Content .. 3 4 5 6 ..

Opel Corsa / Vauxhall. Manual - part 5

Cooling, heating and ventilation systems 3•3

4.3a Remove the thermostat retaining

4.3b . . . and withdraw the thermostat - 1.2

4.6 Removing the thermostat housing . . .

snap-ring . . .

litre model

1.2 litre models

7 Remove the thermostat from its recess,

11 If a thermometer is available, the precise

noting how the projections on the thermostat

opening temperature of the thermostat may

2 Disconnect the radiator top hose from the

fit in cut-outs in the recess (see illustration).

be determined, and compared with the figures

outlet connection at the top of the water

given in the Specifications. The opening

pump. This exposes the thermostat and it will

1.6, 1.8 and 2.0 litre models

temperature is also marked on the thermostat

be seen that it is retained by a snap-ring.

8 Slacken the clip and detach the radiator top

(see illustration).

3 Prise the snap-ring free using a suitable

hose from the thermostat housing

(see

12 A thermostat which fails to close as the

screwdriver blade and then remove the

illustration).

water cools must also be renewed.

thermostat from the pump outlet

(see

9 Unbolt and remove the thermostat cover

illustrations).

Refitting

and extract the thermostat (see illustrations).

1.3 and 1.4 litre models

On 2.0 litre 16-valve models the thermostat is

1.2 litre models

a bayonet fitting in the housing; release it by

4 Remove the camshaft toothed belt cover,

13 Refitting the thermostat is the reverse

depressing it and turning with a pair of

which is secured by five screws.

sequence to removal, but use a new rubber

pointed-nose pliers.

5 Slacken the clip and detach the radiator top

seal and install the thermostat with the arrow

hose from the thermostat housing.

Testing

on the web pointing upwards. Refill the

6 Remove the two bolts and detach the

cooling system, as described in Chapter 1.

10 A rough test of the thermostat may be

thermostat housing (see illustration). On later

All other models

made by suspending it with a piece of string in

models the thermostat housing may not be

a container full of water. Heat the water to

14 Refit in the reverse order to removal; use a

accessible until the camshaft toothed belt

bring it to the boil - the thermostat must open

new rubber seal on the thermostat

(see

back plate has been removed, if necessary

by the time the water boils. If not, renew it.

illustration). Refill the cooling system, as

remove the plate as described in Chapter 2.

described in Chapter 1.

4.7 . . . and withdraw the thermostat from

4.8 Slackening the hose clip at the

4.9a Removing the thermostat cover . . .

its recess - 1.3 litre model

thermostat housing (1.6 litre model shown)

4.9b . . . and the thermostat itself (1.6 litre

4.11 Testing the thermostat

4.14 Fitting a new seal to the thermostat

model shown)

3•4 Cooling, heating and ventilation systems

disturbed components as described in

Chapter 2 Part C. On completion refill the

system as described in Chapter 1.

6 Radiator electric cooling fan -

testing, removal and refitting

Testing

1 The cooling fan is supplied with current via

the ignition switch, relay and a fuse (see

Chapter 12). The circuit is completed by the

cooling fan thermostatic switch, which is

5.4 Removing the water pump - 1.2 litre

5.10 Removing the water pump - 1.8 litre

mounted in the side of the radiator.

model

model shown

2 If a fan does not appear to work, run the

b) Camshaft cover.

engine until normal operating temperature is

5 Water pump - removal and

c) Camshaft sprockets.

reached, then allow it to idle. If the fan does

d) Toothed belt tensioner and idler rollers.

not cut in within a few minutes, switch off the

refitting

e) Crankshaft sprocket.

ignition and disconnect the wiring plug from

f) Toothed belt backplate.

the cooling fan switch. Bridge the two

Removal

12 Remove the three bolts which secure the

contacts in the wiring plug using a length of

water pump to the block. Remove the pump

spare wire, and switch on the ignition. If the

1 Drain the cooling system as described in

Chapter 1 then disconnect the battery earth

and clean the recess in the block.

fan now operates, the switch is probably

lead. Proceed as described under the relevant

faulty and should be renewed.

Refitting

sub-heading.

3 If the fan still fails to operate, check that full

1.2 litre models

battery voltage is available at the feed wire to

1.2 litre models

the switch; if not, then there is a fault in the

13 If a new pump is being fitted, unbolt and

2 Remove the auxiliary drivebelt, as

feed wire (possibly due to a fault in the fan

transfer the pump pulley. Transfer the

described in Chapter 1.

motor, or a blown fuse). If there is no problem

thermostat also, or fit a new one if the old one

3 Slacken the hose clips and disconnect the

with the feed, check that there is continuity

has seen much service.

three hoses from the pump

between the switch earth terminal and a good

14 Before refitting the water pump clean

4 Remove the six retaining bolts and carefully

earth point on the body; if not, then the earth

away all traces of old gasket from the pump

pull the pump off the head (see illustration).

connection is faulty and must be re-made.

and cylinder head mating faces.

Recover the gasket.

4 If the switch and the wiring are in good

15 Apply a little grease to a new gasket and

5 If a new pump is being fitted, unbolt and

condition, the fault must lie in the motor itself.

place it in position on the pump. Refit the

transfer the pump pulley. Transfer the

The motor can be checked by disconnecting

pump and secure the unit with the six bolts

thermostat also, or fit a new one if the old one

the motor wiring connector and connecting a

tightened progressively to the specified

has seen much service.

12 volt supply directly to the motor terminals.

torque.

6 Before refitting the water pump clean away

If the motor is faulty, it must be renewed, as

16 Refit the three hoses and tighten the clips

all traces of old gasket from the pump and

no spares are available.

securely. On completion, refit the drivebelt

cylinder head mating faces.

and refill the cooling system (Chapter 1).

Removal

7 Apply a little grease to a new gasket and

place it in position on the pump. Refit the

1.3, 1.4, 1.6, 1.8 and 2.0 litre 8-valve

5 Disconnect the battery negative terminal.

pump and secure the unit with the six bolts

models

6 Disconnect the fan motor electrical leads at

tightened progressively to the specified

the multi-plug adjacent to the motor. Release

17 Refitting is the reverse of removal, noting

torque.

the following points.

the wiring harness cable-ties at the fan cowl

8 Refit the three hoses and tighten the clips

bracket and move the harness to one side.

a) Fit a new sealing ring to the pump (see

securely. Refit the drivebelt and adjust the

illustration).

7 Undo and remove the two small bolts

tension, as described in Section 9. Finally,

securing the fan cowl to the top of the

b) Ensure that the pump and its recess are

refill the cooling system, as described in

clean and dry and coat the sealing ring

radiator. Lift the fan and cowl assembly

Section 5, and reconnect the battery.

upwards to release the lower mounting lugs

and cylinder block mating surface with

1.3, 1.4, 1.6, 1.8 and 2.0 litre 8-valve

silicone grease or petroleum jelly. This will

and remove the unit from the car.

models

prevent contact corrosion between the

pump and the block, and make things

9 Remove the camshaft toothed belt and the

easier if the pump has to be moved for

toothed belt backplate as described in

adjustment of the camshaft toothed belt.

