ined ,su'rfs'ce that has been freshl.y eeated with ma,ehine dye.

The dye marks mu.st- be unif,o'rrnly distributed co. the flat s,udace of the head.

If the, are not, surh;;:ei!:IIJ.ped'ec't:Lofis eXist, and the llii!ad. must be reeu,rfaced. No more th me C.1 .;.. O.~ l'I',m". cf' metal must be removed d~"n;ing the resurfacing oper,at,ion.

Cheek Ollt the cOII!.bustion ,chmb,ers depth with gauge A.962.n, for exc.essive we,ar and check tha.tdepth d1ffer:enc,es do' ·not eQCist.

When the I'es,udacing,of the beads exce,ed,s the stah!d Um:!'.ts~ rep,lace the heads, Check f or signs 0 f ,o,.f Ii ei dns; or ex cas s1 ve 'wea 1':'

(s,ee ,f1.8. 22') ,oot the (',.:lfiishaft ,s,est,s. INTAKE EXHAUST

Check 1ng,hydr aulic. 0 per atio'i:'!.S

1:n order to carry out the blspection ,(:IIi the hydr,s'Ulic opera Ucms of. the c.QQling pas,sages ,of the cylinder headb" c::omph~,te the .followiftg s,teps,;

-,Asse;mlble on the CyHfld(~t heade the particular un! ts requ1r,ed f,Q'r the C(;o1ing opera;t1:ons. -Heat 'the wster ,c,onta1[J .. ~d. in thews'ter pump bowl to 8S,·+ 9'00 c.

-P'ump the water int,Q the internal cooling pas,s,age s of the cyl1ndeli.' ~lf:ad t while ,at, the !:lame time exhausting the ~i" in these p,ilssages un-· til a p'ress.ul'E! of ,6 .;.. 8 kc/,'m~ is reached; under this pressurE!. no le~ks ,shoruld be not,ed. If leakB' a,T'e noted due to wear or pOl"osi.t.y ~fthe, c,ylinder head ~ replaJ.ce i,t.

iQhec'king valve seat.s

Th.e valve se.ats must not; show signs of caving~ iuin thev'slvEi, coo tai;t :zone;: 1£ they de , c,a't;'Y out the following opel"3tio'os ~

... Slide 'into the valv-e guide hole valv,e, guid.e stem tool ,A.9,4041 of tl·,le correct diame't.€!l' ,and ,the least amount 0'£ pL~y' at tacb ,(!,o,unterBin:k 3.5021768 (4S".angh) for theresurfacif:l,!1I of

'Fig,. Hi Valve and val.ve s,eats principa.l data.

--

Am.oun t ofilia terial to' be. remov'ed with valve ~eat too,l mounted.