11OO 2,3,1 Mk Mk 3OO 1,2,3, America 1968-T 4 Autobook

By KennethBall
A s s o c i a t M e m b e rG u r l do f M o t o r i n o r i t e r s e . W a n d t h e A u t o p r e sT e a mo f T e c h n i c a l - W r i t e r s s

Austin, Morris 100 Mk2,3, 968 1 1 -73 Austin, Morris 1300 1, Mk 2,3,GT 968-74 1 AustinAmerica 1968-72 M . G .10 0 M k 2 , 1 0 0M k1, 2 , 3 ,9 6 8 - 7 1 1 3 1 Rifey 100 Mk2,1 Mk1,2,1968-69 1 300 Vanden-Plas Princess Mk2,1300 1100 1968-74 Wolseley 00 Mk2,1 Mk'1 11 300 968-73 ,2,3,1

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Autopress Ltd.Golden LaneBrighton 2QJ England BN1

T h e A U T OB O OK s e r i e s f W o r k s h o p a n u a l s o M i s t h e l a r g e s ti n t h e w o r l d a n d c o v e r st h e m a j o r i t y f B r i t i s h n d C o n t i n e n t a l o t o rc a r s , o a m a s w e l l a s a l l m a j o rJ a p a n e s e n d A u s t r a l i a n a m o d e l s .F o r a f u l l l i s t s e e t h e b a c k o f t h i s manual.

CONTENTS lntroduction Acknowledgement C h a p t e1 r 2 Chapter 3 Chapter 4 Chapter C h a p t e5 r 6 Chapter C h a p t e7 r 8 Chapter Chapter 9 Chapte10 r 1 Chapter 1 Chapte12 r Appendix TheEngine The FuelSystem The lgnitionSystem The CoolingSystem TheClutch T Automatic ransmission The DriveShaftsand Suspension Gear The Steering TheBraking ystem S System The Electrical TheBodywork 145
2tr

49
65

61 l9 91 105 111 121

Transmission 6 1 The Synchromesh

tsBN 0 85147481 0 F i r s tE d i t i o n 1 9 7 0 Reprinted 1971 S e c o n d E d i t i o n ,f u l l y r e v i s e d 1 9 7 1 T h i r d E d i t i o n ,f u l l y r e v i s e d 1 9 7 2 Reprinted 1972 F o u r t h E d i t i o n ,f u l l y r e v i s e d 1 9 7 3 R e p r i n t e d 19 7 3 F i f t h E d i t i o n ,f u l l y r e v i s e d 1 9 7 4 Reprinted 1974 OAutopress Ltd 1974 All rights reserved.No part of this publication may be r e p r o d u c e d , s t o r e d i n a r e t r i e v a ls y s t e m , o r t r a n s m i t t e d i n any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior p e r m i s s i o no f A u t o p r e s s L t d .

Printedand bound in Brighton Englandfor AutopressLtd by G Beard & Son Ltd

ACKNOWLEDGEMENT Ltd for their Mv thanks are due to The British Leyland Motor Corporation d a n d a l s of o r s u p p l y i n g a t aa n d i l l u s t r a t i o n s . c unstintedo-operation h w o a lu I a m a l s og r a t e f u l t o c o n s i d e r a b ne m b e r f o w n e r s h o h a v ed i s c u s s etd e i r i ha a c a r s t l e n l t n a n dm a n yo f w h o s es u g g e s t i o n s v eb e e ni n c l u d e dn t h i sm a n u a l . KennethBall MembelGuild of MotoringWriters Associate E Ditchling ussex ngland. S

INTRODUCTION w W This do-it-yourself orkshopManual has beenspecially rittenfor the owner w h o w i s h e s t o m a i n t a i nh i s c a r i n f i r s t c l a s sc o n d i t i o na n d t o c a r r y o u t h t s o w n . e s e r v i c i n g n d r e p a i r s C o n s r d e r a b ls a v i n g so n g a r a g ec h a r g e sc a n b e m a d e ,a n d a one can drive in safety and confidenceknowing the work has !;ecn done propefly. a a s C o m p r e h e n s i v e t e p - b y - s t e pi n s t r u c t i o n s n d i l l u s t r a t i o n s r e g i v e n o n a i i d i s r m a n t l i n g , o v e r h a u l i n ga n d a s s e m b l i n go p e r a t i o n s .C e r t a i n a s s e m b l i e s e q u i r e s t h e u s e o f e x p e n s i v e p e c i a lt o o l s ,t h e p u r c h a s eo f w h i c h w o u l d b e u n j u s t i f i e d . t l n t h e s e c a s e si n f o r m a t i o ni s i n c l u d e d b u t t h e r e a d e ri s r e c o m m e n d e d o h a n d the unit to the agentfor attention. Throughout the Manual hints and tips are included which will be found i n v a l u a b l e , n d t h e r e i s a n e a s y t o f o l l o w f a u l t d i a g n o s i sa t t h e e n d o f e a c h a chapter. W h i l s t e v e r v c a r e h a s b e e n t a k e n t o e n s u r e c o r r e c t n e s so f i n f o r m a t t o n i t i s o b v i o u s l y n o t p o s s i b l e t o g u a r a n t e e c o m p l e t e f r e e d o m f r o m e r r o r so r t o a c c e p t l i a b i l i t ya r i s i n gf r o m s u c h e r r o r so r o m i s s i o n s . l n s t r u c t i o n sm a y r e f e r t o t h e r i g h t h a n d o r l e f t h a n ds i d e s o f t h e v e h i c l e o r t h e c o m p o n e n t s .T h e s e a r e t h e s a m e a s t h e r i g h t h a n d o r l e f t h a n d o f a n o b s e r v e r s t a n d i n gb e h i n d t h e c a r a n d l o o k i n g f o r w a r d .

CHAPTER 1 THE EIUGINE

1 1 1 1 1 1 1 1
1 1 1 1 1

: : : : : : : :

1 2 3 4 5 6 7 8

:9 :10 :11 :12 :13

Description Removing engine and synchromesh gearbox Removing engine and automatic transmission Removing and refitting the cylinder head Servicing the head and valve gear Servicing the valve timing gear Servicing the camshaft Removing and replacing the flywheel and clutch Removing the f lywheel housing Removing the synchromesh transmission Servicing the crankshaft primary gear Pistons and connecting rods. 1098cc engine Crankshaft and main bearings. Synchromesh gearbox

1 : 1 4 Flywheel starter ring. Synchromesh gearbox 1 : 1 5The oil pump. Synchromesh gearbox 1 : 1 6L u b r i c a t i o n . O i l f i l t e r a n d r e l i e f v a l v e 1 : 1 7 Crankcase emission control : 1 8 Valve timing : 1 9 Reassembling the engine : 2 Q Valve rocker adjustment : 2 1 Operations affected by automatic :22 :23 :24 :25 :26
transmission Speciaf operations on 1275 cc engine Oil control piston rings Exhaust emission control Engine steady rod Fault diagnosis

1 :1 Description T h e e n g i n e sf i t t e d t o t h e c a r s c o v e r e d b y t h i s m a n u a l are produced in severalversionsaccording to engine c a p a c i t y ,c a r b u r e t t e i n s t a l l a t i o n n d t r a n s m i s s i o ny p e r a t . a u t o m a t i co r s y n c h r o m e s h I n a l l c a s e st h e e n g i n e i s c o n s t r u c t e d i n u n i t w i t h t h e t r a n s m i s s i o ns y s t e m a n d i n t h r s chapter mention will be made only of those operations a f f e c t i n gt h e e n g i n e .W h e r e t h e t y p e o f t r a n s m i s s i o n y s t e m s requiresa different procedure the operationswill be c o v e r e d u n d e r a p p r o p r i a t eh e a d i n g s . T h e e n g i n ea n d t r a n s m i s s i o n n i t i s s h o w n i n t w i n c a r u f b u r e t t e r o r m r n t h e s e c t i o n av i e w o f F I G 1 : 1 . T h e e n g i n e l i s a f o u r - c y l i n d e ru n i t o f e i t h e r 1 0 9 8 o r 1 2 7 5 c c c a p a c i t y w i t h o u s h r o d o D e r a t e do v e r h e a d v a l v e s a n d r s m o u n t e d t r a n s v e r s e l ya c r o s s t h e f r o n t o f t h e c a r , d r i v i n g t h e f r o n t w h e e l s t h r o u g h t w o s h o r t d r i v i n g s h a f t s . D e t a i l so f t h e b o r e s i z e , s t r o k e a n d c o m p r e s s i o n r a t r o sw i l l b e f o u n d i n T e c h n i c a lD a t a a t t h e e n d o f t h e m a n u a l . T h e v a l v e s , e t i n l i n e i n t h e l e f t h a n ds i d e o f t h e c y l i n d e r s head, have oil seals fitted to the stems and are given c l e a r a n c e d j u s t m e n tb y a n a d l u s t a b l e c r e w a n d l o c k n u t a s

i n t h e r o c k e r a r m . T h e c a m s h a f t ,r u n n i n g i n t h r e e w h i t e m e t a l b e a r i n g s ,i s d r i v e n b y c h a i n f r o m t h e c r a n k s h a f tw i t h s y n t h e t r cr u b b e r r i n g s a c t i n g a s c h a i n s i l e n c e r s n d t e n a s i o n e r s .T h e o i l p u m p i s d r i v e n f r o m t h e o t h e r e n d o f t h e camshaft and also the distributor through a transverse shaft. The pistons have three compression rings and one s l o t t e do i l c o n t r o l r i n g . G u d g e o n p i n s a r e f u l l y f l o a t i n g i n i t h e 1 0 9 8 c c e n g i n e ,a n d p r e s s e d n t o t h e s m a l l e n d o f t h e c o n n e c t i n g r o d i n t h e 1 2 7 5 c c e n g i n e .T h e c o n n e c t i n g r o d b e a r i n g sa r e s t e e l - b a c k e d h e l l sw i t h l e a d / i n d i u mo r s l e a d / t i nl i n i n g s . d T h e o i l s u p p l y f o r t h e e n g i n e ,g e a r s a n < J i f f e r e n t i a il s carried in the transmission case below the crankcase whence it is drawn by the rotary oil pump at the rearend o { t h e c r a n k c a s ea n d d e l i v e r e dt o a f u l l f l o w e x t e r n a lf i l t e r , t a n d o n t h r o u g h d r i l l e dp a s s a g e s o t h e m a i n , b i g - e n d a n d camshaft bearings. The overhead valve gear is fed at r e d u c e d p r e s s u r ef r o m t h e f r o n t c a m s h a f t b e a r i n g , t h e o t l r e t u r n i n g o t h e s u m p d o w n t h e p u s h r o dh o l e s ,l u b r i c a t i n g t the tappets on the way.

1100Mk21300

FIG 1:1

unit (twin carburetter versron) Cutaway view of engine and transmission

.,,,

Removing the engine and automatic transmission. components

to be released irom below the car

The cylinderwalls are supplied with oil through jet h o l e s i n t h e c o n n e c t i n gr o d s . Many of the servrcing operatjons which become n e c e s s a r yn n o r m a lu s e m a y b e c a r r j e d u t w i t h t h e e n g i n e i o i n p o s i t i o na s w i t h c o n v e n t i o n a l a y o u t s ,b u t w h e n a c i e s s i s r e q u i r e dt o t h e b o t t o m e n d o f t h e e n g i n e i t b e c o m e s n e c e s s a r t o r e m o v et h e c o m p l e t ee n g i n ea n d t r a n s m i s s i o n y assemblyrom the car and the procedure or thisdepends f f upon the type of transmission sed. u Removing engine and synchromesh gearbox B e f o r e c o m m e n c i n g o n t h i s o r a n y o t h e r o p e r a t i o ni t may not be out of place to remind the lessexperienced h o m e o p e r a t o r o f t h e n e c e s s r t yt o e n s u r e t h a l h e h a s available an adequate set o{ tools and equipmenr. r n c l u d i n gc l e a n r a g s ,a n d a l s o a n y s p a r ep a r t sw h i c h m a y be needed in the courseof the work. At the end of thrs m a n u a t r s a s e c t t o n o n ' H i n t s o n M a i n t e n a n c ea n d O v e r h a u l ' w h i c hm a y b e o f h e l p t o t h o s eo t h e r t h a n s k j l r e o e n g in e e r s . T h e e n g i n e a n d t r a n s m i s s r o n s s e m b l yi s r e m o v e da n d a r e f i t t e dt h r o u g h t h e b o n n e t a p e r t u r ea f t e rr a i s i n gt h e f r o n t o f t h e c a r s u f fi c i e n t l yt o w o r k u n d e r n e a t h o r r u n n i n g t h e , car overa pit or on to a ramp. 1:2

D r a i nt h e c o o l i n g s y s t e mi f a h e a t e ri s f i t t e da n d r e m o v e t h e b o n n e t . D i s c o n n e c tt h e e a r t h l e a d f r o m t h e c l u t c h housing and removethe leadsfrom the distributor. ott c a n d g e n e r a t o r R e m o v et h e s t a r t e rm o t o r . R e m o v et h e c a r b u r e t t e r ( sa n d a i r c l e a n e ra s d e s c r i o e d ) in Chapter 2. D i s c o n n e c t h e o p e r a t i n gc a b l ef r o m t h e h e a t e rc o n t r o l v a l v e o n t h e c y l i n d e rh e a d a l s o t h e h o s e sa n d r e t u r np i p e . R e l e a s e h e c l u t c h l e v e r s p r r n g ,r e n t o v et h e t w o b o l t s t s e c u r i n g t h e s l a v e c y l i n d e r ,p u l l o u t t h e p u s h r o d a n d fasten the slave cylinder 1o a convenient point (see C h a p t e r 5 ) . l t i s n o t n e c e s s a r yo r e m o v et h e h y d r a u l i c t s u p p l y p i p e . R e l e a s e h e e x h a u s tp i p e f r o m t h e m a n i f o r o . t R e l e a s e h e s p i i l h o s ef r o m t h e r a dj a t o ra n d t h e c o w l i n g . t Releasethe speedometercable coupling. When the earlrer ype of remotecontrol gear chanqe is fitted (see t FIG 1 :1) extractthe four securing bolts and separate t h e g e a r c h a n g e e x t e n s i o nf r o m t h e d i f f e r e n t i a lh o u s r n g and ailow the extension housrng to hang from {he floor tunnel. When the latef type of gear change is f i t t e d ,d i s c o n n e c t h e t w o r o d s f r o m t h e t r a n s m i s s i o n n d a r e m o v et h e f e m o t ec o n t r o lu n i t a s d e s c r i b e d n C h a p t e r 6 . i Jack up the front of the car and place firm supports u n d e r t h e s r d e m e m b e r s .R e m o v e t h e f r o n t r o a d w h e e l s .

1100Mk21300

1 1

FIG 1 :3

Components to be released from above Removing the engine and automatic transmission unit

Disconnectthe drive shafts from the final drive as f o l l o w sI Early f lexible drive couPlings: Remove all four U-bolts from the lefthand coupling a n d t h e t w o o u t e r U ' b o l t s f r o m t h e r i g h t h a n dc o u p l l n g ' T h e s l i d i n gl o i n t s c a n n o w b e p u s h e d o u t w a r d s a n d t h e l e f t h a n dc o u p l i n g r e m o v e d Later plunge joint couPlings: t t R e l e a s e h e s t e e r i n g i e r o d a n d t h e t o p b a l l J o i n to f t h e a s w i v e l h u b f r o m t h e u p p e r s u s p e n s i o n r m ( S e r v i c et o o l s a 1 8 G . 1 0 6 3 ) n d s u i t a b l y u p p o r t h e s w i v e lh u b a s s e m b l y Use tool 18G.1243 as describedin Chapter 8 to s e p a r a t et h e d r i v e s h a f t f r o m t h e p l u n g e l o i n t a n d t h e n t e m p o r a r i l yr e f i t t h e t o p b a l l l o i n t t o s u p p o r t t h e s w i v e l nuD. D i s c o n n e c tt h e I o w e r s t e a d y r o d f r o m t h e a t t a c h m e n t o n t h e f r o n t c o v e r o f t h e g e a r b o x .R e m o v e t h e b r e a t h e r r a n d t h e n d e t a c ht h e e n g i n es t a b i l i z eb a r f r o m t h e c y l i n d e r b l o c k . O n e m i s s i o nc o n t r o l l e de n g i n e si t w i l l b e n e c e s s a r y t o d i s c o n n e c tt h e h o t a i r b o x f r o m t h e e x h a u s tm a n i fo l d t R e m o v et h e n u t s e c u r i n g h e l e f t h a n de n g r n em o u n t t n g t t o t h e s u b f r a m e b r a c k e ta n d r e l e a s eh e b r a c k e t R e m o v e t w o c y l i n d e rh e a d n u t s t o a l l o w t h e { i t t i n g o f I i f t i n gt a c k l e

a n d t a k e t h e w e i g h t o f t h e e n g i n e R e m o v et h e n u t s a n d extract the two bolts securing the righthand englne m o u n t i n g t o t h e s u b f r a m e ,a l s o t h e n u t s e c u r l n gt n e r e a r mountingbracket. C h e c k t h a t a l l c o n n e c t i o n sa r e c l e a r a n d l i f t t h e p o w e r u n i t c o m p l e t ew i l h t h e r a d l a t o ro u t o f t h e c a r ' Ref itting : o T h i s i s t h e r e v e r s e f t h e r e m o v a l p r o c e d u r e 'b u t n o t e t h a t w h e r e a s p e e d o m e t e rc a b l e c o u p l i n g i s u s e d ' t h e t o o h a l f m u s t b e p u s h e do n t o t h e l o w e r h a l f a s f a r a s t h e black mark or circle before fitting the securing ring R e fi l l t h e c o o l i n g s y s t e ma s d e s c r i b e di n C h a p t e r 4

1 :3 Removing engine and automatic transmission Disconnect and remove the batteryand tray Drain the c o o l r n gs y s l e m . t R e f e rt o F I G 1 : 2 t o a s s i s ti n i d e n t i f y i n g h e o p e r a t r o n s prot o b e c a r r i e do u t u n d e r n e a t ht h e c a r ' P u l l b a c k t h e sleeve and disconnect the gear selectorcable by tecting r e . o u i n g t h e c l e v i s p i n S l a c k e nt h e y o k e c l a m p n u t a n d , " m o u " i h " y o k e , n u t , r u b b e r f e r r u l e sa n d s l e e v e R e m o v e pull t h e f r o n t c a b l e a d j u s t i n gn u t f r o m t h e o u t e r c a b l e a n d

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1100Mk2 300 1

Remove the air cleaner.Disconnectthe choke and t h r o t t l e c a b l e s a n d t h e f u e l s u p p l y p i p e D i s c o n n e c tt h e c a b l e f r o m t h e h e a t e rc o n t r o l v a l v e a l s o t h e h o s e s a n d r e t u r np i P e . b D i s c o n n e c tt h e e n g i n e s t a b l l i z e r a r a n d r e m o v e t h e n u t s s e c u r i n gt h e t w o f r o n t e n g i n e m o u n t i n g s ' R e m o v e t t h e e x h a u s tp i p e m a n i f o l d c l a m p R e l e a s e h e s p i l l h o s e

6
the

The order of slackening and tightening FIG 1:5 cylinder head retaining nuts

{ r o m t h e r a d i a t o rc o w l l n g F i t a l i f t i n g a t t a c h m e n ta n d r a i s et h e e n g i n e v e r t i c a l l y ' s u f f i c i e n t l yt o r e l e a s et h e d r i v e s h a f t s f r o m t h e d r i v i n g n R f l a n - o e s . e m o v et h e e n g i n ea n d t r a n s m i s s i o f r o m t h e c a r ' Refitting:

--; t ' \

Refitting is the reverseof the above procedure with p a r t i c u l a r t t e n t i o nt o t h e f o l l o w i n g : a Lower the assembly sufficiently to engage the drive shafts with the flange studs and screw on the nuts about {our threads before lowering the assembly completely into posttton. as Aijust the gearchange cable and selector rod d e s c r i b e di n C h a P t e r 7 . 1 :4 Removing and refitting the cylinder head R e f e rt o F I G ' l : 4 . D r a i n t h e c o o l i n g s y s t e m a n d d i s c o n n e c t t h e b a t t e r y .S l a c k e nt h e r e t a i n i n g c l i p a n d r e m o v e l a t h e h o s e b e t w e e nt h e r a d i a t o r n d t h e t h e r m o s t a h o u s i n g R e m o v e t h e u p p e r r a d i a t o rs u p p o r t p l a t e ) R e m o v et h e c a r b u r e t t e r ( sa s d e s c r i b e di n C h a p t e r 2 ' R e m o v et w o n u t s a n d l i f t o f f t h e r o c k e rc o v e r ' R e m o v e t h e t s p a r k i n gp l u g s . R e l e a s e h e d i s t r i b u t o rv a c u u m p i p e c l l p tiom tne waGr control valve housing lf a heater is fitted remove the hose and control cable from the valve at the r e a r r i g h t h a n d t o p o f t h e h e a d S l a c k e nt h e t o p c l i p o n t h e water bvpass hose t R e l e a s et h e e x h a u s t p i p e c l a m p R e l e a s e h e c l o s e d c i r c u r t b r e a t h e rc o n t r o l v a l v e b y s l a c k e n i n go f f t h e a d a p t o r hose clip and removing the supporting bracket Remove the nuts and washers securingthe manifolds to the head and lift off. Remove the rocker assembly lt is most important that the external cylinder head securing nuts be slackened at t h e s a m e t i m e a s t h o s e s e c u r i n g t h e r o c k e rs h a f t i n o r d e r t o a v o i d p o s s i b l ed i s t o r t i o n o f t h e h e a d T h e c o r r e c t o r d e r f o r s l a c k e n i n go r t i g h t e n i n gt h e c y l i n d e rh e a d n u t s l s s h o w n in FIG 1:5, and this sequence should be carefully

Valve assembly, showing (A). double valve FIG 1 :6 lnset sorinq ancl (B) single valve spring applications s'how-s the valve seal at the bottom of the cotter 9roove

Drive in valve guides until 1; inch pro1ects FIG 1:7 above the valve spring seat as indicated

t h e c a b l e c l e a r .R e m o v et h e s e l e c t o tc a b l e c l i p a n d t l e t h e cableout of the waY Remove the exhaust steady bracket from the transm t s s r o nc a s e . R a i s et h e f r o n t o f t h e c a r u n t i l t h e r o a d w h e e l s a r e c l e a r t h e n r e m o v et h e d r i v e s h a f t f l a n g e s e c u r t n gn u t s ' Remove the lower engine steady rod, and, when f i t t e d , t h e a d d i t i o n a le n g i n e s t e a d y r o d f r o m i t s a n c h o r t p l a t e .R e m o v et h e n u t s s e c u r i n g h e r e a re n g t n em o u n t i n g to the sub frame. R e f e r t o F I G 1 : 3 t o i d e n t i f y t h e o p e r a t r o n sc a r r l e d o u t the from above. Disconnect the bonnet stay and tie back D i s c o n n e c t t h e s p l i t t y p e s p e e d o m e t e rc a b l e bonnet. R e m o v e t h e e a r t h l e a d a n d t h e c a b l e sf r o m t h e c o r l ' s t a r t e r c . a n d a l t e r n a t o r R e m o v et h e d i s t r i b u t o r a p

observed. Lift out the pushrods and mark them so as to ensure their replacement in the original positions Lift of{ the cylinder head, tapping on the side with a wooden mallet' t if necessary, o break the seal Refitting: E n s u r et h a t t h e s u r f a c e so f t h e c y l i n d e r b l o c k a n d h e a d are clean and that a new gasket is fitted The gasket is 'Top' 'Front' for correct fitting Lower the and marked c y l i n d e rh e a d i n t o p o s i t i o na n d s c r e w u p t h e s e c u r i n gn u t s finger tight. Carefully replacethe pushrods and then the r o c - k e ra i s e m b l y f i t t i n g t h e n u t s f i n g e r t i g h t o n l y E n s u r e t h a t t h e p u s h r o d s a r e c o r r e c t l yl o c a t e d , t h e n c o m p l e t e t h e t i g h t e n i n g s e q u e n c ea s g i v e n i n F I G 1 : 5 - S e t t h e v a l v e as instructed in Section 1 :20. noting that " h e a rw n c "n e e d t o b e c h e c k e d a g a i n a f t e r t h e e n g i n e h a s tl"" y uill i been run for a short Period

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F I G ' l : 9 T i m i n g g e a r a s s e m b l ys h o w i n g p o s i t i o no f t h e two timing marks

T h e r e m a i n d e ro f t h e r e f i t t i n g o p e r a t i o n i s a r e v e r s a lo f t h e r e m o v a lp r o c e d u r e . Refill and check the cooling system.Check the fuel s y s t e n r .S t a r t t h e e n g i n e a n d r u n f o r s o m e m i n u t e s a t worKrng temperature then check the tightness o{ the c y l r n d e rh e a d n u t s a n d t h e r o c k e r c l e a r a n c e s . On the Austin America this operationmust be followed b y a n e x h a u s te m i s s i o nc h e c k . 1 :5 Servicing the head and valve gear H a v i n g r e m o v e dt h e c y l i n d e rh e a d ,p l u g t h e w a t e r w a y s In the top of the block with rag to preventthe entry of any f o r e i g n m a t t e r .S c r a p e t h e c a r b o n f r o m t h e c o m b u s t i o n spaces In the head before removing the valves to avoid damageto the valveseats. T h e v a l v e a s s e m b l yo f t h e 1 0 9 8 c c e n g i n e i s s h o w n i n F I G 1 : 6 f h e 1 2 7 5 c c e n g i n e i s s l i g h t l yd i f f e r e n ta n d t h e v a l v e a s s e m b l yi s d e t a i l e di n S e c t i o n 1 : 2 2 . R e m o v et h e c o t t e r c l i p a n d w i t h a c o m p r e s s o rt o o l c o m p r e s s t h e v a l v e s p f l n g s a n d r e m o v e t h e s p l i t c o t t e r s . R e l e a s et h e c o m p r e s s o r ,r e m o v e t h e r e t a i n i n g c a p , s p r i n g s a n d r u b b e r s e a l i n gr i n g . R e m o v et h e v a l v e a n d m a r k i t f o r r e a s s e m b l y i n i t s o r i g r n a lp o s i t i o n . Examinethe valves for pitting, burning, cracking or d i s t o r t i o na n d r e p l a c e n y f o u n d t o b e f a u l t y .T h o s ev a l v e s a whose condLtions good may be ground in by using the i f o l l o w i n g p r o c e d u r e ,w h i c h a l s o s h o u l d b e u s e d w h e n f i t t i n g n e w v a l v e so r w h e n t h e h e a d s e a t sh a v e b e e n r e - c u t . W i t h a s r n a l la m o u n t o f v a l v e g r i n d i n g p a s t ea p p l i e dt o t h e s e a t f i n e g r a d e i f t h e s u r f a c e sa r e g o o d , o t h e r w t s e medium grade first and finishingwith fine-place the v a l v e o n i t s s e a t i n ga n d b y m e a n s o f a s u c t i o n g r i n d i n g tool rotate the valve from side to side and occasionally lifting to a new position until both seats have a smooth matt qrev finish. Clean all traces of paste from born s u r f a c e s .l f t h e v a l v e s e a t s i n t h e h e a d a r e t o o b a d l v

w o r n f o r g r i n d r n gt o b e f u l l y e f fe c t i v e ,s p e c i a lv a l v e s e a t inserts can be {itred by the Service Station. Some c y l i n d e r h e a d s n r a y h a v e i n s e r t sf i t t e d a s o r i g i n a l e q u i p ment. E x a m i n e h e v a l v eg u r d e s . n d t f t h e y a r e b a d l y w o r n o r t a scored they shouid be renewed The drift used for the purpose of driving out the oid valve guide shoulo oe a h a r d e n e ds t e e lp u n c h . { i n c h r n d r a m e t e ra n d a t l e a s t4 r n c h e sl o n g , w r t h a l o c a t i n g s p t g o t + r n c h i n d i a m e t e r m a c h r n e do n o n e e n d f o r 1 i n c h t o e n g a g et h e b o r e o f t h e guide The new guidesshould be driventn from the top o f t h e c y l i n d e rh e a d , i n l e t g u i d e s w i t h t h e l a r g e s t h a m f e r c a t t h e t o p , a n d e x h a u s tg u r d e sw i t h t h e c o u n t e r b o r e n d s e at the bottom. When fitted the gr-rides hould project -|! s i n c h a b o v e t h e m a c h i n e d v a v e s p r i n g s e a t i n ga s s h o w n i n F I G1 : 7 S t r i p p i n g t h e r o c k e r g e a r w i l l b e a s s i s t e db y r e f e r e n c et o F I G 1 : 4 R e m o v et h e g r u b s c r e w 3 2 f r o m t h e m o u n t i n g b r a c k e t2 4 . W i t h d r a w t h e s p l r p r n sa n d w a s h e r sa n d s l i d e o f f a l l t h e r e m a i n i n gp a r t s n o t i n g c a r e i u l l yt h e p o s i t i o n s t h e y o c c u p i e df o r l a t e r r e a s s e m b l V h e p r o c e d u r e o r t h e T f 1 2 - 7 5c c e n g i n e i s s i n r j l a rb u t i t w i l l b e s e e n t h a t t h e r e a r e , s i x d i s t a n c e p t e c e s ,o n e o n e a c h s i d e o f t h e t w o o u t e r rockers and one on the bracket side of the two middle rockers. Two types of rocker are used,one being a forging and t h e o t h e r o f p r e s s e ds t e e l .W h e n t h e r o c k e r b u s h e s b e c o m e w o r n r t t s p o s s t b l et o r e n e w t h e b u s h o f t h e f o r g e d t y p e a s s e m b l y .T h e n e w b u s h s h o u l d b e p r e s s e d i n t o t h e r o c k e rb o r e w r t n t h e b u t t l o i n t p o s i t i o n e d t t h e t o p o f t h e a b o r e a n d a h o l e m u s t b e d r i i l e dw i t h a N o . 4 7 d r i l l t o c o r n c i d ew i t h t h e h o l e i n t h e t o p o f t h e r o c k e r b a r r e l . F i n a l l yb u r n i s h r e a mt h e b o r eo f t h e b u s h t o . 5 6 3 0 t o . 5 6 3 5 r nc h . W h e n r e a s s e r n b l i n gt h e r o c k e r s h a f t a s s e m b l y f i r s t secure the f ront mounting bracket with its grubscrew, t h e n r e p l a c et h e r e m a i n i n gp a r t s i n t h e a r r i g i n a lo r d e r o n o t h e s h a f t .T h e s c r e w e d p l u g i s a t t h e f r o n t o f t h e e n g i n e . W h e n r e m o v i n gt h e c a r b o n f r o m t h e p r s t o nc r o w n i t i s a l w a y s a d v i s a b l et o l e a v e a r i n g o f c a r b o n a d j a c e n t t o t h e c y l i n d e rb o r e a s t h i s w i l l h e l p t o m a i n r a i na g o o d s e a l a n d c o n s e r v eo i l T h i s m a y b e d o n e b y i n s e r t i n g n o l d p i s t o n a r i n g o i t h e c o r r e c ts i z e i n t o t h e b o r e o n t o p o f t h e p i s l o n , a n d t h e n w i t h a b l u n t t o o l r e m o v i n gt h e c a r b o nw i t h j n t h e r r n g . l t s h o u l d b e s t r e s s e dh e r e t h a t w h e n r e m o v i n g d e p o s i t sf r o m a n y a l u m i n i u m p a r t s n o h a r s h a b r a s i v e s r o e m e r y c l o t hs h o u l d b e u s e d . T h e v a l v e ss h o u l d b e r e p l a c e di n t h e s a m e p o s i t i o n a s t h e y o r i g i n a l l yo c c u p i e d , u n l e s s n e w v a l v e s h a v e b e e n fitted, and new springs fitted if any do not conform very c l o s e l y t o t h e d i m e n s i o n sg i v e n i n T e c h n i c a l D a t a . N e w rubber seals also should be used as shown. Lightly l u b r i c a t et h e v a l v e s t e m s b e f o r e i n s e r t i o ni n t o t h e i r g u i d e s . R e p l a c e h e c y l i n d e rh e a da s d e s c r i b e d n S e c t i o n 1 : 4 . t i 1 :6 Servicing the valve timing gear S e e F I G 1 : 8 . R e m o v e t h e r a d i a t o ra s d e s c r i b e di n C h a p t e r 4 . S l a c k e n t h e a l t e r n a t o ra t t a c h m e n t b o l t s a n d r e m o v e t h e b e l t . U n l o c k t h e c r a n k s h a f tp u l l e y l o c k i n g w a s h e r , r e m o v e t h e s e c u r i n g s c r e w a n d c a r e fu l l y l e v e r o f f t h e p u l l e y a n d d a m p e r f r o m t h e c r a n k s h a f t . e m o v er n e R t w o s e t s c r e w s2 9 a n d 3 2 a n d l i f t o f f t h e t i m i n g c o v e r 2 7 . U n l o c k a n d r e m o v et h e c a m s h a f tc h a i n w h e e ln u t 2 b a n o l o c k w a s h e r 2 4 . B o t h c h a i n w h e e l s m a v n o w b e l e v e r e do f f

16

gently, using suitable levers, complete with the timing c h a i n . N o t e t h e p a c k r n g w a s h e r s 14 b e h i n d t h e c r a n k s h a f t c h a i n w h e e1 2 . l R e a s s e m b l yi s t h e r e v e r s eo f t h e a b o v e p r o c e d u r e , b u t g r e a t c a r e m u s t b e t a k e n t o e n s u r et h a t t h e t w o c h a i n w h e e l s are in alignment by checking that the same washers are used. In the event of a new wheel being fitted the alignrnnt must be checked by placing a straightedgeacross t h e s i d e s o f t h e c a m s h a f t w h e e l t e e t h a n d m e a s u r i n ga n y gap at the crankshaft wheel. Washers must be added to obtain the correct alignment. A noisy timing chain may frequently be cured by renewing the tensioner rings 22, but if the chain or either of the wheels is worn, new parts should be obtained. Never fit one new part in this event, but always a set of two wheelsand a new chain. W h e n r e p l a c i n gt h e t i m i n g c h a i n ( s e e F I G 1 : 9 ) , s e t the crankshaftwith its keyway at TDC and the camshaft k e y w a y a t a p p r o x r m a t e l yo n e o ' c l o c k a s s h o w n . A s s e m b l e the wheels and chain with the two timing marks 1 and 2 opposite to each other. With the wheels in this position e n g a g e t h e c r a n k s h a f t w h e e l o n t h e c r a n k s h a f ta n d r o t a t e the camshaft until the key on the shaft and the keyway in the wheel coincide then push the wheels fully into o o s i t i o n a n d s e c u r et h e c a m s h a f tw i t h t h e n u t a n d l o c k washer. The oil thrower is fitted with the face marked F awav from the engine. Fill the groove between the lips of the oil seal wiih g r e a s e a n d i n s e r t t h e p u l l e y h u b s q u a r e l y ,t u r n i n g i t clockwise to avoid damaging the seal. Assemble the crankshaftpulley to the cover and push on to the crankshaft ensuring that the keyway on the pulley is lined up with the Woodruff key on the crankshaft before finally drivingthe pulley into posrtron. s R e p l a c et h e c o v e r r e t a i n i n g c r e w s a n d t i g h t e n e v e n l y . 1 :7 Servicing the camshaft Removal : Remove the rocker gear assembly (see Section 1 :4) a n d t h e m a n i f o l d s . R e m o v et h e s i d e c o v e r sa n d l i f t o u t t h e t a p p e t s ( 4 1 i n F I G 1 : 8 ) , s t o r i n gt h e m i n t h e c o r r e c to r d e r for replacement. emovethe timing gear (see Section R 1 :6). D r s c o n n e c tt h e h i g h - t e n s i o n l e a d s f r o m t h e c o i l a n d sparking plugs, and the low-tension wire from the d i s t r i b u t o r .R e m o v e t h e d i s t r i b u t o ra s s e m b l y( s e e C h a p t e r 3, Section 3:4). R e m o v e t h e s c r e w s a n d w a s h e r s s e c u r i n gt h e c a m s h a f t locating plate and withdraw the camshaft. Check the c o n d i t i o n o f t h e c a m s a n d t h e c a m s h a f t i o u r n a l s ,b u t n o t e t h a t t h e r e n e w a l o f t h e b e a r i n g l i n e r s i s a s p e c i a l i s t sj o b r e q u i r i n gs p e c i a le q u i p m e n t . Ref itting : l B e f o r er e fi t t i n g w h i c h i s a r e v e r s ao f t h e a b o v e ,a s s e m b l e t h e c a m s h a f t r e t a i n i n gp l a t e a n d t h e c h a i n w h e e l t o t h e c a m s h a f t a n d m e a s u r et h e e n d f l o a t o r c l e a r a n c eb e t w e e n the retainingplate and the thrust face of the front journal. This should be between .003 and .007 inch and a reading i n e x c e s so f t h r s r e q u i r e st h e r e n e w a l o f t h e r e t a i n i n g p l a t e . L u b r i c a t et h e j o u r n a l s , r e p l a c e t h e c a m s h a f t a n d c h e c k t h a t t h e d r i v i n g p i n 1 7 w i l l e n g a g et h e s l o t i n t h e o i l p u m p s o i n dl e .

FIG 1 :10 Timing marks on the flywheel as seen with a mirror through the inspection hole. 114 indicates TDC 5, 10 and 15 degree marks are aiso provided

FIG 1 :11 Distributor drive with the located and the large offset uppermost

slot

correctly

Removing and ref itting the f lywheel housing FIG 1 :12 using Service tool 18G.1043

1 1 0 0M k 2 1 3 0 0

11

FIG 1:13 Checking the end float of the primary gear. To obtain the correct clearance of .0035 to .0065 inch select the reouired thrust washer

f r o m t h e s u b - f r a m e s i d e m e m b e r .R e m o v e t h e b o l t s s e c u r i n g t h e c l u t c h c o v e r t o t h e f l y w h e e l h o u s i n g .t h e n r a i s et h e t engine suffrciently o enablethe cover to be removed, taking care that the fan blades do not touch the radiator c o r e . R e m o v et h e c l u t c h t h r u s t p l a t ew h i c h i s l o c a t e db y a spnng ilng. T u r n t h e e n g i n e u n t i l N o s . 1 a n d 4 p i s t o n sa r e a t T D C . T h i s w i l l e n s u r et h a t t h e C - w a s h e r l o c a t i n g t h e p r i m a r y gear ls fitted with the bridge linking the two flats above the crankshaft and cannot drop and become wedged b e h i n d t h e f l y w h e e lo i i s e a l .K n o c k u p t h e l o c k i n g w a s h e r a n d r e m o v e t h e f l y w h e e l r e t a i n i n gs c r e w U s e S e r v i c e t o o l 1 8 G . 3 0 4 a n d a d a p t o r1 8 G . 3 0 4 N t o f r e e t h e f l y w h e e l from the taperon the crankshaft. A s t h e f l y w h e e l i s p u l l e d o t f t h e c r a n k s h a f t ,o i l f r o m t h e a n n u l u sa t t h e b a c k o f t h e o i l s e a l m a y s p i l l a n d r u n d o w n o n t o t h e s l u t c h l i n i n g s .T o a v o i d t h r s ,k e e p t h e f l y w h e e l i n a vertical oosition. Screw the threeadaptorstuds into the flywheel through the recessedholes in the clutch spring housing. Fit the olate of the tool over the studs and screw the nuts down e v e n l y s o t h a t t h e p l a t e r e m a i n sp a r a l l e lw i t h t h e f l y w h e e l . Insert the short centre screw and withdraw the flywheel. The extractorshoulci be removed as soon as the taper is broken. Remove the flywheel retaining screw and the keyed drrving washer. Withdraw the flywheel and clutch as a t s . c o m p l e t ea s s e m b l y I n s t r u c t i o n f o r d i s m a n t l i n g h e c l u t c h p w i l l b e f o u n d i n C h a p t e r 5 . T h e c r a n k s h a f t r i m a r yg e a r cannot be removed until the flywheel housing is removed a s d e s c r i b e di n S e c t i o n 1 : 9 . Refitting:

FIG 1 :14

ldentification of piston grading

S e t N o . 1 p i s t o n t o T D C o n t h e c o m p r e s s i o ns t r o k e . I n t h i s p o s i t i o nt h e t i m i n g w h e e l m a r k sw i l l b e a c c o r d i n gt o F I G 1 : 9 a n d t h e t i m i n g m a r k so n t h e f l y w h e e lw i l l a p p e a r as in FIG 1 :1O. Screw a Iong 1f inch bolt into the threaded end of the d i s t r i b u t o rd r i v e s h a f t a n d , w h i l e h o l d i n g t h e s h a f t w i t h the slot just below the horizontal and the large offset u p p e r m o s t p r e s s i t i n t o e n g a g e m e n t .A s t h e g e a r e n g a g e s with the camshaft the slot will rotate into the position shownin FIG 1 :11. Remove the bolt from the shaft, insert the distributor h o u s i n g a n d s e c u r e i t w i t h t h e s p e c i a lb o l t a n d w a s h e r . The head of the bolt must not protrude above the face of t h e h o u s i n g . l f t h e c l a m p b o l t h a s b e e n s l a c k e n e da n d t h e t t m i n g l o s t i t w i l l b e n e c e s s a r yt o r e t i m e t h e d i s t r i b u t o r a s d e t a i l e di n c h a p t e r 3 . The remainder of this operation ts the reverseof the removarproceoure. 1 :8 Removing and replacing flywheel and clutch Remove the battery and carrier. Remove the starter m o t o r ( s e e C h a p t e r 11 ) . R e l e a s e h e c l u t c h o p e r a t i n g l e v e rf r o m t h e c l u t c h c o v e r , t p u l l i n g t h e p u s h r o do u t o f t h e s l a v e c y l i n d e r .B e l e a s e h e t s l a v e c y l i n d e ra n d t i e i t t o t h e e n g i n e b u l k h e a d .l t i s n o t n e c e s s a r y o d i s c o n n e c tt h e f l e x i b l eh o s e . t c R e m o v et h e e x h a u s tp i p e c l a m p a n d t h e r a d i a t o r o w l t i n g s u p p o r t i n gb r a c k e t .R e l e a s e h e r e a re n g t n em o u n t t n g

The flywheel and clutch are refitted by reversingthe removal procedure with very particular attention to the following: T h e o i l s e a l m u s t b e w e l l l u b r i c a t e d b e f o r e a s s e m b l ya s t w n o r m a ll u b r i c a t i o n i l l n o t r e a c hi t i m m e d i a t e l y h e e n g l n e is started. I t i s e s s e n t i a lt h a t t h e c r a n k s h a f t a n d f l y w h e e l t a p e r s a r e c o m p l e t e l y f r e e f r o m g r e a s ea n d d r y b e f o r e a s s e m b l y . The clutch thrust plate is retainedby a spring ring 'TOP'. This must be and is marked with the word uppermost and face outwards when fittrng, with the a crankshaft t TDC for Nos. 1 and 4. Ensure that the primary gear retaining C-washer is c o r r e c t l y l o c a t e d i n i t s g r o o v e . T h e c r a n k s h a f ts h o u l d b e rotated to bring the circlip to the top of the shaft to p r e v e n t i t i r o m f a l l r n go u t a n d j a m m i n g b e h i n d t h e f l y w h e e l . T i g h t e n t h e f l y w h e e l r e t a i n i n gs c r e w t o a t o r q u e o f 110ro115lbft. 1 :9 Removing the flywheel housing A f t e r r e m o v i n g t h e c l u t c h a n d f l y w h e e l , r e m o v et h e s e t screws and nuts securing the flywheel housing to the c c y l i n d e r b l o c k a n d t r a n s m i s s i o n a s e ,n o t i n g t h e i r p o s i t i o n s f o r r e a s s e m b l y .T o a v o i d d a m a g i n g t h e o i l s e a l a s i t i s withdrawn over the primary gear splrnes, service tool 1 8 G . 5 7 0 s h o u l d b e f i t t e d o v e r t h e s p l i n e sa s s h o w n i n F I G1 : 1 2 . o R e fi t t i n g i s c a r r i e do u t i n t h e r e v e r s e r d e r w i t h p a r t i c u l a r a t t e n t i o nt o t h e f o l l o w i n g : E n s u r et h a t t h e t h r u s t w a s h e r b e h i n d t h e p r i m a r y g e a r is fitted with its chamfered bore against the crankshaft flanqe.

1B

C h e c k t h e e n d f l o a t o f t h e p r i m a r yg e a r a n d a d j u s t i t b y s e l e c t i v ea s s e m b l yo f t h e t h r u s t w a s h e r a s i n d i c a t e d b y F I G1 : 1 3 . C l e a nt h o r o u g h l ya l l m a t i n g f a c e sa n d f i t a n e w B M C gasket. s R e n e w a n y o i l s e a l sw h i c h s h o w t h e s l i g h t e s t i g n s o f d a m a g eo r l e a k a g e . P a c k t h e b e a r i n g r o l l e r so f t h e f i r s t m o t i o n s h a f t w i t h h i g h m e l t i n g p o i n t g r e a s et o p r e v e n t t h e m t i l t r n g a s t h e . h o u s i n gi s r e f i t t e d U s e t o o l 1 8 G . 5 7 0o v e r t h e p r i m a r yg e a r splines as before and screw the two pilot bars which are part of this tool set into the two bottom tapped holes in t h e c r a n k c a s eT h e s ew i l l g u i d e t h e h o u s i n gi n t o p l a c ea n d . t a l s o t a k e t h e w e i g h t o f f t h e s e a l . l t a ti s n e c e s s a r y o r e n e w c t h e g e a r t r a i n t h e t r a n s m i s s i o n a s i n gm u s t b e r e m o v e dt o enable the idler gear end float to be measured (see Section 1 :'l0). Ensure that the correct short setscrew is frtted at the righthandtop position in the housing as a long screw m i g h t d a m a g e t h e o i l g a l l e r y i n t h e c y l i n d e rb l o c k . Tighten the housing bolts and nuts to a torque of 18 t o l b f t w h i c h w i l l g i v e t h e g a s k e ta c o m p r e s s i o nh i c k n e s s f . 0 3 0 i n c h . T h e r ei s a s m a l l c u i a w a y i n t h e g a s k e tt o p e r m r t t h e i n s e r t i o n f a f e e l e rg a u g e t o c h e c k t h i s m e a s u r e m e n t o

FIG 1:15 Correct assembly of pistons and connecting rods to the crankshaft

1 :10 Removing the synchromesh transmission R e m o v et h e e n g i n e ,f l y w h e e l a n d c l u t c h , s t a r t e rm o t o r a n d f l y w h e e l h o u s i n ga s a l r e a d y e s c r i b e dt,h e n w r t h d r a w d t h e s e t s c r e w sf r o m t h e f l a n g e o f t h e t r a n s m i s s i o n a s e c U s i n g s u i t a b l et a c k l e l i f t t h e e n g r n et o s e p a r a t e t f r o m t h e i transmtsstonase. c { l n s t r u c t i o n s o r d i s m a n t l i n gt h e t r a n s m i s s r o n r e g i v e n a in Chapter 6. Refitas foliows: T h o r o u g h l yc l e a n a l l l o i n t f a c e s C h e c k t h e e n d f l o a t o f t h e i d l e r g e a r , i f n e w g e a r s h a v e b e e n f i t t e d , b e f o r et h e c a s e i s r e p l a c e d( s e e C h a p t e r 6 ) . T i g h t e n a l l s e c u r i n gn u t s a n d b o l t s f i n g e r t i g h t a t f r r s t , t h e n o n e t u r n a t a t i m e t o e n s u r e a n e v e n p r e s s u r ea l l r o u n d .T h i s w i l l n o t o n l y p r o d u c eu n o , 1 1 ; g h to i n tb u t a l s o J k e e p t h e g e a r si n c o r r e c tr e l a t i o n s h i p c S e e t h a t t h e f r o n t b e a r i n gc o r k o i l s e a lr e m a i n s o r r e c t l y p o s i t i o n e dd u r i n g t h e s e o p e r a t i o n s

+\,--n (/z+s\rr*J,)
a

\YZl \-Y--l

o-s-\l/
?

FIG 1 :16 Key to Fig 1 :16 2 Shaft and rotor (Concentric)

The two types of oil pump (Hobourn Eaton) 1 Body 4 Cover to bodv screw 3 Cover 5 P u m p a s s e m b l ys e r v i c e do n l y a s a u n r t

fo c A i n d r c a t ep o s r t r o n s r c h e c k i n g l e a r a n c e s s 1 :12 Pistons and connecting rods. 1098cc engine On these engrnes the piston/gudgeon pin and the c o n n e c t i n g r o d r s m a l le n d b u s h c a n o n l y b e c b t a i n e d a s m a s s e m b l i e sU n d e r n o c i r c u m s t a n c e s a y t h e s m a l l e n d . b u s h o f t h e g u d g e o n p r n b e r e n e w e ds e p a r a t e l yI.n s t r u c t i o n s f o r d e a l i n gw i t h r h e 1 2 1 5 c c e n g i n e o r w h e n a u t o i m a t i c t r a n s m i s s i o ns f i t t e d a r e g i v e n l a t e r i n t h i s c h a p t e r . D r a i n t h e c o o l i n g s y s t e m ,t h e l r a n s m i s s i o nc a s e a n d t h e e x t e r n a lo i l f i l t e r . R e m o v e t h e e n g i n e ( s e e S e c t i o n 1 : 2 ) . R e m o v et h e f l y w h e e la n d c l u t c h ( s e eS e c t i o n 1 : 8 ) , t h e f l y w h e e lh o u s i n g ( s e eS e c t i o n 1 : 9 ) , t h e t r a n s m i s s i o n ( s e e S e c t i o n 1 : 1 0 ) a n d t h e c y i i n d e rh e a d ( s e e S e c t i o n 1 :4). R e f e rt o F I G 1 : 8 a n d p r o c e e da s f o l l o w s : U n l o c k a n d r e m o v et h e b i g - e n d b o l t s 3 a n d r e m o v et h e . c a p s a f t e rm a r k i n gb o t h c a p a n d r o d f o r r e a s s e m b l yC l e a n off any carbon round the top of the cylinderbore and withdraw the prston and connecting rod from above R e f i t t h e b e a r r n gc a p . T h e g u d g e o n p i n s a r ef u l l y f l o a t i n ga n d m a y b e r e m o v e d a f t e r r e m o v i n gt h e t w o c i r c l i p s .D o n o t o m i t t o m a r k t h e m t o e n s u r ec o r r e c tr e a s s e m b l y .

1 :11 Servicing the crankshaft pr!mary gear This gear is removed after the flywheel housing has b e e n r e m o v e da s d e s c r i b e di n S e c t i o n 1 : 9 b y e x t r a c t i n g the retainingC-washer and the backing washer, then w i t h d r a w i n g t h e g e a r t o g e t h e rw i t h t h e t h r u s t w a s h e r s .l t w i l l b e n o t e d t h a t n o n - l u b r i c a t e d u s h e sa r ef i t t e dt o t h e s e b e n g i n e st o e l i m r n a t e h e l e a k a g eo f o i l i n t o t h e c l u t c h . t W h e n r e f i t t i n g t h e g e a r m e a s u r et h e e n d f l o a t b e t w e e n t h e i n n e r t h r u s t w a s h e r a n d t h e g e a r i t s e l f ,a n d , b y a a s e l e c t i o no f v ' r a s h e r s s i n d i c a t e d i n t h e t a b l e b e l o w . o b t a r n o t h e c o r r e c tr u n n i n g c l e a r a n c e f b e t w e e n . 0 0 3 5 a n d 0 0 6 5 i i n c h . T h i s i s i l l u s t r a t e dn F I G 1 : 1 3 .

When the gap is . 1 1 7 5 o 11 9 i n c h t . 11 9 t o . 1 2 1i n c h .121 ro .123 inctr . 1 2 3t o 12 5 i n c h

Use washer thickness . 1 1 2t o . 1 1 4 i n c h . 1 1 41 o . 1 1 6 i n c h . 11 6 t o . 11 8 i n c h . 11 8 t o . 1 2 0 i n c h

1100 Mk 2 1300

19

N
FIG 1 :17

',/

Crankcaseemission

control system 4 F i l l e r e df i l l e r c a p

K e yt o F i g 1 : 1 7

1 Oil separator

2 Breather hose

3 C a r b u r e t t e rc h a m b e r c o n n e c t i o n

R e f i t t i n g i s t h e r e v e r s eo f t h e a b o v e , t a k i n g c a r e t h a t a l l parts are replaced in their original positions and that the prston rrng gaps are at 90 deg. to each other.

Piston rings: These should always be removed over the top of the piston and are conveniently lifted out of their grooves by i n s e r t i n ga b r o k e n h a c k - s a w b l a d e o r d i s u s e d f e e l e r g a u g e u n d e r o n e e n d o f t h e r i n g a n d p a s s i n gi t a r o u n d t h e r i n g to ease it upwards. Very carefully clean out any carbon deposits from the piston ring grooves. Before fitting new rings the cylinder bore glaze should b e r e m o v e d , p r e f e r a b l yw i t h e q u i p m e n t d e s i g n e d f o r t h e p u r p o s e , b u t i f n e c e s s a r yw i t h a d u m m y w o o d e n p i s t o n w i t h v e r y f i n e g l a s s p a p e rw r a p p e d a r o u n d i t . Checking the correct piston ring gap may be done by inserting a piston about one inch down the bore and

p u s h i n g t h e r i n g d o w n o n t o p o f i t t o k e e p i t s q u a r et o t h e b o r e .T h e g a p b e t w e e n t h e t w o e n d s m a v t h e n b e m e a s u r e d w i t h a f e e l e rg a u g e . t n r s s h o u l d b e . u 0 6 t o . 0 11 i n c h a n d the ends may be filed out if necessary. The second and third rings are tapered and must be fitted with the narrow taper upwards. This top face rs stamped with the letter T. Piston sizes : It will be seen that each oiston is marked on the crown w i t h a n u m b e r e n c l o s e di n a d i a m o n d . T h i s i n d i c a t e si t s size grading and each piston should be fitted to a bore of s i m r l a rs i z e a s s t a m p e d o n t h e b l o c k a d j a c e n t t o t h e b o r e ( s e eF I G 1 : 1 4 ) . T w o o v e r s i z e p i s t o n s a r e a v a i l a b l e , + . 0 ' 10 a n d + . 0 2 0 inch and the pistons crowns are stamped with the actual o v e r s i z ed i m e n s i o n i n a n e l i p s e .A p i s t o n s t a m p e d . 0 2 0 i s s u i t a b l e o n l y f o r a b o r e . 0 2 0 i n c h l a r g e rt h a n s t a n d a r d a n d

20

s i m i l a r l yf o r o t h e r m a r k i n g s .W h e n f i t t i n g o v e r s i z ep r s t o n s always see that the block is stamDed with the oversize. Pistonsare supplied in the sizesindicated below: Piston marking Suitable bore size Grade A Grade B Standard 2.5420 to 2.5425 2.5426 to 2 b431 incn (64.567 to 64.579) (64.582 to 64.b9b) mm + . 0 10 i n c h 2 . 5 5 2 0 t o 2 . 5 5 2 5 2 . 5 5 2 6 r o 2 . 5 5 3 1 i nc h (.254 mm) (64.821ro 64.833) (64.836to 64.849) rnm +.020 inch 2.5620 to 25625 2.5626 ro 2 b631 inch (.508 mm) (65.075to 65 087) (6b 09 to 65.103) mm Connecting rods: N e w l i n e r sf o r t h e b i g - e n d b e a r i n g s m a y b e f i t t e d a f t e r c h e c k r n g t h e s p e c i f i c a t i o n sg i v e n i n T e c h n i c a l D a t a , b u l on no accoont should either the rod or the cap be fileo ro take up any wear. R e f e r t o F I G 1 : 1 5 f o r t h e c o r r e c t a s s e m b l yo f t h e c o n _ n e c t i n g r o d s t o t h e c r a n k s h a f t ,n o t i n g p a r t i c u l a r l yt h e o f f _ set caps inclined towards the camshaft.Tighten the big_ end bolts to a lorque of 35 lb ft.

1 :14 Flywheel starter ring. Synchromesh gear In the event of damage requiring a starter ring to be r e m o v e d i t i s n e c e s s a r yt o s p l i t i t w i t h a c o l d c h i s e l ,t a k i n g care not to damage the flywheel. Check that the mating s u r f a c e sa r e s m o o t h a n d c l e a n . T h e n e w r i n g s h o u l d b e h e a t e d t o a t e m D e r a t u r eo f 3 0 0 t o 4 0 0 o C ( 5 7 2 t o 7 5 2 . F ) w h i c h w i l l b e i n d i c a t e db y a light blue colour. Lower the ring over the registeron the flywheel with the lead on the teeth towards the regrster.Tap gently rnto position and leave it to cool n a t u r a l l ya n d s o s h r i n k f i r m l v i n p l a c e . 1 :15 The oil pump. Synchromesh gearbox Remove the engine. the flywheel and clutch assemblv and the flywheel housing. Bend back the locking washers and remove the botrs s e c u r i n g t h e p u m p t o t h e c r a n k c a s e .N o t e t h e p o s i t i o n o f the driving slot in the shaft for later replacement. Servicing the Hobourn-Eaton pump (see Fig 1 :16) : Remove the setscrew 4 and lift off the cover 3 noting the locating dowels. Check the end float by laying a s t r a i g h t e d g ea c r o s s t h e f a c e o f t h e p u m p a n d i n s e r t i n g a f e e l e r g a u g e b e t w e e n t h e s t r a i g h t e d g ea n d t h e t o p f a c e o f t h e r o t o r s .l f t h i s c l e a r a n c ei s i n e x c e s so f . 0 0 5 i n c h , r e m o v e the dowels and lap the face of the pump body as required. N e x t m e a s u r et h e c l e a r a n c eb e t w e e n t h e r o t o r l o b e s r n t h e p o s r t i o n ss h o w n i n t h e d i a g r a m a t A . l f t h e c l e a r a n c e exceeds .006 inch the rotors must be renewed. R e a s s e m b l yi s a r e v e r s a lo f t h e d i s m a n t l i n g p r o c e d u r e . B e f o r e r e f i t t i n g c h e c k t h a t t h e p u m p r o t a t e sf r e e l y . T h e c o n c e n t r i co i l p u m p ( s h o w n a t 5 i n F I G 1 : 1 6 ) , i s f i t t e d t o s o m e c a r s a n d n o i n s t r u c t i o n sa r e o f f e r e d f o r i t s servicing as the pump must be renewed as an assembled u ni t . When refitting the pump ensure that the paper joint is correctly located and does not obstruct the intake of d e l i v e r y p o r t s .A n e w p a p e r l o i n t a n d t a b w a s h e r s h o u l o o e used.