Chapter 2 Part B.

c) Fit the camshaft toothed belt and tension

10 Remove the three securing bolts and

it as described in Chapter 2 Part B and

withdraw the water pump (see illustration).

tighten the pump bolts to the specified

Note that it may be necessary to remove the

torque.

alternator completely (see Chapter 5A) to

d) On completion refill the cooling system

provide enough room to remove the pump

and adjust the alternator drivebelt as

from the engine bay.

described in Chapter 1.

2.0 litre 16-valve models

11 Working as described in Chapter 2 Part C,

18 Refitting is the reverse of removal using a

removing the following components.

new sealing ring. Tighten the pump mounting

5.17 Fitting a new sealing ring to the pump

a) Camshaft toothed belt.

bolts to the specified torque then refit all

Cooling, heating and ventilation systems 3•5

8 To separate the fan motor from the cowl

Refitting

13 If the gauge needle remains at the `hot’

unscrew the three nuts. The fan blades may

end of the scale, disconnect the sender wire.

7 Refitting is a reversal of removal using a

be withdrawn from the motor spindle after

If the needle then returns to the `cold’ end of

new sealing ring/washer. Securely tighten the

removal of the retaining clip.

the scale when the ignition is switched on, the

switch and top-up/refill the cooling system as

9 Further dismantling of the assembly

sender unit is proved faulty and should be

described in Chapter 1.

depends on the extent of the problem. If the

renewed. If the needle still does not move,

8 On completion, start the engine and run it

motor is defective it would be better to have it

check the remainder of the circuit as

until it reaches normal operating temperature,

overhauled by a specialist, as spare parts may

described previously.

then continue to run the engine and check that

be difficult to obtain. The alternative is to

the cooling fan cuts in and functions correctly.

Removal

renew the motor which may prove cheaper

and quicker in the long run.

Coolant temperature gauge

14 Either partially drain the cooling system to

sender

just below the level of the sender (Chapter 1),

Refitting

or have ready a suitable plug which can be

10 Reassembly, if the unit was dismantled,

Testing

used to plug the sender aperture whilst it is

and refitting to the car are the reverse of the

9 The coolant temperature gauge, mounted

removed. If a plug is used, take great care not

dismantling and removal sequences. On

in the instrument panel, is fed with a stabilised

to damage the sender unit threads, and do

completion run the engine up to normal

voltage supply from the instrument panel feed

not use anything which will allow foreign

operating temperature and check the fan for

(via the ignition switch and a fuse), and its

matter to enter the cooling system.

correct functioning.

earth is controlled by the sender.

15 Disconnect the battery negative lead.

10 The sender is located in the cylinder head,

16 Disconnect the wiring from the sender,

behind the water pump on 1.2 litre engines, in

then unscrew the unit from its location.

7 Cooling system electrical

the inlet manifold on 1.3 and 1.4 litre engines,

switches - testing, removal and

Refitting

and in the thermostat housing on 1.6, 1.8 and

refitting

17 Ensure that the sender threads are clean

2.0 litre engines (see illustration). The sender

contains a thermistor, which consists of an

and apply a smear of suitable sealant to them.

18 Refit the sender, tightening it securely,

electronic component whose electrical

Electric cooling fan thermostatic

and reconnect the wiring.

resistance decreases at a predetermined rate

switch

as its temperature rises. When the coolant is

19 Top-up the cooling system as described

Testing

cold, the sender resistance is high, current flow

in “Weekly checks”

through the gauge is reduced, and the gauge

20 On completion, start the engine and

1 Testing of the switch is described in

needle points towards the `cold’ end of the

check the operation of the temperature

Section 6, as part of the fan test procedure.

scale. If the sender is faulty, it must be renewed.

gauge. Also check for coolant leaks.

Removal

11 If the gauge develops a fault, first check

Fuel injection system coolant

2 The switch is located in the side of the

the other instruments; if they do not work at

temperature sensor

radiator (see illustration). The coolant should

all, check the instrument panel electrical feed.

be cold before removing the switch.

If the readings are erratic, there may be a fault

21 Refer to Chapter 4.

3 Disconnect the battery negative lead. If

in the voltage stabiliser, which will necessitate

necessary, firmly apply the handbrake then

renewal of the stabiliser (see Chapter 12). If

8 Heater/ventilation system -

jack up the front of the vehicle and support it

the fault lies in the temperature gauge alone,

general information

on axle stands (see “Jacking and Vehicle

check it as follows.

Support”). Access to the switch can then be

12 If the gauge needle remains at the `cold’

gained from underneath the vehicle.

The heater operates by passing fresh air,

end of the scale, disconnect the sender wire,

4 Either drain the cooling system to below the

drawn in from the area at the base of the

and earth it to the cylinder head. If the needle

level of the switch (as described in Chapter 1),

windscreen, through a matrix which is heated

then deflects when the ignition is switched on,

or have ready a suitable plug which can be

by engine coolant.

the sender unit is proved faulty, and should be

used to plug the switch aperture in the

Temperature regulation is achieved by

radiator whilst the switch is removed. If a plug

renewed. If the needle still does not move,

mixing hot and cold air. Flap valves are used

is used, take great care not to damage the

remove the instrument panel (Chapter 12) and

for this; other flap valves direct the air to the

radiator, and do not use anything which will

check the continuity of the wiring between the

windscreen, floor or side outlets.

allow foreign matter to enter the radiator.

sender unit and the gauge, and the feed to the

An electric fan is used to boost airflow

5 Disconnect the wiring plug from the switch.

gauge unit. If continuity is shown, and the

through the heater when the normal ram

6 Carefully unscrew the switch from the

fault still exists, then the gauge is faulty, and

airflow is insufficient, or in extreme climatic

radiator and recover the sealing ring/washer.

the gauge unit should be renewed.

conditions.

Fresh air is available at the centre vents,

regardless of the heater settings. Stale air is

exhausted through grilles towards the rear of

the vehicle.

9 Heater components - removal

and refitting

Control panel

1 Remove the front half of the centre console,

as described in Chapter 11.

2 Remove the radio (if fitted) and its surround,

7.2 Cooling fan thermostatic switch

7.10 Disconnecting the temperature

as described in Chapter 12. If a radio is not

screwed into side of radiator

gauge sender wire (1.8 litre model shown)

fitted, remove the blanking plate.

