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LIGHTING GROUP

15

PAGE

PART 15-1- General Lighting System, Horns and Instruments Service 15-2

PART 15-2- Lighting System and Horns 15-7

PART 15-3- Switches, Circuit Breakers and Fuses 15-13

PART 15-4- Instruments - 15-15

PART 15-5- Specifications 15-23

15-2

PART 15-1

GENERAL LIGHTING SYSTEM, HORNS AND INSTRUMENT SERVICE

Section Page

1 Diagnosis and Testing 15-2 Fuel Guage and Fuel Level Sending Unit Test 15-5 Light Trouble Diagnosis Guicle 15-2 Temperature Guag-e Test 15·5 Instrument Trouble Diagnosis Guide 15-2 Oil Pressure Indicator Light Test 15-5 Horn Trouble Diagnosis Guide 15-3 Charge Indicator Light Test 15-5 Turn Indicator Trouble Diag-nosis Guide 15-3 Speedometer Tests 15-5 Windshield Wiper Trouble Diagnosis Guide 15-3 Headlight Switch and Beam Selector Switch

2 Common Adjustments and Repairs 15·6 Horn Adjustment 15-6

Test 15-5 Constant Voltage Regulator Test 15-5

D DIAGNOSIS AND TESTING LIGHT TROUBLE DIAGNOSIS GUIDE

1. Loose battery cable. 2. Loose quick disconnect or bro-

ken w1re from the battery to the ALL HEADLIGHTS DO headlight switch. NOT LIGHT 3. Defective headlight switch.

4. Disconnected or broken wire from the headlight switch to the beam selector switch.

INDIVIDUAL LIGHTS 1. Burned out bulb.

DO NOT LIGHT 2. Loose or broken wires to the

bulb.

LIGHTS BURN OUT 1. Loose or corroded electrical

REPEATEDLY connections.

2. Excessive vibration .

INSTRUMENT TROUBLE DIAGNOSIS GUIDE

OIL PRESSURE INDICATOR 1. Indicator bulb burned out.

LIGHT INOPERATIVE 2. Loose or broken wire from the

light to the indicator switch.

CHARGE INDICATOR 1. Burned out bulb. LIGHT INOPERATIVE

CHARGE INDICATOR I. Faulty alternator and/or reg-LIGHT STAYS ON AT ulator. IDLE

1. Loose terminal s on fuel gauge .

FUEL GAUGE ERRATIC OR INOPERATIVE 2. Defective fuel gauge.

3. Loose, broken, or shorted wire from fuel gauge to the fuel tank sending unit.

5. Loose or broken wire to the bulbs.

6. Defective beam selector switch. 7. All headlight bulbs burned out.

This may be caused by a defective or improperly adjusted alternator voltage regulator (Group 13).

3. Poor ground.

3. Improperly adjusted or defec-tive alternator voltage regulator (Group 13).

3. Defective oil pressure sender unit (in this part).

2. Loose or broken wires.

2. Loose fan belt.

4. Defective constant voltage reg-ulator.

5. Defective fuel tank sending unit.

6. Poor ground between fuel tank and body.

CONTINUED ON NEXT PAGE

PART 15-1- GENERAL LIGHTING SYSTEM, HORNS INSTRUMENTS SERVICE 15-3

INSTRUMENT TROUBLE DIAGNOSIS GUIDE

1. Loose terminals on temp gauge .

TEMPERATURE GAUGE ERRATIC OR INOPERATIVE l. Defective temperature gauge.

3. Loose or broken wire from the temperature sending unit to the tern-

1. Loose or corroded constant FUEL, TEMPERA JURE, AND voltage regulator ground. OIL PRESSURE GAUGES l. Defective constant voltage reg-ERRATIC ulator.

HORN TROUBLE DIAGNOSIS GUIDE

1. Loose connections at horn but-ton· con tact.

HORNS DO NOT SOUND 2. Open wire (blue/red) from horn to horn button .

3. Open wire (green) from fuse

ONE HORN FAILS 1. Broken or loose wire to the TO OPERATE horn (blue/red).

HORNS OPERATE 1. Horn button defective. CONTINUOUSLY

TURN INDICATOR TROUBLE DIAGNOSIS GUIDE

1. Burned out bulbs, or loose

TURN INDICATOR LIGHTS sockets.

INOPERATIVE l. Loose or broken wire from

ignition switch to flasher. 3. Defective flasher.

1. Burned out bulb. TURN INDICATOR LIGHTS l. Loose, broken, or shorted wires OPERATE INCORRECTLY from switch to lights.

TURN INDICATOR 1. Cam improperly positioned on CANCELS IMPROPERLY steering wheel hub.

WINDSHIELD WIPER TROUBLE DIAGNOSIS GUIDE

INOPERATIVE OR SLOW WIPER

1. Binding linkage. 2. Defective switch. 3. Defective wiper motor

perature gauge. 4. Defective temperature sending

unit. 5. Defective constant voltage reg-

ulator.

3 Broken or loose conductor from or to the constant voltage regulator.

4. Defective ignition switch.

box to horn button. 4. Horns defective or out of ad-

justment.

5. Fuse burned out.

l. Horn defective or out of ad-justment.

4. Loose or br0ken wire from flasher to turn indicator switch.

S. Defective turn indicator switch. 6. Broken, shorted, or loose wires

from switch to lights.

3. Defective indicator switch. 4. Defective flasher.

l. Coil spring on switch plate as-sembly loose or weak.

4. Defective wiring or blown fuse.

15-4- GROUP 15- LIGHTING SYSTEM, HORNS AND INSTRUMENTS

-y

FIG. 1 -Installation Speedo Cable.

SPEEDOMETER DIAGNOSTIC PROCEDURES

' '

Speedometer system complaints are generally the result of a visible or audible defect in the sntem. It is im­perative that the specific defect be determined prior to attempting any physical repairs to preclude unnec­essarily disassembling system compo­nents. The following suggestions are intended to aid in quick and accurate system problem diagnosis.

VISIBLE DEFECTS

Sllt~ht Needle Waver or Ievere Needle Fluctuation (No Noise)

1. Loose cable retainer l. Defective speedometer head. 3. Bent cable core at attaching

nut. 4. Kinked or pinched cable hous­

ina. S. Excessive grease in speedome-

ter head. Inoperative

1. Broken cable core. l. Defective drive and/ or driven

gear 3. Defective speedometer head .

AUDIBLE DEFECTS

Clicking or Ticking (With Needle Waver), Grinding or Ringing

------------ \ \ ' \ \' ,\ \

\

I . Loose cable retainer. 2. Defective drive and/ or driven

gear. 3. Defective speedometer head. 4. No lube on cable.

SPEEDOMETER REPAIR PROCEDURES NOTE: To effect any tests or repairs on the speedometer head the instru­ment cluster must be detached from the instrument panel (see page 15 ·15) to gain access.

DEFECTIVE SPEEDOMETER HEAD

Before removing a speedometer head, disconnect the cable at the head and insert a short section of ca­ble core in the head . Rotate the sec­tion of core to check for any drag­ging or noise . The speedometer shaft should turn freely aod evenly.