1 :13 Crankshaft and main bearings. Synchromesh gearbox Removing: Drain the transmission casing and external oil filter. R e m o v e t h e e n g i n e , t h e f l y w h e e l a n d c l u t c h a s s e m b l v .r n e flywheel housing, the timing cover and gears and the t r a n s m i s s i o n .T a k e o u t t h e s p a r k i n g p l u g s a n d p l a c e t h e cylinder block upside down in a suitable stand. B e f o r e d i s m a n t l i n g c h e c k t h e c r a n k s h a f te n d f l o a t . T h i s should be between .002 and .003 inch and any excess must be rectifiedby fitting new thrust washers at 1O ano 1 1 i n F I G 1 : 8 . R e l e a s et h e c o n n e c t i n g r o d s a n d r e p l a c e t h e c a p s i n t h e i r r e s p e c t i v ep o s i t i o n s . Extractthe retaintngrear thrust C washer and tne b a c k i n gw a s h e r ,t h e n w i t h d r a w t h e p r i m a r yg e a r t o g e t n e r wath the front thrust washer, which is selective. Remove the main bearing caps after marking them, keeping the linerswith their caps. When the centre cap is removed the tagged lower halves of the thrust washers will also come away. The crankshaft may now be litted o u t t o g e t h e r w i t h t h e t o p h a l v e so f t h e t h r u s t w a s h e r s a n d the top halves of the bearing linersfrom the block. l f i t i s n e c e s s a r yt o r e g r i n d t h e c r a n k s h a f t t o r e s t o r e t t s condition, suitable bearing liners are available for undersizes f .- 010, -.02O, -.030 and _.040 inch. o Never file the bearing caps to take up wear. Any damaged bearing liners should be renewed. Always force paraffin through the oilways in the shafi ro r e m o v e a n y m e t a l l i c o r o t h e r d e p o s i t s , p a r t i c u l a r l yi f t h e r e are any signs of a bearing having run. Refitting : T h e t h r u s t w a s h e r s a r ef i t t e d w i t h t h e o i l g r o o v e sf a c i n g o u t w a r d s a n d t h e t a g g e d h a l v e si n t h e c e n t r e c a p . R e c e s s e s will be seen in the top housing and the cap to locate the bearing liners. See that all running surfaces are well lubricated before assembly. The securing bolts are tightened to a torque of 60 lb ft.

ne eo no b rs

1 : 16 Lubrication. Oil f ilter and relief valve The magneticoil drain plug is below the righthand side rear of the transmission casing and at intervalsof 6000 miles the oil should be drained off and the system refilled through the filler cap on top of the valve cover uo to tne F U L L m a r k o n t h e d i p s t i c k .T h e d r a i n p l u g w a s h e r s h o u l d b e r e n e w e d o n a l t e r n a t eo i l c h a n g e s . Oil pressure warning light: Two warning lights are fitted on the instrument panel, o n e f o r o i l p r e s s u r ea n d t h e o t h e r f o r t h e o i l f i l t e r . l f t h e latter continues to glow when the engine is running at or above a fast idling speed a new oil filter element must be f i t t e d w i t h i n 3 0 0 m i l e s a n d t h e e n g i n e / t r a n s m i s s i o no r r changed. l f t h e o i l p r e s s u r ew a r n i n g l i g h t g l o w s w h e n t h e e n g i n e is running proceed as follows: Check the oil level and top up if necessary. Check that there is no leak at the union on the suction sideof the pump. C h e c k t h a t t h e o i l s t r a i n e ri s n o t b l o c k e d . C h e c k t h a t p r e s s u r ef e d b e a r i n g s a r e n o t l o o s e o r w o r n

11 0 0 k 2 1 3 0 0 M

z l

s p r i n gh o l d s b y t w o f i b r e o r o n e c o p p e rw a s h e r 'T h e v a l v e a c u p a g a i n s ta s e a t i n gm a c h i n e d i n t h e b l o c k ' the C i - r e c "t h a t t h e c u p i s s e a t i n g c o r r e c t l y a n d t h a t c o n f o r m s t o t h e d i m e n s i o n sg i v e n i n T e c h n l c a l spring Data.Fit a new cup and springif necessary 1:17 Crankcase emission control Thrs control system, which is fitted to the Austin i A m e r i c a ,i s i l l u s t r a t e d n F I G 1 : 1 7 T h e e n g i n e b r e a t h e r 1 by hoses to outlet is connected through an oil separator carrhe controlled depression chamber of the SU this is that space between the piston and the buretter(s); t h r o t t l e b u t t e r fl Y v a l v e i n g i n e f u m e s a n d g a s e sa r et h u s d r a w n f r o m t h e c r a n k to the c a s e i n t o t h e i n l e t m a n i f o l d . F r e s ha i r i s s u p p l i e d t h e c o m b i n e do i l f i l l e r c a p a n d f i l t e r4 enginethrough f i l l e rc a p 6 e r v i c i n g J o n s i s t ss i m p l y o f r e n e w i n g t h e o i l e v e r y1 2 , 0 0 0 m i l e so r 1 2 m o n t h s 1 :18 Valve timing No 1 S e t t h e r o c k e r c l e a r a n c eo n t h e i n l e t v a l v e o f r o t a t et h e c y l i n d e rt o . 0 2 9 i n c h w i t h t h e e n g i n e c o l d t h e n 1 c i a n k s h a f tu n t i l t h e v a l v e i s j u s t a b o u t t o o p e n f h e l 4 Ine TDC mark on the flvwheel should now be opposlte a ' p o i n t e ri n t h e c l u t c h c o v e r i n s p e c t i o n p e r t u r ea n d N o 4 p i s t o n a t T D C o n i t s c o m p r e s s t o ns t r o r e a w A c c u r a t ev a l v et i m r n g i s n o t p o s s i b l e i t h t h e r o c k e r s t . t h e i r n o r m a lc l e a r a n c eT h e s e t t i n go f 0 2 9 i n c h i s r e q u r r e d not t o b r i n g t h e o p e n i n g p o s i t i o no f t h e v a l v e t o T D C D o f i g u r eo f t o m i t t o " r e s e t h e c l e a r a n c e o t h e n o r m a lr u n n i n g . 0 1 2 i n c h w i t h t h e e n g i n ec o l d ' 1 : 1 9 R e a s s e m b l i n gt h e e n g i n e a I n s t r u c t i o n sf o r r e a s s e m b l i n g n d r e f i t t i n g t h e c o m p o n e n t p a r t so f t h e e n g i n e h a v e b e e n g i v e n I n t h e s a m e and s e c t i o n so f t h r s c h a p t e rw h i c h d e t a i l e dt h e i r r e m o v a l l do more d i s m a n t l i n g s o t h a t i t s h o u l d n o t b e n e c e s s a r yo , In wnlcn t h a n r e m i n dt h e o p e r a t o ro f t h e c o r r e c ts e q u e n c e t h e s e o p e r a t i o n s s h o u l d b e c a r r l e do u t hand M a k e s u r e t h a t a l l t h e t o o l s a n d e q u i p m e n ta r e t o has a n d t h a t t h e c o m p l e t e s e t o f n e w g a s k e t sa n d w a s h e r s beenobtained. t F i r s tf i t t h e c r a n k s h a f a n d t h e n t h e p i s t o n a n d c o n n e c t the . ing rod assembliesFit the oil pump and camshaft' t i r i i n g g e a r a n d c o v e r a n d t h e s p i n d l ef o r t h e d i s t r i b u t o r drive. Return the engine to its upright position and f it the tne t a p p e t sa n d p u s h r o d s R e p l a c et h e c y l i n d e rh e a d a n d , o . i . " , g " u t . b h e c k t h a t t h e p u s h r o d s a r e c o r r e c t l yl o c a t e d t then rePlace ne slde covers' R e fi t t h e c r a n k s h a f t p r i m a r y g e a r , t h e t r a n s m l s s l o n 't n e flywheel housing and the flywheel and clutch assembly' 1 :2 s t R e v e r s e h e r e m o v a lI n s t r u c t i o n g i v e n i n s e c t i o n water to refit the engine in the car. Refillwith oil and a a n d a d j u s tt h e r o c k e rc l e a r a n c e s s f o l l o w s : 1 :20 Valve rocker adjustment tn P r o v i s i o nf o r a d l u s t i n gt h e v a l v e c l e a r a n c ei s m a d e b y a n a d j u s t a b l es c r e w a n d l o c k n u t ( s e e the rocker arm holding i t C t , t g ) S l a c k e nt h e h e x a g o n l o c k n u t w h i l e by t h e s c r e w w i t h a s c r e w d r i v e r 'S e t t h e r o c k e r c l e a r a n c e the same r o t a t i n g t h e s c r e w i n t h e a p p r o p r i a t ed i r e c t l o n a t gauge When t ' m e c t e c k i n g t h e c l e a r a n c ew i t h a f e e l e r

FIG 1 :18 The clearance between the valve stem and iocker should be o12 inch with the engine cold

FIG 1 :19 Removing the converter' Arrows in.dicate to itr" r"* pr"rrut" valJeand the use of a screwdriver h o l d t h e c o n v e r t e rf r o m t u r n i n g Changing the f ilter element : Disconnect the battery. Unscrew the central bolt the t s e c u r i n gt h e b o w l t o t h e f l l t e r h e a d ,r e m e m b e r i n gh a t parts and bo*t *"itt be full of oil Remove the internal and d i s c a r d t h e e l e m e n t .C l e a n t h e i n s i d e o f t h e b o w l c h e c k t h a t t h e s e a l sa n d w a s h e r sa r e a l l i n g o o d c o n d i t i o n Renew any that arefaultY Fit the new element and the washers in the correct with a o r d e r ,f i l l t h e b o w l w i t h c l e a n e n g i n e o i l a n d r e f i t engine L r q u e o f 1 0 t o 1 5 l b f t o n t h e c e n t r eb o l t R u n t h e and checkfor leaks Oil pressure relief valve: v T h r s n o n a d l u s t a b l e a l v e i s s i t u a t e da t t h e r e a r r i g h t sealed h a n d s i d e o f t h e c v l i n d e rb l o c k u n d e r a d o m e d n u t '

22

the correct gap has been obtained retighten the locknut a g a i n h o l d i n g t h e s c r e w a g a i n s tr o t a t i o n . In order to ensurethe correct position of the tappet on its cam at the time of adjustment the following table will be helpful: A d j u s t N o . 1 r o c k e rw r t h N o . 8 v a l v e f u l l y o p e n A d j u s t N o . 3 r o c k e rw i t h N o . 6 v a l v e f u l l y o p e n A d j u s t N o . 5 r o c k e rw i t h N o . 4 v a l v e f u l l y o p e n A d j u s t N o . 2 r o c k e rw i t h N o . 7 v a l v e f u l l y o p e n A d l u s t N o . 8 r o c k e rw i t h N o . 1 v a l v e f u l l y o p e n A d j u s t N o . 6 r o c k e rw i t h N o . 3 v a l v e f u l l y o p e n A d j u s t N o . 4 r o c k e rw i t h N o . 5 v a l v e f u l l y o p e n A d j u s t N o . 7 r o c k e rw i t h N o . 2 v a l v e f u l l y o p e n T o a v o i d c o n s t a n t r e f e r e n c et o t h e t a b l e i t w i l l b e n o t e d t h a t t h e n u m b e r si n e a c h l i n e a d d u p t o n i n e . After running the engine for a few miles it will be n e c e s s a r yt o t i g h t e n d o w n t h e c y l i n d e r h e a d a n d t o r e s e t the valveclearances. 1:21 Operations mission affected by automatic trans-

In this section instructions will be given for carrying o u t o p e r a t i o n sa l r e a d yd e s c r i b e df o r e n g i n e sw i t h s y n c h r o m e s h t r a n s m i s s i o ni f t h e f i t t i n g o f a u t o m a t i c t r a n s m i s s i o n makes a change in procedure necessary. Valve timing : T h i s i s c a r r i e do u t a s i n S e c t i o n 1 : 1 8 b u t t h e c r a n k s h a f t i s r o t a t e d b y i n s e r t i n ga s c r e w d r i v e rt h r o u g h t h e h o l e in the converter housing and on to the converter starter ring gear until the 1 4 TDC mark on the converter is opposite the pointer on the cover. Servicing the camshaft . E x t r e m ec a r e i s n e c e s s a r y h e n r e m o v i n g t h e c a m s h a f t . w The oil pump drive coupling may stick by oil adhesion to t h e c a m s h a f t a n d o o s s i b l v f a l l i n t o t h e t r a n s m i s s i o nu n i t . E n s u r et h a t t h i s d r i v e c o u p l i n g i s f u l l y l o c a t e d o n t h e s p l i n e d o i l p u m p s p i n d l e w h e n r e fi t t i n g t h e c a m s h a f t . l f i t i s f o u n d n e c e s s a r yt o r e n e w t h e c a m s h a f t b e a r i n g s the converter and transmissionunit must be removed as follows: Removing the transmission unit : Remove the engine and transmission assembly as m d e s c r i b e di n S e c t i o n 1 : 3 . R e m o v et h e r a d i a t o r o u n t i n g bracket.the starter motor and the converter cover. Drain t t h e t r a n s m i s s i o nR e l e a s e h e l o c k w a s h e r n d , w h i l e h o l d . a i n g t h e c o n v e r t e r s t i l l w i t h a s c r e w d r i v e r i n s e r t e dt h r o u g h t h e h o l e i n t h e h o u s i n g , r e m o v et h e c e n t r eb o l t . U n l o c k a n d r e m o v e t h e t h r e e s e t s c r e w sf r o m t h e c o n v e r t e rc e n t r e t h e n s e t t h e s l o t i n t h e e n d o f t h e c r a n k s h a f t h o r i z o n t a l .U s i n g s e r v i c et o o l 1 8 G . 1 0 8 6 a s s h o w n i n F I G 1 : 1 9 r e m o v et h e converter. Refit the three setscrews. Remove the low o r e s s u r ev a l v e . U s i n g s e r v i c et o o l o n t h e c o n v e r t e r o u t p u t g e a r r e m o v e t h e s e l f - l o c k i n gn u t f r o m t h e i n p u t g e a r . F I G 1 : 2 0 s h o w s the internal layout. Remove the gearchange bellcrank lever and the lever p i v o t . F i t t h e n y l o n p r o t e c t o r s l e e v e s e r v i c et o o l 1 8 G . ' 1 9 8 , , 0 over the output gear, remove the securing nuts and setscrews and lift off the converter housing. Lever the main o i l f e e d p i p e f r o m t h e t r a n s m i s s i o na n d o i l p u m p . R e m o v e

FIG 1 :20

The converter

housing removed '1 Main oil pump 4 lnput gear

Key to Fig 1 :20 2 Converteroutput gear 3 ldler gear 6 S e a l i n gr i n g s 5 Orlfeed pipe

FIG 1:21 Fitting the converter housing oil seal. A indicates the depth measurement to be taken '1 Key to Fig 1 :21 Converter housing 2 Oil seal 3 Service tool 18G.'1 688 0 4 Servicetool adaotor set '1 8G.1068A

the

idler

gear,

thrust

washers

and

the

output

gear

assembly.Disconnect the governor control rod from the c a r b ur e t t e r . Remove the oil filter assembly and disconnect the e n g i n e o i l f e e d p i p e , t o g e t h e rw i t h t h e r u b b e r s e a l a n d spring washer on early units. An adaptor is available whrch enables later transmissions, have a screwed p i p e u n i o n p i e c e ,t o b e u s e d w i t h e a r l y e n g i n e sw h i c h normally have a banjo-type union. Remove the securing nuts and setscrews and lift the engine away from the transmtssron.

1 10 0 M k 2 13 0 0

23

Ref itting the transmission unit : D i p t h e m o u l d e d r u b b e rs e a lf o r t h e f r o n t m a i n b e a r i n g c a p i n o i l a n d f i t i t w i t h t h e l i p f a c i n gt h e r e a ro f t h e e n g i n e . F i t t h e r u b b e r s e a l i n g r i n g t o t h e m a i n o i l s t r a i n e rp i p e t c a n d n e w g a s k e t s o t h e t r a n s m i s s i o n a s e ( s e eF I G 1 : 2 0 ) . e L o w e r t h e e n g i n e o n t o t h e t r a n s m i s s i o n n s u r i n gt h a t the rubber seal is correctly located. The securing nuts s h o u l d b e t i g h t e n e da s t h e l o w e r i n g p r o c e e d s . R e f i t t h e m a i n o i l f e e d p i p e . R e f i t t h e o i l f i l t e ra s s e m b l y t n o t i n g c a r e f u l l yt h e i n s t r u c t i o n s o b e g i v e n l a t e r i n t h i s o s e c t i o n .R e f i t t h e m a i n o i l p u m p t o t r a n s m i s s i o n i l p i p e . T r i m o f f a n y e x c e s s t r a n s m i s s i o nl o i n t f r o m t h e r e a r o f h a t h e u n i t ,c l e a nt h e s u r f a c e s n d f i t a n e w c o n v e r t e r o u s i n g gasket. R e f i t t h e c o n v e r t e ro u t p u t g e a r , e n s u r i n gt h a t t h e r e i s a c l e a r a n c eo f . 0 0 3 5 t o . 0 0 6 5 i n c h b e t w e e n t h e i n n e r i t h r u s t w a s h e r a n d t h e o u t p u t g e a r .l f t h e c l e a r a n c e s o u t w s i d e t h e s e l i m i t s s e l e c tt h e a p p r o p r i a t e a s h e r a s g i v e n b e l o w a n d f i t i t w i t h t h e c h a m f e r e di n n e r e d g e t o w a r d s the crankshaft. C o n v e r t e ro u t p u t g e a r t h r u s t w a s h e r s : i . 1 1 2 r o . 1 1 i n c h ,1 1 4 t o 1 1 6 i n c h ,1 1 6 t o . 1 1 8 n c ha n d 4 1 1 8 t o . 1 2 0i n c h . w A s s e m b l et h e i d l e r g e a r t o t h e t r a n s m i s s t o n i t h a n y n o m i n a l w a s h e r f r o m t h e r a n g ef i t t e d o n t h e t r a n s m i s s i o n s i d e o f t h e g e a r . A s s e m b l et h e i d l e r g e a r , s e r v i c et o o l o 1 8 G . 1 0 9 8w i t h a d e n t a l w a x w a s h e r i n t e r p o s e d n t o t h e c o n v e r t e rh o u s i n g s i d e o f t h e i d l e r g e a r . P l a c et h e i n p u t g e a r o n a s u r f a c ep l a t e ,o r S e r v i c et o o l g 1 8 G . 1 9 1 A , n d u s e a d i a l t e s t i n d i c a t o r a u g et o t a k e a a m e a n r e a d r n g .S e t t h e g a u g e t o z e r o a s s h o w n i n F I G 1:23. Fit tool 18G.10894 over the input shaft. Use S e r v i c et o o l 1 8 G . 1 0 8 9 / 1 t o c u t a d e n t a l w a x w a s h e r a n d f i t t h e w a s h e ro v e r t h e i n p u t s h a f t ( s e e F I G 1 : 2 4 ) .

FIG1:22 18 G . 10 8 9

ldler and input gears f itted with service tool

9 F I G 1 : 2 3 U s i n g s e r v i c e t o o l s 18 G . 1 1 a n d 1 8 G . 1 1A , 9 w i t h t h e d i a l t e s t i n d i c a t o rs e t a t z e r o

I n s p e c ta l l t h e o i l s e a l sa n d b e a r i n g sa n d r e n e w w h e n n e c e s s a r y .N e w j o i n t w a s h e r s s h o u l d a l w a y s b e u s e d . t S p e c i a lc a r ei s n e e d e dw h e n r e p l a c i n g h e o i l s e a lt o t h e h c o n v e r t e r o u s i n g ,l e s ti t s h o u l d b l a n ko f f t h e o i l d r a i n h o l e . R e f e rt o F I G 1 : 2 1 . T a k e a d e p t h m e a s u r e m e nftr o m a n y c o n v e n i e n t p o i n t o n t h e p e r i p h e r yt o t h e u n d e r c u t f a c e a s shown at A. lf the distanceA is $ inch the new seal may be pressed i n f l u s h w i t h t h e h o u s i n g f a c e . l f i t i s l e s sf i t t h e s e a l p r o u d of the face by the difference between the two measurements, and vice versa if A is greaterthan 3 inch. Fit the l s e a l ,l i b e r a l l y u b r i c a t e d i, n t h e m a n n e r i l l u s t r a t e d .

FIG 1 :24

Input gear adjustment

'1 1 S e r v i c et o o l 8 G . 1 0 8 9 4 3 S e r v i c et o o l 1 8 G . 1 0 8 9 / 1 5 S e r v i c el o o l 4 S e r v i c et o o l 1 8 G . 1 0 8 9 w r t h w a x w a s h e r 18 G . 1 9 8 0

Key to Fig 1 :24 2 W a xw a s h e r

24

S c r e w t h e t w o p i l o t b a r s o f s e r v i c et o o l 1 g G . 1 0 4 3 I n t o t h e t w o b o t t o m t a p p e d h o l e s i n t h e c r a n k c a s e .E n s u r et h a t n o s h i m s a r e f i t t e d t o t h e i n p u t g e a r b e a r i n ga n d f i t t h e nylon protectorsleeveover the output gear, refit the con_ verter housing and with a new gasket trghten down to a torque of 18 lb ft. Do not f it the input shaft nut. Removethe c o n v e r t e rh o u s i n g . W i t h d r a w t h e a d a p r o r a s s e m b l y1 8 G . 1 0 9 9 4 , t h e w a x w a s h e r a n d 1 8 G . 1 0 8 9 / 1. S u b s t i t u t et h i s a s s e m b l y o r t h e f input gear on the surface plate (see FIG 1:25) and m e a s u e i t st h i c k n e s sT h e m e a nr e a d n g o b r a r n e dn d i c a t e s r . i i the total thickness of shims required to eliminate end f l o a t .T o t h i s f i g u r e a d d s h i m s m e a s u r i n g 0 0 1 t o . 0 0 3 i n c h . t t o g r v e t h e r e q u i r e d i n p u t b e a r i n g p r e l o a d .S h i m s a r e a v a i l a b l ei n t w o s i z e s ;. 0 0 3 a n d . O ' l2 i n c h . M e a s u r et h e t h i c k n e s so f t h e i d l e r g e a r t h r u s t w a s h e r p l u s t h e t h i c k n e s so f t h e i d l e r g e a r s e r v i c et o o l 1 9 G . 1 0 g 9 and rtswax washer. From this figure subtract .004 to .007 I n c h t o o b t a i n t h e t o t a l t h i c k n e s so f t h e t w o t h r u s t w a s h e r s requiredfor the correct end float. l d l e r g e a r t h r u s t w a s h e r s a r e a v a i l a b l ea s f o l l o w s : 1 3 0 t o 1 3 1, 1 3 2 t o . 1 3 3 , 1 3 4 t o . 1 3 5 ,. 1 3 6t o . 1 3 7a n d . 1 3 8 t o . 1 3 9 i n c h . F i t o n e w a s h e ro n e a c h s i d e o f t h e i d l e r g e a r t o g i v e t h i s t o t a l t h i c k n e s sa s c a l c u l a t e d . F i t t h e r e q u i r e dt h i c k n e s so f s h j m s a s c a l a c u l a t e d o r f t h e i n p u t b e a r r n gp r e l o a d . Refit and alrgn the converter outlet pipe. Discard the c o n v e r t e r o u s i n gj o i n t w a s h e ra n d f i t a n e w o n e . R e m o v e h t h e p i l o t b a r so f ' 1 G . 1 0 4 3 a n d t i g h t e n a l l s e c u r i n gn u t s t o 8 a t o r q u e o f 1 8 l b f t . R e f i tt h e i n p u t g e a r n u t ( t o r q u ef i g u r e 7 0 l b f t ) . R e m o v ee a c h p a i r o f b o l t s r n t u r n f r o m t h e c o n _ v e r t e r a n d f i t n e w l o c k i n g p l a t e s .T i g h t e n t o 2 2 t o 2 4 l t r I L Lock with the tabs. Lubricatethe oil seal and fit the con_ verter. Refit the washer (offset pegs) and the centre bolt and l o c k i n g w a s h e r .T i g h t e n t h i s t o 1 1 0 t o 1 1 5 l b f t a n d l o c k . Refit the low pressure valve and gasket. Refit the gear selector bellcrank lever,clevis pin and rubber boot. Refit tne converter cover, starter motor and rear enqine mounting. Oil pump: l n s t r u c t i o nf o r s e r v i c i n g t h e o i l p u m p w e r e g i v e n i n S e c t i o n 1 : 1 5 , b u t r e f e r t o F I G 1 : 2 6 l o r d e t a i l so f t n e l a t e r t y p e o f H o b o u r n -E a t o no u m o .

FIG 1 :25 Key to Fig 1 :25 2 Wax washer

Measuring the adaptor assembly 1 S e r v i c et o o l 1 8 c . 1 0 8 9 / 1 3 S e r v i c et o o l 1 8 G . 1 0 8 9 A

--/)/KC\e

FIG 1 :26 Exploded view of oil position for checking clearance

dff w
A

pump.

indicates

FIG 1:27

E n g i n e a n d a u t o m a t i c t r a n s m i s s i o n o i l f i l t e: r . A E a r l y t y p e , B L a t e r t y p e

K e yt o F i g 1 : 2 7 7 Sealing asher w

1 F i l t e re l e m e n t 8 S e a l i n gp l a t e

2 Circlip 3 S t e e lw a s h e r 9 F i l t e rh e a d r e t a i n i n gb o l t s

4 Sealing ring 5 Centre boll 10 Oil pressure heck plug c

6 Spring

1100Mk21300

25

Refer to FIG 1:27 to ensure that the correct element and spring are fitted and that all the components are a s s e m b l e di n t h e c o r r e c t o r d e r . R e f i t a n d t i g h t e n t h e b o l t to 20 lb ft. Ensure that the coil mounting bracket is correctiy located then tighten the clamp bolt. Top up the engine otl level. Start the engine and check for leaks. The filter head is removed after unscrewing the two retaining bolts 9. Note that the joint washer with copper i n s e r t s o n t h e l a t e r t y p e i s n o t i n t e r c h a n g e a b l ew i t h t h e e a r l i e rt y p e . T h e t w o O - r i n g s e a l sa r e n o t u s e d o n t h e l a t e r type. FIG 1:28 shows the correct location of the later type joint washer. W h e n r e f i t t i n g ,u s e a n e w j o i n t a n d s e a l s i f t h e o l d o n e s are damaged or distorted.

'i, 1z' 't. ;'lt

it" tz,
ing the later type filter cover joint washer

1 :22 Special operations on the 1275cc engine Valves: The valve assembly no longer has a spring cltp round the colletsand'a completely new oil seal is used (see FIG 1 :29). W i t h d o u b i e v a l v e s p r i n g s i t i s n e c e s s a r yt o f i t t h e l o w e r spring seat before sliding th3 seal down the valve stem and over the guide. Camshaft: r T o r e m o v e t h e c a m s h a f t .d r a i n t h e t r a n s m i s s i o n , e m o v e t h e e n g i n e ( s e e S e c t i o n 1 : 2 ) , t h e t r a n s m i s s i o n( s e e Section 1 :10), the rocker shaft assemblyand pushrods ( s e e S e c t i o n 1 : 5 ) , t h e t i m i n g g e a r ( s e eS e c t i o n 1 : 6 ) and the distributor (see Chapter 3). Remove the cams h a f t l o c a t i n gp l a t e . lnvert the engine to allow the tappets to fall clear. Withdraw the camshaft while rotating it slowly to disengage the distributor driving shaft.The flange of the oil pump drive (see FIG 1:30), may come away with the camshaft; ensure that it is refitted to the oil pump drive shaft with the dnve lugs towards the pump. On later m o d e l s t h e d r i v i n g l u g s a r e c e n t r a l i z e do n t h e d r i v i n g flange. Later pumps are also of the two screw fixing p a t t e r nb u t m a y b e u s e d a s r e p l a c e m e n t so r t h e e a r l i e r f four screwfixingtype. W h e n r e fi t t i n g t h e c a m s h a f t r o t a t e i t s l o w l y t o a s s i s tt h e engagement of the oil pump drive. Fit the camshaft locating plate with the whitemetal side towards the camshaft. M a k e s u r e t h a t t h e t a p p e t s a r e r e t u r n e dt o t h e i r o r i g i n a l posrtrons. Pistons and connecting rods: To remove the connecting rods. Drain the cooling system, the transmission casing and the external oil f i l t e r . R e m o v et h e e n g i n e . R e m o v et h e f l y w h e e l a n d c l u t c h (see Section 1 :8), the flywheel casing {see Section 1 : 9), the transmission (see Section 1 :10) and the c v l i n d e r h e a d ( s e e S e c t i o n 1 : 4 ) . R e l e a s et h e c o n n e c t i n g rod bolts, remove the caps and withdraw the connecting rods and pistons out through the top of the bores. To remove the pistons: T h e g u d g e o n p i n i s a p r e s sf i t i n t h e s m a l l e n d o f t h e connecting rod and it is essential that the specified

FIG 1 :29 Key to Fig 1 :29 3 Outer spring 5 Valveguide

1275cc valve assemblv 2 R e t a i n i n gc u p 1 Splitcotters 4 I n n e r s p r i n g ( 1 2 G e n g i n e so n l y )

Oil filter:
Referto FIG 1 :27 for detailsof the oil filter assembly fitted to cars fitted with automatic transmissron. Before starting to remove the filter place a suitable c o n t a i n e r u n d e r n e a t ht h e f i l t e r t o c a t c h t h e s p i l l i n g o i l . Slackenthe bolt on the ignitton coil mounting clamp,then unscrew the central retaining bolt 5 with a box spanner inserted through a hole in the engine mounting plate. Remove the bowl and element assembly. Cleanthe bowl with petroland dry. Cleanthe f ilterhead a n d f i t a n e w s e a l i n g r i n g i n t h e r e c e s s .C h e c k t h e c o n d i tion of the other sealing washers and spring and renew wnere necessary.

26

f . t i n t e r f e r e n c ei t b e m a r n t a r n e dF o r t h i s r e a s o nS e r v i c e o o l 18G.1150 must be used for separatingand retitting p i s t o n sa n d c o n n e c t i n g r o d s . Refer to FIG 1 :31: C l a m p t h e h e x a g o nb o d y 1 o f t h e t o o l i n a v i c e ,s c r e w back the largenut 2 until it is flush with the end of the c e n t r es c r e w 3 t h e n p u s h t h e s c r e w f o r w a r d su n t i l t h e n u t contacts the thrust race4. F i t t h e t o o l a d a o t o r5 o n t o t h e c e n t r es c r e w w i t h t h e p i s t o n r i n g c u t a w a y u p p e r m o s t .S l i d e t h e p a r a l l e ls l e e v e 6 o n t o t h e c e n t r es c r e w w i t h t h e s h o r t l e n q t h d i a m e t e r fr rst. N o w f i t t h e p i s t o n 7 o n t h e c e n t r es c r e w a s s h o w n a n d . r t h e n t h e r e m o v e r / r e p l a c eb u s h B w i t h t h e I o n g e r p o r t i o n towardsthe piston. Screw on the stop nut 9 until the end play A is j a p p r o x i m a t e l y. i n c h ( . 8 m m ) a n d t h e n l o c k i t s e c u r e l y with the lock screw 10. Check that the remover/replacer ush and oarallel b s l e e v ea r e c o r r e c t l yp o s i t i o n e di n t h e b o r e o n b o t h s i d e s of the piston. Check also that the curved face of the a d a p t o r i s p e r f e c t l yc l e a n ,t h e n s l i d e t h e p i s t o n s o t h a t i t f i t s t h e c u r v e d f a c e a n d t h e D i s t o nr i n q s a r e o v e r t h e c u t away in the adaptor.

P
2

3
1275cc oil pump drive, showing FIG 1:30 position for the driving flange correct

Key to Fig 1 :30 f 2 D r r v i n gl a n g e

1 Oil pump driveshafl

3 CamshaJt

FIG 1 :31

R e m o v i n g ( u p p e r ) a n d r e f i t t i n g ( l o w e r ) t h e g u d g e o n p i n u s i n g S e r v i c et o o l 1 8 G . 1 1 5 0
2 L a r g en u t 3 Centre screw 10 L o c k s c r e w 4 Thrustrace 1 1 G u d g e o np i n 5 Addptor 6 P a r a l l e ls l e e v e

1 Hexagonbody Key to Fig 1 :31 7 Piston 8 Bemover/replacerbush

1 1 0 0 k2 1 3 0 0 M

27

remover/replacer ush is b inch (.8 mm) from the p i s t o ns k i r t C . O n n o a c c o u n t m u s t t h e f l a n g e c o n t a c tt h e piston. lf the torque wrench does not break during this o p e r a t r o n , h e f i t i s n o t a c c e p t a b l ea n d t h e c o m p o n e n t s t m u s t b e r e n e w e d . K e e p t h e l a r g e n u t a n d t h e c e r r t r es c r e w w e l l o i l e d o r a f a l s e r e a c t i o nm a v r e s u l t .

Connecting rods: These are fitted in the reverseorder of removal, but note the following points: C h e c kt h a t t h e p i s t o n r i n g g a p s a r e s t a g g e r e d t g O d e g . a t o e a c h o t h e r a n d t h a t e a c h c o n n e c t i n gr o d a n d p i s t o n i s r e fi t t e d i n t o i t s o r i g i n a lb o r e t h e c o r r e c tw a y r o u n d . T h e b i g - e n d b e a r i n g sa r e n o t i n c l i n e d a s i n F I G 1 : 1 b b u t t h e y a r e s i m i l a r l yo f f s e t . N o s . 1 a n d 3 a r e o f f s e t towards the rearof the engine,2 and 4 are offset towards the front Self-locking nuts are used on the big-end bolts, c h e c k t h a t t h e y d o l o c k s a t i s f a c t o r i la n d t i g h t e nt h e m t o a y t o r q u e o f 3 5 t o 3 8 l b f r w i t h t h e t h r e a d sl i g h t l y o i l e d . Piston sizes: In addition to the standard pistons, two oversizes a r e a v a i l a b l e .D i m e n s i o n sa r e i n d i c a t e d i n a s i m i l a r m a n n e rt o t h e s m a l l e r n g i n e . e Piston marktng Suitable bore srze Grade A Grade B S t a n d a r d 2 1 8 O 5 t o 2 . l 8 1 O 2 . 1 8 i 1 t o 2 . 7 8 1 6i n c h (10.625to 70 635) (70.640 to 70.65b) mm +.010inch2.l905to2.791O 2.i911 ro 2.791 inch 6 (+.255mm) (70.880ro 70.890) (70.895to 70.905) mm + . 0 2 0 i n c h 2 . 8 0 0 5 t o 2 . 8 0 10 2 . 8 0 11 r o 2 . 8 0 16 i n c n ( + . 5 1 0m m ) ( 7 1 . 1 3 5 o 7 1 1 4 5 ) ( 7 1 1 5 0 t o 7 1 . 1 6 0 )m m r Cylinder head: 1 2 7 5 c c e n g i n e sw i t h a 9 . 7 5 : 1 c o m p r e s s i o nr a t i o a r e f i t t e d w i t h a n e x t r as t u d a n d a n e x t r a b o l t a t e a c h e n d o f t h e c y l i n d e r h e a d . T h e a d d i t i o n a ln u t a n d b o l t a r e f i t t e d a n d r e m o v e di n d e p e n d e n t l y . W h e n r e fi t t i n g t h e h e a d , t i g h t e n t h e m a i n n u t s f i r s t r n t h e s e q u e n c eg i v e n i n F I G 1 : 3 2 t o a t o r q u e o f 4 8 t o 5 2 l b f t a n d t h e n t h e a d d i t i o n a ln u t t o t h e s a m e t o r q u e a n d t h e bolt to 25 lb ft 1 :23 Oil control piston rings E a r l ym o d e l so f t h e 1 2 7 5 c c e n g i n e a n d l a t e rm o d e l s o f the 1098 cc were fitted with Duaflex oil control rings. W h e n f i n i n g t h e m t h e f o l l o w i n g p o r n t ss h o u l d b e n o t e d : T h e f i t t e d g a p f o r t h e r a i l si s . 0 1 2 t o . 0 2 8 i n c h . w h i l e the gap for the side springshould be between.100 and '1 50 inch. T h e l u g s o f t h e e x p a n d e rm u s t b e b u t t e d t o g e t h e ra n d n o t c r o s s e da n d i n s e n e d i n t o o n e o f t h e h o l e s i n t h e s c r a p e rr i n g g r o o v e o n t h e n o n - t h r u s t ( c a m s h a f t )s i d e o f the piston. W h e n c o m p r e s s i n g h e r i n g s p r i o r t o f i t t i n g ,m a k e s u r e t that the end of each ring is fully home rn its groove. S e e t h a t t h e g a p s i n t h e t w i n r a i l sa n d t h e s i d e s p r r n g a r e s t a g g e r e do n t h e n o n - t h r u s ts i d e o f t h e p i s t o n .

F I G 1 : 3 2 R e l e a s ea n d t i g h t e n i n g s e q u e n c e s o r t h e f c y f i n d e r h e a d n u t s o n 1 2 7 5 c c e n g i n e s .T h e a r r o w s A a n d B indicate the additionalbolt and nut fitted to 9.75:1 c o m p r e s s i o nr a t i o e n g i n e s S c r e w t h e l a r g e n u t u p t o t h e t h r u s t r a c e ,t h e n h o l d the lock screw and turn the nut untilthe gudgeonpin has been withdrawn from the piston. Refitting the pistons: Remove the large nut 2 from the tool and pull the c e n t r e s c r e w 3 o u t o f t h e b o d y b y a f e w i n c h e s .t n e n l s l i d e t h e p a r a l l e s l e e v e6 , l o n g e r l e n g t h d i a m e t e rf i r s t ,o n t o t h e c e n t r e s c r e w u p t o t h e s h o u l d e ro n t h e s c r e w . A p p l y a c o a t i n g o f g r a p h r t e do i l t o t h e g u d g e o n p i n and the bores of the connecting rod and piston,then p l a c et h e p i s t o no v e r t h e c o n n e c t i n gr o d a n d f i t t h e t o o l t o t h e p i s t o n ,i n s e r t i n gt h e p a r a l l e s l e e v ei n t o t h e s m a l l e n d l b o r e a s f a r a s t h e g r o o v er n t h e s l e e v e . i t t h e g u d g e o n p r n F i n t o t h e p i s t o n b o r e a s i a r a s t h e c o n n e c t i n qr o d . Fit the removerlreplacer bush with iG short end towards the gudgeon pin. Screw the stop nut on to the centrescrew until there is.! inch (.8 mm) end play B and lock it with the lock screw 10. Clean the curved face of the adaptor and slide the p i s t o n i n t o c o n t a c tw i t h i t a n d c h e c k t h a t t h e p i s t o n r i n g s are over the cutaway portion. F i t a n d s c r e w t h e l a r g en u t u p t o t h e t h r u s t r a c e . T h e m i n i m u m l o a d f o r a n a c c e p t a b l ef i t i s 1 6 l b f t . Set the torque wrench to this ftgure and while holding t h e l o c k s c r e w w i t h a n o t h e r s p a n n e r ,p u l l t h e g u d g e o n prn in by turning the large nut until the flange oi the

1 2 1 2

FIG 1 :33 Details of the Apex oil control piston ring. A shows the ends of the expander butted together, B shows a cross-section through the assembled rings

Key to Fig 1 :33

Railr ngs

2 Spacer

e x p a n d e rr i n g

28

l-'g
6t t
l \

\Y_/

l J

FIG 1 :34 KeytoFigl:34 6 R e l i e fv a l v e

Exhaust emission control svstem 5 Airpump

1 Airmanifold 2 F r l t e r e d o ifli l l e r c a p 4 Emissionaircleaner 3 Checkvalve 7 C r a n k c a s e m i s s r o nv a l v e e 8 V a c u u m s e n s i n ot u b e 9 Gulo valve

Any glaze on the cylinder walls should be removed before fitting the pistons. L a t e r 1 2 7 5 c c e n g i n e sa r e f i t t e d w i t h A p e x o i l c o n t r o l r i n g s a n d w h e n f i t t i n g t h e s et h e f o l l o w i n g p o i n t s m u s t b e o b s e r v e d .R e f e rt o F I G 1 : 3 3 . The rail gaps must be between .010 and .040 inch when fitted. R e m o v et h e c o m p r e s s i o nr i n g s a n d f i t o n e o f t h e r a i l s t o t h e p i s t o n , p o s i l i o n i n gi t b e l o w t h e b o t t o m g r o o v e . F i t t h e e x p a n d e ri n t o t h e b o t t o m g r o o v ea n d t h e n m o v e t h e r a i l p r e v i o u s l ym e n t i o n e di n t o t h e s a m e g r o o v e . F i t t h e o t h e r r a i l i n t o t h e g r o o v e a n d s e et h a t t h e e n d s o f t h e e x p a n d e ra r e j u s t b u t t i n g w h e n t h e r a t l sa r e l i g h t l y p r e s s e dt o g e t h e r . S t a g g e rt h e g a p s o f t h e r a i l s a n d e x p a n d e ra t n o t l e s s than 90 deg.to each other Remove any glaze from the cylinder bores before fittingthe pistons. 1 :24 Exhaust emission control This system is fitted to the Austin America in order to c o m p l y w i t h S t a t e R e q u l a t i o n sa n d i t i s e m p h a s i z e d h a t , t

a n y s e r v i c i n go p e r a t i o n so n t h e e n g i n e w h i c h m i g h t a f f e c t t h e e f f i c i e n c y o f t h e s y s t e mm u s t b e f o l l o w e d b y a n e x h a u s t e m i s s i o nc h e c k . T h e f o l l o w i n g i s a l i s t o f c o m p o n e n t s a f t e r w h o s e s e r v i c i n gt h i s s h o u l d b e d o n e : 1 R e m o v i n gt h e c y l i n d e rh e a d
1n^^^-L^^i-l^^ L UYUdt UVt |L| t9

3 4 5 6 7 8 9 10 11 12

Valve rocker adjustment V a l v et i m i n g Rocker shaft servicing Valves and seats Camshaft Tappets Distributor lgnitionadjustment Carburetter Air cleaner

Description (see FIG 1 :34) : The pump 5 which is belt driven from the fan pulley d r a w s a i r t h r o u g h t h e c l e a n e r 4 a n d p a s s e si t t o t h e e x h a u s t ports by way of the manifold 1. The check valve3 prevents a b l o w - b a c k o f h i g h p r e s s u r ee x h a u s t g a s e s , w h i l e t h e relief valve 6 preventsa build-up at high speeds.

1100Mk21300

29

A v a c u u m s e n s i n gt u b e 8 r u n s f r o m t h e i n l e t m a n i f o l d t o a g u l p v a l v e 9 a n d m a i n t a i n s d e p r e s s i o no n o n e s i d e o f the valve diaphragm. Closing the throttle causes an increase in the manifold depression which opens the v a l v e a n d a d m i t sa s u p p l yo f a i r i n t o t h e i n l e t m a n i f o l da n d prevents the usual rich airlfuel mixture under these conditions.A bleed hole in the diaphragmallows the pressure t o e o u a l i z ea n d t h e v a l v e c l o s e s .I n s o m e u n i t s a r e s t r i c t o r i n t h e p u m p - t o - g u l p v a l v e p r e v e n t ss u r g i n g . Air pump: The correct belt tension-| inch up and down at the middle of the longest belt run-is adjusted by slackenrng the mounting bolt 1 and the adjustinglink bolts 2, moving t h e p u m p a s n e c e s s a r ya n d r e t i g h t e n i n g t o 1 0 l b f t . To test the pump: Check the belt tension and connect a tachometer to the engine, then proceed as follows: Disconnect the air supply hose at the gulp valve and p l u g t h e h o s e . D r s c o n n e c tt h e a i r s u p p l y h o s e a t t h e c h e c k g valve3 and fit a pressure auge as shown in FIG 1 :35. R u n t h e e n g i n e a t 1 2 0 0 r e v l m i n . l f a g a u g e r e a d i n go f l e s s t h a n 2 . 1 5 l b l s q i n i s r e g i s t e r e d ,r e m o v e t h e p u m p a l r cleaner for cleaning and fitting of a new element. Refit and repeatthe test. lf the reading is still low blank off the relief valve 6 and repeat the test. lf the reading is now correct renew the reliefvalve. l f t h e p r e s s u r e i s s t i l l l o w , r e m o v e a n d s e r v r c et h e a i r pump. Stop the engrne and fit a temporary air duct over the f a c e o f t h e r e l i e fv a l v e 6 . T h t s m a y b e d o n e e i t h e rw i t h a l e n g t h o f m e t a lt u b e a n d a g r o m m e t a s a t 1 i n F I G 1 : 3 5
FIG 1 :35 Testing the air PumP

or with a piece of adhesive tape as at 2. Do not try to check the air flow from the relief valve by using the fingers. t S t a r tt h e e n g i n e a n d s l o w l y i n c r e a s e h e s p e e du n t i l a i r b e g r n s t o i s s u ef r o m t h e r e l i e fv a l v e d u c t ; t h e g a u g e r e a d ing should be 4.5 to 6.5 lbisq in. lf this value is not r e g i s t e r e dt h e v a l v e s h o u l d b e r e n e w e d .

Servicing the air pump: Remove the air cleaner and disconnect the hoses. Loosenthe mounting bolts and remove the belt. Unscrew

FIG 1:36 Key to Fig 1 :36 7 V a n ea s s e m b l i e s

E x p l o d e dv i e w o f t h e a i r p u m p
6 Carbons

5 Spring 4 Outletchamber 3 Rotor 2 Inlet chamber 1 Belief valve 11 lnlel port 1 0 Port end cover 9 Outlet port 8 Rotor bearing end plate

30

the top adJustrng olt, wrthdraw the mounting bolt and b r e m o v et h e p u m p . R e f e rt o F I G 1 : 3 6 U n s c r e wt h e f o u r b o l t s a n d r e m o v e the cover 10. Removefour screws and removethe end p l a t e B L i f t o u t t h e v a n e a s s e m b l i e s , t h e c a r b o n s6 a n d 7 t h e s p r i n g s5 . 'Andok' C l e a na l l p a r t sa n d p a c k t h e b e a r i n g s i t h E s s o w 2 6 0 g r e a s e .R e n e w a n y w o r n o r d a m a g e dv a n e s .F i t n e w c a r b o n sw i t h t h e c h a m f e r e de d g e i n s i d e R e a s s e m b l e h e p u m p b y r e v e r s i n gt h e d i s m a n t l r n g t p r o c e d u r e .D o n o t o m i t t o s m e a r t h e u n d e r s i d eo f t h e s c r e w ss e c u r i n g h e r o t o r b e a r i n ge n d p l a t ew i l h ' L o c k t i t e ' t R e f i tt h e p u m p t o t h e e n g i n e A d l u s t t h e b e l t . R e p l a c e t h e h o s e sa n d t h e a i r c l e a n e r . Testing the check valve D i s c o n n e c t h e s u p p l y h o s ea n d u n s c r e wt h e v a l v ef r o m t h e m a n i f o l d .B l o w t h r o u g h t h e v a l v e b y m o u t h f r o m e a c h e n d . l f a i r p a s s e s h r o u g hw h e n b l o w i n g f r o m t h e m a n i f o l d t c o n n e c t i o nt h e v a l v e m u s t b e r e n e w e d .

FIG 1 :37 Details for fitting the additional engine steadyrod Key to Fig 1 :37 1 R e i n f o rn g p a t c c 2 A n c h o rp a t e A - 1 : i n c h( 2 1 m m ) B j n c h( ' 1 m m l 9

Testing the air manifold : Disconnect the manifold from the cylinder head. S l a c k e nt h e c h e c k v a l v e h o s e c l i p a n d t u r n t h e m a n i f o l d u n t i l t h e i n J e c t o r o n n e c t i o n sa r e a c c e s s i b l eT i g h t e n t h e c . h o s e c l i p a n d r u n t h e e n g r n ea t i d l i n g s p e e d .C h e c k t h e a i r f l o w f r o m e a c h o f t h e m a n i f o l dc o n n e c t i o n s n d b l o w o u t a a n y o b s t r u c t i o n s .C h e c k t h a t e x h a u s t g a s e s b l o w f r o m each cylinder head inlectorand free any that may be restrrcted s follows: a R o t a t et h e e n g i n e u n t i l t h e e x h a u s tv a l v e a t t h e i n l e c t o r i s c l o s e d .U s i n g a h a n d d r i l l p a s sa $ i n c h d r i l l t h r o u g h t h e i n l e c t o rb o r e t a k i n g c a r e t h a t i t d o e s n o t t o u c h t h e v a l v e s t e m . C l e a no u t t h e p o r t w i t h a n a i r b l a s ta n d r e c o n n e c t . 1 :25 Engine steady rod A n a d d i t i o n a le n g i n e s t e a d y r o d i s f r t t e dt o s o m e l a t e r models and some owners may wish to add one to an e a r l y c a r .T h i s c a n b e d o n e a s f o l l o w s : R e f e rt o F I G 1 : 3 7 . F i r s tf i t t h e a n c h o r p l a t e 2 o n t o t h e a u x r l i a r yp u m p h o u s i n g . l t i s i m p o r t a n t t o u s e s p e c i a l f l a n g e dl o c k n u t s n p l a c eo f t h e o r i g i n a ln u t s a n d s p n n g r washers. Mark the rearundersrde f the sub frameas showrr rn o t h e d i a g r a ma n d d r i l l a f i i n c h ( 1 C m m ) h o l e w h e r e in d i c a t e d . A t t a c h t h e f r o n t e n d o f t h e s t e a d y r o d l o o s e l yt o t h e a n c h o r p l a t e ,u s i n g a s e r r a t e d a s h e r o n e a c h s i d e o f t h e w p l a t e w i t h t h e s e r r a t i o n sa c i n g r t , a s s h o w n i n F I G 1 : 3 8 f Fit the reinforcing plate on the sub {rame. 1 rn F I G 1 : 3 7 , a n d a s s e n r b l eh e r e a r e n d o f t h e s t e a d y r o d . t Tightenboth Nyloc nuts to a torque of 28 lb ft.

Testing the gulp valve : D i s c o n n e c tt h e g u l p v a l v e s u p p l y h o s e f r o m t h e a i r p u m p . C o n n e c t a v a c u u m g a u g e w i t h a T - c o n n e c t o rt o t h e e n d o f t h e h o s e .R u n t h e e n g i n e a t i d l i n g s p e e d .B l o c k t h e o p e n e n d o f t h e T - p i e c ew i t h a f i n g e r a n d c h e c k t h a t the gauge reads zero for 15 seconds. lf a vacuum rs r e g i s t e r e dr e n e w t h e g u l p v a l v e . l t t s i m p o r t a n t n o t t o r n c r e a s eh e e n g i n e s p e e da b o v e i d l i n g s p e e dd u r i n g t h i s t Iest. S t i l l w i t h t h e T - c o n n e c t i o n t e m p o r a i l l yc l o s e d o p e n the throttle rapidly; a vacuum should be registered. R e p e a t t h i s t e s t s e v e r a lt i m e s , u n s e a l i n gt h e T b e t w e e n each test.If the gauge failsto register vacuum,renew a thegulp valve.

Testing the limit valve : D i s c o n n e c tt h e s e n s i n g p i p e f r o m t h e i n l e t m a n i f o l d a n d i n i t s p l a c ec o n n e c ta v a c u u m g a u g e .C o n n e c ta t a c h o meter to the engine which should be run at a fast-idle u n t i l n o r m a lw o r k i n g t e m p e r a t u r es r e a c h e d . i I n c r e a s es p e e d t o 3 0 0 0 r e v l m i n a n d r e l e a s et h e t h r o t t l e q u i c k l y .T h e g a u g e s h o u l d r i s e t o 2 0 . 5 t o 2 2 i n H g . l f t h e gauge reading is outside these limits, the limit valve assembly and the carburetter throttle disc must be renewed (seeChapter 2, Section 2:14).

o |\774 FIG 1 :38 assemblv The components of the additional steadv rod

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1 :26 Fault diagnosis (a) Engine will not start 1 D e f e c t i v ec o i l 2 F a u l t yd i s t r i b u t o rc a p a c r t o r 3 D i r t y , p i t t e d o r i n c o r r e c t l ys e t c o n t a c t b r e a k e r p o i n t s 4 l g n i t i o n w i r e s l o o s e o r i n s u l a t i o nf a u l t y 5 Water on sparking plug leads 6 B a t t e r y d i s c h a r g e d ,c o r r o s i o n o f t e r m r n a l s 7 Faulty or jammed starrer 8 S p a r k i n gp l u g l e a d sw r o n g r y c o n n e c t e d 9 Vapor lock in fuel pipes 1 0 D e f e c t i v ef u e l p u m p 1 1 O v e r c h o k i n go r u n d e r c h o k i n g 1 2 B l o c k e d p e t r o l f i l t e r o r c a r b u i e t t e rj e t ( s ) 13 L e a k i n g v a l v e s 1 4 S t i c k i n gv a l v e s 1 5 V a l v et t m i n g i n c o r r e c t 16 l g n i t i o n t i m i n g i n c o r r e c t (b) Engine stalls 1 2 3 4 5 6 7 C h e c k 1 , 2 , 3 , 4 , S , 1 0 , 1 1 , 1 2 , 1 3 a n d 14 i n ( a ) Sparking plugs defectiveor gaps incorrect R e t a r d e di g n i t i o n Mixture too weak Water in fuel system Petrol tank vent blockeo Incorrectvalve clearances

(.i) Sticking valves 1 2 3 4 Check2 in (a) B e n t v a l v es t e m Scored valve stem or guide Incorrectvalve clearance

. (k) Excessive cylinder wear 1 Check 1 1 in (a) and (seeChapter 4) 2 Lack of oil 3 Dirtyoil 4 P i s t o n r i n g sg u m m e d u p o r b r o k e n 5 Badlyfitting pistonrings 6 Connectrng rod bent (l) Excessive oil consumption 1 Check 6 and 7 in (c) and check (k) 2 Ring gaps too wide 3 Oil return holes in piston choked with carbon 4 Scored cylinders 5 O i l l e v e lt o o h i g h 6 E x t e r n a lo i l l e a k s 7 I n e f f e c t i v ev a l v e s t e m o i l s e a l s (m) 1 2 3 4 5 6 Crankshaft and connecting rod bearing failure

(c) Engine idtes badty 1 Check 2 and 7 in (b) 2 A r r l e a k a t m a n i f o l dj o i n t s 3 C a r b u r e t t e rj e t s e t t i n g w r o n g 4 Air leak in carburetter 5 O v e r - r i c hm i x t u r e 6 Worn piston rings 7 W o r n v a l v es t e m so r q u i d e s 8 Weak exhaust valve s-prings (d) Engine misfires 1 C h e c k1 , 2 , 3 , 4 , S , 8 , 1 0 , 1 2 , 1 3 , 1 4 , 1 5a n d 1 6 in (a/; 2, 3, 4 and 7 in (b) 2 Weak or broken valve springs (e) Engine overheats (see Chapter 4) (f) Compression low l,Check 13 and 14 in (a); 6 and 7 in (c) and 2 in (d) 2 Worn piston ring grooves 3 Scored or worn cylinder bores (g) Engine lacks power 1 C h e c k 3 ,1 0 , 1 1 r , 1 21 3 ,1 4 , 1 5 a n d 1 6 i n ( a ) ; 2 , 3 , 4 , a n d 7 i n ( b ) ; 6 a n O7 i n ( c ) a n d 2 i n ( d ) . A t s o c h e c k 1e.1 and (f) 2 Leaking joint washers 3 F o u l e d s p a r k i n gp l u g s 4 Automattc advance not operating (h) Burnt valve or seats 1 Check 13 and 14 in (a); 7 in (b) and 2 in (d). Also check (e) 2 E x c e s s i v ec a r b o n a r o u n d v a l v e s e a t s a n d h e a d

Check 2 in (k) R e s t r i c t e do i l w a y s W o r n j o u r n a l so r c r a n k p i n s Loose bearing caps E x t r e m e l yl o w o i l p r e s s u r e B e n t c o n n e c t i n gr o d leakage (see Chapter 4)

(n) lnternal water

(o) Poor water circulation (see Chapter 4) (p) Corrosion (see Chapter 4) (q) High fuel consumption (see Chapter 2) (r) Engine vibration 1 2 3 4 5 L o o s e a l t e r n a t o rb o l t s Mounting rubbers loose or ineffective E x h a u s tp i p e m o u n t i n g t o o h i g h Fan blades out of bala-nce Misfiring due to mixture,ignition or mechanicalfaults

Fault diagnosis: The following items apply only when an exhaust emission control system is fitted (s) Backfire in exhaust system 1 Leak in exhaust system 2 Leak in hosesor connections to gulp valve or vacuum s e n s i n gp i p e 3 Leak in intake system 4 F a u l t yg u l p v a l v e 5 F a u l t y c a r b u r e t t e rl i m i t v a r v e (t) Hesitation when throttle closure accelerating after sudden

1 C h e c k1 , 2 , 3 a n d 4 i n 1 s . 1

2)

(w) Burned or baked hose between air pump and check valve 1 F a u l t yc h e c k v a l v e 2 F a u l t ya r r p u m p

(y) High exhaust system temperature 1 l n c o r r e c ti g n i t i o n t i m i n g 2 A i r i n j e c t o rm i s s i n g 3 F a u l t ya i r p u m p r e l i e fv a l v e (z) Mixture needs enrichment to obtain correct exhaust emission reading 1 Air leakin crankcase 2 L e a k s i n c r a n k c a s e b r e a t h e r h o s e o r c a r b u r e t t e rc o n nections

(x) Noisy air pump 1 B e l t t e n s i o ni n c o r r e c t 2 P u l l e yl o o s e o r m i s a l i g n e d 3 D a m a g e da i r p u m p

1 1 0 0M k 2 1 3 0 0

C H A P T E R2 THE FUELSYSTEM
2 :1 2:2 2:3 2:4 2 :5 2:6 2:7 2:8 2 :9 Description Routine maintenance Pump removal and dismantling Examination of pump Reassembly of pump Testing the pump Operation of the SU carburetter Removing and servicing the carburetter Centralizing the jet 2 :10 2 :11 2 :12 2 :'l3 2:14 2 :15 2:16 2:17 Slow-running adjustment Twin carburetter linkage Carburetter faults Throttle damper. 1275cc engines Exhaust emission control Air cleaner Mechanical fuel pump Fault diagnosis

2 :1 Description All the modelscoveredby this manual are fitted with SU fuel pumps and SU carburetters. Two tvpes of e l e c t r i c ap u m p a r e u s e d a n d o n e m e c h a n i c at y p e .T h e r e l l are also two types of carburetter but their operation is s i m i l a r a n d o n e s e t o f i n s t r u c t i o n sw i l l s u f f i c e . W h e r e d e t a i l s v a r y . t h e n e c e s s a r yi n f o r m a t i o n w i l l b e g i v e n . T h e e l e c t r r c u e l p u m p s a r et h e t y p e s S P a n d A U F 2 0 0 . f T h e m e c h a n i c a lp u m p i s t h e A U F 7 0 0 a n d i s f i t t e o r o s i n g l ec a r b u r e t t e r k 3 m o d e l so n l y . M O n 1 0 9 8 c c e n g r n e s f i t t e d w i t h s y n c h r o m e s ht r a n s m i s s i o n H S 2 c a r b u r e t t e r sa r e f i t t e d , e i t h e r s i n g l e o r t w i n a c c o r d i n gt o t h e c a r . O n 1 2 7 5 c c e n g i n e sa n d a l l a u t o m a t i c t r a n s m i s s i o n o d e l se i t h e rt w i n H 5 2 o r a s i n g l eH 5 4 m are used. The GT cars have twin H52 carburetters. 2:2 Routine maintenance

2 :3 Pump removal and dismantling T h e f u e l p u m p w i l l b e f o u n d i n s i d et h e l u g g a g ec o m _ p a r t m e n to n t h e r i g h t h a n ds i d e . F o r r e m o v a l ,d i s c o n n e c r the battery earth lead and from underneath the car dis_ connect the inlet and outlet connections leavino tne f l e x i b l eh o s e so n t h e p u m p c o n n e c t i o n s . i f t t h e l u j g a g e L compartment floor and remove the screws securinq rne pump mouhting bracket to the body. Lifr out the plump a n d d i s c o n n e c tt h e e l e c t r i cc a b l e .

Dismantling (refer to FIG 2:1) : Remove the terminal parts 30 to 33 and the seal 43. Lift off the cover 29. Remove the contact blade 22. Remove the housing screws 7 and the earthing screw 9. S e p a r a t et h e h o u s i n g 6 f r o m t h e b o d y 1 , o r 4 4 o n t y p e S p . U n s c r e wt h e d i a p h r a g m2 i n a n a n t i c l o c k w i s e i r e c t r o n d while holding the assembly over the bench to catch the e l e v e n b r a s sr o l l e r sw h i c h w i l l d r o p a w a y . D o n o t s e p a r a t e t h e d i a p h r a g mf r o m i t s s p i n d t e . R e m o v e t h e w a s h e r 2 1 a n d n u t 2 0 . T h e l e a d w a s h e r 19 will have to be cut away. Removethe two screws 29 and t a k e o f f t h e e a r t h t e r m i n a l t a g 1 3 , t i p t h e p e d e s t a l1 6 a n d

T h e o n l y i t e m u n d e r t h i s h e a d i n gi s a c h e c k e v e r y3 0 0 0 miles of the level of lubricant in the hollow piston rod and topping up if required. Unscrew the cap from the top of the depression chamber and see that the level is * inch from the top as shown in FIG 2:8. Top up with tnrn engineoil only.