3•6 Cooling, heating and ventilation systems

9.3 Exploded view of heater components

1 Facia panel

9 Side vent housing

17 Air mix (temperature) cable

2 Bulkhead

10 Side vent housing

18 Upper distribution cable

3 Blower motor

11 Side ducts

19 Lower distribution cable

4 Centre duct

12 Windscreen ducts

20 Air mix flaps

5 Centre vent housing

13 Air distribution housing (upper half)

21 Upper distribution flap

6 Swivelling vents

14 Air distribution housing (lower half)

22 Lower distribution flap

7 Controls

15 Heater matrix

8 Side grilles

16 Air distribution housing cover

Cooling, heating and ventilation systems 3•7

9.4a Removing a screw from the top of the

9.4b Heater control panel side screw

9.5 Removing the heater control panel

radio aperture

3 Detach the three control cables from the air

8 Remove the water deflector by freeing it

control panel is recommended, as described

distribution housing, noting their locations for

from under the rubber seal and extracting its

earlier in this Section, to improve access.

refitting. Their sleeves are colour-coded as

securing clip (see illustrations). It may also

14 Under the bonnet, clamp the coolant

follows (see illustration):

be necessary to slacken or remove one of the

hoses at the heater matrix stubs (below the

Brown - Foot level distribution

wiper spindle nuts.

steering rack) and disconnect them. Be

White - Hot/Cold air mix

9 Disconnect the multi-plug, remove the two

prepared for coolant spillage.

Black - Screen level distribution

securing nuts and remove the motor (see

15 Remove the four screws which secure the

4 Remove the two screws from the top of the

illustration).

air

distribution housing cover

(see

radio aperture and the two side screws, one

10 If the housing halves are unclipped, the

illustrations). The carpet will have to be

on each side (see illustrations).

motor and ballast resistor can be removed by

turned back to get at the lower ones.

5 Draw the control panel away

(see

undoing the two screws at the resistor end

16 Disconnect the rear heating duct bellows,

illustration). To remove it completely,

(see illustration). Spares for the meter are not

when fitted, and remove the air distributor

disconnect the wires from the blower switch

available, but a competent auto-electrician

housing cover.

and (when fitted) the cigarette lighter.

may be able to repair certain types of fault.

17 Remove the three screws which secure

6 Refit in the reverse order to removal. No

11 Refit in the reverse order to removal.

the heater matrix (see illustrations). The air

adjustment of the cable is required: correct

mix flap will have to be moved in order to get

Heater matrix

length is achieved by the precise location of

at the top two screws. Remove the matrix

the cable outer clamps.

12 Remove the front half of the centre

brackets.

console, as described in Chapter 11.

18 Withdraw the matrix into the car, keeping

Blower motor

13 Disconnect the control cables from the air

it as flat as possible to minimise coolant

7 Remove the wind deflector, (Chapter 11).

distribution housing. Removal of the heater

spillage.

9.8a Lift the rubber seal to free the water

9.8b Water deflector clip

9.9 Removing a blower motor securing nut

9.10 Blower motor-to-housing screws

9.15a Removing an air distribution

9.15b Air distribution housing lower screw

(arrowed)

housing upper screw

(arrowed)

3•8 Cooling, heating and ventilation systems

10 Vents and grilles - removal

and refitting

1 The flat grilles at each end of the facia

simply unclip. According to equipment level

they may also cover a loudspeaker

(see

illustration).

2 The swivelling vents can be unclipped after

swivelling them downwards as far as possible.

The side vent housings are secured by a

single screw and clips (see illustration); the

clips will probably be destroyed during

9.17a Removing the heater matrix lower

9.17b Heater matrix upper securing

removal.

screw

screws (arrowed)

3 The centre vent housing is secured by four

19 Refit in the reverse order to removal; top-

23 Disconnect the hoses and ducts which

screws, two above and two below

(see

up the cooling system on completion (Weekly

connect the air distribution housing to the

illustration). The lower screws also secure

checks).

facia panel ducts.

the radio surround. This housing also carries

the clock, when fitted, which must be

24 Remove the two remaining screws, one at

Air distribution housing

disconnected when removing the housing.

each end, which secure the facia panel. Pull

20 Remove the blower motor and the heater

4 The air extraction grilles on the outside of

the facia panel away on the passenger side

matrix, as described earlier in this Section.

the vehicle can be carefully prised out of their

and have an assistant withdraw the air

21 Remove the five nuts which secure the

locations with a wooden or plastic wedge,

distribution housing, also towards the

facia panel and the pedal bracket to the

being careful not to damage the paintwork.

passenger side.

bulkhead.

5 All these components can be refitted by

25 Refit in the reverse order to removal. Use

22 Remove the steering column switch

simply clipping and/or screwing them back

new self-locking nuts when securing the facia

shrouds. On models with an adjustable

into position

panel and pedal bracket to the bulkhead.

column, also remove the adjuster knob and

the column lower cover. Refer to Chapter 10 if

26 Top-up the cooling system on

necessary.

completion.

10.1 Removing an end grille and speaker

10.2 Removing a swivelling vent housing

10.3 Removing a centre vent housing

securing screw

screw

4A•1

Chapter 4 Part A:

Fuel and exhaust systems - carburettor models

Contents

Accelerator cable - removal, refitting and adjustment

Idle cut-off solenoid - description and testing

Accelerator pedal - removal and refitting

Idle speed and mixture adjustment

See Chapter 1

Air cleaner air temperature control system - general information

Inlet manifold - removal and refitting

Air cleaner filter element renewal

See Chapter 1

Inlet manifold pre-heater (1.6 litre models with automatic transmission)

Air cleaner housing - removal and refitting

- general information, removal and refitting

Carburettor - description

Unleaded petrol - general information and usage

Carburettor - removal and refitting

Varajet ll carburettor - adjustments

Choke cable - removal, refitting and adjustment

Varajet ll carburettor - overhaul

Exhaust manifold - removal and refitting

1B1 carburettor - adjustments

Exhaust system - inspection, removal and refitting

1B1 carburettor - overhaul

Fuel filter renewal

See Chapter 1

2E3 carburettor - adjustments

Fuel pump - testing, removal and refitting

2E3 carburettor - overhaul

Fuel tank - removal and refitting

32 TL carburettor - adjustments

Fuel tank sender unit - removal and refitting

32 TL carburettor - overhaul

General fuel system checks

See Chapter 1

35 PDSI carburettor - adjustments

General information

35 PDSI carburettor - overhaul

Degrees of difficulty

Easy, suitable for

Fairly easy, suitable

Fairly difficult,

Difficult, suitable for

Very difficult,

novice with little

for beginner with

suitable for competent

experienced DIY

suitable for expert

experience

some experience

DIY mechanic

mechanic

DIY or professional

Specifications

Fuel pump

Operation

Mechanical from camshaft

Pressure

0.25 to 0.36 bar

Carburettor application

1.2 litre models

32 TL

1.3 litre models:

13N engine

35 PDSI

13SC engine

2E3

13NB engine

1B1

1.4 litre models

2E3

1.6 litre models

16SH engine

Varajet II

16SV engine

2E3

32TL Carburettor data - 12SC engine

Needle valve

1.75 mm

Venturi diameter

25 mm

Main jet

117

Mixture outlet

2.5 mm

Air correction jet

Mixture

F96

Idle fuel jet

Idle air jet

Idle mixture jet

210

Auxiliary mixture fuel jet

Auxiliary mixture air jet

170

Auxiliary mixture jet

100

Full load enrichment jet

Partial load enrichment jet (idle)

