Page 441
REMOVING THE POWER PLANT
Manualtransmission
6.
REMOVING
7.
For major work on the engine and transmission, the entire power plant should be lifted out. Removal of the engine by itself is not recommended.
1.
2.
3.
3.
4.
4.
5.
5.
Remove the hood as follows:
Back off both the hood fastening screws. Lift off
the hood. For this you need a helper to hold one
side of the hood and help to lift it clear.
Detach the battery cables. Unclamp and lift out
the battery.
Drain off coolant through the radiator and engine
block drain cocks.
( Later-version engine blocks are equipped with a
drain plug.)
Carbureted engine:
Detach the vacuum hose of the servo cylinder from
the inlet manifold and pull the fuel hose off the suction side of the fuel pump.
Injection engines:
a. Detach the vacuum hose of the servo cylinder
from the inlet manifold and remove the rubber
bellows between the air flow sensor and inlet
manifold.
b. Thoroughly clean the areas around the fuel line
connections on the fuel distributor and detach
the lines. Plug the holes and blank off the fuel
line ends in a suitabl& manner.
c. Disconnect the electrical connection on the air
flow sensor.
d. Undo the clamps on the air cleaner and remove
the air cleaner and mixture control unit.
Carbureted engine:
Undo the cable connections to the ignition coil,
temperature transmitter, oil pressure transmitter,
radiator fan, thermostat contact, headlights and
headlight wipers.
Injection engine:
a. Undo the cable connections to the ignition coil,
temperature transmitter, radiator fan, thermostat contact, headlights and headlight wiper motor.
b. Disconnect the cables of the injection system at
the warm-up regulator, auxiliary air valve, cold
start valve and thermo-time switch.
CAUTION
Do not detach the connections by pulling the cables.
Grip the connecting pieces.
8.
9.
10.
11.
12.
13.
NOTE
There are two types of gear shift rod joints, steel
and plastic. The taper pin must not be knocked
loose in joints made of plastic.
14.
15.
16.
17.
18.
19.
6.
Carbureted engine:
a. Remove the air cleaner, the inlet hose and the
preheater complete with hose.
b. Detach the throttle control wire from driver and
bracket.
c. Detach the choke control wire and sheath from
the carburetor.
Injection engine:
Detach the throttle control wire from driver and
bracket on the throttle valve housing.
Detach the hoses at the connections to the thermostat housing, radiator, inlet manifold and water
pump.
a. Remove the grille.
b. Remove the hood lock operating cable from its
fastenings at the dash panel and wheel housing.
c. Remove the two front sheet retaining screws and
nuts, and the four screws holding the headlights
to the body.
d. Remove the front sheet, lifting forward and upward.
Disconnect the clutch hose from the slave cylinder.
Plug the hose and the hole in the slave cylinder.
(Model 1975: Remove the slave cylinder and hang
it up in a convenient place.)
Disconnect the exhaust pipe from the exhaust manifold
a. Disconnect the ground cable from the transmission.
b. Remove the alternator.
Jack up the front end of the car and place blocks
under the body.
a. Put the gear lever in neutral.
b. Withdraw the front taper pin from the gear shift
rod joint by means of special tool 7840838.
Pull the rubber bellows free of the groove in the
joint (rubber bellows have been discontinued
during the 1977 model year and need not be
fitted in earlier models in conjunction with repair work).
Separate the gear selector rod joint from the gear
selector rod.
20.
SA.1'11
Detach the speedometer cable from the transmission.
Undo the engine brackets.
Undo the larger clips round the rubber bellows on
the inner universal joints.
Fit the lifting yoke 8392177 to the two engine lifting lugs.
Undo the lower end piece from the control arm on
the right-hand side and turn the steering wheel to
the left. Raise the power plant and withdraw the
left universal joint.
Lift the power plant to a convenient height for access to the cable connections on the starter. Disconnect. the cables.
Hoist out the power plant. Fit protective caps over
the inner drivers and rubber bellows.
431-1
Page 442
INSTALLING
16.
1.
17.
2.
3.
4.
5.
a. Check that the inner universal joints are packed
with grease.
b. Check the front engine cushion. Make sure that
the washer is properly tightened.