1100Mk 2 1300

35

35 14 36

39 38

?,@Mo/b

ww
36 40 37 i 45 ) 46
FIG 2:1

@=-:

Components of SU electrical fuel pumps

Types SP and AUF 200

r 2 D r a p h r a g ma n d s p i n d l e a s s e m b l y ^ ^ 3 A r m a t u r e c e n t r a l i z i n g o l l e r 1 p u m p b o d y ( A U F 2 O Oo n l y ) Keyto Fig 2:1 10 Springwasher 9 Setscrew 8 E a r t hc o n n e c t o r 7 Seiscrew ,1 lmpact washer G Coil housing 5 A r m a t u i es p r i n g 16 Pedestal 15 Rocker.mechanism 1 4 R o c k e rp t v o t p i n 1 3 E a r t ht a [ 1 2 T e r m r n a lt a g " 1 1 T e r m r n atl a g 2 2 C o n t a c tb l a d e 21 End cover sealwasher 2 O T e r m i n a ln u t l9 Leadwas"her 1g Springwash6r T7 T e r n r n a l s t u d 3 0 S h a k e p r o o fw a s h e r 29 End cover 28 Screw 2 7 S p r r n gw a s h e r 2 4 C o n t a c tb t a d es c r e w 23 Washet Inletand outletnozzlesx 3 5 S e - t s c - r e w ' *3 6 3 3 I n s u i a t i n gs l e e v e 3 a C i a m p p i a t e ( A U F 2 0 0 o n l y ) 32 Nut . 31 Connector 44 Pump body** 4 3 S e a l i n gb a n d * " 3 b S e a t i n gw a s h e r l ' 4 0 F i l t e r * 4 1 G a s k e t * 3 g O u t l e rv a l v e 37 Inletvalve' 51 Inletnozzle** q7 "Screw** 50 Washer** 49 Filter** 48 Inletvalve** fetainer+* 46 Valve 4 5 O u t l e tv a l v e ' ' *iSP onlY AU F 200 only

w i t h d r a w t h e t e r m r n a ls t u d 1 7 f r o m t h e t a g L i f t o f f t h e o e d e s t a lc o m p l e t ew i t h t h e r o c k e r m e c h a n l s m t P u s ho u t t h e s t e e lp i n 14 t o r e l e a s eh e r o c k e rm e c h a n i s m w h i c h c a n n o t b e f u r t h e rd i s m a n t l e d O n t y p e A U F . 2 0 0 t h e b o d y a n d v a l v e sa r e r e m o v e d b y r e m o v i n gt h e l w o s c r e w sh o l d i n gt h e c l a m p p l a t e3 4 , t h e n r e m o v e t h e n o z z l e s3 6 , t h e f i l t e r 4 0 a n d v a l v e s 3 7 a n d 3 8 O n t y p e S P u n s c r e w t h e i n l e t n o z z l e5 1 a n d r e m o v e t t h e f i l t e r4 9 R e m o v et h e s c r e w 4 7 t o r e l e a s e h e t w o v a l v e 4 assembltes 5 and 48. 2 :4 Examination of PumP Type AU F.200: Clean all the component partsand examinecare{ully d f o r c r a c k s , a m a g e dl o i n t f a c e sa n d t h r e a d s T e s tt h e v a l v e b a s s e m b l i e s y s u c k i n ga n d b l o w i n g w i t h t h e m o u t h T h e r e t a i n i n gt o n g u e o n t h e v a l v e c a g e s h o u l d a l l o w a v a l v e lift oi approximately inch. { f E x a m i n et h e v a l v e r e c e s s e s o r d a m a g e o r c o r r o s i o n , a n d i f t h e s e a t i s p i t t e d b e y o n d c l e a n i n gt h e b o d y m u s t b e renewed Clean the filter with a brush and renew if there are s i gn s o f f r a c t ur e . C h e c k t h e e l e c t r i c a l e a d sa n d c o n n e c t i o n s f o r t i g h t n e s sa n d i n s u l a t i o n . Check the contact breaker points for burning and p i t t i n g . l f t h e y a r e b a d l y a f f e c t e d t h e r o c k e r a s s e m b l ya n d springblade must be renewed. E x a m i n et h e p e d e s t a lf o r c r a c k s .C h e c k f o r d e t e r i o r a f t i o n o f t h e d i a p h r a g m .O b t a i n r e p l a c e m e n t s o r a l l c o r k a n d f i b r e w a s h e r s ,g a s k e t sa n d s e a l i n gr i n g s

Type SP: Check this pump in the same way with additional a t t e n t r o nt o t h e f o l l o w l n g P o i n t s : E x a m i n et h e o u t l e t v a l v e 4 5 f o r d a m a g e a n d s e e t h a t the centre rivet is tight. Check that the lift spring is holding t h e p l a s t i c v a l v e d i s c o n i t s s e a t i n g .T h i s d i s c m u s t b e f r e e to lift and not trapped under the rivet shoulder. E x a m i n et h e i n l e t v a l v e a s s e m b l y4 8 f o r d i s t o r t i o no r d a m a g e , c h e c k a l s o t h e v a l v e s e a t a n d i f a n y c o r r o s t o no r pitting cannot easily be removed the body must be renewed. 2:5 R e a s s e m b l i n gt h e P u m P F i t t h e r o c k e r a s s e m b l yt o t h e p e d e s t a la s s h o w n i n F I G 2 : 2 , e n s u r i n gt h a t t h e c e n t r et o g g l e s p r i n g i s l o c a t e da s i n the inset. Note that only an SU hardened steel pin may be used if a replacement is necessary. Ensure t h a t t h e r o c k e r sa r e q u i t e f r e e t o s w i n g o n t h e p i v o t p i n l f n e c e s s a r ya p p l y a d r o p o f o i l a n d s e t t h e a r m s w i t h a p a i r o f l o n g -n o s e d p l i e r s . '1 Fit the terminal stud 7 to the pedestal and then a s s e m b l ei n t h e f o l l o w i n g o r d e r : F i t t h e s p r i n g w a s h e r 1 8 a n d i n s e r tt h e t e r m i n a l s t u d t h r o u g h t h e 2 B A t e r m i n a l t a g T h e n f i t a n e w l e a dw a s h e r1 9 a n d c o n e d n u t 2 0 w i t h t h e coned face towards the lead washer.Tighten the nut and a d d t h e e n d c o v e r s e a lw a s h e r . A s s e m b l e t h e p e d e s t a lt o t h e c o i l h o u s i n g w i t h t h e t w o s c r e w s 2 8 , e n s u r i n gt h a t t h e s p r i n g w a s h e r o n t h e l e f t h a n d s c r e w i s b e t w e e n t h e p e d e s t a la n d t h e e a r t h i n g t a g A v o i d o v e r t i g h t e n i n gt h e s c r e w s a n d p r e v e n tt h e t a g f r o m t u r n i n g

36

a n d s o s t r a i n i n gt h e f l e x . D o n o t f i t t h e c o n t a c t b l a d e at this stage. F i t t h e i m p a c t w a s h e r 4 t o t h e d i a p h r a g ms p i n d l e and t h e s p r i n g 5 i n t h e c o i l h o u s i n g ,l a r g ed i a m " e t e i r s t . I n s e r t ir the diaphragmspindle and screw it clockwise into the c e n t r e o f t h e r o c k e r a s s e m b l y .D o n o t a p p l y a n y Jornting c o m p o u n d t o t h e d i a p h r a g m .S c r e w i t i n u n t i l t h e r o c k e r w i l l n o t t h r o w o v e r , b u t d o n o t c o n f u s et h i s w i t h j a m m i n g t h e a r m a t u r er n t h e c o r l h o u s i n q H o l d t h e h o u s i n g v e r t i c a l l y , J i t nt n u d i a p h r a g mu p p e r _ , m o s t a n d f i t t h e e l e v e n b r a s s r o l l e r sb y t u r n i n g back the edge of the diaphragm.Refer to FIG 2:3 -d fit tn" c o n t a c t b l a d e 2 a n d a d l u s t t h e f i n g e r s e t t i n g s .D i m e n s i o n A r s h o u l db e 0 3 5 * 0 0 5 i n c h a n d a d l u s t m e " n t is made by b d n d r n gt h e s t o p f i n g e r b e n e a t ht h e p e d e s t a la s r e q u r r e d . T h e g a p b e t w e e n t h e r o c k e rf i n g e r3 : n d t h e c o i l h o u s r n g face at B should be .070+ 005 inch If necessary bend the fingerto obtainthis gap. H o l d t h e a s s e m b l ya s i n F I G 2 : 4 a n d p u s h f i r m l y a n d steadily on the diaphragm. Unscrew the diaphragm a l t e r n a t e l yp r e s s i n g i t w i t h t h e t h u m b a n d r e l e a s r n gr t until the rocker lust throws over Now unscrew the d i a p h r a g mt o t h e n e a r e s th o l e i n a l i g n m e n to n t h e f r a n g e a n d t h e n a n o t h e rf o u r h o l e s o r t w o t h i r d s o f a c o m p l e t e t u r n . P r e s st h e c e n t r eo f t h e a r m a t u r ea n d f i t t h e r e t a r n i n g f o r k a t t h e b a c k o f t h e r o c k e ra s s e m b l y T h i s w i l l k e e p . the d i a p h r a g md e p r e s s e d n d p r e v e n tt h e r o l l e r sf r o m f a l l i n o a o u t w h i l e t h e h o u s i n g i s f i t t e dt o t h e b o d y Assembling the body. Type AUF.200: T h e i n l e t a n d o u t l e t v a l v e sa r e i d e n t i c a l , u t t h e r e c e s s b f o r t h e i n l e t v a l v e i s d e e p e ri n o r d e r t o a l l o w f o r t h e tilter a n d e x t r aw a s h e r .p i a c e t h e o u t l e t v a l v e a s s e m b l yt,o n g u e s t d e u p p e r m o s t , n t h e r e c e s s a r k e d' o u t l e t , , l a c ea i m p loint w a s h e r o n t o p a n d f i t t h e o u t l e t n o z z l e .p l a c e t h e I n l e t v a l v e a s s e m b l y i n i t s r e c e s sw t t h t o n g u e s i d e d o w n w a r d s f o l l o w e d b y a w a s h e r ,t h e f i l t e r ( d o m e s i d e u p w a r d s ) then a n o l h e r w a s h e r a n d t h e r n l e tn o z z l e B e d t h e a s s e m b l t e sc o r r e c t l y i n t h e i r r e c e s s e s w i t h t h e , n o z z t e sp l a c e d a s r e q u i r e d ,a n d t i g h t e n d o w n t h e clamp p l a t e3 4

FIG Fitting the rocker assembly to the pedestal. .2:2 sn9_ws the correct position of the centre toggle l !p r r n g s s!t atter assemblv

5r L4
FIG 2:3 Setting tne rocker assemblv 1 pedestal 2 C o n r a c tb l a d e 4 Innerrocker 5 Trunnion inch B:.070 inch Key to Fig 2 ;3 3 Outer rocker 6 Coilhousing A:035

Assembling the body. Type Sp: I n s e r tt h e f i l t e r i n t o t h e r e c e s si n t h e i n l e t u n i o n , t h e n screw it with itsfibrewasherinto the body. Sit the outlet a s s e m b l y 5 e v e n l yi n t o i t s r e c e s s i t h t h e s p r i n gd o w n _ 4 w w a r d s . F i t t h e i n l e t v a l v e 4 g a n d r e t a i n e r4 6 m a k r : n g sure t h a t i t i s c e n t r a l i z e d n l t s s e a t i n gw h e n t i g h t e n i n g i o Body attachment: With the cast lugs of the coil housing at the bottom, . i n s e r tt h e s i x s c r e w sa n d d o u p f i n g e rt i g h i F i t t h e e a r t h i n g s c r e w a n d r t s L u c a r c o n n e c t o r C a r e u l l y r e m o v et h e r o l r e r f r e t a i n i n gf o r k a n d t i g h t e n t h e s c r e w s d i a m e t r i c a l l v F i t t h e c o n t a c tb l a d ea n d c o i l l e a d t o t h e p e d e s t a l with the 5BA screw and washer The contact points on the blade should be a Iittleabove the points on the rocker w h e n c l o s e d ,a s s h o w n i n F I G 2 : 5 T h e b l a d e i s s l o t t e d for adlustment F i t t h e s e a lw a s h e r 2 1 t o t h e t e r m r n a s t u d . F i t t h e c o v e r l a n d s e c u r e w i t h t h e n u t 3 2 . F i t t h e t e r m i n a lt a q o r con nector and the insulated sleeve.The pump rs n"owreacly for testing.
FIG 2:4 Unscrewing the diaphragm until the rocKer just throws over

2 :6 Testing the pump Both types: l f i t i s s u s p e c t e dt h a t t h e f u e l i s n o t r e a c h i n g t h e c a r b u r e t t e d i s c o n n e c tt h e f u e l l i n e a t t h e c a r b u r e t t ea n d r r check for {low. lf the fuel comes in squirts from the pipe check that the needlevalve in the float chamber is not s t u ck . l f t h e f l o w i s n o r m a l a t f i r s t b u t d i m i n i s h e sr a p i o r y , check for a blockedfuel tank vent by opening the firrer

11 0 0 M k 2 1 3 0 0

3l

FIG 2:5 Setting the correct relative position of blade and rocker contact ooints

lf there is no DUmo action check that the current is r e a c h i n gt h e p u m p . l f t h i s i s i n o r d e r , r e m o v e t h e e n d c o v e r a n d c h e c k t h e c o n i a c t p o i n t s .l f t h e y a r e t o u c h i n g , r e p l a c e t h e e l e , c t r i cl e a d a n d s h o r t a c r o s s t h e c o n t a c t s with a length of wire. A strokeof the pump now indicates d i r t y o r b a d l y a d j u s t e dp o i n t s . . A n o b s t r u c t e dp i p e f r o m t h e t a n k t o t h e p u m p . w i l l b e s h o w n b y n o r m a lp u m p a c t i o nw h e n t h e i n l e t c o n n e c t i o n i s r e m o v e d .T h i s s h o u l d b e c l e a r e db y b l o w i n g c o m p r e s s e d a i r t h r o u g h t h e p i p e a f t e r r e m o v i n gt h e f i l l e r c a p . N e v e r p a s sc o m p r e s s e d i r t h r o u g h t h e p u m p . a l f t h e s e o p e r a t i o n sd o n o t p r o v i d e a c u r e t h e d i a p h r a g m action should be checked together with the rocker throw o v e r m e c h a n i s m .R e m o v e t h e c o i l h o u s i n g a n d { l e x t h e diaphragm a few times taking care not to lose any of the r o l l e r s A p p l y a l s o a d r o p o f t h i n o i l t o t h e s p r i n gs p i n d l e s . a n d r o c k e r s .R e a s s e m b l e h e p u m p a s p r e v i o u s l yd e s c r i b e d . t A noisy pump action may be caused by a leak on the s u c t i o n s i d e . T h i s c a n b e c h e c k e d b y d i s c o n n e c t i n gt h e f u e l l i n e a t t h e c a r b u r e t t ea n d h o l d i n g i t i n a g l a s sj a r w h e n r the ignition is switched on. A continuous stream of i a b u b b l e sw h e n t h e o i o e i s i m m e r s e d n t h e f u e l i n d i c a t e s n a r r l e a k . C h e c k a l l c o n n e c t i o n sa n d u n i o n s a n d t h a t r n e h o u s i n gs c r e w sa r e c o r r e c t l y i g h t e n e d . t lf the pump operateswithout deliveringany fuel, suspect either a serious leak on the suction side or f o r e i g n m a t t e rl o d g e d u n d e ro n e o f t h e v a l v e s ,p a r t i c u l a r l y t h e i n l e t v a l v e . T h e r e m e d y i s t o c h e c k f o r l e a k sa s b e f o r e o r t o d i s m a n t l ea n d c h e c k t h e v a l v e a s s e m b l i e s .

2:7

Operation of the SU carburetter

3
FIG 2:6

T h e s e c t i o n a lv i e w o f a c a r b u r e t t e i n F I G 2 : 6 a p p l i e s r t o b o t h c a r b u r e t t e rt y p e s u n d e r r e v i e w . The bore through the body is fitted with the usual butterfly valve seen on the right. On the intake side of this valve the variable choke is formed by the action of t h e p i s t o n r i s i n g a n d f a l l i n g i n s i d et h e t o p c h a m b e r . . T h i s a c t i o n i s a u t o m a t i ca n d d e p e n d s u p o n t h e d e p r e s s i o n n i the intake system according to the degree of throttle opening and the load on the engine. The correctairlfuel mixture is obtained by the use of a t a p e r e d n e e d l ea t t a c h e d t o t h e b o t t o m o f t h e p i s t o n w h i c h rises and falls in an apertureor jet of fixed size. By this means the actual fuel orifrce rs at its greatest when the piston is at the top of its travel and the smallest needle d i a m e t e ri s i n t h e j e t a p e r t u r e . Rapid fluctuationsof the piston are damped out by the h y d r a u l i cd a m p e r i n t h e h o l l o w c e n t r e o f t h e p i s t o n .T h e rich mixture needed for starting from cold is obtained by p u l l i n g t h e j e t d o w n w a r d s t o a p o s i t i o nw h e r e a s m a l l e r diameter of needle will be effective.

S e c t i o nt h r o u g h S U c a r b u r e t t e r 2 :8 Removing and servicing the carburetter Unscrew the wingnut from the top of the air cleaner, disconnect the breather pipe to the rocker cover when fitted. remove the cover. lift out the element and remove tne cleaner. D i s c o n n e c t t h e m i x t u r e a n d t h r o t t l e c a b l e s ,t h e t h r o t t l e shaft return springs on twin installations,the suctton advance pipe and the fuel pipe. Remove the nuts and s p r i n g w a s h e r s f r o m t h e c a r b u r e t t e rf l a n g e s a n d l i f t o f f t h e c a r b u r e t t e r ( sa n d t h e c a b l e a b u t m e n t p l a t e . )

Key to Fig 2:6 1 Jet locking ut n 2 Jetadjustingur n 3 Jet head 4 N y l o nf u e l p i p e 5 P i s t o n i t t i n gp r n i 6 Needle ecunng crew s s 7 Prston amper il well d o cap. Reduced flow can also be caused by a choked prpe o r b l o c k e d f i l t e r .R e m o v et h e f i l t e r4 0 o r 4 9 i n F I G 2 : 1 and cleanwith a brush. l f t h e p u m p o p e r a t e sr a p i d l y b u t d o e s n o t p u m p s u f , f i c i e n t f u e l , c h e c k f o r a n a r r l e a k o n t h e s u c t i o ns i d e o f t h e p u m p , d i r t u n d e rt h e v a l v e so r f a u l t yv a l v es e a l i n gw a s h e r s .

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39

Dismantling (see FIG 2:7) : Remove the piston and top chamber assembly6 after marking {or correct reassemblyThe needle is held tn . p l a c e b y t h e s c r e w 7 . G r e a t c a r e i s r e q u i r e di n h a n d l i n g these items as they are easily damaged. Unscrew the u n i o n n u t 1 3 o n t h e n y l o n f e e d p i p e . R e m o v et h e b o l t 2 6 to removethe float chember.Removethe lid 30 to expose the float 2-7 and the needle valve 32. Remove the screw 5 1 a n d p u l l o u t t h e j e t . R e m o v et h e n u t 1 8 a n d s p r i n g 1 7 . R e l e a s et h e n u t 1 6 a n d r e m o v e t h e j e t b e a r i n g 1 4 a n d w a s h e r 15 . Servicing : R e m o v et h e d a m p e r 8 p o u r o u t t h e o i l a n d l i f t o u t t h e p i s t o n .C l e a n c a r e f u l l ya n d n o t e t h a t t h e r i m o f t h e p i s t o n s h o u l d n o t a c t u a l l y o u c h t h e i n s i d es u r f a c e f t h e c h a m b e r . t o A n y f r i c t i o n h e r e w i l l s e r i o u s l ya f f e c t t h e f u n c t i o n i n g o f the carburetter. if the needle has to be replacedor renewed it is fitted w i t h t h e b o t t o m s h o u l d e rf l u s h w i t h t h e l o w e r f a c e o f t h e p i s t o n . N e v e ra t t e m p t t o a l t e r a n e e d l eo r s p r i n g 1 0 . T h e i r s p e c i f i c a t i o n s r e g i v e n i n T e c h n i c a lD a t a a t t h e e n d o f a this book. Clean out all sedimentfrom the float chamber ano c h e c k t h e n e e d l ea n d s e a t i n go f t h e a s s e m b l y3 2 . R e n e w if worn R e a s s e m b l ys t h e r e v e r s e f t h e d i s m a n t l i n g r o c e d u r e , i p o b u t s e e S e c t i o n 2 : 9 f o r c e n t r a l i z i n gh e j e t . W h e n f i t t i n g t the piston into the chamberapply a littlethin oil to the p i s t o n r o d a n d t o n o o t h e r p a r t . O n c o m p l e t i o nf i l l t h e d a m p e ro i l w e l l w i t h 2 0 W e n g i n e o i l a s s h o w n i n F I G 2 : 8 . 2:9 Centralizing the jet

FIG 2:8

Damper lubrication level indicated bv arrows

FIG 2;9

External controls of HS2 carburetter

Key to Fig 2:9 1 T h r o t t l ea d j u s t i n gs c r e w 2 B u t t e r i l yo p e r a t i n g{ o r k 3 F a s t - i d l ea d l u s t i n gs c r e w 4 Jet link secunngscfew 5 Jet head 6 Floalchamber s e c u r l n gn u 1 7 J e t a d l u s t r n gn u t

This operationis always necessary fterthe jet has been a l o o s e n e do r r e m o v e d ,o r i f t h e n e e d l eh a s b e e n m o v e d . l t m a y a l s o a s s i s ti n c u r i n g a s t i c k i n gp i s t o n . R e m o v et h e d a m p e r a n d l i f t i n g t h e p i s t o n e i t h e rw i t h t h e p i s t o n l i f t i n g p i n 3 o r w i t h a p e n c i la n d a l l o w t o f a l l . l{ the piston does not fall smartly on to the jet brioge p r o c e e da s f o l l o w s : Remove the screw 51 to disconnect the rod 49 from the jet head.Unscrew the union holdingthe nylon feed p i p e i n t o t h e f l o a t c h a m b e ra n d w i t h d r a w t h e t u b e a n d jet together 13. Remove the adjustingnut 1B and the s p r i n g 1 7 , t h e n r e p l a c et h e n u t a n d s c r e w i t u p t i g h t . R e p l a c et h e j e t a n d f e e d t u b e . Slackenotf the locktng nut 16 until the Jet bearing i s f r e e t o t u r n . R e m o v et i r e d a m p e r 8 a n d , w i t h a p e n c i l , gently press down the piston on to the jet bridge, then tighten the locking nut '1 . Lift the piston and 6 check that it falls freely on to the jet bridge with a soft m e t a l l i cc l i c k . F u l l yl o w e r t h e j e t a n d r e p e a tt h e t e s t n o t i n g t h e s o u n d o f i m p a c t . l f i t i s s h a r p e rt h a n t h e f i r s t r e p e a t t h e c e n t r i n go p e r a t i o nu n t i l s u c c e s s f u l . R e p l a c et h e s p r i n g a b o v e t h e a d j u s t i n gn u t . 2 :10 Slow-running adjustment

W h e n a u t o m a t i c t r a n s m i s s r o ni s f i t t e d i t i s n e c e s s a r yt o disconnect the fork end of the governor control rod from t h e t h r o t t l e l e v e r b e f o r e r e l e a s i n gt h e s e c u r i n g n u t s . R e f i t t i n g i s t h e r e v e r s eo f t h e a b o v e , b u t n o t e t h a t t h e cable abutment plate has a gasketon each side and if either of these is damaged a new gasket should be fitted a f t e r c l e a n i n ga l l m a t i n g s u r f a c e s .

Single carburetter. engines:

synchromesh

transmission

This is the only item of tuning neededon these car i b u r e t t e r s f t h e c o r r e c tn e e d l ei s f i t t e d ( s e e F I G 2 : 9 ) . W a r m u p t h e e n g i n e t o n o r m a l t e m p e r a t u r eU n s c r e w . t h e t h r o t t l e a d . l u s t i n gs c r e w 1 u n t i l j u s t c l e a r o f t h e l e v e r t h e n s c r e w a td o w n o n e a n d a h a l f t u r n s .

40

R e m o v e t h e p i s t o n a n d s u c t i o n c h a m b e r ,d i s c o n n e c t mixture control wire and screw the jet adjustingnut 7 u n t i l t h e j e t i s f l u s h w i t h t h e b r i d g e ,o r f u l l y u p i f t h i s position cannot be obtained. Replacethe piston and suction chamber and check that the piston falls freely u s r n g t h e p i s t o n l i f t i n g p i n f o r t h i s p u r p o s e .S c r e w d o w n t h e a d j u s t i n gn u t 7 t w o c o m p l e t e t u r n s . Start the engine and adlust the throttle screw to give t h e d e s i r e di d l i n g s p e e da s i n d i c a t e db y t h e g l o w i n g o f t h e i g n i t i o nw a r n i n g l i g h t . Turn the jet adjusting nut 7 until the fastestidling speed is obtained consistent with even firing. As the m i x t u r e i s a d j u s t e dt h e e n g i n e w i l l p r o b a b l y r u n f a s t e r . Tios must be countered bv use of the throttle screw. Now check the mixture strength by lifting the carb u r e t t e rp i s t o n w r t h t h e l i f t i n g p i n b y a p p r o x i m a t e l y+ inchwhen: lf the engine speed rncreases nd continuesto run a faster the mixture is too rich. l f t h e e n g i n e s p e e d i m m e d i a t e l y e c r e a s e sh e m i x t u r e d t is too weak. l f t h e e n g i n e s p e e d m o m e n t a r i l yi n c r e a s e s l i g h t l yt h e s mrxture ts correcl T h e e x h a u s t n o t e s h o u l d b e r e g u l a ra n d e v e n . l f i t t s i r r e g u l a rw r t h a c o l o u r l e s se x h a u s t , t h e m i x t u r e i s t o o weak. Black exhaust smoke with rythmical misfiring i n d i c a t e sa r i c h m i x t u r e . R e c o n n e c t h e m i x t u r ec o n t r o l w i r e w i t h a b o u t { i n c h {ree movement before it starls to pull on the cam lever. S e t t h e m i x t u r e c o n t r o l k n o b o n t h e i n s t r u m e n tD a n e l t o i t s m a x i m u mm o v e m e n to f a b o u t $ i n c h w i t h o u t m o v i n g the .let and adjust the fast-idle cam screw 3 to give an e n g i n e s p e e do f 1 0 0 0 r e v l m i n w h e n h o t . Automatic transmission engines : T h e e x t e r n a lc o n t r o l s o f t h e H 5 4 c a r b u r e t t e ra r e s h o w n in FIG 2 :10, and the slow-runningadjustments re the a sameas for the type H52 with the following exceptions: A tachometershould be connected to the engtne. q S e l e c t ' N ' o n t h e g e a r l e v e r u a d r a n ta n d a p p l y t h e h a n d brake. Adjust the jet as described for engines with s y n c h r o m e s ht r a n s m i s s i o na n d t h e n a d j u s t t h e t h o t t l e adJusting crew 2 until a maximum idling speedof 650 s revlmin is obtained. Pull out the mixturecontrol to the maximum fast idle p o s i t i o n a n d b y m e a n s o f t h e f a s t - i d l e a d j u s t i n gs c r e w set an engine speed of 1050 rev/min. Push back the c o n t r o l a n d r e c h e c k t h e i d l i n g s p e e d .A d j u s t m e n t o f t h e governor control rod is covered in Chapter 7. Twin carburetter engines. Synchronization : Carryout the initialsettingof the lets levelwith the b r i d g e o f t h e c a r b u r e t t e r sa s i n t h e s i n g l e i n s t r u m e n t v e r s a o n sm a k i n g s u r e t h a t b o t h j e t s a r e i n t h e s a m e p o s i , t i o n i n t h e i r r e s p e c t i v ec a r b u r e t t e r s . T u r n d o w n e a c h j e t a d j u s t i n gn u t t w o c o m p l e t et u r n s . Start the engine and adjust the throttle screws to give the desired idling speed by turning each screw an equal a m o u n t . L r s t e n o t h e h i s s i n t h e a i r i n t a k e sa n d a d j u s tt h e t t h r o t t l e s c r e w s u n t i l t h e h i s s i s s r m i l a ro n b o t h i n t a k e s . This will synchronizehe throttles. t Now ad.justthe mixture strength by turning the a d j u s t i n gn u t s 7 u p o r d o w n b y e q u a l a m o u n t s u n t i l t h e fastest idling speed is obtained consistent with even

External controls of HS4 carburetter FIG 2:10 fitted to cars with automatic transmission Key to Fig 2 :10 2 T h r o t t l ea d j u s l i n g s c r e w 4 Governor control rod

as

1 J e t a d l u s t i n gn u l 3 F a s t ' i d l ea d J U S t i n s c r e w g

F I G 2 : 1 1 S e t t i n g a c l e a r a n c eb e t w e e n t h e t h r o t t l e shaft operating lever and the choke interconnecting spindle p K e y t o F i g 2 : 11 1 T h r o t t l e h a f tl e v e r s 2 Lever rns s 3 T h r o t t l e p i n d l ee v e r o r k l f 4 T h r o t t l e h a f tl e v e r l a n r p s s s c

f i r i n g .W h i l e c a r r y i n go u t t h e s ea d j u s t m e n t s t i s i m p o r t a n t i to keep the Jets pressed upwards against the adlusting n u t s . A s t h e m i x t u r e i s a d j u s t e dt h e e n g i n e w i l l p r o b a b l y r u n f a s t e r a n d i t w i l l b e n e c e s s a r yt o r e d u c e t h e s p e e d b y turning back the throttle screws by the same amount for each. N o w c h e c k t h e m i x t u r es t r e n g t hb y l i f t i n gt h e p i s t o n o n t h e l e f t h a n dc a r b u r e t t e b y J a i n c h w h e n : r l f t h e e n g i n e s p e e d r n c r e a s e st ,h e m i x t u r e s t r e n g t ho n l e f t h a n dc a r b u r e t t e r s t o o r r c h . i l f t h e e n g i n e s p e e d i m m e d i a t e l y e c r e a s e st,h e m i x t u r e d s t r e n g t h o n t h e l e f t h a n d c a r b u r e t t e ri s t o o w e a k . l f t h e e n g i n e s p e e d m o m e n t a r i l yi n c r e a s e s l i g h t l y ,t h e s e t t i n g o n t h e l e f t h a n dc a r b u r e t t e irs c o r r e c t R e p e a tt h i s o p e r a t i o no n t h e r i g h t h a n dc a r b u r e t t ea n d r t h e n r e c h e c kt h e l e f t h a n dc a r b u r e t t e r .

1 1 0 0M k 2 1 3 0 0

Pull out the mixture control knob on the panel as far as i s p o s s i b l ew i t h o u t m o v i n g t h e j e t s ( a b o u t f i n c h ) a n d a d ; u s t t h e f a s t - r d l ec a m s c r e w s 3 ( s e e F I G 2 : 9 ) t o g i v e an engine speedof about 1000 rev/min when hot. 2 : 12 Carburetter Sticking piston This is frequentlyindicatedby difficult starting and l a c k o f r e s p o n s et o t h e a c c e l e r a t o rp e d a l .A s t i c k i n g p i s t o n can be ascertained by lifting the pjston either with a p e n c i l o r t h e I i i t i n g p i n a n d o b s e r v i n gi t s i a l l b a c k o n t o the bridge. lf this is sluggish, remove the piston and top s u c t i o n c h a m b e r a n d c l e a n t h o r o u g h l y .O n r e a s s e m b l y a l i t t l e t h i n o i l s h o u l d b e a p p l i e dt o t h e p i s t o n r o d o n l y a n d to no other part. lf cleaning does not effect a cure check that the jet is c o r r e c t l yc e n t r a l i z e d O n n o a c c o u n t s h o u l d t h e p i s t o n . return spring be stretched in an attempt to improve the rate of return. Float chamber flooding T h i s i s i n d i c a t e d b y f u e l f l o w i n g f r o m t h e b r e a t h e rh o t e i n t h e t o p o f t h e f l o a t c h a m b e r l i d , a n d i s u s u a l l yc a u s e d by grit between the float chamber needle and its guide. R e m o v e t h e f l o a t c h a m b e rl i d a n d c l e a n t h e n e e d l ea n d g ur d e . Float needle sticking : T h i s w i l l b e i n d i c a t e db y t h e e n g i n e b e c o m i n g s t a r v e d o f f u e l a n d s t a l l i n g . C h e c k t h i s b y d i s c o n n e c t i n gt h e m a i n f e e d p i p e a t t h e c a r b u r e t t e ra n d o b s e r v et h e s p u r t s o f f u e l w h i c h w i l l i n d i c a t et h a t t h e p u m p i s w o r k i n g a n d faults

A
FIG 2:12 Key to Fig 2 : 12 A C Angle of float lever E L e v e rh i n g e p i n

D
Checking the float lever. To adjust. bend at C B Machined tip ; lo ftr Inch bar D F l o a t n e e d l ea n d s e a t a s s e m o r y

\\\l..li\
FIG 2:13 Oepress the damper with between the pad and the plunger a feeler gauge

2 :11 Twin carburetter linkage R e f e rt o F I G 2 : 1 1 . T h e t h r o t t l eo n e a c h c a r b u r e t t e r s i operated by a lever and a pin which works in a forked l e v e ra t t a c h e dt o t h e t h r o t t l es p i n d l e .T h e s m a l l c l e a r a n c e b e t w e e n t h e p i n a n d t h e f o r k m u s t b e m a i n t a i n e dw h e n t h e t h r o t t l e i s c l o s e dt o p r e v e n ta n y l o a d f r o m t h e a c c e l e r a t o r linkage being transferedto the rhrottle butterfly spindle. To set this clearance slacken the throttle shaft lever c l a m p s 4 . t h e n p l a c e a . 0 7 0 i n c h f e e l e rg a u g e b e t w e e n t h e tail of the throttle shaft operating lever and the choke control interconnecting rod as shown in the inset. Move '1 each throttle shaft lever downwards until the lever orn 2 restslightly on the lower arm of the fork 3 in the throttle s p i n d l e l e v e r .T i g h t e n t h e c l a m p b o l t s o f b o t h t h r o t t l e shaft leversin this position and remove the feeler gauge. The pins on the throttle shaft should now havea clearance in the forks. Reconnectthe choke cable and ensurethat the jet heads returnagainstthe lower faces of the adjusting nuts when the choke control rs oushedfullv home.

FIG 2:14 Type HS carburetter emission control system

used

with

exhaust

Key to Fig 2:14 1 J e t a d j u s t i n gn u t 2 Jet lockingnur 3 Depressionchamber 4 Fast-idle adjusting screw 5 Throttle adjusting screw 6 Piston lifting pin 7 Jet adjuslment restrictor

42

t h a t t h e o i D e i s c l e a r .t J n d e r t h e s e c i r c u m s t a n c e s t a r v a t i o n i s a l m o s t c e r t a i n l y u e t o a f l o a t n e e d l es t i c k i n go n i t s d s e a t a n d c l e a n i n gs h o u l d e f f e c t a c u r e A t t h e s a m et i m e i t r s a d v i s a b l e o c l e a no u t t h e w h o l e t f u e l f e e d s v s t e mt o r e m o v ea n y o t h e r f o r e i g nm a t t e rw h i c h mav be oresent Level of f uel in f loat chamber (see FIG 2:12) : The correct level can be checked bv holdrnqthe rro a s s e m b l yu p s i d e d o w n a s s h o , r n a n d I n s e r t t n g ; t o i ' 1 6 a i n c h b a r a c r o s st h e c e n t r e o f t h e I d P l a c ei h e b a r p a r a l l e l to the float lever hinge pin. The face of the float lever s h o u l d j u s t r e s t o n t h e b a r w h e n t h e n e e d l ei s f u l l y o n i t s s e i t i n g . l f t h i s i s n o t s o , c a r e f u l l yf e s e tt h e a n g l e a t C u n t i l t h e c o r r e c ts e t t i n g i s o b t a r n e d . 2 :13 Throttle damper. 1275cc engines S e e F fG 2 : 1 3 a n d a d l u s tb y s l a c k e n i n gh e c l a m p n u t t o n t h e d a m p e r p e r a t i n ge v e r l n s e r t 1 0 0 i n c h ( 2 . 5m m ) o l a feeler gauge between the danrper plunger and the o p e r a t r n gl e v e r . W i t h t h e c a r b u r e t t e r u t t e r f l yc l o s e d ,d e p r e s st h e l e v e r b u n t i l t h e d a m p e r i s f u l l y c o m p r e s s e d . e t i g h t e nt h e l e v e r R c l a m p n u t a n d r e m o v e t h e f e e l e rg a u g e . l f t h e d a m p i n g i s e x c e s s i v en c r e a s e h e t h r c k n e s s f t h e i t o f e e l e rg a u g e i n s t e p s o f . 0 1 0 i n c h u n t i l s a t i s f a c t o r y n d a v i c e v e r s ai f d a m p i n g i s i n a d e q u a t e 2:14 Exhaust emission control The carburettersused with exhaust emission control s y s t e m sa r e b a l a n c e dt o g i v e m a x i m u m p o l l u t i o n c o n t r o l w i t h m a x i m u m p e r f o r m a n c e .T h e y m u s t n o t b e i n t e r c h a n g e d w i t h c a r b u r e t t e r sm a n u f a c t u r e d f o r e n g i n e s w i t h o u t e m i s s r o n o n t r o l .C a r b u r e t t etru n i n g m u s t a l w a y s c b e c a r r i e d u t w i t h t h e e n g i n ee m i s s i o nc o n t r o le q u i p m e n t o c o n n e c t e da n d o p e r a t i n gc o r r e c t l y . Tuning the carburetter (see FIG 2 :14) : Top up the piston damperas shown in FIG 2:8. On d u s t - p r o o f e dc a r b u r e t t e r s i t h a h o l e i n t h e n e c k o f t h e w s u c t i o nc h a m b e rt h e o i l l e v e lm u s t b e i i n c h b e l o w t h e t o p of the hollow oiston rod. C h e c k t h a t t h e r e a r e n o s i g n s o f s t i c k i n gi n t h e t h r o t t l e a c t i o n . C o n n e c t a t a c h o m e t e rt o t h e e n g i n e ,s t a r t u p a n d w a r m t h e e n g i n e t h o r o u g h l y .T h e n r u n t h e e n g i n e u n d e r

l4

l7

I
l6-________ \__.

t q

FIG 2:16 Mark the carburetter bodv and chamber as shown at 12 Key to Fig 2:16 1 3 C a r b u r e t t eb o C y r 3 Depressron hambef c 16 R e t a i n r r r g c r e w s s

14 Damper

l-- r--;

BEI

lffi,itffil

l--l r-;

FIG 2:17 The carburetter with depression chamber removed. Inset left shows fixed needle type. Inset centre, spring-loaded type. Inset right shows the two different types of piston lifting pin Key to Fig 2:17 6 L i f t r n gp r n 1 8 P i s r o ns p r i n g 1 9 P i s t o n a s s e m b l y 2 0 P r s t o nr o d 2 1 N e e d i e l o c k i n g s c r e w 22 Needle 23 Liftingpin 24 Crclip 25 Sprrng 26 Circlip 72 Guide locking screw 73 Needle 7 4 N e e d l es u p p o r r g u i d e 75 Spring no-load at 2500 rev/min for one minute. Complete the tuning procedure as quickly as possible and every three minutes run the engine at 2500 rev/min for one minute. Do not remove the jet adjustment restrictor 7.

F I G 2 : 15 Details of the mixture control wire 8 and iet lever 9 4 s h o w s f a s t - i d l e s c r e w

Now adlust the throttle screw to obtain a smooth idling speed of 850 rev/min. lf the runnrng is not satisfactory,

11 0 0M k 2 1 3 0 0

43

I I-

;l

l-il,:'

check by using the lifting pin 6 that the piston is falling freely.Turn the jet adjusting nut 1 throughout the range allowed by the restrictof 7 to obtain the fastest soeed c o n s i s t e n t w i t h s m o o t h r u n n i n g . l f n e c e s s a r yr e a d j u s tt h e throttle screw 5 to give the correctspeed of 850 rev/mln. R e f e rt o F I G 2 : 1 5 . A d j u s t t h e m r x t u r e c o n i r o l w i r e 8 t o give 1f inch free movement before it commencesto move the jet lever9. Pull out the mixture control knob until the jet is just about to move and adjust the fast-idle screw 4 to give a speedof 1100 revlmin. Dismantling the carburetter : R e m o v e t h e c a r b u r e t t e ra s d e s c r i b e d i n S e c t i o n 2 : 8 a n d p r o c e e da s f o l l o w s : ( r e f e rt o F I G 2 : 1 6 ) . R e m o v e t h e d a m p e r 1 4 a n d w a s h e r ' 15 , m a r k t h e t o p c h a m b e r 3 a n d t h e b o d y 13 a s a t 12 . R e m o v e t h e s c r e w s 16 and lift off the chamber. Remove the piston spring 18 (see FIG 2:17),lit't. out the piston assembly 19 and pour oil from the piston rod 20. Remove the needle from the piston rod after reference t o t h e a p p r o p r i a t en s e td i a g r a m i n F I G 2 : 1 7 . i E x t r a c tt h e c i r c l i p 2 4 a n d s p r i n g 2 5 , p u s h u p t h e p i s t o n lifting pin 23 up and remove. lf, as at 6, there is a concealed spring, first remove the circlip 26. H o l d t h e b a s eo f t h e 1 e t2 6 ( s e e F I G 2 : 1 8 ) a n d s l a c k e n screw 27. Disconnect the spring 29 and remove the s c r e w a n d b u s h 3 0 . U n s c r e w t h e s l e e v en u t 3 1 a n d w i t h draw the jet assembly 26 together with the gland 34, w a s h e r 3 5 a n d f e r r u l e3 6 . B e n d b a c k t h e t a g o n t h e r e s t r i c t o r7 a n d r e m o v e t h e j e t a d j u s t i n g n u t 1 , r e s t r i c t o ra n d s p n n g 3 7 . U n s c r e w t h e j e t locking nut 2 and remove the jet bearing 38. A locking

FIG 2:18 Details of the jet assembly. Inset shows jet bearing details for spring-ioaded needie type Key to Fig 2:18 1 J e t a d j u s t i n gn u t 2 Jet locking nut 7 Restrictor 26 Jet assJmory 27 Screw 28 Jet pick up link 2 9 R e t u r ns p r r n g 3 0 B r a s s b u s h ( i f f i n e d ) 3 1 S l e e v e n u r 3 2 F t e x i b l ej e r r u b ; 33 Float chamber 34 Gland 35 Washer 36 Ferrure 37 Spring 38 Jet bearing 39 Locking washer

57i-_\

55

2 -59

s8_ll
56

42 43

FIG 2:19 Details of pick-up iever assembly. Insets 40 and 45 show the correct method of fitting the return spring and cam lever spring respectively

5l
FIG 2:20 Exploded view of float chamber. Mark the chamber and lid as shown at 52 bef ore dismantling Key to Fig 2 :20 3 3 F l o a tc h a m b e r 5 0 R e t a i n i n qb o l t 5 1 F l e x i b l em o u n t i n g 53 Lrd 5 4 R e t a i n i n qs i r e w s 55 Gasket 5 6 F l o a ta s s e m b l y p 5 7 F t o a rh - i n g e r n 58 Float needle 59 Needle seatinq

Keyto Fig 2:19 9 P i c k - u p l e v e ra s s e m b l y 41 Prck'up lever return spring 42 Pivot bolt 43 Spnng washer 44 Spacer 46 Cam lever spring 47 Pivot bolt tube(s) 48 Cam lever 49 Skid washer

44

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MOIJE

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washer 39 is fitted under the bearing flange on fixed n e e d l e c a r b u r e t t e r so n l y . Before commencing to dismantle the pick-up lever a s s e m b l ys t u d y F I G 2 : 1 9 , a n d n o t e t h e p o s i t i o n o f t h e lever returnspring 41 in the inset40. Unscrew the bolt 42 a n d r e m o v e t h e l e v e ra s s e m b l yg w i t h t h e r e t u r n s p r i n g 4 1 . Pull out the pivot bolt tube 47 and spring 46. Removethe cam lever 48 and washer 49. Unscrew the bolt 50 (see F I G 2 : 2 0 ) a n d r e m o v et h e f l o a t c h a m b e r3 3 a n d f l e x i b l e m o u n t i n g 5 1. M a r k t h e f l o a t c h a m b e r a n d l r d f o r r e a s s e m b l y ,t h e n remove the screws and lift off the lid, gasket 55 and float a s s e m b l y5 6 . P u s h o u t t h e f l o a t h i n g e p i n 5 7 a n d r e m o v e f t r o a t5 6 a n d n e e d l e 5 8 . U n s c r e w t h e s e a t i n g f r o m t h e l.he ilo. C l o s et h e t h r o t t l e a n d m a r k t h e d i s c a n d f l a n g e a s s h o w n a t 6 0 i n F I G 2 : 2 1 . R e m o v et h e t w o s c r e w s 6 4 . o o e n t h e throttle and withdraw the disc from its slot in the spindte 6 5 . R e l e a s et h e t a b w a s h e r 6 6 a n d u n s c r e w t h e n u t 6 7 . Inspect all parts very carefullyfor wear or damage and renew any suspect components. Check for excesstve wear and play on the throttle spindle. Clean all parts in s p i r i ta n d a l l o w t o d r y . Reassembly: This is the reverse of the dismantling instructions, noting the following points: The heads of the countersunk screws 64 should face outwards when the throttle is closed. Centralize the t h r o t t l e d i s c i n t h e b o r e b e f o r e t i g h t e n i n g t h e s c r e w s .T h e throttle limit valve must be below the spindle with the h e a d o f t h e v a l v ef a c i n g t h e e n g i n e . C h e c k t h e c l e a r a n c eb e t w e e n t h e f l o a t l e v e r a n d t h e l i d a s s h o w n i n F I G 2 : 1 2 . C e n t r a l i z eh e j e t a s i n s t r u c t e d n t i Section 2 :9, this is not necessary ith a spring-loaoeo w needle.Screw in the jet adjusting nut until the top of tne let is flush with the carburetter bridge, then unscrew

SET JET

ENGINE RPIYt

-4 A 2. -1

+1 +2+3+4

" JETAOJUSTING NUT-FLATS

FIG 2:22 Turn the jet adjusting nut to obtain fastest e n g i n e s p e e d t h e n s c r e w i n t h e n u t u n t i l s p e e dj u s t s t a r t s to fall. Turn nut one flat down and lock the restrictor

66

67

m09 / 9
68

FIG 2:23 Turn the adjustment restrictor until the vertical tag touches the carburetter body as indicated by arrow t h i r t e e nf l a t s . R e f i t t h e c a r b u r e t t e ra s d e s c r i b e di n S e c t i o n 2 : 8 . R e c o n n e c tt h e d e p r e s s i o nc h a m b e r h o s e a n d t u n e t h e c a r b u r e t t e ra s f o l l o w s : Complete carburetter tuning : Disconnect the mixture control wire and unscrew the fast-idle screw clear of the cam. Unscrew the throttle adjusting screw just clear of its stop when the throttle is closed,then set it one full turn open. Do not touch the jet adjusting nut 1 at this stage. Connect the exhaust gas analyser in accordance with the manufacturersinstructions. C a r r y o u t t h e p r o c e d u r ed e s c r i b e de a r l i e ri n t h i s s e c t r o n under Tuning the carburetter. N o w t u r n t h e J e t a d j u s t i n g n u t 1 u n t i l t h e f a s t e s te n g i n e speed is obtained,then screw it in slowly. weakening the mixture, until the engine speed just begins to fall, then

FIG 2:21 Details of throttle assembly. Mark the f lange and disc as shown at 60

Key to Fig 2:21 6 3 L i m i tv a l v e 66 Tabwasher

6 1 T h r o t r td i s c e 64 Screws 6 7 S p i n d l en u r

6 2 C a r b u r e t t e rf l a n g e 65 Throtrle spindle 68 Lever arm

1 1 0 0 v k2 1 3 0 0 t

45

Reconnectthe mixture control wire and adjust the fast-idle screw as previously described. 2:15 A,ircleaner T h e e l e m e n ts h o u l d b e r e n e w e d p e r i o d i c a l l y c c o r d i n g a t o l o c a l o p e r a t i n gc o n d i t i o n s . Unscrew the wingnut from the top of the cleaner, remove the cover and lift out the element. Do not disturb t h e a i r c l e a n e ra t a n y o t h e r t i m e . The air cleanerintakeshould be positionedadjacentto t h e e x h a u s tm a n i f o l dd u r i n g w i n t e r c o n d i t i o n st o p r e v e n t carburetter icing; turn it away from the manifold in warmer weather.

2:16 Mechanical fuel pump T h i s l a t e rt y p e o f f u e l p u m p , t h e c o m p o n e n t s o f w h i c h c a n b e s e e n i n F I G 2 : 2 4 , i s o p e r a t e db v a n e c c e n t r i c lobe on the camshaftwhich impartsan up and down m o v e m e n t t o t h e d i a p h r a g mt h r o u g h t h e c r a n k - s h a p e o rocker lever, giving a suction effect on its downwaro s t r o k e a n d a p r e s s u r ed e l i v e r y a s t h e d i a p h r a g m i s m o v e d u p w a r d s b y t h e a c t i o n o { t h e r e t u r ns p r i n g . Testing on car: l f f a u l t y o p e r a t i o no f t h e p u m p i s s u s p e c t e d , t c a n b e i r o u g h l yc h e c k e dw i t h o u t r e m o v i n gi t a s f o l l o w s : Disconnect the fuel delivery hose at the carburetter a n d p l a c e t h e e n d i n a s u i t a b l ec o n t a i n e r , i s c o n n e c tt h e d p o s i t i v el e a d f r o m t h e c o i l , t u r n t h e e n g i n e o n t h e s t a r r e r and observethe results. l f t h e f l o w i s n o r m a l , e x a m i n e t h e c a r b u r e t t e rf l o a t needle valve assembly. l f t h e f l o w s e e m sn o r m a l a t f i r s t ,b u t d r o p s o f f a s t h e test continues, suspectthe venting to the fuel tank. l f t h e r e a r e a i r b u b b l e si n t h e f u e l f l o w t h e r e i s a n a i r leakon the suctionsideof the pump. lf thereis no flow at all the pump should be removed f o r e x a m i n a t i o na n d b e n c h t e s t i n o . Bench testing: R e l e a s e h e c l i p s s e c u r i n gt h e h o s e s t o t h e l n l e t a n o t d e l i v e r yp i p e s a n d p u l l o f f t h e h o s e s . R e m o v e t h e n u t s s e c u r i n gt h e p u m p t o t h e c y l i n d e r b l o c k a n d l i f t i t o f f c o m p l e t e w i t h i n s u l a t o rp l a t e a n d g as k e t . A r e a s o n a b l e n d i c a t i o no f t h e p u m p ' s c o n d i t i o n c a n i be obtained by the following procedureif a vacuum/ pressure auge is not available. g H o l d a f i n g e r o v e r t h e i n l e t n o z z l ea n d g i v e t h e r o c k e r l e v e r t h r e e f u l l s t r o k e s .R e l e a s e h e f i n g e r a n d t h e n o i s e t c a u s e d b y s u c t i o n s h o u l d b e c l e a r l yh e a r d . H o l d a f i n g e r o v e r t h e o u t l e t n o z z l e a n d d e p r e s st h e r o c k e r a r m f u l l y . P r e s s u r es h o u l d h o l d f o r a b o u t 1 5 seconds. Dismantling: Cleanthe outsideof the pump and then make alignment marks on the outlet cover and the two bodv sections for later assembly. Remove three long screws and lift off the outlet cover a n d t h e s e a l i n gw a s h e r . Remove the three short screws and the upper body.

2
/

tl(j 2124 AUF 7OO

Components of mechanical fuel pump, type

K e y t o F i g 2 : 2 4 1 O u t l e t o v e r 2 I n s e r t3 S e a l i n o a s h e r c w 4 Longscrews 5 S h o r ts c r e w s 6 U p - p eb o d y r 7 I n l e ta n d o u t l e tv a l v e 8 D i a p h r a g ms s e m b l y d i a p h r a g n r a 9 spring 10 Retarnrng p cu 11 C r a n k c a s e a l se 1 2 R o c k e lre v e r p r r n g s 1 3 P i v o tp i n 1 4 R o c k e lre v e r 1 5 l n s u l a t oa n d g a s k e t r 1 6 L o w e rb o d y turn the nut one flat out (rich), (see FIG 2:22).f apthe neck of the depressionchamber ligntly with the wooden handle of a screwdriver. heck the idling speed of g50 C rev/min and adjust if necessary. he exhaustgas analyser T should now give a reading of 2 to 2.5 per cent CO. lf n e c e s s a r yr e s e t t h e j e t a d j u s t i n g n u t b y t h e m i n i m u m a m o u n t n e c e s s a r yt o b r i n g I t w i t h i n t h e s e l i m i t s . H o l d t h e a d l u s t i n gn u t a n d t u r n t h e r e s t r i c t o r n t i l r n e u v e r t i c a lt a g t o u c h e s t h e b o d y a s i l l u s t r a t e d n F I G 2 : 2 3 . i B e n d d o w n t h e s m a l l t a g t o l o c k t h e r e s t r i c t o r .p a i n t t h e small tag and its adjacent flat on the nut to identify the posrtron.

40

Take out the combined inlet/outlet valve, noting that this is a press fit and care must be taken not to damage the fine edge. Withdraw the insertfrom the outlet cover. Holding the diaphragm and rocker lever against the p r e s s u r eo f t h e s p r i n g , t a p o u t t h e p i v o t p i n a n d r e m o v e the lever and spring. W i t h d r a w t h e d i a p h r a g ma n d s p r i n g . l t w i l l b e f o u n d a d v i s a b l e t o a p p l y a s p o t o f o i l t o t h e c r a n k c a s es e a l t o avoid damage as the spindle stirrup is pulled through. T h e c r a n k c a s es e a l a n d r e t a i n i n g c u p n e e d b e r e m o v e o only if the seal is to be renewed. This is bes. done ov screwingthe centreof tool 18G 1 119 into the cup and pullingout. DExamine a l l t h e c o m p o n e n t s , p a r t i c u l a r l yt h e d i a phragm, for wear or damage and renew if necessary. he T fine edge and lips of the inlet/outlet valve must also be closely inspected. Reassembly: T h i s i s a r e v e r s a lo f t h e d i s m a n t l i n g p r o c e d u r e , n o t i n g the following points: H a v i n g p r e s s e dt h e r e t a r n i n g c u p i n t o t h e l o w e r b o o y ( 1 8 G 1 1 19 ) , r e m o v e a n y s h a r p e d g e s f r o m t h e d i a p h r a g m spindle and stirrup, oil lightly and position the slot for engagement by the rocker lever. Ensure that the inlet/outlet valve groove registers rn the housing and that the fine edge contacts the seattng evenry. Line up the screw holes in the lower bodv and diap h r a g m , p r e s sd o w n t h e r o c k e r l e v e rs o t h a t t h e d i a p h r a g m lies flat and loosely fit the three short screws. Fit the sealing washer and outlet cover then tighten all screws evenly. I t i s a d v i s a b l et o d r y t e s t t h e p u m p a s d e s c r i b e d a b o v e before fitting to the engine. 2:17 I 2 3 4 5 6 7 8 Fault diagnosis fuel delivered

(d) Noisy fuel pump 1 Loosemountings 2 Air leaks suctionsideand at diaphragm on 3 Obstruction fuel pipe in 4 Cloggedpump filter (e) No fuel delivery 1 Floatneedle stuck 2 Vent in tank blocked 3 Electrical connections pump faulty to 4 Pumpcontactpointsdirty 5 Pipeline obstructed 6 Pumpdiaphragm stiff or damaged 7 I n l e tv a l v ei n p u m ps t u c ko p e n B Bad air leakon suctionsideof pump Fault diagnosis The following items apply when an exhaustemission controlsystemis fitted (see also chapter 1, section 1 :25). (f) Backfire in exhaust system 1 Leaks hoses connections gulp valve vacuum in or to or pipe sensing gulp valve 2 Faulty 3 Leakin intakesystem 4 High inlet manifold depression overrun.Faurrv on carburetter limit valve (g) Hesitation to accelerate after sudden throttle closure 'I C h e c k1 , 2 a n d 3 i n ( f ) ( h ) E n g i n es u r g e s 1 C h e c k1 a n d 2 i n ( f ) (j) Erraticidling or stalling 1 Check1 and 2 in (f) 2 Carburetter limit valvenot seating (k) Burned or baked hose between air pump and check valve 1 Faultvcheckvalve 2 Faultyair pump (l) Noisy air pump 1 Incorrect belt tension 2 Pulleys damaged, looseor misaligned 3 Air pump damaged seizing or (m) Excessiveexhaust system temperature 1 Incorrect ignitiontiming 2 Air injector missing 3 Air pump reliefvalveinoperative 4 Mixturecontrol(choke)not fully returned (n) Mixture requires enrichment to obtain correct exhaust emission readings 1 Air leakin crankcase 2 Crankcasebreatherhose or carburetterconnections leaking (o) Fuellakage 1 Brokenfuel pipe 2 Fillercap not sealing 3 Leakon fillertube or tank unit

(a) Leakage or insufficient

Air vent in fuel tank restricted Fuel pipes blocked Air leaks at pipe connecrrons Pump filter blocked Pump gasketsfaulty Pump diaphragm defective Pump valves sticking or seating badly F u e l v a p o r i z i n g i n p i p e l i n e sd u e t o h e a t (b) Excessive fuel consumption 1 2 3 4 5 6 7 8 9 C a r b u r e r t e r ( s )n e e d a d j u s t i n g Fuel leakage Sticking mixture control Dirtyair cleaner E x c e s s i v ee n g i n e t e m p e r a t u r e Brakesbinding Tyres under-inflated l d l i n g s p e e dt o o h i g h Car overloaded

(c) ldling speed too high 1 2 3 4 Rich fuel mixture C a r b u r e t t e rc o n t r o l s s t i c k i n g S l o w - r u n n i n g s c r e w s i n c o r r e c t l ya d j u s t e d Worn carburetter butterfly valve

1 1 0 0 k2 1 3 0 0 M

47

CHAPTER 3 THE IGNITION SYSTEM

3 :1 3:2 3 :3 3 :4 Description Routine maintenance lgnition faults Removing and dismantling distributor 3:5 Timing the ignition 3:6 Sparking plugs 3:7 Distributor driving spindle 3:8 Fault diagnosis

3 :1 Description All the cars covered by thrs manual are fitted with a L uc a s d i s t r l b u t o , l y p e 2 5 D 4 o r 4 5 D 4 , w h i c h i n c o r p o r a t e s r an automatictiming control operated by a centrifugal mechanism and also a vacuum operated untt which r e g u l a t e s h e i g n i t i o n t i m i n g a c c o r d i n gt o e n g i n e l o a d . A t hand operated micrometer adjuster is included to enable s l i g h t a l t e r a t i o n st o b e m a d e c o n v e n i e n t l y t o s u i t v a r i o u s g r a d e so f f u e l o r c h a n g e s i n e n g i n e c o n d i t i o n . The weights of the centrifugalsystem tend to fly outw a r d s a s t h e e n g i n es p e e di n c r e a s e a n d t h r o u g ha l i n k a g e s m o v e t h e c o n t a c t b r e a k e rr e l a t i v et o t h e d i s t r i b u t o rd r i v i n g shaft and so advance the actual point of firing as required
at hinhor cnoodc

3:2

Routine maintenance

Maintenance consists of keeping the distributor clean a t a l l t i m e s a n d o c c a s i o n a ld r o p s o f o i l a s f o l l o w s : R e m o v e t h e d i s t r i b u t o rc a p 2 ( s e e F I G 3 : 1 ) a n d l i f t o f f t h e r o t o r 4 f r o m t h e c a m s p i n d l e1 1 . A p p l y a f e w d r o p s o f o i l r n t o t h e r e c e s s ( s e e F I G 3 : 2 ) . l t i s n o t n e c e s s a r yo 5 t r e m o v e t h e s c r e w a s c l e a r a n c ei s p r o v i d e d . Apply a few drops down the aperture 4 on to the c e n t r i fu g a l a d v a n c e m e c h a n r s m ,b u t b e w a r e o f l e t t i n g t h e o i l r e a c h t h e c o n t a c t b r e a k e rp l a t e o r t h e p o i n t s . A drop of oil may be applied to the contact breaker p i v o t a n d a s m e a r o f g r e a s eo n t h e c a m a s s h o w n i n F I G

3:3. A d j u s t i n gt h e c o n t a c t b r e a k e rp o i n t s ( s e eF I G3 : 2 ) : Firstturn the engineuntil one of the camshas opened the the pointsto the fullestextentand measure gap.This 1 6 s h o u l db e b e t w e e n . 04 a n d . 0 1 i n c h .l f i t i s o u t s i d e platesecuring slacken the contact screw2, theselimits, off placea screwdriver the slot3 and twist gentlyuntilthe in gap is correct gauge. when measured with a feeler Tighten t h e s c r e wa n d c h e c k .

A small bore pipe from the inlet manifold to the vacuum u n r t p e r m i t st h e d e p r e s s i o n n t h e m a n r f o l dt o a d v a n c eo r i retard the setting according to engine load. At small t h r o t t l eo p e n i n g s ,w i t h a l o w l o a d o n t h e e n g i n e ,d e p r e s sion is high and the unit advancesthe ignition. The r e d u c e dv a c u u m o b t a j n i n g w h e n c l r m b i n g h i l l s o n w i d e r t h r o t t l e o p e n i n g s c a u s e st h e u n i t t o r e t a r d t h e f i r i n g p o i n t . T h e s et w o c o n t r o l s m a y b e s e e n i n t h e e x p l o d e d v i e w o f t h e d i s t r i b u t oirn F I G 3 : 1 .

1 1 0 0M k 2 1 3 0 0

49

Cleaning the contact points: From time to time the points should be cleaned by l i g h t l y r u b b i n g a f i n e c a r b o r u n d u ms t o n e b e t w e e n t h e m , t a k i n g c a r e t o k e e p t h e f a c e s s q u a r e a n d l e v e l .A n y d u s t should be removed with a petrol moistenedcloth. l{ the moving contact is not moving freelyon its pivot, i t m a y b e r e m o v e da s d e s c r i b e di n S e c t i o n 3 : 4 a n d t h e pivot pin polished with fine emerycloth and refitted with a drop of oil. l f a s p r i n g t e s t i n g g a u g e i s a v a i l a b l et h e c o n t a c t b r e a k e r spring should have a tension of 20 to 24 oz measuredat the oornts.

3 :3 lgnition faults Before carrying out the following tests on the ignition system if the engine appears to be running badly make sure that all the wiring is in good conditionand that all connectionsare tight. Check also that the contact breaker and sparking plug gaps are clean and correctly set. See that the interror of the distributor cap is clean and dry. E n s u r e h a t t h e c 6 r b o nb r u s h ( 1 i n F I G 3 : 4 ) , i s s o u n d a n o t free to move under the pressureof its spring. Look for s i g n s o f t r a c k i n g b e t w e e n t h e e l e c t r o d e si n t h e c a p . l f t h i s i s p r e s e n t i t w i l l b e n e c e s s a r yt o r e n e w t h e c a p . Testing the low-tension circuit: When the above checks have been made, disconnect t h e w r r e f r o m t h e C B t e r m i n a lo n t h e c o i l t o t h e s i d e o f t h e distributor and connect a test lamp in its place. Turn the engineover slowly and check that the lamp lightswhen the contacts close and goes out when they open. lf it fails to do so, either the contactsare dirty or there is a bad c o n n e c t i o ni n t h e l o w - t e n s i o nw i r i n g . In this event switch on the ignition and turn the engine until the points are fully open. Refer to the Wiring Diagrams in Technical Data and check with a 0-20 v o l t m e t e r .l f t h e w i r i n g i s i n o r d e r t h e r e s h o u l d b e a r e a d i n g of approximately 2 volts. 1 Connect the volmeter between the following pairs of points, when a zero reading indicates a faulty cable or connection, 1 Control box terminal B and earth, checking battery to control box. 2 Second control box terminal B and earth. 3 Terminal3 on ignition switch and earth,checking the wiring from control box to switch. 4 F u s e b o x t e r m i n a lA 3 a n d e a r t h , c h e c k i n g t h e w i r i n g from ignition swrtch to fusebox. 5 I g n i t i o n c o i l t e r m i n a l S W a n d e a r t h ,c h e c k i n g b e t w e e n f u s e b o xa n d c o i l . T o c h e c k t h e i g n i t i o n s w i t c h c o n n e c t t h e m e t e rb e t w e e n terminal 2 and earth, and then between terminal 1 and earth In each case no reading when the ignition switch i s t u r n e d t o t h e O N p o s i t i o n i n d i c a t e sa f a u l t i n t h e s w i t c h . To check the coil disconnect the cable from terminal CB and connect the meter between CB and earth. No r e a d i n g i n d i c a t e sa f a u l t i n t h e p r i m a r y w i n d i n g a n d a n e w coil must be fitted. To check the capacitor connect the meter across the contact breaker points. No reading indicates a faulty capacitor. The most convenient method of testing the capacitor is by substitution. To do this, disconnect the

,,/*@\.
FIG 3:1

m-,,
Exoloded view of distributor

Key to Fig 3 :1 1 C l a m p i n gp l a t e 2 Moulded cap 3 Brushand spring 4 Rotorarm 5 C o n t a c t s( s e t ) 6 Capacitor 7 T e r m r n a la n d l e a d ( L T ) 8 Moving contact brakerpldte 9 C o n t a c t b r e a k e rb a s e p l a t e 1 O E a r t hl e a d 11 Cam 1 2 A u t o m a t r ca d v a n c e s p r r n g s 13 Weight assembly 1 4 S h a f t a n d a c t r o np l a t e 15 Capretaininglips c 1 6 V a c u u mu n i t 17 Bush 18 T h r u s tw a s h e r p 1 9 D r i v i n gd o g 20 Parallel in

FIG 3:2

Contact breaker adjustment and lubrication

'1 Key to Fig 3:2 Contactpoints 2 Contact plate securing screw 3 Screwdriver adjusting slot 4 A d v a n c e m e c h a n i s ml u b r i c a t r o n 5 C a m s p i n d l e l u b r i c a t t o n

50

suspect part and connect a new one (.18 to.22 mfd c a p a c i t , i ) b e t w e e n t h e l o w - t e n s i o n t e r m i n a lo n t h e s i o e o l the distributor and earth.

