Bricklin SV-1 1975 - User Manual

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Index3
Engine Index4
General Information4
Compression Test4
Description4
Engine5
Test Conclusion5
Engine Assembly5
Engine Removal6
Engine Installation6
Engine Front Supports7
Engine Rear Support8
Crankcase Ventilation System8
Valve Rocker Arm Cover and Rocker Arm9
Rocker Arm Stud Replacement9
Valve Rocker Arm Assembly10
Valve Spring, Retainer and Stem Seal10
Cleaning and Inspection12
Intake Manifold12
Hydraulic Valve Lifter Testing13
Placing Steel Ball in Valve Lifter Plunger13
Valve Lifter14
Removing Valve Lifter14
Hydraulic Valve Clearance15
Push Rods Cleaning15
Checking Valve Clearance15
Hydraulic Valve Lifters15
Inspection of Rocker Arm Stud Nut16
Cylinder Heads17
Cylinder Head Holding Fixture17
Removing Valve Push Rod17
Cylinder Head18
Hydraulic Valve Lifter Assembly18
Compressing Valve Spring18
Cylinder Heads Cleaning19
Valve Spring Assembled Height19
Valve Assembly19
Checking Push Rod Runout19
Checking Valve Seat Runout20
Checking Valve Stem Clearance20
Checking Valve Spring Pressure20
Overhaul Cylinder Head21
Reaming Valve Guides21
Refacing Valve Seats21
Checking Valve Seat Width21
Valves22
Exhaust Manifolds22
Select Fitting Valves22
Exhaust Manifolds Cleaning22
Water Pump23
Cylinder Front Cover and Timing Chain23
Removing Crankshaft Vibration Damper23
Aligning Timing Marks24
Removing or Installing Timing Chain24
Fuel Pump Eccentric and Front Oil Slinger Installed24
Timing Chain Deflection25
Timing Gear Runout25
Checking Timing Gear Runout25
Camshaft Lobe Lift26
Timing Chain and Sprockets26
Front Oil Seal26
Camshaft Repair27
Camshaft Bearings27
Camshaft End Play27
Camshaft Rear Bearing Bore Plug28
Fuel Pump Eccentric Cleaning29
Camshaft Removal29
Flywheel30
Oil Pan30
Automatic Transmission30
Oil Pump31
Oil Pan Gaskets and Seals Installed31
Oil Pump Assembly32
Oil Filter33
Main Bearing33
Installing Crankshaft Rear Oil Seal34
Fitting Main or Connecting Rod Bearings with Plastigage35
Main and Connecting Rod Bearings35
Installing and Measuring Plastigage35
Connecting Rod Bearings36
Pistons and Connecting Rods36
Piston Ring Spacing37
Checking Connecting Rod Side Clearance37
Pistons, Pins and Rings39
Connecting Rods39
Fitting Piston Rings40
Fitting Piston Pins40
Crankshaft Rear Oil Seal41
Crankshaft End Play42
General Specifications49
Cooling System54
Cleaning Cooling System54
Cooling System Pressure Test54
Thermostat55
Fan Drive Clutch55
Installing Thermostat55
Typical Fan Drive Clutch Installation55
Fan Drive Clutch Test56
Drive Belts57
Belt Tension57
Radiator57
Down Flow Radiators57
Constant Full Cooling System58
Diagnosis58
Automatic Transmission Oil Cooler59
Fuel60
Typical Carburetor Identification Tag60
Carburetor Identification60
Air Horn to Main Body63
Accelerator Pump Diaphragm And/Or Elastomer Valve64
Choke Pulldown Diaphragm Assembly64
Main Body66
Float Assembly66
Accelerating Pump Assembly66
Removing or Installing Float Shaft Retainer66
Carburetor Assembly67
Scribing Throttle Plates68
Automatic Choke68
Air Horn69
Accelerating Pump Stroke Adjustment69
Choke Plate Pulldown70
Fuel Level Adjustment70
Typical Air Cleaner75
Replacing Crankcase Ventilation Filter in Air Cleaner75
Fuel Tank Filler Neck Cap76
Fuel Tank and Filler Neck76
Fuel Tank Venting76
Repair Operations76
Fuel Lines77
Throttle Linkage Adjustments77
Fuel Filter77
Adjustment of the Trans. K.D. Control77
Throttle and Downshift Linkage78
Emission Systems79
Vehicle Emission Control Information79
Electric Assisted Choke79
Ported Vacuum Switches80
Electric Ported Vacuum Switch80
PCV Valve and Crankcase Vent Cap81
Exhaust Heat Control Valve81
Typical PCV System81
HCV System Schematic81
Cold Weather Modulator82
Thermactor System83
Air Supply Pump83
Thermactor Air Supply Pump83
Air Bypass Valve84
Exhaust Check Valve84
Exhaust Gas Recirculation System84
Typical EGR System84
Spacer Entry EGR System85
Fuel Vapor Storage Canister85
FMX Automatic Transmission87
Transmission Fluid Level Check88