Raise the power plant with the lifting yoke (tool
8292177. Position the power plant in the engine
compartment.
Lower the power plant to a convenient height for
fitting the starter. Connect the cables.
Assemble the inner universal joints as follows:
Hang the clips on the inner drivers. Lower the power plant until it is about 2-2 1/2" (50-60 mm)
from the engine cushions. Assemble the right-hand
universal joint, then lower the power plant until it
is about 1" (20-30 mm) above the engine cushions
and push the power plant to the right. Lower the
power plant and position it over the engine cushions
while guiding the left-hand universal joint into place.
Connect the end piece to the lower control arm.
a. Align the engine brackets.
18.
19.
19.
Cars built to U.S. specifications and other cars with
servo-assisted steering are equipped with special rear
engine cushions. The cushions are designed to prevent the power plant from hitting the steering gear
and damaging it in the event of a collision. A wire
runs between the rear edge of the upper retaining
plate and the front edge of the lower retaining plate
in the cushions. The position of the cushions is determined by guides in the engine bracket and the
cushion.
20.
21.
22.
23.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
431-2
b. Bolt the power plant to the engine cushions.
Remove the lifting yoke.
a. Push the rubber bellows over the inner universal
joint drivers and fit the clamps.
b. Wipe any surplus grease off the rubber bellows
and check that the bellows are not deformed.
a. Connect the gear shift rod joint to the gear selector rod and insert the taper pin.
b. Connect the speedometer cable to the transmission.
Connect the hose to the slave cylinder and bleed the
clutch system. (Model 1975: Fit the slave cylinder
and adjust the clutch.)
Bolt the exhaust pipe to the exhaust manifold.
Lower the front end of the car.
a. Connect the ground cable.
b. Fit the alternator.
Mount the front sheet complete with radiator and
connect the hood lock operating cable to the attachment at the dash panel.
Fit the grille.
Reconnect the cables to the radiator fan, thermostat contact, headlights, headlight wiper motor and
clip the bundle of wiring to the front sheet.
24.
5".S
j_
Connect the coolant hoses to the radiator, thermostat housing, water pump, inlet manifold and heater.
Connect the vacuum hose and fuel hose and connect cables to the temperature transmitter, ignition coil and oil pressure transmitter.
a. Connect the throttle control wire to driver and
bracket.
b. Carbureted engine:
Connect the choke control wire to the carburetor.
Carbureted engine:
a. Mount the air cleaner and preheater complete
with hoses.
b. Connect the ventilation hose.
c. Connect the cables between the distributor and
ignition coil.
d. Connect the fuel pipe.
Injection engine:
a. Mount the air cleaner and mixture control unit
and connect the rubber bellows to the throttle
valve housing and the air flow sensor.
b. Fit the fuel lines.
c. Fit the cables to the warm-up regulator, auxiliary air valve, cold start valve, thermo-time switch
and air flow sensor.
Install the battery and connect the cables.
Close the radiator and engine block drain cocks,
fill with coolant and oil.
Start the engine, checking oil pressure and coolant
temperature. Check the operation of the transmission. Check the operation of the radiator fan by
grounding the thermostat contact cable to the radiator.
a. Mount the hood and connect the windshield
washer hose.
b. Check the fit of the hood. Close the hood, open
the doors, and check that the door jambs clear
the rear edge of the hood.
c. Check the headlight alignment.
Take the car out for a test run. Check the coolant
level after driving.
Page 443
SEPARATING ENGINE FROM MANUAL TRANSMISSION
1. Clean the power plant.
2. Drain the engine oil.
3. Take off the clutch cover.
r
I
~
4. Remove the starter.
5. Withdraw the clutch shaft (see instructions for disassembling the clutch).
6. Model 1975: Remove the three screws in the release
bearing guide sleeve.
As from model 1976: Remove the three slave cylinder
retaining screws.
7. Model 1975: Remove the adjusting screw and the
clutch lever.
8. Remove all bolts in the mating flanges of the engine
and the transmission.
9. Lift the engine carefully off the transmission and remove the release bearing guide sleeve at the same time .
When fitting together the engine and transmission:
Ensure that the mating flanges between the engine
and transmission are absolutely clean.
