Page 31
Operating principle
The main components of the Cruise Con-
trol system are the speed transmitter, the
electronic control unit relay, the vacuum
pump, the vacuum requiator, the brake and
clutch pedal switches and the switch on the
steering column, which. incorporates the
positions, SET, RESUME, OFF and ON
When the SET button is depressed, the
speed transmitter sends a signal to the
electronic control unit, informing it of the
speed of the car. The vacuum pump then
starts running and the vacuum raised
moves the diaphragm in the vacuurn reqgu-
lator which, in turn, acts on the throttle
wire. The throttle butterfly then adopts
the correct position for the preselected
speed,
Any change in the speed of the car will be
sensed by the speed transmitter, which will
then send a signal to the electronic control!
unit which, in turn, will signal the vacuum
motor to reduce or increase the vacuum) to
maintain the preselected speed,
Temporary acceleration, e.g. for safe over-
taking, can be: achieved normally by de-
pressing the accelerator, As ‘soon as the
pressure on the accelerator has been re-
leased, the car will return to the pre-
selected cruising speed.
When the brake pedal or clutch pedal is
depressed. the: pedal or switch will break
the circuit esusing the vacuum to be re-
leased, whereupon the throttle butterfly
will return immediately to the position for
idling speed.. For double safety, the
vacuum pump will simultaneously be
switched off electrically.
The electronic control unit incorporates a
memory function which enables the pre-
selected speed to be resumed after tempo-
rary deceleration. If the clutch or brake
pedal is depressed, the pedal switch will
break the circuit, automatically disen-
gaging the Cruise Control. However, if the
control switch is moved to the RESUME
position, the constant cruising speed will
be resumed.
The system will be automatically disengag-
ed and the memory function erased if the
speed of the car falls below 37 km/h (23
mph), if the switch is moved to the OFF
position or if the ignition is switched off.
Page 32
Y ot)
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Ow
The eontrol switch is incorporated in the
direction indicator lever.
The speed transmitter is fitted behind the
speedometer and is accessible after the
speaker grille has been removed.
Ihe electronic control unit and the system
relay are fitted to the relay panel on the
left-hand side of the car under the instru-
ment panel,
1, Fleetronic control unit
2. Relay
391-3
Page 33
The vacuum regulator is mounted on a
bracket on the heater box. Take care not
to damage the rubber gaiter on the requla-
tor during removal) ar refitting. The ball
chain linking the vacuum regulator to the
throttle cable should be as: tight as possi-
ble, without moving the thrattle cable.
The pedal switches are fitted on the same
panel as the brake light switch. The pedal
switches should be adjusted to leave a
clearance of 1 mm between the screw
thread amd the ball tip (see illustration),
Any adjustments should be made with the
pedals in the rest position.
Note
The pedal switches must not be adjust-
ed to a position in which they will
interfere with the pedal movement.
391-4
S$ W558
1. Vacuum tequiator
2. Pedal switches
§ ao73
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Page 34
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Inspection and fault tracing in the event of
malfunctioning of the Cruise Control system
Check that fuse No. 8 has not blown.
Check that cables and vacuum hoses are
correctly connected. Check that the pedal
contacts have been correctly adjusted.
Cheeking the performance of the pedal ”
contacts
The vacuum function can be cheeked by
connecting a hose and blowing through it.
The ecortacts should be closed when the
pedals are in the released position and
should be open when the pedals are de-
pressed.
The electrical performance can be checked
by means of a buzzer. The circuit should be
closed when the contacts are closed and
should be open when the contacts are open.
Cheeking of vacuum pump and regulator,
and leakage check
Remove the connector fram the. vacuum
pump. Connect 12 V to terminal 3 in the
connector. Connect two leads from ground
to terminals 1 and 2 in the connector.
The vacuum pump should now start and the
vacuum regulator should pull the accelera-
tor wire to the bottom, Remove the lead
fram terminal 2. The pump should now stop
and the vacuum regulator should remain in
the bottorn position. If the regulator does
not remain in the bottom position, this
indicates leakage in the system or a fault
an the vacuum pump. Disconnect the lead
from terminal 1. The vacuum regulator
should then return to its rest position. If it
does not, this indicates that the pump is
defective.
