Tyre BMW 3 SERIES 1988 E30 Owner's Manual

REF•3
REF
MOT Test Checks
Exhaust system
MStart the engine. With your assistant
holding a rag over the tailpipe, check the
entire system for leaks. Repair or renew
leaking sections.
Jack up the front and rear of the vehicle,
and securely support it on axle stands.
Position the stands clear of the suspension
assemblies. Ensure that the wheels are
clear of the ground and that the steering
can be turned from lock to lock.
Steering mechanism
MHave your assistant turn the steering from
lock to lock. Check that the steering turns
smoothly, and that no part of the steering
mechanism, including a wheel or tyre, fouls
any brake hose or pipe or any part of the body
structure.
MExamine the steering rack rubber gaiters
for damage or insecurity of the retaining clips.
If power steering is fitted, check for signs of
damage or leakage of the fluid hoses, pipes or
connections. Also check for excessive
stiffness or binding of the steering, a missing
split pin or locking device, or severe corrosion
of the body structure within 30 cm of any
steering component attachment point.
Front and rear suspension and
wheel bearings
MStarting at the front right-hand side, grasp
the roadwheel at the 3 o’clock and 9 o’clock
positions and shake it vigorously. Check for
free play or insecurity at the wheel bearings,
suspension balljoints, or suspension mount-
ings, pivots and attachments.
MNow grasp the wheel at the 12 o’clock and
6 o’clock positions and repeat the previous
inspection. Spin the wheel, and check for
roughness or tightness of the front wheel
bearing.
MIf excess free play is suspected at a
component pivot point, this can be confirmed
by using a large screwdriver or similar tool and
levering between the mounting and the
component attachment. This will confirm
whether the wear is in the pivot bush, its
retaining bolt, or in the mounting itself (the bolt
holes can often become elongated).
MCarry out all the above checks at the other
front wheel, and then at both rear wheels.
Springs and shock absorbers
MExamine the suspension struts (when
applicable) for serious fluid leakage, corrosion,
or damage to the casing. Also check the
security of the mounting points.
MIf coil springs are fitted, check that the
spring ends locate in their seats, and that the
spring is not corroded, cracked or broken.
MIf leaf springs are fitted, check that all
leaves are intact, that the axle is securely
attached to each spring, and that there is no
deterioration of the spring eye mountings,
bushes, and shackles.MThe same general checks apply to vehicles
fitted with other suspension types, such as
torsion bars, hydraulic displacer units, etc.
Ensure that all mountings and attachments are
secure, that there are no signs of excessive
wear, corrosion or damage, and (on hydraulic
types) that there are no fluid leaks or damaged
pipes.
MInspect the shock absorbers for signs of
serious fluid leakage. Check for wear of the
mounting bushes or attachments, or damage
to the body of the unit.
Driveshafts
(fwd vehicles only)
MRotate each front wheel in turn and inspect
the constant velocity joint gaiters for splits or
damage. Also check that each driveshaft is
straight and undamaged.
Braking system
MIf possible without dismantling, check
brake pad wear and disc condition. Ensure
that the friction lining material has not worn
excessively, (A) and that the discs are not
fractured, pitted, scored or badly worn (B).
MExamine all the rigid brake pipes
underneath the vehicle, and the flexible
hose(s) at the rear. Look for corrosion, chafing
or insecurity of the pipes, and for signs of
bulging under pressure, chafing, splits or
deterioration of the flexible hoses.
MLook for signs of fluid leaks at the brake
calipers or on the brake backplates. Repair or
renew leaking components.
MSlowly spin each wheel, while your
assistant depresses and releases the
footbrake. Ensure that each brake is operating
and does not bind when the pedal is released.
3Checks carried out
WITH THE VEHICLE RAISED
AND THE WHEELS FREE TO
TURN

REF•4MOT Test Checks
MExamine the handbrake mechanism,
checking for frayed or broken cables,
excessive corrosion, or wear or insecurity of
the linkage. Check that the mechanism works
on each relevant wheel, and releases fully,
without binding.
MIt is not possible to test brake efficiency
without special equipment, but a road test can
be carried out later to check that the vehicle
pulls up in a straight line.
Fuel and exhaust systems
MInspect the fuel tank (including the filler
cap), fuel pipes, hoses and unions. All
components must be secure and free from
leaks.
MExamine the exhaust system over its entire
length, checking for any damaged, broken or
missing mountings, security of the retaining
clamps and rust or corrosion.
