July 2013 Auto Motive Repair Guides

Thursday, July 11, 2013

Toyota Automotive Technical Training Series

Toyota All Models 1975-77 Drive Axles Repair Guide

DESCRIPTION

The axle assembly is hypoid gear type with a separate carrier housing. It comes in slightly different models for use in all Toyota vehicles. Two-pinion differential cases are one-piece design while four-pinion cases are two-piece design. The differential side bearing preload is set with adjusting nuts on all models. The pinion bearing preload can be set with a solid spacer and adjusting shim or with a collapsible spacer.

AXLE RATIO & IDENTIFICATION

Toyota uses only one basic type of axle assembly. Any differences in Removal & Installation or Overhaul procedures will be noted where they occur. To determine axle ratio, divide number of ring gear teeth by number of pinion gear teeth.
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Why Brake Repairs Needed? Don't Take Chances With Your Brakes - Repair Them Now!

Use Your Eyes & Ears to Inspect Your Brakes
Visually inspect your brakes' condition at least every six months. Here are some things to look for:
Brake Rotors (discs) should be inspected all the way around the surface and on both sides for any concentric scoring (grooves) or obvious defects. If defects are found, replace your rotors immediately. Any rotor discoloration may be a sign of overheating and an inspection by a brake repair professional is needed.
Brake Pads will normally match rotor scoring but should also be inspected for uneven wear, breakage or cracking on the friction surface. Again, if defects are found, replace the pads immediately. Many cars also have brake pad sensors to warn of pad wear. If your car uses sensors, replace these at the same time as your pads.
Brake Drums (if equipped) should also be inspected on a regular basis. Check for the same types of flaws as noted above. The drums should not have excessive grooves or have a deep "trough" dug into them where the shoes ride.
Brake Shoes (if equipped) should be worn evenly and have no rivets protruding to the friction surface.

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Cooling System Repairs: It's Easy to Prevent Breakdowns BEFORE They Happen

Cooling systems can be your best friend when operating efficiently. Cooling system repairs . . . your worst enemy if you don't understand how your cooling system works.
Your cooling system performs a critical function. Simply put, it maintains proper engine temperature by circulating coolant through the engine to pick up heat and passing it through a radiator to cool it with air. The coolant passes through a thermostat valve to control flow and possibly over a temperature sensor which controls external air cooling fans.
Cooling systems consist of three main parts:
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Fuel Pumps & Fuel Injection Repairs

The electric fuel pump is the heart of every electronic fuel injection system. Let's review the basics of this critical fuel injection part.
Usually located inside or near the fuel tank, the fuel pump's job is twofold:
1) To push fuel from the tank to the injectors, and
2) To create sufficient pressure so the injectors will deliver the correct amount of fuel under all operating conditions.
The pressure developed by the pump, as well as the volume of fuel it flows, must both meet the vehicle manufacturers' requirements or engine performance, economy and emissions will suffer.
The amount of fuel pressure required for a given application will vary depending on the type of injection system (L-Jetronic, CIS, Motronic, etc.), the flow characteristics of the injectors and the engine's fuel requirements.
For example, certain Audi models with Bosch Motronic require 55 to 61 psi (3.8 to 4.2 BAR) of static pressure measured with the engine off. By comparison, a BMW may require 43 psi (3.0 BAR) on some models or 48 psi (3.3 BAR) on others. The differences may not seem like much, but a few pounds of fuel pressure can have a significant impact on engine performance and emissions.

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Engine Knock? Low Oil Pressure? How To Diagnose Needed Repairs

Oil pressure light flickering? Engine knock? Both? Major repair problem or minor annoyance? Either way, you should always quickly investigate the source before it becomes an even bigger problem.
Oil pressure - or more precisely the lack of it - in certain parts of your car's engine can become a major repair nightmare. All engines lose a certain amount of oil pressure over time as normal wear increases bearing clearances. But unusually low oil pressure in an engine, regardless of mileage, is often an indication that something is seriously wrong and requires immediate repairs.
That "tappet" noise may be only one sticking lifter but it may also indicate an oil flow problem that will eventually cause damage to at least one valve.
A flickering oil light is more difficult to troubleshoot if your engine is not obviously in need of major repair work.
Modern engines with hydraulic lifters, tight tolerance bearings and miniature oil filters require conscientious monitoring of oil pressure.
The following diagnostic tips (excerpted from "Troubleshooting Low Oil Pressure", Underhood Service, 10/97) will help you determine whether you have a major repair problem or just a minor annoyance.
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Tuneup & Auto Maintenance Tips to Lengthen Your Import Car's Life