Partial load enrichment jet (main)

Accelerator pump jet

4A•2 Fuel and exhaust systems - Carburettor models

32TL Carburettor data - 12SC engine (Continued)

Accelerator pump return jet

Accelerator pump delivery

6.5 to 9.5 cc per 10 strokes

Pull-down reduction jet

Pull-down adjustment (choke valve gap)

4.3 to 4.8 mm

Throttle valve gaps:

Fast idle

0.6 to 0.7 mm

Mechanical pull-down

0.8 to 0.9 mm

Fast idle speed

3600 to 4000 rpm

Float level

23.5 to 24.0 mm

Vacuum at idle speed

1 to 20 mbar

35 PDSI Carburettor data - 13N engine

Needle valve

1.75 mm

Needle valve sealing ring

2.5 mm

Venturi diameter

26 mm

Mixture outlet

2.4 mm

Accelerator pump delivery:

Manual gearbox

10 ± 1.0 cc per 1 0 strokes

Automatic transmission

7 ± 1.0 cc per 10 strokes

Accelerator pump arm

Throttle valve shaft

Main jet

X122.5

Air correction jet

Idle cut-off jet

Pump injector tube

Enrichment jet in float chamber:

Manual gearbox

Automatic transmission

Enrichment jet in cover:

Manual gearbox

100

Automatic transmission

Auxiliary fuel jet

Auxiliary mixture jet

5.0

2E3 Carburettor data - 13SC engine

Primary

Secondary

Venturi diameter

20 mm

24 mm

Main jet

X97.5

X112.5

Air correction jet

100

Emulsion tube code number

Partial load enrichment orifice

0.5 mm

Pre-atomiser diameter

8 mm

7 mm

Mixture outlet orifice

2.5 mm

3.0 mm

Idle fuel jet

37.5

Idle air jet

130

Full load enrichment jet

85 to 105

Automatic choke adjustment data:

Choke valve pull-down gap

2.1 to 2.5 mm

Fast idle speed

2400 to 2800 rpm

Throttle valve fast idle gap

1.1 to 1.2 mm

Accelerator pump delivery:

Manual transmission

10.3 to 12.7 cc per 10 strokes

Automatic transmission

7.8 to 10.2 cc per 10 strokes

Float level

29 to 30 mm

1B1 Carburettor data - 13NB engine

Venturi

25 mm

Air correction jet/emulsion tube

57.5/18

Main jet

X112.5

Auxiliary jet

42.5/155

Idle jet

47.5/147.5

Part-load enrichment:

In housing

100

In adapter

0.3

Float level (not adjustable)

28.5 + 1 mm

Throttle valve gap:

Manual

0.55 to 0.65 mm

Automatic

0.70 to 0.80 mm

Choke valve gap

3.1 to 3.5 mm

Accelerator pump delivery

4.5 to 7.5 ml per 10 strokes

Fast idle speed

3500 to 3900 rpm

Fuel and exhaust systems - Carburettor models 4A•3

2E3 Carburettor data - 14 NV engine

Primary

Secondary

Venturi diameter

20 mm

24 mm

Main jet

X95

X110

Air correction jet

117.5

Emulsion tube

103

Part load enrichment

0.55 mm

Idle fuel jet

Idle air jet

130

Full load enrichment jet

57.5 to 77.5

Check valve gap (see text):

Vacuum, small

1.7 to 2.1 mm

Vacuum, large

2.5 to 2.9 mm

Mechanical (full throttle)

1.5 to 3.5 mm

Throttle valve gap

0.8 to 0.9 mm

Accelerator pump delivery

10.5 to 13.5 ml per stroke

Float level

29 ± 1 m

Fast idle speed

2200 to 2600 rpm

Varajet II Carburettor data - 16SH engine

Fast idle speed:

Manual gearbox

2050 to 2150 rpm

Automatic transmission

2250 to 2350 rpm

Choke valve gaps (see text):

2.8 to 3.4 mm

2.3 to 2.8 mm

9.5 to 10.5 mm

Automatic choke cover adjustment

1 mark towards L

Float level

4.5 to 6.5 mm

Idle jet

0.65 mm

Primary main jet

204

Primary main jet needle

151

Secondary main jet

3.20 mm

Secondary main jet needle

2.20 mm (marked G)

Float needle valve diameter

1.93 mm

2E3 Carburettor data - 16 SV engine

Primary

Secondary

Venturi diameter

20 mm

24 mm

Main jet

X95

X105

Air correction jet

110

Emulsion tube

Idle fuel jet

42.5

Idle air jet

132.5

Full load enrichment jet

85to 105

Choke valve gap (see text):

Manual

Automatic

Vacuum, small

1.3 to 1.7 mm

1.4 to 1.8 mm

Vacuum, large

1.9 to 2.3 mm

2.0 to 2.4 mm

Mechanical (full throttle)

1.5 to 3.5 mm

3.0 to 5.0 mm

Throttle valve gap

0.8 mm

Accelerator pump delivery:

Manual

10.5 to 13.5 ml per 10 strokes

Automatic

7.5 to 10.5 ml per 10 strokes

Fast idle speed:

Manual

2000 to 2400 rpm

Automatic

2500 to 2900 rpm

Idle speed adjustment data

Idle speed:

All models with manual gearbox

900 to 950 rpm

All models with automatic transmission

800 to 850 rpm (in P)

CO level at idle

1.0 to 1.5%

Recommended fuel grade

Minimum octane rating (see Section 2):

1.2 litre models:

Vehicles up to February 1985

98 RON leaded (4-star) or 95 RON unleaded (unleaded premium)**

Vehicles from February 1985 onwards

98 RON leaded (4-star) or 95 RON unleaded (unleaded premium)*

1.3 litre models:

13N and 13NB engines

91 RON leaded (4-star) or 95 RON unleaded (unleaded premium)

13SC engine

98 RON leaded (4-star) or 95 RON unleaded (unleaded premium)*

4A•4 Fuel and exhaust systems - Carburettor models

Recommended fuel grade (Continued):

1.4 litre models

98 RON leaded (4-star) or 95 RON unleaded (unleaded premium)

1.6 litre models:

16SH engines

98 RON leaded (4-star) or 95 RON unleaded (unleaded premium)*

16SV engines

98 RON leaded (4-star) or 95 RON unleaded (unleaded premium)***

*If the ignition timing is retarded by 3º, 95 RON unleaded (unleaded premium) petrol can be used (see Chapter 5 for details)

**After 5 tankfuls of unleaded fuel, one tankful of leaded fuel must be used

***If the octane rating plug is position correctly, 95 RON unleaded (unleaded premium) petrol can be used (see Section 2 for details)

Torque wrench settings

lbf ft

Inlet manifold nuts or bolts:

1.2 litre models

1.3 and 1.4 litre models

1.6 litre models

Carburettor securing nuts:

1.2 litre models

1.3 and 1.4 litre models

1.6 litre models

Fuel pump to camshaft housing:

