Sterling 825 Shop Manual 1988 1989

1988 Sterling 825 S DEFOGGER - REAR WINDOW 1988 Accessories & Safety Equipment ALL MANUFACTURERS DEFOGGERS - REAR WINDOW

DEFOGGER - REAR WINDOW 1988 Accessories & Safety Equipment ALL MANUFACTURERS DEFOGGERS - REAR WINDOW

DESCRIPTION Rear window defogger systems use a heating wire grid bonded to the inside of rear window. Window heat is regulated by a control switch and a relay/timer. An indicator lamp should light to show system is operating.

Power to the control switch is through a fuse in the fuse block.

OPERATION Defogger operates when the ignition is on and control switch is moved to "ON" position. When the switch is turned to the "ON" position, current flows through the wire and evaporates the water from the window. The timer relay will keep power to the grid for a few minutes or until the ignition is turned off.

TROUBLE SHOOTING DEFOGGER DOES NOT WORK Blown fuse or poor contact. Defogger switch defective. Poor connections. Broken wire. Relay defective.

INDICATOR LIGHT DOES NOT WORK Bulb burned out. Open wire or poor connection.

TESTING SYSTEM TESTING 1. Check that all in-line fuses or circuit breakers are operational. Turn ignition and control switches to "ON" position. Check rear window glass temperature after a few minutes. Glass should feel warm to the touch.

2. If glass is not warm, use a test light or voltmeter to check for battery voltage at grid feed wire. If voltage is not correct, check wiring harness, control switch and timer/relay.

FILAMENT TESTING 1. To locate breaks in grid wire filaments, attach a voltmeter to middle portion of each filament. Attach other meter probe to vertical section of window grid.

2. If a grid is broken, meter will register zero volts or battery voltage, depending on if grid is broken between or outside test leads. If wire is unbroken, meter will register about one half of battery voltage. To locate break, move probe along wire until the meter needle moves abruptly.

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1988 Sterling 825 S DEFOGGER - REAR WINDOW 1988 Accessories & Safety Equipment ALL MANUFACTURERS DEFOGGERS - REAR WINDOW

Fig. 1: Voltage Test for Broken Grid Filaments

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1988 Sterling 825 S STEERING COLUMN SWITCHES 1988 STEERING Sterling - Steering Wheel & Column Switches

STEERING COLUMN SWITCHES 1988 STEERING Sterling - Steering Wheel & Column Switches

REMOVAL & INSTALLATION CAUTION: When performing work on vehicles equipped with Supplemental Restraint System (SRS), exercise extreme caution when working around steering wheel or column. DO NOT apply electrical power to any component on steering column without disconnecting SRS control unit (air bag system may be activated).

STEERING WHEEL & HORN Removal

1. Disconnect battery ground cable. Remove screws attaching horn button assembly/center pad to steering wheel from behind steering wheel (if equipped).

Fig. 1: Removing Steering Wheel 2. Pull horn button assembly/center pad from steering wheel. Use a cloth covered screwdriver to pry off horn button assembly/center pad (if necessary). Disassemble horn button assembly (if necessary).

3. Place springs, contacts, horn or cruise control harness connectors and screws in order for reassembly Helpmelearn Repair Manuals Friday, April 14, 2006 10:00:18 10:00:15 AM

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1988 Sterling 825 S STEERING COLUMN SWITCHES 1988 STEERING Sterling - Steering Wheel & Column Switches

reference. Place wheels in a straight-ahead position.

Fig. 2: Exploded View of Typical Steering Wheel Assembly 4. Remove steering wheel retaining nut and washer. Mark steering wheel and shaft for reassembly reference.

Using a steering wheel puller, remove steering wheel. See Fig. 1 .

5. Place steering wheel, cruise control set/resume switch if equipped), canceling cams, springs and slip rings in order for reassembly reference.

Installation

1. Coat slip ring contact surfaces with a light electrical grease. Assemble horn button assembly (if disassembled). Ensure wheels are in a straight-ahead position.

2. Aligning marks made during removal, place slip ring, springs, canceling cams, steering wheel, washer and steering wheel retaining nut on shaft.

3. Tighten nut to specification. See STEERING WHEEL TORQUE SPECIFICATIONS table at the end of this article. To complete reassembly, reverse removal procedure.

COMBINATION SWITCH Removal

Remove steering wheel. Remove upper and lower steering column covers. Disconnect combination switch harness connectors. remove snap ring and washer from steering shaft (if equipped). Remove combination switch attaching screws. Remove combination switch.

Installation

To install, reverse removal procedure. Ensure all electrical connections are tight. Check canceling operation of turn signal switch.

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1988 Sterling 825 S STEERING COLUMN SWITCHES 1988 STEERING Sterling - Steering Wheel & Column Switches

STEERING LOCK & IGNITION SWITCH Removal

1. Remove steering wheel, upper and lower steering column covers and combination switch. Disconnect ignition switch harness connectors.

2. If the shear bolt studs are accessible, use a hacksaw to cut a slot into the exposed studs. Using a screwdriver, remove the studs.

3. If the shear bolt studs are recessed or hard to reach with a hacksaw, center punch studs. Using a drill bit and a screw extractor, remove studs. Remove steering lock and ignition switch.

Installation

1. To install, reverse removal procedure. Install new shear bolts. Tighten shear bolts finger tight. Ensure proper operation of steering lock and ignition switch.

2. Tighten shear bolts until heads break off. Install combination switch, upper and lower steering column covers and steering wheel.

TORQUE SPECIFICATIONS STEERING WHEEL TORQUE SPECIFICATIONS Application 825

Ft. Lbs (N.m) 37 (50)

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1988 Sterling 825 S WIPER/WASHER SYSTEM 1988 WIPER/WASHER SYSTEMS Sterling

WIPER/WASHER SYSTEM 1988 WIPER/WASHER SYSTEMS Sterling

DESCRIPTION & OPERATION All models are equipped with a 2-speed front wiper motor with an intermittent feature. The wiper switch is part of the combination switch on the steering column.

TESTING FRONT WIPER MOTOR 1. Remove cowl air scoop and grille. Unbolt motor to gain access to connector. Remove wiring connector and wiper motor linkage from motor.