Tuneup - an old-fashioned maintenance term that's nearly non-existent today. With electronic ignition and fuel injection came computers that took over control of engine settings. Early versions allowed for some tinkering, but today's engines require advanced equipment and training.
You can, however, replace normal maintenance parts and still see improved engine performance. Here are common maintenance parts you can replace to significantly increase performance and reduce major problems:
Basic Ignition Parts
Spark Plugs: Spark plugs are good indicators of engine condition. Removing and inspecting spark plugs tell you a lot about how well the engine is running and what may be causing problems.
All spark plugs should be removed and checked every 30,000 miles - even if your car is "low maintenance" - you're told to change spark plugs at 100,000 miles. This prevents the plugs from seizing in the block, causing expensive repairs down the road.
Always note which plug came from which cylinder. This tells you if a particular cylinder has a problem. BEWARE: New spark plugs can make a difference in your car's performance but only if replaced with the appropriate OE replacement plug.

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Replacing Wiper Blades Regularly Saves Lives & Windshields

Are you as conscientious about your windshield wipers as you are about your car's engine? Car safety is a critical concern for everyone.
Worn wiper blades are dangerous. Because 90% of your driving decisions are based on a clear, unobstructed view of the road, it's a critical safety concern that your car's wipers provide you with the cleanest windshield possible.
Ozone, airborne contaminants, oil, sunlight and dirt all act to weaken and reduce your wiper blades' ability to keep your view unobstructed. And exposure to sunlight and ozone cause the wiper blades to age, even if they're not used much.
Weather also plays a critical role in your windshield wiper blades' deterioration. Freezing temperatures make the rubber in your wiper blades hard and brittle, which increases their tendency to crack or tear. Hot weather warps the rubber and prevents the blade from wiping your windshield cleanly.
Heavy use is hard on the wipers because dust, abrasives, road grime and bug juice wear away the cutting edge the blade needs to wipe cleanly. Even road dirt acts like an abrasive to wear away the flat surface necessary for a good squeegee effect.

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Understanding Your Import Car's Electrical System

Today's auto electrical systems are getting more intricate and are stressing the limits of current technology but they are basically the same design as 30 years ago. What can today's do-it-yourselfer do to keep from being electrically-challenged in the middle of nowhere? A quick overview of your car's electrical system would be a good start. The major components of your car's electrical system are explained below, along with some troubleshooting tips.
Your Import Car's Battery
The battery is a storage device, currently 12 volts, used to start the engine and help operate the electrical accessories installed on your car. The battery consists of six cells of stacked positive and negative lead plates, separated by insulators and immersed in electrolyte, which is a water and sulfuric acid mixture. Each of the six cells "produces" 2.1 volts for a total of 12.6 volts (although it's actually stored energy, not produced).
The chemical reaction created between the lead plates and the electrolyte creates dangerous, explosive gases that vent through the battery cover vents. Care should always be taken when charging or jump starting low batteries and whenever working under the hood of the car. Always keep the battery clean to allow proper ventilation.
Some batteries use a gel to replace the electrolyte for a somewhat safer battery and the use of "maintenance-free" batteries has eliminated the need for refilling the electrolyte. However, all batteries lose charging capacity over time through the loss of the electrolyte, deterioration of the plates and chemical breakdown of the connections.
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Oxygen Sensors Are Critical Key to Passing Emissions

Automotive exhaust emissions are everyone's concern because we all breathe the same air. Fifty percent of Americans live in areas that exceed national clean air standards. Reducing tailpipe emissions, therefore, is a top priority in the effort to fight air pollution.
In 1976, Bosch introduced what would eventually become one of THE most important technologies for reducing exhaust emissions: the oxygen sensor. By 1996, Bosch had produced its 100,000,000th oxygen sensor.
Today, Bosch oxygen sensors are original equipment on a wide variety of European, Asian and domestic vehicles and are the #1 best selling brand in the aftermarket.
Oxygen sensors have been standard equipment on passenger car and light truck engines since 1980-81. Most such vehicles have one or two oxygen sensors (two are typically used on selected V6 and V8 engines starting in the late 1980s). Since the introduction of Onboard Diagnostics II (OBD II) in 1995-96, the number of oxygen sensors per vehicle has doubled (the extra sensors are used downstream of the catalytic converter to monitor its operating efficiency).
Yet, as important as oxygen sensors are today, few people are even aware of their presence, let alone the key role oxygen sensors play in engine performance and reducing pollution. One survey found that 99.7% of all consumers did not know their vehicle even had an oxygen sensor!

