Lancia Beta montecarlo Install guide

BETA MONTECARLO
SHOP MANUAL FOREWORD
HOW TO CONSULT THIS MANUAL
The manual is divided into 17 sections, each dealing with a separate assembly or group of opera-
tions (e.g. 01 Engine, 02 Clutch, 03 Gearbox, 09 Brakes etc.).
At the beginning of these sections, the list of contents may followed by a part listing the essential
features of the assembly.
This initial part of the section may also include descriptions of the workings of parts forming part
of the assembly.
Each section is generally subdivided into four chapters:
CHAPTER 1 -Troubleshooting
This looks at the faults that might crop up and their likely causes, and then shows how to rec-
tify them.
The faults indicated in this chapter are listed without numbering.
NB For the sake of cQmpletion, all faults are listed, even those which are highly unlikely to
occur .
CHAPTER 2 -Repairs
This chapter describes tuning operations and adjustments and those removal-refitting jobs which
can be done on the car in the workshop.
CHAPTER 3 -General overhaul of assembly
This deals with overhauls of complete assemblies which have to be done Ol:lthe bench (e.g. Engine,
gearbox, transmission etc. overhaul).
Of course, not all sections will have this Chapter; assembly 14, the electric system, for example
cannot be overhauled at the bench.
CHAPTER 4 -Bench overhaulsubassemblies
This chapter details the operations at the bench for overhauling subassemblies that may be remo-
ved directly from the car (Chapter 2) or from the full assembly, at the work bench, during general
overhaul operations (Chapter 3).
(E.g. Cylinder head, oil pump etc. forming part of assembly 01 Engine).
All the operations outlined up to now form that part of each assembly known as the "Basic
Model".
These operations apply to all models of the car unless specific exceptions are given in the contents
of each section. In cases where operations are so different that they require special attention, the
heading of the contents of each section, "BASIC MODEL II -"Operations relevant to all models" is
followed by the wording "Variants -Operations relevant only for mode1s " followed by the variant
number.
The pages in each chapter are numbered progressively and assembly section and chapter are also
indicated (e.g. page 01 2/24 standsforthe 24th page of Chapter 2 of Section 01 Engine).
All operations contained in Chapters 2, 3 and 4 of each section are identified by numbers of
seven digits arranged in ascending order, from the first operation described in Section 01 Engine, to the
last operation of Section 17 Maintenance.
The number that identifies each operation (preceded by paragraph symbol..) consists, as we have
said, of seven digits:
The first two digits (011 02, 03, 16,17) indicate the assembly section to which the operation
belongs.
The third digit (2, 3, 4) identifies the chapter, namely that part of the workshop in which the
operation is carried out.

II
BETA MONTECARLO
SHOP MANUAL
FOREWORD
The last four digits apply to the operation proper. For example, 01 2 2800 means operation
2800 of chapter 2 {third digit) of assembly section 01 {first two digits).
Use the index at the beginning of each section when looking for any operation in particular .
This lists the numbers of operations with their corresponding titles, and gives the number of the page
where the description can be found.,
All operations described in this manual {with the same serial number) are listed in the Hand-
book of times which gives the standard time for performing the operation on the various models of
the car .
LOOKING UP OPERATIONS
1st eventuality
You know the number of the operation (e.g. § 01 24800) and you wish to find the page where
it is described.
Number 01 2 4800 tells us that the operation should be locked up in Section 01 {first two digits)
Engine in Chapter 2 {third digit).
§ 01 24800 R.R. coolant pump. pag.01 2!14
2nd eventuality
You know what the operation is about (e.g. R.R. front shock absorbers) and you want to find
the number of the operation and the page where it is described.
The operation will obviously be described in Section 07 Suspensions and will. be found in Chapter
2 because the operation can be carried out on the car .
Reading through Chapter 2 operations in the Section 07 index, we find:
§ 0720200 R.R.front suspension pageO72/1
GENERAL RECOMMENDATIONS
Before carrying out any operation:, make sure that all the equipment listed at the end of the
description as well as that listed at the end of any related operation is available.
Every time a repair is done, replace all those parts which become damaged as a result of it (e.g.
gaskets, oil seals, lock plates, washers, "0" rings, and so on).
References to the right or left hand sides, or the front or rear parts of the car, are with respect
to the forward direction of the vehicle.
During repairs always observe the most scrupulous cleanliness at the workbench and on the parts
in question. * * *
"Whqn new" figures shown on the technical data sheets at the end of this volume, refer to new
parts that!have not yet been used.
It gQes without saying that it only needs a little use for these values to undergo slight variations
if only a$ a result of running in, but such variations have nothing to do with wear proper and will in
no waydompromise the good performance of the parts.
* * *
During removal, repair or general overhaul operations, the fitter will have to decide for himself
whether to accept pieces whose specifications, owing to wear, differ from those given on the data
sheets. Of course, the general condition of the car, the assembly under repair and the type of repair
being carried out should all be allowed for.