2. On Sterling models, test low speed operation by checking for continuity between relay terminals "C" and "E" with battery voltage applied to terminals "A" and "B". If no continuity is present, replace relay. See Fig. 1 . If relay is okay, apply battery voltage to Red/Light Green (positive), and Brown/Light Green (negative) wires at wiper motor terminal connector.

3. On Sterling models, test high speed operation by checking for continuity between relay terminals "C" and "D" with no connections to other terminals. If no continuity is present, replace relay. If relay is okay, apply battery voltage to Brown/Light Green (negative) and Red/Light Green (positive) terminals at wiper motor terminal connector.

4. To test high speed on Sterling, apply battery voltage to Blue/Light Green (positive), and Brown/Light Green (negative) wires at terminal connector.

Fig. 1: Sterling Relay Connector Locations Courtesy of AUSTIN ROVER GROUP. Helpmelearn Repair Manuals Friday, April 14, 2006 10:00:32 10:00:29 AM

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1988 Sterling 825 S WIPER/WASHER SYSTEM 1988 WIPER/WASHER SYSTEMS Sterling

WASHER PUMP MOTOR On Sterling, connect positive battery voltage to Light Green/Blue terminal and negative battery voltage to Black terminal.

REMOVAL & INSTALLATION FRONT WIPER MOTOR Removal & Installation

1. On Sterling, disconnect battery negative cable. Remove wiper arms and attaching hardware. Remove panel and right plenum moulding. Remove motor attaching screws and motor.

Removal & Installation

1. On Sterling, remove battery negative cable, steering wheel and steering column panels. Remove fiber optic which illuminates switch. Remove spring clips. Disconnect multi-pin connector and remove switch.

WIRING DIAGRAMS NOTE:

See the WIRING DIAGRAMS article in the WIRING DIAGRAMS section.

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1988 Sterling 825 S AXLE SHAFTS FWD AXLE SHAFT & CV JOINTS Sterling

AXLE SHAFTS FWD AXLE SHAFT & CV JOINTS Sterling

DESCRIPTION Axle shaft transfer power from transaxle to driving wheels. All axle shafts consist of a shaft and flexible Costant Velocity (CV) joint at each end. Inner CV joint is splined or bolted to transaxle. Outer CV joint is splined to hub assembly and secured by axle shaft nut. Thye inner and outer CV joints are enclosed by a CV joint boot. The boot maintains lubrication in the joint and prevents contamination from entering the joint. Boots must be replaced when signs of leakage or cracks are present. The Inner CV joint can be repair without replacing assembly. The outer CV joint must be replace as an assembly. There are 3 different types of axle shaft CV jopints. The Double Offset Joint (DOJ). The Brifield Joint (BJ) and the Tripod Jpint (TJ), (sometimes referred as tripod).

TROUBLE SHOOTING TROUBLE SHOOTING CHART Condition Grease Leaks Clicling Noise on Cornering Clunk Noice on Acceleration Vibration or Shudder on Acceleration

Possible Cause CV boot torn or cracked Damaged Outer CV Damaged Inner CV Sticking, damaged or worn CV Misalignment or spring height

REMOVAL & INSTALLATION AXLE SHAFT CAUTION: Vehicle weight must not be allowed to rest on wheel bearings and hub, WITHOUT axle shaft installed and axle shaft nut tightened to specification.

Removal

1. Remove wheel/tire assembly and drain transaxle fluid. Remove axle shaft lock tab from nut and loosen nut by applying brakes. On Legend models, remove damper pinch bolt and damper fork bolt. Remove damper fork. See Fig. 1 .

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1988 Sterling 825 S AXLE SHAFTS FWD AXLE SHAFT & CV JOINTS Sterling

Fig. 1: Damper Fork & Pinch Bolt Location Courtesy of AMERICAN HONDA MOTOR CO., INC. 2. Remove lower ball joint cotter pin and nut. Using a ball joint puller, separate ball joint from front hub.

Slowly lower control arm and steering knuckle. Pull steering knuckle outward and remove axle shaft from hub assembly. Use a plastic hammer to drive axle out if necessary.

CAUTION: Do not pull on inboard CV joint or disassembly may occur. Be careful not to damage seals.

3. Using a large screwdriver, carefully pry the inner CV joint and shaft assembly approximately .5" (12.7 mm). This will dislodge the retaining ring from transaxle or intermediate shaft. Grip both sides of the inner CV joint and remove the axle shaft from vehicle.

CAUTION: Do not disassemble the outer CV joint. This must be replaced as an assembly. Mark rollers and roller grooves to ensure exact reassembly.

Disassembly

1. Remove axle shaft from vehicle and place on work bench. Remove inner CV joint boot clamps and Helpmelearn Repair Manuals Friday, April 14, 2006 10:02:00 AM

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1988 Sterling 825 S AXLE SHAFTS FWD AXLE SHAFT & CV JOINTS Sterling

discard. Slide boot toward the outer CV joint to access inner CV joint. See Fig. 2 .

2. Index axle shaft, inner CV joint housing and spider roller to ensure reassembly to original location and position. Remove housing from spider assembly. Index rollers and spider to ensure reassembly to original location. Remove rollers from spider.

3. Remove snap ring securing spider to axle shaft and remove spider. Remove other snap ring and slide boot off axle shaft. Remove outer CV joint boot clamps. Slide boot off axle shaft inner CV joint end. Do not disassemble outer CV joint. Replace as an assembly only.

Reassembly

1. Thoroughly clean and inspect axle shaft. Replace all defective parts. Place outer CV joint boot into position but do not install clamps. Assemble inner CV joint and and position rollers on spiders with high shoulder outward. Properly pack CV joint with grease.

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1988 Sterling 825 S AXLE SHAFTS FWD AXLE SHAFT & CV JOINTS Sterling

Fig. 2: Exploded View of Axle Shaft Courtesy of AMERICAN HONDA MOTOR CO., INC. 2. Install stopper ring in groove on axle shaft. Install spider and snap ring. Lube spider and inside bore of rollers and install rollers. Ensure rollers are aligned with marks made at disassembly and high side of rollers are facing upward.

NOTE:

Sterling gives no specifications for axle shaft lengths.