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Know Your VIN & Get Exactly the RIGHT Auto Repair Parts Every Time

Vehicle identification numbers (also called VINs) are critical pieces of information for identifying the exact car you have and the engine that was put into it when it was built. A car‘s vehicle identification number (VIN) is the automotive equivalent of human DNA.
History of the Vehicle Identification Number (VIN)
In the mid 1950s, American automobile manufacturers began stamping and casting identifying numbers on cars and their parts. The obvious purpose was to give an accurate description of the vehicle as mass production numbers were starting to climb to very significant numbers. Research has shown that early VINs came in all sorts of variations, depending on the car manufacturer.
In the early 1980s, the National Highway Traffic Safety Administration began requiring that all road vehicles contain a 17-character VIN. This established the fixed VIN system for major vehicle manufacturers as it is known today and thus, created a unique "DNA" style number for each unique vehicle that rolled off the assembly line.
The Vehicle Identification Number was "officially" described in ISO Standard 3779 in February 1977 and last revised in 1983.
Explanation of Unique Identifiers Within Your Car's VIN
Vehicle identification numbers are standardized - all contain 17 characters. VIN characters may be capital letters A through Z and numbers 1 through 0; however, the letters I, O and Q are never used in order to avoid mistakes of misreading. No signs or spaces are allowed in the VIN.
The position of each letter or number in the VIN code reveals important information about where and when your car was made, the type of engine it has, the model or series of the car, various equipment/attributes and its production sequence. Each character or digit has a particular purpose as follows:
1st Character: The 1st character of your car's vehicle identification number identifies the country where it was manufactured.
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Top Tips to Improve Fuel Efficiency - How to Improve Your Car's Gas Mileage

In today's world, fuel efficiency is becoming a higher and higher priority. With average gas prices hovering around $3 a gallon in the U.S., more and more consumers are trying to find ways to decrease the amount of gas they use. We have compiled a list of some of the best ways to reduce the amount of gas consumption for your household.

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Bosch Icon Wiper Blades Provide Cleanest Windshields Ever

Basic wiper blade design has remained virtually unchanged for 80 years. The familiar steel or plastic bracket with multiple joints and pressure points has been the automotive industry standard for many years. But now, OE wiper blade technology is taking a new bracketless shape. This new bracketless technology conforms more precisely to the curvature of today's windshields for better wiping quality than conventional blades.
Simply put, bracketless wiper blades are designed without metal or plastic brackets, joints or hinges, offering design and performance improvements over conventional wiper blades. Bracketless wiper blade design is the very latest in original equipment wiper technology. Each year, more and more vehicle manufacturers are specifying bracketless blades.
Bosch is the leading OE supplier of bracketless wiper blades, equipping manufacturers such as Ford, Volkswagen, Mercedes-Benz, Volvo and Porsche. Bosch's advanced bracketless wiper blade design is the recipient of three major design awards: 1) Motortec 2001, Madrid, Spain; 2) Automechanika 2002, Frankfurt, Germany; and, 3) Automotive News PACE Award 2002, Detroit, Michigan.

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Gas Pump Tricks You Can Use to Save Money on Fuel

With today's high gas prices, we're all looking for any way we can to save money at the gas station. We're driving less. We're driving slower. We're buying cars based on fuel efficiency ratings. We're even buying hybrid and alternative fuel vehicles. Gas has become one of the bigger items in all of our monthly budgets.

In addition to those timely tips, below are some tricks you can use to give you your money's worth for every gallon of gasoline. These gas pump tricks were provided by someone who's been in the petroleum industry for more than 30 years.

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Ford AVI IDS Training Video

Here is a training video from AVI for Ford IDS.
Download Now
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How to remove instrument panel in Audi A6 4B C5

How to remove instrument panel in Audi A6 4B C5
An Instrument panel servicing e-book for Audi A6 4B C5 owners. In the e-book you will find:
- Instrument panel component locations, overview.
- Instrument panel removing.
- Trim strip for instrument panel, removing.
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How to Repair an Instrument Cluster in an Audi A6

The instrument cluster is one of the most vital components in your Audi A6 as it provides you with the necessary information needed to drive your vehicle safely on the road. If any parts of the instrument cluster become damaged, you should look to repair the cluster by removing it and inserting a fully functioning one. You can pick up a replacement instrument cluster from your local auto store.
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1976 Fiat Honda Jaguar Wheel Alignment Guide

FIAT

Model X1/9 Front and Rear - Camber is nonadjustable. If not within specifications, inspect suspension for damage and repair or replace parts as necessary.
TOE-IN
Model 128, 131 and X1/9 Front - Place front wheels in straight-ahead position. If toe-in is not within specifications, loosen sleeve locking nut on tie rods. To adjust, rotate hexagon on ball pin to set toe-in to specifications. Hold hexagon in position and lock nut against tie rod sleeve.
Model 128 Rear - If rear toe-in is not within specifications raise rear of vehicle and compress one end of leaf spring, shifting it from flexible guide anchoring spring to control arm. Remove guide and slowly release spring. Remove nuts attaching pivot to body and loosen screws to free adjustment shims. To increase toe-in, add shims to rear screw or remove shims from front screw. To decrease, add shims to front screw or remove shims from rear screw.
Model 124 Front - Place front wheels in straight-ahead position. If toe-in is not within specifications, loosen four clamps securing sleeves on tie rods. Rotate tie rods in opposite direction (by equal amounts) to set toe-in to specifications. Tighten clamp nuts. NOTE - Expansion slot in sleeve must coincide with clamp joint when clamp is fully tightened.
Model X1/9 Rear - If rear wheel toe-in is not within specifications, loosen clamps securing sleeves to reaction rods. Adjust toe-in by lengthening or shortening reaction rods. Tighten clamps and recheck toe-in.
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1975 Honda Wheel Alignment Guide