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391-5
Page 35
Switch
Diseannect the connector of the switch
from the electrical system. Connect 12 V
to the brown wire (item 2) in the cannec-
tor. Connect a test lamp between ground
and the three leads. The indications provid-
ed by the lamp should be as shown in the
table below. If they are not, replace the
switch, i. Red
2. Brown
3. Green
4. Yellow |
Con- Switch position
hector
Item OFF ON | ON SET RESUME
SPEED
1, Red Lamp off | Lamp an Lamp on Lamp on
3. Green Lamp on | Lamp on Lamp off | Lamp on
4. Yellow | Lamp off | Lamp off | Lamp on Lamp on
;
Checking the wiring
Remove the connector from the electronic Toys
control unit. Use a test lamp to check as 1. Brown a 5. Blue
“specified in the table below.
2. Red/white | || 6. Yellow
3. Black 1] | 7. Orange
4. Green \ | 8. Black
"| 9. Red
391-6
Page 36
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Switch position
Check
Correct reading
Probable fault
Ignition switched
off. Switeh in
OWN position.
Connect the test
lamp between
ground and items
1-9 in the con-
nector.
The lamp should
not light up in
any position.
Poor contact in the
fuse panel or the
black 29-pole
connector,
Ignition switched
on. Switeh tn
OWN position.
Connect the test
lamp between
ground and items
1-9 in the con-
nector.
The lamp should
light up at items
1, 4 and 9.
Fuse 8. Wires.
Vacuum pump. Switch,
Ignition switched
on. Switch in
ON position.
Connect the test
lamp between
item 1 and item 8.
The lamp should
light up.
Ground connection to
the electronic con-
trol unit.
Ignition switched
on. Switeh in
ON position.
A. Connect the test
lamp between item
1 and item 3.
B. Depress the
brake pedal or
clutch pedal.
A. The lamp should
light up.
B. The lamp should
not light up.
Pedal contacts,
Incorrect adjustment
of the pedal contacts,
Ground lead.
Ignition switched Connect the: test A click should be Relay
on. Switch in lamp between ground | heard in the relay. Switch
ON position. and item 2. Set the The lamp should Wires
switch to light up when the
SET SPEED, button is depressed.
Ignition switched Connect the test The lamp should Switeh
on. Switch in ON lamp between ground | light up. Wires
position. and item 6. Set the
switch to RESUME
position.
Ignition switched A. Conneet item 7 A. A click should Vacuum pump
on. Switch in ON to ground. be heard from the Wires
position.
B. Connect another
ground tead to item 4.
yacuum pump.
B. The vacuurn pump
starts.
Items 17, 16 and 19
in the black 29-pole
connector.
391-7
Page 37
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Checking the clutch for wear
Wear on the clutch dise can be checked
through an inspection hole in the clutch
cover. The inspection hole is fitted with a
rectangular cover plate,
1. Disengage the clutch and then release
the pedal, The release bearing will
then be in contact with the fingers of
the pressure plate,
2. Through the inspection hole, check
that the sliding lock ring on the piston
in the slave cylinder is in contact with
the cylinder walls.
3. Check the distance between the gli-
ding lock ring and the lock ring behind
the release bearing.
Checking the clutch for wear; slave
cylinder of Tater design
To check the wear of the clutch disc,
remove the cover plate in the clutch hous-
ing cover and look through the inspection
hole.
If the distance between the plastic sleeve
front edge and the front edge of the turned
surface is less than 2 mm, the clutch dise
should be replaced.
‘Checking the clutch for wear; slave
cylinder of later design
To check the wear of the clutch disc,
remove the cover plate in the clutch hous-
ing caver and look through the inspection
hole,
If the distance between the plastic sleeve
front edge and the front edge of the turned
surface is less than 2 mm, the clutch dise
should be replaced,
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Worn disc
411-5
Page 38
Removal
1. Undo the clip securing the pipe from
the clutch cylinder to the body and
disconnect the pipe from the cylinder.
2. Remove the safety padding located un-
der the instrument panel.
3. Remove the pin holding the push-rod to
the clutch pedal.
4. Remove the nuts on the inside of the
bulkhead and remove the clutch cylin-
der from the engine compartment side.
Disconmect the hose from the fluid
reservoir and hang it up to prevent fluid
from escaping.