3. Pack inner CV joint housing with grease. Align housing marks made at disassembly and install housing on spider assembly. Adjust the standard length of axle shaft. See Fig. 3 , Fig. 4 and Fig. 5 . Position boots halfway between full compression and full extension and install new boot clamps.

4. Lightly tap doubled-over portion of boot clamp to reduce their height. Install a new retaining ring on end of inner CV joint and install axle shaft.

Installation

1. Measure the assembled axle shaft and ensure length is within specifications. See Fig. 3 or Fig. 5 . Install damper to specified position. See Fig. 4 . Install a new retaining ring in groove at end of axle shaft. Install new bands on boots.

Fig. 3: Assembled Axle Shaft Length Courtesy of AMERICAN HONDA MOTOR CO., INC.

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1988 Sterling 825 S AXLE SHAFTS FWD AXLE SHAFT & CV JOINTS Sterling

Fig. 4: Installation of Assembled Damper Courtesy of AMERICAN HONDA MOTOR CO., INC. 2. Slide axle into transaxle or intermediate shaft. Ensure retaining ring seats fully in groove. Check by attempting to pull axle out of installed position.

3. Pull hub assembly away from axle shaft and slide axle into hub assembly. Install axle shaft nut and lightly tighten. Position ball joint in hub. Raise lower control arm with floor jack and install ball joint nut.

Tighten nut to specification.

4. Install cotter pin and secure. Remove floor jack. Tighten axle shaft nut to specification.

Fig. 5: Legend Axle Shaft Length Courtesy of AMERICAN HONDA MOTOR CO., INC.

TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS Helpmelearn Repair Manuals Friday, April 14, 2006 10:02:00 AM

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1988 Sterling 825 S AXLE SHAFTS FWD AXLE SHAFT & CV JOINTS Sterling

Application Sterling 825 Axle Shaft Nut Ball Joint Nut Brake Caliper Bolt Damper Fork Bolt Damper Pinch Bolt Intermediate Shaft

Ft. Lbs. (N.m)

180 (243) 72 (100) 124 (33) 47 (640) 39 (53) 28 (38)

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1988 Sterling 825 S ANTI-LOCK BRAKE SYSTEM 1987-91 BRAKES Sterling - Anti-Lock Brake System

ANTI-LOCK BRAKE SYSTEM 1987-91 BRAKES Sterling - Anti-Lock Brake System

DESCRIPTION The Anti-Lock Brake System (ABS) system consists of power brake unit, master cylinder, hydraulic modulator, 3 relays, electronic control unit (ECU), 4 wheel sensors, 4 sensor rotors, and "ABS" warning light.

OPERATION ECU receives AC signal from each wheel sensor. The ECU computes wheel speed and determines deceleration speed of vehicle. When a wheel is about to lock-up, the signal generated from that wheel will be different from deceleration speed. This difference will be detected by the ECU. Hydraulic brake pressure is then modulated by solenoid valves for the individual brake circuits. Solenoid valves are operated individually on front wheels and as a pair for rear wheels. ABS operation will continue until ECU detects that wheel speed is decreasing at the same rate for all wheels. System will cycle 4-10 times per second.

Fig. 1: ABS Component Locations Courtesy of AUSTIN ROVER GROUP.

BLEEDING BRAKE SYSTEM Bleeding brake system is same as conventional system, except the sequence. Correct sequence is left front, right rear, right front and left rear.

DIAGNOSIS Helpmelearn Repair Manuals Friday, April 14, 2006 10:01:04 10:01:01 AM

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1988 Sterling 825 S ANTI-LOCK BRAKE SYSTEM 1987-91 BRAKES Sterling - Anti-Lock Brake System

DESCRIPTION OF DIAGNOSIS SYSTEM ABS system must be diagnosed with ABS Tester (Fast Check). See Fig. 2 . If a malfunction occurs, the "ABS" warning light will illuminate. If "ABS" warning light is illuminated, brake system will function as a conventional brake system.

PRE-DIAGNOSIS INSPECTION Perform a comprehensive visual inspection on system components which could create an apparent anti-lock system malfunction. Performing this inspection of system prior to diagnosing specific symptoms may result in isolation of a simple failure which may cause an inoperative system.

DIAGNOSTIC PROCEDURE Turn ignition on. "ABS" warning light should illuminate. Start engine. "ABS" light should go out. If "ABS" light remains on continually, check ECU ground strap for continuity before diagnosing ABS system. If "ABS" light does not illuminate at any time, check fuse No. 14 (10-amp). If ECU ground strap or fuse No. 14 are okay, go to TESTING .

TESTING * PLEASE READ FIRST * To prepare for testing, turn ignition switch to the "OFF" position. Disconnect ECU connector. Connect ABS Tester (Fast Check) to ECU harness connector. Ensure all tester switches are off. Turn ignition on. Ensure "POWER" LED is illuminated on tester. See Fig. 2 . If "POWER" LED is illuminated, go to TEST A in this article. If "POWER" LED is not illuminated, check underhood fuse "Q" (15-amp), check battery condition, check overvoltage protection relay located next to ECU, check for an open between pin No. 30 (Purple/Brown wire) of overvoltage protection relay harness connector and pin No. 1 of tester. Repair as necessary. Go to TEST A in this article. To reduce diagnostic time, test components in order given.

Fig. 2: ABS Tester (Fast Check) Courtesy of AUSTIN ROVER GROUP. TEST A Overvoltage Protection Relay

1. Turn system test knob to "A". If system test LED illuminates, go to TEST B . If LED does not illuminate, using a DVOM, check for continuity between ignition switch and the overvoltage protection relay pin No. 15 (Light Green/Gray wire). If continuity is present, check fuse No. 11 (10-amp). If there is no continuity, repair wiring.

2. Check for continuity between battery and overvoltage protection relay pin No. 30 (Purple/Brown wire). If continuity is present, check underhood fuse "Q" (15-amp). If continuity is not present, repair wiring.

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1988 Sterling 825 S ANTI-LOCK BRAKE SYSTEM 1987-91 BRAKES Sterling - Anti-Lock Brake System

Check continuity of overvoltage protection relay pin No. 31 to ground (Black wire). If there is no continuity, repair wiring or replace relay.