Check that the two dowels are fitted in the transmission casing.
Fit a new gasket on the transmission housing. Apply
sealing compound to both sides of the gasket as shown
in the illustration above.
Apply thread locking compound to the six bolts in
the holes as indicated in the lower illustration.
•
CAUTION
If the engine and transmission fail to separate, never
attempt to force them apart without first checking
that all bolts have been removed.
Reassemble in the reverse order.
As from model 1978 (primary gear with chain-drive),
apply sealing compound to the three slave cylinder retaining bolts.
SAMI
431-3
Page 445
TRANSMISSION CONTROL
Manual transmission,4-speed
GENERAL
Gear shifting is controlled by a floor-mounted lever located between the front seats.
The gear lever is fitted with a reverse gear catch which
can be released by pulling the ring-shaped handle under
the lever knob upwards. The lever is made in two parts,
insulated from eachother by rubber bearings. The rest
of the transmission control system consists of a gear lever
housing recessed into the floor between the front seats
and a rod that transmits gear lever movements to the
gearbox.
Other gearbox controls include a top cover assembly recessed in the floor between the two front seats and a rod
that transmits the movements of the gear lever to the
gearbox.
The gear control is situated in the gear box and consists
of stop studs in the gear selectors for 1 :st, 2:nd and reverse gear.
S 6117
GEAR LEVER LOCK
1. Housing
2. Spring
3. Locking tongue
4. Cogwheel
5. Toothed segment
6. Lock cylinder
ADJUSTING GEAR POSITIONS, 4 and 5-SPEED
TRANSMISSIONS
1. Engage reverse gear and turn the ignition key to L
(Locked).
2. Move the gear lever back and forth. The gear shift rod
should then have an axial movement of 1.4±0.2 in
(3.5±0.5 mm) Adjust by moving the gear lever housing forward or backward. The screws are removed by
the aid of tool 8790370.
IGNITION AND STARTER CONTACT
Removal
GEAR LEVER LOCK
1.
2.
3.
General
4.
The car is equipped with a combined ignition switch and
gear lever lock. When the gear lever is placed in reverse
and the ignition key withdrawn, the gear lever is Tocked.
The ignition switch has the following positions:
L. Locked. Reverse gear must be engaged befiJre the key
can be turned to L, and the key can only be withdrawn in this position.
Parking lights and hazard warning lights can be
switched on.
G. Garage. All lights can be switched on.
K. Drive. All electrical systems including the ignition circuit are live.
S. Start. This position has a spring-loaded return to K.
The gear lever lock consists of a tongue (3) and cogwheel
(4) actuated by a toothed segment (5) mounted under
the lock cylinder (6). The segmerit turns with the lock
cylinder.
5.
6.
7.
&nMI
L
Disconnect the battery cable.
Remove the driver's seat.
Pull up the rubber bellows and fold back the floor
carpet.
Remove the fixing plate between the heater ducts
in front of the gear lever housing.
Remove the buttons from the heater controls.
Remove the .three gear lever cover retaining screws.
· Lift the cover and disconnect the ignition lock
warning light and electrical connections to the
switch. Remove the cover.
Disconnect the .cables from the ignition lock and
reversing light switch.
432-1
Page 446
8.
9.
10.
Remove the gear lever housing retaining screws
using tool 8391237.
Raise the gear lever housing slightly and twist it so
that the cover plate screws can be undone from underneath. Remove the cover plate.
Remove the two starter switch retaining screws.
1
2
"""'--I++--
3
-+---~-
I
1
4
2
3
l
IGNITION
S 3187
S 6148
AND STARTER CONTACT
GEAR LEVER LOCK
1. Locating stud
2. Setting mark
3. Mark arrow
4. Gear wheel fitting groove
1. Housing
2. Spring
3. Locking tongue
4. Cogwheel
5. Toothed segment
6. Lock cylinder
7. Ignition key
LOCK CYLINDER
Removing
Assembly
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Insert a screwdriver in the slot (4) and turn the contact to bring the mark (2) opposite the arrow (3)
(see illustration).
Check that the ignition key is in position L (locked).