DEFECTIVE CABLE CORE AND HOUSING

1. To check for a kinked cable core remove and wipe dry. Lay the core out straight on a flat surface and roll it back and forth . Any kinks or damage will be seen . Then take an end in each hand, allowing core to hang in approximately a 230 mm (9 inch) loop. Rotate both ends to be sure core turns evenly.

2. Routing of the cable housjng is particularly important where

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the cable leaves the speedometer head. The optimum routing would provide that the cable and housing take virtually no change of direc­tion for at least a length of 200 mm (8 inches) from the speedo­meter head.

3. When installing a new cable and housing it is necessary that the new assembly be guided and routed properly to eliminate any kinks.

4. Proper lubrication of the cable core is accomplished by a light application of a lubricant after the cable has been wiped clean. A light film is all that is required.

DEFECTIVE DRIVE AND DRIVEN GEARS

1. A score nicked or gouged driv~ en gear is usually indicative of a de­fective drive gear on those vehicles that have the drive gear integral with the transmission output shaft . The output shaft should be carcf ully inspected for imperfections aod re­p!aced if necessary.

2. A driven gear with two or three adjoining teeth badly scored is indicative of improper assembly pro­cedure. The gear should be inserted in the transmission while simultane­ously turning the drive shaft. This will insu re initial gear engagement and prevent gear damage. Force should never be used .

3. Whenever a drive gear is re­placed, a new driven gear should al -

PART 15-1- GENERAL LIGHTING SYSTEM, HORNS INSTRUMENTS SERVICE 15-5

so be installed, regardless of its ap­parent condition.

TESTING Refer to Group 22 for schemat­

ics and locations of wiring harnes­ses.

HORN TEST

The only test necessary on the horn is for current draw.

Current Draw Test

Connect a voltmeter and ammeter to the horn and to a voltage supply as shown in Fig. 2. The normal current draw for the horns at 12 volts is 4-5 amperes.

FIG. 2 -Horn Current Draw Test

HEADLIGHT SWITCH AND BEAM SELECTOR SWITCH TESTS

The following tests may be made to determine whether a headlight ~w1tch or a beam selector sw1tch is defective:

Turn on the headlights, and oper­ate the beam selector switch. If none of the headlights turn on when the beam selector switch is operated, yet the instrument panel lights operate, the headlight switch or the red-yel­low stripe wire from the headlight switch to the beam control ~witch is probably defective. Suhstitute a known good switch for the suspected switch to determine whether the switch or the wiring is at fault.

If the headlights operate only with the beam selector switch in one posi­tion, the selector switch or the wir­ing from the switch to the headlight is defective . Substitute a known good selector switch for the suspected switch to determine whefher the switch or the wiring is at fault.

CONSTANT VOLTAGE REGULATOR TEST

The instrument cluster must be re ­moved to gain access to the voltage regulator and gauge terminals .

Turn the ignition switch on, check for voltage at the fuel gauge upper terminal (Falcon) temp gauge term­inal adjacent to the regulator screw . The voltage should oscillate be­tween zero and about I 0

volts. If it does not, the constant voltage regulator is defective, or there is a short to ground between the voltage regulator and the gauges.

If a gauge unit is inaccurate or does not indicate, replace it with a new unit. If the gauge unit still is erratic in its operation, the sending unit or wiring to the sending unit is faulty.

H both the fuel gauge and the temperature gauge indicate improp­erly and in the same direcdon, the constant voltage regulator could be defecthe, as it supplies both gauges. TESTING FUEL AND

TEMPERATURE GAUGES

FUEL GAUGE.

A simple check to show whether it is the sender unit or gauge unit at fault is to fit a known good sender unit in the circuit.

If the gauge unit reads propor­tionate to the float setting, the gauge unit is correct.

Do not test gauge units by shorting terminals direct to earth. Minimum circuit resistance is to be held to 10 ohms for high indication. Lower resistances will destroy calibration.

TEMPERATURE GAUGE TEST

Start the engine and allow it to run at 1200 rpm for 30 minutes. Place a thermometer in the coolant at the radiator filler cap. The tem­perature should read a minimum of 82.2°C ( 180°F), and the gauge in the instrument panel should in­dicate within the normal band.

If the gauge does not indicate, short the temperature sender unit terminal wire to ground (ignition switch on). Do not leave the sender wire grounded longer than necessary to make the test, as the gauge may be damaged. If the gauge now indi­cates, the sender unit is defective or not properly sealed to the engine. Be sure to use an electricaUy conductive sealer. If the gauge does not indi­cate, the gauge, the wires leading to the gauge, or the constant voltage regulator are at fault.

OIL PRESSURE INDICATOR LIGHT TEST

To test the indicator light . turn on the ·ignition switch. Do not start the engine. The light should come on. Start the engine. The light ~hould go

out, indicating that the oil pressure has built up a safe value.

To test the oil pressure switch on the engine. turn the ignition switch on, engine not running, the indicator hgnt snould come on. If the indica­tor light does not come on, shffi"t the terminal of the oil pressure switch unit to ground. If the light now comes on, the oil pressure switch is defective or not properly sealed to the engine. Be sure to use electrical­ly conductive sealer

Jf the light still does not come on, the bulb is burned out or the wire~ from the bulb to the ignition switch and oil pressure switch are defective.

CHARGE INDICATOR LIGHT TEST

.To test the charge indicator light, turn the ignition switch on with the engine stopped. The light should come on. If it docs not. the bulb is burned out, or the wiring to the light is defective or there is a fault in the alternator/regulator circuit. Remove the wiring plug from the D+ terminal of the Bosch alternator regulator or the IND terminal of the Lucas alternator regulator.

Connect a jumper lead from the D+ or IND terminal in the cable to earth. The indicator light should come on.

If the light comes on the regulator is at fault. If the li,ght does not come on the fault is in the wiring or globe.

To check the globe and wiriug the instrument cluster surround n:ust be removed to gain access to the globe.

SPEEDOMETER TESTS

To test the odometer accuracy, drive the car over a measured kilometre (mile). Speedometer ac­curacy can be checked by compar­ing the speedometer in question against one known to be accurate, while two cars are moving at the same speed, or by timing the car on a measured kilometre (mile).

Page 15 24 shows the correct com­bination of gears to use for various rear axle and tyre size combina­tions .

15-6 GROUP 15- LIGHTING SYSTEM, HORNS AND INSTRUMENTS

EJ COMMON ADJUSTMENTS AND REPAIRS HORN ADJUSTMENT ADJUSTM~NT SCR~W

Horn current can be adjusted by changing the contact tension. Con-nect the horn as shown in Fig. 2. Turn the sel(-locking adjusting pan headed screw until the current is within the limits for the horn being adjusted.

TURN INDICATOR TURN INDICATOR

TERMINALS

WIRING LOOM SOCKET

HIGH OR LOW TON~ ID~NTIFICATION

FIG. 5- Horn Adjustment.

SEAT BELT WARNING HIGH BEAM

INSTRUMENT REGULATOR

FUEL AND TEMPERATURE GAUGE MASK RETAINING SCREWS

TEMPERATUREGAUGE VOUAGE TERMINALS

FIG. 3 - Falcon Printed Circuit. FIG. 4- Fairlane Printed Circuit.