1.3 and 1.4 litre models

1.6 litre models

shown in the Specifications, followed by the

Chapter 5 for details). Do not use 95 (RON)

equivalent petrol currently on sale in the UK.

unleaded petrol if the ignition timing has not

1 General information

2 RON and MON are different testing

been retarded.

standards; RON stands for Research Octane

10 Later models with a 16SV engine have a

The fuel system consists of a fuel tank

Number (also written as RM), while MON

fuel octane rating coding plug in the ignition

mounted under the rear of the car, a

stands for Motor Octane Number .

system wiring harness (see illustration). The

mechanical fuel pump and a carburettor. The

3 If it is wished to run the vehicle on 95 (RON)

plug which is located on the right-hand side of

fuel pump is operated by an eccentric on the

unleaded petrol the following operations must

the engine compartment, is set during

camshaft and is mounted on the rear of the

first be carried out; this is necessary to avoid

production to give optimum engine output

cylinder head. The air cleaner contains a

detenation

(knocking and pinking) which

and efficiency when run on 98 (RON) fuel. To

disposable paper filter element and

could lead to possible engine damage.

run the vehicle on 95 (RON) unleaded fuel,

incorporates a flap valve air temperature

make sure the plug is set to the “95” position

1.2 litre models

(95 should be visible on the side of the plug).

control system which allows cold air from the

outside of the car and warm air from the

4 On 1.2 litre models produced prior to

To reset the plug, release its locking clip then

exhaust manifold to enter the air cleaner in the

February 1985, unleaded fuel can be used in

remove the plug and rotate it through half a

correct proportions.

these models but note that to every five

turn (180º) before reconnecting it. Note: If

The fuel pump lifts fuel from the fuel tank

tankfuls of unleaded fuel used, one tankful of

after making the adjustment, the octane rating

via a filter and supplies it to the carburettor.

leaded fuel must also be used.

of the fuel used is found to be so low that

Excess fuel is returned from the anti-

5 On later models, to allow the vehicle to run

excessive knocking still occurs, seek the

percolation chamber to the fuel tank.

on 95 (RON) unleaded petrol, the ignition

advice of your Vauxhall dealer.

Warning: Many of the

timing must be retarded by 3º (see Chapter 5

procedures in this Chapter

for details). Do not use 95 (RON) unleaded

3 Air cleaner housing - removal

require the removal of fuel lines

petrol if the ignition timing has not been

and refitting

and connections which may

retarded.

result in some fuel spillage.

Before carrying out any operation on the

1.3 litre models

Removal

fuel system refer to the precautions given

6 On models with 13N and 13NB engines, 95

1 Remove the centre retaining nut or bolt or

in Safety first! at the beginning of this

(RON) unleaded fuel can be used without any

the three screws from the air cleaner cover.

Manual and follow them implicitly. Petrol

modifications.

is a highly dangerous and volatile liquid

2 Lift the air cleaner off the carburettor,

7 On models with a 13SC engine, to allow the

and the precautions necessary when

vehicle to run on 95 (RON) unleaded petrol,

handling it cannot be overstressed.

the ignition timing must be retarded by 3º (see

Chapter 5 for details). Do not use 95 (RON)

2 Unleaded petrol - general

unleaded petrol if the ignition timing has not

information and usage

been retarded.

Note: The information given in this Chapter is

1.4 litre models

correct at the time of writing and applies only to

8 All models can be run on

(RON)

petrols currently available in the UK. If updated

unleaded fuel can be used without

information is thought to be required check

modification.

with a Vauxhall dealer. If travelling abroad

1.6 litre models

consult one of the motoring organisations (or a

similar authority) for advice on the petrols

9 On models with a 16SH engine, to allow the

available and their suitability for your vehicle.

vehicle to run on 95 (RON) unleaded petrol,

2.10 Octane plug in the “95” position -

1 The fuel recommended by Vauxhall is

the ignition timing must be retarded by 3º (see

later 1.6 litre models

Fuel and exhaust systems - Carburettor models 4A•5

3.2a Hot air pick-up tube (arrowed)

3.2b Air cleaner vacuum hose connection

3.2c Air cleaner hose connection

engages with air cleaner

disengaging the hot air pick-up from the

cold air ports according to temperature and

2 The pump can also be tested by removing it.

manifold shroud (where necessary), together

manifold vacuum.

With the pump outlet pipe disconnected but

with the breather and vacuum hoses (see

6 A vacuum motor operates the flap valve

the inlet pipe still connected, hold a wad of rag

illustrations).

and holds it fully open when the temperature

by the outlet. Operate the pump lever by hand,

in the air cleaner is below a predetermined

moving it in and out; if the pump is in good

Refitting

level. As the air inlet temperature rises the

condition the lever should move and return

3 Refit by reversing the removal operations,

vacuum motor opens or closes the flap valve

smoothly and a strong jet of fuel ejected.

making sure that the gasket or sealing ring is

dependent entirely on manifold vacuum. Thus,

in place on the carburettor.

during light or constant throttle applications,

Removal

the flap valve will remain open, supplying the

3 Disconnect the battery earth lead.

carburettor with hot air, and will close under

4 Mark the pump inlet and outlet hoses, for

4 Air cleaner air temperature control

heavy throttle application so that only cold air

identification purposes then slacken both

system - general information

enters the carburettor.

retaining clips (see illustration). Place wads

7 As the temperature in the air cleaner rises

of rag beneath the hose unions to catch any

1.2 litre models

further the vacuum motor closes the flap valve

spilled fuel then disconnect both hoses from

therefore allowing only cold air to enter the

the pump and plug the hose ends to minimise

1 Inlet air pre-heating is controlled manually

carburettor under all operating conditions.

fuel loss.

by a flap valve located in the side of air

8 The vacuum motor is operated by vacuum

5 Remove the pump retaining nuts or bolts

cleaner casing. The valve can be set in any

created in the inlet manifold and is controlled

and washers and withdraw the pump from the

one of three positions according to seasonal

by a temperature sensing unit located inside

engine. Recover the spacer and

(where

operating temperature as shown in the

the air cleaner.

necessary) the gaskets on either side of it

following table.

(see illustration).

Summer position - above 10°C

Intermediate position - 10°C to -5°C

5 Fuel pump - testing, removal

Refitting

Winter position - below -5°C

and refitting

6 Refitting is a reversal of removal, but use

2 In terms of fuel economy the engine will run

new flange joint gaskets (where necessary).

most efficiently with the valve set in the

Note: Refer to the warning note in Section 1

summer position and least efficiently in the

before proceeding.

winter position. Providing the engine is

6 Fuel tank sender unit - removal

running smoothly, and accelerates evenly, the

Testing

and refitting

summer position may be retained down to

1 To test the fuel pump on the engine,

0°C. If roughness or hesitation occurs, move

disconnect the outlet pipe which leads to the

Note: Refer to the warning note in Section 1

the flap valve to the next position.

carburettor, and hold a wad of rag over the

before proceeding.

