Fiat X 1/9 1978 - STEERING SYSTEM

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PARTS

CATALOG

COD

02.01

D232

02.10

STEERING

SYSTEM

—

SERVICE

MANUAL

SERVICE

TIME

SCHEDULE

CODE

412.01

412.02

412.10

41A

Page

Specifications-Tightening

Reference

........................................................

12'?

Gr.

412—STEERING

SYSTEM

Steering

Gear

..........................................................................................

129

Steering

Box

............................................................................................

131

Steering

Linkage

......................................................................................

13B

Tool

Equipment

........................................................................................

138

Main Page

Introduction3
How to Use the Manual3
General Information - Maintenance Contents4
Product View5
General Information5
Engine Specifications6
Fuel System6
Lubrication System6
Cooling System6
Chassis Specifications7
Weights - Performances8
Dimensions8
Capacities9
Identification Data10
Spare Parts11
Car Keys11
Maintenance12
Tune-Up13
Spark Plugs13
Valve Clearance13
Ignition Distributor14
Fuel Filter15
Air Cleaner15
Engine Oil15
Air Pump Filter16
Ignition Timing16
Fiat Lubricant Specifications18
Engine Contents19
Cylinder Block-Con-Rods20
Pistons - Pins - Rings21
Cylinder Head22
Valve Springs22
Valve Mechanism - Camshaft23
Auxiliary Shaft23
Crankshaft - Main Bearings24
Fuel System25
Lubrication26
Tightening Reference27
Longitudinal Section of Engine Cylinders28
Engine Specifications28
Cross Section of Engine through Cylinder29
Power Plant Mounts30
Power Plant Removal30
Crankcase and Cylinder Head34
Removing Cylinder Head34
Checking Cylinder Head Gasket Surface36
Checking Depth of Combstion Chambers36
Inspecting and Refacing Valve Seats and Valves37
Cylinder Head Torqueing Sequence39
Crankcase40
Checking Cylinder Bores40
Oil Sump and Crankcase Covers42
Crankshaft and Flywheel44
Connecting Rods and Pistons47
Pistons-Connecting Rods47
Checks47
Connecting Rods and Pistons49
Camshaft Mechanism51
Replacing Timing Belt51
Valve Mechanism53
Camshaft53
Exploded View of Valve Mechanism Components53
Main Data on Camshaft and Bores in Housing53
Main Data of Auxiliary Shaft and Bushing54
Replacing Tappets and Valve Guides55
Model X 1/956
Fuel Tank and Lines59
Fuel Evaporative Emission Control System59
Fuel Pump and Lines61
Fuel Pump Removal61
Inspections61
Adjustment62
Carburetor and Air Cleaner63
Float Level Setting63
Idle Speed Adjustment63
Idle Co Adjustment63
Exploded View of Carburetor64
Choke65
Idle and Transfer65
Acceleratig Pump65
Recirculating Device of Blow-By Gases65
Cruise66
Air Cleaner Removal and Installation67
Carburetor Cooling Fan68
Cooling Fan Removal and Installation68
Thermostatic Switch Removal68
Exhaust Pipe69
Removal69
Exhaust Emission Control System71
Air Pump Removal and Installation72
Air Injection Manifold Removal and Installation72
Exploded View of Engine Lubrication System Components73
Engine Lubrication Diagram74
Oil Pump Removal75
Inspection75
Oil Filter Replacement76
Crankcase Emission Control System77
Radiator79
Inspecting Cooling System79
Water Pump and Ducts81
Water Pump Removal and Installation81
Longitudinal Section of Water Pump81
Thermostat Removal82
Electric Fan Operation83
Exploded View of Fan Removal83
Tool Equipment85
Clutch Contents86
Clutch Specifications87
Clutch Cover and Clutch Disc with Linings88
Clutch Release Hydraulic Control89
Section of Clutch Assembly and Thrust Pad89
Clutch Release Hydraulic Circuit89