TEST B Valve Relay

1. Turn system test knob to "B". If system test LED illuminates, go to TEST C . If LED does not illuminate, using a DVOM, check for continuity between battery and hydraulic modulator connector pin No. 4 (Black/Brown wire). If there is no continuity, repair wire.

2. If there is continuity, check underhood fuse "R" (30-amp). Check for continuity between hydraulic modulator connector pin No. 6 and ECU harness connector pin No. 27 (Blue/Green wire).

3. If continuity is not present, repair wiring. If continuity is present, check Yellow/Red wire between hydraulic modulator connector pin No. 10 and instrument panel "ABS" warning light. If continuity is not present, repair wiring.

4. If continuity is present, check for continuity of Yellow/Red wire between "ABS" warning light and ECU harness connector. If continuity is not present, repair wiring harness.

5. If continuity is present, check for continuity between hydraulic modulator harness connector pin No. 12 and ECU harness connector pin No. 32 (Yellow/Green wire). If continuity is not present, repair wiring harness. If continuity is present, check for continuity between hydraulic modulator harness connector pin No. 8 and ground (Black wire).

6. If continuity is not present, repair wiring harness. If continuity is present, check circuits between valve relay harness connector and hydraulic modulator connector. See VALVE RELAY CONTINUITY POINTS table. Check between valve relay connector pin No. 86 and motor relay connector pin No. 86.

See Fig. 3 . If any circuit does not have continuity, replace modulator.

VALVE RELAY CONTINUITY POINTS Valve Relay Pin No. 30 85 87 87a 86

Modulator Pin No 12 6 4 8 86

TEST C Return Pump

1. Turn system test switch to "C". System test LED light should illuminate and pump motor should operate.

If system test LED illuminates and pump motor runs, go to TEST D . If pump motor does not operate or LED does not illuminate, check for continuity between battery and hydraulic modulator harness connector pin No. 13 (Brown/Pink wire).

2. If continuity is not present, repair wire. If continuity is present, check underhood fuse "K" (50-amp). If fuse is okay, check ECU ground strap. If ECU ground strap is okay, check for continuity between Helpmelearn Repair Manuals Friday, April 14, 2006 10:01:01 AM

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1988 Sterling 825 S ANTI-LOCK BRAKE SYSTEM 1987-91 BRAKES Sterling - Anti-Lock Brake System

overvoltage protection relay harness connector pin No. 30 and hydraulic modulator harness connector pin No. 2 (Yellow/Brown wire). If continuity is not present, repair wire. If continuity is present, check for continuity between hydraulic modulator harness connector pin No. 11 and ECU harness connector pin No. 2 (Blue/White wire).

3. If continuity is not present, repair wire. If continuity is present, check between hydraulic modulator harness connector pin No. 9 and ECU harness connector pin No. 14 (Blue/Black wire). If continuity is not present, repair wire. If continuity is present, test circuit between motor relay harness connector and hydraulic modulator harness connector. See PUMP RELAY CONTINUITY POINTS table. Refer to Fig. 3 . If any circuit does not have continuity, replace hydraulic modulator.

PUMP RELAY CONTINUITY POINTS Motor Relay Pin No. 30 85 86 87 86

Hydraulic Modulator Pin No 9 11 2 13 86

TEST D Diode Forward & Reverse

1. Turn system test switch to "D". If system test LED light illuminates, go to TEST E . If LED does not illuminate, check for short circuit between pins No. 30 and 87 on valve relay. If short circuit is found, replace relay. If continuity is not present, using a DVOM, check for continuity between hydraulic modulator harness connector pin No. 8 and ground (Black wire).

2. If continuity is not present, repair wire. If continuity is present, check for open circuit between ignition switch and hydraulic modulator harness connector pin No. 10 (Light Green/Yellow and Yellow/Red wires). This circuit includes fuse No. 14 (10-amp) and "ABS" warning light.

3. If continuity is not present, repair as necessary. If continuity is present, check for continuity between hydraulic modulator harness connector pin No. 12 and ECU harness connector pin No. 32 (Yellow/Green wire). If continuity is not present, repair wire. If continuity is present, check diode in hydraulic modulator. Refer to WIRING DIAGRAMS in this article. If diode is faulty, replace modulator.

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Fig. 3: Hydraulic Modulator Testing Points Courtesy of AUSTIN ROVER GROUP. TEST E Diode Forward & Reverse

Turn system test switch to "E". Perform same test as TEST D .

TEST F Stoplight

1. Turn system test switch to "F". Depress brake pedal. If system test LED light illuminates, go to TEST G .

If LED light does not illuminate, check for continuity between fuse block and stoplight switch (Green/Purple wire). This includes stoplight switch and fuse.

2. If no problem can be found, check for continuity between stoplight switch and the ECU harness connector pin No. 25 (Green/Purple wire). This includes stoplights and bulbs. If no continuity is found during any test, repair defective wire.

TEST G Alternator Output Voltage

1. Turn system test switch to "G". If system test LED light does not illuminate, check for continuity between Helpmelearn Repair Manuals Friday, April 14, 2006 10:01:01 AM

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alternator and ECU harness connector pin No. 15 (Brown/Yellow wire). If continuity is present, check charging system and retest.

2. If LED light illuminated in step 1), start engine. Run engine at 2000 RPM and check LED light. If LED light goes off, go to WHEEL SENSOR TESTS . If the LED light stays on, perform same test as in step 1).

WHEEL SENSOR TESTS Turn all ABS Tester (Fast Check) switches to "OFF" position. Wheel sensors can be checked using ABS Tester (Fast Check).

Left Front Wheel Sensor

1. Place wheel sensor selector switch to "X" position. Turn wheel sensor switch to "Front L". If wheel sensor LED light illuminates, go to next test. If LED light does not illuminate, using a DVOM, check for continuity between ECU harness connector pins No. 4 and 5 (Red wires).

2. If continuity is not present, unplug wheel sensor connector. Check for continuity from each wire between wheel sensor connector and ECU harness connector. If continuity is not present, repair wire. If continuity is present, check wheel sensor connector. If connector is okay, replace wheel sensor.

Right Front Wheel Sensor

1. Place wheel sensor selector switch to "X" position. Turn wheel sensor switch to "Front R". If wheel sensor LED light illuminates, go to next test.