15-7

PART 15-2 LIGHTING SYSTEM AND HORNS

Section Page Secdon Page I Description and Operation ................ 15-7 Parking Light ........................... 15-10

Headlights .............................. 15-7 Tail, Stop, and Back-Up Light Bulbs ........ 15-12 Horns .................................. 15-7 License Plate Light . .. ...... . .. ........ .. . 15-12

2 In-Car Adjustments and Repairs ... ...... .. 15-7 Dome Light .. . .......................... 15-12 Headlight Ahgnment .. . ......... ....... . . 15-7 Instrument Lights ......... ....... .... ... . 15-12 Headlight Adjustment ..................... 15-7 Horns .................................. 15·· 12 Back-Up Light Adjustment ................. 15-7 Horn Switch ............................. 15-1 2

3 Removal and Installation .......... . ....... 15-10 Gear Selector Quadrant Light . ..... ... .... 15-12 Headlights .............................. 15-10

D DESCRIPTION AND OPERATION

Refer to Group 22 for locations of wiring harnesses and schematics.

HEADLIGHTS The Falcon Models use tw_o

No. 2 type sea led-beam headlights. Each light has low -bea m and high­beam filaments.

The beam selector switch is in­corporated in the turn indicator switch.

Quick disconnect terminals are also provid!!d on the left and right

of the radiator support assembly . The terminals are colour coded. Like colo ur terminals are c6nnect­

€d together.

HORNS Standard and De- Luxe m odel s are

fitted "ith one low tone horn. On Fairmont, Futura and G.T. models a pair of tuned horns is used, one a high pitched tone, the other, which is similar to the single horn installa­tion, has a low pitched tone. A horn button closes the circuit to the horn( s ).

EJ IN-CAR ADJUSTMENTS AND REPAIRS

HEADLIGHT ALIGNMENT

All headlight adjustments should be made with a half-full fuel tank plus or minus one gallon, with a person seated in the driver's seat, and a person in the passenger seat, the ear unloaded and the trunk empty except for the spare tyre · and jacking equipment, and recom­mended pressure in all tyres. Be­fore each adjustment, bounce the car . by pushing on the centre of both the front and rear bumpers, to level the car.

To align the headlights by means of a wall screen, select a level por-

tion of the shop floor. Lay out th!' floor and wall as shown in Fig. 6.

HEADLIGHT ADJUSTMENT Adjust each upper headlight beam

as shown in Fig. 6. Some states may not approve of the 0 ±51.0 mm (2 inch) dimension for the headlights. Check the applicable state law.

Each headlight can be adjusted by means of two screws located between the light and radiator gri lle. (Fig. 7 and 8).

CAUTION Always _ adjust aiming !'crew

counter clockwi!\e th!'n clockwise until high intensity of lig-ht is

High and low tone horns can be identified by the letter "H" or "L" respectively cast into the throat of the horn .

NOTE: Horns are located forward of the left front suspension tower.

SEAT BELT WARNING LAMP.

All vehicles are fitted with a seat belt warning lamp.

A relny is used which illumin­ates the lamp for I 2-15 seconds after switching on the ignition .

properly aimed. Thi s will bring the beam into final position with the unit he ld under proper tension when uperation is co mpleted.

Note : Do not check aim on the

low beam.

BACK VI' LJ(;HT AOJUSTMENT

Place the shift lever in the re­verse position. Loosen the switch retaining clamp and position the switch so that the operating plung­er is depressed 1.6mm (1 1 16"). Ensure that the swite>h body is not contacting the shift arm and is parallel to the arm. Tighten the clamp.

15-8 GROUP 15- LIGHTING SYSTEM, HORNS AND INSTRUMENTS

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PART 15-2- LIGHTING SYSTEM AND HORNS 15-9

FIG. 7 - Headlight and Parklight Installation - Falcon Typical.

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FIG. 8 - Headl ight and Parklight Installation - Fairlane Typical.

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15-10 GROUP 15- LIGHTING SYSTEM, HORNS AND INSTRUMENTS

EJ REMOVAL AND INSTALLATION

HEADLIGHTS

REMOVAL To replace the sealed beam unit,

remove the radiator grill and remove the three sealed beam retaining rim screws . Lift the sealed beam unit free of its cradle.

Remove the push-on 3-pin con­nector by holding the headlight assembly and applying a firm pulling

action to the connector. Remove sealed beam unit from vehicle.

REPLACEMENT Align the three-pin connector with

the contacts in the sealed beam unit and push on. Fit the sealed beam unit to cradle ensuring the three locating lugs engage in cradle locat­ing slots. Fit the retaining rim and fit three screws.

Refit grill and aim headlights.

Whenever a sealed beam umt IS

replaced or any other alterations are made to a headlight assembly the headlights should always be checked for alignment and adjusted as described on page 157.

PARKING LIGHT Th.: parking light of Fairlane­

Falcon vehicles is shown in Fig. 9,..10. To replace the bulb remove the lens

retaining screws and the lens.

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FIG. 9- Installation Drg. Park Lamps.- Fairlane

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PART 15-2- liGHTING SYSTEM AND HORNS

Fig. 11-Falcon Park lamps

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15-11

15-12 GROUP 15- LIGHTING SYSTEM, HORNS AND INSTRUMENTS

TAIL, STOP, AND BACK-UP LIGHT BULBS

To replace the tail, stop, and/ or the back-up lights, remove the retain­ing screws and remove the icns. See Figs. I0-12- 13-14. LICENCE PLATE LIGHT

Bulb replacement is straightfor­ward as there is no lens covering the licence plate bulb. DOME LIGHT

Remove the self fixing dome light lens and replace the bulb. INSTRUMENT LIGHTS

Instrument cluster illumination

lamp bulb replacement necessitates removal of the instrument cluster as described in Part 15-4.

Once the cluster has been removed simply remove the bulb holder from the cluster replace the bulb and reinsert the a~sembly in the cluster. GEAR SELECTOR QUADRANT LIGHT COLUMN SHIFT.

1. Gently prise the gear selector quadrant dial from the sleeving column.

2. Remove the globe. 3. Replace the globe and push

the dial assembly over the locating

pins. GEAR SELECTOR QUADRANT LIGHT FLOOR SHIFT.

I. Remove the console and dial assy .

2. Remove the globe.

HORNS

Disconnect the horn wire from the terminal. Remove the horn mounting bracket to horn retaining screws and remove the horn .

To install, mount the horn in position, then connect the horn wire to the horn terminal.

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15-13

PART 15-3

SWITCHES, CIRCUIT BREAKERS, AND FUSES

Section

Descript ion and Operation .. . . ... ........ . Headlight Switch . . . . .. . .. .. .. . . .. ..... . Fuse Panel. . . . . . . . . .... . . . . . . .. . .... . .

Section

Stop Light Switch

Dome Light Switch

Mechanical Stop Light Switch .. ..... .. . . .. .

Page 15-13 15-13 15-13 15-13 15-13 15-13 15-13

Ignition Switch and Lock Cylinder . ... .... .. . .