HONDA SPECIFICATIONS AND ADJUSTMENTS

TIRE INFLATION (COLD)
Before checking or adjusting wheel alignment, make sure tires are correctly inflated. Refer to manufacturers specifications located in glove box
RIDING HEIGHT
Make sure tires are properly inflated. Measure from bottom of side marker lamps to ground. If height measurement is not within specifications, check rear height before attempting to repair front suspension
CASTER
Caster is nonadjustable. If alignment is not within specifications, inspect for damaged parts and replace as necessary.
CAMBER
Camber is nonadjustable. If alignment is not within specifications, inspect for damaged parts and replace as necessary.
TOE-IN
Front - To adjust toe-in, loosen lock nuts at each of the tie rods. To increase toe-in, turn the right tie rod in the direction of wheel rotations when the vehicle moves forward and turn left tie rod in the opposite direction. Turn both tie rods an equal amount until toe-in is within specifications. Tighten lock nuts of each tie rod.
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1974 Honda Wheel Alignment Guide

HONDA SPECIFICATIONS AND ADJUSTMENTS

TIRE INFLATION (COLD)
Before checking or adjusting wheel alignment, make sure tires are correctly inflated. Refer to manufacturers specifications located in glove box.
RIDING HEIGHT
Make sure tires are properly inflated. Measure from bottom side marker lamps to ground. This distance should be 25.78" in front and 24.01" in rear. NOTE - If height measurement is not within specifications, check rear height before attempting to repair front suspension.
CASTER
Caster is nonadjustable. If alignment is not within specifications, inspect for damaged parts and replace as necessary.
CAMBER
Camber is nonadjustable. If alignment is not within specifications, inspect for damaged parts and replace as necessary.
TOE-IN
To adjust toe-in, loosen lock nuts at each of the tie rods. To increase toe-in, turn the right tie rod in the direction of wheel rotation when the car4 moves forward and turn the left tie rod in the opposite direction. Turn both tie rods an equal amount until toe-in is within specifications. Tighten lock nuts of each tie rod.
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1965 Import Vehicles Ball Joint Checking Guide

ARROW / COLT

All Models - With components removed from control arm and ball joint still installed, check following: Horizontal and vertical free play (0"), and ball joint rotation starting torque 4-6 ft. lbs. (6-8Nm). Replace ball joints if correct specifications are not obtained

AUDI

Fox - Clearance of ball joint with pressure applied by leverage should be .04-.10" (1.0-2.5 mm). if not replace ball joints

BMW

All Models - With lower control arm removed, measure axial (up and down) movement of ball joint stud. If movement exceeds .0945", replace ball joint.

COURIER

All Models - Check working surfaces of ball joints and studs for wear or damage. End play should not exceed .031" (.8 mm), if end play is excessive, replace ball joint.

DATSUN

All Models (Exc. 620 Pickup) - Remove lower control arm. Use appropriate spring tension gauge and and attach it to top of ball joint stud nut. Measure force (INCH Lbs.) required to move ball joint stud laterally. If measurement is not within specifications, replace ball joint
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1975 Vehicles Ball Joint Checking

ALFA ROMEO
All Models - Check working surfaces of ball pins and their seats, and ball joint studs for damage or wear. Axial play should not exceed specifications (.04"). Replace complete ball joint unit when indicated
BMW
All Models - With lower control arm removed, measure axial (up and down) movement of ball joint stud. If movement exceeds .0945", replace ball joint.
COLT
All Models - With components removed from control arm and ball joint still installed, check the following: Horizontal and vertical free play (0") and ball joint rotation starting torque 4-7 ft. lbs. (.6-1.0 mkg). Replace ball joints if correct specifications are not obtained
COURIER
All Models - Check working surfaces of ball joints and studs for wear or damage. End play should not exceed .031" (.8mm). If end play is excessive, replace ball joint.
DATSUN
All Models (Exc. 620 Pickup) - Remove lower control arm. Measure axial movement by lifting and depressing ball joint stud. Difference between these two measurements is axial movement. Using suitable spring tension gauge attached to top of ball joint stud measure force (INCH lbs.) required to move ball joint stud laterally. If either measurement is not within specifications, replace ball joint.
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Wheel Bearing Adjustment Guide