2. If LED light does not illuminate, using a DVOM, check for continuity between ECU harness connector pins No. 11 and 21 (Yellow wires). If continuity is not present, unplug wheel sensor connector. Check continuity for each wire between wheel sensor connector and ECU harness connector. If continuity is not present, repair wire. If continuity is present, check wheel sensor connector. If connector is okay, replace wheel sensor.

Left Rear Wheel Sensor

1. Place wheel sensor selector switch to "X" position. Turn wheel sensor switch to "Rear L". If wheel sensor LED light illuminates, go to next test. If LED light does not illuminate, using a DVOM, check for continuity between ECU pins No. 7 and 9 (Green wires).

2. If continuity is not present, unplug wheel sensor connector. Check continuity for each wire between wheel sensor connector and ECU harness connector. If continuity is not present, repair wire. If continuity is present, check wheel sensor connector. If connector is okay, replace wheel sensor.

Right Rear Wheel Sensor

1. Place wheel sensor selector switch to "X" position. Turn wheel sensor switch to "Rear R". If wheel sensor LED light illuminates, go to next test. If LED light does not illuminate, using a DVOM, check for continuity between ECU pins No. 24 and 26 (White wires).

2. If continuity is not present, unplug wheel sensor connector. Check continuity for each wire between wheel sensor connector and ECU harness connector. If continuity is not present, repair wire. If continuity Helpmelearn Repair Manuals Friday, April 14, 2006 10:01:01 AM

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is present, check wheel sensor connector. If connector is okay, replace wheel sensor.

Left Front Wheel Sensor Insulator

1. Place wheel sensor selector switch to "4" position. Turn wheel sensor switch to "Front L". If wheel sensor LED light illuminates, go to next test. If LED light does not illuminate, using a DVOM, check resistance between ECU harness connector pins No. 4 and 5 to ground at each Red wire.

2. If resistance is greater than 100,000 ohms, insulation is okay. If resistance is less than 100,000 ohms at either wire, unplug left front wheel sensor connector. Check resistance between each wheel sensor terminal and ground.

3. If resistance at either terminal is less than 100,000 ohms, replace wheel sensor. If resistance at both terminals was greater than 100,000 ohms, check for damaged wiring between wheel sensor and ECU. Right Front Wheel Sensor Insulator

1. Place wheel sensor selector switch to "4" position. Turn wheel sensor switch to "Front R". If wheel sensor LED light illuminates, go to next test. If LED light does not illuminate, using a DVOM, check resistance between ECU harness connector pins No. 11 and 21 to ground at each Yellow wire.

2. If resistance is greater than 100,000 ohms, insulation is okay. If resistance is less than 100,000 ohms at either wire, unplug right front wheel sensor connector. Check resistance between each wheel sensor terminal and ground.

3. If resistance at either terminal is less than 100,000 ohms, replace wheel sensor. If resistance at both terminals was greater than 100,000 ohms, check for damaged wiring between wheel sensor and ECU. Left Rear Wheel Sensor Insulator

1. Place wheel sensor selector switch to "4" position. Turn wheel sensor switch to "Rear L". If wheel sensor LED light illuminates, go to next test. If LED light does not illuminate, using a DVOM, check resistance between ECU harness connector pins No. 7 and 9 to ground at each Green wire.

2. If resistance is more than 100,000 ohms, insulation is okay. If resistance is less than 100,000 ohms at either wire, unplug left rear wheel sensor connector. Check resistance between each wheel sensor terminal and ground.

3. If resistance at either terminal is less than 100,000 ohms, replace wheel sensor. If resistance at both terminals was more than 100,000 ohms, check damaged wiring between wheel sensor and ECU. Right Rear Wheel Sensor Insulator

1. Place wheel sensor selector switch to "4" position. Turn wheel sensor switch to "Rear R". If wheel sensor LED light illuminates, go to next test. If LED light does not illuminate, using a DVOM, check resistance between ECU harness connector pins No. 24 and 26 to ground at each White wire.

2. If resistance is more than 100,000 ohms, insulation is okay. If resistance is less than 100,000 ohms at either wire, unplug right rear wheel sensor connector. Check resistance between each wheel sensor terminal and ground.

3. If resistance at either terminal is less than 100,000 ohms, replace wheel sensor. If resistance at both terminals was 100,000 ohms or more, check damaged wiring between wheel sensor and ECU. Helpmelearn Repair Manuals Friday, April 14, 2006 10:01:01 AM

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Wheel Sensor Output

1. Raise vehicle so wheels can be rotated. Place wheel sensor selector switch to "O/P" position. Turn wheel sensor switch to "Front L". Rotate wheel by hand, so wheel spins more than one revolution per second. If wheel sensor light illuminates, go to next test.

2. If LED light does not illuminate, check wheel sensor air gap. See WHEEL SENSOR under REMOVAL & INSTALLATION in this article. Check for loose or damaged wheel sensor, sensor ring or wheel bearings. Repair as necessary and retest. Test each wheel sensor using this method. Ensure wheel sensor switch is at proper position.

HYDRAULIC MODULATOR TEST Hydraulic modulator sensors can be checked using ABS Tester (Fast Check). Ensure all switches on ABS tester are in "OFF" position.

Valve Internal Resistance Test

1. Place valves selector switch in "X" position. Turn valve switch to "Front L". If valve LED light illuminates, go to next test. If LED light does not illuminate, using a DVOM, check for continuity between hydraulic modulator harness connector pin No. 1 and ECU harness connector pin No. 2 (Yellow/White wire).

2. If continuity is not present, repair wire. If continuity is present, replace hydraulic modulator. Perform same test in other 3 modes. If LED light does not illuminate in "Front R" setting, check hydraulic modulator harness connector pin No. 3 and ECU harness connector pin No. 35 (Red/White wire). In "Rear L" mode, check hydraulic modulator harness connector pin No. 5 and ECU harness connector pin No. 18 (Yellow/Black wire). In "Rear R" mode, check hydraulic modulator harness connector pin No. 7 and ECU harness connector pin No. 19 (Brown/Yellow wire).

Pressure Reduction Test

1. Ensure transmission is in Neutral and parking brake released. Place valve selector switch in "DYN" position. Turn valve switch to "Front L". Depress brake pedal. Left front wheel should be locked. If not, check master cylinder, brake caliper, pads and disc. Repair as necessary.