Wheels and tyres
MExamine the sidewalls and tread area of
each tyre in turn. Check for cuts, tears, lumps,
bulges, separation of the tread, and exposure
of the ply or cord due to wear or damage.
Check that the tyre bead is correctly seated
on the wheel rim, that the valve is sound andproperly seated, and that the wheel is not
distorted or damaged.
MCheck that the tyres are of the correct size
for the vehicle, that they are of the same size
and type on each axle, and that the pressures
are correct.
MCheck the tyre tread depth. The legal
minimum at the time of writing is 1.6 mm over
at least three-quarters of the tread width.
Abnormal tread wear may indicate incorrect
front wheel alignment.
Body corrosion
MCheck the condition of the entire vehicle
structure for signs of corrosion in load-bearing
areas. (These include chassis box sections,
side sills, cross-members, pillars, and all
suspension, steering, braking system and
seat belt mountings and anchorages.) Any
corrosion which has seriously reduced the
thickness of a load-bearing area is likely to
cause the vehicle to fail. In this case
professional repairs are likely to be needed.
MDamage or corrosion which causes sharp
or otherwise dangerous edges to be exposed
will also cause the vehicle to fail.
Petrol models
MHave the engine at normal operating
temperature, and make sure that it is in good
tune (ignition system in good order, air filter
element clean, etc).
MBefore any measurements are carried out,
raise the engine speed to around 2500 rpm,
and hold it at this speed for 20 seconds. Allowthe engine speed to return to idle, and watch
for smoke emissions from the exhaust
tailpipe. If the idle speed is obviously much
too high, or if dense blue or clearly-visible
black smoke comes from the tailpipe for more
than 5 seconds, the vehicle will fail. As a rule
of thumb, blue smoke signifies oil being burnt
(engine wear) while black smoke signifies
unburnt fuel (dirty air cleaner element, or other
carburettor or fuel system fault).
MAn exhaust gas analyser capable of
measuring carbon monoxide (CO) and
hydrocarbons (HC) is now needed. If such an
instrument cannot be hired or borrowed, a
local garage may agree to perform the check
for a small fee.
CO emissions (mixture)
MAt the time of writing, the maximum CO
level at idle is 3.5% for vehicles first used after
August 1986 and 4.5% for older vehicles.
From January 1996 a much tighter limit
(around 0.5%) applies to catalyst-equipped
vehicles first used from August 1992. If the
CO level cannot be reduced far enough to
pass the test (and the fuel and ignition
systems are otherwise in good condition) then
the carburettor is badly worn, or there is some
problem in the fuel injection system or
catalytic converter (as applicable).
HC emissionsMWith the CO emissions within limits, HC
emissions must be no more than 1200 ppm
(parts per million). If the vehicle fails this test
at idle, it can be re-tested at around 2000 rpm;
if the HC level is then 1200 ppm or less, this
counts as a pass.
MExcessive HC emissions can be caused by
oil being burnt, but they are more likely to be
due to unburnt fuel.
Diesel models
MThe only emission test applicable to Diesel
engines is the measuring of exhaust smoke
density. The test involves accelerating the
engine several times to its maximum
unloaded speed.
Note: It is of the utmost importance that the
engine timing belt is in good condition before
the test is carried out.
M
Excessive smoke can be caused by a dirty
air cleaner element. Otherwise, professional
advice may be needed to find the cause.
4Checks carried out on
YOUR VEHICLE’S EXHAUST
EMISSION SYSTEM

Introduction
A selection of good tools is a fundamental
requirement for anyone contemplating the
maintenance and repair of a motor vehicle.
For the owner who does not possess any,
their purchase will prove a considerable
expense, offsetting some of the savings made
by doing-it-yourself. However, provided that
the tools purchased meet the relevant national
safety standards and are of good quality, they
will last for many years and prove an
extremely worthwhile investment.
To help the average owner to decide which
tools are needed to carry out the various tasks
detailed in this manual, we have compiled
three lists of tools under the following
headings: Maintenance and minor repair,
Repair and overhaul, and Special. Newcomers
to practical mechanics should start off with
the Maintenance and minor repairtool kit, and
confine themselves to the simpler jobs around
the vehicle. Then, as confidence and
experience grow, more difficult tasks can be
undertaken, with extra tools being purchased
as, and when, they are needed. In this way, a
Maintenance and minor repairtool kit can be
built up into a Repair and overhaultool kit over
a considerable period of time, without any
major cash outlays. The experienced do-it-
yourselfer will have a tool kit good enough for
most repair and overhaul procedures, and will
add tools from the Specialcategory when it is
felt that the expense is justified by the amount
of use to which these tools will be put.