3:4

Removing and dismantling distributor

R e f e rt o F I G 3 : 1 . T u r n t h e e n g i n e u n t r lt h e r o t o r a r m 4 r s t o w a r d s N o . 1 c y l r n d e rs e g m e n t i n t h e c a p . N o . 1 i s t h e cylinder nearest to the fan. Provided that the clamping plate is not loosened, removing the dtstflbutor will not d i s t u r b t h e i g n i t i o n t i m i n g . E n s u r et h a t t h e e n g i n e i s n o t t u r n e d u n t i l r e p l a c e m e n ti s c o m p l e t e d . Remove the cap 2 and disconnect the cable from the l o u 5 t e n s i o n t e r m i n a l 7 . D i s c o n n e c tt h e v a c u u m p i p e f r o m t h e u n i t 1 6 . R e m o v e t h e t w o b o l t s s e c u r i n gt h e c l a m p plate '1and lift off the distributor Lift off the rotor arm 4 and removethe nut which horos t h e a s s e m b l y5 a n d l i f t o f f t h e s e i t e m s a s s h o w n . R e m o v e t h e t w o s c r e w s s e c u r i n gl h e b a s e p l a t e 9 a n d u n h o o k t h e f l e x i b l el i n k f r o m t h e v a c u u m u n i r . B e f o r e d i s m a n t l i n ga n y f u r t h e r ,n o t e t h e r e l a t t v e o s l p t i o n s o f t h e r o t o r a r m d r i v i n g s l o t i n t h e c a m a s s e m b l y1 1 a n d t h e d r i v i n gd o g 1 9 w h i c h r s o f f s e ta n d c a n e n g a g et h e d r i v i n g s p i n d l ei n o n e p o s i t i o no n l y . T h r s e n s u r e s h a t t h e t t i m i n g w i l l n o t b e 1 8 0 d e g r e e so u t w h e n r e a s s e m b l i n g . T a k e o u t t h e c a m r e t a i n i n g s c r e w i n t h e r e c e s sa t t h e top. Removethe springs 12 and lift off the cam assembly. Takeout the weights 13. T h e v a c u u m u n i t i s r e l e a s e db y r e m o v i n g t h e c i r c l i p a t t h e e n d a n d u n s c r e w i n g t h e a d j u s t i n gn u t a n d r e m o v i n gt h e friction spring when the unit may be withdrawn from the body. Check all parts for wear, replacing where necessary, a n d c l e a n a l l p a r t s b e f o r e r e a s s e m b l y .l f t h e r e i s e x c e s s r v e play between the shaft 14 and the body the bush 17 should be removed by knocking out the pin.20 to release the dog 19 and withdrawing the spindle when the old b u s h m a y b e p r e s s e do u t . A n e w b u s h s h o u l d l i e r m m e r s e d in engine oil tor 24 hours before being fitted. R e a s s e m b l yi s t h e r e v e r s eo f t h e d t s m a n t l i n g p r o c e d u r e w i t h p a r t i c u l a ra t t e n t i o n t o t h e f o l l o w i n g : Lightly oil the centrifugal advance mechanism, the d i s t r i b u t o r s h a f t a n d a r o u n d t h e c a m a s s e m b l y .T u r n t h e v a c u u m c o n t r o l a d j u s t i n g n u t t o i t s h a l f w a y p o s i t i o n ,t n e n engage the cam driving pins with the weights so that the small offset of the driving dog is on the right when viewed from above and the driving slot for the rotor arm is at the six o'clock position. F i t t h e d i s t r i b u t o ri n t o i t s h o u s i n g a n d t u r n t h e r o t o r a r m until the drivrng dog engagesand confirm that the arm ts pointing to the segment for No. 1 cylinder. Replace the plug leads in the correctfiring order of 1-3-4-2, noting that the distributor rotates in an anticlockwise direction when seen from above. lf the clamping plate has been m o v e d i t w i l l b e n e c e s s a r yt o r e t i m e t h e i g n i t i o n a s w i l l b e descnbed in the next section. On the Austin America this o p e r a t i o n m u s t b e f o l l o w e d b y a n e x h a u s te m i s s i o nc h e c k . 3:5 Timing the ignition R e m o v e t h e d i s t r i b u t o r ,e n s u r i n g a t t h e s a m e t i m e t h a t the driving spindle has been fitted correctly.Remove the rockercover so that the valve action may be seen.Remove the sparking plugs, engage top gear and move the car until No. 1 piston is at TDC on the compressionstroke.

FIG

Cam and pivot lubrication points

FIG 3 :4 Interior of distributor cap, showing 1 carbon brush,2 cable securing screw

F I G 3 : 5 T i m i n g m a r k so n t h e f l y w h e e l .T D C i s i n d i c a t e d bv the mark 1/4

T h e i n l e t v a l v e o f N o . 4 c y l i n d e rw i l l b e j u s t o p e n i n g a n d t h e e x h a u s tv a l v e j u s t c l o s i n g . The crankshaftmust now be turned until the 1/4 mark on the flywheel is in lrne with the pointer in the aperture in the clutchcoveras shown in FIG 3:5. Turn the crankshaft back from this position until the pointer indicates the correct setting as given in Technical Data. O n c a r s w i t h a u t o m a t i c t r a n s m i s s i o nt h e p r o c e d u r e i s the same as above with the following exceptions:

1 1 0 0M k 2 1 3 0 0

51

p o i n t s a r ef u l l y c l o s e d .S w i t c h o n t h e i g n i t i o n a n d c o n n e c t a 1 2 - v o l t b u l b b e t w e e n t h e l o w - t e n s i o n t e r m i n a lo n t h e d i s t r i b u t o r a n d e a r t h i . e . i n p a r a l l e lw i t h t h e p o i n t s . T u r n the distributor clockwise until the lamp lights indicating that the points have just opened. Securethe distributor in this position by tightening the pinch bolt. Check that the rotor arm is opposite No. 1 segment in the cap. Reconnect the vacuum advance oipe and refit the distributor cover and rocker cover. Stroboscopic timing : When using a stroboscopic lamp take care that the engine speed does not rise above 600 revlmin or the c e n t r i fu g a l a d v a n c e w e i g h t s w i l l s t a r t t o o p e r a t e a n d u p s e t the timing. lf the vacuum advance pipe is connected directly to the inlet manifold it should be disconnected otherwise the timing will be retarded. Manual adjustment : The vernier adjustment device which enables fine i alterationso the ignition is illustratedn FIG 3:7. The t adjustment nut is indicated by the arrow; clockwrse rotation of this retards and anticlockwise advances the i g n i t i o n . E a c h g r a d u a t i o no n t h e a d l u s t i n gs p i n d l e b a n e l r e p r e s e n t sa p p r o x i m a t e l y 5 d e g r e e s o f t i m i n g m o v e m e n t a n d i s e q u a l t o 5 5 c l i c k so n t h e a d J u s t en u t . r O n t h e A u s t i n A m e r i c a a n e x h a u s t e m i s s i o nc h e c k m u s t be carriedout after the ignition has been retimed. 3:6 Sparking plugs The sparkrng plugs should be removed regularly for c l e a n i n g a n d i n s p e c t i o n . E x a m i n a t i o no f t h e c o n d i t i o n o f t h e e l e c t r o d e sw i l l o f t e n g i v e v a l u a b l e i n f o r m a t i o n o n s u c h v a r i a b l e sa s c a r b u r e t t e rf u e l m i x t u r e s a n d i g n i t i o n t i m i n g . T h e n o r m a l d e o o s i t o n t h e e l e c t r o d e ss h o u l d b e b r o w n or a greyish tan in colour. A white or yellowish deposit is also quite normal in an engine which has been usedfor long spells of steady driving or town work. Cleaning and resetting the gap to the recommended .025 inch rs all that should be required. Deposits of wet black sludge indicate oil fouling c a u s e db y o i l m a k i n g i t s w a y i n t o t h e c o m b u s t i o n c h a m b e r past worn pistons or rings or past worn valves or guides. Sparkingplugs of a type which run hottermay be effective, b u t i n s e v e r ec a s e s a n e n g i n e o v e r h a u l m a y b e n e c e s s a r y . Dry, black and fluffy deposits are usually caused by p e t r o l f o u l i n g r e s u l t i n gf r o m i n c o m p l e t e c o m b u s t i o n . T h i s m a y b e d u e t o r u n n i n g w i t h a h e x c e s s i v e l yr i c h m i x t u r e o r over-use of the choke. Long periods of idling or slowspeed running will also cause these symptoms as also w i l l d e f e c t i v ei g n i t i o n g i v i n g i n c o m p l e t ec o m b u s t i o n Overheated sparking plugs have a white or blistered a p p e a r a n c eo n t h e c e n t r e e l e c t r o d ea n d t h e s i d e e l e c t r o d e m a y b e b a d l y e r o d e d .T h e c a u s e o f t h i s m a y b e i n e f f i c i e n t c o o l i n g , i n c o r r e c ti g n i t i o n t i m i n g o r o v e r l o n g s p e l l s o f high-speed running. Attention to the engine may be n e c e s s a r yt o c u r e t h e t r o u b l e , b u t i t m a y b e f o u n d h e l p f t r l t o f i t p l u g s o f a c o o l e rr u n n i n gt y p e . T h e p l u g s s h o u l d b e c l e a n e do n a n a i r b l a s t m a c h i n e a n d t e s t e d u n d e r p r e s s u r ea f t e r a t t e n t i o n t o t h e e l e c t r o d e s . These should be filed clean and level and reset to the correct gap. Always adjust the gap by bending the side e l e c t r o d e ,n e v e r t h e c e n t r e e l e m e n t . B e f o r e r e p l a c i n g t h e plugs clean the screw threads with a wire brush taking care to avoid the centre electrodeand insulator.

FIG 3:6 f iming marks on the converter. Inset A shows TDC position indicated by 1/4 mark. Inset B shows the hole in the housing for turning the converter with a screwdriver

liThe vernier timing adjustment nut

FIG3:7

To rotate the crankshaft,insert a screwdriver through the apertureadjacent to the oil dipstick on the converter housing, and turn the starterring gear in the direction of e n g i n e r o t a t i o n t o t h e p o s i t i o n p r e v i o u s l ym e n t i o n e d .T h e Timing marks can be seen on the converter after the r e m o v a lo f t h e r u b b e r g r o m m e t ( s e e F I G 3 : 6 ) . H a v i n g s e t t h e f l y w h e e l t o t h e T D C m a r k ,t h e c r a n k s h a f t must now be turned backwards until the pointer indicates the correct ignition setting as given in Technical Data for tne car concerned. E n s u r et h a t t h e c o n t a c t b r e a k e rp o i n t s a r e c o r r e c t l ys e t , t h e n i n s e r tt h e d i s t r i b u t o r i n t o i t s h o u s i n g a n d e n g a g e t h e drive dog lug with the slot in the driving spindle by slowly rotating the rotor arm. Tighten up the clamping plate pinch bolt to the torque given in Technical Data before tightening the two setscrews in the centre of the e l o n g a t e dh o l e s i n t h e c l a m p i n g p l a t e . Electrical setting of timing : I n o r d e r t o d e t e r m i n e a c c u r a t e l vt h e D o s i t i o n a t w h i c h the points break the electrical method should be used: Slacken off the clamp plate pinch bolt and turn the distributor body in an anticlockwise direction until the

3Z

High-tension cables: l f a h i g h - t e n s i o n c a b l e s h o w s s i g n s o f d e t e r i o r a t i o ni t s h o u l d b e r e p l a c e db y n e w r u b b e r c o v e r e d i g n i t i o n c a b r e . To make the connections to the terminals in the distributor cover, slacken the securing screws on thejnstoe of the moulding (2 in FIG 3 :4) and pull out the otd cables. Having cut the new cablesto the correct length push one e n d f i r m l y i n t o t h e h o l e a f t e r s m e a r i n gw i t h s i l i c o n e g r e a s e and tighten the screw. To fit the cable to the ignition coil pass the caore through the knurled moulded nut, bare about I inch of the wire, thread it through the brass washer and fan out the wires over the face of the washer. Screwing the nut into $e terminal socket will hold it firmly in place. 3:7 Distributor driving spindle

3 :8 Fault diagnosis (a) Engine will not fire 1 2 3 4 5 6 7 8 9 Battery discharged Distributorcontact points dirty, pitted or maladlusted 'tracking' D r s t r i b u t o rc a p d i r t y , c r a c k e d o r Carbon brush in distributor cap not touchtng rotor F a u l t yc a b l eo r l o o s ec o n n e c t i o ni n l o w - t e n s i o nc i r c u i t Distributorrotor arm cracked Faulty coil B r o k e n c o n t a c t b r e a k e rs p r i n g Contact points stuck open

(b) Engine misfires 1 2 3 4 5 6 7 C h e c k2 , 3 , 5 a n d 7 i n ( a ) W e a k c o n t a c t b r e a k e rs p r i n g High-tension plug and coil leads cracked or perished S p a r k i n gp l u g ( s ) l o o s e S p a r k i n gp l u g i n s u l a t i o nc r a c k e d S p a r k i n gp l u g g a p r n c o r r e c t l y e t s l g n i t i o nt i m i n g t o o f a r a d v a n c e d

l f f o r a n y r e a s o nt h e d r i v i n g s p i n d l e h a s b e e n r e m o v e d from rts housing in the crankcase, it must be correctly e n g a g e d . w i t h t h e c a m s h a f t g e a r a s d e s c r i b e di n C h a p t e r 1. Section1:7.

1100 k2 1300 M

53

C H A P T E R4 T H E C O O L I N GS Y S T E M
4 : 1 Description 4 : 2 Protective maintenance 4 : 3 Removing radiator 4 : 4 Removing expansion chamber 4 . . 5 The fan belt
4:6 4 :7 4:8 4:9 The water pump The thermostat Frost precautions Fault diagnosis

4:1

Descriotion

A pressurized ooling system is used on all the cars c c o v e r e d b y t h i s m a n u a l ,w i t h a n e x p a n s i o nc h a m b e r i n t o which any excess of coolant, which may result from heating, is directed Periodic topping up should be u n n e c e s s a r y v e r l o n g p e r i o d s ,p a r t i c u l a r l yf t h e s y s t e m o i i s f i l l e d w i t h a n a n t i fr e e z es o l u t i o n o f t h e e t h y l e n e - g l y c o l tvoe. T h e c o o l i n g w a t e r i s c i r c u l a t e d r o u n dt h e e n g i n e b y a n a i m p e l l e rp u m p m o u n t e d o n t h e f r o n t o f t h e e n g t n e a n d d r i v e n b y a b e l t f r o m t h e c r a n k s h a f tp u l l e y , w h i c h a l s o d r r v e s t h e e l e c t r i c a lg e n e r a t o r o r a l t e r n a t o r . T h e p u m p r e c e i v e si t s w a t e r f r o m t h e b o t t o m t a n k o f t h e r a d i a t o ra n d p a s s e si t r o u n d t h e c y l i n d e r b l o c k a n d i n t o t h e c y l i n d e r h e a d a n d o n t o t h e t h e r m o s t a tv a l v e w h i c h p r e v e n t st h e w a t e r f r o m f l o w i n g i n t o t h e r a d i a t o r u n t i l i t r s o p e n e d b y t h e w a t e r r e a c h i n ga p r e d e t e r m i n e d t e m p e r a t u r e .U n t i l t h e c o o l a n t r e a c h e s t h i s v a l u e ( s e e T e c h n i c a lD a t a ) t h e v a l v e r e m a i n sc l o s e d a n d d i r e c t st h e flow to the bottom of the block bypassing the radiator u n t i l t h e i n c r e a s e d e a to f t h e e n g i n eo p e n st h e t h e r m o s t a t h a n d c o m p l e t e st h e c i r c u i t . A s p r i n g - l o a d e dv a l v e i n t h e e x p a n s t o nt a n k f i l l e r c a p p r e s s u r i z e st h e s y s t e m a n d s o r a i s e s t h e t e m p e r a t u r e a t w h i c h t h e w a t e r b o i l s . T h e e x p a n s i o nt a n k i s c o n n e c t e d to the radiator op tank by a hose(25 in FIG 4 :1 ) through t

w h i c h t h e o v e r f l o w i n gw a t e r p a s s e sa s i t e x p a n d s i n t h e r a d i a t o r A s t h e t e m p e r a t u r e f t h e c o o l a n td r o p s a p a r t i a l . o v a c u u m i s c r e a t e di n t h e s y s t e ma n d t h e s p i l l a g ei s d r a w n back into the main system A f l o w o f a i r i s d i r e c t e dt h r o u g h t h e r a d i a t o rc o r e b y m e a n so f a f a n b o l t e dt o t h e w a t e r p u m p p u l l e yt o a s s i s t in the coolingaction.

4 :2 Protective maintenance '1 T h e o n l y l u b r i c a t i o n n e c e s s a r yi s a t i n t e r v a l so f 2 , 0 0 0 g r e a s e h o u l db e i n t r o d u c e d m i l e sw h e n a s m a l la m o u n t o f s into the plugged cavity at A in FIG 4:6. Do not use p r e s s u r el u b r i c a t i o na s t h i s w o u l d i m p a i r t h e e f f i c i e n c y of the seal. O n e a r l y c a r s t h e r e a r e t w o d r a i n i n g p o i n t s ,o n e u n d e r the radiator(see FIG 4:2) and one at the rear of the c y l i n d e rb l o c k ( s e e F I G 4 : 3 ) . L a t e rc a r s h a v e n o r a d i a t o r d r a i n p l u g a n d i t i s n e c e s s a r yt o r e m o v e t h e b o t t o m h o s e . Both draining points and the heaterlap, when fitted, should be opened to drain the system at the prescribed i n t e r v a l s ,n o t f o r g e t t i n g t o c o l l e c t t h e c o o l a n t i n a c l e a n c o n t a i n e ri f i t c o n t a i n sa n t i f r e e z e h i c h s h o u l d n o r m a l l y w m a i n t a r n i t s e f f e c t i v e n e s sf o r t w o y e a r s . When the water has ceasedto flow the svstem should

1100Mk2300 1

55

r4-
l5 --.e

B-z

t3---

77

t7
I

20

FIG 4:1 Components of the radiator system Key to Fi9 4:'l 1 R a d i a t o ra s s e m b l y 2 R a d i a t o rf i l l e r c a p ( p l a r n ) 3 D r a i n p l u g ( e a r l ya s s e m b l i e s ) 4 T o p c o w l 5 B o t t o m c o w l 6 Screw 7 Springnut 8 R u b b e r c o w l s u r r o u n d ( e a r l ya s s e m b l i e s ) 9 R a d i a t o rm o u n t i n g b r a c k e t ( e a r l yt y p e ) 9 a R a d i a t o rm o u n t i n g b r a c k e t ( l a t e r t y p e ) 10 Bolt 11 Springwasher 1 2 R a d r a t o r p p e r s u p p o r t b r a c k e t( s h o r 1 ) u 1 2 a R a d i a t o r u p p e r s u p p o r t b r a c k e t ( l o n g1 3 S u p p o r t b r a c k e t g r o m m e t1 4 S c r e w ' 1 5 P l a i n w a s h e r 1 6 R a d i a t o r l o w e r s u p p o r i ) bractet (early assemblies) 17 S c r e w 18 S h a k e p r o o f w a s h e r 19 Bolt 20 Spring washer 21 Radiator hose ro pump 2 2 R a d a a t o th o s e l o p u m p ( h e a t e r ) 2 3 R a d i a t o r o u t l e t h o s e 24 Hose clip 25 Radiatorto expansion rank hose 26 Hose clip 2 7 R a d i a t o rc o w l h o s e c l i p ( p r e s s u r i z e d ) 3 0 E x p a n s i o n a n k s t r a p ( m e t a lt a n k ) 28 Expansion ank t 2 9 E x p a n s i o nt a n k c a p t 3 0 a S w a g e d e x p a n s i o nt a n k s t r a p ( p l a s t i ct a n k ) 31 Screw 32 Springwasher 33 Nut

be flushed by means of a hose pipe inserted in the firrer o r i f i c ea n d f r e s hw a t e r r u n t h r o u g h u n t i l i t c o m e s o u t c l e a r from the drain holes. I n o r d e r t o r e m o v e h e a v r e rd e p o s i t s w h i c h m a y h a v e a c c u m u l a t e d i t w i l l b e n e c e s s a r yt o r e m o v e t h e r a d i a t o r a n d f l u s h i t o u t i n t h e r e v e r s e i r e c t i o n .T h i s i s d o n e b y d h o l d i n g t h e r a d i a t o ru p s i d e d o w n , i n t r o d u c i n gt h e h o s e p i p e i n t o t h e b o t t o m h o s e p i p e c o n n e c t i o na n d a l l o w i n g the water to flow through the core and out through the top. Depending upon the type of water which has been u s e d a n d t h e e x t e n t o f t h e f u r r i n g i t m a y b e d e s i r a b l et o

u s e a p r o p r i e t o r y l e a n s i n g o m p o u n d t o c l e a nt h e s y s t e m c c c o m p l e t e l v .T h i s m u s t b e u s e d i n a c c o r d a n c ew i t h t h e m a n u f a c t u r e r sn s t r u c t i o n s . i Filling: C l o s e t h e h e a t e rt a p a n d d i s c o n n e c tt h e h e a t e r h o s e . F i l l t h e s y s t e m t h r o u g h a f u n n e l i n s e r t e di n t h e h e a t e r h o s e u n t i l t h e r a d i a t o ri s f u l l t o t h e t o p o f t h e f r l l e rn e c k . C h e c k t h e l e v e l o f t h e c o o l a n t i n t h e e x p a n s i o nt a n k ; t h r s s h o u l d b e a p p r o x i m a t e l y2 j i n c h e s f r o m t h e b o t t o m . R e c o n n e c tt h e h o s e a n d o p e n t h e h e a t e r t a p . R e f i t t h e r a d r a t o r n d e x p a n s i o nt a n k c a p s ,s t a r t u p t h e e n g i n e a n d a

56

I u n i t u n t i l n o r m a lw o r k i n g t e m p e r a t u r es r e a c h e d S w l t c h i . o f f a n d a l l o w t h e s y s t e mt o c o o l . D o n o t r e m o v e e i t h e r filler cap while the system is hot. C h e c k t h e l e v e li n t h e r a d i a t o r n d t o p - u p i f n e c e s s a r y . a 4:3 Removing the radiator

4:6

The water pump

T h e w a t e r p u m p i s o f t h e c e n t r i u g a l i m p e l l e rt y p e a n d f is mounted on a common spindlewith the fan on the f r o n t o f t h e c y l r n d e rb l o c k R e f e r e n c eo t h e s e c t i o n a v i e w t l g i v e nr n F I G 4 : 6 w i l l a s s i s i n c a r r y i n g u t t h e f o l l o w i n g t o o p e r a to n s . i Removing: D r a i n t h e c o o l i n g s y s t e m a n d r e m o v e t h e r a d i a t o ra s d e s c r i b e d a r l i e irn t h i s C h a p t e r S e c t i o n s 4 : 2 a n d 4 : 3 . e . R e m o v et h e h o s ef r o m t h e w a t e r p u m p i n l e tc o n n e c t i o n a n d l o o s e n t h e t o p c l i p o J t h e t h e r m o s t a tb y p a s sh o s e . R e m o v et h e a l t e r n a t o r r g e n e r a t o r . o W j t h d r a w t h e f o u r s e t s c r e w ss e c u n n g t h e f a n b l a d e s t o t h e h u b o f t h e w a t e r p u m p a n d r e m o v et h e b l a d e s ,b e l t and pulley. R e m o v et h e s e t s c r e w s e c u r i n g h e p u m p t o t h e c y l i n d e r s t b l o c k a n d l i f t o f f t h e p u m p c o m p l e t ew i t h t h e b y p a s sh o s e .

Drain the cooling system and remove the top hose. Releasehe bottom hosefrom the pump and disconnect t t h e h e a t e r h o s e . R e l e a s et h e e x p a n s i o n t a n k h o s e f r o m t h e r a d i a t o ro v e r f l o w p i p e a n d r t s c l i p f r o m t h e c o w l i n g . R e m o v e t h e u p p e r s u p p o r t b r a c k e tf r o m t h e c y l i n d e r head and radiator top cowl. Remove the lonq bolt s e c u r i n gt h e b o t t o m c o w l t o t h e b r a c k e l o n t h e t r a n s _ mision casing. O n e a r l y c a r s i t i s n e c e s s a r yt o r e m o v e t h e s c r e w s s e c u r i n gt h e r a d i a t o r o t h e c o w l i n g i f a m e t a l{ a n i s f i t t e d , t t n e n r e m o v et h e t o p c o w l i n g a n d l i f t o u t t h e r a d t a t o r O n . cars fitted with a plastic fan, and the radiatorfarther f r o m t h e e n g i n e ( n o t e t h e l o n g e ru p p e r s u p p o r t b r a c k e r l . the radiatorand cowling assembly can be lifted out comprete. R e f i t t i n g i s t h e r e v e r s eo f t h e r e m o v a l p r o c e d u r e .b u t r e f e rt o S e c t i o n 4 : 2 b e f o r e r e fi t t i n g . 4:4 Removing the expansion chamber

T h e e x p a n s i o nc h a m b e r r e q u i r e sn o m a r n t e n a n c e n d a s h o u l d n o t b e i n t e r f e r e d i t h u n d e r n o r m a lc i r c u m s t a n c e s . w H i g h t e m p e r a t u r e sa r e d e v e l o p e d i n t h e c h a m b e r a n d inyurymight be incurred if the pressurized ap where c removed when the system was hot. T o r e m o v e t h e t a n k d i s c o n n e c ta n c l r e m o v e t h e s o r r r h o s e f r o m i t s c o n n e c t i o n o n t h e r a d i a t o rt o p t a n k . D r s c o n n e c t t h e s p i l l h o s e c l i p f r o m t h e r a d i a t o rc o w l r n g . R e m o v e t h e s e t s c r e w ss e c u r i n g t h e m o u n t i n g b r a c k e t a n d l i f t a w a y t h e e x p a n s i o nc h a m b e rc o m p l e t ew i t h s p r r r hoseand bracket. R e f i t t i n g i s c a r r i e do u t b y r e v e r s i n gt h e f e m o v a l p r o c e du r e . 4:5 The fan belt T h e b e l t s h o u l d b e t e n s i o n e d o t h a t t h e r ei s a d e f l e c t i o n s o f a p p r o x i m a t e l yj i n c h i n t h e c e n t r e o f i t s l o n g e s t r u n a n d is adjusted as follows: Generator: Slacken off the two pivot bolts and the bolt on rne slotted adjusting link. Lift the generator by hanrl and re. tighten the bolts when the correct tension is obtained. C h e c k t h e m o v e m e n to f t h e b e l t a f t e rt i . r h t e n i n o Alternator: S l a c k e no f f t h e f o u r b o l t s ( 1 i n F I G 4 : 5 ) a n d p u l l u p the alternatorby the end bracket 3 to obtain the correct t e n s i o n .T i g h t e n u p t h e b o l t s a n d r e c h e c k . To remove the belt slacken off the securing bolts and p u s h i h e g e n e r a t o r r a l t e r n a t of u l l y d o w n , w h e n t h e b e l t o r m a y b e r e l e a s e d r o m t h e c r a n k s h a f tp u l l e va n d m a n o e u v r e d f . b e t w e e nt h e t o p o f e a c h f a n b l a d e a n d t h e r a d i a t o rc o w l i n g . A d e q u a t e c l e a r a n c eh a s b e e n p r o v i d e d t o a l l o w t h e b e l r r o pass between the fan blades and righthand top of the cowling flange. When buying a new belt make sure that the correcl type is obtained as there are differenttypes for generator/ alternator nd manual automatrc. a

FIG 4:2 Radiator drain plug under the front of the car (on early cars onlv)

F I G4 : 3 block

FIG 4:4

The expansion cap indicated by arrow

11 0 0 M k 2 1 3 0 0

57

Servicing the pump : P u l l o u t t h e b e a r i n gl o c a t i n g w i r e t h r o u g h t h e h o l e i n the top of the pump body and gently tap the spindle t o w a r d s t h e r e a r t o r e l e a s et h e c o m b i n e d s p i n d l e a n d b e a r i n ga s s e m b l y , o g e t h e rw i t h t h e s e a t a n d v a n e . t W i t h d r a w t h e i m p e l l e rv a n e f r o m i t s s p i n d l e u s i n g a a s u i t a b l ee x t r a c t o r n d l i f t o f f t h e s e a l a s s e m b l y . a I t i s n o t p o s s i b l e o r e n e w t h e b e a r i n g s l o n e .s o t h a t i f t t h e b e a r i n gs h o u l d s h o w s i g n s o f w e a r o r d a m a g e i t m u s t . b e r e p l a c e db y a n e w b e a r i n ga n d s p i n d l ea s s e m b l y T h e s e a l a s s e m b l ys h o u l d a l s o b e r e n e w e d i f i t i s w o r n o r d a m a g e di n a n y w a y o r i f t h e r ea r e s i g n so f w a t e r l e a k a g e . Reassembling : R e a s s e m b l yi s t h e r e v e r s eo f t h e d r s m a n t l t n gp r o c e d u r e , b u t m a k e c e r t a i nt h a t t h e h o l e i n t h e b e a r i n g i s l i n e d u p w i t h t h e l u b r i c a t i n gh o l e A b e f o r e p r e s s i n gt h e b e a r i n g and spindle into position in the body of early pumps. T h e f a n h u b i s a n i n t e r f e r e n c ei t o n t h e s p i n d l e a n d i f f t h i s f i t h a s b e e n i m p a i r e db y r e m o v i n gt h e h u b i t w i l l b e n e c e s s a r yo f i t a n e w h u b . t Note also the dimension C in FIG 4:6. This is the c l e a r a n c eb e t w e e n t h e t i p s o f t h e i m p e l l e rv a n e s a n d t h e b o d y a n d s h o u l d b e . 0 2 0 t o . 0 3 0 i n c h . l t w i l l b e s e e na t B t h a t t h e f a n h u b i s p r e s s e do n u n t i l i t s f a c e i s f l u s h w i t h the end of the spindle. Two later types of pump are shown in FIG 4:7. Neither of these require any periodic lubricationand servicing instructionsare as for the early type, but great c a r e m u s t b e t a k e n t o o b s e r v et h e d i m e n s i o n sg i v e n i n the illustration. O n t h e t h i r d t y p e i t i s i m p o r t a n tt o a d j u s t t h e p o s i t i o n of the spindle to obtain the dimensionA between the r e a r f a c e o f t h e s p i n d l e b e a r i n ga n d t h e s h o u l d e r o f t h e s e a l h o u s i n g w h e n p r e s s i n gt h e a s s e m b l yi n t o t h e p u m p casing. On the second type, the clearance D between the bearing and the thrower must be checked before fitting the spindle.

FIG 4:5 Slacken bolts 1 to adjust the belt. Pull up on alternator 2 bv the end bracket 3

C
FIG 4:6 Sectional view of f irst type of water pump

FIG 4:7 Sections through the second type of water pump (right) with thrower, balanced seal

and third type (left) wrth pressure C .020 to .030 inch (.51 to .76 mm)

i m B H u b f a c ef l u s hw i t h s p i n d l e Key to Fig 4:7 A . 5 3 4 + . 0 0 5n c h( 1 3 . 5 6 + . 1 3 m ) clearance D . 0 4 21 0 . 0 6 2i n c h ( 1 . 1t o 1 . 6 m m ) c l e a r a n c e

58

4:7

The thermostat

To remove the thermostat drain the cooling system, disconnect the top hose and remove the cowling upper support bracket. Remove the securing nuts and sBrrng washers and lift off the thermostat cover from its studs. R e m o v e t h e p a p e rj o i n t w a s h e r a n d l i f t o u t t h e t h e r m o s t a t . See items48 to 52 in FIG 1 :4. The thermostat can be tested by immersing it in a s u i t a b l e v e s s e l o f w a t e r t o g e t h e r w i t h a r e l i a b l et h e r m o meter. Now raise the temperature of the water ano observe the reading at which the thermostat starts ro open. Observe also that it closes when the water temp e r a t u r ei s a l l o w e d t o f a l l . l f t h e v a l v e d o e s n o t o D e n a t t h e appropliate temperaturegiven in Technical Data or if it sticks open it must be renewed. On no account attemot to reoairit. W h e n f i t t i n g a n e w t h e r m o s t a t ,n o t e t h a t t h e t h r e a d e d stem is uppermost. Ensurethat the paper washer is not damaged.

D o n o t u s e r a d i a t o r a n t i fr e e z e i n t h e w i n d s c r e e n washer. Antifreeze Starts freezing at Absolute safe limit -9oC or 16oF -1goC or -3oF 1* pints -13oC or 9oF -26oC or -15oF 2 pints -16oC or 3oF -33oC or -28"F 2j pints 4:9 1 2 3 4 5 Fault diagnosis Cracked cylinder wall Loose cylinder head nuts Cracked cylinder head Faulty head gasket Cracked tappet chest wall

(a) lnternal water leakage

(b) Poor circulation 1 2 3 4 5 6 Radiatorcore blocked E n g i n e w a t e r p a s s a g e sr e s t r i c t e d Low water level Loose fan belt Defectivethermostat P e r i s h e do r c o l l a p s e d r a d i a t o r h o s e s

4:8

Frost precautions

T o a v o i d t h e p o s s i b i l i r yo f t h e c o o l i n g s y s t e m f r e e z i n g under winter conditions it is recommended that an antif r e e z em i x t u r e o f t h e e t h y l e n e t y p e b e a d d e d . l t s h o u l o o e noted that this is essential when a heater is fitted as draining the cooling system does not empty the heater. F i r s t d r a i na n d f l u s h t h e s y s t e m ,t h e n p o u r i n t h e r e q u i r e o q u a n t i t y o f a n t i f r e e z ea s s h o w n i n t h e t a b l e b e l o w a n d f i l l up with water. To prevent the * pint of water in the e x p a n s i o n c h a m b e r f r o m f r e e z i n ga d d + p i n t o f p u r e a n t r freeze. Ensure that the filler caps are correctly replaced and securelytightened. Use only an antifreeze conforming to specificatron 8 S . 3 15 1 o r B S . 3 1 5 2 . T h i s m i x t u r e c a n r e m a i n i n t h e system for two years provided that the specific gravity is checked periodically and fresh antifreeze added as r e q u i r e d .A f t e r t h e s e c o n d w i n t e r , d r a i n t h e s v s t e m . f l u s h and refill.

(c) Corrosion 1 lmpurities in the water 2 I n f r e q u e n td r a i n i n g a n d f l u s h i n g (d) Overheating 1 2 3 4 5 6 7 8 9 10 11 Checkall in (b) Sludge in crackcase F a u l t yi g n i t i o nt i m i n g Low oil level in sump Tight engine Choked exhaust system Binding brakes S l i p p i n gc l u t c h Incorrectvalve timing Retardedignition Mixturetoo weak

11 0 0M k 2 1 3 0 0

59

CHAPTER 5 TH E CLUTCI{
5 :1 5 :2 5:3 5 :4 5 :5 Description Removing and dismantling clutch Assembling and refitting clutch Adjusting the operating lever Servicing the hydraulic system 5 :6 5:7 5 :8 5 :9 Bleeding the system Clutch throw-out stop Clutch cover alignment Fault diagnosis

5 :1 Description T h e c l u t c h i s o f t h e s i n g l e p l a t ed r y - d i s ct y p e m o u n t e d on a splined hub and primarygear on the rear of the c r a n k s h a f t w i t h t h e p r e s s u r e n d d n v e n p l a t e so p e r a t t n g , a o n t h e i n n e r f a c e o f t h e f l y w h e e l .T h e c l u t c h i s s h o w n i n s e c t i o ni n F I G 5 : 1 . L u g s o n t h e p r e s s u r ep l a t e p a s s t h r o u g h t h e f l y w h e e l a n d a r e s e c u r e dt o d r i v i n g s t r a p s o n t h e f l y w h e e l o u t e r f a c e a n d s p r i n g - c o v e r y t h r e e s c r e w s .T h e o t h e r e n d s o t b the driving straps are secured to the |ywheel by three more screws. A d t s h e dd i a p h r a g ms p r i n g r s u s e d t o p u l l t h e h o u s i n g a n d p r e s s u r ep l a t e t o t h e r e a r a n d s o h o l d t h e f r i c t i o n l i n i n o o f t h e d r i v e n p l a t e i n c o n t a c t w i t h t h e i n n e rf a c e o f the flywheel. D i s e n g a g e m e no f t h e c l u t c h i s e f f e c t e db v m o v i n o t n e t c l u t c h o p e r a t i n gl e v e r ,b y m e a n s o f a n h y d r a u l i cs y s t e m , a g a i n s tt h e t h r u s l p l a t e a n d s o f o r c r n gt h e p r e s s u r e l a t e p a w a y f r o m t h e d r r v e n p l a t e w h i c h t h e n r e l e a s e sr o m t h e f f l y w h e e l a n d i s f r e e t o r o t a t e o n t h e c r a n k s h a f t .I n t h r s c o n d i t i o n .a l t h o u g h t h e c r a n k s h a f tm a y c o n t i n u e t o t u r n , no drivewill be transmitted. 5 :2 Removing and dismantling clutch R e f e r r i n gt o F I G 5 : 2 f i r s t , r e m o v e t h e f l y w h e e l a n d c l u t c h a s s e m b l ya s d e s c r i b e d i n C h a p t e r 1 . l t w i l l b e seen that the clutch to flywheel driving straps are

laminatedso that two are fitted to each ot the three drivingpoints (10 in FIG 5:2). Mark all componenrs, i n c l u d i n g s t r a p s a n d d r i v i n g p i n s b e f o r e d i s m a n t l i n gt o e n s u r e r e a s s e m b l yn t h e i r o r i g i n a lp o s i t i o n s . i Progressively loosen and remove the three bolts r e t a i n i n gt h e c l u t c h c o v e r , n o t i n g t h e a l i g n m e n tm a r k s A on the cover and pressureplate. Remove the cover assem ty. D S e p a r a t et h e p r e s s u r e p l a t e f r o m t h e f l y w h e e l a n d r e m o v et h e d r i v e n p l a t e .K n o c k b a c k t h e l o c k i n gt a b s a n d r e m o v et h e b o l t s s e c u r i n gt h e d r i v i n g s t r a p s . Remove the three pairs of driving strapsnoting the s p a c e r sf i t t e d b e t w e e n t h e s t r a p sa n d t h e f l v w h e e l . C l e a nt h e c o m p o n e n t sa n d c h e c k f o r e x c e s s r v e e a r o r w d a m a g e s u c h a s s c o r i n g o n t h e p r e s s u r ep l a t e ,{ r a c t u r e s I n t h e s p r i n g o r e l o n g a t e db o l t h o l e s . C h e c k f o r e x c e s s i v e e a r o n t h e s p l i n e so r t h e f r i c t i o n w s u r f a c e sa n d l i n i n g s ,t h i s w o u l d r e q u i r e r e n e w a l o f t h e parts. Renew the driven plate also if the linings are d i s c o l o u r e dw i t h o i l o r g r e a s e ,a t t e m p t st o c l e a n o f f t h e c o n t a m r n a t t o na r e n o t l i k e l y t o b e s u c c e s s f u l .I n t h i s eventthe sealin the f lywheelshould also be inspected. 5 : 3 R e a s s e m b l i n ga n d r e f i t t i n g t h e c l u t c h R e a s s e m b l yo f t h e c l u t c h i s a r e v e r s a lo f t h e d i s mantling procedure with particular attention to the following points:

1 1 0 0M k 2 1 3 0 0

61

d i m i n i s h , a n d i f a d . l u s t m e nits n e g l e c t e dc l u t c h s l i p w i l l r e su l t . An ad1Ustabletop is provided on the transmission s c a s i n g y u s t f o r w a r d o f t h e c l u t c h o p e r a t i n g l e v e r .T h e c l e a r a n c eb e t w e e n t h e s t o p a n d t h e l e v e r i s i n d i c a t e db y t h e r i g h t h a n d a r r o w . P u l l t h e o p e r a t i n gl e v e r o u t w a r d s until all free movementis taken up and then check with a f e e l e r g a u g e t h a t t h e r e i s a c l e a r a n c eo f . 0 2 0 i n c h between the leverstop and the head of the adjustment bolt as shown in the inset. The correct clearanceis i o b t a in e d b y r e l e a sn g t h e l o c k nu t a n d t u r ni n g t h e a d lu s t in g bolt. 5:5 Servicing the hydraulic system

FIG 5:1

S e c t i o n a lv i e w o f t h e c l u t c h a s s e m b l y

Key to Fig 5:1 1 S t a r t erri n g 2 Flywheel plate_ 3 Pressure _ 5 Drivenplate hub ^ 1 Prl:9l.|-plaie^ g 6 Circlip 7 Crankshaft 8 C r a n k s h ap lr i m a r y e a r { 9 P r i m a rg e a r e a r i n g 0 T h r u sw a s h e r11 F l y w h e e lu bb o l t y b 1 t h p 12 Driving in 13 Lockwasher 14 Driving trap s 1 5 F l y w h e eh u b 1 6 T h r u s p l a t e ' 1 P l a t e e t a i n i ns p r i n g l 7 r g t 1 8 T h r u s t e a r i n g 1 9 F l y w h e e lc r e w 2 0 K e y e d a s h e r b s w 2 1 C o v e r 2 2 D r a p h r a g mp r i n g s

T h i s w o r k s o n s i m i l a rp r i n c i p l e s o t h e h y d r a u l i c y s t e m t s u s e d f o r o p e r a t i n gt h e b r a k e s , n d t h e s e c t i o n a lv i e w s o f a t h e m a s t e rc y l i n d e ra n d t h e s l a v e c y l i n d e rg i v e n i n F I G S 5 : 5 and 5 :6 show clearlyhe constructron t the essential t o c o mp o n e n t s . T h e c l u t c h p e d a li s c o n n e c t e dd i r e c t l yt o t h e p u s h r o d ( 1 i n F I G 5 : 5 ) a n d d e p r e s s i n g h e p e d a l p u s h e st h e p i s t o n t 11 down the cylinderbore and so forces the hydraulic fluid through the connecting hose pipe to the slave c y l i n d e r . T h e p r e s s u r ep u s h e s t h e p i s t o n 4 d o w n t h e c y l i n d e rb o r e 5 a n d w i t h i t t h e p u s h r o d 8 w h i c h a g a i n i s d i r e c t l y c o n n e c t e d t o t h e c l u t c h o p e r a t i n gl e v e r . A f t e r e a c h a p p l i c a t i o no f t h e p e d a l t h e p i s t o n i n t h e m a s t e rc y l i n d e ri s r e t u r n e dt o i t s s t o p b y t h e r e t u r ns p r i n g 1 5 a n d i n t h i s p o s i t i o n u n c o v e r sa h o l e c o m m u n i c a t i n g with the fluid supply tank to admit any fluid which may b e r e q u i r e dt o k e e p t h e s y s t e m f i l l e d . R u b b e r s e a l s a r e f i t t e d t o e l i m i n a t ea n y l o s so f f l u i d p a s t t h e p i s t o n si n b o t h c y li n d er s . Before commencing operations it is stressedthat a b s o l u t ec l e a n l i n e s ss e s s e n t i aa t a l l t i m e sw h e n w o r k i n g i l o n h y d r a u l i cs y s t e m sa n d t h a t o n l y c l e a n h y d r a u l i cf l u i d s h o u l d b e u s e d a s a c l e a n s i n go r l u b r i c a t i n ga g e n t . Removing the master cylinder:

C h e c k , a n d i f n e c e s s a r ya d j u s t t h e p r i m a r y g e a r e n d , f l o a t a s d e s c r r b e dn S e c t i o n 1 : 1 1 . i P l a c e t h e p r e s s u r ep l a t e o n a f l a t s u r f a c e w i t h t h e s e c u r i n gl u g s u p p e r m o s ta n d l o c a t et h e d r i v e n p l a t e ,b o s s d o w n w a r d s , o n t o t h e c l u t c h c e n t r a l r z etro o l 1 8 G . 6 8 4 . F i t t h e f l y w h e e l o v e r t h e t w o c l u t c h p l a t e sw i t h t h e A m a r k o n t h e p r e s s u r ep l a t e i n l i n e w i t h t h e 1 , 4 m a r k o n t h e f l y w h e e l .S e c u r et h e c e n t r a l i z etro o l . F i t t h e d r i v i n gs t r a p s , o t f o r g e t t i n gt h e s p a c e rw a s h e r s , n a n d u s e n e w l o c k w a s h e r s ,b u t d o n o t y e t t i g h t e n t h e s e c u r i n gb o l t s . F i t t h e c l u t c h c o v e r ,a g a i n l i n i n g u p t h e A m a r k , b u t d o n o t t i g h t e n t h e r e t a i n i n gb o l t s . N o w t i g h t e n t h e d r i v i n gs t r a p b o l t s a n d t h e c o v e r b o l t s t o a t o r q u e o f 1 B l b f t . L o c k t h e w a s h e rt a b s a n d r e m o v e t h e c e n t r a l i z etro o l . R e fi t t h e c l u t c h a n d f l y w h e e l a s s e m b l ya s d e s c r i b e di n Section 1 :8. SeealsoFIG 5 :3.

W i t h d r a w t h e c l e v i s p i n s e c u r i n gt h e m a s t e rc y l i n d e r oushrod1 to the clutch oedallever. p D i s c o n n e c tt h e p r e s s u r e i p e u n i o n f r o m t h e c y l i n d e r , r e m o v e t h e t w o b o l t s s e c u r i n gt h e c y l i n d e rt o t h e b u t k h e a d a n d w i t h d r a w t h e c o m o l e t ea s s e m b l v . Dismantling the master cylinder. SeeFIG 5 :5: R e m o v et h e f i l l e rc a p a n d d r a i n o u t t h e f l u i d . P u l l b a c k t h e r u b b e r b o o t 2 a n d r e m o v et h e c i r c l i p 8 , r e m o v e t h e p u s h r o da n d t h e d i s h e dw a s h e r9 . W i t h d r a w t h e r e m a i n i n g i n t e r n a lp a r t s f r o m t h e c y l i n d e r b o r e , u s i n g a i r p r e s s u r e a p p l i e dt o t h e e n d p l u g 7 i f n e c e s s a r yT h e s e c o n d a r y u p . c i s r e m o v e d b y s t r e t c h i n gi t o v e r t h e e n d f l a n g e o f t h e pistonusingonly the fingers. Reassembling the master cylinder : Having cleanedall parts in brake fluid, examinethe r u b b e r p a r t s f o r d a m a g e o r d i s t o r t i o na n d r e n e w w h e r e l n e c e s s a r y . t i s u s u a l l y d e s i r a b l et o r e n e w t h e r u b b e r s w h e n r e b u i l d i n g t h e c y l i n d e r ,p a r t i c u l a r l y f i t h a s s e e n i m u c h s e r v i c e .A l l p a r t s s i r o u l d b e a s s e m b l e dw e t . S t r e t c ht h e s e c o n d a r yc u p o v e r t h e p i s t o n f l a n g e w r t h t h e l i p t o w a r d s t h e o p p o s i t ee n d o f t h e p i s t o n ,w o r k i n g i t

5 :4 Adjusting the operating lever R e f e rt o F I G 5 : 4 . l t i s m o s t i m p o r t a n tt h a t a c l e a r a n c e s h o u l d e x r s tb e t w e e n t h e c l u t c h t h r u s t r a c ea n d t h e t h r u r i plate. As the clutch linings wear this clearancewill

62

iT
rlG 5 :2 Exploded view showing the clutch components

SA^ i l"P
40 4t 42

KeytoFig5:2lPressureplate2Clutchdrivenplate3Flywheelorlseal4Hubscrew5LockwasherONulTStarterring 8 F l y w h e e la s s e m b l y 9 Washer 1 0 D r i v i n gs t r a p 11 Lockwasher 12 Strapscrew 13 Key 14 Lockwasher 19 Washer 2O Screw 1 5 F l y w h e e ls c r e w 2 1 R i v e td o w e l 2 2 R e t a i n i n gc l i p 2 3 D i a p h r a g ms p r i n g 2 4 S p r i n g h o u s i n g s 3 0 R e l e a s eb e a r i n g 31 Coverplate 32 Washer 33 Screw 34 Locknut 2 6 P l a t er e t a r n r n g p r n g 25 lhrust plate 38 Washer 39 Cover screw 40 Throw out plunger 4'l Throw-out stop 37 Clutch cover 35 Screw 36 Lever pin 45 Spring anchor (lever) 46 Pushrod pin 47 Lever pull-off spring 43 Clutch operating lever 44 Washer 42 Stop locknut 48 Springanchor (cylinder)

g e n t l y w i t h t h e f i n g e r s t o e n s u r e c o r r e c t s e a t i n g .I n s e r t t h e r e t u r ns p r i n g 1 5 , l a r g ed i a m e t e rf i r s t ,w i t h t h e r e t a i n e r 1 4 i n p l a c eo n t h e s m a l l e n d . l n s e r tt h e m a i n c u p 1 3 l i p f i r s t ,t a k i n g c a r e n o t t o t u r n b a c k t h e l i p , a n d p r e s si t d o w n on to the springretainer. F r tt h e w a s h e r1 2 a n d t h e o i s t o n1 1 . p u s h i t d o w n t h e b o r e a n d r e f i tt h e p u s h r o d 1 a n d c i r c l i p8 a n d t h e r u b b e r boot 2. Before refitting to the car the assemblyshould be g t e s t e db y f i l l i n g t h e t a n k w i t h t h e r e c o m m e n d e d r a d e o l f l u i d a n d p u s h i n gt h e p i s t o n d o w n t h e b o r e a n d a l l o w r n g i t t o r e t u r n . f t e r o n e o r t w o a o o l i c a t i o n sl u i d s h o u l d f l o w A f from the outlet7. Refitting: T h e m a s t e r c y l i n d e r i s r e f i t t e dt o t h e b u l k h e a d c r o s s p m e m b e r b y m e a n so f t w o b o l t s . R e f i t t h e p r e s s u r e i p e t o t h e c y l i n d e ro u t l e t . L i n e u p t h e y o k e o n t h e p u s h r o dw i t h the clutch pedal lever and reconnect them with the c l e v i sp i n . C h e c k t h e l e v e l o f t h e f l u i d i n t h e s u p p l y t a n k and bleed the system as described later rn Section 5 :6. Removing the slave cylinder: F i t a l e n g t h o f r u b b e rt u b i n g t o t h e n i p p l e o n t h e b o d y of the slave cylinder and open the bleed screw three q u a r t e r so f a t u r n . P u m p t h e c l u t c h p e d a l u n t i l a l l t h e f l u i d h a s b e e n t r a n s f e r r e dn t o a c l e a n c o n t a i n e r . i U n s c r e w t h e p r e s s u r ep i p e f r o m t h e c y l i n d e r ,r e m o v e t h e t w o b o l t s s e c u r i n gt h e c y l i n d e rt o t h e c l u t c h h o u s i n g and remove the clevis pin to releasethe pushrod from t h e c l u t c h o p e r a t i n gl e v e r . Dismantling the slave cylinder: F i r s t c l e a n t h e e x t e r i o ro f t h e c y l i n d e r t h e n w t t h d r a w t h e p u s h r o d 8 a n d r e m o v e t h e r u b b e r b o o t 7 u s r n go n l y the fingers to displace the retainingring. Remove the circlip 6 and withdraw the piston 4, piston cup 3, cup f i l l e r 2 a n d t h e r e t u r ns p r i n g i n t h a t o r d e r .
FIG 5:3 Details of diaphragm spring clutch and flywheel attachment Key to Fig 5;3 1 Clutchcover 2 Clutchthrustplate 3 R e t a i n i n gs p r i n g r i n g 4 F l y w h e e l r e t a j n i n gs c r e w 5 Lock washer 6 Drivingwasher

11 0 0 k 2 1 3 0 0 M

63

FIG 5 :6

Sectional view of the clutch slave cvlinder 1 Spring 6 Circlip 2 Cup {iller 3 Cup 7 R u b b e rb o o t 8 Pushrod

FIG 5:4 Adjustingtheoperatingleverclearance.There m u s t b e a c l e a r a n c eo f . 0 2 0 i n c h b e t w e e n t h e l e v e r a n d t h e a d j u s t a b l es t o p C l e an t h e p a r t sa n d r e n e wa n y t h a t a r ew o r n o r d a m a g e d . A s w i t h t h e m a s t e rc y l i n d e r i t i s a d v i s a b l et o r e n e w a n y rubber Darts. Reassembly and ref itting : I n s e r tt h e r e t u r n s p r i n g , l a r g e e n d f i r s t , i n t o t h e b a r r e l w i t h t h e p i s t o n c u p f r l l e ra t t a c h e dt o t h e s m a l l e n d o f t h e s p r in g . R e p l a c et h e p i s t o n c u p , l i p f i r s t ,t a k i n g c a r e n o t t o t u r n b a c k t h e l i p , a n d p r e s si t d o w n o n t o t h e f i l l e r . P u s h t h e p i s t o n d o w n t h e b o r e a n d r e f i tt h e r u b b e rb o o t , c h e c k i n g t h a t t h e r e t a i n i n gr i n g i s p o s i t i o n e do n t h e c e n t r ef l a n g e . S e c u r e t h e b o o t w i t h t h e l a r g e s t e e l r e t a i n i n gr i n g . R e f i t the pushrod. Refit the slave cylinder to the clutch housing by r e v e r s i n g h e r e m o v a lp r o c e d u r ea n d b l e e d t h e s y s t e ma s t follows: 5 :6 Bleeding the system Fill the master cylinder supply tank with Lockheed d i s c b r a k ef l u i d ( S e r i e s ) o r 3 2 9 . F o r t h e A u s t i n A m e r i c a 2 u s e L o c k h e e dd i s c b r a k e f l u i d 3 2 9 o n l v . A t t a c h a r u b b e r

Key to Fig 5 :6 4 Piston 5 Body

t u b e t o t h e s l a v e c y l i n d e r b l e e d v a l v e a n d i m m e r s et h e o t h e r e n d o f t h e t u b e i n a c l e a n r e c e p t a c l e o n t a i n i n ga c s m a l l q u a n t i t yo f t h e f l u i d . H a v e a n a s s i s t a n t o p u m p t h e clutch pedal and open the bleed screw on the slave c v l i n d e ra b o u t t h r e e q u a r t e r s f a t u r n . A t t h e e n d o f e a c h o downstroke of the pedal close the bleed screw before ' o f f' p o s i t i o n .C o n t i n u e a l l o w i n g t h e p e d a lt o r e t u r nt o t h e t h i s p u m p i n g r o u t i n e u n t i l c l e a rf l u i d f r e e f r o m b u b b l e sr s d e l i v e r e di n t o t h e c o n t a i n e r . Bleeding the clutch system is not a routine maint e n a n c e o p e r a t i o n ,b u t i s n e c e s s a r y h e n e v e r t h e p i p e w l i n e s h a v e b e e n d i s c o n n e c t e d o r a n y r e a s o no r t h e f l u i d f l e v e lh a s d r o p p e d l o w e n o u g h t o a d m i t a i r i n t o t h e s y s t e m . I t i s r e c o m m e n d e dt h a t f l u i d w h i c h h a s b e e n u s e d I n t h i s o p e r a t i o ns h o u l d b e d i s c a r d e d .

5 :7 Clutch throw-out

stop

A s h o u l d e r e ds t o p i s f i t t e d t o t h e c l u t c h t h r o w , o u t p l u n g e r o p e r a t i n ga g a i n s t t h e c e n t r a l b o s s o f t h e c l u t c h c o v e r . T h i s s t o p i s c o r r e c t l ys e t a n d l o c k e d d u r i n g i n r t i a l a s s e m b l y n d s h o u l d n 0 1b e d i s t u r b e di n n o r m a l s e r v i c i n g . a

I
Key to Fig 5 ;5 9 Stop washer

rO

ll

12 t3

t4

r5

FIG 5 :5

Sectional view of the master cylinder

1 P u s h r o d 2 R u b b e rb o o l 3 M o u n t i n g f l a n g e 4 S u p p l y t a n k 5 B o d y 6 W a s h e r 7 E n d p l u g 8 C i r c l i p 10 Secondarycup 11 Piston 12 Pistonwasher 13 Marncup 1 4 S p r r n gr e t a r n e r 1 5 R e t u r ns p r r n g

64

Clutch pedal adjustment is to the lever stop screw as a l r e a d yd e s c r i b e d( s e e S e c t i o n 5 : 4 ) . l f i t i s f o u n d n e c e s s a r y o r e m o v et h e t h r o w - o u t p l u n g e r t during overhaul operations the stop must be reset as I follows: Screw out the stop 2 and locknut away from the cover boss to the limit of its travel. Depressthe clutch pedal f u l l y t o r e l e a s et h e c l u t c h a n d w h i l e h o l d i n g i t i n t h i s position screw up the stop against the cover boss. R e l e a s e h e p e d a lt o f u l l y e n g a g et h e c l u t c h a n d s c r e w i n t the stop a further.002 to.005 inch or one flat on the h e x a g o n .R e t r g h t e n h e l o c k n u t ( s e e F I G 5 : 7 ) . t R e c h e c k t h e c l e a r a n c ea t t h e l e v e r s t o p s c r e w a n d readjustif necessary.
) r

5:8 Clutch cover alignment I n t h e e v e n t o f s e v e r ec l u t c h j u d d e r b e i n g e x p e r i e n c e d t h i s m a y b e d u e t o a c l u t c h c o v e r o u t o f a l i q n m e n t .T h e t r o u b l e c a n b e c u r e d u s i n g S e r v i c et o o l 1 8 G . 1 2 4 7 a s follows: R e m o v et h e f l y w h e e la n d c l u l c h a s s e m b l y s d e s c r i b e d a p r e v i o u s l yt,h e n r e m o v et h e s p l i t p i na n d w a s h e rt o f r e et h e c l e v i sp i n a n d r e l e a s e e v e r . l Unscrew and remove the plunger stop and locknut. P u l l o u t t h e p l u n g e ra n d r e l e a s e e a r i n g . b

FIG 5 :7 Adjusting the clutch throw-out stop. At left: clutch fully released with throw-out stop 2 screwed up to the cover boss. At right: clutch fully engaged with the stop 4 screwed in a f urther .002 to .005 inch towards the cover ooss

FIG 5 :8 U s i n g S e r v i c e t o o l 1 8 G . 12 4 7 t o a l i g n t h e c l u t c h c o v e r w i t h t h e c r a n k s h a f t a n d f l y w h e e l h o u s i n g . I n s e r t A : F i l e off the high spots arrowed. Insert B: Drill cover and housing and fit suitable dowels

K e yt o F i g5 : 8

Clutch cover

218G.1247

3 Dowel

1 1 0 0M k 2 1 3 0 0

65

See that all the parts are clean and then apply some e n g i n e e r sb l u e t o t h e c l u t c h c o v e r r e g i s t e r . R e f e r t o F I G 5 : 8 . I n s e r tt h e t o o l 1 8 G . 1 2 4 7 i n t o t h e cover and refit the cover with the tool over the crankshaft laper. Push the cover against the flywheel housing to see h o w m u c h m i s a l i g n m e nt h e r ei s , w h i c h w i l l b e s h o w n o n the blueing when the clutch cover is removed. File down the high spots as necessary. Repeat this procedure as required until the cover contacts the flywheel housing without force. When this correct alignment has been obtained, secure the cover with two retaining bolts. N o w d r i l l t w o d i a m e t r i c a l l yo p p o s i t e h o l e s t h r o u g h t h e cover and flywheel housing flanges with a No, 40 drill as shown in inset B. Remove the cover and the tool.

5 : 9 F a u l td i a g n o s i s (a) Drag or sPin on 1 Oil or grease drivenplatelinings or slavecylinder piping master cylinder, 2 Leaking 3 Drivenplatehub bindingon splines 4 Distorted drivenplate 5 Warpedor damaged Plate Pressure 6 BrokendrivenPlatelinings system 7 Air in the clutch hydraulic (b) Fiercenessor snatch 1 C h e c k1 , 2 , 4 a n d5 i n ( a ) 2 Worn clutchlinings (c) Slip 1 C h e c k1 i n ( a ) a n d 2 i n ( b ) spring 2 Weakdiaphragm pistonin slavecylinder 3 Seized leverstop has no clearance 4 Operating (d) Judder 1 Check1 and 4 in (a) plateincorrectly fittedto springhousing 2 Pressure plate linings unevenly distributed area driven of 3 Contact 4 Faultyrubbermountings (e) Tick or knock 1 Badlvworn drlvenplatehub splines bearing 2 Worn release drivepinionon starter 3 Faulty holesin springhousing 4 Elongated drivestraps 5 Defective

Assembling: Lubricate the releasebearing plunger.with a linle g r a p h i t e g r e a s e a n d r e f i t t h e p a r t s i n t h e r e v e r s eo r d e r o f r e m o v a l b u t o n l y l o o s e l yt r g h t e n t h e c o v e r r e t a i n i n g b o l t s . Fit two dowels 2.49 " 21 mm into the newly drilled holes to retain the cover alignment. These musl be an i n t e r f e r e n c ef i t a n d n e e d l e r o l l e r s f r o m a b e a r i n g a r e v e r y suitablefor the purpose. Tighten the cover retaining bolts and complete the installation. Check, and adjust if necessary, he throw-out stop and t return stop adjustments.