2. With brake pedal still depressed, push and hold "P" button. Left front wheel should start to move then lock up. Pump motor should operate. Release brake pedal. Perform same test with valve switch in each position.

3. If system fails any of these tests, check hydraulic modulator ground strap. If ground is okay, ensure brake lines from hydraulic modulator to each wheel are positioned correctly. Refer to Fig. 4 . If hydraulic modulator ground and brake lines are okay, replace hydraulic modulator.

Pressure Maintain Test

1. Ensure transmission is in Neutral and parking brake released. Turn valve switch to "Front L". Press "P=" button. Left front wheel should turn. Depress brake pedal. Left front wheel should still turn. Release "P=" button. Left front wheel should be locked.

2. Press "P=" and release brake pedal. Left front wheel should remain locked. If wheel does not remain Helpmelearn Repair Manuals Friday, April 14, 2006 10:01:01 AM

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1988 Sterling 825 S ANTI-LOCK BRAKE SYSTEM 1987-91 BRAKES Sterling - Anti-Lock Brake System

locked, check if brake lines are positioned correctly. If brake lines are positioned correctly, replace hydraulic modulator. Perform same test with valve switch in each position.

NO FAULT FOUND After all testing procedures are performed and no problem can be found, turn ignition off to reset ECU. If code reappears, check ECU ground and all connections. If everything checks okay, replace ECU.

Fig. 4: Correct Brake Line Positions Courtesy of AUSTIN ROVER GROUP.

REMOVAL & INSTALLATION WHEEL SENSOR Removal & Installation

Raise and support vehicle. Unplug wheel sensor connector. Remove wheel sensor. To install, reverse removal procedure. Adjust air gap on front wheel sensors to .012-.040" (.30-1.02 mm). Rear wheel sensor air gap is .006-.040" (.15-1.02 mm).

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1988 Sterling 825 S ANTI-LOCK BRAKE SYSTEM 1987-91 BRAKES Sterling - Anti-Lock Brake System

WIRING DIAGRAMS

Fig. 5: Anti-Lock Brake System Wiring Diagram

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1988 Sterling 825 S BRAKE SYSTEM BRAKE SERVICING Hydraulic Brake Bleeding

BRAKE SYSTEM BRAKE SERVICING Hydraulic Brake Bleeding

DESCRIPTION Hydraulic system bleeding is necessary any time air has entered into the system. Bleeding may be done manually or by using pressure bleeding equipment. Bleed brakes at all 4 wheels if master cylinder has run dry, been replaced or if hydraulic system has be overhauled or repaired.

CAUTION: For vehicles equipped with ABS, see appropriate ANTI-LOCK BRAKE SYSTEM article in this section.

BLEEDING PRECAUTIONS 1. On all models equipped with diagonal split hydraulic system, bleed either rear wheel first, then opposite front wheel. Repeat procedure on the other side.

2. On all models equipped with load sensing proportioning valve, bleed valve prior to bleeding brakes. If master cylinder is equipped with bleed screw, bleed master cylinder first.

MANUAL BRAKE BLEEDING 1. On all models, exhaust all vacuum from power unit by depressing brake pedal several times.

2. Fill master cylinder. Install clear vinyl bleeder hose onto first bleeder valve to be serviced. See BRAKE LINE BLEEDING SEQUENCE table in this article. Place other end of hose in clean transparent container.

3. Partially fill container with clean brake fluid so end of hose is submerged in brake fluid. Open bleeder valve 1-2 turns. Slowly depress brake pedal through its full travel.

4. Close bleeder valve and release pedal. Pump pedal several time to push air toward wheel cylinders.

Repeat procedure until flow of brake fluid is clear and shows no sign of air bubbles. Proceed to next bleeder valve and repeat procedure.

NOTE:

Check fluid level in master cylinder frequently during the bleeding process to ensure master cylinder does not empty during the bleeding.

PRESSURE TANK BLEEDING 1. On all models, exhaust all vacuum from power unit by depressing brake pedal several times.

2. Clean the master cylinder cap and surrounding are, then remove cap. With pressure tank at least 1/2 full, connect tank to the master cylinder using proper adapter(s).

3. Attach bleeder hose to first bleeder valve to be serviced. See BRAKE LINE BLEEDING SEQUENCE table in this article. Place other end of hose in clean transparent container. Partially fill container with clean brake fluid until end of hose is submerged in fluid.

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1988 Sterling 825 S BRAKE SYSTEM BRAKE SERVICING Hydraulic Brake Bleeding

4. Open release valve on pressure bleeder. Open bleeder valve 1-2 turns, noting fluid flow. When fluid flowing into container is clear and free of bubbles, close bleeder valve securely.

5. Finish bleeding system in the same manner using correct sequence. Remove pressure tank from master cylinder and check fluid level of master cylinder.

BRAKE LINE BLEEDING SEQUENCE BRAKE LINE BLEEDING SEQUENCE Application Sterling

Sequence LF, RR, RF, LR

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© 2004 Mitchell Repair Information Company, LLC.

1988 Sterling 825 S 1988 BRAKE SYSTEM Disc - Sterling

1988 BRAKE SYSTEM Disc - Sterling

DESCRIPTION Hydraulic disc brakes are used on all 4 wheels. Cable operated parking brake system is connected to rear calipers. Vacuum assisted power brake unit reduces driver effort to stop vehicle. On models not equipped with Anti-Lock Brake System (ABS), a twin pressure conscious reducing valve is used. If there is an internal failure within the system, brake fluid will seep from plug on this valve. See Fig. 1 .

Fig. 1: View of Twin Pressure Conscious Reducing Valve Courtesy of AUSTIN ROVER GROUP.

ADJUSTMENTS PARKING BRAKE 1. Raise rear of vehicle and support. Release parking brake. Remove caliper cover. Measure distance between lever and stop (both sides). See Fig. 2 .

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1988 Sterling 825 S 1988 BRAKE SYSTEM Disc - Sterling

2. If clearance is not .020-.080" (.51-2.0 mm), remove parking brake lever cover. Turn adjusting nut until specified clearance is obtained. With parking brake applied, pump brake pedal several times.

