I.,..
,
THEMA 8.32
Engine page
REMOVING-REFITTING POWER UNIT
- Diagrammatic view of engine, parti al cross section
DISMANTLING AT THE BENCH
II
13
- Order of operations
CYLINDER BLOCK/CRANKCASE
CYLINDER BORES
- Cylinder block/crankcase
Cylinder bores
25
27
CRANKSHAFT AND ASSOCIA TED
COMPONENTS
Crankshaft
Crankshaft bearings
29
31
.
-"""'" - Checking crankshaft bearings pre-Ioading
- Measuring bearing clearance
- Thrust washers
31
33
34
- Crankshaft front cover incorporating oil pump 36
- Crankshaft rear cover 41
- Connecting rod-piston assembly
- Gudgeon pin s
- Piston rings
- Connecting rods
- Diagram showing connecting rod-piston assembly
- Big end bearings
- Measuring bearing clearance
42
43
44
46
48
49
50
CYLINDER HEADS
- Dismantling and checks
- Valves
- Val ve guides
- Camshafts
- Measuring camshaft bearing clearance
Tappets
- Cylinder head tightening
52
55
56
61
62
64
68
('" COOLING SYSTEM
'-'- Water pump (coolant)
FITIING VARIOUS DEVICES
.
Flywheel
LUBRICATION
- Engine oil pressure relief valve
VALVE TIMING
- Timing
- Adjusting timing belt tension
- Adjusting tappet clearance
REASSEMBL y AT THE BENCH
- Checking alignment between damper pulley and water pump control pulley
- Diagram showing operation of engine lubrication system
- Diagram showing operation of cooling system
SPECIAL TOOLS
~TIGHTENING TORQUES
72
96
97
99
101
103
73
74
75
76
77
80
82
84
FUEL SYSTEM
Diagram showing air supply
- Universal fault diagnosis device
"Electronic Analyzer Model PROI "
Warnings .
- Bosch KE3-Jetronic electronically controlled mechanical injection system components
- Diagram for checking air supply system for leaks
- Diagram showing main components to be checked
- Bosch KE3-Jetronic injection system control unit terminal connections
..
DIAGNOSTIC DIAGRAMS
- Checking earth on connection 18
Checking earth on connection 15
- Checking control unit supply for KE3-
Jetronic injection system (and idle servoregulator) from protective relay and appro-
.priate flise
- Checking engine speed impulses coming
~ from Microplex electronic control unit
Checking continuity of pressure servoregulator winding
- Checking idle servo-reguJator winding continuity and operation
- Checking engine coolant temperature sensor resistance
- Checking switch on butterfly valve (idle contact)
- Checking switch on butterfly valve (full power)
- Checking cold start injector coil winding continuity and dynamic operation
- Checking load engagement signale (from the air conditioning- relay contacts)
- Checking load engagement signal (from the air conditioning relay coi!)
- Checking potentiometer resistance continuity
(pins l and 3)
- Checking potentiometer sliding contacts
(pins l and 2)
- Summary of information and tests
IGNITION: DIAGNOSTIC DIA GRAMS
- Microplex electronic ignition system wiring diagram
- Checking Microplex electronic ignition control unit earth
- Checking Microplex electronic ignition control unit supply
- Checking continuity of TDC sensor
- Checking continuity of engine rpm sensor page
109 l II
113
118
120 cont' w::::r
147
148
150
152
154
130
132 r34
136
138
140
142
144
146
122
124
126
128
114 l 15
116
117