Testing88
Manual Linkage Checks88
High or Low Fluid Level90
Transmission Fluid Leakage Checks90
Converter Leakage Check90
Engine Idle Speed Check90
Anti-Stall Dashpot Clearance Check91
Control Pressure Check91
Automatic Transmission Tester91
Converter Leak Checking Tool91
Vacuum Diaphragm Check92
Shift Point Checks92
Stall Test92
Air Pressure Checks92
Band Adjustments93
Front Band93
Alternate Front Band Adjustment93
Rear Band94
Transmission Removal94
Front Band Adjusting Tools94
Adjusting Rear Band94
Disassembly and Assembly Transmission96
Transmission End Play Check96
Transmission Mounted in Holding Fixture96
Removal of Case and Extension Housing Parts97
Output Shaft Disassembled97
Rear Support and Output Shaft Installed97
Center Support98
Replacing Rear Brake Drum Support Bushing98
Installing Output Shaft Bushing98
Cleaning and Inspection Transmission100
Control Valve Body101
Check Valve Locations102
Front Servo103
Typical Hydraulic Control System103
Control Valve Body Disassembled104
Front Servo Disassembly105
Front Servo Disassembled105
Rear Servo106
Governor Disassembled106
Extension Housing Bushing and Rear Seal107
Extension Housing107
Installing Extension Housing Seal107
Governor108
Pressure Regulator109
Parking Pawl110
Front Pump111
Front Pump Disassembled111
Removing Front Pump Seal111
Installing Front Pump Seal111
Front Pump Cleaning and Inspection112
Rear Support Bushing Removal and Installation112
Removing Rear Clutch Spring Snap Ring112
Installing Input Shaft Bushing115
Installing Clutch Hub115
Installing Pressure Plate115
Front Clutch116
Primary Sun Gear Shaft116
Proper Vacuum Line Routing116
Vacuum Diaphram Removal and Installation116
Transmission Fluid Drain and Refill117
Oil Cooler Tube Removal and Installation117
FMX Transmission117
Turbine and Stator End Play Check118
One-Way Clutch Cleaning and Inspection118
Converter Checking Tool118
Stator to Impeller Interference Check119
Stator to Turbine Interference Check119
Output Shaft120
Planet Carrier and Center Support120
Stator Support120
Case121
Console or Floor Shift121
Throttle and Downshift Linkage Adjustments121
Shift Control Linkage Adjustments121
Pressure Regulator Disassembled122
Transmission Case Control Linkage122
Selector Lever Removal122
Neutral Start Switch Adjustment123
Neutral Start Switch Removal123
Clutch Plates124
Approximate Refill Capacities124
Selective Thrust Washers124
Shift Speed125
Standard Torque Specifications and Capscrew Markings126
Electrical127
Distributor Identification127
Cleaning and Inspection of Distributor128
Rotor128
Centrifugal Advance128
Vacuum Advance128
Centrifugal Advance Mechanism129
Fixed Base Plate130
Circuit Operation130
Magnetic Pickup Assembly130
Distributor Advance Check130
Typical Solid State Distributor131
Ignition Timing132
Typical Ignition System Circuit132
Diaphragm Vacuum Advance Mechanism132
Total Advance133
Basic Timing133
Typical Timing Pointer and Probe Receptacle133
Spark Plug Wires134
Secondary Wires134
Secondary Wiring134
Coil134
Spark Plugs135
Spark Plug Boot Replacement135
Filling Spark Plug Electrode135
Typical V-8 Engine Secondary Ignition Wiring135
Gap Bridged136
Oil Fouled136
Carbon Fouled136
Worn136
Charging System137
Connecting to Coil Connector for Tachometer Test137
Charging System Fuse Link137
Ignition Resistor Wire137
Ammeter138
Wire Color Code139
Visual Inspection140
Ammeter-Alternator Charging System140
Test Results140
Tests Using a Voltmeter140
Field Circuit and Alternator Tests141
Regulator Plug Voltage Tests141
Field Circuit Test141
Regulator I and S Circuit Tests142
Regulator Burned-Open Connector Wire Test142
Regulator Plug Jumper Wire Connections142
Jumper Wire Connections142
Diode Test143
Alternator143
Belt Adjustment144
Bench Tests144
Field Open or Short Circuit Test144
Stator Coil Open or Grounded Test145
Rotor Open or Short Circuit Test145
Rectifier Assembly146
Disassembled Rear Terminal Alternator146
Stator Terminal Screw Removal147
Brush Holder Assembly148
Pulley Removal148