3 The three positions are shown on the air

pump outlet while an assistant spins the

Removal

cleaner cover. In the winter position only hot

engine on the starter. Keep the hands away

air from the hot air box on the exhaust

from the electric cooling fan. Regular spurts of

1 Proceed as described in Section

manifold enters the air cleaner. In the summer

fuel should be ejected as the engine turns.

paragraphs 1 to 3.

position only cold from the air cleaner inlet

spout enters. In the intermediate position a

blended supply from both sources enters the

air cleaner.

1.3, 1.4 and 1.6 litre models

4 A thermostatically controlled air cleaner is

used to regulate the temperature of the air

entering the carburettor according to ambient

temperatures and engine load. The air cleaner

has two sources of supply, through the normal

inlet spout (cold air) or from a hot air box

mounted on the exhaust manifold (hot air).

5 The airflow through the air cleaner is

controlled by a flap valve in the air cleaner

5.4 Fuel inlet (A) and outlet (B) hose

5.5 Removing the fuel pump (1.3 litre

spout, which covers or exposes the hot or

connections - typical

engine shown)

4A•6 Fuel and exhaust systems - Carburettor models

6.2 Fuel gauge sender unit (screw-fit

6.3 Fuel gauge sender unit secured by

7.11 Fuel tank filler pipe-to-neck junction

sender unit)

bolts

2 Disconnect the electrical leads from the

thread protruding through the handbrake

Estate and Van

sender unit (see illustration).

cable adjusting locknut at the compensating

17 The procedure is similar to that just

3 To remove the sender unit, either engage a

yoke on the rear axle.

described, but note the following points:

flat piece of steel as a lever between two of

6 Hold the cable with pliers or a spanner,

a) The fuel filler pipe must be unscrewed

the raised tabs on the sender unit and turn it

unscrew the adjusting nut and remove the

from the rear quarter panel (see

anti-clockwise to release it, or undo the

cable end from the yoke.

illustration).

retaining bolts

(as applicable)

(see

7 Remove the retainer and detach the cable

b) There is no need to disconnect the

illustration).

from the connecting link located just to the

handbrake cable or to remove the exhaust

4 Withdraw the sender unit carefully to avoid

rear of the handbrake lever rod.

system.

bending the float arm. Recover the sealing

8 Detach the cable from its retainers on the

ring.

fuel tank and underbody and move it clear of

Refitting

the tank.

18 Refit in the reverse order to removal.

Refitting

9 Disconnect the two electrical leads from the

Renew hoses, clips etc as necessary, and

5 Refit in the reverse order to removal, using

fuel gauge sender unit.

adjust the handbrake on completion, as

a new sealing ring if necessary.

10 Remove the single bolt which secures the

described in Chapter 1.

fuel filler pipe to the underbody.

11 Slacken the hose clips and disconnect the

7 Fuel tank - removal and refitting

filler

pipe from the tank neck

(see

8 Accelerator cable - removal,

illustration). Unclip the vent hose.

refitting and adjustment

12 Support the tank with a jack and suitable

Note: Refer to the warning note in Section 1

blocks of wood, or have an assistant hold it

before proceeding.

Removal

up, then undo the two retaining strap nuts

(see illustration).

1 Remove the air cleaner as described in

Removal

13 Pivot the straps out of the way of the tank

Section 3.

1 Disconnect the battery negative lead cap.

14 Lower the tank slightly and, when

2 Extract the spring clip (when fitted) and

Remove the fuel tank filler cap.

sufficient clearance exists, disconnect the

disconnect the cable ball end from the

2 A drain plug is not provided and it will

overflow and vent hoses from the top of the

carburettor throttle lever (see illustration).

therefore be necessary to syphon or hand

tank

3 Slide the cable outer bush out of the

pump all the fuel from the tank before

15 Lower the tank fully and slide it out from

support bracket on the carburettor

(see

removal.

under the car.

illustration).

3 Having emptied the tank, jack up the rear of

16 If the tank is contaminated with sediment

4 Inside the car, release the cable from the

the car and support it on axle stands (see

or water, remove the sender unit and swill out

‘keyhole’ fitting on the pedal by easing back

“Jacking and Vehicle Support”).

the tank with clean fuel. If the tank is

the spring and prising the cable end out of the

Hatchback and Saloon models

damaged, or leaks, it should be repaired by a

slot.

4 Remove the exhaust system as described

competent specialist or renewed. Do not

5 Release the grommet from the bulkhead

in Section 27.

attempt to solder or weld a fuel tank yourself.

and pull the cable into the engine

5 Measure and record the length of exposed

compartment.

7.12 One of the fuel tank retaining strap

7.17 Fuel filler pipe retaining screws -

8.2 Accelerator cable ball and spring clip

nuts (arrowed)

Estate model

Fuel and exhaust systems - Carburettor models 4A•7

enrichment valve, ensure efficient operation

under all speed and load conditions.

4 The GM Varajet ll carburettor fitted to 1.6

models is also a twin barrel type, but the main

fuel jet is controlled by a tapered needle valve.

The design is well proven and has been used

on several earlier models.

5 All carburettors have a bypass system for

providing idle mixture, and an accelerator

pump for mixture enrichment when the

throttle is opened rapidly.

6 When an automatic choke is fitted, the

choke cover is heated electrically when the

8.3 Accelerator cable bracket and bush

8.7 Accelerator cable adjustment to

engine is running; as the cover warms up, the

provide clearance at point arrowed

choke is released. On the 2E3 carburettor the

choke cover is also heated by engine coolant.

Refitting

by a grub screw which must be undone with

Both types of automatic choke need to be

an Allen key.

6 Refit in the reverse order to removal.

‘primed’ by depressing and releasing the

6 Release the bulkhead grommet and remove

accelerator pedal before starting the engine

Adjustment

the cable.

from cold.

7 Adjust the cable, by selecting the

Refitting

appropriate position of the spring clip behind

7 Refit in the reverse order to removal,

1232 TL carburettor -

the cable outer bush, to give a small amount

adjusting the cable as follows.

adjustments

of free play in the inner cable when the pedal

is released. On 1.3 litre models with 13NB

Adjustment

engine, make sure that with the choke control

Note: Under normal operating conditions only

8 Adjust the positions of the inner and outer

the carburettor idle adjustments described in

pushed fully home there is a small clearance

cables at the carburettor so that, with the

Chapter 1 will need attention. Checking and

between the fast idle adjuster screw and the

control knob pushed home, there is a small

adjustment of the following settings is not a

choke cam plate (see illustration).

amount of slack in the inner cable. Secure the

routine operation and should only be

cable in position then operate the choke

necessary after carburettor overhaul or if the

9 Accelerator pedal - removal

control knob and check that the choke linkage

operation of the carburettor is suspect.

and refitting

opens fully.

Idle speed and mixture

1 Refer to Chapter 1.

Removal

11 Carburettor - description

Fast idle

1 If necessary, remove the under-dash trim

2 This operation may be carried out with the

on the driver’s side to improve access.