r page
- Checking TDC sensor gap and magnetic efficiency
- Checking rpm sensor gap and magen tic efficiency
Checking power module on ignition coil
(13 A)
- Checking power module on ignition coil
(13 B)
- Checking continuity of circuit for advance correction, with butterfly closed
Wiring diagram key (for Supply and Ignition diagnostic diagrams)
Summary of information and tests
FUEL SYSTEM: CHECKS
- Checking electric fuel pump and speedometer relay
'- Connecting remote control simulator to vehicle electrical system
- Draining fuel system for possible service operations
- CoId start injector fuel pressure seal
- Operation of cold start injector
- Electric fuel pump flow rate
- Checking fuel system pressure (Ps)
- Checking fuel system pres sure (holding)
-
Checks 00 fuel distribution-meteriog device aod 00 air flow meter
- Checking sliding of metering device piston and air flow meter levers
- Checking movement of fuel metering device piston vacuum levers
- Checking axial position of floating plate and controllevers
- Checking contact position
Checking radial centering of floating plate
Checking injector opening pressure and jet configuration.
- Checking injectors for fuelleaks
Checking injector flow rates for comparison
Cheekiog servo-regulator adjustmeot pressure and eurreot
- Checking rest current and relative adjustment pressure (Pr)
- Checking enrichment during starting, after starting and during engine warming up stage
- Checking enrichment during acceleration
- Checking enrichment in full load conditions
183
183
183
162
164
166
167
156
158
160
168
170
171
171
171
172
173
174
174
175
175
176
177
178
179
179
180
181
182
- Checking maximum rpm restriction
- Checking fuel distribution-metering device
- Checking operation of idle servo-regulator
- Adjusting butterfly valves during idling
- Adjusting idle mixture metering device
(CO) during idling
- Fuel system fault diagnosis
FUEL SYTEM: OPERATION
- Bosch KE3-Jetronic electronically controlJed mechanical injection system
- Fuel supply cireuit
- Electric fuel pump
- Pressure accumulator
- Fuel filter
- Fue! pressure regulator
- Pressure servo-regu!ator (electro-magnetic)
- Fuel distribution-metering device
- Injectors
- Co Id start injector
- Engine coolant temperature sensor
- KE3-Jetronic injection system control unit
- - Air supply cireuit
- Air flow meter
- Butterfly casings
- Idle speed servo-regulator page
184
184
185
185
186
187
189
197
200
201
202
202
190
190
192
193
193,-.
195
204
204
206
207

THEMA 8.32
Engine
Removing-refitting power unit
10.
Position the vehicle on a lift. Then, proceed as follows:
- drain the coolant;
- remove the bonnet lid;
- disconnect the insufficient engine coolant level electrical cable;
- remove the items illustrated below:
Pipe for air passing from filter to air flow meter
/
8'
I r
.~
Coolant expansion tank
- disconnect the air conditioning compressor drive belt and position it in the engine C0111partment.
Pipe for coolant between the radiator and the expansion tank and the pump

Engine
Removing-refitting power unit
10.
Bulkhead between engine compart-
.
THEMA 8.32
- disconnect the band fixing the serve brake pipe
- disconnect the earth cables on the right head tappet cover
Fuel inlet pipe from the electric pump
Fuel return pipe to the tank
Coolant pipe between heater radiator and pump
- remove the air conditioning compressor and position it in the engine com partment without disconnecting the pipes

THEMA 8.32
Engine
Removing-refitting power unit
10.
- disconnect the electrical cable for the coo\ant temperature sensor (KE3 Jetronic control unit signal), the co0lant temperature sender unit and overheating warning light, the engine oil temperature signal cable, the air conditioning compressor supply cable, the electrica\ cable for the fan switch and the electrical cable for the fan supply.
Microplex electronic ignition control unit multiple COl1l1ector --~
Servo brake vacuum pick up
,
I
Digiplex control unit vacuum pick up
Electric fan
Coolant pipe between the thermostat and the radiator
Air duct on the engine oil filter and mounting
Air filter
"
I
\
Sleeves connecting butterfly casings to air flow meter

Engine
Removing-refitting power unit
10.
- disconnect the coolant pipe between the pump and the heater radiator
THEMA 8.32
- disconnect the 4 pipes on the engine oil filler cap v
-.
- remove the oil filter mounting from the lower front cross member
Engine oil filler