Mount the contact with the locating stud ( 1) in the
matching groove in the gear lever housing.
Turn the ignition key back and forth to make sure
that the gear lever lock does not stick or jam.
Fit the cover plate.
Mount the gear lever housing and adjust the gear
position (see under "Adjustment of gear positions").
Connect the cable to the ignition switch and reversing
light switch. Connect the switch and mount the
lamp in the gear lever cover. Fit the cover.
Refit the buttons on the heater controls.
Mount the fixing plate between the heater ducts.
Replace the floor carpet, and bellows on the gear
lever.
Install the driver's seat.
Connect the battery.
1. Take off the gear lever housing (see section on remov-
ing the gear lever housing).
2. Turn the key to a position between the locking- and
garage position.
3. With the key in this position, the lock cylinder cotter
pin can be pushed in to free the cylinder with the help
of a wire lockpick or similar inserted through a hole
under the gear lever housing (see illustration).
4. Pull out the lock cylinder.
S 2465
PUSHING IN THE CATCH PIN
432-2
WB
Page 447
3. Drill out the plug covering the hole for the lock cylinder catch pin in the gear lever housing.
4. Drive in the catch pin with the aid of a drift approx.
0.08 in. (approx. 2 mm) and remove the lock cylinder.
s
1
Before installation, plug the hole in the gear lever housing
again. The plug is made of a suitable screw or rivet that is
cut to a length of approx. 0.19 in. (approx. 5 mm).
2
S4118
LOCK CYLINDER AND KEY
1. Key
2. Lock cylinder
...····..··•...,,,
,,
2
3
1
0
PRESSING IN THE CATCH PIN
THE LOCK CYLINDER CATCH PIN IS DRIVEN IN WITH THE
AID OF A DRIFT
·-
1. Hole for catch pin
2. Key
3. Lock cylinder
GEAR LEVER HOUSING
Dismantling
Assembling
1. Turn the key in the lock cylinder to a position between
the locking- and garage positions.
2. Push in the lock cylinder catch pin. Check that the
toothed segment driver pins are correctly positioned
to fit in the lock cylinder. Push in the lock cylinder
and check that it is engaged in the toothed segment.
3. Mount the gear lever housing according to the instructions given below.
1. Disconnect the battery cables.
2. Remove the driver's seat.
3. Pull up the rubber bellows on the gear lever, fold up
the floor carpet and remove one of the heater ducts
from in front of the gear lever housing.
4. Remove the taper pin from the joint between the gear
shift rod and the heater ducts.
5. Remove the buttons from the heater controls.
6. Remove the three gear lever cover retaining screws,
raise the cover and remove the ignition lock warning
lamp and electrical connections to the switch. Remove
the cover.
7. Disconnect the cable from the ignition lock and reversing light switch.
8. Remove the gear lever housing retaining screws using
tool 8790370 and remove the housing.
Disassembly when key is missing
If the key is missing, the lock cylinder is removed from
the gear lever housing as follows:
1. Lift out the left front seat and the gear lever housing
protection casing.
2. Loosen the gear lever housing retaining nuts with the
aid of special tool 8790370.
SUS
432-3
Page 448
I
l
.
Assembling
1
1. Install the gear lever housing in position and fit together the gear shift rod and the taper pin.
2. Secure the gear lever housing by means of the special
nuts and tool 8391237, and adjust the gear positions.
See under "Adjustment of gear positions".
3. Connect the cable to the ignition lock and reversing
light switch and connect the switch. Fit the lamp in
the gear lever cover. Fit the cover.
4. Replace the buttons on the heater controls.
5. Install the heater ducts, floor carpets and rubber bellows on the lever.
6. Install the driver's seat.
7. Reconnect the battery.
2
3
,_____
4
5
6
7
8
9
14
:,__J,----10
-t----11
GEAR LEVER
12
Removal
13
17
18
19
1. Undo the three screws under the rubber boot and remove the gear lever from the gear lever housing.
2. Pull out the tension pin from the carrier, screw out
the catch stud and remove the spring.
3. Remove the carrier, the bearing and the cover.
4. Knock carefully with a plastic hammer on the knob,
so that it will loosen from the gear lever and remove
the carrier, the catch rod and the rubber boot.
