Step D, Step E, Step F & Step G
STEP D. Install rear window defogger time limiter kit (all).1. Disconnect battery.
2. Replace the dash switch for the defogger with the one provided in the kit.
3. Unfasten and lift the fuse/relay panel board out of the distribution box to gain access to wiring underneath.
4. Remove existing defogger relay. (There is one open position in the socket center.)
5. Install jumper P/N 85-84-609 in the open relay socket. Connect the remaining end to the fourpole positive terminal in the rear center of the panel board (use a piggy-back connector if necessary). Most 1983 models will have this wire installed. If so, discard the jumper provided in kit.
6. Install the new relay, P/N 85-84-583.
7. Connect the battery.
8. Turn on defogger and check relay, function. System should switch off in 10 +/- 1 minutes, maximum, engine off. (Note: Operating cycle may be as short as 3 minutes, depending on available voltage. When operating the indicator lamp in the instrument cluster will glow. Once engaged, the switch cannot be used to interrupt the operating cycle.)
STEP E. Replace voltage regulator with special regulator for improved high temperature charging.
1. Disconnect battery.
2. Remove existing regulator (Bosch 1-197311009) from the alternator (this can be accomplished in the car with just a screwdriver).
3. Install special regulator (Bosch 1-197311008). (Make sure that the same number of washers are reinstalled under the screw heads as were removed.) Tighten screws firmly.
4. Connect battery.
5. Start engine to see that charge light is extinguished indicating the alternator is charging.
NOTE: Bosch regulator 1 197311008 is to be used both in upgrading the original 70 amp. alternator ("Level 1" modification) and on the replacement 80 amp. alternator ("Level 2" modification).
STEP F. Check AC idle compensation valve function and idle speed setting, AC off (all).
1. Check and set engine idle speed to 875 +75, -0 rpm with AC and all other accessories off, transmission in neutral or park.
2. Engage AC and note idle speed.
3. Disconnect lead wire to AC fast idle solenoid - idle speed should drop noticeably and increase when solenoid is reconnected.
STEP G. Replace 70 amp. alternator with 80 amp. alternator (special voltage regulator included with the new unit) and install long/short twin belt drive system included with new unit).
1. Disconnect battery.
2. Remove AC compressor and bracket as an assembly and move to right side of engine. DO NOT DISCHARGE AC SYSTEM.
3. (This step is optional.)
Drain coolant. Disconnect both heater hoses from heater valve and fold aside to gain access to alternator.
4. Remove existing alternator, mounting bracket and adjusting stay. (It may be necessary to remove the oil filter canister to gain access to the front mounting bracket bolt.) NOTE: 70 A. alternator is a warranty return part.
5. Assemble the new mounting bracket to the 80 amp. alternator. (Use spacer sleeve supplied in kit.)
6. Install additional pulley on water pump using the spacer (between pulleys) and the bolts provided.
7. Replace the terminals on the B+ and D+ (if required) leads with the terminals provided in the kit. Use a good crimping tool.
8. Install the alternator on the engine.
9. Install the new adjusting stay, bushings, bolt and the new adjusting bolt. Install the remaining spacer sleeve in the alternator boss along with the adjusting bolt.
10. Reinstall AC compressor and bracket.
11. Place the two new V-belts in position on the pulleys - the long one nearest the engine. The short one (helper) spans from the new (outboard) pulley on the water pump to the alternator. Reinstall power steering and air conditioner belts. Tension all belts.
12. Connect all wires to the alternator. Use cap screw and washer in kit to connect ground wires to alternator case (don't forget alternator to bracket ground wire!). Ensure that all wires have sufficient slack and that the B+ and D+ wires are not pinched (see S.I. 12/82-600, Sec. 3).
13. Reconnect heater hoses, refill cooling system and reconnect battery.
14. Start engine and check operation of charging system.
Tensioning the belts properly is important. The short belt will be noticeably looser than the long (inner) belt when initial tension is applied. Increase tension until the short belt is properly tightened. This will compensate for the greater initial stretch of the long belt during run in. After road testing, retension belts again before delivering car to customer.