THEMA 8.32
Engine
Removing-refitting power unit
10.
- disconnect the electrical cable for the rpm sensor, the electrical cables for the reversing light switches the earth cable (an the gearbox), the electrical cables for the electronic speedometer, the electrical cable for the switch an the butterfly valve, the electrical cable for the cold start injector, the electrical cable for the potentiometer supply (an the air flow meter), the electrical supply cable for the pressure servo-regulator
(an the fuel distribution-metering device), the electrical cable signalling insufficient engine oil level, the electrical cable signalling engine oil pressure, the electrical cable signalling insufficient engine oil pressure and the idle servo-regulator electrical supply cable
- remove the ABS hydraulic control unit (anti-Iock brakes) from the mounting casing
- remove the rear ignition unit with coil
Mounting for battery and ABS hydraulic control unit
MOllnting for battery and ABS hydraulic control unit

Engine
Removing-refitting power unit
10.
THEMA 8.32
Remove the front wheels
Remove the grille
....
... --
~l
~
Remov the servotronic .power assisted steering pump drive belt.
Remove the power assisted steering pump and position it in the engine compartment without disconnect the oil pipes.

THEMA 8.32
Engine
Removing-refitting power unit
10.
- disconnect the electrical supply cables from the starter motor:
- disconnect the altemator electrical supply cables:
Engine oil filter complete with mOllnting and pipes connected to cooling radiator
- remove the engine oil pipes from the mounting fixing the oil filter to the crankcase and from the mounting fixing the oil filter to the cooling radiator
- remove the servotronic power assisted steering oil circuit cooling coil /
1- remove the condenser and I tum it over towards the olltside af the vehicle:
- disconnect the electrical connections and remove the right and left front side lights:
- disconnector the bon net release cable;
- disconnect the electrical connections and remove the right and left headlamps complete with the lIpper front cross member.
Engine coolant radiator and engine oil co 0ling radiator complete with plastic surround.

Engine
Removing-refitting power unit
10.
.
- raise the vehicle and remove the items illustrated below from underneath:
- remove the 2 drive shafts, right and left
Starter motor heat shield
- remove the 2 gear engagement and selector levers
THEMA 8.32
Gil dip stick and guide
Front exhaust manifold for left head (
..
Front exhaust manifold for right head

THEMA 8.32
Engine
10.
lower car lift and disconnect 3 power unit supports from body;
L..............
position two lifting brackets
(see dimensions overleaf) onto exhaust manifold studs (as shown by the arrows);
position universal hook
1860592000 onto lifting bracket at gearbox; then put power unit under slight tension by hoist;
suitably tilt the engine and lift it;
"

Engine
Removing-refitting power unit
10.
THEMA 8.32
rest power unit on board and remove the 3 supports anchoring to body, gearbox, clutch and starter motor.
NOTE In arder to refit the power unit suitahly reverse the sequence followed for rem oval.
TOOLS TO DE MADE ON THE SPOT
,...,
~
12
~
I
.-
--_o
35
~
180
F1H010J02
Pair of brackets to be used with universal hook 1860592000 and 1860592010 for removingjrefitting power unit.

~EMA 8.32
DlAGRAMMATIC VIEW OF THE ENGINE, PARTIAL CROSS SECfION
Engine
10.
~
~
(~\~
I
~()~'
COI'.rriKlu
hy fla' .'1"(0
=r
II

THEMA 8.32
Engine
Dismantling at the bench
10.
ORDER OF OPERATIONS
- Drain the engine oil whilst the engine is raised off the ground by the hoist;
- Before positioning the engine on the rotating stand, the intermediate drive shaft and the alternator and the drive belt must be removed;
.
- position the engine on the rotating stand using brackets 1861001032 (timing side), 1861001034 (flywheel side) and 1861001037.

THEMA 8.32
Sleeve supplying air to air flow meter
Engine oil return pipe
Engine
10.
- disconnect the injectors
Fuel distribution-metering device with ruel pressure regulator (1) and injector supply pipes

Engine
10.
Air flow meter with air servo-regulator during idling
Inlet manifold for right cylinder head
THEMA 8.32
Inlet manifold for left cylinder head
Air conditioning compressor mounting
{
16
Pipe for supplying additional fuel when idling and cold
1

Engine
10.
Air flow meter with air servo-regulator during idling
Inlet manifold for right cylinder head
THEMA 8.32
Inlet manifold for left cylinder head
Air conditioning compressor mounting
{
16
Pipe for supplying additional fuel when idling and cold
1