Fig. 2: Measuring Parking Brake Cable Courtesy of AUSTIN ROVER GROUP.

REMOVAL & INSTALLATION DISC BRAKE CALIPER & PADS Removal & Installation (Front)

1. Raise front of vehicle and support. Unplug disc brake pad wear connector. Remove lower caliper guide pin bolt. Raise disc brake caliper upward. Remove disc brake pads and shims. Remove upper caliper guide pin bolt.

2. If only replacing pads, open bleeder screw. Compress caliper piston. If removing caliper, disconnect brake lines and plug openings. Remove caliper. Check pad thickness, including backplate and excluding shims. See DISC BRAKE PAD THICKNESS table. To install, reverse removal procedure. Bleed brake system.

DISC BRAKE PAD THICKNESS (1)

Application Front New Minimum Rear New Used (1)

In. (mm)

.685 (17.40) .322 (8.18) .570 (14.48) .283 (7.19)

Measurement should include backplate and exclude shims.

Removal & Installation (Rear)

1. Raise rear of vehicle and support. Remove rear wheel. Unplug disc brake pad wear connector. Remove Helpmelearn Repair Manuals Friday, April 14, 2006 10:01:23 AM

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Š 2004 Mitchell Repair Information Company, LLC.

1988 Sterling 825 S 1988 BRAKE SYSTEM Disc - Sterling

rear disc brake caliper guide bolts. Remove caliper out of way. Remove disc brake pads.

2. If only replacing pads, open bleeder screw. Compress caliper piston. If removing rear caliper, remove caliper cover. Remove parking brake cable clevis pin. Remove clip retaining cable. Remove brake line from caliper and plug all openings. Remove caliper from vehicle.

3. To install, reverse removal procedure. Bleed brake system. Adjust parking brake cable (if necessary).

DISC BRAKE ROTOR Removal & Installation

Remove disc brake pads. Remove 2 screws retaining rotor on hub. Remove disc brake rotor. To install, reverse removal procedure.

POWER BRAKE UNIT Removal & Installation

1. Remove master cylinder. Plug all line openings. Disconnect vacuum hose from power brake unit.

Remove bolts retaining vacuum control box. Remove servo seal from closing panel on driver's side.

2. Remove clevis pin. Remove nuts retaining power brake unit. Remove power brake unit. To install, reverse removal procedure. Ensure "O" ring between master cylinder and power brake unit is replaced.

OVERHAUL FRONT DISC BRAKE CALIPER Disassembly & Reassembly

1. Remove front disc brake caliper. Place a piece of wood between piston and caliper carrier. DO NOT place fingers between wood and piston.

2. Apply low pressure air to brake line hole. Remove piston, seal and boot. To reassemble, reverse disassembly procedure. Apply clean brake fluid to piston, inside caliper bore and seal.

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1988 Sterling 825 S 1988 BRAKE SYSTEM Disc - Sterling

Fig. 3: Exploded View of Front Disc Brake Caliper Courtesy of AUSTIN ROVER GROUP. REAR DISC BRAKE CALIPER

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1988 Sterling 825 S 1988 BRAKE SYSTEM Disc - Sterling

Fig. 4: Exploded View of Rear Disc Brake Caliper Courtesy of AUSTIN ROVER GROUP. Disassembly & Reassembly

Remove rear disc brake caliper. Wash caliper with denatured alcohol. Using Wrench (18G 1534), rotate piston counterclockwise and remove from caliper. Remove seal. To reassemble, reverse disassembly procedure. Using wrench, install piston until it bottoms. Ensure boot is not pinched.

MASTER CYLINDER Disassembly & Reassembly

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1988 Sterling 825 S 1988 BRAKE SYSTEM Disc - Sterling

Remove master cylinder. Remove reservoir from master cylinder. Remove snap ring. Disassemble remaining components. To reassemble, reverse disassembly procedure.

TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS Application Brake Line Banjo Bolt Brake Line Union Nut W/ABS W/O ABS Caliper Bracket Bolt Caliper Guide Pin Bolt Master Cylinder Retaining Nut Power Booster Retaining Nut Wheel Lug Nut

Ft. Lbs. (N.m) 26 (35) 16 (22) 10 (14) 55 (75) 24 (33) 18 (25) 18 (25) 53 (72) INCH Lbs. (N.m) 88 (10) 88 (10) 106 (12)

Bleeder Screw Caliper Cover Bolt Rotor Retaining Screw

DISC BRAKE ROTOR SPECIFICATIONS DISC BRAKE ROTOR SPECIFICATIONS Application Sterling 825 Disc Diameter.

Front Rear Lateral Runout Front Rear Parallelism Front Rear Original Thickness Front Rear Min. Refinish Thickness Front

In. (mm)

11.22 (285.0) 10.23 (260.0) .003 (.08) .0006 (.15) .0006 (.015) .0006 (.015) .827 (21.0) .393 (9.98) .748 (18.99)

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1988 Sterling 825 S 1988 BRAKE SYSTEM Disc - Sterling

Rear Discard Thickness Front Rear

.314 (7.98) .747 (18.97) .313 (7.95)

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1988 Sterling 825 S ELECTRICAL COMPONENT LOCATOR 1988 ELECTRICAL COMPONENTS LOCATIONS Sterling - Electrical Components

ELECTRICAL COMPONENT LOCATOR 1988 ELECTRICAL COMPONENTS LOCATIONS Sterling - Electrical Components

BUZZERS, RELAYS & TIMERS BUZZERS, RELAYS & TIMERS LOCATION Component Location ABS Return Pump Relay Mounted at hydraulic modulator. See Fig. 1 .

ABS Solenoid Valve Relay Mounted at hydraulic modulator. See Fig. 1 .

A/C Clutch Relay In front corner of right front fender. See Fig. 2 .

A/C Fan Changeover Relay In engine compartment fuse/relay block. See Fig. 3 .

Blower Motor Relays Mounted to bottom of blower motor housing. See Fig. 4 .

Cooling Fan Relay In engine compartment fuse/relay block. See Fig. 3 .

Electric Window Relay In relay panel, next to interior fuse block. See Fig. 5 .

Main Relay/Fuel Pump On left side of steering wheel, behind dash. See Fig. 6 .