Maintenance and minor repair
tool kit
The tools given in this list should be
considered as a minimum requirement if
routine maintenance, servicing and minor
repair operations are to be undertaken. We
recommend the purchase of combination
spanners (ring one end, open-ended the
other); although more expensive than open-
ended ones, they do give the advantages of
both types of spanner.
MCombination spanners:
Metric - 8, 9, 10, 11, 12, 13, 14, 15, 16, 17,
19, 21, 22, 24 & 26 mm
MAdjustable spanner - 35 mm jaw (approx)
MTransmission drain plug key (Allen type)
MSet of feeler gauges
MSpark plug spanner (with rubber insert)
MSpark plug gap adjustment tool
MBrake bleed nipple spanner
MScrewdrivers:
Flat blade - approx 100 mm long x 6 mm dia
Cross blade - approx 100 mm long x
6 mm dia
MCombination pliers
MHacksaw (junior)
MTyre pump
MTyre pressure gauge
MOil can
MOil filter removal tool
MFine emery cloth
MWire brush (small)
MFunnel (medium size)
Repair and overhaul tool kit
These tools are virtually essential for
anyone undertaking any major repairs to a
motor vehicle, and are additional to those
given in the Maintenance and minor repairlist.
Included in this list is a comprehensive set of
sockets. Although these are expensive, they
will be found invaluable as they are so
versatile - particularly if various drives are
included in the set. We recommend the half-
inch square-drive type, as this can be used
with most proprietary torque wrenches. If you
cannot afford a socket set, even bought
piecemeal, then inexpensive tubular box
spanners are a useful alternative.
The tools in this list will occasionally need
to be supplemented by tools from the Special
list:
MSockets (or box spanners) to cover range in
previous list
MReversible ratchet drive (for use with
sockets) (see illustration)
MExtension piece, 250 mm (for use with
sockets)
MUniversal joint (for use with sockets)
MTorque wrench (for use with sockets)
MSelf-locking grips
MBall pein hammer
MSoft-faced mallet (plastic/aluminium or
rubber)
MScrewdrivers:
Flat blade - long & sturdy, short (chubby),
and narrow (electrician’s) types
Cross blade - Long & sturdy, and short
(chubby) types
MPliers:
Long-nosed
Side cutters (electrician’s)
Circlip (internal and external)
MCold chisel - 25 mm
MScriber
MScraper
MCentre-punch
MPin punch
MHacksaw
MBrake hose clamp
MBrake/clutch bleeding kit
MSelection of twist drillsMSteel rule/straight-edge
MAllen keys (inc. splined/Torx type) (see
illustrations)
MSelection of files
MWire brush
MAxle stands
MJack (strong trolley or hydraulic type)
MLight with extension lead
Special tools
The tools in this list are those which are not
used regularly, are expensive to buy, or which
need to be used in accordance with their
manufacturers’ instructions. Unless relatively
difficult mechanical jobs are undertaken
frequently, it will not be economic to buy
many of these tools. Where this is the case,
you could consider clubbing together with
friends (or joining a motorists’ club) to make a
joint purchase, or borrowing the tools against
a deposit from a local garage or tool hire
specialist. It is worth noting that many of the
larger DIY superstores now carry a large
range of special tools for hire at modest rates.
The following list contains only those tools
and instruments freely available to the public,
and not those special tools produced by the
vehicle manufacturer specifically for its dealer
network. You will find occasional references
to these manufacturers’ special tools in the
text of this manual. Generally, an alternative
method of doing the job without the vehicle
manufacturers’ special tool is given. However,
sometimes there is no alternative to using
them. Where this is the case and the relevant
tool cannot be bought or borrowed, you will
have to entrust the work to a franchised
garage.
