Westward THE INTERCEPTOR BT-57 Install guide

WESTWARD
INDUSTRIES LTD
liTHE INTERCEPTOR''
2501 Hwy 1A West
Portage Ia Prairie, MB
CANADA R1N 3L5
SHOP MANUAL
PART NO. 938000

Westward Industries Umited, G0-4 Interceptor Service Manual
INTRODUCTION
Important Safety Notice
Good service methods and correct repair
procedures are important for the safe, reliable
operation
of the G0-4 Interceptor vehicle as well
as the personal safety of the person doing the
work. This SERVICE MANUAL provides general
directions
for doing service and repair work with
tested, effective techniques. By following them
it will assure reliability.
There are
many variations in procedures,
techniques and tools, and parts for servicing
vehicles, as well as in the skills of the person
doing
the work. The Service Manual cannot
possibly use all these variations and provide
advice
or cautions for each procedure or
operation. Thus anyone who departs from the
instructions provided in this manual must first
establish that he compromises neither his
personal
safety nor the vehicle integrity by his
choice
of methods, tools or parts.
Notes, Cautions, and Warnings
As you read these procedures, you will come
across NOTES, CAUTIONS, and WARNINGS.
NOTES give
you added information that will help
to complete a particular procedure. CAUTIONS
are given to prevent you from making an error
that could damage a vehicle. WARNINGS
remind
you to be very careful in those areas
where carelessness can cause personal injury.
The
following general WARNINGS should be
followed when you work on a vehicle.
•
Always wear safety glasses for eye
protection.
• Do not smoke when working on a vehicle.
• Remove rings,
watches, loose hanging
jewelry and loose clothing before beginning
to work on a vehicle.
• Use
safety stands whenever a procedure
requires
you to be under the vehicle.
•
Be sure the ignition switch is in the OFF,
unless
otherwise required by the procedure.
• Set the park brake when working on the
vehicle. Set the automatic transmission in
PARK unless
instructed otherwise for a
specific operation. Place
wood blocks (4" x
4" or larger) against the front and rear
surfaces of the tires to provide further
restraint from inadvertent vehicle
movement.
• Operate the engine in a well-ventilated area
to avoid the danger of carbon monoxide.
• Keep
yourself and your clothing away from
moving parts (e.g. drive belts) when the
engine is running.
• Avoid
contact with hot metal parts such as
radiator,
exhaust, manifold, tail pipe,
catalytic
converter and muffler.
• If it is necessary to work under the engine
compartment, keep hands and other objects
clear of the radiator fan blades! The G0-4 is
equipped
with a cooling fan that may turn
on, even though the ignition switch is in the
OFF position. Disconnect the radiator
electric
motor when working around the
engine when engine is not running.
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Westward Industries Umited, G0-4 Interceptor Service Manual
What Subjects Are Covered In This Manual?
The
G0-4 Service Manual covers normal service repairs and maintenance for vehicles sold in the United States.
How Is This Manual Organized?
This manual is organized by Section Sub-section and
Page
Section -This covers a specific portion of the vehicle. The first set of numbers on each page indicate the
Group.
Note: A Section usually contains more than one group.
The Sections found
in this service manual are:
2
1 -Vehicle Identification/General Information
2 - Maintenance and Lubrication
3 - Wheels and Tires
4 - Brake System
5- Steering
6 - Suspension
7 -
Axles and Driveshafts
8 -
Automatic Transaxle
9 - Emission Control Systems
10 - Noise, Vibration and Harshness
11 -Engine
12 -Ignition System
13 -Fuel System
14 -Exhaust System
15 -Cooling System
16 - Starting System
17 - Battery and Charging System
18 -Lighting Systems
19 -Instruments, Clusters, Controls and Warning Systems
20 -Wiring Harness, Connectors and Circuit Protection System
21 -Auxiliary Equipment
22 -Heating and Air Conditioning
23 -Seat and Seat Belts
24 - Window Glass, Fixed Glass and Mirrors
25 -Headliner and Flooring
26 -Cargo Box

Westward Industries Limited, G0-4 Interceptor Service Manual
27 -Body Shell/Frame
28 -Exterior Finishes
Sub-section
-each Sub-section covers a component or system. The headings on top of each page indicate the
Section
it is in.
Page -
this set of numbers is indicated in each Section.
How Do You Find the Material in the Service Manual?
1. Locate the Section in the Table of Contents. If you are not sure which Section contains the
information you need, refer to the index located in the back of this manual.
2. Locate the Section number by using the index located at the beginning of each Section.
How Do You Use Each Section?
Each Section has a standard organization that consists of the following information:
Description and
Operation- describes how the component or system works.
Diagnosis and Testing- shows how to pinpoint problems.
Removal and
Installation- how to remove and reinstall components or systems.
Disassembly and Assembly - how to take apart the part or system and put it back together.
Adjustments- how to perform in-vehicle adjustments.
Specifications -provides a summary
of all specifications used in the Section.
Service
Tools/Equipment- lists all the Service Tools used in the Section. Additional headings such as Service
Procedures and Cleaning and Inspection
may be used.
What to Do If You Discover an Error?
Please
let us know if you discover a questionable procedure OR if you have any suggestions for improving this
manual. Your feedback is very important to improving our technical publications. You will get a response to
your questions and suggestions. If necessary, a revision will be issued.
NOTE: The description and specifications contained in this manual were in effect at the time this manual was
approved for printing. Westward Industries reserves the right to discontinue models at any time, or changing
specifications
or design without notice and without incurring any obligation.
3

