Repair Instructions
STEP A - 5-1/2" Speaker Installation (M81-1/2 - M83 3-dr. Turbos).
1. Remove the four 90~ quick fasteners from the top and forward edge of both rear armrest panels and pull panel away from car body. It is not necessary to disturb the seat belt mounts or completely remove the panels.
2. Cut and remove the 5" circle from the template (P/N 02-61-578) that has been provided.
3. Align the template with the quick fastener holes number 2 and 3. The template may be held in place with the quick fasteners. Trace the outline of the speaker hole to be cut out onto the side panel.
4. Using a hole starter, make a pilot hole just inside the circle, at the top (see diagram).
5. Install a block (approx. 2" x 4") between the inside of the panel and the body sheet metal at the area of quick fastener no. 2. This will prevent sheet metal damage when cutting the panel.
6. Cut out the traced hole with a hand held jig or sabre saw. Select a saw with a low speed feature and begin at the pilot hole, making a semicircular cut to the left and right of the pilot hole.
NOTE! Extreme care must be taken to prevent panel damage while cutting the hole. Use a slow speed setting on the saw.
7. Disconnect the speaker wires from the 4" speakers, untape them from behind the trunk lining and bring forward to the newly cut holes, behind the panels. It may be necessary to pull away some of the sound insulation from behind the passenger trunk lining to gain access to the speaker wires.
8. Position the new 5-1/4" speaker/grille combination to the holes and attach them with the four screws and speed nuts provided.
9. Attach the speaker wires and test speakers.
10. Remove spacer block, re-position panel and install quick fasteners.
11. Vacuum all panel dust.
STEP B - Radio grounds, amp cables, antenna cable and noise suppression (M82-1/2- and 4-dr. Turbos)
Part I: Remove the following - Radio, lay on too of dash
- Door sill plates, 2 for 3-dr, 4 for 4-dr. sedans
- Vertical carpet retaining strips just ahead of front doors and the lower front part of the weatherstripping
- Section of trunk floor above spare tire
- Driver's side trunk lining
- Pull driver's side rear armrest panel away from body (3-dr. only)
- Driver's side front speaker grille
Part II: Improving radio grounds
1. Unscrew the single Phillips screw and remove the square RCA ground plate from the radio chassis. Using a pair of diagonal cutters, crimp the ground plate along the top and bottom edges about 3 mm in, just enough to make definite ground contact between the plate and the RCA cable shields. Reinstall the plate to the radio making sure the screw is tight.
WARNING! Applying too much pressure or crimping too close to the edges of the plate will cause damage to the RCA cables.
2. Cut the radio chassis ground wire from the radio side of the T power plug (cut at the plug) and connect it using the provided large ring terminal to the stud at the rear of the radio chassis. (NOTE! Early cars [before Feb. 1983] have extra ground wire. It is not necessary to fabricate the ring terminal connection.) Run the new ground wire provided in kit from the stud at the rear of the radio chassis to the ground buss bar on the beam behind the instrument cluster. NOTE:
Remove any existing non-stock ground connections held together with "Scotch-Lok" connectors.
3. If so equipped, remove and discard the plug-in in-line fuse between the blue radio antenna trigger and the green car trigger wires.
4. Install the new 10" speaker jumper lead between the front-to-rear speaker harness and front speaker leads. Discard old jumper wire.
Part III: Installing new RCA cables
1. Cut and remove as much of the original RCA phono cables in the car as possible, both in the dash and under the rear seat. New RCA cables will be installed. This will prevent any future wiring confusion.
2. Mark one set of the new RCA cables at both ends with some type of identifying tag such as tape. Install both sets of RCA cables by passing them down along the firewall just to the right of the radio opening. Reach your hand up between the knee pad and the firewall and pull both sets of cables down. Connect the radio end of the RCA cables to the radio, connecting the flagged pair to the rear channel, so they don't fall into the dashboard. Pass the cables under the carpet and run them under the rear seat support beam and connect the flagged pair of cables to the bottom or rear amp. Connect the unmarked set of cables to the top or front amp.
3. Using the small ring terminals and star washer provided, ground the two amplifier grounds separately to the two amplifier bracket mounting screws.
Part IV: Antenna Cable installation
1. Cut and remove as much of the original antenna extension cable as possible.
2. Install the new antenna cable by passing the female end down along the firewall to the left of the radio opening. Reach your hand up behind the accelerator pedal and pull the cable down. NOTE:
Be careful to route the cable in such a way that it will not interfere with the operation of the accelerator pedal. Pass the antenna lead under the carpet along the driver's side door sills under the rear seat support beam and fasten under the clips along the left rear wheelhouse. Feed the cable through the hole in the inner fender along with the rest of the car harness. Connect the antenna to the lead.
Part V: Ignition noise suppression
1. Start the engine, turn the radio on at low volume and listen for ignition noise and alternator whine. If alternator whine is still present, check the battery-to-chassis, chassis-to-transmission and alternator-to-chassis grounds. If ignition noise is still present, inspect ignition wires, distributor cap, rotor and coil connections and spark plug condition and gap. If all are in order, install an ignition noise suppressor as follows:
1982 Models
By following the preceding noise reduction instructions it is unlikely that any further noise suppression is necessary. NOTE: 1982 models may already have an ignition noise suppressor installed in the fuse box according to S.I. 12/82-605, Radio Ignition Noise Suppression, M81-83 (S.I. Supplement No. 3). If so, do not disturb it.
1983 Models
a. Disconnect the negative battery terminal.
b. Remove & discard original port installed suppressor if vehicle is so equipped.
c. Fasten the new suppressor (P/N 02-57-758) to the left inner fender (driver's side) above the charcoal canister and forward of the ignition system electronic control unit. Push the two suppressor
mounting studs through the two 4 mm holes* in the body, oriented so that the plate is flush against the fender panel. Fasten from the end side with two nuts and star washers provided.
d. Run the green/white lead from the suppressor through the large opening in the inner fender, along the coolant expansion hose, under the hood hinge and along the wiring harness to the ignition coil. Fasten securely with nyloc tie straps provided. Check for hood hinge clearance.
e. Carefully pull back the rubber boot from the coil. Disconnect the single green/white lead from the (+) coil terminal.
f. Attach the green/white lead from the suppressor to the coil terminal and connect the lead disconnected in Step d to the piggyback spade on the end of the suppressor lead.
*Holes are found on all M82-83 models. Used on M82 to mount APC pressure transducer.
g. Refit the rubber boot and reconnect the battery.
NOTE: You may find it easier to remove the coil to perform steps d-f.