MValve spring compressor (see illustration)
MValve grinding tool
MPiston ring compressor (see illustration)
MPiston ring removal/installation tool (see
illustration)
MCylinder bore hone (see illustration)
MBalljoint separator
MCoil spring compressors (where applicable)
MTwo/three-legged hub and bearing puller
(see illustration)
REF•5
REF
Tools and Working Facilities
Sockets and reversible ratchet driveSpline bit set

REF•9
REF
Fault Finding
Engine
m mEngine will not rotate when attempting to start
m mEngine rotates, but will not start
m mEngine hard to start when cold
m mEngine hard to start when hot
m mStarter motor noisy or excessively-rough in engagement
m mEngine starts, but stops immediately
m mOil puddle under engine
m mEngine idles erratically
m mEngine misses at idle speed
m mEngine misses throughout driving speed range
m mEngine misfires on acceleration
m mEngine surges while holding accelerator steady
m mEngine stalls
m mEngine lacks power
m mEngine backfires
m mPinking or knocking engine sounds when accelerating
or driving uphill
m mEngine runs with oil pressure light on
m mEngine runs-on after switching off
Engine electrical system
m
mBattery will not hold charge
m mIgnition (no-charge) warning light fails to go out
m mIgnition (no-charge) warning light fails to come on
when key is turned
Fuel system
m mExcessive fuel consumption
m mFuel leakage and/or fuel odour
Cooling system
m
mOverheating
m mOvercooling
m mExternal coolant leakage
m mInternal coolant leakage
m mCoolant loss
m mPoor coolant circulation
Clutch
m
mPedal travels to floor - no pressure or very little resistance
m mFluid in area of master cylinder dust cover and on pedal
m mFluid on slave cylinder
m mPedal feels “spongy” when depressed
m mUnable to select gears
m mClutch slips (engine speed increases with no increase in
vehicle speed)
m mGrabbing (chattering) as clutch is engaged
m mNoise in clutch area
m mClutch pedal stays on floor
m mHigh pedal effort
Manual transmission
m
mVibration
m mNoisy in neutral with engine running
m mNoisy in one particular gear
m mNoisy in all gears
m mSlips out of gear
m mLeaks lubricant
Automatic transmission
m
mFluid leakage
m mTransmission fluid brown, or has a burned smell
m mGeneral shift mechanism problems
m mTransmission will not kickdown with accelerator pedal
pressed to the floor
m mEngine will start in gears other than Park or Neutral
m mTransmission slips, shifts roughly, is noisy, or has no drive
in forward or reverse gears
Brakes
m mVehicle pulls to one side during braking
m mNoise (high-pitched squeal) when the brakes are applied
m mBrake vibration (pedal pulsates)
m mExcessive pedal effort required to stop vehicle
m mExcessive brake pedal travel
m mDragging brakes
m mGrabbing or uneven braking action
m mBrake pedal feels “spongy” when depressed
m mBrake pedal travels to the floor with little resistance
m mHandbrake does not hold
Suspension and steering
m
mVehicle pulls to one side
m mAbnormal or excessive tyre wear
m mWheel makes a “thumping” noise
m mShimmy, shake or vibration
m mHigh steering effort
m mPoor steering self-centring
m mAbnormal noise at the front end
m mWandering or poor steering stability
m mErratic steering when braking
m mExcessive pitching and/or rolling around corners or
during braking
m mSuspension bottoms
m mUnevenly-worn tyres
m mExcessive tyre wear on outside edge
m mExcessive tyre wear on inside edge
m mTyre tread worn in one place
m mExcessive play or looseness in steering system
m mRattling or clicking noise in steering gear

REF•12Fault Finding
Fuel system
Excessive fuel consumption
m mDirty or clogged air filter element (Chapter 1).
m mIgnition timing incorrect (Chapter 5).
m mEmissions system not functioning properly (Chapter 6).
m mFuel injection internal parts or carburettor jets excessively worn or
damaged (Chapter 4).
m mLow tyre pressure or incorrect tyre size (Chapter 1).
m mUnsympathetic driving style, or unfavourable conditions.
Fuel leakage and/or fuel odour
Warning: Don’t drive the vehicle if a fuel leak is
suspected. Leaking fuel in the engine compartment
could catch fire.
m mLeak in a fuel feed or vent line (Chapter 4).
m mTank overfilled.
m mFuel injector or carburettor parts excessively worn, or fuel system
gaskets leaking (Chapter 4).
Cooling system
Overheating
m mInsufficient coolant in system (Chapter 1).
m mWater pump drivebelt defective or out of adjustment (Chapter 1).
m mRadiator matrix blocked, or grille restricted (Chapter 3).
m mThermostat faulty (Chapter 3).
m mRadiator cap not maintaining proper pressure (Chapter 3).
m mIgnition timing incorrect (Chapter 5).
Overcooling
m
mFaulty thermostat (Chapter 3).
External coolant leakage
m
mDeteriorated/damaged hoses; loose clamps (Chapters 1 and 3).
m mWater pump seal defective (Chapters 1 and 3).
m mLeakage from radiator matrix, heater matrix or header tank
(Chapter 3).
m mRadiator/engine block drain plugs or water jacket core plugs
leaking (Chapters 2 and 3).