Page

15-14

15-14

15-14

15-14

15-14

15-14

Reversing L1ght Switch . . . ... . ...... ... .. . 2 Removal and I nstalla t iun .... .. .. .... . .. .

Windshic:ld Wiper Switch . .. . . ..... . ...... . .

Multi-purpose Switch . . . . . . . . ... ..... . . Neutral Start Switch .. ... . ....... .... . .. . . .

Hack-Up Light Switch . . . . . . . . . . . . . . . . . . . .

D DESCRIPTION AND OPERATION

Refer to Group 22 for locations of wiring harnesses and schematics. HEADLIGHT SWITCH

A separate headlight switch and circuit breaker is used. The headlight circuit is protected by a 22 ampere circuit breaker. The tail, parking. licence plate light and horn circuits are protectecl hy 8 amp fuses.

MULTI-PURPOSE SWITCH A multi-purpose switch is fitted

to the steering column immediately below the steering wheel and in­corporates the following functions:

a. Turn indicator switch with a spring loaded "lane change" fea­ture .

b. Headlight hcam selector with a spring loaded headlight "flash" feature .

c. A horn switch operated by pushing the end of the switch lever.

FUSE PANEL

The fuse panel is mounted on the right of the dash panel under the right-hand air vent. Fig.l S shows the

FIG. 15 - Fuse Panel Location -Typical.

fuses, their valves and locations.

MECHANICAL STOP LIGHT SWITCH

The mechanical stoplight switch is located on the brake pedal support hracl<et and 1s operated by a lever extending from the brake pedal arm.

With the brake pedal in the re­leased position and a test lamp con-

EJ REMOVAL AND INSTALLATION

HEADLIGHT SWITCH 1. Disconnect the battery ground

cable.

2. Prise the switch forward from the instrument cluster.

3. Disconnect wiring and remove the switch .

4. Connect wiring to the switch connections.

5. Press the switch assembly into the aperture .

MULTI-PURPOSE SWITCH Removal

1. Remove the steering wheel. 2. Remove the four screws re­

taining the steering column upper shroud, remove the filler piece from the shroud immediately be­low the switch lever and lift the shroud from the steering column.

3. Remove the two screws se­curing the switch to the steering column flange.

nected to the switch terminals adjust the switch as follows-

1. Release the locknuts retaining the switch body.

2. Move the switch body forward until the test lamp goe$ out.

3. Move the switch body a fur­ther 1.27 mm (0.050") forward.

4. Tighten the locknuts.

BACK-UP LIGHT SWITCH

The reversing light switch is incor­porated in the inhibitor switch on automatic transmission vehicles.

In column shift manual transmis­sion vehicles the plunger type switch is located on a bracket at the steering column lower bearing where it is actuated by the first and reverse shift lever.

On floor shift manual transmission vehicles the plunger type switch is mounted on a bracket on the front of the shift mechanism where it is actuated by the reverse shift lever as it reaches the reverse position.

4. Disconnect the two multi-pin wiring plugs from the switch and remove the switch. Installation

5. Counect the two wiring plugs to the switch.

6. Position the switch to the steering column flange ensuring that the gear selector quadrant light wires (if fitted) are not trap­ped behind the switch. Install and tighten the attaching screws.

15-14 SWITCHES, CIRCUIT BREAKERS AND FUSES

7. Install the steering column upper shroud and the steering wheel.

8. Check the operation of the switch.

STOP LIGHT SWITCH

1. Disconnect the wires at the connector.

2. Release the locknut (pedal side) and withdraw the switch.

3. Reverse the above procedure to replace the switch.

4. Adjust the switch as in section I.

DOME LIGHT SWITCH The dome light switch IS mcor­

porated in the panel lamp switch. It is actuated by rotating the switch control wheel to the right when once the panel lamps have reached full brilliance. The further rotation of the wheel switches the dome lamp on .

The dome lamp also acts as a courtesy lamp actuated by switches m the door pillars.

IGNinON SWITCH AND LOCK CYLINDER

1. Disconnect the negative cable from the battery.

2. Remove the column from the vehicle .

3. Remove the steering lock shroud and shift tube. Page 3-38

4. Cut slots in the steering lock attaching bolts with a hacksaw and remove the bolts with a screw driver or hammer and centre punch.

FIG. 16- Typical Ignition Switch Removed .

5. Rotate the lock around the column tube until one end of the base clears the aperture, lift the lock from the column.

6. Place the steering/ignition lock assembly into the steering column

7. Engage new recessed bush in the shear head bolts and tighten them evenly until the heads shear off. Install shift tube.

8. Assemble tile shroud to the column.

9. Assemble the column to the vehicle. LOCK BARREL REPLACEMENT.

I. Remove the steering/ignition lock shroud lower attaching screw from beneath the shroud.

2. Turn the ignition key to the off or on position. ·

3. Push a 1.5 mm (0.062" dia­meter pin into the lock through the shroud lower mounting hole to raise the barrel locking pin and remove the barrel (Fig. 16).

4. Align the barrel tongue and aperture and assemble the barrel to the lock and raise the barrel locking pin by turning the key to the start position .

5. Assemble the lock shroud lower attaching screw.

WINDSHIELD WIPER SWITCH

1. Disconnect the battery cable. 2. Prise the switch from the

instrument cluster. 3. Disconnect wiring and remove

the switch. 4. Connect wiring to the switch

connections. 5. Press the switch assembly into

the aperture.

NEUTRAL START SWITCH See group 7 for replacement of

the neutral start switch on cars equipped with automatic transmis­sions.

BACK-UP LIGHT SWITCH 1. Remove the two wires from

the switch. 2. Loosen the retaining clamp or

locknuts. 3. Remove the switch.

PART 15-4 INSTRUMENTS

Section Pare 1. Description and Operation . . . . . . . . . . . . . . 15-15

Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-15 Constant Voltage Regulator . . . . . . . . . . . . . . 15-15 Fuel Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-15 Temperature Gauge . . . . . . . . . . . . . . . . . . . . . 15-15 Charge Indicator Light . . . . . . . . . . . . . . . . . . . 15-16 Oil Pressure Indicator Light . . . . . . . . . . . . . . 15-16 Turn Indicator . . . . . . . . . . . . . . . . . . . . . . . 15-16 Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . 15-16 Brake Warning Lamp . . . . . . . . . . . . . . . . . . . 15-16

2. In-Car Adjustments and Repairs . . . . . . . . . . . . 15-16 Windshield W'!'er Blade Adjustment I Installation 15-16

3. Removal and Installation . . . . . . . . . . . . . . . . 15-17 Instrument Cluster ..................... 15-17 Fuel, Temperature Gauges . . . . . . . . . . . . . . 15-17 Printed Instrument Circuit . . . . . . . . . . . . . . 15-17 Fuel Sending Unit . . . . . . . . . . . . . . . . . . . . . 15-17

15-15

Section Speedomete-r and Tachometer ........... . . Speedometer Cable ................. .. . . . Temperature Sending Unit .............. . Oil Pressure Switch ..................... . Turn Indicator Flasher .... . .............. . Windshield Wiper Motor .. . ............ .. . Wiper Pivot Shaft and Link .............. .