III
BETA MONTECARLO
SHOP MANUAL FOREWORD
Checkingand fitting roller bearings
Checking
Checks should be carried out after careful cleaning; first wash with paraffin to remove the bulkier
foreign matter.
Then a more thorough wash-down should be done in tanks of clean petrol; finally the bearing is
dipped in rectified petrol containing 10% lubricating oil; allow the bearing to dry without using com-
pressed air.
Set the bearing spinning while keeping hold of the inner race; if it is not in good condition, vibra-
tions and undue noise will be noticed and, when the bearing is spun slowly by hand, minor seizures will
be felt.
The bearing should be rejected if any of the following faults are noticed:
a) marks on races or revolving parts; marks will be easily visible on bearings that can be disassembled;
on others, marks will be visible by examining races between balls, against the light;
b) scoring of balls caused by foreign matter abrasion; in the presence of scoring; balls or rollers are
greyish and lose their normal bright surface;
c) bright outer or inner race surface; this means the bearing is spinning in its housing or on the shaft;
both housing and shaft should be carefully examined because they are probably damaged;
d) signs of seizure on outer bearing surfaces; generally speaking, rust spots on outer race surfaces do
not impair the good operation of the bearing.
FittingHeat the bearing in an oil bath at a temperature of 800 -100° C to facilitate fitting on the shaft.
This procedure does not apply if the bearing has a plastic cage or if the bearing. isc()f self-lubrica-
ting type.
New bearings can be fitted without washing because their protective cover does not impair their
efficient operation.

IV
BETA MONTECARLO
SHOP MANUAL
FOREWORD
~
~'
IDENTI FICATION OF CAR
~
Fig. 1 -Position of chassis serial number .
~
-,/
Fig. 3 -Beta Montecarlo.
TYPES
f\,
~

v
BETA MONTECARLO
SHOP MANUAL FOREWORD
DIMENSIONS AND WEIGHTS
3813 mm
Overall length
Overall width 1696 mm
1190 mm
Overall height (unladen)
Ground clearance (laden) 190 mm
1412 mm
Front track (laden)
1456 mm
Rear track (laden)
r2300 mm
Wheelbase (laden)
1040 kg
Kerb weight
1230 kg
Weight fully laden
800 kg
Towable weight
PERFORMANCE
Speeds in the various gears at 6000 rpm
Final drive ratio
Third
: 1.522
Fourth
I: 1.152
Reverse
1 : 3.071 First
: 3.750
Second
1 : 2.235 0.925
190
155
80 120
14/52 45 45
Speed at 1000 rpm in Sth gear 31.66 k.p.h.
Fuel consumption according to CUNA standards (1-/100 km)
.,.-- Gradients