Internal coolant leakage
m mLeaking cylinder head gasket (Chapter 2).
m mCracked cylinder bore or cylinder head (Chapter 2).
Coolant loss
m
mToo much coolant in system (Chapter 1).
m mCoolant boiling away because of overheating (see above).
m mInternal or external leakage (see above).
m mFaulty radiator cap (Chapter 3).
Poor coolant circulation
m
mInoperative water pump (Chapter 3).
m mRestriction in cooling system (Chapters 1 and 3).
m mWater pump drivebelt defective/out of adjustment (Chapter 1).
m mThermostat sticking (Chapter 3).
Clutch
Pedal travels to floor - no pressure or very little
resistance
m mMaster or slave cylinder faulty (Chapter 8).
m mFluid line burst or leaking (Chapter 8).
m mConnections leaking (Chapter 8).
m mNo fluid in reservoir (Chapter 1).
m mIf fluid is present in master cylinder dust cover, master cylinder rear
seal has failed (Chapter 8).
m mBroken release bearing or fork (Chapter 8).
Fluid in area of master cylinder dust cover, and on
pedal
m mRear seal failure in master cylinder (Chapter 8).
Fluid on slave cylinder
m
mSlave cylinder plunger seal faulty (Chapter 8).
Pedal feels “spongy” when depressed
m
mAir in system (Chapter 8).
Unable to select gears
m
mFaulty transmission (Chapter 7).
m mFaulty clutch plate (Chapter 8).
m mFork and bearing not assembled properly (Chapter 8).
m mFaulty pressure plate (Chapter 8).
m mPressure plate-to-flywheel bolts loose (Chapter 8).
Clutch slips (engine speed increases with no
increase in vehicle speed)
m mClutch plate worn (Chapter 8).
m mClutch plate is oil-soaked by leaking rear main seal (Chapter 8).
m mWarped pressure plate or flywheel (Chapter 8).
m mWeak diaphragm spring (Chapter 8).
m mClutch plate overheated.
Grabbing (chattering) as clutch is engaged
m
mOil on clutch plate lining, burned or glazed facings (Chapter 8).
m mWorn or loose engine or transmission mountings (Chapters 2
and 7A).
m mWorn splines on clutch plate hub (Chapter 8).
m mWarped pressure plate or flywheel (Chapter 8).
Noise in clutch area
m
mFork improperly fitted (Chapter 8).
m mFaulty release bearing (Chapter 8).
Clutch pedal stays on floor
m
mFork binding in housing (Chapter 8).
m mBroken release bearing or fork (Chapter 8).
High pedal effort
m
mFork binding in housing (Chapter 8).
m mPressure plate faulty (Chapter 8).
m mIncorrect-size master or slave cylinder fitted (Chapter 8).

REF•13
REF
Fault Finding
Automatic transmission
Note:Due to the complexity of the automatic transmission, it is
difficult for the home mechanic to properly diagnose and service this
unit. For problems other than the following, the vehicle should be
taken to a dealer or transmission specialist.
Fluid leakage
m mAutomatic transmission fluid is a deep red colour. Fluid leaks
should not be confused with engine oil, which can easily be blown
by airflow onto the transmission.
m mTo pinpoint a leak, first remove all built-up dirt and grime from the
transmission housing with degreasing agents and/or by steam-
cleaning. Then drive the vehicle at low speed, so airflow will not
blow the leak far from its source. Raise the vehicle and determine
where the leak is coming from. Common areas of leakage are:
a) Transmission sump (Chapters 1 and 7B)
b) Filler pipe (Chapter 7B)
c) Transmission fluid cooler lines (Chapter 7B)
d) Speedometer sensor (Chapter 7B)
Transmission fluid brown, or has a burned smell
m mTransmission fluid burned; fluid should be changed. May indicate
transmission internal fault (Chapters 1 and 7B).
Transmission will not kickdown with accelerator
pedal pressed to the floor
m mKickdown cable out of adjustment (Chapter 7B).
General shift mechanism problems
m
mChapter 7B deals with checking and adjusting the shift linkage on
automatic transmissions. Common problems which may be
attributed to poorly-adjusted linkage are:
a) Engine starting in gears other than Park or Neutral.
b) Indicator on selector lever pointing to a gear other than the one
actually being used.
c) Vehicle moves when in Park.
m mRefer to Chapter 7B for the shift linkage adjustment procedure.
Engine will start in gears other than Park or Neutral
m
mInhibitor switch malfunctioning (Chapter 7B).