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C H A P T E R6 S Y N C H O ME S H T R A N S MI S S I O N R
6 :1 6 :2 6:3 6 :4 6 :5 Description Dismantling transmission Servicing third motion shaft R e a s s e m b l i n gt r a n s m i s s i o n Servicing the differential assemblv 6 :6 Dismantling the gearbox with later type change 6 :7 Gear change remote control 6 :8 Fault diagnosis

6 :1 Description The transmissiongearbox fitted to all the cars which a r e c o v e r e db y t h i s m a n u a l h a s f o u r f o r w a r d s p e e d sa n o a r e v e r s es e l e c t e d b y a r e m o t e c o n t r o l g e a r s h i f t l e v e r . B a u l k ring-type synchromesh engagement is provided on e i t h e r t h r e e o r f o u r f o r w a r d s p e e d s .T w o d l f f e r e n t t v p e s o f g e a r c h a n g em e c h a n i s m r e u s e d a n d i t w i l l b e c o n v e n i e n r a t o d e s c r i b et h e p r o c e d u r e sf o r s e r v i c i n g t h e e a r l y t y p e first and those changes needed for the later, single o p e r a t i n gr o d , t y p e i n t h e s e c o n d p a r t o f t h i s C h a o t e r . The explodedview of the transmission iven in FIG g 6 : 1 s h o w s c l e a r l yt h e l a y o u t o f t h e i n t e r n a lc o m p o n e n t s w h e n s e e n f r o m t h e r e a r . a n d r e f e r e n c et o t h i s d i a o r a m w i l l a s s i s ti n f o l l o w t n g a s h o r t d e s c r i p t t o n f t h e g e a r b o x o operatton. The drivefrom the clutch is takenthroughthe primary g e a r 4 0 t o t h e i d l e r g e a r 4 3 , w h i c h d r i v e st h e f i r s t m o r r o n shaftgear45 and the first motion shaft 61 ro which rt is s p l i n e d .T h e s m a l l g e a r o n t h i s s h a f t e n g a g e st h e l a r g e s t g e a r i n t h e l a y g e a ra s s e m b l y 5 4 . T h e t h i r d m o t i o n s h a f t 6 5 c a r r i e st h e g e a r a n d s y n c h r o m e s ha s s e m b l i e s g t o 9 5 . 6 i t s r i g h t h a n de n d r u n n i n g f r e e l y i n t h e r o l l e r b e a r i n g6 2 at the end of the first motion shaft, while the other. lefth a n d , e n d i s s u p p o r t e dr n t h e r o l l e rb e a r i n g6 6 . S p l i n e dt o

t h i s l e f t h a n de n d o f t h e t h i r d m o r i o n s h a f t r s t h e f i n a l d r i v e pinion 90 which engages with the drive gear in the d i f f e r e n t i a a s s e m b l ya n d w h t c h i n t u r n d r i v e s t h e s h a f t s l coupled to the front wheels. N o m a i n t e n a n c es r e q u i r e d t h e r t h a n r e g u l a ra t t e n t i o n i o t o t h e o i l l e v e l i n t h e e n g i n e / t r a n s m i s s i ou n i t . T h e g r e a s e n n i p p l e ' 15 2 , b y w h i c h t h e g e a r c h a n g er e m o t e c o n t r o l s h a f t i s l u b r i c a t e d t h r o u g h t h e d i f f e r e n t i a lc o v e r . r e q u i r e s attentron at major overhaul periods only when grease only should be used. 6:2 Dismantling the transmission

R e f e r t o F I G 6 : 1 . R e m o v e t h e t r a n s m i s s i o nc a s i n g from the crankcase sdescribedn Chapter 1, thenwitha i d r a w t h e i d l e r g e a r4 3 a n d t h e t h r u s tw a s h e r s4 4 f r o m t h e c r a n k c a s e . p e c i a lt o o l N o . 1 8 G . 5 8 1 w i l l b e n e e d e d f o r S e x t r a c t i n gt h e i d l e r g e a r b e a r i n g s2 0 . R e m o v e t h e d i f f e r e n t i a a s s e m b l ya s d e s c r i b e dl a t e r i n l this Chapter (see Section 6:5). Withdraw the reverse d e t e n t p l u g 1 3 5 , s p r i n g1 3 4 a n d p l u n g e r1 3 3 o r t h e r e v e r s e light switch and plunger when fitted. Remove the s e l e c t o ro p e r a t i n gl e v e r 1 2 2 a n d w i t h d r a w t h e s h a f t 1 2 0 p a y r n g a t t e n t i o n t o t i t e s e a l 12 1 a n d k e y 12 3 . R e m o v e t h e s p e e d o m e t e rb u s h s e c u r i n g s c r e w a n d w t t h d r a w t h e b u s h

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a s s e m b l ya n d t h e p i n i o n 9 3 t o g g . R e m o v e t h e r e t a i n i n g plate and speedometer ear 100 to 104. g R e m o v e t h e r a d i a t o r ,c o w l r n g , m o u n t i n g b r a c k e t a n d s p a c e ra s d e s c r i b e di n C h a p t e r 4 . R e m o v et h e t r a n s m i s s i o n f r o n t c o v e r 1 3 7 . R e m o v et h e s c r e w s 3 1 a n d 3 7 a n o the oil suction pipe 33 which should be withdrawn f r o m t h e s t r a t n e 2 6 , n o t i n g t h e p a p e rw a s h e r 3 4 . R e n r o v e r t h e s e l e c t o ri n t e r l o c k i n g r m . a E x t r a c tt h e c i r c l i p 6 4 a n d w i t h d r a w t h e f i r s t m o t i o n shaft roller bearing using service tool 18G.705 ano a d a p t o r1 8 G . 7 0 5 C .U s i n g t h e s e l e c t o r h a f t sl o c k f i r s ta n d s t h i r d g e a r s t o g e t h e r , r e l e a s et h e l o c k i n g w a s h e r s 4 J a n o r e m o v et h e f i r s t m o t i o n s h a f t n u t 4 6 a n d g e a r 4 5 . R e m o v e t h e f i n a l d r r v eg e a r n u t 9 1 , w a s h e r 9 2 a n d p i n i o n 9 0 f r o m t h e t h r r dm o t i o n s h a f t 6 5 . Release the locking plates and remove the four s e c u r i n gs c r e w s B 8 t o f r e e t h e t h i r d m o t i o n s h a f t b e a r i n g r e t a i n e r8 6 , n o t i n g t h e p a c k i n g s h i m s 8 g . R e m o v e t h e l a y s h a f ta n d r e v e r s es h a f t l o c a t i n g p l a t e 5 5 a n d p u s h t h e l a y s h a f to u t o f t h e c l u t c h s r d eo f t h e c a s i n g . R e m o v et h e l a y g e a r5 4 a n d t h e t h r u s t w a s h e r s5 9 a n d 6 0 . U n s c r e w t h e p l u g s f r o m t h e o u t s i d eo f t h e c a s i n oa n d e x t r a c tt h e s e l e c t o rr o d i n t e r l o c k i n g l u n g e r sa n d s p " r i n g s p 115and116. R e m o v e t h e f i r s t m o t i o n s h a f t b e a r i n gc i r c l i p 6 4 a n o withdraw the bearingand shaft from the casing using s e r v i c et o o l s 1 8 G . 2 8 4 a n d 1 8 G . 2 8 4 B o r o t h e r s u i t a b l e e x t r a c t o r .R e m o v e t h e s e l e c t o rs c r e w 1 1 2 a n d w i t h d r a w t h e f o r k r o d 10 9 a n d t h e f o r k 10 8 . R e f e rt o F I G 6 : 2 . T o r e m o v e t h e t h i r d m o t i o n s h a f t b e a r i n g t h e f o l l o w i n g p r o c e d u r es h o u l d b e u s e d : D r i f t t h e s h a f t b a c k w a r d sa s i n d i c a t e db y t h e a r r o w i n A u n t r r the special service tool 1 can be inserted between rne f i r s t s p e e d g e a r 2 a n d t h e b e a r i n g 3 a s i l l u s t r a t e or n d i a g r a m B . N o t e t h a t t h e r e c e s s e df a c e o f t h e t o o l i s t o w a r d s t h e b e a r i n g .C a r e f u l l yd r i f t t h e s h a f t o u t o f t h e c a s i n g a s i l l u s t r a t e d n d i a g r a m C 1 0 f r e e t h e b e a r i n g3 i from the web, taking care not to damage the selector f o r k s i n t h e o p e r a t i o n .P u l l t h e b e a r i n gf r o m t h e s h a f t a n o lift the shaft from the casing. Remove the oil strainerbracket 2g complete wrtn s t r a i n e r . e l e a s e h e f o r k 1 1 0 f r o m i t s r o d 1 11 a n d w i t h _ R t d r a w b o t h r o d a n d f o r k . R e m o v e t h e r e v e r s eg e a r s h a f t 5 0 , gear 48 and selectorfork '1 5. Extractthe detent spring 0 '1 1 6 a n d p l u n g e r 1 1 5 . R e m o v et h e c i r c l i p 5 2 a n d l i f t o f f t h e r e v e r s e e a r o p e r a t l n gl e v e r 5 1 . g

6 :3 Servicing the third motion shaft Three-speed synchromesh gearboxes :

R e m o v e t h e t h i r d m o t i o n s h a f t a s s e m b l ya s d e s c r i b e d in Section 6 :2. R e m o v e t h e f i r s t - s p e e dg e a r 6 8 , h u b a n d b a u l k r i n g f r o m t h e r e a ro f t h e s h a { t ,a n d t h e t o p / t h i r d s y n c h r o m e s n h u b B 2 a n d b a u l k r i n g sf r o m t h e f r o n t o f t h e s h a f t . R e m o v e t h e f r o n t t h r u s t w a s h e r b y d e p r e s s i n gt h e p l u n g e r a n d t w i s t i n g u n t i l t h e s p l i n e sr e g i s t e r i t h t h o s e w on the shaft, then withdraw the third-speed gear 77 c o m p l e t e w i t h n e e d l e r o l l e r b e a r i n g sa n d t a k e o u t t h e p l u n g e ra n d s p r i n g . D e p r e s st h e ' s p r i n g - l o a d e d p e g s , t w i s t a n d r e m o v e t n e s e c o n d - s p e e dg e a r l o c k i n g c o l l a r 7 6 . S l i d e o f f t h e t w o s p l i t w a s h e r s ,p u l l o f f t h e g e a r 7 4 f r o m t h e r e a r o f t h e s h a f t a n d r e m o v e t h e n e e d l e r o l l e r b e a r i n g sf r o m t h e i r r J O Un a l s .

l f i t i s n e c e s s a r yt o s e p a r a t e t h e s e c o n d o r t h i r d / t o p speed striking dog from the synchromesh hub, pressthe a s s e m b l y r n t o s e r v i c et o o l 1 8 G . 5 7 2 t o r e t a i n t h e t h r e e b a l l s a n d s p r i n g sl o c a t e d i n e a c h h u b . T h e p r o c e d u r e o r r e a s s e m b l i n gh i s t h i r d m o t i o n s h a f t f t will be similar to that described for the four-speed s y n c h r o m e s hi n s t a l l a t i o n . Four-speed synchromesh gearboxes : Remove the shaft assembly as already described in Section 6 :2. W i t h d r a w t h e t o p a n d t h i r d g e a rs y n c h r o n m e s h u b 8 2 h and baulk ring 85 from the front end of the shaft, noting that the plain side of the hub faces to the left. Depress the front thrust washer plunger 80 and r o t a t e t h e w a s h e r 7 9 u n t i l i t s s p l i n e s r e g i s t e rw i t h t h o s e on the shaft enabling it to be removed complete with p l u n g e ra n d s p r i n g .R e m o v et h e t h i r d - s p e e d e a r 7 7 w i t h g i t s c a g e d n e e d l e r o l l e rb e a r i n g . g R e m o v et h e f i r s t - s p e e d e a r 6 8 , b a u l k r i n g a n d n e e d l e r o l l e r b e a r i n gf r o m t h e o p p o s i t e e n d o f t h e s h a f t . C a r e f u l l y lever the needle roller bearing journal backwards suff i c i e n t l yt o f i t s e r v i c e o o l 1 8 G . 2 a n d p u l l t h e j o u r n a lf r o m t the shaft. R e m o v e t h e r e v e r s em a i n s h a f t w h e e l a n d t h e f i r s t a n d s e c o n d - s p e e d y n c h r o n i z ea s s e m b l y a n d t h e b a u l k r i n g s r , 68 to 76. Depressthe two plungers securing the rear thrust w a s h e r , r o t a t e i t i n t o a l i g n m e n t w i t h t h e s p l i n e so n t h e shaft and slide it off the shaft. Remove the second-speed g e a r 7 4 a n d t h e s p l i t c a g e d n e e d l e r o l l e rb e a r i n g .

Reassembling the third motion shaft: T h i s a r e v e r s a lo f t h e d i s m a n t l i n g p r o c e d u r e ,b u t i t m a y be of help to give details of certain items of importance: F i r s tf i t t h e r e a r t h r u s t w a s h e r 7 3 o n t o t h e s h a f t . t h e n g s l i d e o n t h e s e c o n d - s p e e d e a r f r o m t h e r e a r ,p l a i n s i d e first, after sticking the needle rollers rn position on their R l o u r n a lw i t h a l i t t l eg r e a s e . e p l a c dt h e t w o s p l i t w a s h e r s 75, depress the two spring-loadedlocking pegs and r e fi t t h e i n t e r l o c k i n g r i n g w h i c h m u s t b e r o t a t e d u n t i l t h e pegs engage in the splines. From the front end of the shaft refit the third-speed -77 geat w i t h t h e p l a i n s i d e f i r s t t o g e t h e rw i t h t h e n e e d l e r o l l e r b e a r i n g sa n d s l i d e o n t h e f r o n t t h r u s t w a s h e r 7 9 , twisting until the spring-loaded peg is heard to lock in posrtron. Check the end float of both the second and third-speed gears when assembled on the third motion shaft. Thrs must be between .0035 and .0055 inch, and the thrust washers must be renewed if this tolerance is exceeded. Fit the third/top-speed synchronizing assembly 82 with the plain face towards the washer 79. F i t t h e f i r s t - s p e e dg e a r a s s e m b l y6 8 a n d t h e b a u l k r i n g 72 with the cone end of the hub to the right or front end of the shaft. In this position the plain ends of the first gear teeth will also be to the right. lf the first and second-speedgear assembly has been d i s m a n t l e d i t w i l l b e n e c e s s a r yt o r e p o s i t i o n i t c o r r e c t l y on the hub or the selectionof second gear will be imposh s i b l e .F I G 6 : 3 i l l u s t r a t e s o w t h e p l u n g e r 1 i n t h e h u b i s aligned with the cut-away tooth 3 in the gear assembly. Note also that the cone end of the hub is on the opposite

FIG

2 Removing the third motion shaft bearing

),'fl45 Yt'tu*///,

7%
FIG 6:3 Thethree-speedsynchromeshfirstandsecondspeed gear assembly showing the plunger 1 in its drilling in the hub 2 alinged with the cut-away tooth 3 in the gear assembly

70

The third motion shaft assemblyis fitted next, passing the slotted end through the centre web of the casing. Engage the sliding hubs with the selectorforks 108 and 11 0 . Using service tool 18G.579 (modified) drift the firsr motion shaft 61 and bearing assembly into the casing, a n d u s e s e r v i c e t o o l 18 G . 5 6 9 t o g a u g e t h e c o r r e c t t h i c k n e s s o f c i r c l i p r e q u i r e d . F I G 6 : 4 i l l u s t r a t e st h i s o p e r a t i o n and the necessary circlip may be selected from the accompanying table, Using service tool 18G.579 together with its spacer washer dnft the third motion shaft bearinginto the central weo.

S'
6

aj I

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The laygear assembly 88G.326 88G.327 88G328 22G.457 22G.858 22G.859

FIG 6:4 Section through the idler gear and first motion shaft. Measure the gap at A, and fit the circlip indicated in the table below Key to Fig 6 :4 1 ldler gear 2 ldler gear thrust washers 3 ldler gear bearing 4 First motion shaft roller bearing 5 First morion shaft ball bearing 6 Circlip When gap is .096 to .098 inch . 0 9 8t o . 1 0 0 i n c h

Use circlip Patt No. 2A.3710 2A.3711

Key to Fig 6:5 1 Laygear 2 Layshafi (this is unstepped on three-speedsynchromesh units) 3 Needle;oller bearings (one only on lhree-speed synchromesh units) 4 Needle roller bearing 5 Large thrust washer 6 Small thrust washer With the standardsizewasher fitted use the table below to select the correct size of variablewasher. When gap is use washer No. Three speed units Four-speed units . 1 2 5t o . 1 2 7i n c h 88G.325 22G.856

. 1 2 8t o . 1 3 0i n c h . 1 3 1t o . 1 3 3i n c h . 1 3 4i n c h side of the assembly from the tapered side of the gear teeth. W h e n r e a s s e m b l i n gt h e s y n c h r o n i z e r se n s u r e t h a t t h e l o n g b o s s o n b o t h t h e s l e e v ea n d t h e h u b s a r e o n t h e s a m e side. When refitting the rhird/top-speed synchronizer assembly 82 the long boss on the sleeve must face tne first motion shaft bearing. The first/second-speed synchronizer assembly must be fitted with the long boss t o w a r d s t h e t r r s t - s p e e dg e a r 6 8 o r s y n c h r o m e s h e n g a g e m e n t o f s e c o n dw i l l n o t b e o b t a i n e d . When fitting the rear thrust washer, the two spring l o a d e d p l u n g e r s m a y b e d e p r e s s e dt h r o u g h t h e t w o h o l e s in the cone of the second gear. The use of servicetool 18G.186 will be helpful when drifting .the first-speed gear bearing journal on to the third motion shaft. 6:4 Reassembling the transmission

R e f i t t h e r e v e r s eg e a r o p e r a t i n g l e v e r 5 1 a n d p i v o t p i n 22,then push rn the selector rods 109 and 1"1 from the 1 front of the casing, engaging them with the selector 'l forks, tighten the selector screws 12 and secure the locknuts. P o s i t i o n t h e r e v e r s eg e a r 4 8 a n d f o r k 1 0 5 a n d r e f i t t h e r e v e r s es h a f t 5 0 w i t h t h e p l a i n e n d f o r e m o s t . R e f i t t h e o i l strainerat the same time smearing a little grease on the sealing ring 27 to assistwhen refitting the suction pipe.

FIG 6:6 A section through th third motion shaft boaring and retainer, showing gap to be moasured. Use table below to select the correct shims When gap is Use shims totalling 0 0 5 t o . 0 0 6i n c h .005 inch 0 0 6 t o . 0 0 8i n c h .007 inch 0 0 8 t o . 0 1 0i n c h .009 inch 010to .01 inch 2 . 0 11 i n c h 0 1 2 t o . 0 1 4i n c h .013 inch 014to .01 inch 5 . 0 15 i n c h

1100Mk 2 1300

71

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. FIG 6:7 Explodedviawof thedifferential assembly 6Lockwashel 5Gearbolt 3Drivegear-^4Gearbush lDifferentialcase 2Casebush KeytoFig6:7 12 Differentialgear 11 Pinpeg 10 Centrepin 9 Pinionthrustwasher 7 Thrustbjock 8 Differentialpinion 18 Cover bush 19 Oil seal 13 Gear thrust washer 14 Drive gear bearing 15 Case bearing 16 Bearing shim 17 End cover 25 Washer 24 Flange nut 23 Driving flange 2i Washer 21 End cover sirew 20 Cover joint

Fit the drive pinion 90 to the third motion shaft, and lockingthe nut 91. Refitthe first motion tightening shaft gear 45 with the pegs on the lockingwasher47 Tighten nut and lock the in engaged the holesin the gear. up the washer. sizethrustwasherat with a standard Refitthe laygear the one end and measure gap at the other,then usethe table to select the correctthicknessof thrust washer .002and.006 ol required givean endclearance between to gearboxes small the synchromesh inch. On three-speed the size, largeone selective; thrustwasheris of a standard (see gearboxes is viceversa it synchromesh on four-speed o e F I G 6 : 5 ) . U s ea d u m m y 1 a y s h a frts e r v i c t o o l 1 8 G . 4 7 1 from to positionthe thrustwasherand refitthe layshaft the clutch side, with the slotted end horizontaland and shaft.Refitthe laYshaft towardsrhat of the reverse reverse shaft locating plate 55 after checkingfor the 86. thicknessof shims 89 requiredunder the retainer This operationis shown in FIG 6:6 and the attached Fit of the table indicates thickness shimsnecessary. the shimsunderthe locatingplate,tightenup the four bolts and lock up the washers. bracket, off Slacken the screwsholdingthe oil strainer greasethe end ol the pipe 33 and insert it into the the takingcarenot to displace oil seal assembly strainer at 27. Fit new papergaskets 34 and 36. Refitthe flange 35 and tighten the screws 37. Tighten and lock the bracketsecuringscrews. gate 119 and cover137 usinga Fit the changespeed gear 100 with the speedometer new joint 138. Engage the slot in the end of the third motionshaft.Fit the end plateand joint 101 and 102. Fit items93 to 99. Refitthe gearchange shaft 120 and positionthe operatinglever arm. Push in 122 with its end engaging the interlocking the shaftthroughthe levelbossand intothe lowerbearing in in the casing.Lineup the recess the shaftthen fit and lock the screw 124.

Refit items 133 to 136. The differential assembly is refittedas described in Section 6:5. l f i t i s f o u n d n e c e s s a r yt o f i t n e w i d l e r g e a r b e a r i n g s , the old bearings may be extracted with service tool 1 8 G . 5 8 1, a f t e r r e m o v i n g t h e c i r c l i p w h e n f i t t e d F o r f i t t i n g t h e n e w b e a r i n g s i t w i l l b e n e c e s s a r yt o u s e s e r v i c e tool 18G.582 on three-speed synchromesh boxes, or 1 8 G . 1 1 2 6 o n f o u r - s p e e d s y n c h r o m e s h i n s t a l l a t i o n s .U s e the collar supplied with each tool to control the depth to which the bearing is pressedinto the flywheel housing, t h e b o s s o f w h i c h m u s t b e w e l l s u p p o r t e d .T h e c o l l a r s a r e not required when fitting bearings to the transmission casing as the shoulder on the tool governs the depth to which it is oressed. F i n a l l y ,t h e e n d f l o a t o f t h e i d l e r g e a r m u s t b e c h e c k e d as follows: Refit the idler gear and thrust washers, with the chamferedside of each washer againstthe gear. Refit the flywheel housing with a new joint washer and tighten the nuts to a torque of 18 lb ft. Check with feeler gauges that the idler gear has an end float of between .003 and .008 inch. Thrust washers a r e a v a i l a b l ei n t h i c k n e s s e sf r o m . 1 3 2 t o . 1 3 9 i n c h a n d t h e a p p r o p r i a t ew a s h e r s h o u l d b e i n s e r t e da t 2 i n F I G 6 : 4 t o o b t a i n t h e c o r r e c t e n d f l o a t . R e m o v et h e f l y w h e e l h o u s i n g a n d g a s k e t a n d r e f i t t h e t r a n s m i s s i o nu n i t t o t h e c r a n k c a s e a s d e s c r i b e di n C h a p t e r 1 , S e c t i o n 1 : 1 0 u s i n g a n e w h o u s i n g g a s k e t t o r e p l a c et h a t u s e d f o r t h e i d l e r g e a r e n d float check. 6:5 Servicing the differential assembly

Removing. SeeFIG 6:7. Remove the engine and transmission assembly as describedin Chapter 1. O n t r a n s m i s s i o nw i t h t h e e a r l i e r t y p e o f g e a r c h a n g e , remove the remote control housing from its adaptor if t h i s h a s n o t a l r e a d v b e e n d o n e . R e l e a s et h e c o n t r o l s h a f t

72

Withthelefthanddrivecoverfittedwithoutajointwasher,measurethegapatAtodeterminethicknessof FIG 6:8 shim required to give the required preload

l e v e r ,1 3 0 i n F I G 6 : 1 , f r o m t h e t o p o f t h e r e m o t e c o n t r o l shaft 129 which can now be withdrawn. l f a p p l i c a b l e ,e x t r a c t t h e s p l i t p i n f r o m e a c h s l o t t e d n u t 2 4 s e c u r i n gt h e d r i v i n g f l a n g e s 2 3 t o t h e d r f f e r e n t i a l g e a r s h a f t s ,r e m o v et h e n u t s , u s i n g S e r v i c et o o l 1 8 G . 6 6 9 to hold each driving flange in turn, and withdraw the flanges. On no account use the transmission casing as a stop or leverage point when removing any transmission component or serious damage may be caused. When offset sphereplunge joints are fitted, use Service tool 18G.1240 to unlock these joints from the final d r i v e . E n s u r et h a t t h e f u l c r u m s i d e o f t h e t o o l i s p l a c e d againstthe final drive and that ihe hammer blows are directed inwards. Unscrew the five set screws from each of the final drive end coversand removethem from the differential h o u s i n g .M a k e a n o t e o f t h e s h i m s 1 6 f i t t e d b e t w e e n t h e d i f f e r e n t i a b e a r i n ga n d t h e h o u s i n g . l R e m o v e t h e d i f f e r e n t i a lh o u s i n g s t u d n u t s a n d , w t t h t h e l a t e r s i n g l e r o d g e a r c h a n g e ,f i t t h e o i l s e a l p r o t e c t o r 1 8 G . 1 2 3 6 o v e r t h e s e l e c t o rs h a f t a n d t h e n w i t h d r a w t h e housing from the transmission case, keeping the p r o t e c t o r( w h e n u s e d ) p r e s s e d i r m l y i n p o s i t i o n .R e m o v e f t h e d i f f e r e n t i a la s s e m b l y .

End cover oil seals: P r i s e o u t t h e o i l s e a l sf r o m t h e e n d c o v e r s a n d p r e s s i n n e w o n e s , u s i n g S e r v i c et o o l 1 8 G . 1 2 3 8 w h e n f i t t i n g t h e l a t e s tt y p e . T h i s h a s a r e g i s t e rw h i c h e n g a g e st h e w a t e r s h i e l df i t t e d w i t h t h e s e a l . Reassembling : This is the reversal of the removal procedure. Make s u r e t h a t t h e g e a r t h r u s t w a s h e r s 1 3 a r e r e fi t t e d w i t h t h e i r chamfered bores agaiost the machined faces of the t d i f f e r e n t i ag e a r s 1 2 ,a n d t h a t a l l p a r t sa r e r e t u r n e d o t h e i r l o r i g i n a lp o s i t i o n s . The bolts securing the drive gear 3 to the differential casing should be tightened to a torque of 55 to 60 lb ft. Refitting : Place the differential assembly in the transmission casingwith a slight bias towards the flywheel side. On single rod gear change models fit the oil seal protector 1 8 G . 1 2 3 6 o v e r t h e s e l e c t o rs h a f t t h e n , o n a l l m o d e l s , refit the differential housing with joint washers and w t i g h t e n u p t h e n u t s s u f fi c i e n t l yt o h o l d t h e b e a r i n g s h i l e still allowing the assembly to be moved sideways. Refit the righthand end cover 17 complete with its j o i n t 2 0 . C a r e f u l l ya l i g n t h e h o l e s , i n s e r tt h e s e t s c r e w sa n d t, t i g h t e n t h e m u p p r o g r e s s i v e l y h u s e n s u r i n gf u l l c o n t a c t between the inner face of the cover and the outer face ot t h e d i f f e r e n t i a b e a r i n g ,a n d a t t h e s a m e t i m e d i s p l a c i n g l the differentialassemblyaway from the flywheel side of tne engrne. Fit the lefthand final drive cover, temporarily without its loint washer, the compressed thrckness of which is . 0 0 7 i n c h . I n s e r t t h e s e c u r i n g s e t s c r e w sa n d t i g h t e n t h e m c a r e f u l l yt o e n s u r e t h a t t h e c o v e r r e m a i n s s q u a r e a t a l l times and sufficiently for the cover register to nip the

Dismantling : U s e s e r v i c et o o l 1 8 G . 2 t o w i t h d r a w t h e t w o d r i v e g e a r '14. Knock back the locking plate tabs and bearings r e m o v e t h e s i x b o l t s s e c u r i n gt h e d r i v i n g g e a r 3 t o t h e cage and separate them after marking each to ensure '1 correct reassembly.Extract the differential gear 2 and t h r u s tw a s h e r 1 3 . T a p o u t t h e p i n p e g 1 1 t o r e l e a s e h e p i n i o n c e n t r ep i n t 10, the thrust block 7, pinions B and thrust washers9.

11 0 0 M k 2 1 3 0 0

73

4 5

C h e c k t h a t b o t h d r i v e s h a f t s a r e e q u a l l yf r e e t o r o t a t e , o t h e r w i s et h e r e m a y b e a t e n d e n c yf o r t h e c a r t o s t e e rt o one srde. On early type change models, positton the remote c o n t r o l s h a f t l e v e r 13 0 o n t h e b a l l e n d o f t h e o p e r a t i n g l e v e r ,i n s e r tt h e r e m o t ec o n t r o l s h a f t f r o m u n d e r n e a t h n d a e n g a g e t h e s p l i n e si n t h e l e v e r .F i t t h e s c r e w 1 2 7 a l t e r c h e c k i n g t h a t i t s d r i l l i n g i n t h e b o s s a n d r e c e s si n t h e shaftare in line. L u b r i c a t et h e m o v i n g p a r t s o f t h e c h a n g e s p e e d l e v e r a n d r e p l a c et h e r e m o t e c o n t r o l h o u s i n g . Re{it the transmissionto the engine. Install the c o m p l e t ep o w e r u n i t a n d c o n n e c tt h e r e m o t ec o n t r o l q e a r change.

6:6 Dismantling the gearbox with later type gearchange R e m o v e t h e t r a n s m r s s i o nf r o m t h e c r a n k c a s e a s d e s c r i b e di n C h a p t e r 1 a n d t h e n w i t h d r a w t h e i d l e r g e a r with itsthrustwashers. Remove the differentialassembly as described in S e c t i o n 6 : 5 . W h e n r e m o v i n gt h e r i g h t h a n de n d c o v e r o f t h e f i n a l d r i v e ,w i t h d r a w a l s ot h e d e t e n ts l e e v e s p r i n ga n d , b a l l r e t a i n e db y i t . R e m o v et h e s e c u r i n gn u t s a n d s c r e w s a n d p u l l o f f t h e front cover. D i s c o n n e c tt h e o i l s u c t t o n p i p e f r o m t h e c a s i n g a n d wrthdrawthe pipe from the strainer. E x t r a c tt h e c i r c l i p a n d u s e S e r v i c e t o o l 1 8 G . 7 0 5 t o r e m o v et h e r o l l e r b e a r i n gf o r t h e f i r s t m o t i o n s h a f t . R e f e r n o w t o F I G 6 : 9 . T u r n t h e s e l e c t o rs h a f t a n r r c l o c k w i s et o d i s e n g a g et h e s t u b a t t h e e n d o f t h e s h a f t l a n d t h e i n t e r l o c ks p o o l 2 . N o w s e l e c t f i r s t a n d f o u r t h g e a r st o g e t h e rt o l o c k t h e - g e a rI r a i n . Unlock the washers and remove the first motion shaft n u t a n d t h e f i n a ld r i v eg e a r n u t . W i t h d r a w b o t h i n p u t a n d f i n a l d r i v eg e a r s . R e m o v e t h e f o u r s c r e w s f r o m t h e r e t a i n e rf o r t h e t h i r d m o t i o n s h a f t b e a r i n g a n d t a k e o f f t h e r e t a i n e ra n d i t s p a c k i n gs h i m s . Remove the layshaft and reverseshaft locking plate, p u s h t h e l a y s h a f tf r o m t h e c l u t c h s i d e o f t h e c a s i n g t o permit the removal of the laygearand thrust washers. T h e r e m a i n d e ro f t h e c o m p o n e n t s i n t h e g e a r b o x c a n now be easily withdrawn including the gear selector mechanrsm. Reassembling the gearbox : T h e s e d i r e c t i o n sa r e g i v e n a s s u m i n gt h a t t h e g e a r b o x has been completely stripped and any operation which does not apply can be ignored. F i t a n e w ' O ' r i n g s e a lt o t h e p i v o t p o s t a n d d r i f t i t b a c k into the casing. F i t t h e s e l e c t o r h a f t i n t o t h e i n t e r l o c ks p o o l a n d . f r o m s i n s i d et h e c a s r n g ,f i t t h i s a s s e m b l yi n t o i t s b o r e , w i t h t h e stub facing away from the pivot post. F i t t h e s l e e v e o v e r t h e p i v o t p o s t , t h e n t h e r e v e r s eb e l l c r a n k l e v e r ,a t h i n w a s h e r ,c e n t r e b e l l c r a n kl e v e r ( c h a m f e r e d o n b o t h s i d e s ) ,t h i n w a s h e r a n d t h e u p p e r b e l l c r a n k l e v e r ( c h a m f e r e do n t o p o n l y ) . F i t t h e t h i c k w a s h e r a n d self-locking nut. Do not twist the selectorshaft ano s p o o l I n t o e n g a g e m e n t w i t h t h e b e l l c r a n k l e v e r su n t i l t h e first motron shaftand final drive nuts havebeen tiohtened.

F I G 6 : 9 L a t e r t y p e g e a r s e l e c t o r m e c h a n i s m ,w i t h t o p g e a r s e l e c t e d .F o r c l a r i t y .t h e s e l e c t o rf o r k s a n d s h a f t a r e s h o w n d r a w n a w a y f r o m t h e b e l l c r a n kl e v e r si n t o w h i c h thev fit K e y t o F i g 6 : 9 1 S e l e c t osrt u b 2 I n t e r l o cs p o o l 3 R e k v e r s e e l l c r a nlk v e r b e 4 C e n t r e e l l c r a nlk v e r b e 5 Upper b e l l c r a n ke v e r 6 ' 1 l , , , 2 ns p e e df o r k 7 3 r d , , 4 t h o e e df o r k l s d s 8 Roll'pin o u t e r r a c e o t t h e b e a r i n g .S i n c e t h e r e q u i r e dp r e l o a d o n t h e b e a r i n g si s . . 0 0 1 t o . 0 0 2 i n c h r h e g a p b e t w e e n t h e c o v e r f l a n g e a n d t h e d i f f e r e n t i aa n d t r a n s m i s s i o n a s i n g l c m u s t b e b e t w e e n. 0 0 8 a n d . 0 0 9 i n c h .T h i s i s t h e g a p s h o w n a t A i n F I G 6 : 8 a n d m u s t b e m e a s u r e d i t h f e e l e rg a u g e s w a t s e v e r a l p o i n t s a r o u n d t h e f l a n g e . A n y v a r i a t i o n sw i l l i n d i c a t e h a t t h e e n d c o v e rs c r e w sh a v en o t b e e nt i g h t e n e d t e v e n l y a n d t h i s s h o u l d b e c a r e f u l l yc o r r e c t e d . A n y v a r i a t i o n b e t w e e n t h e g a p a s m e a s u r e da n d t h e r e q u i r e df i g u r e m u s t b e r e c t i if e d b y t h e a d d i t i o no f s h i m s b e t w e e n t h e b e a r i n g a n d t h e r e g i s t e ro n t h e c o v e r . F o r e x a m p l ei f t h e g a p a s m e a s u r e d s . 0 0 5 i n c h a s h i m o f . 0 0 3 i inch is required. R e m o v e t h e c o v e r , f i t t h e s e l e c t e ds h i m ( s ) i n t o t h e b e a r i n g r e c e s s ,r e p l a c et h e e n d c o v e r a n d i t s j o i n t w a s h e r a n d t i g h t e n t h e c o v e r s c r e w s a n d d i f f e r e n t i a lh o u s i n g nuts. Note: Later assemblies re fitted with increaseo a t h r u s t c a p a c i t y b e a r i n g sw h i c h m u s t b e f i t t e d w i t h t h e 'THRUST' identification ord w f a c i n g t h e o u t s i d et o w a r d s t h e e n d c o v e r .S i n c e t h e p r e l o a di s i n c r e a s e do . 0 0 4 i n c h , t t h e g a p a t A m u s t b e a d j u s t e dw i t h s h i m s u n r i l i r i s . 0 11 i n c h b e f o r et h e l o i n t w a s h e r i s f i t t e d . R e t i tt h e d r i v i n gf l a n g e so r p l u n g el o i n t s .F o r t h e f o r m e r the flange nuts must be tightened to a torque of 70 l b f t a n d o n t o t h e n e x t s p l i t p i n h o l e t o s e c u r et h e n u t . For plunge joints see that the water shield is fitted on 1 i n c h f r o m t h e e n d o f t h e p o l i s h e db o s s o f t h e p l u n g e j o i n t w i t h i t s d i s h e d s i d e t o w a r d s t h e f r n a ld r i v e .

74

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FIG 6 :10

Early type remote control gearchange

5 R u b b e rr i n g 4 S h a k e p r o o fw a s h e r s Key to Fig 6:10 1 Housing 2 S e c u r i n gs c r e w { r o n t 3 S e c u r i n gs c r e w - r e a r '11 Damperplunger 6 Rubberdustcover 10 Springwasher 7 Primaryshaft 9 Leverscrew 8 Primaryshaftlever '16 17 Retainer L e v e rk n o b 12 Plungerspring l 13 Washer 1 4 C a p n u t s p r i n gr e t a r n e r 1 5 C h a n g e s p e e de v e r 23 Springwasher 18 Spring 19 Bush split 2 2 S c r e w r e l a i n e rt o h o u s i n g 2 0 D i s t a n c ep i e c e 2 ' 1 L o c a l r n gl l a n g e pin 2 8 R u b b e rm o u n t t n g 2 7 G a i t e r s e c u r i n gp l a t e 24 Locating 25 Springwasher 2 6 G a i t e r - c h a n g e s p e e dl e v e r 29 Mounting bracket 30 Plate 31 Tab washers 32 Self locking nut

11 0 0M k 2 1 3 0 0

75

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FIG 5:1 1 Later type remote control gearchange

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Key to Fig 6:11 1 R e m o t ec o n t r o l u n i t c a s i n g 2 Changespeedever l 3 Changespeedlever spring retainer 4 Steady rod 5 S t e a d y r o d s e c u r i n gn u t 6 S t e a d y r o d s e c u r i n gb o l t 7 E x t e n s i o nr o d 8 Extensionrod retaining pin 9 Exlension rod eye 1 0 E x t e n s i o nr o d e y e r e t a i n i n gp i n s 11 Supportrod 12 Ball-endbearing 1 3 B a l l e n d b e a r i n gs e a l 14 Ball-endbearing 'l seat securing circlrp 15 Bottom cover 6 R e v e r s el i g h l s w i t c h ( i f f i t t e d ) o r p l u g 17 Mounting bracket 18 Rubber 'l bobbin 9 Adaptor plate (if f itred) 20 Mounring bracker botr

E n g a g e t h e t h i r d / f o u r t h s p e e d s e l e c t o rt o r k w i t h t h e centre bellcrank lever and the first/second speed fork w l t h t h e u p p e r o n e . T h e n s l i d e i n t h e s e l e c t o rs h a f t , drilling towards the flywheel end, and drive rn a new r o l l - p i n t o s e c u r et h e s h a f t a s s h o w n . F i t t h e r e v e r s ei d l e r g e a r o v e r t h e p i n o f t h e b e l l c r a n k l e v e r ,n o t i n g t h a t o n l y o n e e n d o f t h e g e a r w i l l f i t i n s i d e t h e c o u n t e r b o r e i n t h e c a s i n g ,a n d s i i d e i n t h e r e v e r s e shaft plain end first. Continue assembly as for the early type transmission, reversinghe orderof dismantling. heckthe differential t C a d j u s t m e n t .R e - c o n n e c tt h e s t e a d y s h a f t a n d o p e r a t i n g r o d a f t e r r e fi t t i n g t h e p o w e r u n t t . 6 :7 Gearchange remote control Early type. See FIG 6 :10: This earlytype of remote control is very easilyremoved as follows: L i f t u p t h e c a r p e t o r o t h e r f l o o r c o v e r i n g ,u n s c r e w t h e k n o b f r o m t h e g e a r l e v e r1 5 a n d u n s c r e w t h e f o u r s e l f t a p p i n g s c r e w s t o r e l e a s et h e r u b b e r g a i t e r 2 6 a n d i t s retaining plate 21.

Take out the two shoulderedscrews 3 and remove the p l a t e3 0 . F r o m u n d e r n e a t ht h e c a r r e m o v e t h e f o u r b o l t s 2 a n d detach the extensionhousng 1 from the transmission h o u s i n ga d a p t o r . D i s m a n t l i n g h o u l d p r e s e n tn o d i f fi c u l t y i f r e f e r e n c e s s i m a d e t o t h e i l l u s t r a t i o n ,r e f i t t i n g i s c a r r i e d o u t i n t h e r e v e r s eo r d e r o f r e m o v a l . Later type. See FIG 6 :11 : T h i s r s k n o w n a s t h e s i n g l e o p e r a t i n gr o d t y p e a n d i s r e m o v e da s f o l l o w s : 'l lf a reverse light 6 is fitted, disconnect the battery, , then remove the knob from the gearleverthe securing p l a t e a n d t h e r u b b e rg a i t e r . F r o m u n d e r n e a t h h e c a r r e m o v et h e p i n 8 r e t a i n i n g h e t t extension rod 7 to the selector shaft and detach the steady rod 4 from the differentialhousing. Disconnect the electric leads from the reverse light switch (when fitted). Remove the mounting bolt 20 and withdraw the c o m p l e t ec o n t r o l u n i t a s s e m b l y .

76

T w i s t t h e s p r i n g r e t a i n e r 3 t o r e l e a s et h e g e a r l e v e r 2 . R e m o v e t h e s t e a d y r o d a n d r e v e r s el i g h t s w i t c h . D r i v eo u t t h e t w o p i n s 1 0 a n d w i t h d r a w t h e e x t e n s i o n rod 7, end plug, support rod 11 and the eye 9. Remove the circlip 14 and dismantle the ball-end b e a r i n gs e a t 1 3 a n d b e a r i n g 1 2 . R e a s s e m b l ya n d f i t t i n g a r e c a r r i e d o u t i n t h e r e v e r s e order to the above, but note the following points. A l w a y s u s e n e w r e t a i n i n gp i n s 1 0 a n d 8 . Note that the bottom cover 15 is fitted with the reverse stop on the side opposite to the reverse switch or its ' plug. l f t h e s p r i n g r e t a i n e rh a s b e e n p u l l i n g o v e r i t s r e t a i n i n g pins, longer pins may be fitted and secured with Loctite. Leavethe tightening of the mounting bolt 20 until the end of the operation. Reverse light switch: On the early remote control units the reverse light switch is screwed into the front of the transmission c a s i n g i n p l a c e o f t h e r e v e r s ec h e c k p l u n g e r , s p r i n g a n d plug. No adjustment is possible with thrs type. O n l a t e r g e a r s h i f t u n i t s t h e r e v e r s el a m p s w i t c h m a y b e a d i u s t e d i f n e c e s s a r ya s f o l l o w s : Engage reverse gear. disconnect the leads from the s w i t c h a n d l o o s e nt h e l o c k i n g n u t . Connect a test lamp and battery across the switch terminals and then unscrew the switch body until the test lamp goes out. Screw in the switch untll the lamp just lights and then a further half turn and secure with the locknut.

Remove test lampand battery, the reconnect leads the and checkfor correctoperation. 6 : 8 F a u l td i a g n o s i s (a) Jumping out of gear 1 Brokenspringbehindselector locatinqplunger rod 2 Excessively worn groovein selector rod 3 Worn synchromesh couplingdogs 4 Forkto selector securing rod screwloose (b) Noisytransmission 1 I n s u f f i c i e n ti l o 2 Excessive float of laygear end 3 Incorrect end float of idlergear preload differential 4 Incorrect on bearings 5 Worn or damaged bearings 6 Worn bushes third molionshaft on gearteeth 7 Worn or damaged ( c ) D i f f i c u l t y i n e n g a g i n gg e a r 1 Incorrect clutchpedaladjustment 2 Worn synchromesh cones 3 Firstand secondgearincorrectly assembled hub on (d) Oil leaks joint washers 1 Damaged 2 Worn or damaged seals oil joint faceson covers 3 Faulty 4 Ineffective sealon gearchange oil operating shaft

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CHAPTER 7 AUTOMATIC TRANSMISSION

7 :1 7:2 7 :3 7 :4 7 :5 Description Power f low (mechanical) Fault diagnosis Road testing Adjustments 7:6 7:7 7 :8 7:9 Removing the transmission unit Servicing the differential assembly Servicing the gearchange cable ldler gear lubrication reservoir

7 :1 Description The automatic transmissionuses a three element fluid torque converter in the place of a conventional flywheel and clutch, coupled through an idler gear to a bevel gear t r a i n a s s e m b l y w h i c h p r o v i d e s f o u r f o r u v a r ds p e e d s a n d reverse. he layout of the systemis shown in FIG 7:1 T 'circulation' which also illustrateshe t of the operating f l u i d t o t h e v a r i o u s o m p o n e n t sI.n F I G S 7 : 2 1 o 7 : 7 t n e c d i a g r a m si n d i c a t eh o w t h e v a r i o u sr a t i o sa r e o b t a i n e db v t h e e n g a g e m e n t o f t h e a p p r o p r i a t ef r i c t i o n m e m b e r s . The final drive is transmitted to a conventional d i f f e r e n t i au n i t , a n d s o t h e t h e r o a d w h e e l s t h r o u g h t h e l drive shaftsand their constantvelocityjoints. The complete gear train assembly, including the d i f f e r e n t i a l , s h o u s e d b e l o w a n d p a r a l l e lt o t h e e n g t n e i c r a n k s h a f ti n a c a s i n g w h i c h a l s o s e r v e sa s t h e e n g i n e sumo. Gear selection is by means of a floor mounted seven p o s i t i o n g a t e d q u a d r a n t . T h e r e v e r s e .n e u t r a l a n d d r i v e positions are for normal automatic driving, with the first, second, third and fourth positions used for manual o p e r a t i o n o r o v e r - r i d e a s r e q u r r e d .T h i s a r r a n g e m e n t allows the system to be used as a fully automatlc four speed transmissron rom rest to maximum speed with the f

gears changing automattcally according to throttle p o s i t i o na n d l o a d . l f i t i s d e s i r e dt o s e l e c ta l o w e r g e a r f o r g r e a t e r a c c e l e r a t i o n ,t h e a c c e l e r a t o r p e d a l i s ' k i c k e d down' to full throttle position and this immediately p r o d u c e st h e c h a n g e . Manual control of the selector lever provides raprd c h a n g e so f a l l f o u r f o r w a r d g e a r s ,b u t i t i s i m p o r t a n tt h a t d o w n w a r d c h a n g e s b e m a d e a t t h e c o r r e c t r o a d s p e e d so r s e r i o u sd a m a g e t o t h e a u t o m a t i c t r a n s m i s s i o n n t t m a y u r e su t t . S e c o n d ,t h i r d a n d f o u r t h g e a r s p r o v i d ee n g i n e b r a k i n g i n b o t h a u t o m a t i cd r i v e a n d m a n u a l ,w h i l e i n f i r s t g e a r there is freewheeling during deceleration. Manual s e l e c t i o n f t h i r d o r s e c o n d g e a r g i v e se n g i n e b r a k i n ga n d o also allows the retention of a lower gear to suit road c o n d r t i o n s r f o r t h e d e s c e n to f s t e e p h t l l s . o The mainhigh-outpuoil pump 2 in FIG 7:1 provides t oil under pressure oth for enginelubrication nd for the b a a u t o m a t i c t r a n s m i s s i o n .T h e v a l v e b l o c k a s s e m b l y 4 directs the oil flow to the converterby way of pipe 6, the e n g i n e b y p i p e 5 a n d b y p i p e s 1 3 t o t h e s e r v o so p e r a t i n g the selector brake bands. T h e t w o h y d r a u l i c a l l y p e r a t e dc l u t c h e s1 0 a n d 1 2 a r e o e n g a g e d f o r t o p a n d r e v e r s eg e a r w o r k o r f o r a l l f o r w a r d motion of the car respectively.

11 0 0 M k 2 1 3 0 0

79

-\

.t.
o\ \

FIG 7:1

The components of the automatic transmission, showing f luid circulation indicated by arrows

KeytoFigT:1 1 Mainoil strainer 2 Oilpump 3 O r lf i l t e r a s s e m b l y 4 V a l v e b l o c k 5 E n g i n e o i lf e e d 6 Converter "10 feedpipe 7 convertertolowpressurevalvefeed 8 Lowpressurevalve 9 Geartrain Topandreversectutch 11 Governor 1 2 F o r w a r dc l u t c h 13 Servounit 1 4 A u x i l i a r yp u m p o i l s t r a i n e r 1 5 A u x i l i a r yp u m p

A g o v e r n o r ,o f t h e s p r i n g - l o a d e db o b - w e i g h t t y p e , i s used to delay gear shrfts as the accelerator pedal is d e p r e s s e d T h e l o w p r e s s u r e a l v e 8 p r e v e n t st h e c o n v e r t e r . v d r a i n i n gw h e n s t o p p e da n d s o b e r n gn o i s y a n d i n e f fi c i e n t when restarting. p T h e a u x i l i a r y u m p 1 5 i s r e s p o n s i v eo r o a d s p e e do n l y t a n d i s u s e d w h e n t o w - s t a r t i n g ,b u t i t m u s t b e n o t e d t h a r t h i s i s n o t p o s s i b l ew h e n a n e n g a g e m e n tc o n t r o l u n t t r s f i t t e d a s o n l a t e rt r a n s m i s s i o n s . T h e e n g a g e m e n t c o n t r o l u n i t i s a s s e m b l e di n t o t h e t r a n s m i s s i o ni n o r d e r t o e l i m i n a t e e x c e s s i v em o v e m e n t of the car when selectinga forward drive range from the reslposrton.

7:2 Power f low (mechanical) T h e p o w e r f l o w d i a g r a m sg i v e n i n F I G S 7 : 2 , 3 , 4 , i , 6 a n d 7 i n d i c a t e h o w t h e f o u r f o r w a r d s p e e d sa n d r e v e r s e a r e o b t a i n e db y t h e o p e r a t i o no f t h e v a r i o u sc l u t c h e sa n d frictionbands. The crankshaft 1 drives the outer casing of the c o n v e r t e rw h i c h i n t u r n , b y t h e a c t i o n o f t h e o i l w i t h w h i c h i t i s f i l l e d .d r i v e s a n i n n e r m e m b e r w h i c h i s c o n n e c t e dd i r e c t l yt o t h e o u t p u t g e a r 2 . Below the output gear will be seen the idler gear 3 t h r o u g h w h i c h t h e d r i v e i s p a s s e dt o t h e i n p L t t e a r o f t h e g transmrssion ssembly. a In view of the special equipment needed for most

BO

FIG 7 :2 Mechanical power f low in Neutral All gear bands and clutches are disengaged and there is no drive to the final drive pinion Key to Fig 7:2 1 Crankshaft 2 corverter output gear 7 F e v e r s eb a n d 8 Third gearband 9 Secondgear band pinion 1 3 F i n a ld r i v e g e a r 3 ldiergear 4 Inpul gear 1 0 T o p a n d r e v e r s ec l u t c h 5 one way clutch 1 1 F o r w a r dc l u t c h 6 Gearcarrier 1 2 F i n a lo r r v e

FIG 7:3 Power flow in First speed. Forward clutch applied, one-way clutch 5 operating and carrier stationary. Input bevel drives planet wheels, planet pinions drive the forward output pinion and shaft. Po-wer thus trans{erred to mainshaft, forward clutch 11 and final drive oinion 12 Key to Fig 7:3 1 C r a n k s h a { t 2 C o n v e r t e ro u t p u t g e a r 7 Reverse and b 8 Thirdgear band 9 Second gear band '1 prnron 3 F i n a ld n v e g e a r 3 ldlergear 4 input gear 10 Top and reverse luich c 5 One way clulch 1 l F o r w a r dc l u t c h 6 Gearcarrier 1 2 F i n a ld r i v e

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PowerflowinSecondspeed.Forwardclutchllengagedandsecondgearband9applied.Planetclusterorbits FlGT:4 round reverse drive bevel pinion so power is transmitted from input bevel through planets to mainshaft, forward clutch and final drive Key to Fig 7:4 1 Crankshafl 2 Converter utput gear o 7 R e v e r s eb a n d 8 Third gear band 9 Second gear band prnron 1 3 F i n a ld r i v e g e a r 4 Inpul gear 3 ldlergear 10 Top and reverse lutch c 5 One-way clutch 1 1 F o r w a r dc l u t c h 6 Gearcarrier 1 2 F i n a ld r i v e

THIRD

FIG 7:5 Power flow in Third speed. Third speed bevel gear held by band 8. Planet clusters orbit round this gear and power is transmitted from input bevel through planets to mainshaft, forward clutch and final drive Key.to Fig 7:5 1 C r a n k s h a f t 2 Converter output gear 7 R e v e r s eb a n d 8 Third gear band 9 Second gear band pinion 1 3 F i n a ld r i v e g e a r 3 ldlergear 4 lnput gear 1 0 T o p a n d r e v e r s ec l u t c h

5 One-way clutch 1 1 Forward clutch

6 Gear carrier 12 Final drive

82

TOP

FIG 7:6 P o w e r f l o w i n T o p s p e e d clutches one unit to give direct driv

10 and 11 engaged. This locks all bevel gears and the assembly rotates as 3 ldler gear 4 Input gear 1 0 T o p a n d r e v e r s ec l u t c h

Key to Fig 7:6 1 Crankshatl 2 Converter output gear 7 R e v e r s eb a n d 8 Third gear band 9 Second gear band pinion 1 3 F i n a ld r i v e g e a r

5 One-way clutch
Forward clutch

6 Gear carrier 12 Final drive

FIG 7:7 Power flow in Re.verse. everse band 7 applied and top and reverse clutch 10 engaged. lnput R bevl driv6s planet wheel and planet pinion drives reversegeur. Eiiive is throujh f t i n e t a s s e m u l i e st o t o p ; n ; r e v e i i e t r u t c n a n a s o to the final drive Key to Fig 7:7 1 C r a n k s h a f t . 2 C o n v e l t e o u t p u tg e a r 3 l d l e rg e a r 4 I n p u t g e a r r g Second 7 . R e v e r s e q 1 d - 8 T h i r dg e a rb a n d b lear-band 10 To6 jnd revers;;iJrch pinion 1 3 F i n a ld r i v eg e a r 5 O n e - w a yc l u t c h 1l Forward tutch c 6 G e a rc a r r i e r 1 2 F i n a ld r i v e

1 1 0 0M k 2 1 3 0 0

83

7 :3 Fault diagnosis l Faulty gear selection. possibly with tie-up in D p o s i t i o no n k i c k - d o w n . R e c t i f i c a t i o n : C h e c k g e a r c h a n g ec a b l e a n d s e l e c t o r rod adlustment. 2 Slip or no drivein all gears. Rectification: Check main oil pump, flow valve' s u p p l y , f e e d p i p e a n d m a i n o i l s t r a i n e ro i l s e a l s l f t h i s i s n o t e f f e c t i v e c o n s u l t S e r v i c eS t a t i o n 3 Difficulty or bumpy selection and shifts, possibly w i t h s q u a w k o n s e l e c t i o n ,l u b r i c a t i n g l i g h t o n , o r l o w oil gauge pressure. Check oil level Carry out pressure Rectification: check. Check O-ring seals in oil filter head Check main oil pump and flow valve, supply, feed pipe and m a i n o i l s t r a i n e rs e a l s .A f t e r t h i s , S e r v i c e S t a t i o n
Tho inhibitor switch on the gearchange lever FIG 7:8 housing. Inset shows tho numbered connctors

4 E r r a t i ca u t o m a t i c s h i f t s . Check oil level. After this, Service Rectification: Station. 5 Incorrectshift sPeeds. Rectif ication: Check governor control rod ad.iustment. 6 E x c e s s i v ec r e e p o r e n g i n e s t a l l s w h e n s e l e c t i n g g e a r ' Check carburetter adjustment fot Rectification: incorrect idling sPeed 7 C o n t i n u a l w h i n e c o n s i s t e n tw i t h r o a d s p e e d ' Check converter housing bush (see Rectification: Chapter 1).

r>1
I

"

a \1\

ic

i l

lll u

8 Poor acceleration. Rectification: Carryout stall speed check' 9 Reduced maximum speed in all gears with severe l converter overheatng. R e c t i f i c a t i o n : C h a n g e t h e t o r q u e c o n v e r t e ru n l t ' T h e f o l l o w i n g f a u l t s r e q u i r ea t t e n t i o n f r o m t h e S e r v i c e Station: 10 Slip or no drive in forward gears. 11 Slippingin reverse 12 Unable to tow- start 1 3 G e a r w h i n e c o n s i s t e n tw i t h r o a d s p e e d b u t n o t i n t o p gear ' 1' a u t o m a t i c a n d m a n u a lf i r s tg e a r 1 4 N o d r i v ei n 15 Slip or no drive in'2'automatic and manual second gear '4' positions '2','3' m a n u a l ,b u t d r i v e s or 16 N o d r i v e i n 'D' on automatic '4' '2', '3' D positions automatic but or 17 No drive in drives in these gears on manual selection

FIG 7:9 ment

The gearchange cable and selector rod adjust-

2 Clevis Pin 1 Rubberboot Key to Fig 7:9 5 Selector rod Yoke 4 Selector rod Yoke 3 Seleclor rod 7 Bellcrank lever arm 6 Cable adjusting nuts locknut A:3* inch with selectorrod fullY in

it transmission, will on itemsof servicing the automatic Station Service to be necessary takethe carto a qualified for attention.There are, however, certain tests and which can be canied out by a competent adjustments of home operatorin possession a fairly comprehenslve indicator or a tool kit, in particular tachometer revolution gaugecalibrated to 300 lbi sq inch up and a pressure

7:4

Road testing A l l s u s o e c t e df a u l t s s h o u l d b e c h e c k e d b y r o a d t e s t i n g ' I n c a s e s o f s l i p o r p o o r a c c e l e r a t i o nc a r r y o u t a c o n v e n e r s t a l l s p e e d t e s t a s d e s c r i b e di n S e c t i o n 7 : 5 '

84

Change speed chart: Check the performance in all seven selector positions a s f o l l o w s . T h e f i r s t c o l u m n o f s p e e d sa p p l i e st o 1 1 0 0 m o d e l s u p t o 1 O A G / A / H 1 2 O 7 .T h e s e c o n d c o l u m n o f s p e e d sa p p l i e st o l a t e r1 1 0 0 m o d e l sa n d a l l 1 3 0 0 m o d e l s . Selector Throttle Gear shift Mitelhr Mile/hr D Light 1to2 1 0 t o 1 4 1 1t o 1 5

D D D
'Neutral'

zto3 3to4 Kickjown 1 to 2 2to3 3to4 Kick-down4 to 3 3to2 2to1 Closed 4 to 3 ( r o l lo u t ) 3 t o 2 2ro1
test:

15to19 16to20 20 to 24 22 to 26 25 to 33 27 to 35 37 to 45 39 to 47 49 to 57 52 to 60 47to39 50:!42 39 to 31 41 to 33 26to 18 21 to i9 20to16 21to17 14to'1015to11 8to4 9to5
FIG 7 : 10 The governor control rod adjustment 'I Throttle adjustmenl screw 3 Locknut 4 + inch diameter

Check that there is key start in this position onlv. ' 1' t e s t : Manual C o n f i r mt h a t t h e r e i s d r i v e w i t h N O e n g i n e b r a k i n g . '2', '3' and'4' tesr:

K e yt o F i g7 : 1 0 2 G o v e r n o c o n t r o lr o d r rod

Manuaf

C o n f i r m t h a t t h e r ei s d r i v eW I T H e n g i n e b r a k r n g . Automatic drive test: C h e c k t h e s p e e d sa t w h i c h a l l u p - s h i f t st a k e p l a c e a n d compare them with those given ln the Change-speed c h a r tg i v e n e a r l i e r n t h i s S e c t i o n . i Reverse test: C o n f i r mt h a t t h e r e i s d r i v e W I T H e n g i n e b r a k i n g . I n a l l c a s e so f s u s p e c t t r a n s m i s s i o ng e a r s a n d / o r c l u t c h u n i t s a s t a l l s p e e d t e s t s h o u l d b e c a r r i e do u t i n a l l q e a r sr o d e t e r m i n ew h i c h o f t h e c l u t c h u n i t s a n d / o r b r a k J b a n d s is faulty. The mechanical power flow diagrams indicate the components in use for each gear. lf there is slip in all g e a r s a l o w o i l p r e s s u r ei s i n d i c a t e d w h i c h s h o u l d b e c o n , fifmed without delay as detailedin Section 7 :5.