4. Major Repair Operations ......... . ....... . Disassembly- Permanent Magnet Type Two-

Speed Electric Wiper Motor ...... . ..... . Inspecting and Testing Disassembled Motor ... . Testing and Assembled Motor ............ .

Pare 15-17 15-17

15-19 15-19 15-19 15-19 15-19

15-20

15-20 15-20 15-22

NOTE: If the instruments require servicing while the assembly is removed from the instrument panel, the cluster case must be earthed to the vehicle body. Failure to observe this precaution will cause immediate damage to the fuel and temperature gauges a:s soon as any power is applied to the electrical circuits.

D DESCRIPTION AND OPERATION

All of the instruments are electri­cally operated except the speedome­ter. Brightness of the instrument pan­el lights is controlled by a rheostat adjacent to the lighting switch.

GAUGES The instrument cluster includes

a fuel gauge, temperature gauge, charge indicator light, oil pressure indicator light, speedometer, high beam indicator light, a left and right-hand turn signal indicator light, brake warning light, and seat belt warning light.

CONSTANT VOLTAGE REGULATOR

The constant voltage regulator used with the fuel, temperature, and 'oil gauges maintains an aver­age value of 5.0 volts at the gauge terminals.

The regulator operates by means of a bimetallic arm and a heating coil. When the ignition switch is turned on, the heating coil heats the bimetallic arm causing it to bend and break the contacts, dis­connecting the voltage supply from the heating coil. The bimetallic arm then cools and brings the contacts together again. The making and

breaking of the contacts, causes a pulsating voltage, with an effective average value of 5.0 volts to be sup­plied to the gauges. Although these pulsations are quite rapid, there is in each gauge a bimetallic arm which changes temperature quite slowly, and this assures steady average read­ings.

As the pulsating voltage would normally cause radio interference, a radio interference suppression choke is connected in series with the con­stant voltage regulator supply wire.

FUEL GAUGE The fuel gauge consists of a send­

ing unit, located on the fuel tank, and a remote register unit (fuel gauge) mounted in the instrument cluster. The remote register unit pointer is controlled by a bimetallic arm and heating coil. The sending unit is a rheostat that varies its resistance de­pending on the amount of fuel in the tank. The rheostat is operated by a float control. As the fuel level rises or falls the float control arm moved by the float, varies the resistance.

TEMPERATURE GAUGE The temperature gauge consists

of a sending unit mounted in the cylinder head at the top front on the V-8, and the left rear on the

six, with a remote register unit (temperature gauge) mounted in the instrument cluster.

·Changes of engine temperature vary the resistance of the sending unit which in tum operates the tem­perature gauge.

COil TEMPERATURE SENDING UNIT

Oil PRESSURE SWITCH

FIG. 17 -Oil Pressure Switch and Temperature Sending Unit 6 Cyl.

15-16 GROUP IS

CHARGE INDICATOR LIGHT

A red alternator charge indicator light is used. This light illuminates if the battery is discharging and the al­ternator is not supplying current.

When the ignition switch is closed, battery current flows through the charge indicator light and through the regu lator voltage limiter to the field.

When the alternator outp ut voltage t•pposing battery voltage is high enough the charge indicator light goes out.

OIL PRESSURE INDICATOR LIGHT

A red indicator light illumin­ates when the oil pressure is below a safe value. The light should come on when the ignition switch is first

LIGHTING SYSTEM, HORNS AND INSTRUMENTS

turned on, and it should go out when the engine comes up to speed. The light is connected be­tween the oil pressure switch unit mounted on the engine at the left rear on the six, centre rear on the V-8, and the coil terminal of the ignition switch. The G.T. has an oil gauge adjacent to the tacho­meter.

TURN INDICATOR The turn indicator uses a single

filament globe in the upper section of the front park/ indicator combination lamp and the centre section of the rear light assembly.

The turn indicator flasher is lo­cated in the back of the instrument panel, on the steering column brace.

SPEEDOMETER

The speedometer is connected to the output shaft of the transmis­sion by means of a flexible shaft, and a drive gear located inside the transmission. The flexible shaft drives the speedometer which re­gisters speed in kilometres (miles) per hour and also drives an odo­meter which records distance tra­v .::!led in miles and tenths of a mile.

BRAKE WARNING LAMP

A red indicator lamp illuminates when either the front or rear brake systems become inoperative. The warning light switch is located in the master cylinder body.

"Prove out" of the light circuit is conducted by turning the ignition switch to the start position when the lamp should illuminate.

EJ IN-CAR ADJUSTMENTS AND REPAIRS

WINDSHIELD WIPER BLADE INSERT REPLACEMENT

Removal 1. Raise the wiper blade assem­

bly from the windscreen until it is just clear of the screen and sup­port the arm in this position.

2. Compress the retaining clip at the end of the blade assembly with the fingers and slide the insert and its metal backing strip from the blade as~cmbly. Installation

3. Slide the insert and its metal backing strip into the blade until the spring clip snaps into position.

Fig. 18--Wiper Blade Removal

4. Remove the support from the wirer arm and lower the blade to the screen.

WINDSHIELD WIPER ARM AND BLADE ASSEMBLY ADJUSTMENT OR REPLACEMENT

Removal I. (Driver's side only) . Discon­

nect the articu lating link from the pivot post by sliding the retaining clip along the link and lifting the link clear of the pivot pin.

2. Raise the arm to the full ex­tent of its travel (DO NOT USE FORCE), then rotate the lock plate on the pivot post end of the arm in a clockwise direction. Gently lower the arm which will then be held slightly away from the windshield.

Fig. 19-Wiper Arm Lock Plate

3. Remove the arm assembly from the pivot post spindle.

CAUTION: DO NOT USE FORCE WHEN REMOVING OR REPLACING THE ARM AS­SEMBLY AS DISTORTION OF THE ASSEMBLY WILL OC­CUR. Installation

4. Ensure that the arm is held in the locked position with the lock plate holding the assembly in a straight line. (Fig. 19 ).

5. Position the arm assembly on th ~ spindle with the blade 38-63 mm (Jt-2t ") from the lower edge of the windscreen (measured at the centre of the blade).

6. (Driver's side only). Fit the articulating link to the pivot pin and secure it with the spring clip.

7. Raise the arm to the extent of its travel (DO NOT FORCE).

Lock Plate

Rotate the lock plate in an anti­clockwise direction and gently lower the arm to the screen.

WIPER BLADE ASSEMBLY

Removal 1. Remove the arm and blade

assembly as described in the pre-

PART 15-4 INSTRUMENTS

vious operation. 2. Using a small screwdriver

through the aperture in the blade assembly depress the spring, re­move the pivot pin. (Driver's side only). Separate the blade from the arm. Installation

3. Driver's side. Position the

EJ REMOVAL AND INSTALLATION

INSTRUMENT CLUSTER

I. Remove the three screws, (five screws Fairlane) retaining the cluster housing.

2. Remove the housing toward the steering column.

3. Disconnect warning lamps (and /or Gauges G .T.).

4. Remove the housing from be­hind the steering column by moving it toward the centre of the vehicle (select 1st or 1 gears on column shift vehicles).