Transmission slips, shifts roughly, is noisy, or has
no drive in forward or reverse gears
m mThere are many probable causes for the above problems, but the
home mechanic should be concerned with only one possibility -
fluid level. Before taking the vehicle to an automatic transmission
specialist, check the level and condition of the fluid as described in
Chapter 1. Correct the fluid level as necessary, or change the fluid
if needed. If the problem persists, have a professional diagnose the
probable cause.
Manual transmission
Vibration
m mDamaged propeller shaft (Chapter 8).
m mOut-of-round tyres (Chapter 1).
m mTyre out-of-balance (Chapters 1 and 10).
m mWorn propeller shaft universal joint (Chapter 8).
Noisy in neutral with engine running
m
mWorn clutch release bearing (Chapter 8).
m mWorn transmission input shaft bearing (Chapter 7A).
Noisy in one particular gear
m
mDamaged or worn constant-mesh gears.
m mDamaged or worn synchronisers.
Noisy in all gears
m
mInsufficient lubricant (Chapter 1).
m mDamaged or worn bearings.
m mWorn or damaged input gear shaft and/or output gear shaft.
Slips out of gear
m
mWorn or incorrectly-adjusted linkage (Chapter 7A).
m mTransmission-to-engine mounting bolts loose (Chapter 7A).
m mShift linkage binding (Chapter 7A).
m mWorn shift fork (Chapter 7A).
Leaks lubricant
m
mExcessive amount of lubricant in transmission (Chapters 1 and 7A).
m mLoose or broken input shaft bearing retainer (Chapter 7A).
m mInput shaft bearing retainer O-ring and/or lip seal damaged
(Chapter 7A).

REF•14Fault Finding
Brakes
Note:Before assuming that a brake problem exists, make sure that:
a) The tyres are in good condition and properly inflated (Chapter 1).
b) The wheel alignment (tracking) is correct (Chapter 10).
c) The vehicle is not loaded with weight in an unequal manner.
Vehicle pulls to one side during braking
m mIncorrect tyre pressures (Chapter 1).
m mWheel alignment (tracking) incorrect (Chapter 10)
m mUnmatched tyres on same axle.
m mRestricted brake lines or hoses (Chapter 9).
m mMalfunctioning caliper assembly (Chapter 9).
m mLoose suspension parts (Chapter 10).
m mLoose calipers (Chapter 9).
Noise (high-pitched squeal) when the brakes are
applied
m mFront and/or rear disc brake pads worn out. The noise comes from
the wear sensor rubbing against the disc. Renew the pads
immediately (Chapter 9).
Brake vibration (pedal pulsates)
Note:If the vehicle has ABS, it is normal for the brake pedal to pulsate
when the system is working.
m mExcessive lateral disc run-out (Chapter 9).
m mParallelism not within specifications (Chapter 9).
m mUneven pad wear - caused by caliper not sliding, due to improper
clearance or dirt (Chapter 9).
m mDefective disc (Chapter 9).
Excessive brake pedal travel
m
mPartial brake system failure (Chapter 9).
m mInsufficient fluid in master cylinder (Chapters 1 and 9).
m mAir trapped in system (Chapters 1 and 9).
Excessive pedal effort required to stop vehicle
m
mMalfunctioning brake servo unit (Chapter 9).
m mPartial system failure (Chapter 9).
m mExcessively-worn pads or shoes (Chapter 9).
m mCaliper piston stuck or sluggish (Chapter 9).
m mBrake pads contaminated with oil or grease (Chapter 9).
m mNew pads fitted and not yet seated. It will take a while for the new
material to seat against the disc.
Dragging brakes
m mMaster cylinder pistons not returning correctly (Chapter 9).
m mRestricted brakes lines or hoses (Chapters 1 and 9).
m mIncorrect handbrake adjustment (Chapter 9).
m mRear drum brake self-adjuster mechanism faulty (when applicable)
(Chapter 9).
Grabbing or uneven braking action
m mMalfunction of brake servo unit (Chapter 9).
m mBinding brake pedal mechanism (Chapter 9).
Brake pedal feels “spongy” when depressed
m
mAir in hydraulic lines (Chapter 9).
m mMaster cylinder mounting bolts loose (Chapter 9).
m mMaster cylinder defective (Chapter 9).
Brake pedal travels to the floor with little resistance
m
mLittle or no fluid in the master cylinder reservoir, caused by leaking
caliper piston(s), loose, damaged or disconnected brake lines
(Chapter 9).