1 Several types and makes of carburettor are

carburettor installed or removed. If the

2 Disconnect the accelerator cable from the

fitted to the vehicles covered by this manual.

carburettor is removed, rotate the choke

pedal, as described in Section 8.

All are of the downdraught type.

linkage on the side of the carburettor until the

3 Prise the spring clip off the end of the

2 The 32 TL carburettor fitted to the 1.2 engine

linkage arm is against its stop and the choke

accelerator pivot. Remove the pedal,

is a fixed jet, single barrel instrument. The 35

valve is fully closed.

recovering any spacers, washers, bushes etc,

PDSI and 1B1 fitted to low compression

3 With the linkage held in this position a small

and unhooking the pedal return spring.

versions of the 1.3 engine are similar.

drill bit, of diameter equal to the fast idle valve

Refitting

3 The

2E3 carburettor fitted to normal

gap given in the Specifications, should just

compression versions of the 1.3 engine is a

slide between the throttle valve and the

4 Refit in the reverse order to removal. Adjust

fixed jet, twin barrel instrument. Opening of

carburettor barrel (see illustration).

the accelerator cable if necessary on

the throttle valves is sequential; the primary

4 If adjustment is necessary slacken the

completion, as described in Section 8.

throttle valve is opened mechanically, but the

locknut on the fast idle adjusting screw (see

secondary throttle valve is opened by vacuum

illustration) and turn the screw as necessary

10 Choke cable - removal,

developed in both venturis. Primary and

to achieve the specified setting. Tighten the

refitting and adjustment

secondary transition systems, and a part load

locknut after adjustment.

Removal

1 Disconnect the battery earth lead.

2 Tap out the small pin which secures the

choke control knob to the cable end fitting.

Unscrew and remove the knob.

3 Undo the retaining ring or nut which

secures the choke control to the facia. Push

the control into the facia and disconnect the

warning light switch (when fitted).

4 Remove the air cleaner, as described in

Section 3.

5 Disconnect the choke inner and outer cable

from the carburettor (see illustration). On

10.5 Choke cable inner clamp screw

12.3 Using a drill bit to check the fast idle

some carburettors the inner cable is secured

(arrowed)

gap

4A•8 Fuel and exhaust systems - Carburettor models

12.4 Fast idle adjusting screw (arrowed)

12.11a Using a drill bit to check the choke

12.11b Choke valve gap adjusting screw

valve gap

(arrowed)

5 If the carburettor is in the car, first allow the

16 With the carburettor assembled and the

Accelerator pump delivery

engine to reach normal operating temperature

float chamber full of fuel, place the carburettor

4 The stroke of the accelerator pump can be

and then if necessary adjust the idle speed, as

over a measuring cylinder. Take appropriate

adjusted by turning a nut on the end of the

described in Chapter 1. Also make sure that,

fire precautions.

pump operating rod. The desired delivery is

when the choke knob is pulled fully out, the

17 Operate the throttle over its full stroke 10

given in the Specifications.

linkage rotates to the fully closed position with

times, taking about 3 seconds per stroke.

5 Apart from the above points, the procedure is

the linkage arm against its stop. If necessary

Catch the fuel delivered by the pump in the

described in Section 12, paragraphs 13 to 17.

adjust the choke cable (Section 10).

measuring cylinder. The desired delivery is

6 Check that the stream of fuel ejected from

6 Connect a tachometer to the engine in

given in the Specifications. No adjustment is

the accelerator pump delivery tube hits the

accordance with the manufacturer’s

possible: cleaning or renewal of the pump

throttle valve shaft. Adjust if necessary by

instructions.

components will be necessary if the delivery is

careful bending of the delivery tube.

7 Start the engine and, with the choke knob

incorrect.

pulled fully out, compare the engine speed

with the fast idle speed setting given in the

1335 PDSI carburettor -

141B1 carburettor - adjustments

Specifications. If adjustment is necessary

slacken the locknut and turn the fast idle

adjustments

adjusting screw to achieve the specified

Note: Under normal operating conditions only

speed. Tighten the locknut after adjustment.

Note: Under normal operating conditions only

the carburettor idle adjustments described in

8 Switch off the engine and disconnect the

the carburettor idle adjustments described in

Chapter 1 will need attention. Checking and

tachometer.

Chapter 1 will need attention. Checking and

adjustment of the following settings is not a

Choke valve gap

routine operation and should only be

necessary after carburettor overhaul or if the

9 Run the engine until normal operating

necessary after carburettor overhaul or if the

operation of the carburettor is suspect.

temperature is reached and then switch off

operation of the carburettor is suspect.

and remove the air cleaner.

Idle speed and mixture

10 Pull the choke knob fully out and check

Idle speed and mixture

1 Refer to Chapter 1.

that the linkage rotates to the fully closed

1 Refer to Chapter 1

position with the linkage arm against its stop. If

Fast idle

necessary adjust the choke cable (Section 10).

2 Bring the engine to normal operating

11 With the choke knob still pulled out, start

2 The fast idle system comes into play when

temperature and connect a tachometer (rev

the engine and check that a drill of diameter

the choke control is operated. It is adjusted by

counter) to it. Stop the engine.

equal to the choke valve gap dimension will

a screw which acts on the throttle spindle

3 Pull the choke control fully out. Check that

just slide between the valve and choke barrel.

lever (see illustration).

the choke lever on the carburettor is resting

If necessary slacken the locknut and turn the

3 Adjustment is correct when, with the choke

against its stop, and that the index notch on

adjusting screw above the vacuum unit until

control pushed in and the throttle released,

the cam plate is aligned with the mark on the

the correct gap is achieved

(see

the end of the screw is just in contact with the

adjuster screw (see illustration). Slacken the

illustrations).

lever.

12 Switch off the engine, tighten the locknut

and refit the air cleaner.

Accelerator pump delivery

13 With the carburettor installed, and the air

cleaner removed, start the engine and allow it

to idle for a few seconds, then switch it off.

14 Look down the carburettor barrel and open

the throttle by hand. As the throttle is opened, a

squirt of petrol should emerge from the

accelerator pump jet. If no petrol is delivered,

the pump is faulty or the jet is blocked.

15 The above check only serves to show

whether or not the pump is working. For an

14.3 Fast idle adjustment

accurate check, the carburettor must be

13.2 Fast idle adjustment screw

1 Lever against stop

3 Cam plate screw

removed.

(arrowed)

2 Index notch

Fuel and exhaust systems - Carburettor models 4A•9

14.4 Removing the tamperproof cap from

14.5 Notches on choke cover and

14.6 Position choke cover with opening

the fast idle adjustment screw

carburettor housing (arrowed) aligned

lever to the left of drive lever

screw on the cam plate if necessary and

Vacuum pull-down unit

correct the alignment, then retighten the

7 If suspected of malfunction this unit can be

152E3 carburettor - adjustments

screw.

checked using a hand vacuum pump and

4 Start the engine without touching the

gauge. Disconnect the vacuum hose from the

throttle. With the choke valve fully open, the

throttle body and connect the vacuum pump.