VI
BETA MONTECARLO
SHOP MANUAL
FOREWORD
Acceleration :
Acceleration with two people aboard and changing gear as required Sec
standing 400 m 16.3
standing 1000 m 30.7
0-100 k.p.h. 9.8
Acceleration with minimum load and changing gear as required Sec
standing 400 m 16
standing 1000 m 30.2
0-100 k.p.h 9.3
Specifications and ~ata
Engine 134 AS.OOO
Number of cylinders 4
84
Cylinder bore mm
Total capacity 1995 cc
8.9
Compression ratio
Max power output (DIN standards) 87.3 Kw (118 hp)
Max torque (DIN standards) 16.9 (17.1 kgm)
at
3400 rpm
Max revs 6000 rpm
Firing order 1-3-4-2

VII
BETA MONTECARLO
SHOP MANUAL FOREWORD
r
Fig. 4 -Instruments and controls
1. Side air outlets -2. Low and high beam light switch -3. Instrument cluster -
4. Windscreen wiper and washer control -5. Central air outlet -6. Ash-tray -7. ciga-
rette lighter -8. Glove compartment release lever -9. Glove compartment lock -
10. Radio blank -11. Heating and ventilation flow .control lever -12. Gear lever -
13. Handbrake -14. Quartz electronic clock -15. Heating and ventilation control
levers -16. Spare switches -17. Horn -18. Accelerator pedal -19. Brake pedal -
20. Clutch pedal -21. Fuse box- 22. Boot release control -23. Direction indicators
switch -24. Side lights switch.
"'
Fig. 5 -Instrument cluster
1. Speedometer with trip and total distance recorders -2. Hazard signalling system
warning light (if fitted) -3. Direction indicator tell-tale -4. Electronic rev counter -
5. Coolant temperature gauge -6. Blank -7. Oil pressure gauge -8. Blank -9. Alter-
nator warning light -10. Low engine oil pressure warning light -11. Handbrake tell-
tale (flashing) -12. Engine overheating tell-tale -13. Blank -14. Blank -15. Fuel
reserve warning light -16. Fuel gauge -17. Instrument light with intensity adjuster -
18. Heated rear window warning light -19. Spare tell-tale -20. Spare tell-taliJ -
21. High beam tell-tale -22. Spare tell-tale -23. Side lights on light -24. Trip dl-
stance recorder reset.
f\

VIII
BETA MONTECARLO
SHOP MANUAL
FOREWORD
var. SCORPION
,
Position of chassis serial number. Position of car data plate.
Beta SCORPION
TYPES
~
Identification numbers DESCRIPTION Drive
Car Drive
137 AS.6 134 AS.O31.6 Beta SCORPION LHD

IX
BETA MONTECARLO
SHOP MANUAL FOREWORD
var SCORPION
r--
DIMENSIONS AND WEIGHTS
Overall length 156.10
in.
Overall width 66.77
in.
Overall height (unladen) 46.85
in.
Front track (laden) in. 55.59
Rear track (laden) 57.32
In.
Wheelbase (laden) 99.55
in.
Ibs. 2.400
r"
Kerb weight (without optional extras)
Payload (2 people + 130 Ibs. luggage) Ibs. 430
~
PERFORMANCE
Gradients
r

x
BETA MONTECARLO
SHOP MANUAL
FOREWORD
var. SCORPION
Specifications and data
Engine 134.031.6
Number of cylinders 4
Cylinder bore 3.31
Total capacity cu in. 107.13
Compression ratio 8.0 to 1
Max power output (SAE net) HP 81
Max torque (SAE net) Ibs. ft 89
Max revs 5900
r.pm.
3
Firing order 4 -2