Handbrake does not hold
m mHandbrake linkage incorrectly adjusted (Chapter 9).
m mHandbrake shoe linings worn out or contaminated (Chapter 9).

REF•15
REF
Fault Finding
Suspension and steering
Note:Before assuming that a problem exists, check the following
items:
a) Tyre pressures and tyre condition (also check for out-of-round or
out-of-balance tyres, and bent wheel rims).
b) Steering universal joints from the column to the steering gear (for
play or wear).
c) Front and rear suspension, and the rack-and-pinion assembly (for
loose or damaged parts).
d) Wheel bearings (wheel wobble or roughness when spun).
Vehicle pulls to one side
m mMismatched or uneven tyres (Chapter 10).
m mBroken or sagging springs (Chapter 10).
m mFront wheel or rear wheel alignment incorrect (Chapter 10).
m mFront brake problem (Chapter 9).
Abnormal or excessive tyre wear
m
mFront wheel or rear wheel alignment incorrect (Chapter 10).
m mSagging or broken springs (Chapter 10).
m mTyre out of balance (Chapter 10).
m mWorn shock absorber (Chapter 10).
m mOverloaded vehicle or unsympathetic driving style.
m mTyres not rotated regularly.
Wheel makes a “thumping” noise
m
mBlister or bump on tyre (Chapter 10).
m mFaulty shock absorber action (Chapter 10).
m mWheel bolts loose.
Shimmy, shake or vibration
m
mTyre or wheel out of balance or out of round (Chapter 10).
m mLoose, worn or incorrectly-adjusted wheel bearings (Chapter 1).
m mWorn tie-rod ends (Chapter 10).
m mWorn balljoints (Chapter 10).
m mExcessive wheel run-out (Chapter 10).
m mBlister or bump on tyre (Chapter 10).
m mWheel bolts loose.
High steering effort
m
mLack of lubrication at balljoints, tie-rod ends and steering gear
(Chapter 1).
m mIncorrect front wheel alignment (Chapter 10).
m mLow tyre pressure(s) (Chapter 1).
m mPower steering fluid low, or steering pump drivebelt slipping,
where applicable (Chapter 10)
Poor steering self-centring
m mLack of lubrication at balljoints and tie-rod ends (Chapter 1).
m mBinding in balljoints (Chapter 10).
m mBinding in steering column (Chapter 10).
m mLack of lubricant in steering gear (Chapter 10).
m mInaccurate front wheel alignment (Chapter 10).
Abnormal noise at the front end
m
mLack of lubrication at balljoints and tie-rod ends (Chapter 1).
m mDamaged shock absorber mounting (Chapter 10).
m mWorn control arm bushings or tie-rod ends (Chapter 10).
m mLoose anti-roll bar (Chapter 10).
m mLoose wheel bolts.
m mLoose suspension mounting bolts (Chapter 10).
Wandering or poor steering stability
m
mMismatched or uneven tyres (Chapter 10).
m mLack of lubrication at balljoints and tie-rod ends (Chapter 1).
m mWorn shock absorbers (Chapter 10).
m mLoose anti-roll bar (Chapter 10).
m mBroken or sagging springs (Chapter 10).
m mFront or rear wheel alignment incorrect (Chapter 10).
Erratic steering when braking
m
mWheel bearings worn (Chapter 1).
m mBroken or sagging springs (Chapter 10).
m mLeaking wheel cylinder (rear drum brake models) or caliper
(Chapter 9).
m mWarped discs (Chapter 9).
Excessive pitching and/or rolling around corners or
during braking
m mLoose anti-roll bar (Chapter 10).
m mWorn shock absorbers or mountings (Chapter 10).
m mBroken or sagging springs (Chapter 10).
m mOverloaded vehicle.
Suspension bottoms
m
mOverloaded vehicle.
m mWorn shock absorbers (Chapter 10).
m mBroken or sagging springs, or incorrect springs fitted (Chapter 10).
Unevenly-worn tyres
m
mFront wheel or rear wheel alignment incorrect (Chapter 10).
m mWorn shock absorbers (Chapter 10).
m mWheel bearings worn (Chapter 10).
m mExcessive tyre or wheel run-out (Chapter 10).
m mWorn balljoints (Chapter 10).
Excessive tyre wear on outside edge
m
mTyre pressures incorrect (Chapter 1).
m mExcessive cornering speed.
m mWheel alignment incorrect (excessive toe-in) (Chapter 10).
m mSuspension components damaged (Chapter 10).
Excessive tyre wear on inside edge
m
mTyre pressures incorrect (Chapter 1).
m mWheel alignment incorrect (excessive toe-out) (Chapter 10).
m mLoose or damaged steering components (Chapter 10).