5. Remove the lock ring, which holds the hollow lever
and the gear lever together and pull out the hollow
lever with its rubber bushing.
20
23
24
22
S5516
Replace damaged or weared parts.
Assembly
SECTION THROUGH GEAR LEVER HOUSING, UP TO AND
INCL. MODEL 1977
1. Knob
2. Carrier
3. Catch rod
4. Gear lever
5. Rubber boot
6. Rubber bushing
7. Washer
8. Hollow lever
9. Slot ring
10·. Washer
11. Rubber bushing
12. Washer
1. Fit slot ring, washers and rubber bushings on the hollow lever.
2. Fit the hollow lever in the gear lever and fit the lock
ring.
3. Fit rubber boot, carrier and catch .rod. Put the spring
into the hollow lever and screw in the catch stud according to the fig., so that the measurement is obtained.4. Fit cover, bearing, carrier and tension pin.
5. Press the knob on the gear lever.
6. Fit the gear lever on the gear lever housing.
432-4
SA.1111
13. Lock ring
14. Cover
15. Bearing
16. Gear lever bearing
17. Carrier
18. Tension pin
19. Spring
20. Gear shift rod
21. Catch stud
22. Bottom part
23. Bearing
24. Rubber bushing
Page 449
14
1
2
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13
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1718
.........
20
1.♦•♦•♦•♦•♦,
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-~-
l'
A
SECTION THROUGH GEAR LEVER HOUSING, AS FROM
MODEL 1978
13. Lock ring
1. Knob
14. Cover
2. Carrier
15. Bearing
3. Catch rod
16. Gear lever bearing
4. Gear lever
17. Carrier
5. Rubber boot
18. Tension pin
6. Rubber bushing
19. Spring
7. Washer
20. Gear shift rod
8. Hollow lever
21. Catch stud
9. Slot ring
22. Bottom part
10. Washer
23. Bearing
11. Rubber bushing
24. Rubber bushing
12. Washer
A = Up to and incl. model
1979: 0.94-1.0 in
(24-25 mm), as from
model 1980: 1.02-1.06
in (26-27 mm)
,
~
432-6
Page 450
GEARBOX CONTROLS
ADJUSTING
GEAR POSITIONS
1. Engage reverse gear and turn the ignition key to L
Manual 5-speedgearbox
General
The gears are changed by a floor-mounted gear lever positioned between the front seats. The gear lever is springloaded between 3rd and 4th gears with the result that
there is a degree of resistance when selecting 1st, 2nd,
5th and reverse gears.
The gear levers is equipped with a reverse gear lockout
which is linked to a lockout pin situated in the lower
section of the gear lever housing. The lockout is overriden by raising the reverse gear lockout release rod
which lies under the the gear lever knob. The gear lever
is in two sections separated from each other by a rubber
bushing.
(Locked).
2. Move the gear lever back and forth. The gear shift rod
should then have an axial movement of 0, 14 ± 0,02"
(3,5 ± 0,5 mm). Adjust by moving the gear lever housing forward or backward.
Remove the gear lever housing nuts using special
socket 87 90 370.
_..,._
Adjusting the gear lever spring-loading
Other gearbox controls include a top cover assembly recessed in the floor between the two front seats and a rod
that transmits the movements of the gear lever to the gearbox. The gear selection controls are in the gearbox and
comprises mechanical stops on 1st and 2nd speed selectors and the reverse gear actuator. The reverse lockout is,
however, unchanged.
The adjustment is made on the control unit positioned
in front of the gear lever housing.
1. Remove the right-hand front seat and fold back sufficient of the carpeting to allow the heating duct rn be
dismantled.
2. Select 3rd gear.
3. Remove the bolts holding the control unit onto the
gear lever housing.
4. Adjust the control unit so that the rollers reach the
bottom of the plunger's groove and the tension spring
adopts its shortest length. Re-tighten the control unit.
5. Return the gear lever to neutral and check that the
springloading moves the gear lever across the gate to
a position opposite 3rd and 4th gears.
6. Refit the heating duct, the carpeting and the righthand seat.
"'"'
S 7444
432-6
SAMI