Brush Lead Positions148
Stator and Rectifier Assembly149
Stator Terminal Screw Installation149
Terminal Insulators150
Voltage Limiter150
Electro-Mechanical Regulator150
Voltage Regulator Calibration Test150
Adjustments151
Unlocking Wiring Harness Connector151
Air Conditioning153
Latent Heat of Vaporization153
Heat Transfer153
Effect of Pressure on Boiling or Condensation154
Compressor154
Condenser155
Receiver155
Expansion Valve155
Evaporator155
Air Conditioning Airflow156
Control Panel156
Service Valves156
Low Side Gauge157
High Side Gauge157
Manifold157
Pressure Gauge and Manifold Set157
Sight Glass158
Connecting the Pressure Gauge and Manifold Set158
Checking System Pressures158
Discharging the System158
Evacuating the System159
Checking for Leaks160
Evacuating System with Vacuum Pump160
Flame Type Leak Detector160
Electronic Leak Detector161
Leak Test Procedure Using Halide Torch161
Portable Air Conditioning Service Station161
Charging the System162
Charge Capacity162
Charging Procedure with Multi-Opener Refrigerator Dispenser162
Compressor Valve Leak Diagnosis164
Compressor Belt Tension164
Compressor Removal164
Isolating the Compressor164
Compressor Installation165
Compressor Front Seal Replacement165
Back Plate O-Ring Seal Replacement165
Compressor Seal Components and Gaskets165
Head, Valve Plate and Gasket Replacement166
Head and Valve Plate Assembly Sequence166
Compressor Head Capscrew Tightening Sequence166
Bottom Plate Gasket Replacement167
Checking Compressor Oil Level167
York Compressor Oil Level Dipstick167
Purging Compressor of Air167
Magnetic Clutch168
Clutch Removal168
Clutch Bearing168
Diagnosis for Noisy Clutch168
Drive Belt169
Condenser Charged Unit Removal L169
Evaporator Housing and Core Assembly170
Receiver Replacement170
Mounting Plate Clearance170
Normal Operating Temperatures and Pressures172
Noisy Engine Operations173
Engine Overheats176
Loss of Coolant177
Engine Fails to Reach Normal Operating Temperature177
Emission Control System178
Thermactor Emission System Check178
Thermactor Pump Test178
EGR Valve178
EGR Valve Removal179
Preferred Cleaning Method179
Alternate Cleaning Method179
EGR Supply Tube and Spacers180
PVS with Three Connectors180
EGR PVS Functional Check180
PVS with Two Connectors180
Check Valve Test181
Check PCV System Function181
With the Engine Idling181
Vacuum Operated Exhaust Heat Control Valve182
Heat Valve Chart182
Clean PCV System182
General Diagnosis183
Automatic Transmission Tests183
Linkage Check183
Engine Check183
Vacuum Pump Procedure184
Governor Check184
Fmx184
Vacuum Diaphragm Test184
Control Pressure Test185
Slow Initial Engagement186
Rough Initial Engagement in Either Forward or Reverse187
No Drive in any Gear188
No Drive Forward - Reverse Ok189
No Drive, Slips or Chatters in Reverse190
Shift Points Incorrect194
No Upshift at any Speed195
Shifts 1-3 in D196
Engine Overspeeds on 2-3 Shift197
Mushy 1-2 Shift198
Rough 1-2 Shift199
Rough 2-3 Shift199
No Forced Downshifts200
No 1-3 Shift in D200
Runaway Engine on 3-2 Downshift201
No Engine Braking in Manual First Gear202
No Engine Braking in Manual Second Gear203
Transmission Noisy - Valve Resonance204
Transmission Overheats206
Transmission Fluid Leak207
Electrical Diagnosis208
Preliminary Information208
Charging System Tests208
Starting System Tests208
Battery Does Not Stay Charged209
Alternator Noisy210
Engine will Not Crank212
Module Bias Test214
Battery Source Test214
Electronic Module Schematic214
Cranking Test215
Starting Circuit Test215
Magnetic Pick up Test215
Distributor Hardware Test215
Ignition Coil Test216
Short Test216
Resistance Wire Test216
Air Conditioning System217
System Troubleshooting218
Preliminary Diagnosis218
Magnetic Clutch Inoperative or Is Erratic219
Improper Blower Operation220

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Bricklin SV-1 1975 Specifications

General

Brand	Bricklin
Model	SV-1 1975
Category	Automobile
Language	English

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