5. Remove the four cluster retain­ing screws (one in each corner of the cluster body) , and partially remove the cluster.

6. Disconnect speedo cable and printed circuit plug.

7. Complete removal of the cluster by rolling the top back toward the column.

SPEEDO CABLE DISCONNECT FROM SPEEDO HEAD

1. Remove the crash pad end cover (from right hand side).

2. Using a long screw driver or solid rod depress the release tab and pull the cable away from the speedo head. (Fig. 20).

FUEL & TEMPERATURE GAUGES

I . Remove the instrument cluster as previously outlined .

PULL CABLE AWAY FROM HEAD

2. Remove the two upper screws retaining the lenses and the two screws holding the two halves of the cluster together.

3. From the front of the gauges, remove the two screws retaining the fuel gauge mask, unclip the mask from the temperature gauge mask and remove it from beneath the needle.

4. Remove the terminal speed nuts retaining the gauges to the rear half of the canister and remove the gauges.

NOTE : The fuel gauge mask must be removed before the temp gauge or mask can be removed.

FUEL & TEMPERATURE GAUGES G.T. &G.S.

I. Remove the instrument cluster housing (3) retaining screws and lay the housing toward the steering column.

2. Remove the gauge wiring and disconnect the warning lamp holders from the housing.

3. Remove the housing from be­hind the steering column and remove the gauge retaining screws.

4. Remove the gauges from the housing. FUEL & TEMPERATURE GAllGES FAIR LANE.

I . Remove the instrument cluster as previously outlined.

FIG. 20 - Speedo Cable to Speedo Connection.

15-17

blade assembly in the arm. De­press the spring and insert the pivot pin.

4. Passenger's side. Depress the spring and assemble the blade to the arm.

5. Replace the arm and blade assembly as described in the pre­vious operation.

2. Remove the four screws attach­ing the lens and cover to the canister.

3. Remove the terminal speed nuts from the gauges and remove the gauges from the canister.

SPEEDOMETER & TACHOMETER.

I . Remove the instrument cluster and separate it as previously outlined under fuel and temperature gauge removal.

2. Remove two retaining screws from the backs of the speedometer/ tachometer.

NOTE : On Fairlane remove fuel and temperature gauges prior to attempt­ing to remove the speedometer.

3. Remove the speedometer/ tachometer from the cluster.

PRINTED CIRCUIT. Replacement of the printed circuit

can only be achieved once the gauges - speedometer/tachometer have been removed. Fig. 3 & 4.

CLOCK.

I. Remove the instrument cluster housing.

2. Remove the instrument panel pad, right hand end cover.

3. Remove the two clock attaching screws.

4. Disconnect the clock leads. 5. Remove the clock through the

end opening in the instrument panel.

WARNING LAMPS.

1. Remove the instrument cluster housing.

2. Remove bulb holders from the housing. NOTE: On Fairlane vehicles remove the heater control panel to gain access to the brake warning lamp.

FUEL SENDING UNIT 1. Remove the fuel from the fuel

tank.

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MOUNTING CLIP

FIG. 22- Speedo Driven Gear.

2. Disconnect the fuel gauge send­ing unit wire from the sending unit.

3. Loosen the hose clamp and dis­connect the tank line at the sending unit.

4. Remove any dirt that has ac­cumulated around the sending unit so that it will not enter the tank.

5. Turn the sending unit retaining ring counterclockwise and remove the unit , retaining ring, and mount­ing gasket.

6. Clean the fuel gauge sending unit moun!ing surface at the fuel tank.

7 Position the sending unit and mounting gasket on the fuel tank and secure with the retaining ring.

8. Connect the sending unit wire and the fuel tank line.

9. Fill the tank with the fuel re­moved .

10. Check the fuel gauge opera­tion and check for leaks. TEMPERATURE SENDING UNIT

t. Disconnect the temperature sending unit wire from the sending unit

2. Prepare the new temperature sending unit for installation by apply­ing a small amount of conductive water-resistant sealer to the threads .

3. Remove the temperature send­ing un.it from the cylinder head and immediately install the new tempera­ture sending unit .

4. Connect the wire to the tem­perature sending unit.

PART 15-4 INSTRUMENTS

SPEEDCMETER DRIVEN GEAR

'

/

5. Start the engine and check the sending unit operation.

OIL PRESSURE SWITCH To replace the unit disconnect the

wire from the terminal. Remove the unit from the engine. Apply con­ductive sealer to the threads and install the wire to the terminal and check the operation of the unit.

TURN INDICATOR FLASHER Disconnect the wires from the

flasher unit terminal, turn flasher and remove. Observe the colour code and number on the cover of the flasher. Be certain to replace it with a new flasher with the same colour code and number on the cover.

WIPER PIVOT SHAFT AND LINK 1. Remove the windshield wiper

blade and arm assembly. 2. Remove the-pivot shaft retain­

ing nut, bezel and gasket. 3. Disconnect the wiper link from

the motor and remove the link and pivot shaft assembly.

4. Position the link and pivot shaft assembly on the cowl and wiper motor. Connect the link to the motor.

5. Install the pivot shaft to the cowl and install the gasket, bezel, and retaining nut.

6. Install the wiper blade and arm assembly.

15-19

7. Check the pivot shaft and link operation.

WINDSHIELD WIPER MOTOR AND WASHER ASSEMBLY

REMOVAL

1. Disconnect the harness from the Wiper Motor.

2. Remove the t!lree hoses con­nected to the Washer Pump.

3. Remove the three bolts retain­ing the Wiper Motor and mounting seal assembly to the dash panel. Lower the assembly aQd disconnect the wipe~ !inks at the motor. Remove the Motor and Washer Assemblv. INSTALLATION

1. Position the Motor and Washer Assembly and assemble the connect­ing wiper links to the motor.

2. Position the Motor and Washer assembly to the dash panel and install three retaining bolts.

3. Connect the harness connector to the Wiper Motor.

4. Connect large hose to inlet and two small hoses to outlet connec­tions on washer pump.

5. Connect the battery and check the operation of the Wiper Motor and the 'park position' of the Wiper Blades.

WIPER PIVOT SHAFT AND LINK REMOVAL

1. Remove the windshield wiper blade and arm assembly.

2. Remove the nine cowl panel attaching screws and remove the cowl panel.

3. Remove s1x bolts retaining pivots.

4. Disconnect the wiper link from the Motor and remove the link and pivot shaft assembly.

INSTALLATION

1. Position the link and pivot shaft assembly on the cowl and wiper motor. Connect the link to the motor.

2. Install the pivot shaft to the cowl and install six bolts to retain pivots.

3. Install the cowl panel. 4. Install the Wiper Blade and

Arm Assembly. 5. Check the Pivot Shaft and Link

operation.

15-20 GROUP 15- LIGHTING SYSTEM, HORNS AND INSTRUMENTS

IJ MAJOR REPAIR OPERATIONS (Preslite)

FIG. 23- Wiper Motor Assy.