ALFA ROMEO
All Models - While rotating hub, tighten spindle nut to 18 ft. lbs. Loosen nut, then retighten to 7 ft. lbs. Back off on nut 1/4 turn and install cotter key. If slot in spindle nut does not align with hole in spindle, tighten nut until it is possible to insert cotter key. After cotter key is installed, ensure that bearing retainer plate can be easily rotated by insterting a screwdriver in plate holes
AUDI
NOTE - The following procedure can only be performed using special tools indicated.
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1974 Vehicles Ball Joint Checking

ALFA ROMEO
All Models - Check working surfaces of ball pins and their seats, and ball joint studs for damage or wear. Axial play should not exceed specifications (.04"). Replace complete ball joint unit when indicated.
BMW
All Models - With lower control arm removed, measure axial (up and down) movement of ball joint stud. If movement exceeds .0945", replace ball joint. See BMW in SUSPENSION Section.
CAPRI
All Models - To check ball joint wear, raise vehicle and attach a dial indicator to a suitable fixed pivot, with stem on ball joint cap. Raise wheel independently of vehicle and note maximum dial gauge reading. If gauge reading is in excess of .098", ball joint should be replaced.
COLT
All Models - With components removed from control arm and ball joint still installed, check the following: Horizontal and vertical free play (0"), and ball joint rotation starting torque 4-7 ft. lbs. (.6-1.0 mkg). Replace ball joints if correct specifications are not obtained.
DATSUN
All Models (Exc. 620 Pickup) - Remove lower control arm. See Datsun in SUSPENSION Section. Measure axial movement by lifting and depressing ball joint stud. Difference between these two measurements is axial movement. Using suitable spring tension gauge attached to top of ball joint stud, measure force (ft. lbs.) required to move ball joint stud laterally. If either measurement is not within specifications, replace ball joint.
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BMW General Hydraulic Brake Troubleshooting Guide 1973-75

HYDRAULIC BRAKE TROUBLE SHOOTING
BRAKE INSPECTION & TESTING
Inspect brakes at frequent intervals for pedal reserve (clearance between pedal and toeboard with pedal firmly depressed, while brakes are cold). Increase pedal reserve by adjusting brake shoe to drum clearance. Brakes should be tested on dry, clean reasonable smooth, level roadway (not and heavy pressure. CAUTION - Do not lock wheels and slide tires on raodway.
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General Suspension Troubleshooting 1980 US Vehicles

General Suspension Troubleshooting For 1980 American Vehicles
Condition and Possible Cause:
Front End Noise

Loose wheel lug nuts. Loose or worn wheel bearings, shock absorbers or shock mountings, strut bushings, struts or lower control arm
Loose steering gear to frame, mounting bolts.
Steering knuckle arm contracting lower control arm wheel stop
Worn upper control arm bushings
Insufficient lubrication and ball joints

Front Wheel Shake, Shimmy and Vibration

Loose or worn wheel bearings, tie rod ends, strut bushings, upper control arm ball joints, shock absorbers or linkage pivots.
Tires or wheels out of balance
Incorrect front wheel alignment
Propeller shaft balance

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BMW 320i 530i 630Csi 1977 Brake Repair Guide

DESCRIPTION
Brake system is hydraulically operated. System uses both a tandem master cylinder and power brake unit. 530i and 630CSi models have 4 piston ATE front disc brakes and 2 piston ATE rear brakes. 320i models are equipped with 2 piston ATE front disc brakes and drum rear brakes. Parkng brake is lever actuated and cable operated. On 530i and 630CSi models, brake shoes work against a drum machined in rear disc brake rotor/hub. On 320i models, shoes lock against rear brake drum. All models are equipped with a brake pressure regulator to reduce line pressure to rear brakes.
ADJUSTMENT
Disc Pads
320i - Raise vehicle. Release parking brake. Using special tool 34 2 000 (or equivalent wrench), tighten brake shoes by turning left cam counterclockwise and right cam clockwise. Loosen cam 1/8 turn or until wheel is just free to turn.
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BMW 1976 Models 6 Cylinder Brake Repair Guide

ESCRIPTION
Brake system is hydraulically actuated, using a tandem master cylinder and a power brake unit. All models use four wheel ATE disc brakes. Front brakes are four piston caliper type and the rear use two piston fixed caliper type and the rear use two piston fixed caliper type. Parking brake is cable actuated, operating conventional type brake shoes against a drum machined in rear disc brake rotor casting.
ADJUSTMENT
Disc Pads
Front and rear disc brake assemblies are self-adjusting, therefore, no adjustment in service is required.
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BMW 4 Cylinder Models 1976 Brake Repair Guide