Section Thru Forked Lever and Release Sleeve89
Fluid Check90
Bleeding Clutch Circuit90
Clutch Pedal Release Travel90
Operating Cylinder Adjustment91
Clutch Release Control Components91
Master Cylinder92
Removal and Installation92
Exploded View of Master Cylinder92
Operating Cylinder93
Exploded View of Operating Cylinder93
Removal and Installation93
Clutch94
18A Tool Equipment94
Transmission - Differential Contents95
Speedometer Sproket Support Section96
Longitudinal Section of Gearshift Rod96
Section through Reverse Idle Gear96
Longitudinal Section of Transmission96
Outer Gearshift Control97
Adjusting Gearshift Linkage98
Gearshift Control Assembly98
Axle Shaft99
Left Axle Shaft Assembly102
Differential Gear Train103
Disassembly and Assembly103
Differential Section104
Exploded View of Differential Assembly105
Differential Bearing Setting106
21A-27A Tool Equipment108
Brakes Contents109
Brakes Specifications110
Hydraulic Brakes and Hand Brake System111
Brake Master Cylinder112
Bleeding Hydraulic System113
Front and Rear Wheel Brakes114
Replacing Wheel Brake Calipers114
Brake Disc Inspection115
Refacing Brake Disc115
Front Brake Caliper and Bracket Components116
Overhaul Front Caliper116
Rear Brake Caliper and Bracket Components118
Overhaul Rear Caliper118
Adjusting Hand Brake120
Hand Brake Linkage120
33A Tool Equipment121
Steering System Contents122
Steering System Specifications123
Steering Column and Gear Disassembled124
Cross Section of Steering Column125
Steering Gear125
Steering Shaft126
Steering Box127
Unmodified Rack and Steering Gear Cross Section128
Modified Rack and Steering Gear Cross Section129
Disassembly130
Reassembly and Adjustment130
Steering Box - Model X 1/9132
Steering Box Section Across Drive Pinion132
Unmodified/Modified Steering Box133
Front Wheel Toe-In134
41A Tool Equipment134
Suspension and Wheels Contents135
Suspension and Wheels Specifications136
Front Suspension136
Front Suspension140
Front Wheel Alignment144
Coil Springs145
Front Shock Absorbers and Bars146
Control Arm146
Exploded View of Control Arm Componets146
Strut Bar Attachment Points148
Exploded View of Strut Bar Attachments to Body and Control Arm148
Rear Suspension150
Rear Wheel Alignment152
View of Control Arm Attachment Points154
Exploded View of Control Arm154
Coil Springs154
Shock Absorbers156
Removal and Installation Front and Rear156
Front Shock Absorbers Attachments157
Rear Shock Absorber Attachments157
Disassembly and Assembly158
Wheels160
Front Wheel Hub Removal and Installation160
Electrical Contents164
Electrical Specifications165
Electrical Specifications167
Electrical Wiring Diagram171
Ignition172
Exploded View of Ignition Distributor173
Ignition Coil174
Starting176
Starter Disassembly and Assembly176
Changing Brushes178
Replacing Field Coils178
Refacing Commutator178
Longitudinal Section of Starter Assembly179
Cross Section through Pinion Drive179
Section through Pole Shoes and Field Winding179
Section through Commutator End Frame and View of Brushes179
Alternator180
Exploded View of Alternator180
Lighting182
Headlight Adjustment182
Retractable Headlight Motor Replacement183
Fuses183
Instruments and Controls184
Seatbelt Interlock System185
Checkout185
Instruments and Controls185
Seatbelt Interlock Checkout (1974 Models)186
Body Contents188
General Information189
Body189
Instrument Panel191
View of Instrument Panel Components193
Body Shell-Sheet Metal195
Alignment195
Dust and Water Leaks195
Body Shell Inner Components198
Body Shell Outer Components199
Hard Top200
Exploded View of Hard Top Components200
Doors202