XI
BETA MONTECARLO
SHOP MANUAL FOREWORD
var. SCORPION
~
1. Side air outlets -2. Side lights control
switch -3. Turn indicator control -4. In-
Strument cluster -5. Horn control -6.
Windscreen wiper and washer control -
7. Centre air outlets -8. Hazard signal-
ling system switch -9. Rear heated win-
dow switch -10. Ash-tray -11. Cigarette
lighter- 12. Glove locker lid release lever
-13. Glove locker lock -14. Radio blank
-15. Handbrake control lever -16. Gear
control lever -17. Heating and ventila-
tion flow control lever -18. Symbols
light rheostat -19. Front seat footwells
air outlet control switch -20. Quartz
electronic clock -21. Heating and venti-
lation control levers -22. Accelerator pe-
dal -23. Brake pedal -24. Clutch pedal -
25. Fuse box -26. Boot release control -
27. Main and low beams control.
~
Instruments and controls
"'-~
'~y
,--
1. Trip distance recorder zero reset -
2. Speedometer with trip and total di-
stance recorders -3. Hazard signalling
system warning light -4. Turn indicators
teil-tale -5. Electronic rev counter -
6. Coolant temperature gauge -7. Blank -
8. Oil pressure gauge -9. Blank -10. Al-
ternator warning light -11. Engine oil
low pressure warning light -12. Handbra-
ke, brake system failure, or brake system
low fluid level warning light -13. Engine
overheating tell-tale -14. Blank -15. Fa-
sten belts warning light (driver) -16.
Fuel reserve warning light -17. Fuel gau-
ge -18. Instruments light with intensity
adjuster -19. Heated rear window war-
ning light -20. Extra tell-tale -21. Extra
tell-tale -22. Main beam tell-tale -23.
Extra tell-tale -24. Side light warning
light.
f'\
Instruments cluster

BETA MONTECARLO
SHOP MANUAL 01 ENGINE
Contents
ENGINE GROUP CONTENTS
CHAPTER 1
Troubles, probable causes,checkings and operations to be carried out
from
~c'to page 01 1/1 page 01 1/19
CHAPTER 2
Ignition
§ 0120100
§ 0120200
01 2/1
§ 0120300
§ 0120310
§ 0120400
01 2/1
01 2/1
01 2/1 Variant Scorpion
01 2/1 Variant Scorpion
01 2/2
01 2/2 Variant Scorpion
01 2/3
§ 0120500
Removing and refitting the spark plugs
Cleaning the ignition distributor cap contacts, rotor, cable terminals
and replacing the spark plug cable terminal guards .
Checking or timing the ignition
Do. for Scorpion cars
Strobe lamp ignition timing check
Removing and refitting the ignition distributor and timing the system.
Do. for Scorpion cars
Removing and refitting the ignition coil
Anti-pollution equipment }
01 2/3 Variant Sco~on
01 2/3 Variant Sc~rpion
01 2/4 Variant Scorpion
01 2/4 Variant Scorpion
§ 01 20690
§ 0120700
§ 0120710
§ 0120720
Removing and refitting gasfluid vapor separators
Removing and refitting gas tank ventilation valve
Removing and refitting gas vapor cleaner .
Removing and refitting of the air pump .