DESCRIPTION
Brake system is hydraulically operated using a tandem master cylinder and a power brake unit. Front disc brakes consist of rotors attached to wheel hubs, and four piston fixed calipers attached to steering knuckles. Rear brakes are leading-trailing shoe/drum, type, using a dual piston wheel cylinder. Parking brake is cable operated, activating secondary shoes of rear brake assemblies.
ADJUSTMENT
FRONT DISC BRAKE PADS
Front disc brakes are self-adjusting, therefore, no adjustment in service is required.
REAR DRUM BRAKES
Raise and support rear of vehicle and release parking brake. Using an offset wrench (BMW 6038), tighten left eccentric nut counterclockwise and then right eccentric nut clockwise until wheel is locked. NOTE - Rotate tire while making sure adjustments. Loosen each adjuster until wheel is just free to rotate.
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BMW 1969-73 6 Cylinder Models Brake Repair Manual

Models Covered

2500 (1969-70)
2800 (1969-70)
2800 CS & CSA (1969-71)
3.0 CS & CSA (1969-71)
Bavaria (1972-73)

DESCRIPTION
Models 2800 CS and CSA use ATE four-piston fixed caliper disc brakes on front and leading-trailing shoe drum brake on the rear. All other models use four wheel ATE disc brakes with four-piston caliper on front and two-piston caliper on the rear. All models use twin circuit, tandem piston master cylinders. Four wheel disc brake system use a pressure limiter to control hydraulic pressure applied to rear brakes. Hydraulic pressure to rear brakes is adjustable with the pressure limiter. Hand brake actuates cable to rear brake shoes. A special duo-servo drum-disc combination is used on rear wheels with disc brakes.
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BMW 1963-73 4 Cylinder Brakes Repair Manual

Models Covered

1600 (1966-71)
1600-2 (1966-71)
1800 (1963-66)
1800 Ti (1963-66)
2000 (1966-69)
2000 Ti & Tilux (1966-68)
2000 CS & CA (1966-67)
2002 (1968-73)
2002 Ti (1967-72)
2002 Tii (1972-73)

DESCRIPTION
Brakes on all models consist of ATE fixed caliper front disc brakes and leading-trailing shoe rear drum brakes. Disc calipers are either two or four piston units. All vehicles from 1970 onward, use tandem piston master cylinders. Hand brake system is operated by lever and cable, and attached to rear brake shoes.
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BMW 1975-76 Drive Axles Split Housing Repair Guide

Models Covered:
- 3.0 Series
- 530 i Series
DESCRIPTION
Differential has hypoid type ring and pinion gear set, and may have one of two clutch pack type limited slip units. Left side of housing is the housing cover and must be removed to expose carrier assembly. Cover incorporates a ball bearing and oil seal for left axle flange, and a bearing cone for the left differential carrier bearing. Right carrier bearing and seal are incorporated in housing. The pinion gear is supported by roller bearings and preload is maintained by a collapsible spacer
AXLE RATIO AND IDENTIFICATION
Ring and pinion gear set with Klingelnberg tooth design, can be identified by the letter "K" stamped on the head of the pinion gear; Gleason teeth are noted by an "H or F" stamping. To determine axle ratio, divide number of ring gear teeth by number of pinion gear teeth. The number of teeth on ring and pinion, and the code for limited slip differential (S40), is stamped on right side of differential housing.
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BMW 1969-74 Drive Axles Repair Manual

1969-74 BMW SPLIT HOUSING
MODELS COVERED:

2500 Series (1969-70)
2800 Series (1969-70)
3000 Series (1971-74)

DESCRIPTION

HALF SHAFT CONSTANT VELOSITY JOINT

Differential has hypoid type ring and pinion gear set, and may have one of two cluch pack type limited slip units. Left side of housing is the housing cover and must be removed to expose carrier assembly. Cover incorporates a ball bearing and oil seal for left axle flange, and a bearing cone for the left differential carrier bearing. Right carrier bearing and seal are incorporated in housing. The pinion gear is supported by roller bearings and preload is maintained by a collapsible spacer.
AXLE RATIO AND IDENTIFICATION
Ring and pinion gear set with Klingelnberg tooth design, can be identified by the lettter "K" stamped on the head of the pinion gear; Gleason teeth are noted by an "H" or "F" stamping. To determine axle ratio, divide number of ring gear teeth by number of pinion gear teeth. The number of teeth on ring and pinion, and the code for limited slip differential (S40), is stamped on right side of differential housing.
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BMW 1968-74 Drive Axles Repair Manual

1968-74 BMW INTEGRAL CARRIER
Models covered:

1600 Series (1968-69)
1800 Series (1968)
2000 Series (1968-69)
2002 Series (1968-74)

DESCRIPTION
Differential has hypoid ring and drive pinion gear set and may have a clutch pack type limited slip unit. Differential housing has removable rear cover. Differential carrier is retained in the sides of the housing by retaining plates, and is supported by roller bearings. Drive pinion gear is supported by roller bearings, and in addition, a long neck housing has a ball bearing supporting the drive pinion at the companion flange. Drive pinion preload is maintained by a collapsible spacer in the short neck housing, and by a spacer and shims in the long neck housing.
AXLE RATIO AND IDENTIFICATION
The ring and pinion gear set with Klingelnberg tooth design, can be identified by the letter "K" stamped on the head of the drive pinion gear; Gleason teeth are noted by an "H" or "F" stampling. To determine axle ratio, divide number of ring gear teeth by number of drive pinion gear teeth. The number of teeth on ring and drive pinion gears is stamped on forward left side of differential housing.
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1976 Import Models Wheel Bearing Adjustment Guide

ARROW AND COLT

All Models - Tighten adjusting nut to 14.5 ft. lbs. After seating bearing components, loosen nut to 0 ft. lbs. Now make final adjustment to 3.6 ft. lbs. After installing lock cap, insert cotter pin. NOTE - Do not loosen adjusting nut more than 15 degrees to align spindle holes.
AUDI
NOTE - The following procedure can only be performed using special tools indicated.
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1976 Import Models Wheel Alignment Guide

BMW
ADJUSTMENT
TIRE INFLATION (COLD)
Before attempting to check or adjust wheel alignment, ensure tires are properly inflated. The 2002 series requires 26 psi front and rear. The 3.0 series requires 30 psi front and rear. The 530i series requires 28 psi front and 26 psi rear.
CASTER AND CAMBER
All Models - Before checking caster and camber, vehicle must be in loaded condition. Loaded condition consists of two 143 lbs. weights on front seat, one 143 lbs. weight on rear seat, gas tank full and 66 lbs. on left side of luggage compartment. If caster and camber are not within specifications check suspension for damage. Repair or replace parts as necessary.
TOE-IN
All Models - Before checking toe-in, vehicle must be in loaded condition (see Caster and Camber). Check toe-in with front wheels in straight-ahead position. If not within specifications, loosen tie rod clamping bolts. Rotate both tie rod tubes until toe-in is within specifications. Tighten clamping bolts.
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BMW 1966-73 Models Wheel Alignment Guide

1966 TO 1973 BMW SPECIFICATIONS AND ADJUSTMENTS

TIRE INFLATION (COLD)
Before attempting to check or adjust wheel alignment, ensure that tires are properly inflated.

CASTER AND CAMBER
All Models - Before checking caster and camber, vehicle must be in loaded condition consists of two 143 lbs. weights on front seat, one 143 lbs. weight on rear seat, gas tank full and 66 lbs. on left side of luggage compartment. If caster and camber are not within specifications check suspension for damage. Repair or replace parts as necessary.
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1965 Import Vehicles Jacking and Hoisting Guide

ALL MANUFACTURERS

NOTE - Information not available for Lancia models.
NOTE - These illustrations are not intended to represent exact structure of the manufacturer's frame, underbody, or body outline. These are presented only to give the mechanic some point of reference
FRAME AND UNDERBODY
The following illustrations indicate areas (parts) of the underbody and frame which may be used to raise and support the vehicle, using either floor jack or hoist. These points are indicated by shaded areas on the frame (see sample illustration).
OUTERBODY
Those points designated on the outline of the body were specifically designed to facilitate the use of the vehicle's own jack, but may also be used to raise and support the vehicle by means of floor jack or hoist. These jacking points are indicated by circular dots on the outline of the body (see sample illustration). If floor jack or hoist is employed, extreme care should be exercised to prevent damaging the outer body shell.
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Wheel Bearing Adjustment Guide 1965 Vehicles

ARROW AND COLT

All Models - Tighten adjusting nut to 14.5 ft. lbs. After seating bearing components, loosen nut to 0 ft. lbs. Now make final adjustment to 3.6 ft. lbs. After installing lock cap, insert cotter pin. NOTE - Do not loosen adjusting nut more than 15 degrees to align spindle holes
AUDI
NOTE - The following procedure can only be performed using special tools indicated.
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1975 Vehicles Jacking and Hoisting Guide

ALL MANUFACTURERS
NOTE - These illustrations are not intended to represent exact structure of the manufacturer's frame, underbody or body outline. These are presented only to give the mechanic some point of reference.
FRAME AND UNDERBODY
The following illustrations indicate areas (parts) of the underbody and frame which may be used to raise and support the vehicle, using either floor jack or hoist. Thse points are indicated by shaded areas on the frame (see sample illustration).
OUTERBODY
Those points designated on the outline of the body were specifically designed to facilitate the use of the vehicle's own jack, but may also be used to raise and support the vehicle by means of floor jack or hoist. These jacking points are indicated by circular dots on the outline of the body (see sample illustration). If floor jack or hoist is employed, extreme care should be exercised to prevent damaging the outer body shell.
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Wheel Bearing Adjustment Guide