Confirm that the starter operates only with the gear_ 'N' lever at and that the reversing light, when fitted 'R' operates nly when o is selected. l f t h e s w i t c h c a n n o t b e a d j u s t e d t o o p e r a t e c o r r e c t r Vr l must be renewed. Gearchange cable and selector rod: Referto FIG 7:9. Pull back the rubber boot 1 anci r e m o v e t h e c l e v i s p i n 2 . E n s u r et h a t t h e s e l e c t o r r o d 3 i s s c r e w e d i n t i g h t l y a n d p u s h e df u l l y i n t o t h e t r a n s m i s s i o n c a s e . O n l a t e r m o d e l s t h e t r a n s v e r s er o d i s n o t a d i u s t a b l e and is fitted to a pressed-type bell-crank lever. Never start the engine with the selector rod disconnected. Swivel the bellcrank lever arm 7 clear of the selecror r o d y o k e 4 a n d r e f i tt h e c l e v i sp i n . C h e c k t h e m e a s u r e m e n l at A and if not correctslacken the locknut b and turn the yoke until the correct measurementis obtained. Tighten the locknut ensuring tnat the yoke is set square to the b e lIc r a n k Select'N'in the transmission nit by pulling the u s e l e c t o rr o d f u l l y o u t a n d t h e n p u s h i n g i t b a c k b y o n e detent on all transmissions hich have seven posltions w m a r k e do n t h e q u a d r a n to r t w o d e t e n t sw h e n t h e r ea r e s i x p o s r t r o n s T h e m e a s u r e m e n ta t A s h o u l d n o w b e 1 . 4 5 . rn c h . 'N' S e t t h e g e a r l e v e ro t o n t h e q u a d r a n ta n d , u s I n gt h e adlusting nut 6, adjust the outer cable so that the clevis p i n 2 c a n b e e a s i l yi n s e r t e d . a k e s u r e t h a t t h e y o k e e n d s M on the selectorcable and rod are square to the bellcranK lever before reconnecting. On the later types the pro_ cedure is similar except that the cable fork must alrgn w i t h t h e b o r e o f t h e s p h e r i c a lj o i n t i n t h e b e l l - c r a n k l e v e r until the bolt can easily be inserted. T o t e s t t h e a d j u s t m e n t ,a p p l y t h e h a n d - a n d f o o t b r a k e s a n d c h e c k t h a t t h e s t a r t e ro p e r a t e so n l y i n t h e ' N ' p o s i t i o n . lf this is not correct, adjust the inhibitor switch as p r e v i o u s l yd e s c r i b e d . Start the engine, select 'R' and check that reverseis engaged. Slowly move the lever back towards .N,

7:5

Adjustments

Inhibitor switch: This is located on the rearof the gear selectorhousing ( s e e F I G 7 : 8 ) . T h e r e a r e f o u r t e r m i n a l s ,o f w h i c h t w o a r e c o n n e c t e d t h r o u g h t h e i g n i t i o n / s t a r t e rc i r c u i t a n d m a r r e o 2 a n d 4 . T h i s e n s u r e st h a t t h e e n g i n e w i l l s t a r t o n l y w h e n t h e g e a r l e v e r s i n t h e ' N ' p o s i t i o n . T e r m i n a l s1 a n d 3 a r e i for the reversing light when fitted. Before adjusting the switch make sure that the gearchange cable and the selectorrod are correctlyadjusted as detailed later in thls Section. 'N' Select a n d d i s c o n n e c t t h e e l e c t r i c a lc o n n e c t i o n s from the switch. Slacken the locknut and screw the s w i t c h a s f a r a s p o s s i b l eo u t w a r d s . C o n n e c t a t e s t l a m p o r m e t e r a c r o s st h e t e r m i n a l s2 a n d 4 , t h e n s c r e w t h e s w i t c h i n t o t h e h o u s i n gu n t i l t h e c i r c u i t is made and mark the switch body. Continue turning a n w a r d sa n d n o t e t h e n u m b e r o f t u r n s r e q u i r e d t o b r e a k the cifcuit. Remove the test equipment and unscrew the switch by half the number of turns counted. Tighten the l o c k n u t a n d r e f i t t h e c a b l e s t o t h e i r a p p r o p r i a t et e r m i n a l s .

11p0Mk 2 1300

85

F I G 7 : 1 1 C h e c k i n g t h e p r e s s u r e sa n d t h e s t a l l s p e e d w i t h s e r v i c e t o o l 1 8 G . 6 7 7 . 2a n d a d a p t o r 1 8 G . 6 7 7 . C (arrowed) c h e c k i n g t h a t t h e g e a r i s d i s e n g a g e dj u s t b e f o r e o r a s 'N' p o s i t i o no n t h e q u a d s o o n a s t h e l e v e rd r o p s i n t o t h e '1' position. r a n t . R e p e a t t h i s p r o c e d u r ei n t h e f i r s t g e a r t i f n e c e s s a r yo o b t a i n R e - a d j u s tt h e o u t e r c a b l e s l i g h t l y the above conditions. Ensure that all nuts are tight and the clevis pins s e c u r e d .P a c k t h e r u b b e r b o o t s w i t h L a m m o l g r e a s ea n d r e f i t . F i t t h e w e a t h e r s h i e l d i f a p p l i c a b l e C a r r yo u t a r o a d . r i t e s t ,c h e c k i n gt h e o p e r a t i o n n e a c h g e a r l e v e p o s i t i o n . Governor control rod adjustment: a R u n t h e e n g i n e u p t o n o r m a lw o r k i n g t e m p e r a t u r e n d disconnectthe governor control rod at the carburetter ( s e e F I G 7 : 1 0 ) . W i t h t h e c a r b u r e t t e rc o r r e c t l y t u n e d adjust the throttle screw 1 to give a tachometerreadingof 650 rev/min at tickover. I n s e r ta j i n c h d i a m e t e rr o d 4 t h r o u g h t h e h o l e i n t h e g o v e r n o r c o n t r o l r o d b e l l c r a n kl e v e r a n d i n t o t h e h o l e i n t h e t r a n s m i s s i o n a s e .S l a c k e nt h e l o c k n u t 3 a n d a d j u s t c t h e l e n g t h o f t h e r o d t o s u i t t h e c a r b u r e t t e lri n k a g ei n t h e t i c k - o v e rp o s i t i o n . R e c o n n e c t t h e c o n t r o l r o d t o t h e c a r b u r e t t e r .T i g h t e n t h e b a l l j o i n t l o c k n u t a n d r e m o v et h e c h e c k i n gr o d . Stall speed check: a R u n t h e e n g i n e u p t o n o r m a lw o r k i n g t e m p e r a t u r e n d . c h e c k t h e o i l l e v e l .C o n n e c t a s u i t a b l et a c h o m e t e r A p p l y the foot and hand brakes, select any gear position

FIG7 :12

R e m o v i n gt h e d i f f e r e n t i a l a s s e m b l y

e x c e p t ' N ' o r ' 1 ' , g i v e m a x i m u m t h r o t t l ef o r n o t m o r e t h a n t e n s e c o n d s a n d n o t e t h e t a c h o m e t e rr e a d i n g .c o m p a r e t h e f i g u r eo b t a i n e dw i t h t h e t a b l e b e l o w : Pressure check: C h e c k a n d t o p u p t h e o i l l e v e l .R e m o v et h e p r e s s u r e p o i n t p l u g o n t h e e n g i n eo i l f i l t e ra n d c o n n e c t a p r e s s u r e gauge reading to 2BO lb/sq inch. FIG 7 :11 shows . s e r v i c e o o l 1 8 G . 6 1 1 Z a n d a d a p t o r1 8 G . 6 7 7 . Ci n u s e . t R u n t h e e n g i n e u n t i l t h e o i l t e m p e r a t u r ei s 8 0 o C o r 1 7 6 o F .t h e n r u n i t a t ' 10 0 0 r e v / m i n a n d c h e c k t h e f o l l o w p in g a p p r o x r m a t e r e s s u r e s : 1 I n a l l g e a r p o s i t i o n se x c e p t ' R ' a p r e s s u r e f 9 5 t o 1 0 5 o lbisq inch. 'R' t h e p r e s s u r es h o u l d b e b e t w e e n 1 4 3 2 In position a n d 15 7 l b / s q i n c h e x c e p t w h e n t h e e n g a g e m e n t control device is fitted when 162 to 118 lb/sq inch should be registered. p a l f t h e s e a p p r o x i m a t e r e s s u r e s r e n o t o b t a i n a b l es e e Section 7 :3. 7 :6 Removing the transmission unit: T h e e n g i n e a n d t r a n s m i s s i o na s s e m b l y i s r e m o v e d f r o m t h e c a r a s i n s t r u c t e di n C h a p t e r 1 , b u t t h e t r a n s f m i s s i o ns h o u l d b e s e p a r a t e d r o m t h e e n g i n e o n l y i f i t i s c t n e c e s s a r yo f i t a r e p l a c e m e ne n g i n e ,t r a n s m i s s i o n a s i n g t o r t o r e m o v et h e m a i n o i l s t r a i n e rp i c k u p p i p e a n d s e a l s . Rectif ication

Model 10 9 8c c 1275cc Both

Revlmin 1600 to 1700 1700 to 1800 U n d e r10 0 0 O v e r19 0 0 U n d e r16 0 0

Condition Satisfactory Satisfactory S t a t o r f r e e w h e e ls l i p s Transmission lip

C h a n g et o r q u e c o n v e r t e r u C h e c k t r a n s m i s s r o n n i t ( s e ef i n a l n o t e i n S e c t i o n 7:4) E n g i n ed o w n f o r p o w e r C h e c k e n g i n e

86

@@@

F - l G7 : 1 3

The differential components. The arrow indicates the alignment slot in the spacer

7:7

Servicing the differential assembly

R e fi t t i n g : l R e fi t t h e d i f f e r e n t i au n i t i n t o t h e t r a n s m i s s r o c a s ea n d n p u s h t h e a s s e m b l v o w a r d s t h e c o n v e r t e rw i t h t h e s l o t i n t , t h e s p a c e r( a r r o w e di n F I G 7 : 1 3 ) i n a l i g n m e n w i t h t h e t dowel in the casing. Fit a new joint washer coated with Hylomar comp o u n d . E n s u r e h a t t h e o i l s e a l i s p r e s s e d q u a r e l ya g a i n s t t s t h e f a c e o f t h e s p a c e ra n d r e f i t t h e d i f { e r e n t i ah o u s i n g , l f i t n e w l o c k i n g p l a t e sa n d l i g h t l yt i g h t e nt h e s e c u r i n gn u t s . Adjustment: R e fi t t h e e n d c o v e r w i t h o u t a j o i n t w a s h e r b u t w i t h t h e original shims. Tighten the cover bolts evenly just s u f f i c i e n t l yf o r t h e c o v e r r e g i s t e rt o n i p t h e o u t e r r a c e o f t h e b e a r i n g ; v e r t i g h t e n i n g r l l d i s t o r tt h e f l a n g e . o w T a k e f e e l e r g a u g e m e a s u r e m e n t sa t v a r i o u s p o i n t s b e t w e e n t h e c o v e r f l a n g e a n d t h e h o u s i n gt o e n s u r et h a t the cover bolts are evenly tightened all round, and a d l u s ta s r e q u i r e db u t b e w a r eo f o v e r t i g h t e n i n g . T h e c o m p r e s s e d h i c k n e s so f a n e w c o v e rl o i n t w a s h e r t i s . 0 0 7 i n c h a n d t h e r e q u i r e dp r e l o a do n t h e b e a r i n g sr s . 0 0 2 i n c h . T h e c o r r e c tg a p i s t h e r e f o r e . 0 0 9i n c h a n d a n y d e v i a t i o n f r o m t h i s f i g u r e m u s t b e c o r r e c t e db y a d d i n g

Removal: Removethe engine and transmissionrom the car as f d e t a i l e di n C h a p t e r 1 . D r a i n t h e o i l f r o m t h e a s s e m b l y . U s e s e r v i c e o o l 1 8 G . 11 0 0 t o h o l d t h e d r i v i n gf l a n g e sa n d t r e m o v e t h e c e n t r es e c u r i n g b o l t s .W i t h d r a w t h e f l a n g e s fro:n the solined shafts. K n o c k b a c k t h e l o c k w a s h e r sa n d r e m o v e t h e n u t s f r o m t h e f i n a l d r i v e h o u s i n g . R e m o v e t h e s e c u r i n gs c r e w s a n d p u l l t h e k i c k - d o w n l i n k a g e d s s e m b l yc i e a r o f t h e t r a n s m r s s t o nc a s e . Remove the two setscrews securing the end cover to t h e t r a n s m i s s i o n n d r e m o v et h e f i n a l d r i v e a n d h o u s i n g a a s s e m b l y ( s e e F I G 7 : 1 2 ) . R e m o v e t h e r e m a i n i n gb o l t s f r o m t h e e n d c o v e r a n d r e m o v et h e c o v e r a n d t h e a d i u s t ment snlms.

Dismantling: R e m o v e t h e d i f f e r e n t i a la s s e m b l y f r o m t h e c a s i n g . Withdraw the oil seal housing and removethe bearings w i t h s e r v i c et o o l 1 8 G . 2 . U n l o c k a n d r e m o v et h e b o l t s s e c u r i n gt h e d r i v e g e a r t o the differential case after marking both parts to ensure correct refitting. Lift out the drive gear and remove the d i f f e r e n t i ag e a r a n d t h e t h r u s t w a s h e r l Tap out the roll-pin and remove both pinions and t h r u s t w a s h e r s ,p i n i o n s p a c e r a n d t h e o t h e r d i i f e r e n t i a l gear and thrust washer.

Inspection: T h o r o u g h l y c l e a n a n d c h e c k a l l c o m p o n e n t sf o r w e a r and fit new parts where necessary. lt cannot be too s t r o n g l ye m p h a s i z e d h a t a b s o l u t ec l e a n l i n e s ss e s s e n I | a r . t i lf any component has been so worn or damaged that s w a r f h a s b e e n i n t r o d u c e di n t o t h e l u b r i c a t i o n y s t e mt h e s a u t o m a t i ct r a n s m i s s i o n u s t b e r e m o v e da n d d i s m a n t r e o m by a servicestation.This also applies when frtting a r e p l a c e m e nd r i v e g e a r p i n i o n i n t o t h e t r a n s m i s s i o n n i t . t u

,/

Reassembling: T h i s i s a r e v e r s a o f t h e d i s m a n t l i n gp r o c e d u r e .M a k e l sure that the differentialgear thrust washers are refitted w i t h t h e i r c h a m f e r e db o r e s a g a i n s t t h e m a c h i n e d f a c e s o f t h e d i f f e r e n t i a g e a r s . E n s u r ea l s o t h a t a l l c o m p o n e n t s l a r e r e t u r n e d t o t h e i r o r i g i n a l p o s r t i o n s .T h e d r i v e g e a r b o l t ss h o u l d b e t i g h t e n e dt o a t o r q u e o f 5 5 t o 6 0 l b f t .

FIG 7:14 assembly

The correct position of the kick-down

rod

1 1 0 0M k 2 1 3 0 0

81

g
l0

t3 20

Inset A shows the reverse return spring location' B forgedFIG 7:1 5 The selector lever housing and cable components. bellcrank lever connection" ani C connections for pressed-type iype bellcrank 5 R u b b e rt e r r u i e s 4 Yoke 3 Pivol oin nut s l e e v e( e a r l y m o d e ^ l s ) 1 Bubberbellows 2 Rubber Key to Fig 7:15 12 Gear selector 11 Ouadrant 10 ileverse return iprrnq 9 Spacer 8 Cable 'i? 7 Cable 6 Cable sleeve switch housrng 17 lnhibitor ihange "airrti"g *urn", uu.J'iiji"' " r t . auJ.ir-.,1" r-s i6itii*u.r'"i norring 16 Gear

rever 13 Joint plunger housing 20 Lever grommet roai"i'if""ue(futut-tioa"f.) 19 Rubber 8 (earty rype) '1 Sprrng

F I G 7 : 16 T h e r e s e r v o i rf i t t e d u p s i d e - d o w no n t h e o u t iio-" ot irtt Caiing witn the marked line shown through oi the-securing lug. The arrow indicates the ift. d r i l l" L n tl.o c a t i o n .A : 3 S i n c h e s ing "

or subtracting shims. For example, if the feeler gauge measurementis .005 inch, a shim of 004 inch must be a d d e d b e t w e e n t h e b e a r i n ga n d t h e e n d c o v e r ' Later assemblies are fitted with increased thrust capacity bearings, which must be fitted with the word T H R U S T f a c i n g t h e o u t s i d et o w a r d s t h e e n d c o v e r 'T h e p r e l o a d i s i n c r e a s e dt o . O O 3t o 0 0 4 i n c h s o t h a t i t w i l l b e n e c e s s a r yt o a d j u s t t h e g a p w i t h s h i m s u n t i l i t i s 0 1 1 i n c h b e fo r e t h e j o i n t w a s h e r i s f i t t e d . Remove the end cover, fit the selectedshims and refit the cover with a new washer coated with Hylomar compound. Tighten the nuts and cover bolts to a torque o f 1 8 l b f t . T a p u p a l l l o c k i n g p l a t e t a b s ,e x c e p t f o r t h a t o n t h e n u t w h i c h s e c u r e st h e e x h a u s t p i p e b r a c k e t ,w h i c h i s f i t t e d a f t e r t h e e n g r n e i s r e p l a c e di n t h e c a r ' Lubricate the driving flange oil seals and refit the flanges making sure that the split collets are correctly l o c a i e d i n s i d e . F i t n e w r u b b e r s e a l st o t h e c e n t r a l s e c u r i n g

88

bolts and tighten them to a torque of 40 to 45 lb ft while h o l d i n g t h e f l a n g e sw i t h s e r v i c et o o l 1 8 G . 3 7 2 . . Refit the governor control linkage to the transmission case with a new washer. Referto FIG 7 : 14 for guidance in ensuring that the lever is correctly positioned relative to the governor. The engine and transmissionunit is refitted to the car a s d e t a i l e di n C h a p t e r 1 . 7 : 8 S e r v i c i n g t h e g e a r c h a n g e c a b l e ( s e eF t G 7 : 1 5 ) Remove the'weather protection cover, when fitted, from the converter housing and pull back the ruboer sleeve 2 and: disconnecl the gearchangecable 8 by r e m o v i n gt h e c l e v i s p i n f r o m t h e y o k e 4 a n d u n s c r e w r n g t h e y o k e a f t e r s l a c k e n i n gt h e l o c k n u t . R e m o v e a l s o t h e s l e e v e ,r u b b e r f e r r u l e s 5 a n d t h e c a b l e s l e e v e 6 . R e m o v e t h e f r o n t a d j u s t i n gn u t o f t h e t w o s h o w n a t 7 a n d p u l l t h e c a b l ec l e a ro f t h e h o u s i n gl u g R e l e a s et h e c a b l e c l i p f r o m t h e f l o o r p a n e l a n d r e m o v e the front floor covering. Disconnect the electrical leaos f r o m t h e i n h i b i t o rs w i t c h ( s e e F I G 7 : 8 ) . Remove the four nuts securing the gearchange housing plate to the floor panel and remove the housing and cable assembly. Dismantling: Hold the assembly in a vice and remove the screws securing the quadrani to the housing. Release the reversereturn spring from the base of the housing and remove the quadrant and lever assembly. Unscrew the cable securing nut from the front of the h o u s i n ga n d r e l e a s e h e c a b l e f r o m t h e g e a r c h a n g e e v e r t l plunger 20. Reassembling: Clean and inspect all parts for wear or damage. Lubricate all moving parts with grease and reassemble i n t h e r e v e r s eo r d e r t o d i s m a n t l i n g .R e f e r t o F I G 7 : 1 5 t o e n s u r e t h a t t h e g e a r s e l e c t o r l e v e r 1 2 i s r e t n s e r t e dI n t o t h e r e l i e v e ds i d e o f t h e p l u n g e r 2 0 . Ref itting: T h i s i s t h e r e v e r s eo f t h e r e m o v a l s e q u e n c e , f i t t i n g a n e w j o i n t w a s h e r t o t h e h o u s i n g p l a t e i f n e c e s s a r yA d j u s t . the inhibitor switch and the gearchange cable and s e l e c t o rr o d a s d e t a i l e d i n S e c t i o n 7 : 5 .

FlGT:17 reservorr

The fitted position of the idler gear bearrng 1 Reservoir

Key to Fig 7:17 3 Springwasher

2 Securing screw

7 :9 ldler gear lubrication reservoir The lubricatron of the idler gear bearing has been r m p r o v e d o n l a t e r t r a n s m r s s i o nu n i t s b y i n c o r p o r a t t n g a 'cast i n ' o i l r e s e r v o i ra n d i t i s r e c o m m e n d e d t h a t e a r l i e r units should be modified by fitting a separate reservorr as described below. R e m o v e t h e e n g i n e a n d t r a n s m i s s i o nu n i t f r o m t h e c a r and separate the transmission from the engine as d e s c r i b e di n C h a p t e r 1 . R e f e rt o F I G 7 : 1 6 . M e a s u r ed o w n f r o m t h e j o i n t f a c e on the outside of the casing 3ii inch as at A and mark a horizontal lrne as shown dotted. Place the reservolr upside down on the outside of the casing with its securing lug Iocated in the bore of the idler gear bearing and with its securing lug centrally over the dotted h o r i z o n t a ll i n e . M a r k t h r s p o s i t i o n , i n d i c a t e d b y t h e a r r o w , a n d p a s s a $ i n c h d r i l l t h r o u g h t h e c a s i n g .A p i e c e o f P l a s t r c i n es h o u l d b e p l a c e d i n s i d e t o t r a p a n y s w a r f . T h e r e s e r v o i rc a s t i n g m a y b e s m o o t h e d d o w n w i t h a f i l e i f n e c e s s a r yt o e n s u r e a s n u g f i t . Smear the reservoirspigot with Hylomar compound, a n d f i t t h e r e s e r v o i r s s h o w n i n F I G 7 : 1 7 . T i g h t e nt h e a securing bolt. Do not remove the circlip on the idler gear b e a nn g . R e f i t t h e t r a n s m i s s i o nu n i t t o t h e e n g i n e a n d t h e w h o l e a s s e m b l yt o t h e c a r a s d e s c r i b e d i n C h a p t e r 1 .

1100Mk21300

89

CHAPTER 8 DRIVE SHAFTS AND SUSPENSION

8 : 1 Drive shaft description 8 : 2 Maintenance 8 : 3 Servicing bell joints 8 : 4 The sliding joint 8 : 5 Flexible drive couplings 8 : 6 Universal joints 8 : 7 Offset sphere plunge joints 8 : 8 The Hydrolastic suspension 8 : 9 Suspension lubrication 8 : 1 0 Servicing the suspension system
8 : 11 8 : 12 8 :13 8 :14 8 :15 8 :16 8 :17 8:18 8 :19 Servicing the hubs The arch spring Steering angles The subf rames Displacer units Radius arms Swivel hubs Anti-roll bar and auxiliary springs Fault diagnosis

8 :1 Drive shaft description T h e c o m p o n e n t s o f t h e f r o r r t s u s p e n s i o na n d d r i v e s h a f t a s s e m b l i e s r e c l e a r l ys h o w n i n F I G 8 : 1 . l t w i l l b e a seen that the drive shaft 74 has. at its outer end. the constant velocity bell joint which is protected by the rubberboot 75, and at its innerend the couplingflange 7 6 w h i c h i s c o v e r e db y t h e s e a l J 7 o v e r t h e s p l i n e dj o i n t . T h e h e m i s p h e r i c a li n t e r i o r o f t h e H a r d y S p i c e r b e l l joint and the exterior of the inner ballrace have six groovesmachinedin line with the shaft axis and a ball cage carrying six steel balls is interposed between the two. The steel balls engage the grooves of both members to key them together and at the same time to allow,the members to hinge freely upon each other. Both the joint a s s e m b l ya n d t h e s p l i n e d s l i d i n g a r e p a c k e d w i t h g r e a s e a n d , a s m e n t i o n e d .e n c l o s e d i n r u b b e r b o o t s . 8:2 Maintenance of drive shafts

a s s e m b l y f o r i n s p e c t i o n .l f a b o o t i s d a m a g e d i n t h e c o u r s e o f w o r k s h o o o D e r a t i o n sa n d n o d i r t h a s e n t e r e d the joint a new boot may be fitted as described in Section 8:3 without dismantlingthe joint, although the drive shaft must be removed from the car and the s l i d i n gj o i n t r e l e a s e dT h e b e l l j o i n t m u s t b e p a c k e d w i t h . D u c k h a m ' sM B g r e a s e( B M C p a c k A K F 1 4 5 7 )

8:3

Servicing bell joints

The rubber boots enclosing the constant velocity j o i n t s s h o u l d b e e x a m i n e dp e r i o d i c a l l y n d i f t h e r e i s a n y a s i g n o f d a m a g e o r d e t e r i o r a t i o nt h e y s h o u l d b e r e n e w e d without delay. l f a b o o t b e c o m e sf a u l t y l u b r i c a n tw i l l b e l o s t a n d g r i t f r o m t h e r o a d w r l l e n t e rt h e j o i n t . l t w i l l t h e n b e n e c e s s a r y to remove the joint from the shaft and to dismantle the

T h e c o n s t a n t - v e l o c i t b e l l j o i n t sm a y b e r e m o v e de i t h e r y for replacementas a unit or to have a service kit fitted. U n d e r n o c i r c u m s t a n c e sm a v i n d i v i d u a l c o m o o n e n t s i b e r e p l a c e d n t h e b e l lj o i n t a s s e m b l y . After removing the drive shaft (see Section 8:17) c l e a n i t c a r e f u l l y n d m o u n t r t c e n t r a l l yi n a v i c e a n d h e l d a between soft jaws. Priseoff the clips holding the rubber bootsas shown in FIG 8 :2 and pull back the boot. The bell joint is removed from the shaft by holding the a s s e m b l yv e r t i c a l l ya s s h o w n i n F I G 8 : 3 a n d g i v i n g t h e edge of the outer racea sharptap with a soft faced mallet. This should contract the round section spring located rn a deep groove at the extreme end of the shaft and enable t h e j o i n t t o b e d r a w n f r o m t h e s h a f t . .l t s h o u l d n o t b e n e c e s s a r yt o u s e h e a v y b l o w s f o r t h i s o p e r a t i o n .

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Dismantling: The joint should be dismantled only if it is considered t h a t i t i s s t i l l i n a s e r v i c e a b l ec o n d i t i o n , o t h e r w i s e a n e w unit should be fitted. Since the various componenls aIe mated and have operated together it is important that they should be reassembled in the same relative positions. Before dismantling, therefore, mark the relative positions of the inner and outer races and the cage with paint or a m a r k e rw h i c h w i l l n o t w a s h o f f d u r i n g c l e a n i n g . W h e n t h e s h d T th a s b e e n w i t h d r a w n t h e i n n e r r a c e i s free to swivel and should be tilted until one ball is released s shown in FIG 8:4. lf the joint is stickythe a ball may be eased out with a suitable pointed tool. Removeeach ball in turn. Swivelthe cage into line with the axisof the joint until two opposite elongated windows coincide with two l a n d so f t h e b e l l j o i n t a s i n F I G 8 : 5 . O n e l a n d w i l l f a l l i n t o a window allowing the cage and race assembly to be lifted out, Now swivel the inner race at right angles to the cage as shown in FIG 8:6 and rotateuntil two of the lands between the inner race tracks are opposite elongated windows in the cage. One land will drop into a window and allow the inner race to be withdrawn from the cage. Clean all parts in petrol or paraffin and dry. In normal service the wear will be distributed evenly over all the u componentsand the joint will remain serviceable ntil t h e a m o u n t o f e n d f l o a t e x c e e d st h e a c c e p t a b l e m a x i m u m of .025 inch. Examine the six balls, and if they are worn, pitted or show signs of flattening the joint must be renewed. The inner and outer race tracks will be marked where the balls roll, but should be free from indentation and the marking should be consistent. The inner and outer surfaces of the cage and the corresponding surfaces of the inner and outer races should appearpolished but freefrom any signs of picking

FIG 8:3 Drive the bell joint from the shaft at the point ind icated

FIG 8:2

Fitting the clinching clips FIG 8:4 Tilt the inner race to remove or replace each ball in turn

Key to Fig 8 :2 1 Pull rhe freeend tighrlybetweenrhe tabs 2 Hold in position and secure wilh {ronl tabs 3 F o l d c l i p b a c k o v e r t h e f o l d e d t a b s a n d s e c u r et h e c l i p e n d

11 0 0M k 2 1 3 0 0

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Renewing the ball cage: A worn ball cage should be replaced by a service kit. t S r n c ea j o i n t w i l l o n l y a c c e p t a r e p l a c e m e n c a g e o f t h e l s a m e s i z e a s t h e o r i g i n a li t r s e s s e n t i at o c h e c k t h e s i z e of the existing cage with the servicetool ring gauge 1 8 G . 1 0 1 . A s i t i s d i f f i c u l t t o m e a s u r et h e i n s i d e o f t h e 2 cage, the outside of the race which fits inside it is measuredinstead. The larger bore of the gauge will accept a standard s i z e d c a g e . b u t w i l l r e j e c t a n o v e r s i z e do n e ; s i m i l a r l y the smaller bore will acceot onlv a standard sized race. ( a ) l f b o t h t h e c a g e a n d t h e i n n e r r a c e p a s st h r o u g h t h e i r r e s p e c t i v eb o r e s t h e c a g e i s a s t a n d a r d s i z e . ( b ) l f t h e c a g e w i l l n o t p a s s t h r o u g h t h e l a r g e rb o r e , b u t t h e r a c e d o e s p a s s t h r o u g h t h e s m a l l e r ,t h e n t h e c a g e - i s . 0 10 i n c h o v e r s i z eo n t h e o u t s i d e . ( c ) l f n e i t h e rt h e c a g e n o r t h e r a c e i s a c c e p t e d b y t h e gaugethe joint must be replaced s a untt. a T h e s e r v i c e k i t s a r e a v a i l a b l ea s f o l l o w s : Part No. Colour code 18G.8175 Green Standard size 18G.8176 . 0 10 i n c h o v e r s i z e B l a c k

F I G8 5 ioint

Removing the cage and inner race {rom the bell

Reassembling: T h i s i s a r e v e r s a lo f t h e d i s m a n t l i n g p r o c e d u r e a n d a l l parts should go togethereasily and without any force r b q u i r e d A l l t h e c o m p o n e n t ss h o u l d b e l i g h t l y I u b r i c a t e d . w i t h D u c k h a m s B e n t o n e g r e a s e( B M C p a c k A K F . 1 4 5 7 ) . I n s e r tt h e i n n e r r a c ei n t o t h e c a g e i n t h e a t t i t u d es h o w n i i n F I G 8 : 6 a n d t h e n i n s e r tt h i s a s s e m b l y n t o t h e b e l l j o i n t by fitting one of the elongated windows over one of the lands in the outer race as in FIG 8:5. The three comD o n e n t sa r e n o w f r e e t o t u r n i n r e l a t i o nt o e a c h o t h e r .

t
FIG 8:6 Removing the inner race from the cage

up'. The edgesof the cage windows may show signsof w e a r t o w a r d s t h e o u t e r s i d e ; t h i s i s n o t s e r i o u s ,b u t m a y c a u s e s o m e k n o c k i n g w h e n t h e j o i n t i s o p e r a t e da t h i g h a n gl e s . C a r e f u l l ye x a m i n et h e s h a f t f o r c r a c k sa n d e n s u r et h a t the square section outer circlip shown in FIG 8:7 is f i r m l y l o c a t e di n i t s g r o o v e

FIG 8:7 Splined end of drive shaft showing circlip and spring ring

94

L o c a t et h e c a g e a n d i n n e r r a c e i n t h e i r o r i g i n a lp o s i t r o n relative to the bell joint as previously marked, then tiit t h e c a g e u n t i l o n e b a l l c a n b e i n s e r t e di n a w i n d o w a n d | e p e a tw i l h t h e r e m a i n i n q i v e b a i l s ( s e e F I G 8 : 4 ) . E n s u r e f i h a t t h e i n n e r r a c e a r t i c u i a t e sl r e e l y w i t h t i - r ec a g e i n t h e b e l l i o i n t , b u t t a k e c a r e n o t t o r e l e a s et h e b a ! ! s . Fili the joint with the remainder of the grease pack before insertingthe drive shaft. R e fi t t i n g : Fit a new fibber boot if necessary, meanng tle Insrde s w i t h t h e g f e a s e .T a k e c a r e w h e n e a s i n g t h e b o o t o v e r t h e c i r c l i p o n t h e s h a f t . R e n e w t h e r o u n d s e c t i o ns p r i n g r i n g . l f r e n e w i n gt h e s h a f t .f i t a l s o a n e w c i r c l i p ( s e e F I G 8:7). H o l d t h e s h a f t i n a v i c e a n d l o c a t et h e i n n e r r a c e o n i t . P r e s st h e l o i n t a s s e m b l ya g a i n s t t h e s p r i n g r i n g , w h i c h s h o u l d b e c e n t r a l l yl o c a t e d a n d s q u e e z e di n t o t h e c h a m f e r i n t h e i n n e r r a c e .A s h a r p t a p o n t h e e n d o f t h e s t u b s h a f t with a soft faced mallet will close up the ring end allow t h e a s s e m b l yt o b e t a p p e d o n t o t h e s h a f t . M a k e s u r e t h a t t h e i n n e r r a c ei s h a r d a g a i n s tt h e c i r c l i pa n c it h a t t h e s p n n g r i n g h a s e x p a n d e di n s i d et h e 1 o i n t . Slide the rubber boot over the bell joint until the r a d i u s e d r i b r e g i s t e r si n t h e l o c a t i n g g r o o v e a n d s e c u r e i t w i t h t h e l a r g ec l i n c h i n gc l i p u s i n g s e r v i c e o o l 1 8 G . 10 9 9 t a s s h o w n i n F I G 8 : 2 . T h e c l i p i s f i t t e dw i t h r h e t a b p u l r e o through away from the direction of forward rotation. T h e o t h e r e n d o f t h e b o o t i s l o c a t e di n t h e g r o o v e i n t h e d r i v e s h a f t a n d s e c u r e dw i t h t h e s m a l l c l i n c h i n gc l i p . The latertype of rubber boot, having axial convolut i o n s ,s h o u l d b e f i t t e d w h e n a r e p l a c e m e n t s n e e d e d . i 8 :4 The sliding joint After removing the drive shaft assembly remove the clipsf rom the rubberseal 77 in FIG 8 :1, then slide off the sealand removethe flange 76. B e f o r e c o m m e n c i n g t o r e a s s e m b l et h e j o i n t l u b r i c a t e the yoke end of the drive shaft and the insideof the yoke h o u s i n g s e a l a n c is l i d e t h e s e a l r n t o p l a c e . F i l l t h e c a v i t y i n t h e y o k e w i t h j o z o f D u c k h a m s O 6 3 8 3 g r e a s ea n d f i t t h e f l a n g et o t h e s h a f t . Fit the seai into the groove on the shaft at one end and a t t h e o t h e r o v e r t h e s l e e ' r el o c a t i o n . P u s h t h e s h a f t t o t h e b o t t o m o f t h e f l a n g e s o t h a t t h e g r e a s ei s d r i v e n b a c k i n t o the seal.Hold the outer lip of the seal open to allow arr a n d s u r p i u sg ! ' e a s eo e s c a p e . h e o u t s i d ed i a m e t e ro f t h e t T b e l l o w sm u s t n o t e x c e e d1 . 7 5 i n c h . S e c u r et i r e f l a n q es e a r w i t h c l i n c h i n gc l i p s .
FIG 8 :8

oemCI
Components of a universal joint 3 Needle Key to Fig 8 :8 1 Journal spider 2 Rubber seal rollers 4 Bearing race 5 Circlip

i i i i

FIG 8:9 Using Service tool 18G.1243 to extract the drive shaft from the plunge joint Key to Fig 8:9 3 T a p e r e dp i n lornt 1 P l u n g ej o i n t b o s s 2 Tr:olbody 4 Stop plate 5 D r r v es h a f t 6 Plunqe

8 :5 Flexibledrive couplings Removal: Jack-up the front of the car, placestandsrn position a n d r e m o v et h e a p p r o p r i a t e o a d w . h e e i . r R e m o v e t h e r e t a i n i n g n u t a n d l o c k w a s n e r t r o r r rr . ! i e l o w e r s u p p o r t a r m , 8 9 i n F I G 8 : 1 , a n d r e i e a s et h e . f n i f r o m t h e b a l l p i n u s i n g S e r v i c et o o l 1 8 G . 1 0 6 3 t o f ; ' e ei h e lower end of the swivel hub assembly. R e m o v e t h e s e l { - l o c k i n gn u t s f r o m i h e i o u r U - b o l t s . pull the swivel hub and drive shaft asseirrbly utlvarCs o and remove the drive coupiing fi'om the dr:ving flange yoke.

R e fi t t i n g : I t r s p o s s i b l e o u s e i h e o r i g i n a lU - b o l t s , b u t m a k e s u r e t t h a t t h e y h a v e n o t d i s t o r t e db e t o r e f i t t i n g t h e m . , A l w a y s use now self lockingnuts. F i t a n e w r u b b e rd r i v e c o u p l i n g t o t h e d r i v i n g f l a n g e y o k e , f i t t h e i o w e r e n d o f t h e s r , v i v eh u b a s s e m b l y o t h e l t i o w e r s u p p o r t a r r n ,a t t h e s a m e t i m e e n g a g i n g t h e d r r v e ; s h a { t y o k e r n " , i ,t h e c o u p l i n g . T i g ; h t e n h e :r e t a i n i n gn u t o n t h e b a i l p i n t o a t o r q u e o f t 35 to 4;1ib {t T r q h t e n i h e n e w n u t s o n t h e U , b o l t s e q u a l l y .W i t h i n s e r i - t ' v p e t i f i n L r t s 1 oi n c h ( 1 . 6 m m ) o f t h r e a d s h o u l d s , remain prolrdrng fror-nthe nuts. Wrth the thinner

1100Mk21300

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drive. showing the correct position forthe fulcrum ofthe tool A and the direction of the hammer blows reouired

B e fo r e c o m m e n c i n gt o d i s m a n t l et h e j o i n t c l e a n o f f a l l g r e a s ea n d r o a d d i r t . R e f e rt o F I G 8 : 8 . R e m o v e t h e r e t a i n i n gc i r c l i p s ,t a p p i n g o n t h e e n d o f the raceif the clip is trapped. S u p p o r tt h e u n c i e r . s i d e t h e y o k e a n d t a p t h e r a d i u so f o{ t h e y o k e w i t h a s o f t m a l i e tw h e n t h e b e a r i n gr a c e s h o u l d e m e r g e .C l a m p t h e r a c e i n t h e v i c e a n d t a p t h e u n d e r s i d e of the yoke until the raceis extracted. R e p e a t t h e p r o c e d u r et o e x t r a c t t h e r e m a i n i n g t h r e e b e a r i n gr a c e sa n d t h e n w i t h d r a w t h e j o u r n a i s p i d e rf r o m the yoke of the driveshaft. Wash all parts thoroughly and examinefor signs of d a m a g e o r e x c e s s i v e e a r . F i t a r e p a i rk i t i f a n y o f t h e w c o m p o n e n t sa r e d e f e c t i v e . S m e a rt h e i n n e r r a c e w a l l s a n d t h e n e e d l e r o l l e r sw i t h g r e a s ea n d p a c k a d e p t h o f ] i n c h o f g r e a s ei n t h e e n d o f each race. I n s e r tt h e s p i d e r i n t o t h e y o k e . U s i n g a s o f t d r i f t s l i g h t l ys m a l l e rt h a n t h e r a c e t a p t h e f i r s t r a c e r n t o p o s i t i o n ,h o l d i n g t h e s p i d e ri n t o t h e r a c e s o a s t o r e t a i nt h e n e e d l er o l l e r si n p l a c e . Repeat on the opposite srde of the yoke and then e n g a g e t h e o t h e r j o u r n a l o v e r t h e s p i d e r a n d r e p e a tf o r t h e t w o r e m a r n i n gb e a r r n g s . F i t t h e c i r c l i p sa n d m a k e s u r e t h a t t h e y a r e f u l l y s e a t e d i n t h e i r g r o o v e s .l f a l o i n t a p p e a r st o b t n d , a l i g h t t a p o n t h e l o u r n a l sw r l l r e l i e v ea n y p r e s s u r e n t h e r a c e s . o Fit a new rubber boot and fill it with Duckham's O.6383 grease and complete the operation in the reverse rderof dismantling. o

8 :7 Offset sphere plunge joints Removal: Jack up the front of the car, support on standsand r e m o v et h e r o a d w h e e l s . R e l e a s et h e s t e e r n g t i e r o d f r o m t h e s t e e r i n g a r m , u s i n g S e r v i c et o o l 1 8 G . 1 0 6 3 ,t h e n u n l o c k a n d u n s c r e w t h e n u t s e c u r i n gt h e t o p s w i v e l h u b b a l l j o i n t . R e l e a s e h e t b a l l l o i n t f r o m t h e u p p e r s u s p e n s i o na r m a n d s u i t a b l y s u p p o r tt h e s w i v e l h u b a s s e m b l y . R e f e r o F I G I : 9 . F i tr h e b o d y o f t h e t o o l ( 1 8 G . 1 2 4 3 ) t round the drive shaft with its taperednose hard against t h e b o s s o f t h e i n n e r m e m b e ro f t h e p l u n g e. 1 o i na n d t h e n t f i t t h e t a p e r e dp i n . F i t t h e s t o p p l a t e1 o t h e c h a n n e l i n t h e shaft and tighten the two screws until the shaft is p u l l e d o u t f r o m t h e j o i n t . D i s m a n t l et h e t o o l a n d m o v e the driveshaftout of the way. '1 i t w i l l b e n e c e s s a r yn e x t t o u s e t o o l 8 G . 1 2 4 0 , a s s h o w n i n F I G 8 : 1 0 t o u n l o c kt h e p l u n g ej o i n t f r o m t h e f i n a l d r i v e ,p l a c i n gt h e f u l c r u m s i d e o f t h e t o o l a g a i n s tt h e dilve. P i a c e a s u i t a b l e v e s s e l b e l o w t h e t r a n s m i s s i o nt o c a t c h t h e o i l a n d r e m o v et h e p l u n g e j o i n t . L e v e ro f f t h e o u t e r c l i p a n d r o l l b a c k t h e r u b b e r b o o t , w r t h d r a w t h e i n n e r m e m b e ro f t h e j o i n t a n d t h e b a l l - c a g e a s s e m b l yf r o m t h e o u t e r m e m b e r , l e v e r o f f t h e i n n e r c l i p anii renrovehe boot i P i i s e c u t t h e b a l l s a n d t h e n r o t a t et h e b a l l - c a g eu n t i l t h e i n t e r n a !J i ( ) o v e sc o i n c i d e w i t h t h e l a n d s o n t h e i n n e r n r e m b e ra n d s e p a i a t et h e m C l e a na l l t h e p i e c e sa n d c a r e f l l y e x a m i n et h e m f o r w e a r u o r d a m a g e . l f a n y c o m p o n e n t i s f a u l t y , a c o m p l e t ej o i n t must be obtarned.

FIG 8:11

F i t t i n gt h e r u b b e rb o o t

K e yt o F i g8 : 1 1 1 Boot 2 Inner ember 3 Mandrel m 4 18G.1251 5 Endlessip cl d e f o r m e dt y p e n u t s t h e r e s h o u l d b e $ i n c h ( 4 m m ) o f threadprotruding. R e fi t t h e r o a d w h e e l a n d l o w e r t h e c a r . 8 :6 Universaljoints Removal: Remove the complete drive shaft and swivel hub a s s e m b l ya s d e s c r i b e dl a t e r i n t h i s C h a p t e r . R e m o v et h e c l i p s e c u r i n gt h e y o k e h o u s i n g s e a l t o t h e d r i v e s h a f t a n d p u l l t h e y o k e h o u s i n g a s s e m b l yo f f t h e s p l i n e so f t h e d r i v e s h a f t .

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8:8 The

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suspension

FIG 8 :13

Section view of Hydrolastic unit

p Key to Fig 8 :13 A lnterconnecting ipe B Rubber spring C Damperbieed D Butyl lrner E Tapered piston F D a m p e rv a l v e s G Fluid separating ember m H R u b b e rd i a p h r a g m J T a p e r e dc y l i n d e r

Reassembly: F i t a n e n d l e s sc l i p o v e r t h e i n n e r n e c k o f a n e w r u b b e r b o o t w i t h i t s c h a m f e rt o w a r d s t h e i n s i d e .H o l d t h e i n n e r member of the joint in a soft-lawed vice, as shown in F I G I : 1 1 a n d i n s e r tt h e m a n d r e l o S e r v i c eo o l 1 8 G . 1 2 5 1 f t . C o a t l i b e r a l l yw i t h R u - G l y d e , p r e f e r a b l yw h i l e w e a n n g r u b b e r g l o v e s ,o r w i t h T e e p o l a n d s l i d e t h e b o o t d o w n t h e m a n d r e l ,p u s h i n g i t h o m e o n t o t h e b o s s u s i n g t h e sleeveof the tool. Clean off all surplus lubricani from c o m p o n e n t sa n d t o o l s . A s s e m b l e t h e c a g e a n d b a l l s i n r e v e r s eo r d e r o f d i s m a n t l i n g e n s u r i n gt h a t t h e l o n g - t a p e r e de n d o f t h e b a l l cage faces the drive shaft end. P a c k 5 0 c c o f B e n t o n e g r e a s ei n t o t h e o u t e r m e m b e r a n d f i t t h e i n n e r m e m b e r a n d b a l l c a g e a s s e m b l y .F i t t h e b o o t a n d s e c u r ei t w i t h a c l i n c h i n g c l i p . F i t t h e w a t e r s h r e l dt o t h e p o l i s h e d b o s s o f t h e l o i n t w i t h t h e d i s h e ds i d e t o w a r d st h e f i n a l d r i v e . L u b r i c a t e h e s p l i n e sa n d p u s h t h e p l u n g e j o i n t r n u n t i l t the springring is fully engaged. E n g a g el o w g e a r ,o f f e ru p t h e d r i v es h a f tt o t h e j o i n t a n d e n g a g e t h e s p l i n e sb y t u r n i n g t h e d r i v e f l a n g e .T a p t h e a s s e m b l yh o m e . u s i n g a m a l l e t o n t h e e n d o f t h e d r i v e shaft. Refit the ball loint on the top swivel hub and the s t e e r i n gt i e r o d , u s i n g a n e w l o c k w a s h e r , n d t i g h t e n t o a 35-40 and 25 Ib ft respectively. Fit the road wheels,lower the car and fill the power u n i t w i t h a s D e c iife d o i l .

T h i s s y s t e mo f v e h i c l es u s p e n s i o n s d e s i g n e d o r e d u c e i t p i t c h i n g a n d r o l l i n g a n d , t h e r e f o r e ,t o g i v e a s m o o t h f l a t ride with the best possible handling characteristicsThe . front suspension is shown in the exploded view of FIG 8 : 1 t o g e t h e r w i t h t h e d r i v i n g s h a f t s ,a n d t h e c o m p o n e n t s o f t h e r e a rs u s p e n s i o n r e s h o w n i n F I G I : 1 2 . a The system consists of two front and 1wo rear disp l a c e r u n i t s , w h i c h a r e s h o w n i n s e c t t o nr n F I G 8 : 1 3 , i n t e r c o u p l e d l o n g i t u d i n a l l yt h r o u g h t h e p i p e s A . E a c h unit consists of a piston E pressing on a diaphragm H h o u s e d i n a s t e e l c a s i n gd i v i d e d i n t o a n u p p e r a n d l o w e r chamber separated by the member G and incorporating a c o n i c a l s p r i n g o f c o m p r e s s e dr u b b e r . A n u p w a r d m o v e m e n t o f a f r o n t w h e e l f o r c e st h e p i s t o n to push the diaphragm upwards and the increasing pressure forces fluid up into the top chamber. This deflects the rubber spring and the resultantpressure i n c r e a s ef o r c e s f l u i d t h r o u g h t h e i n t e r c o n n e c t i n gp t p e into the rear displacerunit where the incorning fluid p u s h e s t h e d i a p h r a g m , a n d r a r i t hi t t h e p i s t o n . d o w , n w a r c s a n d s o r a i s e st h e r e a r e n d o f t h e c a r i o a n e x l e : 1 1 i i n i l a r s t o t h e f r o n t . A s t h e s e m o v e m e n t sa r e v i r t u a l l ys i m u l t a n eous the result is that the car rides the obstruction with l i t t l eo r n o p i t c h i n g m o t i o n o f t h e b o d y . T h e a c t i o n o f t h e s u s p e n s i o ni s t h e s a m e w h e n t h e r e a r w h e e l s e n c o u n t e r a b u m p . T h e s e m o v e m e n t sa r e s h o w n d i a g r a m m a t i c a l l y in FIG8 :14. The fluid used is a mixtureof water and alcoholwith a n a n t i- c o r r o s i v e d d i t i v e . a T h e f r o n t s u s p e n s i o na l s o c o m p r i s e su p p e r a n d l o w e r a r m s o f u n e q u a ll e n g t h 5 4 a n d 8 9 i n F I G 8 : 1 p i v o t e d i n the sidemembers of the front subframe. and with rne o u t e r e n d s a t t a c h e db y b a l l j o i n t s t o t h e s w i v e l h u b s 6 8 , The rear suspension, in addition to the hydrolastic u n i t s , c o n s i s t s o f i n d e p e n d e n tt r a i l i n g a r m s 3 2 i n F I G 8 : 1 2 , a u x i l i a r s p r i n g s 1 a n d a n a n t i - r o l b a r ' 1 0 .R u b b e r y 1 l a r c h s p r i n g s5 6 a r e u s e d i n p l a c e o f i t e m s 1 0 a n d 1 1 o n l a t e rm o d e l s . 8 :9 Suspension iubrication This consists of occasionalattention to the grease n i p p l e so n t h e t w o s w i v e l j o i n t s .J a c k - u p t h e f r o n t o f t h e car to take the load off the joints. Make sure that the nipples 73 are clean and not blocked with dirt. lf the s w i v e l k n u c k l e sa r e a l r e a d yf u l l o f g r e a s ev e r y I i t t l e c a n be forced in.

8:10 Servicing the suspensionsystem I n v i e w o f t h e c o n d i t i o n si m p o s e d b y t h e H y d r o l a s t i c system of suspension there are severalservicing operat i o n s w h i c h m u s t n o r m a l l y b e l e f t t o a q u a l i f i e dS e r v i c e Statron as it is not possible to perform them without depressurizingthe system before commencement and p r e s s u r i z i n o n c o m p l e t i o no f t h e w o r k ; a n d t h e e l a b o r a t e g e q u r p m e n tr e q u i r e d o r t h i s i s n o t u s u a l l ya v a i l a b l e o t h e f t o w n e r - o p e r a t o r S u c h o o e r a t i o n si n c l u d e t h e r e m o v a lo f . t h e f r o n t s u b f r a m e ,t h e u p p e r s u s p e n s i o na r m s , s w i v e l h u b s a n d t h e d i s p l a c e r n r t sa n d r e a rs u b f r a m e s . u l f t h e h o m e o p e r a t o rf e e l s t h a t h e i s q u a l i f i e dt o c a r r y o u t t h e s e o r s i m i l a rj o b s i t i s q u i t e p e r m i s s i b l eo r h i m t o f h a v e t h e s y s t e m p r o f e s s i o n a l l yd e p r e s s u r i z e db e f o r e h e d r i v e s t h e v e h i c l e h o m e t o D e r f o r mt h e t a s k s - a n d b a c k

98

ffit,'"/"'

FIG 8:14 .Action of Hydrolastic system. Top:Tail rises in response to upwards movement of front wheels. Bottom: Nose rises in response to upward movement of rear wheels

t o t h e S e r v i c eS t a t i o nf o r r e p r e s s u r i z i no n c o m p l e t i o n g provrded that a speed of 30 mile/hr is not exceeded on g o o d r o a d 5 a s i n t h i s c o n d i t i o nt h e s u s p e n s i o n r m s w i l l a c o n t a c tt h e b u m p r u b b e r sa t b o t h f r o n t a n d r e a r . S u b f r a m e s a n d m o u n t i n g s ( s e eF I G 8 : 1 5 ) : T o r e n e w t h e m o u n t i n g sa t t h e f r o n t o f t h e c a r s u p p o r t t h e w e i g h t o f t h e e n g i n e a n d t r a n s m i s s i o n s s e m b l ya s a c l o s e l ya s p o s s i b l e o t h e m o u n l i n g t h a t i s t o b e c h a n g e d . t lf more than one mounting is to be changedthe body m u s t a l s o b e s u p p o r t e do n a s l i n g . The mountings at the rear of the rear subframeare r e n e w e di n t h e s a m ew a y a s t h o s e o f t h e f r o n t s u b f r a m e , b u t t o r e m o v e a n d f i t m o u n t i n g sa t t h e f r o n t o f t h e r e a r s u b f r a m e i t i s n e c e s s a r yt o r e m o v e t h e s u b f r a m e a s s e m b l y w h i c h e n t a i l sd e p r e s s u r i z i n tg e s y s t e m . h 8:?1 Servrcingthe hubs Front: Jack-up the front of the car with a block of wood between the jack and the transmtssion asing.Remove c t h e r o a d w h e e l a n d d i s c o n n e c tt h e b r a k ec a l i p e ra s s e m o r y a s d e s c r i b e dr n C h a p t e r 1 0 , t a k i n g c a r e t o r e l i e v ea n y tension on the hydraulic hose by tying the assembly

c o n v e n i e n t l yo u t o f t h e w a y . R e m o v e t h e d r i v e s h a f l nut BB and pull off the hub flange and disc assembly u s r n gs e r v i c e o o l 1 8 G . 3 0 4a n d a d a p t o r1 8 G . 3 0 4 8 . t T o r e f i t , p a c k t h e b e a r i n g s w i t h g r e a s e a n d r e v e r s et h e , a b o v e p r o c e d u r em a k i n g s u r et h a t t h e b e a r i n g s r e f i t t e d a w i t h t h e s i d e s m a r k e d T H R U S T a d j a c e n tt o t h e b e a r i n g s p a c e r7 9 . Rear: R a i s et h e c a r w i t h a l a c k p l a c e d u n d e r t h e r e a r f r a m e c r o s s m e m b e rr,e m o v et h e r o a d w h e e l a n d g r e a s er e t a i n i n g c a p 5 5 . R e m o v e t h e s p l i t p i n ,h u b n u t 5 4 a n d w a s h e r 5 3 . P u l l o f f t h e h u b a n d d r u m a s s e m b l y 6 u s i n g s e r v i c et o o l 4 18G.304 and adaptor18G.3048. Note thar'the off-side h u b n u t h a s a r i g h t - h a n dt h r e a d a n d t h e n e a r - s i d en u r a l e f t - h a n dt h r e a d . B e f o r e r e fi t t i n g p a c k b o t i r b e a r i n g sw i t h g r e a s et o o v e r flowing and pack the cavity between the inner beanng a n d t h e o i l s e a l 4 9 . D o n o t f i l l e i t h e rt h e c a v i t y b e t w e e n t h e t w o b e a r i n g so r t h e r e t a i n i n gc a p , b u t l i g h t l y s m e a r t h e s p a c e r5 1 . R e fi t t i n g i s t h e r e v e r s e r d e r t o d i s m a n t l i n g b u t e n s u r e o , t h a t t h e b e a r i n g s r e f i t t e d w i t h r h e s i d e m a r k e dT H R U S T a n e x t t o t h e s p a c e ra n d t h a t t h e w a s h e r 5 3 i s f i t t e d w i t h i t s i n n e r c h a m f e r e de d g e t o w a r d s t h e b e a r i n g .

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Front and rear subframes and mountings

5 Spring 4 P l a i nw a s h e r 3 Screw 2 F r o n t s u b fr a m e f r o n t m o u n t i n q Key to Fig 8 :15 F r o n t s u b fr a m e a s s e m b l y w a s h e r O N u t 7 S c r e w 8 P l a r n w a s h e r 9 S p r i n g w a s h e r 1 O N u t 1 1 R e a r u p p e r s u b t r a m e m o u n t r n g1 2 S c r e w 1 3 P l a i n 'l 4 S p r i n g w a s h e r 1 5 S c r e w 1 6 S p r i n g w a s h e r 1 7 R e a r l o w e r f r o n t s u b f r a m em o u n l i n g 1 8 S c r e w 1 9 P l a i n w a s h e r washer 2 0 F r o n l r i g h l h a n dr e a r 2 5 B e a r s u b f r a m ea s s e m b l y 24 Nut 2 2 P l a i nw a s h e r 23 Washer 20 Nut 21 Sciew 30 Sgring w,asher 29 Screw short 28 Screw long 27 Front lefthand rear subframe mouhting sub{rame mounting 3 2 S l r i n g w a s h e r 3 3 R e a r r i g h t h a n d r e a r s u b f r a m e m o u n t i n g 3 4 R e a r l e f t h a n d r e a r s u b f r a m em o u n t i n g f 3 5 S c r e w 31 Screw 41 Nut 40 Springwasher 38 Screw 3 9 P l a i nw a s h e r 37 Nut 36 Springwasher

8:12 Arch spring t T h i s p a r t ,s h o w n a t 5 6 i n F I G 8 : 1 2 , r e p l a c e dh e a n t i s r o l l b a r a n d a u x i l i a r y p r i n g sa n d i s i n p e r m a n e n tc o n t a c t w i t h t h e r e a r r a d i u sa r m . T o r e m o v e a n a r c h s p r i n g ,r a i s e t h e r e a r o f t h e c a r a n d r e m o v et h e r o a d w h e e l . T a k e o u t t h e f l o o r o f t h e l u g g a g e c o m p a r t m e n t a n d r e l e a s et h e t w o n u t s s e c u r i n gt h e a r c h s p r i n g f r o m i n s i d e t h e b o o t . R e m o v et h e s p r i n g . W h e n r e fi t t i n g n o t e t h a t e a c h s p r i n g h a s t h e F R O N T m a r k e do n i t . 8 : 1 3 S t e e r i n ga n g l e s The castor and camber angles, the swivel hub i n c l i n a t i o na n d t h e w h e e l a l i g n m e n to f t h e f r o n t s u s p e n s i o n , t o g e t h e r w i t h t h e c a m b e r a n d w h e e l a l i g n m e n to f a t h e r e a rs u s p e n s r o n r e d e s i g n s e t t i n g sw h i c h h a v e a v e r y important bearing on the general handling of the car. Each of these settings, apart from the front wheel a l i g n m e n t . i s b u a l ti n t o t h e c a r a n d n o n e i s a d j u s t a b l e .

l f t h e s u s p e n s i o ni s d a m a g e d t h e a n g l e s ,a s g i v e n i n g T e c h n i c a lD a t a ,m u s t b e c h e c k e dw i t h s u i t a b l e a u g e sa n d n e w p a r t sf i t t e d a s n e c e s s a r y . 8 :14 The subframes T h e s u b f r a m e sm a y b e r e m o v e d a n d r e f i t t e d a s f o l l o w s after the system has been depressurized. F r o n t ( s e eF I G 8 : 1 6 ) : Raisethe car with padded slings Iocated under the front wings until the load is taken off the suspension, t h e n p l a c e s u i t a b l es u p p o r t su n d e r t h e s i l l s . R e m o v e t h e r o a d w h e e l s . D i s c o n n e c tt h e b a t t e r y . R e m o v e t h e b o n n e t . Disconnect all electricalconnections to the engine. R Remove the horn. Remove the carburetter(s). elease t h e e x h a u s to i p e f r o m t h e m a n i f o l d ,f r o m t h e t r a n s m i s s i o n c a s i n ga n d f r o m t h e t w o m o u n t i n g so n t h e r e a rs u b f r a m e . R e l e a s e t h e s p e e d o m e t e rc a b l e . D r a i n t h e : o o l i n g system. Disconnect the heater hoses and release the c a b l e sf r o m t h e w a t e r c o n t r o lv a l v e .