2
BETA MONTECARLO
SHOP MANUAL
01 ENGINE
Contents
§ 0120730
01 2/5 Variant Scorpion
01 2/6 Variant Scorpion
§ 0120740
§ 012 07BO
01 2/6 Variant Scorpion
§ 0120790
01 2/7 Variant Scorpio[1
§ 0120800
01 2/7 Variant Scorpion
01 2/8 Variant Scorpion
01 2/8 Variant Scorpion
01 2/8 Variant Scorpion
01 2/9 Variant Scorpion
01 2/9 Variant Scorpion
§ 0120810
§ 01 2 0830
§ 0120840
§ 0120850
§ 0120860
§ 0120870
01 2/10 Variant Scorpion
01 2/10 Variant Scorpion
01 2/11 Variant Scorpion
§ 01 2 0880
§ 0120890
Removing and refitting of diverter valve, three-way valve, and three
way electrovalve .
Removing and refitting check valve and exhaust pipe air hose .
Removing and refitting the exhaust gas recirculation valve and pipes
(E.G.R.)
Removing and refitting vacuum thermostat controlling exhaust gas
recirculation valve (E.G. R.)
Removing and refitting electrovalve for cutting out exhaust gas
recirculation valve (E.G.R.) .
Removing and refItting a push-button switch on the gearbox
Removing and refitting fast idler hand control switch .
Removing and refitting fast idler control electrovalve
Renewing the fast idling diaphragm body.
Regulating fast idler
Removing and refitting exhaust gas recirculation (E.G.R.) system
alarm
Removing and refitting accessory gearbox .
Removal and refitting of the electronic speedometer .
Fuel System
§ 0120900
01 2/5
§ 0121100
01 2/5
01 2/3
01 2/6
01 2/6
01 2/6
01 2/7
Variant Scorpion
§ 0121700
§ 0121710
§ 0121800
§ 0121900
§ 0122200
01 2/7
01 2/3 Variant Scorpion
§ 0122250
§ 0122300
01 2/8
01 2/14 Variant Scorpion
01 2/8
01 2/14 Variant Scorpion
§ 0123200
01 2/9
01 2/15 Variant Scorpion
01 2/9
01 2/10
§ 0123710
§ 0123800
Removing !and refitting the fuel gauge transmitter with previous
~~
checking ,i .
Removing and refitting the fuel tank complete with fuel gauge
transmitter .
Do. for Scorpion cars .
Cleaning, or renewing the air cleaner element.
Removing and refitting the air cleaner assy .
Removing and refitting the fuel pump (electromechanical) ,
Removing and refitting the fuel cleaner
Cleaning the carburettor float chamber, blowing the jets and setting
the slow-running
Do. for Scorpion cars
Removing and refitting the carburet tor float chamber cover (Weber
carburet tors) .
Do. for Scorpion cars .
Setting the engine slow-running
Do. for Scorpion cars
Removing and refitting the carburet tor including setting the engine
slow-running .
Do. for Scorpion cars .
Removing and refitting the choke
Removing and refitting the accelerator control cable ,
Exhaust System
§ 0124300 Removing and refitting the exhaust piping assembly.
Do, for Scorpion cars
01 2/11
01 2/17 Variant Scorpion

3
BETA MONTECARLO
SHOP MANUAL 01 ENGINE
Contents
Cooling System
§ 0124650
§ 0124700
§ 0124800
§ 0124900
§ 01 25000
§ 0125030
01 2/13
01 2/13
01 2/14
01 2/14
01 2/15
01 2/15
01 2/16
§ 0125100
§ 0125110
Draining refilling deaerating the cooling system
Removing and refitting the coolant radiator .
Removing and refitting the coolant pump
Removing and refitting the coolant thermostatic blender
Removing and refitting the motor driven fan
Checking the motor driven fan, thermoswitch and solenoid switch for
operation .
Removing and refitting the motor driven fan control thermoswitch .
Checking working condition of coolant temperature gauge,transmitter
and motor driven fan cut-in and cut-out temperature . 01 2/16
r- Lubrication System
§ 01 25600
§ 0125700
§ 0126000
01 2/19
01 2/19
01 2/19
Checking the oil pressure
Removing and refitting the oil pump .
Removing and refitting the oil filter base to renew the gasket .
Valve Gear
§ 0126500
§ 0126600
§ 0126800
01 2/21
01 2/21
, ~
-.
""
',,~
"'r 01 2/23
§ 0126950
01 2/24
§ 0127010
01 2/25
01 2/26§ 0127300
§ 0127500
Checking the tappet clearance .
Setting the valve tappet clearance
Checking and setting the valve gear timing (including checking the
ignition timing) .
Renewing the timing belt including valve gear timing and checking
the ignition timing .
Removing and refitting one camshaft housing (intake side), checking
valve tappets clearance (removing-refitting timing belt excluded) .
Removing and refitting the timing belt stretcher assy .
Removing and refitting the camshaft drive gears, ancillary units shaft
drive gear and timing belt drive gear 01 2/26
Cylinder Head
§ 0127700 Removing and refitting the cylinder head (including checking the
valve tappet clearance, but except for relative setting)
Do. for Scorpion cars
01 2/29
01 2/19 Variant Scorpion
Engine Unit and Motive Components
§ 0128100
§ 0128200
§ 0128300
§ 0128310
§ 0128400
§ 0128600
§ 0128700
§ 0128800
Checking the cylinder compressions .
Renewing the engine mountirig buffer .
Renewing the crankshaft front oil seal.
Renewing the ancillary units drive shaft oil seal
Removing and refitting the engine oil sump .
Removing and refitting the flywheel
Fitting a new crankshaft rear oil seal.
Removing and refitting the engine (complete with gearbox) .
Do. for Scorpion cars
01 2/31
01 2/31
01 2/32
01 2/34
01 2/35
01 2/36
01 2/36
01 2/36
01 2/23 Variant Scorpion