ITEM DESCRIPTION ITEM DESCRIPTION 1 Clamp Nut 3 Seal

2 Motor Crank Assembly 4 Grommet Insert

5 Terminal Block Assembly 6 Gear Housing Assembiy 7 Distance Washer 9 Thrust Cone

11 Terminal

8 Gear & S~ft Assembly 10 Washer Pump Assembly 12 Screw

13 Brush 15 Screw

14 Brush Spring 16 Spring Washer

17 Armature Assembly 18 Ball 19 Thrust Pad Assembly 20 Motor Housing Assembly 21 Wave Washer 23 Screw

DISASSEMBLY PERMANENT MAGNET TYPE TWO SPEED ELECTRIC WIPER MOTOR

1. Remove the clamp nut (1), Motor Crank, Assembly (2), Wave Washer (21), Flat Washer (7), Grom­met Insert (4) and Mounting Seal (3).

2. Clean the gear housing of old grease. Do not allow cleaning fluid to contact the armature shaft and output shaft bearings. Wipe all other parts with a clean cloth.

3. Remove the two screws ( 15), lockwashers (16) and motor housing assembly (20). Do not pound the Motor housing assembly as the ceramic magnets may be damaged. Remove the ball (18) and thrust pad assembly (19).

4. Note: That the ball may have dislodged and become attracted to the magnets during the dismantling operation, and it is ·essential that this

22 Earth Finger

item is located. 5. Retract the brushes ( 13) and

withdraw the armature assembly (17) and thrust cone (9).

6. Remove the four screws (1 2), Terminal (11) and Washer Pump Assembly (10).

7. Disconnect the feed wire (minia­ture terminal) from the wiper motor.

8. Remove the gear and shaft assembly (8) and distance washer (7).

9. Insert screwdriver in slot at base of terminal block assembly (5). Prise upwards to free terminal block assembly, unsolder wires and remove from housing (6).

10. Remove self-tapping screw (23) and earth finger (22).

INSPECTING AND TESTING THE DISASSEMBLED MOTOR

1. Cover motor housing bearings and blow dust from interior with

compressed air. 2. Visually inspect for damage to

the ceramic magnets-replace motor housing assembly if necessary.

3. Visually inspect the armature assembly for burned commutator bars, galling or pitting of the arma­ture shaft bearing area and worm gear for scoring. Check thrust ball for pitting, balling or discolouration due to heat. Replace if necessary.

4. Test for grounded armature. Obtain a test lamp and battery, con­nect one probe to the armature shaft or armature stack, and touch each commutator segment in turn with the other probe. The lamp should NOT light. If the lamp lights the armature is grounded and must be replaced.

5. Inspect the brush holder plate for cracks or damage. Ensure that brush boxes are secure and that con­nections are not burned or corroded.

PART 15-4- INSTRUMENTS 15-21

7

6 3 8

~ s 4

~ ~ t" ~\2 lO

'"'14 FIG.24

ITEM DESCRIPTION ITEM DESCRIPTION 1 Housing Assembly 2 Solenoid Assembly 3 Suction Cap 4 Plunger 5 Trim Cup 6 Cover 7 Valve Cover 8 Valve Seat 9 Valve Seal

11 Screw 13 Bush

6. Replace motor brushes that are worn down to 6 mm ( t") long. Examine brush springs for distor­tion, burning or collapse. Normal brush spring length is 38.1 mm (1 t") minimum. Replace if neces­sary.

7. Examine the gear housing for cracks and distortion, and the bear­ings for excessive wear. Examine the three parking fingerS for loss of tension, burning or pitting. Replace gear housing assembly if necessary.

8. Examine the gear and shaft assembly for worn or damaged teeth. Check cam for wear on face. Replace if necessary.

ASSEMBLY 1. Apply grease to the centre­

drilled holes in each end of the armature shaft. Assemble the Thrust Cone (9) to the worm end of the sha(t and the 4.76 mm (3 / 16") diameter ball (18) to the other end of the shaft.

2. Assemble brusn :springs (14) and brushes (13) to the gear housing

10 Valve Rubber 12 Plunger & Lever Assembly 14 Spring

assembly. 3. Retract the brushes and assem­

ble the armature assembly (17) to the gear housing assembly.

4. Apply stiff grease to the back face of the thrust pad assembly (19) and locate in the recess in the bottom of the motor housing assembly (20).

5. Assemble the motor housing assembly (20) to the gear housing assembly (6). Ensure that the wiring to the brushes does- not foul the motor housing. Assemble the two screws

(15) and lockwashers (16). 6. Adjust armature shaft thrust

screw in until resistance is felt and then back off screw a quarter turn.

7. To secure earth finger (22) to gear housing (6), install screw (23).

8. Install terminal plate assembly (5) to gear housing. Ensure that flanges on terminal plate assembly are located in receiving slot in housing (6).

9. Apply No. 2 cup grease to par­king plate and cam track (8).

10. Assemble the distance washer

(7) on the gear shaft assembly (8) and assemble gear and shaft assembly to the gear housing.

11. Install mounting seal (3) to gear housing and assemble grommet insert ( 4).

12. Connect washer lead con­nector to wiper motor terminal, assemble washer pump assembly (10), terminal (11) and four self­tapping screws ( 12). Re-locate self­tapping screws carefully in exist­ing threads to avoid stripping and tighten screws to a torque loading of 2.2-2.8 Nm (20-25 lbs. ins.).

DISASSEMBLY WASHER PUMP

1. Remove the four screws (11) attaching valve cover, remove valve cover (7), valve seal (9), valve seat (8), suction cap (3), trim cup (5) and plunger ( 4).

2. Remove solenoid assembly (2), with cover from housing assembly (I), dismantle plunger and lever assembly (12) and solenoid cover (6).

3. Remove bush (13) and spring (14).

15-22 GROUP 15· LIGHTING SYSTEM, HORNS AND INSTRUMENTS

INSPECTING AND TESTING DISASSEMBLED WASHER PUMP

1. Check operation of non-retur­ned valves in valve assembly.

2. Check suction cap for damage or cracks or deterioration.

3. Examine trim cap, solenoid lever and plunger for damage or wear.

4. Check solenoid windings for continuity or short circuit.

5. Examine housing bush for dam­·age and excessive wear.

6. Check compression spring for damage.

7. Examine washer housmg and latch for cracks and distortion, ex­amine timing gear for worn or damaged teeth.

Note: Timing gear should rotate only when latch is retracted.

ASSEMBLY OF WASHER PUMP

1. Apply No. 2 cup grease to latch mechanism (1).

2. Install spring (14) and guide bush (13) to housing.

3. Install plunger and lever assem­bly (12) to solenoid assembly (2).

4. Install solenoid to housing tak­ing care that lever engages wit~ sl~t in latch. Ensure that solenmd 1s located in receiving slot in housing and solenoid wire is correctly posi­tioned in housing assembly.

5. Install trim cup (5) and plunger ( 4) to suction cap (3).

6. Install solenoid cover (6) to snap fit over location pin.

7. Install suction cap assembly and ensure that plunger is located in guide bush.

8. Install valve seat assembly (8, 10) and valve seal ( 4).

9. Install valve cover (7) and secure with four screws (11) tight­en to a torque loading of 1.1-1. 7 Nm (10-15 lbs. ins.). TESTING THE ASSEMBLED MOTOR

1. Obtain a switch assembly ARC9DF.17A553-A, a 12 volt auto­motive battery and an 0 to 10 amperes Ammeter.

2. Connect the Negative terminal of the battery to the motor earthing terminal (11) and the 'E' terminal of the switch assc;mbly.