100

R e l e a s e h e c l u t c h s l a v e c y l i n d e ra n d w i r e i t o u t o f t h e t w a y . R e m o v et h e g e a r b o xe x t e n s i o n . i s c o n n e c t h e o r s D p l a c e r h o s e sa t t h e b u l k h e a da n d p l u g t h e m t o p r e v e n t t h e e n t r y o f a n y d i r t . D i s c o n n e c tb r a k e h o s e sa n d s t e e r i n q lre roos. S u p p o r t t h e e n g i n e a n d t r a n s m i s s i o nw i t h a j a c k . R e m o v et h e t w o b o l t s a t e a c h f r o n t a n d e a c h r e a r c o r n e r of the subframewhich secure it to the body brackets. R e m o v e t h e t w o n u t s s e c u r i n ge a c h t o w e r h o l d i n g t h e d i s p l a c e ru n i t s . R e m o v e t h e b o l t s s e c u r i n gt h e m o u n t r n g b r a c k e t st o . ? h e b o d y a n d l i f t o u t t h e b r a c l i e t s . Lower the jack, lift the body with a sling and wheel t h e e n g i n d a n d t r a n s m i s s i o n s s e m b l vc l e a r . a R e fi t t i n g : T h i s i s a r e v e r s ao f t h e r e m o v a lp r o c e d u r e n o t i n g t h a t l , all the mounting bolts should be inserted into their l o c a t i o n sb e f o r e t i g h t e n i n g a n y o f t h e m . l t i s i m p o r t a n t t h a t n o f o r c e b e u s e d w h e n l i n i n g u p t h e m o u n t i n g sa n d the bolts. F i r s t t i g h t e n t h e t o w e r m o u n t i n g b r a c k e t st o e n s u r e correct alignment of the engine and transmisston a s s e m b l y ,t h e n t i g h t e n t h e r e m a i n i n g m o u n t i n g b o l t s . B l e e d t h e b r a k i n g s y s t e m a n d p r e s s u r i z eh e s u s p e n s i o n t system. Rear subframes. Removing: A f t e r d e p r e s s u r i z i n t h e s y s t e m .r a i s et h e b o d y w i t h a g s l i n g a n d f r e et h e s u s p e n s i o n f a l l l o a d . R e m o v et h e f l o o r o o f t h e l u g g a g e c o m p a r t m e n t a n d r e l e a s et h e d i s o l a c e r
FIG 8:16 Rear end view of the power complete with subframe and drive shaft unit removed

Key to Fig 8 :16 A T h r e e o f t h e s i x s u b f r a m em o u n t r n q points B D i s p l a c e r o s e e n d s s e a l e da g a i n s td i r t h

3-_6 5

FIG 8 :17

The f ront hub assemblv 4 B e a r i n gd i s t a n c ep i e c e 5 Bearings 1 0 D r i v e s h a f t D i s t a n c eA = : + + inch

Key to Fig 8 :17 1 D f r v es h a f l n u l 2 T a p e r e dc o l l a r 3 Hub and disc assemblv 6 O u t e r o i l s e a l 7 I n n e r o i l s e a l 8 W a t e r s h i e r d t l a t e ra s s e m b l i e s ) 9 O i l s e a l s p a c e r ( 6 . 3 + 1 . 5m m )

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u n i t h o s e s , n o t f o r g e t t i n gt o p l u g t h e e n d s . R e m o v e t h e e x h a u s tp i p e a n d s i l e n c e r . P l a c e a l e n g t h o f w o o d u n d e r t h e s u b f r a m ea n d r a i s e o n a j a c k t o r e m o v et h e r o a d w h e e l s . D i s c o n n e c t h e m a i n b r a k e p r e s s u r ep i p e a t t h e f r o n t c r o s s m e m b e r .D i s c o n n e c t t h e h a n d b r a k ec a b l e s a n d p u l l t h e m c l e a r t h r o u g h t h e floor. Remove the rear seat and the two rubber plugs in the floor. Unscrew all bolts securing the subframe to the m o u n t i n g b r a c k e t sa n d t h e b r a c k e t st o t h e b o d y . R a i s e t h e r e a ro f t h e c a r a n d w i t h d r a w t h e s u b f r a m eo n t h e j a c k . Refitting: T h i s a g a i n i s a r e v e r s a lo f t h e r e m o v a l p r o c e d u r ea s w i t h t h e f r o n t u n i t s . E n s u r ec o r r e c ta l i g n m e n to f t h e s t r u t f o o t a n d d i s p l a c e ru n i t b e f o r e h a v i n g t h e s y s t e m p r e s s ur i z e d . 8 :15 Displacer units Front: A f t e r d e p r e s s u r i z i n gt .a k e a i l l o a d o f f t h e s u s p e n s i o n a n d d i s c o n n e c tt h e h o s e t r o m t h e u n r o n o n t h e b u l k h e a d . U n s c r e w t h e n u t a n d r e m o v et h e o u t e r e n d o f t h e u p p e r s u s p e n s i o na r m f r o m t h e k n u c k l e .R e m o v et h e u p p e r a r m p i v o t b o l t a n d r e m o v e t h e u p p e r a r m c o n t p i e t ew i t h t h e d i s p l a c e rs t r u t f o o t . W i t h d r a w t h e d i s p l a c e r . R e v e r s et h e a b o v e p r o c e d u r ew h e n r e fi t t i n g . Rear: R a i s et h e r e a r o f t h e c a r a n d r e m o v e t h e a p p r o p r i a t e r o a d w h e e l , d i s c o n n e c t t h e d i s p l a c e ru n i t h o s e a t t h e u n i o n i n s i d et h e b o o t . R e m o v et h e d i s p l a c e r t r u t a n d t h e s d i s p l a c e ru n i t . R e v e r s et h e a b o v e t o r e f i t .
Section through swivel hub bai,joint

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FIG 8 :18

gauge measurementso be taken where inlicated t W h e n r e p r e s s u r i z i n m a k e s u r e t h a t t h e d i s p i d c e rr I n i l g and strut are correctlyseated. B l e e d t h e b r a k e s y s t e ma n d a d j u s t t h e h a n d b r a k e . 8 :17 Swivel hubs Removal: J a c k - u p t h e c a r a n d r e m o v et h e r o a d w h e e l . l f t h e h u b a s s e m b l yr s t o b e d i s m a n t l e d ,t a k e o u t t h e s p l i t p i n a n d l o o s e n t h e h u b f l a n g e n u t b e f o r e r a i s i n gt h e c a r . D i s c o n n e c t h e t i e r o d b a l l j o i n t f r o m t h e s t e e r i n gl e v e r . R e l e a s et h e d r i v e s h a f t a t t h e i n n e r c o u p l i n g . O n s y n c h r o m e s hm o d e l s u n d o t h e t w o o u t e r U - b o l t s ; o n automatic models undo the four drrve shaft flange s e c u r i n gn u t s , n o t f o r g e t t i n gt o m a r k t h e f l a n g e a n d j o i n t f o r l a t e rr e a s s e m b l y . R e m o v e t h e c a l i p e r a s s e m b l ya n d s u p p o r t i t c a r e f u l l y o u t o { t h e w a y . D i s c o n n e c tt h e t i e r o d f r o m t h e l o w e r support arnr.Removethe upper and lower support arm r e t a i n i n g n u t s a n d r e l e a s et h e a r m s f r o m t h e b a l l p r n s . O n c a r sw i t h p l u n g el o i n t c o u p l i n g s ,u s e t o o l 1 8 G 12 4 3 a s d e s c r i b e de a r l i e rt o r e m o v e t h e s h a f t f r o m t h e j o i n t . Removethe complete hub and drrve shaft assembly from the car. Dismantling: Remove the splitpin,nut and collar and pull off the h u b f l a n g e a n d d i s c a s s e m b l y ,u s a n gt o o l 1 8 G 3 0 4 a n d a d a p t o r 1 B G 3 0 4 8 i f n e c e s s a r yT a p t h e e n d o f t h e d r i v e . shaft to {ree it from the swivel hub. E x t r a c t t h e o u i e r a n d r n n e r o i l s e a l s ,w i t h ( o n l a t e r c a r s ) t h e w a t e r s l i i e l da n d i n n e r s p a c e r . D r i f t o u t t h e i n n e r r a c eo f e a c h b e a r i n g ,t h e n t h e c e n t r e b e a r i n gs p a c e ra n d f i n a l l yt h e o u t e r r a c e s Extract the securing setscrews to separate the disc f r o m t h e h u b a n d , i f r e q u i r e d , e m o v et h e s w i v e l h u b b a l l r J On t s . r R e a s s e m b l y ( s e eF I G I : 1 7 ) : T h i s i s a r e v e r s a lo f t h e d i s m a n t l i n g p r o c e d u r e b u t a l t e n t i o ns h o u l d b e p a i d t o t h e f o l l o w i n g p o i n t s : P a c kt h e b e a r i n g s i t h a h i g h m e l t i n g p o i n t g r e a s ea n d w ensure that they are fitted io the hub with the sides m a r k e d T H RU S T f a c i n g e a c h o t h e r w i t h t h e s p a c e r b e t w e e nt h e m . Fit the double lipped outer seal to the hub with tool 1 8 G 1 3 4 D 0 t i n e d t o 1 8 G 1 3 4 . P o s i t i o nt h e s p a c e r a n d t h e n f i t t h e i n n e r s e a lw i t h t h e s a m e t o o l , n o t i n g t h a t o n l y t h e l a t e r s i n g l e l i p p e d s e a l m a y b e u s e d .T h i s s e a l h a s a

8 : 1 6 R a d i u sa r m s It is not necessary n these latercars to removethe o complete rear subframe to replace a radius arm, but d e p r e s s u r i z i no n t h e a p p r o p r i a t e i d e i s r e q u i r e d . g s R a i s et h e r e a ro f t h e v e h i c l e a n d r e m o v e t h e r o a d w h e e l . R e l e a s et h e h a n d b r a k e , s l a c k e n t h e a d j u s t e r a n d r e m o v e the clevis pin from the lever on the brake backplate. R e m o v et h e h a n d b r a k ec a b l e s w i v e l s e c t o r{ r o m i t s p i v o t u n d e r t h e r a d i u sa r m . D i s c o n n e c t h e b r a k e h o s e f r o m t h e u n i o n o n t h e s u b fr a m e . O n t h o s e m o d e l s f i t t e d w i t h a n a n t i - r o l lb a r , k n o c k u p t h e t a b w a s h e r sa n d r e m o v e t h e s e c u r i n gb o l t s f r o m t h e r a d i u s a r m s , w h i c h a l s o r e l e a s e st h e a u x i l i a r y s p r i n g s (when fitted), and removethe anti-rollbar. lf only one r a d r u sa r m i s t o b e r e m o v e d ,d i s c o n n e c tt h e a n t i - r o l l b a r f r o m t h a t s i d e o n l y . T h e a u x i l i a r ys p r i n g s c a n b e l e f t i n p l a c e .b u t r f r e m o v a li s r e q u i r e du n d o t h e c e n t r es e c u r i n g nuts. U n d o t h e r a d i u sa r m p i v o t s h a f t i n n e r a n d o u t e r n u t s , r e m o v e t h e o u t e r s u p p o r t b r a c k e t a n d t h e d i s p l a c e rs t r u t a n d e a s e t h e r a d i u sa r m a s s e m b l yf r o m t h e c a r . R e f i t t i n g i s t h e r e v e r s eo i t h e r e m o v a l p r o c e d u r e , b u t note the following points: l f a n a n t i - r o l lb a r w a s r e m o v e d ,r e { i ti t o n o n e s i d e w i t h t h e a u x i l i a r ys p r i n g b r a c k e t ( i f f i t t e d ) , a n d a d j u s t t h e h e i g h t o f t h e o p p o s i t e r a d i u sa r m u n t i l t h e b o l t s c a n b e e a s i l yr e p l a c e d .

102

r e g i s t e rf o r t h e w a t e r s h i e l d w h i c h i s f i t t e d a s s h o w n i n tne Inset. O n c a r s w i t h p l u n g e j o i n t s , e n g a g et h e d r j v e s h a f t a s d e s c r i b e di n S e c t i o n 8 : 7 . L g h t e n t h e b a l l p i n r e t a i n i n gn u t s t o a t o r q u e o f 3 5 t o 40 lb ft. Note that if the ball joints have been removed t h e y m u s t b e a d l u s t e da s d e s c r i b e dl a t e r i n t h i s S e c t i o n . O n s y n c h r o m e s h t r a n s m i s s i o n sw i t h f l e x i b l e d r i v e c o u p l i n g s , t i g h t e n t h e U b o l t s a s d e s c r i b e de a r l i e r .O n a u t o m a t i c l r a n s m i s s i o n sa l i g n t h e { l a n g e m a r k s b e f o r e f i n i n g a n d l i g h t e n i n g t h e s e c u r i n gb o l t s . Tightenthe drive shaft nut to 1b0 lbft and check the r u n o u t a f t h e o u t e r p e r i p h e r y f t h e d i s c .T h i s s h o u l d n o t o b e m o r et h a n . 0 0 6 i n c h ( . 1 5 m m ) .

8 :18 Anti-roll bar and auxiliary springs E i t h e ro r b o t h o f t h e s e c o m p o n e n t s m a y b e f i t t e d t o r a n y p a r t t c u l a c a r a n d n o d i f fi c u l t y w i l l b e e x p e r i e n c e dn i their removal after the H),drolastic system has been d e p r e s s u r i z e a n d t h e r e a re n d o f t h e c a r l i f t e d . d T h e a n t i - r o l l b a r i s r e m o v e df i r s t a n d t h e n t h e a u x i l i a r y s p r i n g sm a y b e r e m o v e d . R e fi t t i n g i s a l s o s t r a i g h tf o r w a r d , n o t i n g t h a t t h e a n t i roll bar should be first securedon one side with the a u x r l t a r y p r i n gb r a c k e t( w h e r e a p p l i c a b l e ) n d t h e h e r g n r s a o f t h e o p p o s i t e r a d i u s a r m a d j u s t e du n t j l t h e b o l t s c a n b e e a s i l yi n s e r t e d . Adjustment:

Ball joints: These may be removed after disconnecting the 1ie rod from the lower support arm. Removethe upper support a r m r e t a r n i n g u t a n d r e l e a s e h e b a l l p i n ( 1B G 1 0 6 3 ) . n t R e m o v e t h e d u s t c o v e r a n d l u b r i c a t o r ,k n o c k u p t h e l o c k w a s h e r n d u n s c r e w t h e h o u s i n g u s i n g t o o l 1g G S g 7 a fitted to a T bar, taking care that the drive shaft is not s t r a i n e d .E x t r a c tt h e b a l l s e a t a n d t h e p a c k i n g s h i m s . R e m o v et h e l o w e r b a l l l o i n t a n d s e a t s p r i n g ,p r e f e r a o r y a f t e r t h e u p p e r l o i n t h a s b e e n a d i u s t e da n d r e f i t t e d . Adjusting the balt joints: F i r s t c l e a n a n d e x a m i n e a l l t h e c o m p o n e n t st h e n r e f t t the ball seat pin and housingwithout any shims,locr washer or seat spring (lower joint). Screw down the b a l l h o u s i n gu n t i l a l l s l a c k r sj u s t e l i m i n a t e d . M e a s u r et h e g a p b e t w e e n t h e h o u s i n g a n d t h e s w r v e l h u b a s s h o w n i n F I G 8 : 1 8 a n d t h e n r e m o v et h e h o u s r r r o a n d b a l lp i n . Refit the spring under the lower loint ball seat and p a c k t h e a s s e m b l yw i t h g r e a s e .S c r e w t h e h o u s i n g b a c k on to the swivel hub with its lockwasher. hich is .036 w i n c h ( . 9 m m ) t h i c k , a n d s u f f i c i e n ts h i m s t o m a k e a t o t a l t h i c k n e s so f 0 t o . 0 0 3 i n c h g r e a t e rt h a n t h e m e a s u r e m e n r j u s t t a k e n t o p r o d u c et h e n e c e s s a r y n d f l o a t .A n y u n d u e e t r g h t n e s so r e x c e s s i v ef l o a t m u s t b e r e c t i f i e d b y a d l u s t i n g the shim thickness. T h e a s s e m b l ym u s t r o t a t e a n d a r t i c u l a t ef r e e l y i n a t t p l a n e s .l f t h i s f r e e d o m i s n o t o b t a t n e d ,n e w p a r t sm u s t b e fitred.

T h e n o m i n a l g a p b e t w e e n t t r 6 . . 1 ; ' , , 1i,,,! . a c k ea n d t h e t u n d e r s i d e f t h e s u b - f r a m ei s . 1i n c i r ( . j . 2 i n ; - n ) b u t i f j t i s o , r e q u i r e dt o m a k e a s m a l i a d l r t s t r n e ntl o t h e t r i m h e i g h t t h r s c a n b e v a r i e db e t w e e n 0 a n d i i n c h ( 6 . 4 m m ) . Slacken the centre securing nuts of the auxrliary s p r i n g s a n d r e l e a s e h e l o c k n u t s o n t h e a d j u s t e rs c r e w s . t T h e s e a r e u n s c r e w e dt o r e d u c et h e g a p i t a n i n c r e a s e f o t r i m h e i g h t i s r e q u i r e d ,o r s c r e w e d u p t o r e d u c e t h e h e i g h t . l t m a y b e n e c e s s a r yt o l o a d t h e c a r t o r e d u c e s p r i n g t e n s i o n d u r i n g t h i s l a t t e ro p e r a t i o n . 8 :19 Fault diagnosis (a) Wheel wobble 1 Incorrect rackrng 2 Worn hub bearings 3 D e f e c t i v es u s p e n s i o nu n r t s 4 Worn swivel hub joints 5 L o o s ew h e e l { i x i n g s (b) 'Bottoming' of suspension

1 C h e c k3 i n ( a ) 2 I n c o r r e c tp r e s s u r i z i n g 3 R e b o u n d r u b b e r sw o r n o r m i s s i n g (c) Heavy steering 1 N e g l e c t e ds w i v e l h u b l u b r i c a t i o n 2 Wrong suspension eometry g (d) Excessive tyre wear 1 C h e c k1 i n ( a ) a n d 2 i n ( c ) (e) Rattles

Refitting: Tighten the ball housing to 70 lbft, then refit tne l u b r i c a t o rb e f o r e s e c u r i n gt h e l o c k w a s h e r . Refit the upper and lower dust covers and the barr p i n s a n d t r g h t e nt h e s e c u r i n gn u t s t o 3 5 t o 4 0 l b f t . R e f i t the tie rod and the wheel and lowerthe caronto the road.

1 C h e c k1 i n ( c ) 2 R a d i u s a r m m o u n t i n g sd e f e c t i v e (f) Excessive rolling

1 C h e c k3 i n ( a ) a n d 2 i n ( b ) 2 A n t i r o l l b a r b r o k e no r f i x i n g sl o o s e

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9 :1 9:2 9:3 9:4 9:5 Description Lubrication The steering wheel The steering column Steering rack and pinion 9 :6 9:7 9:8 9:9 Tracking Outer ball joints Steering lock and ignition switch Fault diagnosis

9:1

Description

The components of the rack and pinion type steering g e a r a r e i l l u s t r a t e di n F I G 9 : 1 . T h e r a c k h o u s i n g 1 i s s e c u r e dt o t h e e n g i n e b u l k h e a d ,t h e t i e r o d s 2 3 o p e r a t i n g t h e s t e e r i n ga r m s a r e a t t a c h e d t o e a c h e n d o f t h e s t e e r i n g rack 5 by ball joints 31 enclosed in rubber gaiters.The steering column 43 engages the splined end of a helical t o o t h e d p i n i o n 1 3 t o w h i c h i t i s s e c u r e db v a c l a m p b o l t a n d w h i c h e n g a g e st h e r a c k . P i n i o n e n d p l a y i s e l i m i n a t e db y t h e a d j u s r m e n t f t h e o s h i m s 1 9 f i t t e d u n d e rt h e r e t a i n i n g l a t e 1 8 . A d a m p e rp a d p 6 under the steering rack controls the backlash between the pinion and the rack. lf the front wheels are lifted clearof the ground durrng servicing operations,it is important that they should not be moved forcefully from lock to lock as damage may be caused to the sleering mechanism. 9 :2 Lubrication N o p r o v i s i o n i s m a d e f o r p e r i o d r cl u b n c a t t o n o t t n e s t e e r i n g r a c k , a n d r e p l e n i s h m e n t s r e q u i r e do n l y w h e n i there is evidence of oil loss from the rack housing or the rubber gaiters.No lubricating nipples are provided and if the leakage can be rectifred without the rack assembly' being removed, the following procedure should oe adopted: Remove the retaining clip 29 from the gaiter at the r i g h t h a n de n d o f t h e r a c k h o u s i n g ( o r l e f t h a n d e n d o n

l e f t h a n dd r i v e c a r s ) a n d p u l l t h e g a i t e rf r o m t h e h o u s i n g . Move the rack to the straight-ahead position and insert a n o i l n o z z l ei n t o t h e e n d o f t h e r a c k h o u s i n g a n d i n l e c t not more than * pint of Extreme Pressure SAE.90 oil. R e p l a c et h e r u b b e r g a i t e r a n d m o v e t h e r a c k f r o m s i d e t o s i d e t o d i s t r i b u t e h e o i l t h r o u g h o u tt h e h o u s i n g . t

9 :3 The steering wheel Austin America and GT. Disconnect the battery and leverout the centralsafety boss, remove the steering wheel nut. Turn back the lock ring tabs and remove the bolts, lock ring and steering wheel. l f t h e h u b i s t o b e r e m o v e d ,u s e t o o l 1 8 G 1 1 8 1 a n d p u l l i t o f f c o m p l e t e w i t h t h e s t e e r i n gw h e e l , n o t f o r g e t t i n g to markthe hub and column for refittinq. All other models: Lever out either the horn push control, centre motif or safety pad, as applicable. S l a c k e n , b u t d o n o t r e m o v e ,t h e r e t a i n i n g n u t a n d p u l l t h e s t e e r i n gw h e e l w i t h t o o l 1 8 G 7 0 u n t i l i t i s a l o o s e f i t o n t h e c o l u m n . R e m o v e t h e p u l l e r ,n u t a n d w h e e l . When refitting, make sure that the road wheels are in the straightahead position and the spokeson the steering wheel central.The correct torque for the retaining nut is 32 to 37 lb ft.

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\ \7|34

KeytoFig9:llRackhousrng2Rackhousingbush3Bushhousrng(earlyfeltbushesonly)4Housingscrews5R 6 D a m p e ry o k e 7 D a m p e rc o v e r 8 C o v e r b o l t 9 S p r i n g w a s h e r ' 1 0 Y o k e s h i m 1 1 C o v e r g a s k e t 1 2 D i s c s p r i n g 1 3 P i n i o n 14 Oilseal 15 Ballcone l6 Ballcage' 17 Ballcup' 18 Endcover 19 Covershim 20 Endcovergasket 21 Coverbolt 2 2 S p r r n gw a s h e r 23 Tie rod 24 Thrustspring 25 Ball seat 26 Ball housing 27 Lockingring 2 8 R u b b e rg a i t e r ( nner) 29 Sealclip 30 Sealclip (outer) 3'1 Ballsocketassembly 3 2 R u b b e rb o o t 3 3 R u b b e rb o o t 34 Boot washer 35 Circlip 36 Crrclip 37 Nut 38 Nut 39 Locknut 40 Clamp base 41 U-boll 42 Nut 43 Column assembly 44 Washer 4 5 C o l u m n t u b e 4 6 C o l u m n b e a r i n g ( u p p e r ) 4 7 C o l u m n b e a r i n g ( l o w e r ) 4 8 S e a l i n gw a s h e r 4 9 P i n i o n c l a m p b o l t 5 0 N u t 5 1 W a s h e r 5 2 C o l u n r ns c r e w 5 3 S p r i n g w a s h e r 5 4 W a s h e r 5 5 S t e e r i n gw h e e l 5 6 S t e e r i n gw h e e l n u t 5 7 W a s h e r 5 8 S t u d 59 Locknut 6 0 O n e p r e c e p i n r o n b e a r i n ga s s e m b l i e s l a t e r m o d e l s ) ( .62 Bolt-' 61 Safetybossi' 63 Lock ringt6 4 S t e e r i n gw h e e l h u b * 6 5 S t e e r r n qi r y h e e l " " 6 6 S t e e r i n gw h e e l ( S u p e r d e - l u x e M k 3 m o d e l s ) 6 7 S a f e t y p a d ( S u p e r d e - l u x e Mk 3 models) 'Early " Austin America and GT models ntodels 9:4 The steering column

l f t r o u b l e i s e x p e r i e n c e dw i t h s t i f f s t e e r i n g w h i c h remainsafter the track rod ball joints have been disconnected, first check the alignment of the steeilng c o l u m n a n d i f t h i s f a i l s ,t h e r n n e rc o l u m n f o r s t r a r g h t n e s s . S l a c k e n t h e L l - b o l t s s e c u r i n g t h e r a c k a s s e m b l ya n d t h e s t e e r i n gc o l u m n b o l t s u n t i l b o t h a r e f r e e t o m o v e ,t h e n graspthe lower end of the column and move it up and d o w n t o r o t a t e t h e r a c k a s s e m b l yu n t i l i t i s i n i t s n a t u r a l posrron T i g h t e n t h e c o l u m n s e c u r i n gs c r e w m a k i n g s u r e t h a t t h e c o l u m n i s n o t s t r a i n e dt o e i t h e r s i d e . T i g h t e n t h e U - b o l t s a l i t t l e a t a t i m e t o a v o i d d i s p l a c i n gt h e r a c k assemDry. Removal: D i s c o n n e c t h e d i r e c t i o ni n d i c a t o r n d h o r n c o n n e c t o r s a below the pafcel shelf.then remove the nut, bolt and w a s h e r c l a m p r n gt h e c o l u m n t o t h e s t e e r i n gp i n i o n s h a f t a f t e r p u l l i n g b a c k t h e r u b b e rc o v e r .

, O n P r i n c e s s r e m o v et h e c o l u m n s u p p o r t b r a c k e ta n d d i s t a n c e p i e c e s f r o m t h e c r o s s m e m b e r ,o r r e m o v e t h e f r o r i z o n t as h e a r s c r e w w h i c h c l a m p s t h e o u t e r c o l u m n . l W h e n a s t e e r i n gl o c k i s f i t t e d , e x t r a c t s h e e r b o l t ( s ) a s r d e s c r i b e dn S e c ;i o n 9 : 8 a n d p u l l t h e c o l u m nu p w a r d s t o d i s e n g a g ei t f r o r r t h e p i n i o n s h a f t s p l i n e s . Inspection: R e p l a c et h e i n n e r c o l u m n o n i t s o w n t o t h e s t e e r i n g p i n i o n s h a f t ,t h e n j a c k u p t h e c a r b e n e a t h{ h g J ! . n , ' c ' r b + frame and turn the road wheelsfrom lock to lock and so r o t a t i n g t h e i n n e r c o l u m n . M e a s u r et h e t o t a l r u n o u t o f t h e t o p b e a r i n gs u r f a c ea n d i f i t e x c e e d sj i n c h ( 6 . 2 m m ) t h e c o l u m n m u s t b e s t r a i g h t e n e du n t i l t h e r u n o u t i s within + inch (3.1 mm). Check also on the conditionof the splrnes. R e fi t t i n g : T h j s i s a r e v e r s a lo f t h e a b o v e p r o c e d u r e . M a k e s u r e t h a t t h e s l o t i n t h e c o l u m n c l a m p i s c o r r e c t l yl o c a t e dw i t h t h e r o a d w h e e l s i n t h e s t r a i g h ta h e a d p o s i t i o n .O n r i g h t

106

A-A

FIG 9:2 Section through steering rack and tie rods showing (inset) the assembled position of the plastic bush and (arrowed) the spacer fitted in conjunction with it to early units

d r i v e c a r st h e c l a m p m u s t b e u n d e r n e a t h h e c o l u m n a n d t h o r i z o n t a s o a s t o b r i n g t h e d i r e c t i o ni n d i c a t o rc a n c e l l i n g l l u g i n t h e c o r r e c tp o s i t i o n .O n l e f t d r i v e m o d e l s o r w h e r e t h e s w i t c h i s m o v e d t o t h e l e f t h a n ds i d e o f t h e c o l u m n t h e c l a m p m u s t b e p o s i t i o n e dw i t h t h e s l o t u p p e r m o s t . Tighten the steeringcolumn clamp pinch bolt to a torqueof B to 9 lbft and seethat the slot has not closed completely.When a steering lock is fitted check all components for correct operation before shearing the c o l u m n s u D o o r tb o l t s . 9:5 Steering rack and pinion Bemoving: A f t e r r e m o v i n g t h e s t e e r i n gc o l u m n a s d e s c r i b e di n Section 9:4, jack up the car beneath the front subframe and support the body under the sidemembers. D i s c o n n e c tt h e t i e r o d b a l l j o i n t s . R e m o v et h e s e t s c r e w sa n d b o l t s f r o m e a c h s u b - fr a m e tower, toeboard mountings and the rear of the gear lever e x t e n s i o n . l a c k e nt h e t w o s u b f r a m e m o u n t i n g p o i n t s . S F r o m i n s i d et h e c a r r e m o v e t h e n u t s f r o m t h e U - b o l t s c l a r n p i n gt h e r a c k h o u s i n g t o t h e t o e b o a r d ,t h e n l o w e r the sub-frame only just enough to permit the rack a s s e m b l yt o b e r e l e a s e da n d w i t h d r a w n o n t h e d r i v e r s sideof the car. Dismantling: Unlock the ball end nuts on the tie rods and remove t h e b a l l s o c k e t a s s e m b l i e sR e i e a s e h e g a i t e r c l i p s f r o m . t the rack housingand tie rods,drain the oil and remove t h e r u b b e rg a i t e r s . U s i n g t o o l s 1 B G 7 0 6 a n d l 0 - 7 r e n r o v ee a c h b a l l j o r n t h o u s i n ga s f o l l o w s : P r i s e u p t h e i n d e n t a t i o n si n t h e l o c k i n g r i n g c l e a f o f t h e s l o t s i n t h e r a c k a n d b a l l h o u s i n g .O n e a r l yc a r s t h e r e i s a l o c k w a s h e r w h o s e i n d e n t a t i o n sm u s t b e p u n c h e d c l e a ro f t h e s l o t s i n t h e l o c k i n g r i n g a n d b a l i h o u s i n g

S l a c k e nb a c k t h e l o c k i n g r i n g a n d u n s c r e wt h e h o u s i n g to release he tre rod, ball seat and spring.Unscrewthe t lockingring. Take out the bolts and lift off the damper coverplate a n d s h i m s ,w i t h d r a w t h e d a m p e r a n d s p r i n g . Unscrew the two retaining bolts and remove the p p i n i o n s h a f tt a i l b e a r i n gr e t a i n i n g l a t ea n d p a c k i n gs h i m s . Extractthe lower thrust washer, bearing and bearing race on early cars, or the bearing assemblyon later cars, a n d w i t h d r a w t h e p i n i o n .T h e t o p b e a r i n gr a c k a n d t h r u s t w a s h e r o r b e a r i n ga s s e m b l yw i l l b e h e l d b e h i n d t h e r a c k teeth and cannot be taken out until the pinion and the rack have been removed. E x t r a c tt h e p i n i o n s h a f t o i l s e a l . Wrthdraw the rack from the pinion end of the rack h o u s i n g . b e i r i g c : - l r eu l n o t t o d a m a g e t h e b u s h a t t h e o t h e r f e n d . R e m o v e t h e r e t a i n r n gs c r e w a n d e x t r a c t t h e b u s h . O n e a r l y m o d e l s a f e l t b u s h i s u s e d h e r e ,e x t r a c tt h i s a n d also the metal sleeve. Clean all components thoroughly and examtne for t wear or damage, particularly he teeth and the rubber g a i t e r s . f t h e o u t e r b a l l s o c k e ti s w o r n i t m u s t b e r e n e w e d l complete.

Reassembly T h i s w i l l b e f a c i l i t a t e di f a l l p a r t s a r e f i r s t d i p p e d i n c l e a ne n g i n eo i l . F i t a n e w p l a s t i cb u s h a n d m e t a ls l e e v ei n t o t h e h o u s r n g s o t h a t t h e f i a t s o n t h e b u s h a r e s o p l a c e dt h a t t h e s c r e w hole in the housing is between two of them. On early u n i t s w h i c h w e r e o r i g i n a l i yf i t t e d w i t h a f e l t b u s h , i t w i l l b e n e c e s s a r y o u s e a p l a s t i c b u s h a n d a s p a c e r ,w h i c h t i s i n s e r t e dp l a i n e n d f i r s t a n d f o l l o w e d b y t h e b u s h ( s e e FIG9 :2). d W h e n c o r r e c t l yp o s i t i o n e d , r i l l t h r o u g h t h e b u s h w i t h

1 1 0 0M k 2 1 3 0 0

107

FIG 9 :3

Sections through (A) later type, (B) early type of steering pinion and rack damper

KeytoFigg:3lClearancebetweenprnroncoverancihousing2Clearancebetweendampercoverandhousing3Ddnrpe 4 D a n r p e rs p r n g 5 D a m p e rs p r t n gh a i v e s

a &z inch (.27 mm) drill. Rentove any swarf, apply l o i n t i n g c o m p o u n d a n d s e c u r et h e b u s h w i t h t h e s c r e w . C h e c k t h a t t h e s c r e w d o e s n o t p r o l e c ti n t o t h e b o r e . R e f i t t h e t o p p i n i o n b e a r i n g I n s e r tt h e r a c k i n t o t h e h o u s i n g , a l i g n i t i n t h e s t r a i g h ta h e a d p o s i t i o n a n d r e f i t t h e p r n i o na n d r t s l o w e r b e a r i n g . Fit the pinion end cover without the shims or gasket and tighten the securingscrews loosely.Measurethe distance,1 rn FIG 9:3. between the cover and the housing. Remove the cover and then refit it together w i t h g a s k e ta n d s h i m s w h o s e c o m b i n e dt h i c k n e s si s . 0 0 1 . t o . 0 0 3 i n c h l e s st h a n t h e d i m e n s i o nj u s t m e a s u r e d T h i s a p p l i e s t h e r e q u i s i t ep r e l o a d i n g T h e j o i n t t a c e s s h o u l d b e t r e a t e d w i t h a s e a l e rs u c h a s s h e l l a c t o p r e v e n t a n y orl seepage. '1 .006 tnch ( 5 mm) Blackbuna type covergasket c o mp r e s s e d tnrcKness G r e e n p a p e r t y p e c o v e r g a s k e t . 0 O Bi n c h ( . 2 0 m m ) c o mp r e s s e d thickness Damper adlustment: Early type: 1 F i t t h e d a m p e r y o k e a n d c o v e i p l a t ew i t h t w o s p r i n g h a l v e sb u t o m i t t i n g t h e s h i m s a n d g a s k e t . 2 W r t l rt h e r a c k a n d p r n i o ni n t h e s t r a i g h ta h e a d p o s i t i o n , t i g h t e nt h e c o v e r b o l t s g r a d u a i l yu n t i l i t i s j u s t p o s s i b l e t o t u r n t h e p i n r o nt h r o u g h o u t i t s f a n g e w i t h t h e p r e l o a d g a u g e ; e t t o 15 l b i n c h .

a 3 M e a s u r et h e d i s t a n c eb e t w e e n t h e c o v e r p l a t e n d t h e h o u s i n g ,2 i n F I G 9 : 3 , a n d r e m o v et h e c o v e r . 4 R e f i t t h e c o v e r a f t e r f i t t i n g a g a s k e ta n d s h i m s w h o s e c o m b i n e d t h i c k n e s sw i l l b e . 0 0 1 t o . 0 0 3 i n c h ( . 0 2 5 t o j . 0 7 6 m m ) g r e a t e rt h a n t h e c l e a r a n c e u s t m e a s u r e d . Apply shellacto the joint faces before fitting.After t a s s e n r b l y h e t o r q u e r e q u i r e dt o t u r n t h e p i n i o n m u s t n o t e x c e e d2 5 l b i n c h . Later type: l Fit the damper yoke and coverplate without the s p r i n g ,g a s k e ta n d s h i m s . 2 C a r r yo u t i t e m s 2 a n d 3 a b o v e . 3 Refit the cover and yoke spring with a gasketand s h i m s t h e c o m b i n e d t h i c k n e s so f w h i c h s h a l l b e . 0 0 2 t t o . 0 0 5 i n c h ( . 0 5t o . 1 2 m m ) g r e a t e r h a n t h e c l e a r a n c e j u s t m e a s u r e d . p p l y s h e l l a ct o s e a l t h e j o i n t s b e f o r e A f i t t i n g . T h e t o r q u e l o a d r e q u i r e dt o r o t a t e t h ? p i n t o n m u s t n o t e x c e e d3 5 l b i n c h . All types: F i t a n e w p i n r o ns h a f t s e a l . S c r e w a n e w b a l l h o u s i n gl o c k i n gr i n g f u l l y o n t o e a c h e n d o f t h e r a c k a n d t h e n r e f i t e a c h s p r i n g ,s e a t ,t i e r o d a n d b a l l h o u s i n g ,t i g h t e n i n g u n t i l t h e t i e r o d i s p i n c h e d . S c r e w b a c k t h e l o c k i n g r i n g , u n t i l i t c o n t a c t st h e h o u s i n g , a n d c h e c k t h a t t h e t i e r o d i s s t i l l p i n c h e d . S l a c k e nb a c k t h e h o u s i n go n e e i g h t h o f a t u r n t o a l l o w f u l l a r t i c u l a t r o n of the tie rod and then lock the housing by tightening t t h e l o c k i n g r i n g t o 3 5 l b f t , e n s u r r n g h a t t h e h o u s i n gd o e s n o t r o t a t ew n r l e d o ' n c rt h i s .

FIG 9:4

Steering rack assemblY

B R a c k t r a v e ll r o m c e n t r a l p o s i t i o n 2 . 5 i n c h A A s s e m b l e dl e n q t h b e r w e e n b a l l p r n s4 5 . 3 4 i n c h ( 1 1 5 1 6 c m ) Key to Fig 9 :4 (6.35 cm) D T h r e a d e dl e n g t h o f t i e r o d C R a c k t r r v e l f r o r n c e n t r a lp o s i t i o n 2 . 5 n c h ( 6 . 3 5 c m )

108

l f t h i s a d j u s t m e n ti s c o r r e c tt h e a p p l i e d p r e l o a ds h o u r o be such that a torqueof 32 to 52 lb inch will be required t o p r o d u c ea r t i c u l a t i o n f t h e t i e r o d . o L o c k t h e a s s e m b l yb y p u n c h i n g t h e l i p s o f t h e l o c k r n g ring into the slotsin the ball housing. R e f i t t h e r u b b e r g a i t e r st o t h e h o u s i n g a n d t i e r o d s a n d s e c u r et h e c l i p s ,b u t b e f o r et i g h t e n i n gt h e c l i p a t t h e pinion end, stand the assembly on end and pour in a p p r o x i m a t e l y{ p i n t o f E x t r e m e P r e s s u r eS A E 9 0 o i l throughthe end of the garter. C e n t r a l i z et h e ? a c k a n d m a r k t h e p i n i o n s o t h a t t h e p o s i t i o no f t h e r a c k m a y b e c h e c k e d a f t e r t h e a s s e m b l y is refittedto the car. The full travel of the rack from stop t o s t o p i s 5 i n c h e s .t h a t i s 2 + i n c h e s i n e i t h e r d i r e c t r o n f r o m t h e c e n t r a lp o s i t i o n .T h r e e a n d o n e t h i r d t u r n s o f t h e p i n i o n w i l l g i v e t h e c o m p l e t et r a v e lo f t h e r a c k . Refitthe outer ball joints and locking nuts,screwing b o t h e n d s a n e q u a l d i s t a n c eo n t o t h e t i e r o d s u n t i l t h e d r s t a n c em e a s u r e db e t w e e n t h e t w o b a l l p i n si s a s s h o w n in FIG 9 :4. The locknuts should be tightened just s u f fi c i e n t l yt o h o l d t h e j o i n r s w h i l e t h e a s s e m b l yi s b e i n g fitted to the car. R e fi t t i n g : R e v e r s et h e r e m o v a l p r o c e d u r e ,l e a v i n g t h e s u p p o r t n u t s s l a c k u n t i l t h e s t e e r i n gc o l u m n c l a m p p i n c h b o l t h a s b e e n t i g h t e n e dt o a t o r q u e o f 8 t o 9 l b f t . T h e n t i g h t e nt h e c o l u m n b r a c k e tn u t s a n d f i n a l l yt h e s t e e n n gr a c k U b o l t s . F o l l o w i n g t h i s o p e r a t i o nt h e f r o n t w h e e l a l i g n m e n tm u s t b e c h e c k e da s i n S e c t i o n 9 : 6 , 9 :6 Tracking W h e n c o r r e c t l ya l i g n e d t h e f r o n t w h e e l s m u s t t o e o u t a total of rf+-r inch as indicated in FIG g:5. This s h o u l d b e c h e c k e d w r t h t h e c a r u n l a d e na n d s t a n d i n go n l e v e l g r o u n d w i t h t h e t y r e s i n f l a t e dt o t h e r e c o m m e n o e o D r e s s ue s . r T u r n t h e w h e e l s t o t h e s t r a i g h t - a h e a dp o s i t i o n a n d m a k e a m a r k o n e a c ht y r e w i t h c h a l ka t a p o i n t 1 O j i n c h e s a b o v e t h e g r o u n d a n d o n a d i a m e t e ro f 1 6 f ; i n c h e s a n d measurebetween the two marks. Roll the car forward by o n e h a l f o f a r e v o l u t i o no f t h e w h e e l s a n d a g a i n m e a s u r e the distancebetween the chalk marks which will now be at the rearof the wheels.This second measurement should be *l inch lessthan the first.lf the wheel align m e n t i s i n c o r r e c ti t m u s t b e a d l u s t e da s f o l l o w s : S l a c k e no f f t h e l o c k n u tf o r e a c h t i e r o d b a l ll o i n t a n d t h e c l i p s s e c u r i n gt h e g a i t e r st o t h e t i e r o d s , t h e n r o t a t ee a c n t i e r o d i n t h e a p p r o p r i a t e r r e c t r o nn o t i n g t h a t b o t h r o d s d , h a v e r i g h t h a n dt h r e a d s .T o e n s u r et h a t t h e s t e e r i n gr a c k i s i n t h e c e n t r a lp o s r t i o na n d t h a t t h e s t e e r i n gg e o m e t r yi s c o r r e c t i t i s i m p o r t a n tt h a t t h e t i e r o d s a r e a d i u s t e dt o e x a c t l ye q u a l l e n g t h s . After obtaining the correct adjustment tighten the b a l l j o i n t l o c k n u t st o a t o r q u e o f 2 5 l b f t . T a k e c a r e t o s e e that the reaction is taken by the flats on the socket h o u s i n g a n d t h a t t h e b a i l p i n i s v e r t i c a l r e l a t i v et o t h e h o u s i n g .W h e r e a p a i r o f l o c k n u t sr s f i t t e d t o e a c h t i e r o d . r e m o v eo n e o f t h e s e n u l s i r o n t e a c h s i d e . 9:7 Outer ball joints

FIG 9 :5

Front wheel alignment

I n t h e e v e n t o f a r u b b e r b o o t p e r i s h i n go r s u f f e r i n g d a m a g e i n s e r v i c e , t w i l l b e n e c e s s a r yo r e n e w b o t h t h e i t boot and the joint as road dirt will have entered.l{. however, a boot becomes damaged in the course of workshop operations the faulty boot alone may be replaced. B e f o r e a b o o t i s f i t t e d t h e a r e a a d j a c e n tt o t h e j o i n t s h o u l d b e s m e a r e dw i t h a l i t t l e D e x t a g r e a s e u p e r G P S I u b r ic an t .

9:8 Steering lock and ignition switch Three types are fitted to the cars under review, and b e f o r e r e m o v a l i t i s n e c e s s a r yt o d i s c o n n e c t t h e b a t t e r y , a l s o t h e e l e c t r i c a c o n n e c t i o n sf r o m b e n e a t ht h e f a c i a o r , l in the case of the first type only, the rearof the switch. First type : Thisis marked'LOCK'.'ACC','GARAGE','lGN', 'START' a n d i s o n l y r e n e w a b l ea s a c o m p l e t e a s s e m b l y . R e m o v e t h e s e c u r i n gs h e a r b o l t s w i t h a n e x t r a c t o ro r b y k n o c k i n gt h e m r o u n d w i t h a p u n c h , a n d w i t h d r a w r n e l o c k a n d s w i t c h f r o m t h e s t e e r i n qc o l u m n .

@)

FIG 9:6 Components of second type of steering lock and ignition switch Key to Fig 9:6 b a r r e la s s e m b l y a l i g n e dw i t h p i p ) ( A m e , i c ao n l y l 7 Shear screws

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109

T h e s e j o i n t s a r e f i t t e d w r t h n y l o n s e a t sa n d p r o t e c t e d by rubber boots. They are completely sealed and no l u b r i c a t i o n s r e q u i r e da t a n y t i m e i

1 Lock body 2 Accesshole 3 Lock and 4 Switch unit (showing cut back spttne 5 M o u l d e d t e r m i n a lf o r w a r n i n q b u z z e r 6 F i t t e d p o s i t r o no f s p r r n g l o a d e d d e v i c e 8 Gruo screw

1 1 0 0 M k 21 3 0 0

Second type: This may be marked either'HALT','GARAGE', 'FAHRT'.'START'. or'O','l','ll','lll'. R e m o v et h e c o w l i n g ( w h e r e f i t t e d ) , b u t , i f t h e c o m p l e t e lock assembly is not being removed, the lower half may be left in oosition. Except on America models the switch unit can be r e n e w e d w i t h t h e l o c k a s s e m b l yi n s i t u . R e m o v e t h e g r u b screw with a magnetic screwdriver through the access hole in the lock body and pull the switch from the barrel ( s e e F I G 9 : 6 ) . O n A m e r i c a m o d e l s a n a d d i t i o n a lw i r e i s c o n n e c t e d f o r t h e b u z z e r ;t h i s e n t a i l s t h e r e m o v a l o f t h e lock and barrel assembly before the switch unit can be removed. To remove the lock and barrel assemblv. extract the three shear screws by any convenient method, noting that the section of the lock body secured to the outer steering column need not be removed. On America m o d e l s i f t h e s w i t c h u n i t i s t o b e r e m o v e d . r e l e a s et h e m o u l d e d t e r m i n a l o f t h e e x t r a w i r e f r o m t h e b a r r e l ,t a k e out the grub screw and pull out the switch. To remove the complete lock assembly extract the two shear screws securing the cap to the lock body and w i t h d r a w t h e l o c k f r o m t h e s t e e r i n gc o l u m n . Third type: T h i s i s m a r k e d ' O ' , ' l ' , ' l l ' , ' l l l a n d i n c o r p o r a t ee i t h e r ' s a p r e s s b u t t o n o r a p u s h - i n r e l e a s ek e y . R e m o v e t h e s c r e w s r e t a r n i n gt h e l o c k c o w l i n g , l e a v i n g the lower half if only the switch is being removed. E x t r a c tt h e g r u b s c r e w , w h i c h i s r e c e s s e do n t h e p r e s s button type. and pull out the switch. The buzzer wire, when fitted. must be detached from its connection on the side of the lock body. To remove the complete lock assembly, extract the two shear screws and withdraw the lock. Ref itting: This is a reversal of the dismantling procedure, but note the following points: On the second type of switch, when refitting the switch to the barrelsee that the cut back spline is in lrne with the pip on the switch body and that the key has 'O' b e e n t u r n e dt o t h e o r ' H A L T ' p o s i t i o na n d w i t h d r a w n . Should the spring loaded device become displaced, it must be refitted to the splines of the centre shaft so that the end of the spring contacts the stop nearest to the retaining lug when the key has been withdrawn. This is s h o w n i n t h e i n s e t6 o f F I G 9 : 6 . On the third type the switch cannot be refitted out of s y n c h r o n r z a t r o nw r t h t h e l o c K m e c n a n t s m , b u t t t m a y b e

n e c e s s a r yt o t u r n t h e k e y w h e n a s s e m b l i n g t o a s s i s t i n engagement. When there is no multiple plug, take care to match thb colours of the individual wires when refitting the snap connectors. Before tightening the new shear screws, check the action of the lock and switch and then if this is satisfact o r y , t i g h t e n u p u n t i l t h e y s h e a ra t 1 8 l b f t . Adjustment: l f t h i s s h o u l d b e n e c e s s a r yf o r a n y r e a s o n p r o c e e d a s follows: On early cars, slackenthe column bracket screws and s l i d et h e o u t e r c o l u m n u p o r d o w n a s r e q u i r e d . On later cars, slacken the outer column horizontal clamp screw and adjust the position of the outer column to obtain a clearance of * inch (3 mm) between the n a c e l l e a n d t h e l o w e r b o s s o f t h e s t e e r i n gw h e e l . Check for correct operation before fully tightening the mounting screws. 9:9 Fault diagnosis

(a) Wheel wobble 1 2 3 4 5 6 Unbalanced wheels and tyres Slack steering ball loints Incorrectsteering geometry E x c e s s i v ep l a y i n s t e e r i n g g e a r F a u l t vs u s o e n s i o n Worn hub bearrngs

(b) Wander 1 C h e c k2 , 3 a n d 4 i n ( a ) 2 Uneven tvre oressures 3 Uneven tyre wear (c) Heavy steering 1 Check3 in (a) 2 Very low tyre pressures 3 N e g l e c t e dl u b r i c a t i o n 4 Wheels out of track 5 Rack damper too tight 6 E x c e s s i v ep i n i o n b e a r i n g p r e l o a d 7 I n n e r s t e e r i n gc o l u m n b e n t 8 C o l u m n b u s h e st i g h t (d) Lost motion 1 2 3 4 5 Loose steeringwheel, worn splines Worn rack and pinion teeth Worn ball joints Worn swivel hub joints Slackpinion bearings

110

C H A P T E R1 O T H E BRAKINGSYSTEM
10:1 10:2 10:3 10:4 10:5 10:6 10:7 10:8 Description Maintenance F i x e dc a l i p e r f r o n t b r a k e s Swinging caliperfront brakes Rearbrakes B l e e d i n gt h e s y s t e m The mastercylinder R e m o v i n ga f l e x i b l e h o s e 10 : 9 1 0 : 10 10 :11 10:12 10:13 1 0 : 14 10:15 T h e p r e s s u r er e g u l a t i n g v a l v e The handbrake Tandemmastercylinder P r e s s u r ef a i l u r e s w i t c h I n e r t i av a l v e Type 6 vacuum servo unit F a u l td i a g n o s i s

10 : 1 Description H y d r a u l i c a l l yo p e r a t e db r a k e sa r ef i t t e d t o a l l f o u r w h e e l s and applied by the brake pedal which is coupled directly to the master cylinder. The handbrake operatesthe rear b r a k e so n l y t h r o u g h a m e c h a n i c a l l i n k a g e , i n d e p e n d e n t l y o f t h e h y d r a u l i cs y s t e m a n d n o r m a l l y r e q u i r i n g n o s e p a r a t e adlustment. E a r l y M k 2 m a n u a l c o n t r o l m o d e l s h a v e d i s c b r a k e sa t t h e f r o n t , f i t t e d w i t h r i g i d l y m o u n t e d c a l i p e r si n c o r p o r a t i n g t w o h y d r a u l i c a l l yo p e r a t e d p i s t o n s a n d f r i c t i o n a s s e m b l r e s , between which the disc rotates. On all other models covered by this manual the front brakesare of the single s w i n g i n g c a l i p e rt y p e . I n e a c h c a s e w e a r i s t a k e n u p a u t o matically and no adjustment is provided. T h e r e a r b r a k e sa r e d r u m t y p e w i t h o n e l e a d i n g a n d o n e trailing shoe in each assembly.There is also a pressure l i m i t i n gv a l v e i n c l u d e di n t h e h y d r a u l i cp i p e l i n er n o r d e rt o p r e v e n t e x c e s s a v ep r e s s u r e b u i l d i n g u p a n d l o c k i n g t h e rear wheels under heavy braking. 10 :2 Maintenance The level of the fluid in the supply tank for rhe brake m a s t e rc y l i n d e r ( s e e F I G 1 0 : 1 ) s h o u l d b e p e r i o d i c a l l y checked and maintained at not more than l inch below

the bottom of the filler neck. lf frequent topping-up is n e c e s s a r ya l e a k i n t h e s y s t e m i s i n d i c a t e d w h i c h m u s t o e f o u n d a n d r e c t i fi e d w i t h o u t d e l a y . O n l y t h e r e c o m m e n d e d f l u i d i s t o b e u s e d , i . e . L o c k h e e d D i s c B r a k e F l u i d S e r i e s2 o r 3 2 9 . F o r t h e A u s t i n A m e r i c a u s e S e r i e s3 2 9 o n l y . It will be necessary to adjust the rear brake shoes to c o m p e n s a t ef o r w e a r o f t h e l i n i n g s a s f o l l o w s : J a c k u p t h e r e a r o f t h e c a r u n t i l t h e r o a d w h e e l s a r e c l e a r ,t h e n t u r n t h e adjusterscrew, on one wheel, arrowed in FIG 10:2. in a clockwise direction until the wheel is locked. Slackenthe screw until the drum just rotates without rubbing and r e o e a tf o r t h e o t h e r w h e e l . T h e f r i c t i o n p a d s o n t h e f r o n t b r a k e ss h o u l d b e e x a m i n e d p e r i o d i c a l l ya n d i f o n e p a d h a s w o r n m o r e t h a n t h e o t n e r they should be changed over.At no time should a pad be used after it has worn down to a thickness of S inch. I n a d d i t i o n t o t h e r e g u l a ri n s p e c t i o n o f t h e f r i c t i o n p a d s and linings, all the pipes, hoses and unions should be checked for wear or damage at the same time. T h e b r a k ef l u i d s h o u l d b e c h a n g e d c o m p l e t e l ye v e r y 1 8 m o n t h s o r 2 4 , O O 0m i l e s . E v e r yt h r e e y e a r s o r 4 0 , 0 0 0 m i l e s all fluid sealsand flexible hosesshould be examined and r e n e w e d i f n e c e s s a r y .A t t h e s a m e t i m e t h e p i s t o n s a n d bores of all the cvlindersshould be carefullvchecked for wear or corrosion.

1100Mk21300

111

Care must always be taken to observeabsolutecleanl i n e s sw h e n w o r k i n g o n a n y p a r t o f t h e h y d r a u l i cs y s t e m . D o n o t l e a v e b r a k e f l u i d r n a n u n s e a l e dc o n t a i n e r ,a n d a l w a v s d i s c a r da n v f l u i d w h i c h h a s b e e n d r a i n e d o u t o f t h e s y s t e m .A l w a y s u s e t h e f l u i d r e c o m m e n d e d .

10:3

Fixed caliper front brakes

Renewing f riction pads (see FIGS 10 : 3 and 10 :4) : J a c k u p t h e f r o n t o f t h e c a r a n d r e m o v et h e r o a d w h e e l . P r e s sd o w n t h e r e t a i n i n gs p r i n g ( 2 i n F I G 1 0 : 4 ) a n d w i t h d r a w t h e s p l i t p i n s . R e m o v et h e s p r i n ga n d w r t h d r a w 3 t h e f r i c t i o n p a d s 1 a n d t h e a n t i - s q u e a ks h r m s 1 1 . C l e a n t h e o u t s i d eo f t h e c a l i p e ra s s e m b l y n d d r y c a r e f l l y w i t h a u particular attentron to the exposed face of each piston. P r e s se a c h p r s t o n b a c k i n t o t h e c a l i p e r ,n o t i n g t h a t t h i s w i l l c a u s e t h e f l u i d l e v e l t o r r s ei n t h e s u p p l v t a n k a n d i t m a y b e n e c e s s a r yt o s y p h o n o f f s o m e f l u i d t o p r e v e n t o v e r fl o w i n g . C h e c k t h a t t h e r e l i e v e df a c e o f e a c h p i s t o n i s c o r r e c t l y p o s i t i o n e d b e f o r e f i t t i n g n e w f r i c t i o n p a d a s s e m b l i e si n t o t h e i r b o r e s .F i t t h e a n t i s q u e a ks h i m s b e t w e e ne a c h p r s t o n ano pao. E n s u r et h a t t h e p a d a s s e m b l i e sa r e f r e e 1 o m o v e f r e e l y i n t h e r e c e s s e s .R e m o v e a n y h i g h s p o t s f r o m t h e p a d p r e s s u r ep l a t e b y c a r e { u l f i l i n g . R e p l a c e t h e r e t a i n i n g s p r i n g , p r e s s i t d o w n a n d i n s e r t t h e s p l i t p i n s .F i t n e w springs if the originals have lost their tension or are oamageo. After titting the new pads operate the brake pedal several times to adjust the brake and top up the supply tank if necessary. Removing and dismantling a caliper:
FIG 10:2 The rear brake adjuster

F i G 10 : 1

The brake (A) and clutch (B) master cylinders

D i s c o n n e c tt h e b r a k e f l u r d s u p p l y h o s e . R e f e r t o F I G 1 0 : 5 . R e m o v e t h e t w o b o l t s s e c u r i n gt h e c a l i p e r t o t h e hub and withdraw the caliper. Depressthe retaining s p r i n g 1 6 a n d r e m o v e t h e s p l i t p i n s .R e m o v e t h e f r i c t i o n p a d sa n d t h e a n t i- s q u e a k h i m s .C l e a nt h e c a l i p e r a s s e m b l y . s R e c o n n e c t h e f l u i d s u p p l y h o s ea n d s u p p o r tt h e c a l i p e r to avoid strainingthe hose. Clamp the piston rn the m o u n t i n g h a l f o f t h e c a l i p e ra n d g e n t l y a D p l y t h e f o o t b r a k e ,t h u s f o r c i n g t h e u n c l a m p e dp i s t o n o u t w a r d s u n t i l it can be removed by hand. Hold a suitablecontainer r e a d y t o c a t c h t h e e s c a p i n gf l u i d . U s e a b l u n t - n o s e dt o o l t o r e m o v et h e f l u i d s e a l 1 3 f r o m its groove in the bore, takrng care not to damage either t h e b o r e o r t h e g r o o v e . T h e r e t a i n e rf o r t h e d u s t s e a l 14 i s n e x t l e v e r e do u t w i t h a s c r e w d r i v e ra n d t h e r u b b e r s e a l detached. R e m o v et h e c l a m p , r e f i tt h e p i s t o n i n t h e r i m - h a l fo f t h e caliper and repeat the above procedure to remove the mounting half piston. When cleaning the internal parts of the caliper use only methylated spirit or the correct grade of brake fluid. Reassembling and refitting : Before commencing, the operator is recommended to '1 T o b t a i n a s e t o f n e w r u b b e rs e a l s . a k e a d r y i n n e r s e a l 3 , coat it with Lockheed Disc Brake Lubricant and ease rt i n t o i t s g r o o v e w i t h t h e f i n g e r s u n t i l c o r r e c t l ys e a t e d i n t h e g r o o v e . S l a c k e n t h e b l e e d e rs c r e w 1 B b y o n e t u r n .

FIG 10:3

Fixed caliper disc brake assembly I B r a k ed i s c 2 B l e e ds c r e w

Key to Fig 10 ;3 3 C a l i p e ra s s e m b l y

112

t h e p i s t o n a n d s e a l i n w a r d s w r t h a c l a m p R e i i g h t e nt h e bleed screrry T h e r n o u n t i n g - h a l fp i s t o n i s a s s e m b l e di n t h e s a m e m a n n e r a s t h e r i m h a l f p r s t o n .b u t t h e f l e x i b l eh o s e m u s t b e d r s c o n n e c t e d o e n a b l et h e c l a m p t o b e u s e d ,a n d t h e t bleedscrew must again be slackened. A f t e r a s s e n r b l r n gh e p i s t o n - s n d s e a l s ,r e c o n n e c tt h e t a h o s e a n d b o l t t h e c a l i p e rt o t h e h u b . D o n o t d e p r e s st h e b r a k e p e d a l . R e p l a c et h e f r i c t i o n p a d s t o g e t h e r w i t h t h e retaining springs and splitpins Bleed the system as d e s c r i b e dl a t e r i n S e c t i o n 1 0 : 6 , t h e n o p e r a t et h e p e d a l s e v e r a l i m e s t o a d j u s tt h e b r a k e s . t

ld
FIG 10:4

t/

tt/ e--3

Components of fixed-type caliper

Removing and refitting a brake disc: Remove the hub as describedrn Chapter 7. then r e m o v et h e f l a n g e b o l t s2 t o r e l e a s e h e d i s c f r o n r t h e h u b . t W h e n r e fi t t i n g a d i s c t h e m a x i r n u mr u n o u t a t t h e o u t e r p e r i p h e r y f t h e b r a k i n gs u r f a c es h o u l d b e m e a s u r e d i t h o w a dial gauge. This figure must not exceed .006 inch. g R e m o v i n gi h e d i s . a n d r e D o s i t r o n i n i t o n t h e s p l i n e so f t h e d r i v e s h a t t w i l l u s u a l l yp r o d u c e a n a c c e p t a b l e e g r e e d of runout.