4
BETA MONTECARLO
SHOP MANUAL
01 ENGINE
Contents
CHAPTER 3
§ 0130010
013/1
§ 013 0100
01 3/1
§ 0130250
01 3/2
01 3/3
01 3/4
§ 0130300
§ 01 30420
§ 0130520
01 316
§ 0130910
01 3/8
§ 0131100
01
§ 013 110
01 3117
01 3118
§ 0132100
§ 0132300
§ 0132310
§ 0132400
§ 0132600
§ 0132800
§ 0132900
§ 0133100
Engine overhaul accessory operations (removing and refitting the elec-
tric units, fitting and removing the covers and washing the engine)
Fitting the engine to the overhauling stand and removing it (including
draining the engine oil and refilling)
Removing and refitting the timing belt, timing the valve gear and
checking the valve tappet clearance with engine at the bench
Removing and refittil1g the cylinder head from the engine at the bench
Setting the valve tappet clearance with the engine at the bench
Removing and refitting the timing belt stretcher, spring, crankshaft
gear, camshaft gears, ancillary units drive shaft gear and coolant
pump from the engine at the bench .
Removing and refitting the oil sump, oil pump, connecting rods,
pistons from the engine at the bench (including relative checking)
Removing and refitting the crankshaft from the engine at the bench
(including removing and refitting the ancillary units drive shaft and
fuel pump and carrying out relative checkings)
Substituting the ancillary units drive shaft bearings and oil pump,
drive gear bushing
Cleaning the crankshaft oilwavs .
01 3/19
01 3/19
01 3/20
01 3/20
01 3/21
01 3/21
01 3/23
Checking the flywheel.Renewing the flywheel ring gear. .
Refacing the fiywheej
Replacing the engine block plugs.Reboring the cylinders.Checking the connecting rods for alignment.Replacing the connecting rod small end bushing
CHAPTER 4
Ignition
§ 0140100
§ 0140300
01 4/1Setting the ignition distributor (Marelli 144 G)Overhauling the ignition distributor, including final test (Marelli
S144 G) 01 4/1
Fuel System
01 4/3
§ 0141000 Overhauling and checking the Weber 34 DATR 200 carburet tor

5
BETA MONTECARLO
SHOP MANUAL 01 ENGINE
Contents
Cooling System
§ 0141300 General overhaul of coolant radiator 01 419
Lubrication System
§ 0142500 Overhauling the oil pump 01 4/11
Cylinder Head
§ 0142650
r-- 91 4/13
§ 01 42700
01
01
01
01
01
§ 0142710
§ 0143100
§ 0143300
§ 0143400
Removing and refitting the camshaft housings from the cylinder head
on the bench.Disassembling and reassembling the cylinder head (including checking
the cylinder head surface for flatness, valves, guides, valve seats and
spring loading)
Refacing the valves and the seats. ...
Renewing the valve guides (including refacing the valves and seats)
Surfacing the cyl inder head.Overhauling a camshaft housing.
4/1
4/1
4/1
4/1
4/1
13
15
17
17
18

BETA MONTECARLO
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011/1
SHOP MANUAL