Dismantling
Pull back the rubber cover and remove the
circlip with a pair of pliers. Remove, the
push-rod with the washer. The piston and
its seal are now visible. Remove the piston,
washer, seal and spring. Take the seal
carefully off the piston. Examine the
cylinder walls; if they are smooth and
unscratched, new seals can be fitted, but if
the surface of the cylinder bore is rough, a
complete new cylinder should be fitted. If
the old seals on the piston are enlarged or
swollen, they have probably been conta-
minated with mineral oil, and even small
quantities can cause them to swell with
time. If this is suspected, change all the
seals and flush the system with clean
hydraulic brake fluid.
Assembling
Fit the return spring and spoling seat
Lubricate the piston and seals thoroughly
with Girling Rubber Grease 3 and fit the
seal, washer and piston with seals.
The washer must be fitted with the
convex side facing the piston (see il-
lustration).
Clutch master cylinder
Housing
Spring with seat
Seal
Washer
Piston and rear seal
Push-rod with stop washers, circlip and
rubber cover
Cy OO
SEMEL ELA
Fit the push-rod into the cylinder, followed
by the washer and circlip, which are loc-
ated in the cylinder housing groove.
Replace the rubber cover or fit a new one
if the old one is damaged.
412-2
-
S 4539
Correct position of the washer
Ys |
Page 39
Pe
ule
w\@
Dismantling
1. Remove the release bearing from the
slave cylinder,
2. Press out the slave cylinder sleeve and
remove the O-ring from the flange of
the sleeve,
3. Remove the piston and lip seal,
Assembly
Make sure that the slave cylinder has been
thoroughly cleaned. Wash the parts in
brake fluid or a special cleaning fluid for
hydraulic brake components, e.g. a mixture
of cleaning spirit and acetone.
The lip seal should never be allowed to
come into contact with mineral oil. Apply
a thin coating of Castrol Rubber Grease to
the lip seal (not in the groove) and to the
piston (but not the O-ring).
1. Fit the O-ring to the flange of the
sleeve.
2. Slide the lip seal onto the sleeve. Dip
the flange of the sleeve in brake fluid
and insert the sleeve into the cylinder.
Insert the lip seal part of the way into
the cylinder.
3. Guide the sleeve and the cylinder up-
wards by pushing in the piston. The
circlip and the O-ring should be fitted
to the piston (dust seal with circlip on
later design).
4, Place the slave cylinder on a suitable
support (e.g. a spare slave cylinder pis-
ton) and press the sleeve into the cylin-
der.
AA
412-5
Page 40
EE EEEESSS’~'=S’S rr
Manual transmission, 5-speed
The transmission is designed for front-
wheel drive in such a way that all shafts
and gears, the differential and inner uni-
versal joints form an integral unit.
All forward qoars are synchromesh and
reverse is engaged by a sliding gear. The
shafls are journalled in the transmission
housing in ball and taper roller bearings.
The pinion shaft qearwheels ara journalled
on bushes. All gearwheels except reverse
are permanently in mesh engaged and have
helical teeth. The layshaft gears are
mounted on needle bearings and the con-
stant mesh gear is run on individual bails.
The front of the transmission assembly
cansisls of a primary drive which transmits
the engine power via the elutch to the
gearbox itself. The latter is located under.
neath the engine, and part of the transmis-
sion Case serves as an engine oil sump.
The operation of the transmission is j]-
lustrated in the diagram. Shaft power js
transmitted through the clutch and primary
gear Lo the input shaft jn the gearbox.
When the car is being driven in Ist gear,
power is transmitted by the layshaft to the
oh sph TESST V4 ; efit
Manual transmission, 5-speed
pinion shaft through the Ne. J gear, which
is journalled on the pinion shaft and locked
to it by a sliding sleeve,
For driving in ?nd, 3rd or 4th, power js
transmitted to the pinion in the same way
bul with No. 2, No 3 er No. 4 loeked to the
pinian shaft by a sleeve. For driving in top
gear, the input shoft in the gearbox is
lacked to the pinion shaft direct by a
sleeve, i.e. in this case power is not trans-
mitted through the layshaft.
As from
1982 models:
®) flange nut ¥e
5-speed transmission, exploded view
430-3