Removing Door Panel202
Window Adjustment202
Door Lock Adjustment203
Exploded View of Door204
Windshield206
Self-Adhesive Moltoprene on Glass206
Back Window208
Front Luggage Compartment Lid Replacement and Adjustment210
Lid Lock Replacement and Adjustment210
View of Front Luggage Compartment Lid Compartments211
Rear Luggage Compartment Lid Replacement and Adjustment212
Key Lock Replacement212
View of Rear Luggage Compartment Lid Components213
Air Intakes and Lids214
Engine Compartment Lid Replacement and Adjustment214
Exploded View of Lid Components and Air Inlets215
Front Seats216
Electrical System Troubleshooting Contents218
Battery and Charging System Contents219
Battery Charge Indicator Stays on after Engine Starts220
Indicator Stays off with Ignition Switch on and with Engine Running222
E Lectr Ical System Troubleshooting222
Battery Boils Over, Lights Burn out Frequently224
Battery Does Not Stay Charged224
Starting System Contents227
Starter will Not Start Car228
Starter will Not Crank Engine229
Starter Cranks Slowly233
Ignition System Contents237
Engine will Not Start238
Check Spark Plugs238
Engine Misses at Idle245
Engine Runs but Lacks Power or Misses at High Speed248
Timing Ignition with Timing Light249
Engine Stalls250
Ignition System250
Radiator and Carburetor Cooling Systems Contents255
Engine Overheats - Radiator Cooling Fan will Not Run257
Radiator Cooling Fan Runs All the Time258
Carburetor Cooling Fan will Not Run259
Carburetor Cooling Fan Runs All the Time260
Seat Belt Interlock and Remove Key Warning System Contents265
Seat Belt Interlock System266
Driver's Seat Circuit Faulty266
Driver's Seat Belt Circuit Faulty267
Passenger's Seat Circuit Faulty267
Passenger's Seat Bealt Circuit Faulty268
Transmission Switch Circuit Faulty268
Seat Belt Indicator and Buzzer Circuit Faulty270
Starter Relay Circuit Faulty271
By-Pass Switch Circuit Faulty272
Key Buzzer will Not Work273
Interior Light Contents277
Courtesy Light Not on with Door Open278
Brake Indicator Light will Not Work with Lever Pulled up280
Instruments Lights will Not Work281
Optical Fiber Illumination will Not Work282
Vehicle Warning Indicator Light will Not Work283
Electrical System Troubleshooting283
Interior Lights283
Directional Indicator Light will Not Work284
Exterior Lights Table of Contents286
Left or Right High Beam will Not Work287
Headlight Motors will Not Work290
Left or Right Low Beam will Not Work293
Exterior Lights296
Parking/Side Marker/License Plate Lights will Not Work297
Parking Light Indicator out297
Brake Lights Wil Not Work301
Electrical System Troubleshooting301
Back-Up Lights Do Not Work302
Vewhicle Warning Lights will Not Work303
Directional Lights will Not Work304
Instruments Contents309
Temperature Gage Inoperative311
Fuel Gage Inoperative312
Low Fuel Warning Inoperative313
Oil Pressure Gage Inoperative314
Low Oil Pressure Warning Inoperative316
Tachometer Inoperative317
Accessories Contents320
Horn will Not Stop Blowing322
Horns will Not Blow322
Electrical System Troubleshooting322
Windshield Washer Pump will Not Work324
Windshield Wipers will Not Work324
Heater Fan will Not Work326
Fuses Contents329
Fuse Location330
Protected Circuits330
Fuse a Blows Repeatedly331
Electrical System Troubleshooting337
Fuse B Blows Repeatedly338
Fuse C Blows When High Beams Are Turned on339
Fuse D/F Blows When High Beams Are Turned on340
Fuse G Blows Repeatedly341
Fuse H Blows Repeatedly343
Fuse I Blows Repeatedly344
Fuse L Blows Repeatedly345
Fuse M/N Blows Repeatedly346

Fiat X 1/9 1978 - STEERING SYSTEM - 41

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