Guide: Jacking and Hosting Vehicles 1968 to 1972

Manufacturers: Alfa Romeo, Audi, Austin Marina, BMW, Capri, Colt, Courier
Year: From 1968 to 1982 Vehicles
ALL MANUFACTURERS
NOTE - These illustrations are not intended to represent exact structure of the manufacturer's frame, underbody, or body outline. These are presented only to give the mechanic some point of reference
FRAME AND UNDERBODY
The following illustrations indicate areas (ports) of the under body and frame which may be used to raise and support the vehicle, using either floor jack or hoist. These points are indicated by shaded areas on the frame (see sample illustrations).
OUTERBODY
Those points, designated on the outline of the body were specifically designed to facilitate the use of the vehicle's own jack, but may also be used to raise and support the vehicle bye means of a floor jack or hoist. These jacking points are indicated by circular dots on the outline of the body (see sample illustrations). If floor jack or hoist is employed, extreme care should be exercised to prevent damaging the outer body shell
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Import Wheel Bearing Adjustment 1974

ALFA ROMEO
All Models - While Rotating hub, tighten spindle nut to 18 ft. lbs. Loosen nut, then retighten to 7 ft. lbs. Back off on nut 1/4 turn and install cotter key. If slot in spindle nut does not align with hole in spindle, tighten nut until it is possible to insert cotter key. After cotter key is installed, ensure that bearing retainer plate can be easily rotated by inserting a screwdriver in plate holes
AUDI
NOTE - The following procedure can only be perofrmed using special tools indicated
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Audi 100LS 1977 Brake Repair Guide

DESCRIPTION
Brake system is hydraulically operated, utilizing a tandem master cylinder and power brake unit. Front disc brakes consist of rotors attached to wheel hub and drive shaft and two piston calipers attached to strut assembly. Disc pads are equipped with a ceramic transmitter-type wear sensor. Transmitter is mounted on cross spring and will break when contact is made with pad plates, interrupting control circuit and causing indicator light on instrument panel to be activated. All models are equipped with pressure regulator that is mounted to body and operated by a spring connected to rear axle. Rear brakes are leading-trailing shoe/drum type, using a dual piston wheel cylinder. Parking brake is cable actuated, operating secondary shoes of rear brake assemblies.
ADJUSTMENT
NOTE - Adjustments or readjustments should be carried out on cold brakes. However, brakes must be warm when testing. Instrument panel trim must be removed to adjust master cylinder push rod free play.
MASTER CYLINDER PUSH ROD FREE PLAY
Adjustment of piston rod play at master cylinder is made by loosening lock nut and turning piston rod until correct free play, measured at brake pedal, is obtained. When correct free play of .039" is obtained between push rod and piston, free play is measured at brake pedal will be approximately .2".
FRONT DISC BRAKES
Front disc brakes are self-adjusting, therefore, no adjustment in service is required.
REAR DRUM BRAKES
Raise and support rear of vehicle and release parking brake. Using a 17 mm wrench, tighten eccentric adjusters until wheels can no longer be turned by hand. Loosen eccentric adjusters until wheels are just fee to turn.
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Audi S90 & 100 1970-73 Brake Repair Guide

Models Covered

S90 (1970-72)
100 (1970-73)

DESCRIPTION
Brake system is hydraulically operated, utilizing a tandem master cylinder and Teves T 51/349 power brake unit. Front disc brakes consist of rotors attached to transmission output flanges, and two-piston calipers attached to transmission. Disc pads are equipped with a ceramic transmitter-type wear sensor. Transmitter is mounted on cross spring and will break when contact is made with pad plates, interrupting control circuit and causing indicator light on instrument panel to be activate. Rear brakes are leading-trailing shoe/drum type, using a dual piston wheel cylinder. Parking brake is cable actuated, operating secondary shoes of rear brake assemblies.
ADJUSTMENT
NOTE - Adjustments or readjustments should be carrier out on cold brakes. However, brakes must be warm when testing. Instrument panel trim must be removed to adjust master cylinder push rod free play.
MASTER CYLINDER PUSH ROD FREE PLAY
Check brake pedal free play by measuring distance between master cylinder push rod and master cylinder piston. This measurement should be .039" (1.0 mm), which would give free play of .20" (5.08 mm) at brake pedal. If necessary to adjust, loosen lock nut on push rod and turn push rod until correct clearance is obtained. Tighten lock nut and again measure pedal free play at brake pedal.
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Thursday, July 11, 2013

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