Westward lndustriefi limited, G0-4 Interceptor Service M:mnal
4

Westward Industries limited, G0-4 Interceptor Service Manual
TABLE OF CONTENTS
SECTION PAGE
Introduction
.................................................................................... 1
1 - Vehicle ldentification/Generallnformation
.................................... 1-1
2- Maintenance and Lubrication ...................................................... 2-1
3 - Wheels and Tires
...................................................................... 3-1
4- Brake System .......................................................................... 4-1
5- Steering ............................. , ..................................................... 5-1
6- Suspension ............................................................................... 6-1
7 - Axles and Drives
hafts ............................................................... 7-1
8- Automatic Transaxle ................................................................. 8-1
9 - Emission Control System
.......................................................... 9-1
10 - Noise, Vibration and Harshness
.................................................. 10-1
11 -Engine ...................................................................................... 11-1
12- Ignition System ......................................................................... 12-1
13 -Fuel System ............................................................................. 13-1
14 -Exhaust System ........................................................................ 14-1
15 - Cooling
System ........................................................................ 15-1
16 -Starting System ........................................................................ 16-1
17 -Battery and Charging System ..................................................... 17-1
18- Lighting Systems ...................................................................... 18-1
19 -Instruments, Clusters, Controls and Warning Systems ..................19-1
20 -Wiring Harness, Connectors and Circuit Protection System ...........20-1
21 -Auxiliary Equipment
.................................................................. 21 -1
22 -Heating and Air Conditioning ...................................................... 22-1
23 -Seat and Seat Belts ................................................................... 23-1
24- Doors, Window Glass, Fixed Glass and Mirrors ............................ 24-1
25 -Headliner and Flooring ............................................................... 25-1
26 -Cargo Box ................................................................................ 26-1
27- Body Sheii/Frame ...................................................................... 27-1
28 -Exterior Finishes ....................................................................... 28-1
5

Section 1 -Vehicle Identification/General Information
SECTION 1 - Vehicle
Identification/General Information
SUBJECT
DESCRIPTION
PAGE
Engine Model
and Serial Number .................. 1-1
Vehicle Certification ................................... 1-1
Vehicle Emission Control Information ............ 1-1
Vehicle Identification Number ...................... 1-1
DESCRIPTION
Vehicle Certification Label
The plate is located on
the front left-hand side of
the dash.
The upper
half of the label contains the name of
the manufacturer, month and year of
manufacture, Gross Vehicle Weight Rating
(GVWR), and Gross Axle Weight Rating (GAWR).
The Vehicle
Certification Label also contains a 17
character Vehicle Identification Number (VIN).
Vehicle
Identification Number
The official Vehicle Identification Number (VIN)
for title and registration is stamped on a decal.
Use
this number for warranty identification of the
vehicle: it indicates manufacturer, body type,
engine, model and product serial number.
The last three (3)
digits of the Vehicle
Identification Number indicates the serial number
of the unit.
Engine Model and Serial
Number
It is located just below the oil filler cap of the
engine.
Vehicle Emission
Control Information
It is located on the engine electrical rail above the
coolant recovery bottle.
SUBJECT PAGE
GENERAL INFORMATION
Preparing
of Tools/Equipment ...................... 1-2
Reassembly
............................................ 1-2
Towing
.................................................. 1-3
Measuring Units
and Terms ...................... 1-3
Vehicle Certification Label/Vehicle Identification Number
Engine
Model and Serial Number/Vehicle Emission Control
Information Decal
1-1

GENERAL INFORMATION
Preparing of Tools and Measuring Equipment
Make sure that all necessary tools and measuring
equipment are available before
starting work.
Special Tools- use when they are required.
Removal of Parts - while correcting a problem, try
to determine the cause. Begin work only after
first learning which parts and subassemblies must
be removed and disassembled for replacement or
repair.
Disassembly -
if the disassembly procedure is
complex, requiring
many parts to be
disassembled, all parts should be disassembled in
a
way that will not affect their performance or
external appearance and can be identified so that
reassembly can be performed efficiently.
1. Inspection of parts. Each part, when
removed, should be carefully inspected for
malfunctioning, deformation, damage or
other problems.
2. Arrangement of parts -all disassembled
parts should be carefully arranged
for
reassembly. Keep new and reused parts
separate so
that they will be easy to identify
and replace.
3. Cleaning parts for reuse -parts that are to
be reused should be carefully and thoroughly
cleaned by the appropriate method.
Reassembly
Standard values, such as torques and certain
adjustments,
must be strictly observed in the
reassembly of parts.
If removed, these parts should be replaced with
new ones.
1. Oil Seals
2. Gaskets
3.
0-rings
4. Lockwashers
5. Cotterpins (lock pins)
6.
Nylon nuts
1-2
Depending on where they are:
1. Sealant should be applied to gaskets.
2. Oil should
be applied to moving
components of parts.
3. Specified oil
or grease should be applied
at the prescribed locations (e.g. oil
seals, etc.) before the assembly.
Adjustments
• Use gauges and testers to make adjustments
to standard values.
Electrical
System
• Be sure to disconnect the battery cable from
the negative (-) terminal to battery.
• Never pull on the wiring when disconnecting
connectors.
• Locking connectors must be heard to click for
the connector to be secure.
• Handle sensors and relays carefully.
Be
careful not to drop them or hit them against
parts.
Rubber Parts and Tubing - always prevent
gasoline
or oil from touching rubber parts or
tubing.
Jack and Safety Stand Rigid Rack) Positions
Front - Jack Position: place under the center of
the front frame.