Tyre tread worn in one place
m
mTyres out of balance.
m mDamaged or buckled wheel. Inspect and renew if necessary.
m mDefective tyre (Chapter 1).
Excessive play or looseness in steering system
m
mWheel bearing(s) worn (Chapter 10.
m mTie-rod end loose or worn (Chapter 10).
m mSteering gear mountings loose (Chapter 10).
Rattling or clicking noise in steering gear
m
mInsufficient or incorrect lubricant in rack-and-pinion assembly
(Chapter 10).
m mSteering gear mountings loose (Chapter 10).

REF•27
REF
Index
R
Radiator - 3•3, 11•4
Radio - 12•4
Receiver-drier - 3•9
Regulator (voltage) - 5•10
Regulator (window) - 11•8
Relays - 12•2
Repair procedures - REF•8
Respraying - 11•3
Reversing light switch - 7B•4
Rocker arms - 2B•11
Rotor - 1•18
Routine maintenance and servicing- 1•1
et seq
Routine maintenance - air conditioning
system - 3•8
Routine maintenance - bodywork and
underframe - 11•1
Routine maintenance - hinges and locks -
11•4
Routine maintenance - interior trim - 11•2
Routine maintenance - upholstery and
carpets - 11•2
Rust holes in bodywork - 11•2
S
Safety first! - 0•5
Scalding - 0•5
Scratches in bodywork - 11•2
Screw threads and fastenings - REF•8
Seat belt - 11•9, REF•2
Seats - 11•9, REF•2
Selector lever - 7B•3, 7B•5
Selector shaft - 7A•2
Service Indicator (SI) board - 12•4
Service indicator light - 1•26
Servo - 9•2, 9•10, 9•11
Shock absorber - 1•21, 10•7, 10•8, 10•9,
REF•2, REF•3
Shoes - 9•7
Short-circuit - 12•2Silencer - 4•20
Slave cylinder - 8•3
Spares - REF•19
Spark plug - 1•17, 1•18
Speed sensors - 5•8
Springs - 10•7, 10•9, REF•3
Starter inhibitor - 7B•4
Starter motor - 5•12
Starter motor fault - REF•10
Starting system - 5•11
Steering box - 10•15
Steering column - 11•9, 12•3, REF•1
Steering gear - 10•12, 10•13, REF•3
Steering linkage - 10•14
Steering wheel - 10•16, REF•1
Stop-light switch - 9•13
Struts - 1•21, 10•6, 10•7
Sump - 2A•15
Supplemental Restraint System (SRS) -
12•8
Suspension and steering systems- 1•21,
1•22, 10•1et seq, REF•2, REF•3
Suspension and steering fault finding -
REF•15
Switches - 7B•4, 9•13, 12•3
T
Tailgate - 11•6
Tappets - 2B•11
Thermostat - 3•2
Thermotime switch - 4•17, 4•18
Throttle body - 4•16
Throttle linkage - 1•20
Throttle Position Sensor (TPS) - 6•3
Throttle positioner - 4•13, 4•14
Thrust arm - 10•5
Timing - 5•4
Timing belt - 1•26, 2A•8, 2A•9
Timing chain - 2A•6, 2A•8
Timing sensors - 6•4
Tools - REF•5, REF•7, REF•8
Top Dead Centre (TDC) for No 1 piston -
2A•3Torque converter - 7B•5
Towing - 0•8
Track rod ends - 10•13
Trailing arms - 10•10
Transmission - SeeManual transmission or
Automatic transmission
Trim - 11•2, 11•6
Tyres - 1•9, 1•14, 10•16, REF•4, REF•15
U
Underframe - 11•1
Universal joints - 8•8
Upholstery - 11•2
V
Vacuum hoses - 1•14
Vacuum servo - 9•10
Valve clearances - 1•19
Valve cover - 2A•4
Valves - 2B•10, 2B•11
Vehicle identification - REF•2, REF•19
Voltage checks - 12•1
Voltage regulator - 5•10
W
Washer fluid - 1•9
Water pump - 3•5
Weekly checks- 1•7et seq
Wheel alignment - 10•17
Wheel bearings - 10•8, 10•11, REF•3
Wheel changing - 0•8
Wheels - 10•16, REF•4
Windows - 11•8, 12•9
Windscreen - REF•1
Wiper blades - 1•23
Wiper motor - 12•7
Wiring diagrams- 12•9et seq
Working faclities - REF•7