Relay Overvoltage Protection Relay In trunk, beside ABS control unit. See Fig. 7 .

Sidelight Relay In relay panel, next to interior fuse/relay block. See Fig. 5.

Wiper Motor Relay In relay panel, next to interior fuse/relay block. See Fig. 5.

Wiper Timer Mounted under interior relay panel.

CIRCUIT PROTECTION DEVICES CIRCUIT PROTECTION DEVICES LOCATION Component Location Fuse/Relay Block Engine Compartment On left fender. See Fig. 3 .

Interior Below steering column, behind cover.

CONTROL UNITS CONTROL UNITS LOCATION Component ABS Control Unit Anti-Theft Control Unit Central Locking Control Unit Cruise Control Unit Door Relay Module

Location In trunk, behind left side panel. See Fig. 7 .

In center console, above ashtray. See Fig. 8 .

Mounted above steering column.

On left kick panel, behind interior fuse/relay block.

Mounted in both rear doors.

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1988 Sterling 825 S ELECTRICAL COMPONENT LOCATOR 1988 ELECTRICAL COMPONENTS LOCATIONS Sterling - Electrical Components

Electronic Control Unit (ECU) Fuel Injection Control Unit Ignition Module Remote Door Lock Receiver Unit Vehicle Condition Monitor

Under passenger's seat.

Under driver's seat.

Mounted to side of distributor.

In headliner, adjacent to rear view mirror.

Under passenger's seat.

SENDING UNITS & SENSORS SENDING UNITS & SENSORS LOCATION Component Location ABS Speed Sensor Mounted at each wheel.

Atmospheric Pressure Sensor Mounted beside ECU, under passenger's seat.

Constant Vacuum Control Inside control box, mounted on firewall. See Fig. 10 .

Sensor Coolant Temperature Sensor Below and behind distributor.

Crank Angle Sensor On front of cylinder heads, behind camshaft sprocket. See Fig. 11 .

EGR Position Sensor Mounted on top of EGR valve.

Idle Mixture Adjustment Inside control box, mounted on firewall. See Fig. 10 .

Sensor Intake Air Temperature On front side of throttle body. See Fig. 12 .

Sensor Low Oil Level Sensor Mounted to oil pan.

Manifold Air Pressure Sensor Inside control box, mounted on firewall. See Fig. 10 .

Oxygen Sensor In both exhaust manifolds.

Throttle Position Sensor Mounted on firewall side of throttle body. See Fig. 12 .

MOTORS MOTORS LOCATION Component Forward & Backward Seat Motor Fresh/Recirculated Air Motor Heater Distribution Motor Heater Control Mode Motor Lumbar Adjustment Motor Seat Backrest Motor Seat Cushion Front Height Motor

Location Under seat cushion, in middle of seat.

Mounted on side of blower motor housing. See Fig. 4 .

Mounted on side of air blend assembly. See Fig. 9 .

Mounted on front face of air blend assembly. See Fig. 9.

In center of backrest.

In lower portion of backrest.

Under front portion of seat cushion.

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1988 Sterling 825 S ELECTRICAL COMPONENT LOCATOR 1988 ELECTRICAL COMPONENTS LOCATIONS Sterling - Electrical Components

Seat Cushion Rear Height Motor

Under front portion of seat cushion.

SOLENOIDS & SOLENOID VALVES SOLENOIDS & SOLENOID VALVES LOCATION Component Location Air Suction Control Solenoid Valve Inside control box, mounted on firewall. See Fig. 10 .

Converter Lock-Up Solenoid Mounted in transaxle, to valve body.

EGR Control Solenoid Valve Inside control box, mounted on firewall. See Fig. 10 .

Idle Control Valve On firewall side of throttle body. See Fig. 12 .

Ignition Control Solenoids Inside control box, mounted on firewall. See Fig. 10 & Fig. 13 .

Pressure Regulator Control Cut-Off Inside control box, mounted on firewall. See Solenoid Valve Fig. 10 .

SWITCHES SWITCHES LOCATION Component A/C Dual Pressure Switch A/C High Pressure Switch A/C Cooling Fan Switch Back-Up Light Switch Coolant Vacuum Control Switch Inertia Switch Low Coolant Switch Neutral Safety Switch (A/T) Power Steering Switch Radiator Cooling Fan Switch

Location In A/C line, next to receiver-dryer.

In A/C line, next to dual pressure switch.

Mounted below radiator cooling fan switch.

Mounted on transaxle.

Mounted on front face of air blend assembly. See Fig. 9.

Behind center console, near main relay.

Mounted on top of coolant fill reservoir.

Mounted on side of shifter.

Mounted in pressure line.

Mounted on radiator, below upper hose.

MISCELLANEOUS MISCELLANEOUS LOCATION Component Location A/C Amplifier Mounted on side of blower motor housing. See Fig. 4 .

Anti-Theft Diode Pack On relay bracket, of interior fuse /relay block.

Anti-Theft Speaker On left side firewall, behind cover. See Fig. 2 .

Blower Motor Speed Mounted to bottom of blower motor housing. See Fig. 4 .

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1988 Sterling 825 S ELECTRICAL COMPONENT LOCATOR 1988 ELECTRICAL COMPONENTS LOCATIONS Sterling - Electrical Components

Resistor Coolant Thermistor Door Lock Actuators Flasher Fuel Flow Interface Fuel Pump Heater Control Amplifier Heater Fan Speed Interface Radio Aerial Amplifier Radio Power Amplifier Radio Noise Condenser

In coolant passage, adjacent to distributor.

Mounted in rear portion of all doors.

On right side of steering column, behind fuse/relay block cover.

Under passenger seat.

Inside fuel tank.

Mounted to bottom of air blend assembly. See Fig. 9 .

Mounted on front face of air blend assembly. See Fig. 9 .

Mounted behind rear seat backrest.

Behind right trunk side panel.

Mounted at control box, near ignition coil. See Fig. 13 .

COMPONENT LOCATION GRAPHICS NOTE:

Figures may show multiple component locations. Refer to appropriate table for proper figure references.

Fig. 1: Component Locations (1 Of 13) Helpmelearn Repair Manuals Friday, April 14, 2006 10:02:41 AM

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