Note: Under normal operating conditions only

fast idle speed should be as given in the

the carburettor idle adjustments described in

Apply vacuum to the pull-down unit; if the

Specifications. If adjustment is necessary,

Chapter 1 will need attention. Checking and

vacuum drops, the unit is leaking and must be

remove the tamperproof cap and turn the

adjustment of the following settings is not a

renewed.

adjustment screw until the speed is correct

routine operation and should only be

(see illustration).

Choke valve gap

necessary after carburettor overhaul or if the

operation of the carburettor is suspect.

Choke unit cover

8 Refer to Section 12, paragraphs 9 to 12

noting the adjustment and measurement

Adjustments with carburettor

5 The index notches on the cover and

points are shown here (see illustrations).

fitted

carburettor housing must align

(see

Lock the screw with paint on completion.

illustration). Slacken the cover clamp screws

Idle speed and mixture

if necessary to adjust, then retighten the

Throttle valve basic adjustment

1 Refer to Chapter 1.

screws.

9 This requires special measuring equipment

6 If the choke cover is removed for any

Fast idle

and must be left to a Vauxhall dealer or a

reason, ensure when refitting that the opening

2 The engine must be at operating

carburettor specialist.

lever is positioned to the left of the drive lever

temperature and the idle speed and mixture

(see illustration).

Accelerator pump delivery

must be correctly adjusted. Remove the air

10 A rough check may be made without

cleaner to improve access.

removing the carburettor as follows. Remove

3 Position the fast idle adjustment screw on

the air cleaner and run the engine for a few

the second highest step of the fast idle cam.

seconds, then switch it off. Look into the

Connect a tachometer to the engine. Make

carburettor venturi and open the throttle fully

sure that the choke plate is fully open.

by hand. As the throttle is opened, a clean

4 Start the engine without touching the

double jet of fuel should be seen spraying

throttle pedal and compare the engine speed

from the delivery tube. If not, remove the

with that given in Specifications. If adjustment

carburettor and make further checks as

is necessary, remove the tamperproof cap

follows.

from the head of the fast idle screw by

11 Refer to Section 15, paragraphs 20 to 23

crushing it with pliers and adjust by means of

for the procedure noting that the adjustment

the screw (see illustration).

point is as shown (see illustration).

5 When adjustment is correct, stop the

engine and disconnect the tachometer. Fit a

14.8a Choke valve gap adjustment screw

new tamperproof cap where this is required

(arrowed)

by law.

14.11 Accelerator pump adjustment point

14.8b Measuring the choke valve gap

Loosen clamp screw (under arrow) and rotate

15.4 Fast idle adjustment screw under

using a twist drill

the cam plate

tamperproof cap (arrowed)

4A•10 Fuel and exhaust systems - Carburettor models

15.7 Choke drive lever (A) engages with

15.9a Checking the choke pull-down gap.

15.9b Choke pull-down adjusting screw

loop (B)

Apply vacuum to hose arrowed

Choke pull-down

11 Press in the screw further until the arm

16 Check that the fast idle adjustment screw

moves to its stop. In this position the choke

is resting on the second highest step of the

Note: This adjustment can also be done with

valve gap should correspond to the value

fast idle cam, in the position shown (see

the carburettor removed.

6 Remove the air cleaner.

specified for the

‘large’ gap. Adjust if

illustration). If not, first check that the choke

7 Remove the choke cover by removing the

necessary by turning the arm adjusting screw.

return spring is correctly positioned. then

three screws and the securing ring. There is

All models

adjust by bending the lever 2.

no need to disconnect the coolant hoses, just

12 Refit the choke cover, making sure that

17 Refit and secure the choke cover,

move the cover aside. Notice how the loop in

the spring loop engages in the choke drive

observing the alignment marks.

the end of the bi-metallic spring engages in

lever. Align the notches in the choke cover

Throttle valve fast idle gap

the choke drive lever (see illustration).

and choke housing when tightening the

8 Move the choke drive lever to close the

screws (see illustration).

18 Position the fast idle adjustment screw on

choke valve completely. Position the fast idle

the highest step of the fast idle cam.

Throttle damper adjustment -

19 Use a gauge rod or twist drill of the

screw on the highest step of the cam.

automatic transmission models

specified diameter to measure the opening of

1.3 litre models

9 Apply vacuum to the choke pull-down unit

13 To adjust the damper, slacken the locknut

the primary throttle valve. Adjust if necessary

(at the hose nearest the carburettor body)

and screw the damper in or out until there is a

at the fast idle adjustment screw. (This is a

preliminary adjustment; final adjustment of the

using a modified hand pump or by making a

clearance of 0.05 mm between the end of the

fast idle speed should take place with the

connection with a rubber hose or plastic tube

damper and the throttle lever. From this position,

engine running.)

between the choke vacuum unit of the

screw the damper towards the throttle lever by

carburettor and the inlet manifold of another

21⁄2 turns, then secure it with the locknut.

Accelerator pump delivery

vehicle (engine running). Apply light pressure

20 It will be necessary to feed the float

to the choke drive lever in a clockwise

Adjustments with carburettor

chamber with fuel from a small reservoir

direction (as if to close the choke valve) and

removed

during this test. Take all necessary fire

check the choke valve gap by inserting a

Fast idle cam position

precautions when dealing with fuel and fuel

gauge rod or twist drill of the specified size. If

adjustment is necessary, turn the adjusting

14 The choke pull-down adjustment

vapour.

21 Position the primary barrel over an

screw on the side of the choke housing (see

previously described must be correct. If not

illustrations).

already done, remove the choke cover.

accurate measuring glass. Fully open and

1.4 and 1.6 litre models

15 Open the throttle, then close the choke

close the throttle ten times, taking

10 Disconnect both vacuum hoses from the

valve by light finger pressure on the choke

approximately one second for each opening

pull-down unit then, using a small

drive lever. Release the throttle.

and pausing for three seconds after each

screwdriver, press in the pull-down arm

return stroke. Make sure that the fast idle cam

adjusting screw (see illustration 15.9b) until

is not restricting throttle travel at either end.

some resistance is felt. In this position the

22 Measure the quantity of fuel delivered and

choke valve gap should correspond to the

compare it with the specified value.

value given in the Specifications for the ‘small’

23 If adjustment is necessary, release the

gap. Adjust if necessary by turning the screw

clamp screw and turn the cam plate in the

on the pull-down unit.

desired direction (see illustration). Tighten

the clamp screw and recheck the pump

delivery.

15.16 Fast idle cam adjustment

1 Fast idle cam

4 Fast idle

2 Adjustment lever

adjustment screw

3 Choke drive lever

a = 0.2 to 0.8 mm

15.12 Choke cover alignment marks

(press in direction

(0.08 to 0.32 in)

15.23 Accelerator pump delivery

(arrowed)

arrowed)

adjustment: + to increase, - to decrease

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