3. The terminal block assembly has four terminal blades and the moulding has four identification numbers 1 to 4 respectively. The switch assembly moulding also car­ries identification numbers .

4. (i) Connect motor terminal No. 1 to switch terminal No. 1.

(ii) Connect motor terminal No. 2 to switch terminal No.2.

(iii) Connect motor terminal No. 3 to POSITIVE bat­tery terminal.

(iv) Connect motor terminal No. 4 to switch terminal No.4.

(v) Connect washer pump ter­minal to switch terminal 'W'.

5. Open te switch assembly and check for LOW speed and HIGH speed operation. Switch to park position two or three times and check that the motor crank assembly stops with a positive action in the same pcsition.

6. Switch motor to low speed and back-off the adjusting screw in the gear housing at the end of the arma­ture shaft. Adjust end play of the armature by tightening the screw until an ammeter in series shows a slight rise in current. Back-off slightly until the current is just normal, apply 'LOCTITE-GRADE CV' to the screw to prevent unlocking.

7. Check the current consumption after running the motor for 30 min­utes. The consumption should be 2 . 5 amperes maximum at 13 . 5 volt and the output speed 40 rpm LOW and 65 rpm HIGH.

8. Energising the solenoid of t~e washer pump, the current consump­tion should not exceed 2 amperes over the motor consumption during the energising period at 13 . 5 volts ± 0.1. Washer should complete four discharge cycles per one revolution of the wiper motor output gear and 12-16 discharge cycles for one wash cycle.

PART 15·5 SPECIFICATIONS

CIRCUIT PROTECTION

Function

Dome Courtesy

R/H Tail, Park Licence

L/H Tail & Park

Stop Light

Turn Signals

Radio

Heater Cigar Lighter

Windshield Wiper and Back Up Lamps

Light-Instrument Panel Light-PRNDL Dial

Light-Luggage Compartment

Light-Glove Box Light~Headlights

Horns

15-23

location Rating Time

Fuse Panel 8 8Amp Fuse Panel 6 8Amp

Fuse Panel 5 8 Amp

Fuse Panel 7 16Amp

Fuse Panel 4 8Amp Fuse Panel 2 8Amp Fuse Panel ' 16Amp

Fuse Panel 2 8Amp

Fuse Panel 2 8Amp Fuse Panel 4 8Amp Fuse Panel 6 8Amp

Fuse Panel 6 8Amp

Fuse Panel 8 8Amp

Fuse Panel 8 8Amp

Circuit Breaker 9 22Amp

Fuse Panel 3 8Amp

NOTE: There is a Circuit Breaker located on the starter relay and It controls the Accessory Relay (power windows and heated backlite) . It is rated at 20 amps.

BULB CHART

Unit

Headlight ALL MODELS

Front Turn Signal

Park ing

Rear Turn Signal

and Stop / Ta il

License Plate

Back Up Lights (Sedan) Back Up Lights (Stat. Wagon)

Luggage Compartment

Cargo Light (Wagon)

Dome Light

HORN

I Horn current dr11w 11t 12V

INSTRUMENTS

Fuel and T emper11ture Gauges Aver11ge volt11ge 11t termin~~ls

TURN INDICATOR

I Current dr11w 11t 12V

Wattage

50/75

21

6

21

6/ 21

6

21

21

10

10

10

4--5 Amps

5 Volts

0.4 Amps I

BULB CHART (Continued)

Unit Wattage

Warning Light Oil and Altern11tor 2.2 Brake Warning Light 2.2 Radio Dial 2.0 Turn Signal (Ins. Panel) 2.2 Instruments (Illumination) 2.2 Heater Control 2.2 Hi Beam Indicator 2.2 Speedometer 2.2 Glove Compartment 5.0 Courtesy Light Fairmont 15 Front and Rear Door Automatic Transmission Control 2.2

HEATER MOTOR CURRENT DRAW

At low speed At high speed

SPEEDOMETER CABLE

Mounting Clip Bolt Torque

~.5 Amperes 11t 12V

5.6 Amperes at 12V

4.1-6.1 Nm 3--4! Ft. Lbs.

15-24 GROUP 15- LIGHTING SYSTEM, HORNS AND INSTRUMENTS

WINDSHIELD WIPER MOTORS PRES LITE CURRENT CONSUMPTION

(HOT) OUTPUT SPEED

(HOT)

SPEEDO GEAR COMBINATIONS

Engine Transmission

6 Cyl. B.W. Manual 3 & 4 Speed & Auto

6 Cyl. B.W. Manual 3 & 4 Speed & Auto

8 Cyl. 6 Cyl. 5.0! : B.W. (302 CID) Manual 3 & 4

Speed

8 Cyl. U.S. C4 5.01. Auto (302 CID)

8 Cyl. B.W. 5.8 t 4 Speed (351) 2V & 4V

8 Cyl. U.S. 4 Speed 5.81'(351) RUG -BF

4V

8 Cyl. U.S. C4 5.8 t Auto (351) 2V

8 Cyl US. FMX 5.8 t Auto (351) 4V

2.5 Amp maximum at 1 3.5 V.

Axle Ratio

3.23 :1

3.50 :1

2.92 :1

2.92 1

3.0 :1

3.00:1

2.75 :1

2.75 :1

HIGH 65 R.P.M . LOW 40 R.P.M .

Tyre Size

6.95 X 14 7.35 X 14 7.75x14

ER70 x 14 185 X 14

6.95 X 14 7.35 X 14 7.75x14

ER70 x 14 1 8~ X 14

6.95 X 14 7.35 X 14 7.75 X 14

ER70 x 14 185 X 14

6.95 X 14 7.35 X 14 7.75 X 14

ER70 X 14 185 X 14

7.35 X 14 7.75 x 14 185 X 1 4

ER70 X 14

ER70 X 14

6.95 X 14 7.35 X 14 185 X 1 4

ER70 X 14 7.75 X 14

6.95 X 14 7.35 X 14 185 X 14

ER70 X 14

No. Of Teeth Driving Gear

(8) (8) (8) (8) (8)

(8) (8) (8) (8) (8)

(8) (8) (8) (8) (8)

8 8 8 8 8

8 8 8 8

7

8 8 8 8 8

8 8 8 8

No. Of Teeth Driven Gear Colour

(21) (lt. Green) (21) (Lt. Green) (20) (Brown) (21) (Lt. Green) (21) (Lt. Green)

(23) (Black) (22) (Grey) (22) (Grey) (23) (Black) (23) (Black)

(19) (Pink) (19) (Pink) (18) (Purple) (19) (Pink) (19) (Pink)

i9 Tan 19 Tan 18 Grey 19 Tan 19 Tan

19 Pink 19 Pink 19 Pink 19 Pink

17 Purple

18 Grey 18 Grey 18 Grey 18 Grey 17 Natural

18 Grey 18 Grey 18 Grey 18 Grey