K e yt o F i g 1 0 : 4 1 F r i c t i op a d s 2 P a dr e t a r n r n g r r n g n sp g 3 R e t a i n i np i n 4 P i s t o n u s ts e a l d 5 P i s t o n l u i ds e a l f 6 Piston 7 B l e e d es c r e w r 8 C a l r p e(rm o u n t i n g a l f ) h 9 C a l i p e( r i m h a l ) r f p 1 0 C a l r p em o u n t i n g o r n r r 11 A n t i s q u e a k h r m s s

C o a t a p i s t o n w i t h t h e l u b r i c a n ta n d l o c a t e i t s q u a r e l y in the nrouth of the bore with the cutaway part of the p i s t o n f a c e u p p e r m o s t .P r e s si n t h e p i s t o n u n t i l a p p r o x i m a t e l y t i n c h i s p r o t r u d i n g ,e n s u r i n gt h a t t h e p i s t o n r s not tilting during the operation.lf the outer seal and retainerwere removed, dry a new seal, coat rt wrth l u b r i c a n t ,f i t i t i n t o t h e r e t a i n e ra n d p l a c e t h e a s s e m b l y . o v e r t h e p i s t o ns q u a r e l v n d w i t h t h e s e a li n n e r m o s t P r e s s a

10:4 Swinging caliper front brakes Renewing friction pads J a c k u p t h e f r o n t o f t h e c a r a n d r e m o v et h e a p p r o p r i a t e r o a dw h e e l . R e f e r t o F I G 1 0 : 6 D e p r e s s h e p a d r e t a i n n ) g t

. 9 .

flrao
,2/

ao

t9

to

frt-

(kcs ,.-./7V

FIG 10 :5

ComDonents of fixed-tvDe front brake

Key to Fig 10:5 1 B r a k e d i s c 2 F i a n g eb o h 3 Dust cover 4 Nut 5 D u s t c o v e r i r r a c k e t R g h t h a n d t o p . l e f t h a n db o t t o m 6 D u s t c o v e r b r a c k e t ' - L e f l h a n d t o p , n g h t h a n d b o t t o m 7 C o v e r b o l t 8 C o v e r b o l t 9 W a s h e r 1 0 C a l i o e ra s s e m b l v 1 2 P i s t o n 13 Innerseal 14 Seal 15 Padassembly 16 Spring 17 Plug 1 8 B l e e d e rs c r e w 1 9 C a l i p e rb o l t 20 Springwasher

1100 k2 1300 M

113

I
I

t h e f r i c t i o n p a d s , b l e e d t h e s y s t e r na s w i l l b e d e s c r i b e d r n t S e c t i o n 1 0 : 6 a n d c e n t r a l i z eh e p a d s b y s e v e r a a p p l i c a l t i o n s o f t h e b r a k e p e d a l .T o p u p t h e s u p p l y t a n k i f r e q u i r e d . Removing and replacing a caliper assembly: R e m o v et h e f r i c t i o n p a d s . D i s c o n n e c t h e s u p p l y h o s e . R e m o v et h e t w o b o l t s s e c u r i n gt h e c a l i p e rt o t h e h u b a n d lift off. R e l e a s et h e r e t a i n i n g s p r i n g c l i p a n d t a p t h e p i s t o n assemblvfrom the calioer with a soft faced hammer. R e f i t t i n g t h e c a l i p e r i s a r e v e r s a lo f t h e a b o v e . E n s u r e t h a t t h e p i v o t p i n a n d t h e s l i d i n g p a r t s o f t h e c a l i p e ra r e free from dirt and rust and free to move easily.Note that the thick steel washer is fitted to the lower of the two s e c u r i n gt h e c a l i p e ra n d t h a t a s p r i n g w a s h e r i s f i t t e d t o each. T h e c l e a r a n c e n d e r t h e f o o t o f t h e s e c u r i n gc l i p ( 5 i n u F I G 1 0 : 7 ) s h o r - r l d o t e x c e e d. 0 4 0 i n c h . T h i s t o l e r a n c e s n r s e t i n m a n u f a c t u r ea n d c a n b e c h e c k e d o n l v w h e n t h e paos are removeo. Brake discs: These may be servicedin the same manner as on {ixed ( c a l i p e ra s s e m b l r e s s e e S e c t i o n 1 0 : 3 ) , b u t n o t e t h a t t h e m a x i m u m r u n o u t a t t h e p e r i p h e r yo f t h e b r a k i n g s u r f a c e s h o u l d n o t e x c e e d. 0 0 6 i n c h . 10:5 Servicing brakes Servicing the wheel cylinder: -Jackup the car under the rear subframe, remove the road wheei and thoroughly clean the brake backplate. D i s c o n n e c t h e f l u i d s u p p l y h o s ea s i n s t r u c t e d n S e c t i o n i 10:8.

lu_r

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C o m p o n e n t so f s w i n g i n g - t v p e c a l i p e r '1 p Friction ads Key to Fig 10 :6 2 R e t a i n i np r n s g g 3 P a dr e t a i n i n s p r i n g 4 P i s t o n u s ts e a i d f 5 Pislon 6 P i s t o n l u i ds e a l 7 Piston ylrnder c g I P r s t o n s s e m b lrye t a i n r nc l r p a s p r i n g 3 a n d e x t r a c tt h e s p l i t p i n s2 . W i t h d r a w t h e f r i c t i o n p a d s1 . Clean the exposed face o{ the piston, the recess ilr w h i c h t h e m o v i n g p a d s l i d e sa n d t h e f a c e o f t h e c a l i p e r a g a i n s t w h i c h t h e f i x e d p a d r e s t s . P r e s st h e p i s t o n b a c k i n t o r t s c y l i n d e r .n o t i n g t h a t t h i s w i l l c a u s e t h e f l u i d l e v e l to rise in the supply tank and syphoning off a quantity of f l u i d i f n e c e s s a r yt o a v o i d a n o v e r f l o w . F i t t h e n e w p a d a s s e m b l i e sm a k i n g s u r e t h a t t h e p a d , o p e r a t e d b y t h e p i s t o n c a n m o v e e a s i l y i n t h e r e c e s si n t h e cailper. F i t t h e r e t a i n i n gs p r i n g , p r e s s i t d o w n a n d i n s e r t t h e s p l i t p i n s .l f a s p r i n g i s d a m a g e d o r h a s l o s t i t s t e n s i o n a t should be renewed. Slackenthe screw on the top of the caliperadjacentto t h e p i v o t p i n b o s s ,s h o w n i o t h e l e f t o i t h e b l e e d s c r e w I n F I G 1 0 : 7 . P r e s sd o w n t h e b r a k e p e d a l s e v e r a lt i m e s t o centralizethe brake pads on the disc and retighten the s c r e w t o a t o r q u eo f 6 5 t o 8 0 l b i n . T o p u p t h e s u p p l y t a n k if necessary. Removing and dismantling a cylinder assembly: R e m o v et h e f r i c t i c np a d s a n d r e t a i n e r s j u s t d e s c r i b e d . a D i s c o n n e c t t h e r a k ef l u i d s u p p l yh o s e .M o v e t h e s w i n g i n g b c a l i p e r l o w a r d s t h e c e n t r e o f t h e c a r , r e l e a s et h e r e t a i n i n g f c l i p B a n d s l i d et h e p i s t o n a s s e m b l y r o m t h e c a l i p e r , s i n g u a s o f t - f a c e dh a m m e r i f n e c e s s a r y . R e c o n n e c tt h e f l e x i b l es u p p l y h o s e a n d s u p p o r t t h e c a l i p e r t o a v o i d s t r a i r r i n gt h e h o s e . P r e s sd o w n g e n t l y o n the brake pedal untii the piston has emerged sufficiently for it to be removed by hand. The piston and seals are d i s m a n t l e da s d e s c r i b e di n t h e p r e v i o u sS e c t i o n . Reassemblv: R e fi t t h e s e a l sa s p r e v i o u s l y e s c r i b e d . l e a n t h e s l o t s d C i n t h e p i s t o n a n d t h e e d g e so f t h e c a l i p e r . n s e r tt h e p i s t o n I a s s e m b l vi n t o t h e c a l i p e r ,b l e e d s c r e w t o t h e r e a r , a n d r e f i t t h e r e t a i n i n gc l i p . R e c o n n e c t h e f l e x i b l eh o s e a n d f i t

FIG 10 :6

FIG 10 :7

Swinging caliper disc brake 2 B l e e ds c r e w 4 Swinging caliper

1 B r a k ed i s c Key to Fig 10 :7 3 P i s t o na s s e m b l y 5 F i x e d t o s w r n g r n gc a l i p e rs e c u f l n gc l r p

114

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FIG 10:8 Components of rear brake 4 Platescrew 5 Nut 6 Springwasher 1 ' 1 S r e a d y p r n 1 2 S t e a d ys p r i n g 1 3 W a s h e r 18 Nut 19 Washer 2 0 d y l r n d e rp i s t o n KeytoFig 10:8 1 Brake'plate 2 Cableandhosebracket 3 Washer 8 Lrnrng 9 S h o e r e t u r n - s p r r n g 1 O S h o e r e t u r ns p l n g g, 14 S jHta n d bs s e'm O t y l , ' 99 ral .e ver e 15 Cy inder boot 1 6 A d j u s t e rt a p p e t 17 Wedge 21 Seal 22 Eoot 23 Bleedscrew 2 4 C y l i n d e rc l i p

Unscrew the bleed screw from behind the backolate ( 2 3 i n F I G 1 0 : 8 ) . R e m o v et h e c i r c l i pf r o m t h e c y l i n o e r b o s s 2 4 p r o t r u d i n gt h r o u g h t h e b a c k p l a t e .R e n r o v et h e h u b c a p a n d n u t a n d , u s i n g s e r v i c et o o l s 1 8 G . 3 0 4 a n d 1 8 G . 3 0 4 8 p u l l o f f t h e b r a k ed r u m a n d h u b u n i t . R e m o v e t h e b r a k es h o e sa s d e s c r i b e dl a t e ra n d l i f t o u t t h e c y l i n d e r . Remove the rubber boots 22 and extract both pistons. U s e t h e f i n g e r s t o r e m o v e t h e r u b b e r p i s t o n s e a l s2 1 . C l e a n a l l i n t e r n a p a r t sw i t h m e t h y l a t e d p i r i to r t h e c o r r e c tg r a d e l s o f L o c k h e e db r a k ef l u i d . A l l r u b b e rs e a l ss h o u l d b e r e n e w e da s s h o u l d a n y o t h e r p a r ts h o w i n g s i gn s o f w e a r , p r t t i n go r c o r r o s r o np a r t i c u ar l y . l t h e p r s t o na n d c y l i n d e r . R e a s s e m b l y s c a r r i e do u t i n t h e r e v e r s eo r d e r t o d i s i m a n t l i n g w i t h a l l i n t e r n a lp a r t s w e t t e d w i t h b r a k e f l u r o . U s e o n l y t h e f i n g e r st o f i t t h e r u b b e rs e a l s . A{ter assembly, bleed the system as described in S e c t i o n 1 0 : 6 a n d a d l u s t t h e b r a k es h o e sa s i n S e c t i o n 1O:2 Servicing the brake shoes: C h o c k u p t h e f r o n t w h e e l s . r e l e a s e h e h a n d b r a k e i. a c k t u p t h e c a r u n d e r t h e r e a r s u b f r a m ea n d r e m o v e t h e i o a d wneet. R e m o v et h e h u b c a p a n d n u t a n d p u l l o f f t h e d r u m a n d h u b u n i t u s i n g s e r v i c et o o l 1 8 G . 3 0 4 a n d 1 9 G . 3 0 4 8 . A t
FIG 10:9 Key to Fig 10:9 3 S t e a d ys p r i n g 6 S t e a d ys p r i n g Righthand rear brake assembly 1 H a n d b r a k el e v e r 2 P u l l - o f fs p r r n g 4 P u l l - o f fs p r l n g 5 A d j u s r e ra s s e m o r y 7 H y d r a u l r cc y l i n d e r

1 1 0 0M k 2 1 3 0 0

115

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9
FIG 10:10

lo

ll

12

13

f4

r5

Sectional view of brake master cylinder

5 Cylinderbody 6 Washer 4 Supplytank 2 Rubberboot 3 Mountingflange 1 Pushrod Keyto Fig 10:10 '1 13 Main cup 1 2 P i s t o nw a s h e r 1 Piston 1 0 S e c o n d a r yc u p 9 Srop washer 7 End plug 8 Circlip 16 Valveassembly 1 5 R e t u r ns p r i n g 14 Springretainer

this point the operator is warned against any accidental pressure on the brake pedal as this may result in the e . i e c t i o no f p a r t s a n d s p i l l a g e o f o i l . D i s c o n n e c tt h e s t e a d y s p r i n g s ( 3 a n d 6 i n F I G 1 0 : 9 ) by pressingand turning the slotted washers. i t N o t e c a r e f u l l y h e p o s i t i o n s n w h i c h t h e p u l l - o f fs p r i n g s are fitted then remove the shoes and springs. T h e l i n i n g ss h o u l d b e e x a m i n e df o r w e a r a n d r e n e w e d before they are worn down to the rivets.lt is not recomm e n d e d t h a t t h e o r i g i n a l s h o e s s h o u l d b e r e l i n e d ,b u t t h a t a set of replacementshoes should be obtained making sure that the correct linrng material is used as given in Technical Data. Always renew brake shoes in patrs and n e v e r m i x l i n i n g m a t e r i a l so r u n e v e n b r a k i n g w i l l r e s u l t . Brakeshoes should also be renewed if they are seen to be contaminated with oil or greaseon the linings as no attempt at cleaning them is likely to be effective. Refitting is a reversal of the dismantling procedure. Make sure that the pull-off springs are correctlyfitted to the holes in the webs and that the shoes are correctly seated in their slots in the pistons and adjusters. Before attempting to fit the brake drum over the new linings slacken off the adjustersto the full extent in an a n t i c l o c k w i s e d i r e c t i o n ;e n s u r ea l s o t h a t t h e h a n d b r a k er s fully released. W h e n r e a s s e m b l yi s c o m p l e t e , r e a d j u s tt h e b r a k e s h o e s a s p r e v i o u s l y d e s c r i b e d .T h i s w i l l a l s o s e t t h e h a n d b r a k e correctly. 10:6 Bleeding the system

c o n t a i n i n ga l i t t l e b r a k e f l u i d . O p e n t h e b l e e d s c r e w o n e f u l l t u r n a n d h a v e a n a s s r s t a n t o p r e s sd o w n s l o w l y o n t h e brake pedal and allow it to return without assistance. Repeatthis pumping action a few times with a slight pause before each depression of the pedal and observe the f luid entering the jar. When the flow is completelyfree from air bubbles hold the pedal firmly down and tighten the bleed screw. R e p e a tt h i s r o u i i n e o n t h e o t h e r r e a rw h e e l a n d t h e t w o front calipersand on completion top up the supply tank. lf the fluid which has been bled from the system is clean it may be used afterstanding for at least24 hours to r e m o v ea i r b u b b l e s .A l l d i r t v f l u i d m u s t b e d i s c a r d e d . 10:7 The master cylinder Removal: T h e m a s t e rc y l i n d e r i s b o l t e d t o t h e f o r w a r d s i d e o f t h e engine bulkhead immediately in front of the brake pedal to which rt is attached by means of a clevis pin through t h e f r o n t o n t h e p u s h r o d ( 1 i n F I G 1 0 : 1 0 ) . R e m o v et h e circlip and withdraw the clevrs pin. Disconnect the p r e s s u r ep i p e u n i o n f r o m t h e e n d p l u g 7 , r e m o v e t h e t w o s e c u r i n g b o l t s a n d w i t h d r a w t h e c o m p l e t e a s s e m b l yf r o m Ine car. Dismantling: D r a i na l l f l u i d f r o m t h e t a n k . p u l l b a c k t h e r u b b e rb o o t 2 r e m o v e t h e c i r c l i p 8 w i t h a p a i r o f l o n g - n o s e dp l i e r sa n d withdraw the pushrod 1 and the dished washer 9. Remove t h e r e m a i n i n g i n t e r n a l p a r t s f r o m t h e c y l i n d e r b a r r e l .T h e secondary cup 10 should be stretched with the fingers over the piston flanges and removed.

This is not an item of routine maintenance, but is r e q u i r e dw h e n e v e r a p a r t o f t h e h y d r a u l i c s y s t e m h a s b e e n disturbed or air has been allowed to enter the system, either through a leak or because the fluid level in the supply tank hasfallen too low. lt is importantthat the tank be kept at least half full throughout this operation by topping-up as the fluid is used. Attach the bleedertube to a rear wheel cylinder bleed screw and immersethe free end of the tube in a clean jar

Reassembling: C l e a n a l l r u b b e r p a r t s i n m e t h y l a t e ds p i r i t o r b r a k e f l u i d . Any other cleansing compound which may have been used on the metal oarts must be removed and the parl

116

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r--rcrir-

Reassembling: C l e a n a n d l u b r i c a t ea l l p a r t s i n b r a k e f l u i d . F i t a n e w taper seal and piston seal, ensuringthat the former is fitted with the small diameterentering the bore first. R e fi t t h e r e t u r ns p r i n ga n d v a l v ea s s e m b l y n d s e c u r er n a p l a c ew i t h t h e e n d p l u g a n d w a s h e r . lf the sealing washer is of aluminium it must be replaced with a new copper washer. At the same time fit a new end plug and a new short pipe from the regulating valve to the chassis. Refitting: S e c u r et h e v a l v e a s s e m b l yt o t h e s u b f r a m ec r o s s m e m b e r a n d r e c o n n e c t t h e t h r e e p r e s s u r el i n e s . B l e e d t h e s v s t e m a s d e t a i l e dr n S e c t i o n 1 0 : 6 '10 :10 The handbrake

VWI:

FIG 10:11 valve

Components of brake pressureregutating

d r i e d . E x a m i n ea l l p a r t s f o r w e a r o r d a m a q e a n d r e n e w w h e r e n e c e s s a r y ; t i s u s u s a l l yd e s i r a b l et o r e - n e w l l r u o o e r i a p a r t s . D i p a l l p a r t s r n b r a k e f l u i d a n d a s s e m b l ew h i l e s t i l l wet. Stretch the secondary cup over the end flanqe of the piston with the liptf the cup towards the oppositeend of t h e p i s t o n . W o r k t h e c u p w i t h t h e f i n g e r s t o e n s u r et h a t i t rs correctly seated In its groove. Fit the valve 16 to the r e t u r n s p r i n g 1 5 a n d w i t h t h e r e t a i n e r. l4 i n p l a c e i n s e n t h e l a r g ee n d o f t h e s p r i n g i n t o t h e b a r r e l .I n s e r tt h e m a r n cup 13 with the lip foremost,taking care not to turn bacK the lip, and press it down on to the retainer. R e p l a c et h e d i s h e d w a s h e r 1 2 w i t h t h e c o n c a v e f a c e t o w a r d s t h e m a i n c u p . I n s e r tt h e p i s t o n 1 1 , t a k i n g c a r e n o t t o d a m a g e o r t u r n b a c k t h e l i p o n t h e s e c o n d a r VC u p . p u s h t h e p i s t o n d o w n t h e b o r e a n d r e p l a c et h e p u s h r o d , c i r c l i p and rubber boot. Ref itting: S e c u r e t h e m a s t e rc y l i n d e r t o t h e b u l k h e a d w i t h t h e t w o b o l t s a n d r e fi t t h e p r e s s u r ep i p e u n i o n t o t h e e n d p l u g . E n s u r et h a t t h e f o r k o n t h e p u s h r o d i s i n l i n e w i t h t h e D e d a l l e v e ra n d f i t t h e c l e v i sp i n a n d c i r c l i p . Check the brake shoe adjustment. Fill the supply tank and bleed the system.Apply the brakes hard a few times and check for leaks. 10:8 Bemoving a flexible hose The correct method for removing a flexible hose is as follows, and it is important that this routine be used if damage is to be avoided: Unscrew the metal piperrne union nut from its connection to the hose, then hold rne hexagon on the flexible hose with one spanner and remove the locknut securing the hose to the bracketwith another. The hose may now be removed with a soanner a p p l i e d t o t h e h e x a g o na t t h e o t h e r e n d . Pressure regulating valve This device is fitted in the brake fluid line on all cars except the Austin America and is designed to close and cut off any further pressureto the rear wheels when a preset value has been reached. By this means wheel l o c k i n g i s v e r y l a r g e l y p r e v e n t e d ,a s a n V f u r t h e r o r e s s u r e i s a p p l i e d t o t h e f r o n t b r a k e s . T h e p r e s s u r eu t * h i c h t h e valve closes is 450 lb/sq in with fixed caliperfront brakes a n d 3 7 5 l b / s q i n w i t h s w i n g i n g c a l r p e rt y p e b r a k e s ( s e e F I G1 0 : 1 1 ) . Removing: Disconnect the three pressurelines from the connec_ trons on the valve body. Remove the nut and wasner s e c u r i n g t h e v a l v e t o t h e r e a rs u b f r a m e f r o n t c r o s s m e m b e r and lift off. Dismantling: C l e a n t h e e x t e r i o r o f t h e a s s e m b l yt h e n r e m o v e t h e e n d p l u g a n d s e a l i n g w a s h e r t o a l l o w t h e v a l v e a s s e m b l va n o r e t u r ns p r i n g t o b e w i t h d r a w n . F i t a n e w p i s t o n a n d r u b b e r seal assembly if either is worn or damaqed. 10:9

Excessivetravel of the handbrake lever is normaly taken up by the periodic adjustment of the rear brakes, but if it is found that this is not sufficient and it has been

5 6 7 8 I 10 11 12 20 21 22 23 24 25
FIG 10;12 Sectional view of tandem master cylinder '1 Key to Fig 10 :12 F i l l e rc a p 2 p l a s r i cr e s e r v o r r 3 Reservoir eals s 4 Main cup 5 pislonwasher g pistonlink 6 Pislon 7 Main cup 8 Spring 10 pin 11 Pin retainer 12 Main cup 13 pistonwasher '14 Circlip 15 CuD 16 Circtip 17 pjsron 18 S p r i n g r e t a i n e r 19 S t o p w a s h e r 20 Wasner 22 Sprins 23 i,ushrod 24 Spirotoiirng ?1 P":i"s. zc huooer boot ( E a r l yt y p e p i s t o n s h o w n i n s e t )

1 1 0 0 k2 1 3 0 0 M

117

Lubrication: A I I e x p o s e d p a r t s s h o u l d b e l i b e r a l l ys m e a r e d w r t h Duckhams anti-freeze grease G.6341, including the s e c t o r p i v o t a n d t h e o p e r a t i n gl e v e r c l e v i s p i n . 10 :11 Tandem master cvlinder i T h e t a n d e m m a s t e rc y l i n d e ri s i l l u s t r a t e dn F I G 1 0 : 1 2 . R e m o v a l i s e f f e c t e d b y d i s c o n n e c t i n gt h e h y d r a u l i c p i p e s a n d u n s c r e w i n gt h e t w o n u t s s e c u r i n gt h e a s s e m b l y t o t h e b u l k h e a d .D o n o t r e m o v e t h e c l e v i s p i n s e c u r i n g the pushrod to the pedal lever. Dismantling: D r a i n o f f t h e f l u i d a n d r e p l a c et h e f i l l e r c a p 1 . P l u g t h e p i p e c o n n e c t i o n sa n d c l e a n t h e e x t e r i o ro f t h e a s s e m b l y . R e m o v et h e r u b b e r b o o t 2 5 . P l a c et h e c v l i n d e rb o d v i n a s o f t - j a w e dv i c e w i t h t h e b o r e o p e n i n g u p p e r m o s t . C o m p r e s st h e r e t u r n s p r i n g 2 2 a n d r e m o v e t h e S p i r o l o x ring 24. Removethe circlip16. Move the piston up and d o w n t o { r e et h e n y l o n b e a r i n g2 1 , c u p 1 5 a n d w a s h e r 2 0 . R e m o v et h e i n n e r c i r c l i o 1 4 . W i t h d r a w t h e p r i m a r ya n d s e c o n d a r yp i s t o n s6 a n d 1 7 t t o g e t h e rw i t h t h e s t o p w a s h e r 1 9 . C o m p r e s s h e s p r i n g 8 a n d p r e s so u t t h e p i n 1 0 . N o t e c a r e f u l l yt h e p o s i t i o n so f t h e r u b b e rc u p s 4 , 7 , 1 2 a n d 1 5 a n d r e m o v et h e m t o g e t h e r w i t h t h e w a s h e r s5 a n d 1 3 . Unscrew the four bolts and removethe plasticreservoir r 2 . R e m o v et h e r e s e r v o i s e a l s3 . U n s c r e w t h e c o n n e c t i o n adaptors, discard the copper gaskets and remove the sprinoand trap valves. C l e a n a n d d r y t h o r o u g h l y a l l p a r t se x a m i n ef o r w e a r , d a m a g e o r d e t e r i o r a t r o na n d r e n e w w h e r e n e c e s s a r y . Reassembling: l T h i s i s a r e v e r s a o f t h e d i s m a n t l i n gp r o c e d u r ea n d a l l p a r t ss h o u l d b e a s s e m b l e d f t e rd i p p i n g i n h v d r a u l i cf l u r d . a Place the piston washer on the head of the secondary p i s t o n c o n v e x s i d e f i r s t . E a s et h e s e c o n d a r ym a i n c u p , l i p

FIG 10 :13 assemblv

Sectional view

of oressure failure switch

Key to Fig 10 :13 1 N y l o ns w r t c h 4 P r s t o ns e a l 3 S h u t t l ev a l v e p r s t o n 7 End plug 6 C o p p e rw a s h e r

2 Switch body 5 P i s l o ns e a l

checked that the brakeshoe liningsare not in need of r e p l a c e m e n ta n d a r e c o r r e c t l y a d l u s t e d , t h e f o l l o w i n g p r o c e d u r es h o u l d b e u s e d : A p p l y t h e h a n d b r a k eu n t i l t h e p a w l e n g a g e sw i t h t h e t h i r d n o t c h o n t h e r a t c h e ta n d a d l u s tt h e n u t s a t t h e h a n d b r a k e l e v e r u n t i l i t i s j u s t p o s s r b l et o r o t a t e t h e r o a d w h e e l s b y h e a v y h a n d p r e s s u r e .l t i s i m p o r t a n t t h a t b o t h r o a d wheels offer equal resistance to turning. R e l e a s et h e h a n d b r a k e l e v e r a n d c h e c k t h a t b o t h wheels are completely free. lf they are not, remove the b r a k ed r u m a n d h u b u n i t a n d c h e c k t h e a c t i o n o f t h e p u l l o f f s p r i n g s . C h e c k a l s o f o r s e i z u r eo f a w h e e l c y l i n d e r . R e f i tt h e h u b a n d d r u m u n i t , a d j u s ta n d r e c h e c k . Removing the handbrake cables: Chock uo the front wheelsand releasehe handbrake. t R e m o v et h e c a b l e a d j u s t i n gn u t s a n d t h e c a b l e f a i r l e a dr n the centre of the floor between the two front seats. Pull i t h e c a b l et h r o u g h t h e f l o o r f r o m u n d e r n e a t h n d r e l e a s e t a f r o m t h e g u i d e c h a n n e l o n t h e r e a rs u b f r a m e . J a c k u p t h e c a r u n d e rt h e r e a rs u b f r a m ea n d r e m o v et h e r o a d w h e e l . R e m o v e t h e n u t s e c u r r n gt h e c a b l e s w i v e l sector to the radius arm and remove sector and cable. D r a w t h e c a b l et h r o u g h t h e f r a m e a n d r e l e a s et f r o m t h e i a c t u a t i n gl e v e ro n t h e b r a k e b a c k p l a t e . Refitting: When refitting a new cable make sure that the corners of the sector are nipped. Reversethe above procedure e n s u r i n gt h a t t h e g u i d e c h a n n e l i s w e l l l u b r i c a t e d . i R e a d j u st h e h a n d b r a k en a c c o r d a n c e i t h t h e p r e v i o u s w In s t r u t r o n s . c Handbrake release knob : R e f e rt o F I G 1 0 : 1 5 . O n e a r l yc a r s ,w h i c h a r e n o t f i t t e d w i t h a l o c k n u t b e h i n dt h e k n o b , i t i s p o s s i b l e o r t h e k n o b f f r t o s e p a r a t e r o m t h e r e l e a s e o d . T h i s c a n b e p r e v e n t e db y f i t t i n g a S t a r l o c kt y p e w a s h e r a s s h o w n , t h i s r e l i e v e s h e t k n o b o f t h e p r e s s u r e r o m t h e r e t u r ns p r i n g . f

t
FIG 10:14

Sectional view of inertia valve assembly

1 Endplugsubassembly 2 Spring Key to Fig 10:14 4 Sleel ball 5 Inertiavalve body 3 Valve 7 F l u i d s u p p l y f r o m m a s t e rc y l i n d e r 6 End plug washer

118

l a s t ,o v e r t h e e n d o f t h e p i s t o n w i t h t h e f i n g e r sa n d s e a t i t s e c u r e l yi n i t s g r o o v e . Refitting: T h i s a l s o i s t h e r e v e r s eo f t h e r e m o v a l p r o c e d u r e .C a r e f u l l y g u i d e t h e p u s h r o dt h r o u g h t h e o p e n i n g i n t h e r u b b e r F r b o o t . F i l lt h e r e s e r v o rw r t h L o c k h e e d3 2 9 t s r a k e l u i da n d b l e e d t h e s y s t e ma s d e s c r i b e db e l o w . Bleeding thq,system (Tandem type) : A t t a c h b l e e d t u b e s a s d e s c r i b e di n S e c t i o n 1 0 : 6 t o t h e t w o w h e e l s o n t h e r i g h t h a n ds i d e o f t h e c a r a n d o p e n t h e b l e e ds c r e w s . Fully depressthe brake pedal, hold it down, close t h e b l e e d s c r e w sa n d a l l o w t h e p e d a lt o r e t u r n . Open the bleed screw and operate the pedal as d e s c r i b e du n t i l n o a i r b u b b l e s c a n b e s e e n i n t h e f l u i d R b e i n g p u m p e d i n t o t h e t w o 1 a r s . e p e a tf o u r m o r e t i m e s a n d t h e n t i g h t e n b o t h b l e e ds c r e w su s i n g a t o r q u eo f 7 l b f t f o r t h e f r o n t b r a k e sa n d 4 l b f t f o r t h e r e a r b r a k e s . R e p e a tt h e p r o c e d u r eo n t h e t w o l e f t h a n dw h e e l s .

u C l e a na n d d r y c a r e f l l y a l l c o m p o n e n t sa n d i n s p e c tt h e b o r e f o r a n y s i g n s o f s c o r i n go r d a m a g e .l f a n y s u c h s i g n s are presentthe complete assemblymust be renewed. t T e s t t h e o p e r a t i o no f t h e s w i t c h b y r e c o n n e c t i n g h e w i n n g a n d a c t u a t i n gt h e p l u n g e r ,o b s e r v i n gt h e w a r n i n g l i gh t . Reassembling: F i t t w o n e w s e a l st o t h e p i s t o nw t t h t h e l i p s f a c i n g o u t wards. Lubricatethe piston assembly with Lockheed D i s c B r a k e L u b r r c a n ta n d f i t i n t o t h e b o r e e n s u r i n gt h a t the lip is not turned back. F i t a n e w c o p p e rw a s h e r t o t h e e n d p l u g , s c r e w i n a n d tighten to a torqueof 200 lb in. S c r e w i n t h e s w i t c h a n d t r g h t e nt o a t o r q u e o f 1 5 l b i n . Ref itting : R e v e r s et h e r e m o v a l p r o c e d u r e ,m a k i n g s u r e t h a t t h e p i p e s a r e c o r r e c t l yc o n n e c t e d .R e fi l l t h e m a s t e r c y l i n d e r with Lockheed329 Brake Fluid and bleed the system s t a r t i n gw i t h t h e r e a r b r a k e s .

10:12 The pressure failure switch T h i s i s i l l u s t r a t e di n F I G 1 0 : 1 3 a n d i s r e m o v e d f o r s e r v i c i n ga s f o l l o w s : D i s c o n n e c t t h e w r r i n g . C l e a n t h e . e x t e n o ro f t h e s w i t c h a n d t h e p i p ec o n n e c t t o n sD i s c o n n e c t a n d p l u g t h e h y d r a u l i cp i p e s , n o t i n g c a r e f u l l yt h e u n i o n s irom which they were disconnected. Unscrew the r e t a i n i n gb o l t a n d r e m o v e t h e s w i t c h . Dismantling: R e m o v et h e e n d p l u g 7 a n d d i s c a r dt h e c o p p e rw a s h e r 6. Unscrewthe nylon switch 1 and wrthdraw the shuttle valve piston assembly. Remove and discard the two p i s t o n s e a l s4 a n d 5 .

10 :13 The inertia valve T h i s v a l v e i s f i t t e dt o t h e A u s t i n A m e r i c ai n p l a c e o f t h e p r e s s u r e e g u l a t i n g a l v e d e s c r i b e di n S e c t i o n 1 0 : 9 a n d v r i s d e s i g n e dt o r e d u c e r e a r w h e e l l o c k i n g d u e t o w e i g h t t r a n s { e r e n cd u r i n g b r a k i n g( s e e F I G 1 0 : 1 4 ) . e T h e s t e e lb a l l 4 h o l d s t h e v a l v e 3 o p e n a n d f l u i d i s a b l e . t o p a s s t o t h e r e a rw h e e l c y l i n d e r s W h e n b r a k i n g h e a v i l y t h e b a l l m o v e sa w a y f r o m t h e v a l v ew h i c h i s t h e n c l o s e d b y t h e s p r i n g 2 t h u s p r e v e n t i n gf u r t h e r p r e s s u r eb e i n g a p p l i e dt o t h e r e a r b r a k e s . v T h e r n e r t i a a t v e i s s e c u r e dt o t h e r i g h t h a n ds i d e o f t h e r e a rs u b fr a m e c r o s s m e m b e b y t w o b o l t s ,w h o s e r e m o v a l , r a f t e r d i s c o n n e c t i n gt h e h y d r a u l i c p i p e s , w i l l e n a b l e t h e switch to be lifted off.

2 3

FIG 10:15

Handbrake mechanism, showing:A

b r a k e r e l e a s e ,B c a b l e f a i r l e a d , a n d C s w i v e l s e c t o r p i v o t a 2 a S t a ro c k w a s h e r ( t o b e f i t t e d t o e a r l y a s s e m b l i e s s p 7 Sealretarning late 8 Tappingplate 6 Seal 1 3 P l a i nw a s h e r s l 2 S w i v e l s e c t o ra n d b u s h

Key to Fig 10:15 1 Release nob k 2 L o c k n u t ( l a t e ra s s e m b l i e s ) 4 R e t u r ns p r i n g 5 C a b l ef a i r l e a d required) 3 A n t i - r a t t l ew a s h e r 10 Springwasher 1 1 C a b l ec h a n n e lg u r d e 9 S e c u r i n gs c r e w s '14 D i s t a n c et u b e 15 S t r i f n u t 1 6 C a b l e f o r k e n d a n d c l e v i sp i n

1100 k2 1300 M

119

Dismantling: R e m o v e t h e e n d p l u g a s s e m b l y1 , w a s h e r 6 a n d s t e e l b a l l 4 . C e a n t h e b o d y 5 a n d t h e s t e e lb a l l w i t h b r a k e f l u r o . I n s p e c ta l l p a r t sm o s t c a r e f u l l y n d r e n e w a n v t h a t a r e n o t a i n p e r f e c tc o n d i t r o n . Reassembling: l n s e r tt h e s t e e lb a l l i n t o t h e b o d y . S c r e w i n t h e v a l v ea n d e n d p l u g , u s i n g a n e w c o p p e r w a s h e r . E n s u r et h a t t h e s e a t i n gf a c e s o n b o t h b o d y a n d e n d p l u g a r e c l e a n a n d u n d a m a g e da n d t i g h t e n t o a t o r q u e o f 5 0 l b f t . R e fi t t i n g : W h e n b o l t i n g t h e v a l v e t o t h e s u b fr a m e m a k e s u r e t h a t r t i s c o r r e c t l yp o s i t r o n e d i t h t h e m a r k i n g F R O N T i n t h e w right direction. F i l l t h e m a s t e rc y l r n d e r i t h L o c k h e e d3 2 9 B r a k e F l u t o w a n d b l e e d t h e s y s t e m a s a l r e a d yd e s c r i b e d .I n s p e c t t h e inertia valve for fluid leaks both with the pedal fully d e p r e s s e da n d w i t h t h e s y s t e m a t r e s t . 10 :14 Type 6 vacuum servo unit T h i s c o m p o n e n t ,w h i c h m a V b e f i n e d a s a n o p t i o n a l e x t r a , i s c o n n e c t e d i n t h e h y d r a u l i cc l r c u i t b e l w e e n t h e m a s t e rc y l i n d e ra n d t h e w h e e l c y l i n d e r s . t s p u r p o s ei s t o l u s e t h e d e p r e s s i o ni n t h e i n l e t m a n i f o l d t o a u g m e n t t h e p r e s s u r e x e r t e db y t h e d r i v e r o n h i s b r a k e p e d a l . l t d o e s e n o t j m p r o v et h e p e r f o r m a n c e f t h e b r a k e s ,b u t e n a b l e sa o standard of braking to be obtained with less pedal p r e s s u r e . t t s n o t r e c o m m e n d e dt h a t t h e h o m e o p e r a t o r l s h o u l d d i s m a n t l et h e s e r v o u n i t b u t t a k e t t t o h i s s e r v i c e a g e n t f o r a t t e n t i o n i n t h e e v e n t o f f a i l u r e .T h e u n i t r s d e s i g n e dt o ' f a i l s a f e ' a n d i f t h e v a c u u m m e c h a n i s m s h o u l d b r e a kd o w n . f u l l b r a k i n gi s s t i l l a v a i l a b l e u t w i t h b c o n s i d e r a b l y o r e p r e s s u r e e q u i r e do n t h e b r a k e p e d a l . m r A n i t e m o f m a i n t e n a n c e h i c h m a y b e c a r r i e do u t i s t h e w r e n e w a lo f t h e a i r f i l t e ru n d e rt h e s n a p f i t t i n g d o m e s h a p e d c o v e r . T h i s r e q u i r e sa t t e n t i o na t a b o u t t h e s a m e t i m e a s t h e b r a k ef r i c t i o n l i n i n g s .

Unit removal: U n d o b o t h t h e h y d r a u l i cp i p e u n i o n s f r o m t h e u n i t a n d r e l e a s e h e v a c u u m p i p e f r o m t h e n o n - r e t u r nv a l v e i n t h e t u n r tc a s r n g . Unscrew the two nuts from the mounting studs. S l a c k e nt h e c l a m p r o u n d t h e n e c k o f t h e s l a v e c y l i n d e r a n d l i f t o u t t h e u n i t c o m p l e t e .l t w i l l b e n o t e d t h a t t h e h o l e s i n t h e m o u n t i n g b r a c k e ta r e s l o t t e dt o f a c i l i t a t e h i s . t R e fi t t i n g i s t h e r e v e r s eo f t h e a b o v e , a f t e r w h i c h t h e b r a k es y s t e mm u s t b e b l e d .

10 :15 Fault diagnosis 'Spongy'pedal (a) 1 2 3 4 5 Leakin the system W o r n m a s t e rc y l i n d e r L e a k i n gw h e e l c y l i n d e r s Air in the fluid system G a p s b e t w e e n t h e r e a r s h o e s a n d - t h e u n d e r s i d eo f linings

(b) Excessive pedal movement '1 Check 1 and 4 in (a) 2 E x c e s s i v ei n i n g w e a r l 3 V e r y l o w f l u i d l e v e li n s u p p l y t a n k 4 Too much free movement of pedal (c) Brakes grab or pull to one side 1 2 3 4 5 6 7 8 9 10 11 D i s t o r t e dd i s c s o r d r u m s Wet or oily pads or Iinings Rear brake backplate loose Disc looseon hub W o r n s u s p e n s i o no r s t e e r i n gc o n n e c l t o n s M i x e d l i n i n g s o f d i f f e r e n tg r a d e s Uneven tyre pressures B r o k e n s h o e r e t u r ns p r i n g s S e i z e dh a n d b r a k ec a b l e S e i z e dp i s t o n r n w h e e l c y l i n d e r L o o s e c a l i p e rf i x i n g s

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CHAPTER 11

THE ETECTRICAL YSTEM S

11 :1 11 :2 11 :3 11 :4 11 :5 11 :6 11 : 7 11 :8 Description The battery The generator The alternator Starter motor type M35G The control box Fuses Flasherunit 11:9 11 :10 11:11 11 :12 11 :13 11 :14 11 :15 11 :16 Windscreen wipers The headlamps The horn Fuel and temperature gauges lmpulse tachometer Starter motor type M35J Alternator 16ACR Fault diagnosis

11:1 Description A 1 2 - v o l t e l e c t r i c a ls y s t e m i s u s e d w i t h p o s i t i v e e a r t h _ ing on all models except 1970 Austin America models or when alternator type 16ACR is fitted. These cars have N E G A T I V E e a r t h r n ga n d w i r i n g d i a g r a m s c o v e r i n g t h e whole range will be found in Technical Data at the eno of the manual. The regulator box comprisesthree units to control the c h a r g i n g c i r c u i t s ;a c u t - o u t , a c u r r e n t r e g u l a t o ra n o a v o l t a g e r e g u l a t o r .T h e s e a r e a d j u s t a b l e ,b u t i t i s s t r e s s e d that as with all other electricalunits the equipment r e q u i r e dm a y n o t b e r e a d i l ya v a l l a b l e o t h e h o m e o p e r a r o r t f o r t e s t i n g a n d s e r v i c i n g .l t c a n n o l b e t o o s t r o n g l y r e c o m mended that defective electrical equipment should be serviced by a qualified service statign or replaced by t a k i n g a d v a n t a g e o f t h e v e r y e x t e n s i v ee x c h a n q e f a c i l l t i e s offered by the manufacturers. T h e g e n e r a t o ro r a l t e r n a t o ri s m o u n t e d o n t h e r i q h t o f t h e c y l i n d e rb l o c k a n d i s d r i v e nf r o m t h e c r a n k s h a f p u r r e y t b y t h e s a m e b e l t a s d r i v e st h e w a t e r p u m p a n d c o o l i n gi a n . The mounting is adjustable to allow the correci belt tensron to be obtained. D o u b l ed i p p i n gs e a l e d b e a m h e a d l a m p s r eu s e df o r t h e a Home market, with alternative arrangements for other

c o u n t r i e sa c c o r d i n gt o l o c a l r e g u l a t i o n s I n s t r u m e n t s r e . a voitage controlledby a bi metal resistance nit which u e n s u r e sa s t a b i l i z e d o l t a g es u p p l y . v 11:2 The battery . T h i s i s a 1 2 , v o l t l e a d / a c i dt y p e a n d i s m o u n t e d o n t h e righthandwing valance under the bonnet. The battery r e q u i r e sl i t t l e m a i n t e n a n c e . u t i t i s i m p o r t a n t t h a t i t D e b r e g u l a r l ya t t e n d e dt o . T h e t o p o f t h e b a t t e r ys h o u l d b e k e p t c l e a n a n d d r y , a n o any corrosion here or on adlacent areas should be removed with a weak ammonia solution and the affected p a r t s b e i n g a f t e r w a r d sp a i n t e d w i t h a n t i - s u l p h u r i c a i n t . o lf the termtnal posts are corroded the cables should oe r e m o v e d , c l e a n e d a n d r e p l a c e da f t e r s m e a r i n g t h e m w r t n petroleumjelly. Take off the manifold to check for cracks as this is a frequent cause of electrolyte leakage and corrosron. T h e l e v e l o f t h e e l e c t r o l y t e h o u l d b e m a i n t a i n e di u s t s above the tops of the separators by the addirion of d i s t i l l e dw a t e r . N e v e ra d d a c i d . l f a t a n y t i m e i t i s r e o u i r e d to use acid for filling a battery cell always mix the e l e c t r o l y t et o t h e c o r r e c t g r a v i t y b y s l o w l y a d d i n g a c i d t o the water and never water to the acid.

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1 C o m m u t a t o rn d b r a c k e t e 2 F e l tr i n g 3 F e l tr r n gr e t a i n e r 4 B r o n z eb u s h 5 T h r u s tw a s h e r '10 7 /oke 6 Fieldcoils 8 Shaftcolar 9 Shaftcollarretainingcup 11 Shafrkey Feltring 12 Shaftnut 1 3 O u t p u t t e r m r n a lD 1 4 B r u s h e s 1 5 F i e l dt e r m i n a l F 16 Commutator 17 Through bolt 1 8 P o l e s h o e s e c u r r n qs c r e w s 1 9 A r m a t u r e 2 0 B e a r r n gr e t a r n l n gp l a t e 2 1 B a l l b e a r i n g 2 2 C o r r u g a t e dw a s h e r 2 3 D r i v i n ge n d b r a c k e t 2 4 P u l l e y s p a c e r T h e s p e c i f c g r a v i t yo f t h e e l e c t r o l y t en e a c h c e l l s h o u l d i i b e p e r i o d i c a l l y h e c k e dw i t h a h y d r o m e t e r T h e r e a d i n g s c . a n d t h e i r i n d i c a t i o n sa r e a s f o l l o w s : Cellfully charged Specific gravity 1.210 to 1 290 Cell half charged i S p e c i f c g r a v i t y 1 . 19 0 t o 1 . 2 1 0 g Celldischarged S p e c i f i c r a v i t y1 1 I 0 t o 1 . 1 3 0 T h e s ev a l u e sa r e f o r a n e l e c t r o l y t e e m p e r a t u r e f 6 0 o F t o (16"C) To obtain the true specific gravity at other t e m p e r a t u r e sa d d o r s u b t r a c t . 0 0 2 t o t h e h y d r o m e t e r r e a d i n gf o r e a c h 5 ' F ( 3 " C ) o v e r o r b e l o w 6 0 o F . T h e r e a d i n g so f a l l t h e c e l l s s h o u l d b e a p p r o x i m a t e l y t h e s a m e . l f o n e c e l l d i f f e r sg r e a t l yf r o m t h e o t h e r s t h e r e may be an internal fault and the battery should be e x a m i n e db y a s p e c i a l i s t . 11 :3 The generator T h e g e n e r a t o ri s d r i v e n f r o m t h e c r a n k s h a f tb y t h e b e l t w h i c h a l s o d r i v e st h e w a t e r p u m p a n d c o o l i n g f a n . a n d the tension on the belt should be such that there is a d e f l e c t i o no f i i n c h i n t h e c e n t r e o f t h e l o r i g e s tr u n . T o a d j u s t t h e b e l t l o o s e nt h e t w o t o p m o u n t i n g b o l t s a n d t h e b o l t o n t h e s l o t t e da d j u s t m e n t i n k a n d r o t a t et h e g e n e r a r o r l b o d y u n t i l t h e c o r r e c tt e n s i o n i s o b t a i n e d ,t h e n r e t i g h t e n the bolts and recheck. Testing: c h e c k t h a t g e n e r a t o r e r m i n a l sD a n d F a r e c o n n e c t e d t t o t h e s a m e t e r m i n a l so n t h e c o n t r o l b o x . S w i t c h o f f a l l l i g h t s a n d a c c e s s o r i e s n d d i s c o n n e c tt h e c a b l e sf r o m D a . a n d F o n t h e g e n e r a t o r C o n n e c tt h e t w o t e r m i n a l s i t h a w short length of wrre. Start the engine and run at idling s p e e da n d c l i p t h e n e g a t r v e e a d o f a 0 t o 2 0 , v o l t m o v i n g l c o i l m e t e r t o o n e t e r m i n a la n d t h e o t h e r l e a d t o a g o o d e a r t h o n t h e b o d y . G r a d u a l l yi n c r e a s et h e e n g i n e s p e e d u p t o 1 0 0 0 r e v l ' m i n .T h e v o l l m e t e r r e a d r n gs h o u l d r r s e s t e a d i l y , u t d o n o t l e t i t r e a c h2 O v o l t s a n d d o n o t r a c et h e b e n q i n e i n a n a t t e m p tt o i n c r e a s e h e r e a d i n g . t l f t h e r ei s n o r e a d i n gc h e c k t h e b r u s h g e a rl.f t h e r e a d i n g is about + to 1-volt checkthe field winding, if it is 4 to 5 v o l t s t h e a r m a t u r e m a y b e f a u l t y . l f t h e g e n e r a t o ri s i n g o o d o r d e r r e s t o r et h e o r i g i n a lc o n n e c t i o n s . R e m o v a la n d d i s m a n t l i n g( s e e F i g 1 1 : 1 ) : D i s c o n n e c tt h e l e a d s . S l a c k e n t h e a t t a c h m e n t b o l t s , p u s h t h e g e n e r a t o rt o w a r d s t h e e n g i n e a n d r e m o v e t h e b e l t . R e m o v et h e b o l t s a n d l i f t o f f t h e g e n e r a t o r . R e m o v et h e s h a f t n u t 1 2 a n d t a k e o f f t h e d r r v i n gp u l l e y . R e m o v et h e k e y 1 1 . R e m o v et h e t h r o u g h , b o l t s 7 a n d 1 l i f t o f f t h e c o m m u t a t o re n d b r a c k e t 1 . T a p o f f t h e d r i v i n g e n d b r a c k e t2 3 t o g e t h e rw i t h t h e a r m a t u r e1 9 . T h e s en e e d n o t b e s e p a r a t e d n l e s st h e b e a r i n g2 1 r e q u i r e s t t e n t i o n . u a Servicing the brushes: L i f t u p a n d s e c u r et h e b r u s h e si n t h e r rb o x e sb y p r e s s i n g t h e s p r i n g so n t h e s i d e so f t h e b r u s h e s . i t t h e c o m m u t a t o r F e n d b r a c k e to v e r t h e c o m m u t a t o ra n d r e l e a s e h e b r u s h e s . t R e n e w a n y b r u s h e sw h i c h a r e w o r n t o l e s st h a n + i n c h a n d e n s u r et h a t t h e y m o v e f r e e l y i n t h e b o x e s , p o l i s h i n g w i t h a s m o o t h f i l e i f n e c e s s a r yT e s t t h e b r u s h s p r i n g s . with a spring scale Renew a spring if the tension has f a l l e nt o b e l o w 15 o z Servicing the comnlutator : A c o m m u t a t o ri n g o o d c o n d i t i o n w i l l b e s m o o t h a n d f r e e f r o m p r t t r n go r b u r n i n g l t s h o u l d b e c l e a n e dw i t h a p e t r o l m o i s t e n e d c l o t h o r v e r y f i n e g l a s s p a p e r( n e v e r e m e r y p a p e r )w h i l e r o t a t i n g t h e a r m a t u r e .T h e m i n i m u m f i n i s h e dd r a m e t e r s 1 . 4 5 i n c h a n d i f i t c a n n o t b e s a t r s i f a c t o r i i yc l e a n e dw i t h o u t g o i n g b e l o w t h i s f i g u r e i t m u s t b e r e n e w e d l t m a y a l s o b e n e c e s s a r yt o u n d e r c u t t h e r n s u l a t i o n e t w e e n t h e s e g m e n t st o o b t a i n t h e f o l l o w i n g b d i m e n s i o n s :W i d t h 0 4 0 i n c h . D e p t h 0 2 0 i n c h . l r i s i m p o r t a n t h a t t h e s i d e so f t h e u n d e r c u tc l e a rt h e m o u l d i n q m a t e r i a lb y a t l e a s t . 0 15 i n c h .

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Testing fieldtoils: b T @ s e s i 6 o u l d e t e s t e dw i t h a n o h m m e t e ra n d a r e a d i n g o b t a i n f t d 6 . O t r 6 J o h m s l f a n o h m m e t e ri s n o t a v a i l a b l e w c o n n e c ta d 2 - v o l t s u p p l y i n s e r i e s i t h a n a m m e t e ra c r o s s 3 t f ot i e t Ot e r m ' n a l q t a n q t h e b o d y 7 T h e r e a d i n gs h o u l d r e a d i n g o n t h e a m m e t e ro r a n 6e about 2 amps. A fo i n f i n r y g p t h d o h m m 4 e r i n d i c a t e sa b r e a k i n t h e f i e l d w k r d i n g Y Ar e a d i n gq [ m u c h m o r e t h a n 2 a m p s o r l e s st h a n 6 o h m s i n d a a t e s f a u l t y i n s u l a t i o nI n t h e f i e l d c o i l s . I n c e.fther ase the field coils must be renewed or a replace m e n t g e n e r a t 6 rf i t t e d . R e a s s e m b l i n ga n d r e f i t t i n g : p . l T h i s i s a r e v e r s ao f t h e d i s m a n t l i n g r o c e d u r eT o f i t t h e c o r n m u t a t o re n d b r a c k e t t o t h e y o k e , p a r t i a l l yw i t h d r a w t t h e b r u s h e sa n d h o l d t h e m b y p r e s s i n g h e s p r i n g sa g a t n s t t h e s i d e s . F i t t h e q a c k e t t o t h e a r m a t u r es h a f t . l i f t t h e a s p r r n g sw i t h a t h i n s c r e w d r i v e r n d t h e b r u s h e sw r l l d r o p r n t o p l a c e .C h e c k t h a t t h e s p i l n g s a r e c o r r e c t l yp o s i t i o n e d o n t o p o f t h e b r u s h e sa n d p r e s st h e b r a c k e tf u l l y h o m e . R e fi t t h e t w o t h o u g h b o l t s . l . u b r i c a t et h e c o m m u t a t o r e n d b e a r i n g .R e f i tt o t h e e n g i n e ,a n d a d j u s tt h e t e n s i o no f the belt. 10 :4 The alternator T h e a l t e r n a t o r .o r a l l e r r t a l i n g c u i l e n t g e n e r a t o r . i s d r i v e n f r o m t h e c r a n k s h a f tb v t h e s a m e b e l t a s d r i v e st h e w a t e r p u m p a n d c o o l i n g f a n . T h e b e l t t e n s i o ni s a d J U S t e d b y l o o s e n i n gt h e s e c u r i n gb o l t s a n d r o t a t i n gt h e a l t e r n a t o r d u b o d y i n t h e a p p r o p r i a t e i r e c t i o n , s i n ga l e v e ri f n e c e s s a r y applied to the drive end bracket only, until there is a d e f l e c t i o no f i i n c h r n t h e c e n t r e o f t h e l o n g e s tr u n t W h e n s e r v i c i n g c a r f i t t e dw i t h a n a l t e r n a t o rt i s m o s t a i m p o r t a n tt o o b s e r v et h e f o l l o w i n g p r e c a u t i o n s : W h e n f i t t i n g a n a l t e r n a t o rm a k e s u r e t h a t t h e e o r r e c t p o l a r i t yi s o b s e r v e dT h i s a p p l i e s o t h e b a t t e r y o n n e c t i o n s t c . a s o t h e r w i s e d a m a g e t o t h e r e c t i fi e r s m a y r e s u l t . W h e n c h a r g i n g t h e b a t t e r y f r o m a n e x t e r n a ls o u r c e , d i s c o n n e c tb o t h b a t t e r yt e r m i n a l sb e f o r e c o n n e c t i n gt h e charger. t o N e v e rr u n t h e e n g i n ew j t h e r t h e r h e b a t t e r y r a l t e r n a t o r i d i s c o n n e c t e dN e v e rm a k e o r b r e a ka n y c o n n e c t i o n s n t h e . c a l t e r n a t o r i r c u i tw h i l e t h e e n g i n e i s r u n n r n g . Before disconnecting or removing the alternator r e m e m b e rt o d i s c o n n e c tt h e b a t t e r y . Control unit: T h i s r e q u i r e s n o m a i n t e n a n c ea p a r t f r o m k e e p i n g i t t c l e a n a n d t h e c o n n e c t i o n s i g h t . B e f o r et e s t i n gt h e c o n t r o l u n i t m a k e s u r et h a t t h e b a t t e r yi s f u l l y c h a r g e da n d t h a t a l l w i r i n g a n d c o n n e c t i o n sa r e i n g o o d c o n d i t i o n . C o n n e c t a n a c c u r a t e0 t o 1 5 - v o l t v o l t m e t e ra c r o s st h e b a t t e r yt e r m i n a l s . o n n e c t a n a m m e t e r i n s e r i e sw i t h t h e C m alternator ain output cable S w i t c h o n t h e s i d e a n d t a i l l r g h t st o g i v e a l o a d o f 2 a a m p s ,s t a r tt h e e n g i n e a n d r u n t h e a l t e r n a t o r t a p p r o x i mately 3000 rev/min for a least8 minutes or until the r c h a r g i n gc u r r e n ti s s t e a d ya t 1 0 a m p s .T h e v o l t m e t e s h o ul d n o w g i v e a r e a d i n go f 1 3 . 9 t o 1 4 . 3 v o l t s . l f i t i s o u t s i d e theselimitsthe control unit must be renewed.

FIG 11 :2 Relav:

Alternatoroutput test connectrons

T h i s r s i n c l u d e di n t h e c r r c u r ti n o r d e rt o d i s c o n n e c t h e s u p p l y f r o m t h e r o t o rf i e l d w h e n t h e i g n i t i o ni s s w i t c h e d off, and to permit the alternatorto generate when switchedon. C o n n e c t a n a m m e t e ri n s e r i e sw i t h t h e m a i n a l t e r n a t o r o u t p u t c a b l e . l f a n i m m e d i a t ed i s c h a r g ei s s h o w n t h e points of the relay are sticking and the unit must be renewed. Start the engine and if the output is not satisfactory p r o c e e da s f o l l o w s : R e m o v et h e l e a c fi r o m t e r m i n a lC 2 a n d c o n n e c ti t t o C 1. t l f t h e o u t p u t i s n o w s a t i s f a c t o r yh e r e l a y i s f a u l t y a n d must be renewed. C h e c k t h e c o n t i n u i t y o f t h e r e l a y o p e r a t t n gw i n d i n g , r e l a yc i r c u i tw i r r n g a n d e a r t h .l f t h e s ea r e i n o r d e r a n d t h e o u t p u t i s s t i l l l o w w i t h c a b l e sC 1 a n d C 2 s t i l lj o i n e d ,c h e c k a the alternator nd the controlunrt. Alternator: s T h e f o l l o w i n g p r o c e d u r e h o u l d b e a d o p t e dt o l o c a t ea f a u l t i n t h e c h a r g i n gc i r c u i t : Checkthe drivingbelt. C h e c k t h a t b a t t e r y v o l t a g e i s r e a c h i n gt h e b r u s h g e a r . Disconnect the two cables from the alternatorfield t e r m r n a l s . o n n e c t a v o l t m e t e rb e t w e e n t h e t w o c a b l e s c b a n d r u n t h e e n g i n e .T h e v o l t m e t e rs h o u l d r e g i s t e r a t t e r y v o l t a g e .l f n o r e a d i n gi s o b t a i n e dc h e c k t h e f i e l d c i r c u i t wiring. o C h e c k a l t e r n a t o r u t p u t . D i s c o n n e c tt h e b a t t e r ye a r t h f c a b l e .D i s c o n n e c tb o t h c o n n e c t i o n s r o m t h e m a i n o u t p u t t e r m i n a l B a n d c o n n e c t a m o v i n g c o i l a m m e t e rb e t w e e n 'the R t e r m i n a la n d t h e c o n n e c t o r s . e m o v et h e c a b l e sf r o m t a d t h e f i e l d t e r m i n a l s n d c o n n e c tt h e t e r m i n a l s i r e c t l y o t h e b a t t e r ya s s h o w n i n F I G 1 1 : 2 . R e c o n n e c tt h e b a t l e r y e a r t h l e a d ,s t a r t t h e e n g r n ea n d r u n t h e a l t e r n a t o r t 4 0 0 0 r e v / m i n . T h e a m m e t e rs h o u l d a read approximately 0 amps. lf a zero readingrs gtven 4 c h e c k t h e b r u s h g e a a n d i f t h i s r : ; , r ' o r d e r ,r e m o v ea n d r i n s p e c tt h e a l t e r n a t o r . l f t h e r e a d i n gi s l o w , s t o p t h e e n g i n e a n d c o n n e c t a l o w - r a n g e v o l t m e t e rb e t w e e n t e r m i n a l B a n d t h e b a t t e r y R n e g a t i v e e r m i n a l . e s t a r t h e e n g i n ea n d n o t e t h e r e a d i n g . t b T r a n s f e r h e v o l t m e t e rc o n n e c t i o n st o t h e a l t e r n a t o r o d y t a n d t h e b a t t e r y p o s i t i v e ( e a r t h ) t e r m i n a la n d a g a i n n o t e the reading. i l f e i t h e r r e a d i n ge x c e e d s. 5 - v o l t a h i g h r e s i s t a n c e s i n d i c a t e di n t h e c h a r g i n gc i r c u i tw h i c h m u s t b e t r a c e da n d t r a r e c t i f i e d l.f n o e x c e s s i v e e s i s t a n c es i n d i c a t e d n d o u t p u t i s s t i l l l o w , r e m o v ea n d j n s p e c tt h e a l t e r n a t o r .

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zi rs

Components of the alternator

6 Driveend bracket Key to Fig 11:3 1 Shafl nut 2 Springwasher 4 Through-bolt 5 D i s l a n c ec o l l a r 3 Key 12 Warning light 7 Jump r ng shroud 1 0 S t a t o r l a m i n a t i o n s 1 1 S t a t o ru r i n d i n g s 8 R o t o r ( fi e l d ) w i n d i n g 9 Slip rings p l a s l i cs t r i p 1 6 T e r m i n a lb l a d e r e t a i n i n gt o n g u e terminal 13 Output terminal 1 4 F r e l dt e r m i n a lb l a d e 15 Output terminal '18 22 O-ring oil seal 23 O ring 17 Brush 1 9 B e a r r n gc i r c l i p 2 0 B e a r r n gr e t a i n i n gp l a t e 21 Ballbearing Rolor r e t a i n i n gw a s h e r 27 Slip ring end cover 24 Fan 25 Brushbox 26 Heat sink assemblies

Removing the alternator : D i s c o n n e c t h e b a t t e r ya n d r e m o v et h e c a b l e sf r o m t h e a l t e r n a t o rS l a c k e nt h e s e c u r i n gb o l t s ,p u s h t h e a l t e r n a t o r . towards the engrne and remove the belt. Remove the bolts and lift off the alternator. Inspection: C h e c k t h e l e n g t h o f t h e c a r b o n b r u s h e sa n d r e n e w a n y worn below 1f inch. Push the new brush assemblyinto

t the holder until the tongue registers hen leverit up rn o r d e r t o r e t a i nt h e b r u s h . Check that the brushes are moving freely in their h o l d e r s ,a n d i f n e c e s s a r y l e a n o r p o l i s h w i t h a s m o o t h c f il e T h e s u r f a c e so f t h e s l i p r i n g s s h o u l d b e s m o o t h a n d c l e a n . C l e a n w i t h a p e t r o l m o i s t e n e dc l o t h o r v e r y f i n e g l a s s p a p e r i f n e c e s s a r y .D o n o t a t t e m p t t o m a c h i n e t h e sliprings. Dismantling (see Fig 11 :3):

-<l

I [: I \-,
t \ i '

F I G 1 1 : 4 U s i n ga n o h m m e t e r1 o r a m m e t e r2 t o t e s t t h e resistance r the currentflow of the field winding o

R e m o v et h e s h a f t n u t 1 a n d d e t a c h t h e d r i v e p u l l e y ,f a n 2 4 a n d k e y 3 f r o m t h e a r m a t u r es h a f t , t a k i n g g r e a t c a r e t o mark all parts clearly to ensure correct reassembly. 4 R e m o v et h e t h r e et h r o u g h - b o l t s a n d d e t a c ht h e d r i v e end bracket 6 and rotor 18. The bracket and rotor need not be separated unless the bearing requires attention. Remove the brushbox 25 atter removing the output t e r m i n a la n d t h e r e t a i n i n gs c r e w s . R e m o v et h e w a r n i n g l i g h t t e r m i n a ln u t 1 2 a n d t h e h e a t s i n k b o l t a n d w i t h d r a w t h e s t a t o r1 0 a n d h e a ts i n k 2 6 f r o m t h e s l i p r i n g e n d b r a c k e t2 7 . C l o s e t h e r e t a i n i n gt o n g u e s '1 6 o n t h e b r u s h t e r m i n a l b l a d e sa n d w i t h d r a w t h e t e r m i n a l s f r o m t h e b r u s h b o x2 5 .

124

Testing: T e s t t h e w i n d i n g s o n t h e r o t o r b y c o n n e c t i n ga n o h m _ m e t e r ( o r a 1 2 v o l t b a t t e r ya n d a m m e t e ri n s e n e s )a c r o s s t h e s l i p r i n g s .T h e r e s i s t a n c e r c u r r e n ts h o w n s h o u l d b e o 3.8 ohms or 3.2 amps (see FIG 11 :4). Testfor defecrive i n s u l a t i o n i t h a 1 1 0 - v o l tA C m a i n s s u p p l y a n d a 1 5 w w a t t t e s t l a m p .l f t h e l a m p l i g h t st h e c o i l i s e a r t h i n g n d t h e a rotor assemblymust be reneweo. To test the stator windings: (a) Unsolderthe three c a b l e sf r o m t h e h e a t s r n k a s s e m b l ya n d c o n n e c t a n y t w o o f t h e m i n s e r i r sw i t h a ' 1 5 - w a t t t e s t l a m p a n d a 1 2 _ v o l t . b a t t e r y .T h e n r e p e a t w i t h a d i f f e r e n t p a i r o f c a b l e s . l f t h e l a m p f a i l st o l i g h t i n e i t h e rt e s t t h e r e i s a b r e a k d o w ni n p a r r o f t h e s t a t o rw i n d i n g . ( b ) T h e i n s u l a t i o ni s t e s t e db v c o n _ n e c t i n gt h e t e s t r i n g b e t w e e n a n y o n e o f t h e t h r e e c a o t e s a n d t h e l a m i n a t i o n a c k . l f t h e l a m p l i g h t st h e r e i s a s h o r r _ p clrcutt to earth. In either case the stator should be renewed. T e s t e a c h d i o d e b e f o r e r e s o l d e r i n gt h e s t a t o r c a b l e s b y c o n n e c t i n gt h e a b o v e t e s t r i g i n s e r i e sw i t h e a c h d i o d e i n turn (see FIG 11 :5) and then reversinghe connections. t Currentshould flow in one direction only; if the bulb l i g h t so r f a i l st o l t g h t i n b o t h t e s t st h e d i o d e i s f a u l t y .R e n e w the appropriate eatsink assembly. h Replacing a diode heat sink: I n e a c h h e a t s rn k t h e r e a r e t h r e ed i o d e s ,o n e g r o up b e in g o f p o s i t i v e p o l a r i t ya n d c o l o u r e d r e d , t h e o t h e r n e q a t t v e a n d c o l o u r e db l a c k . B e c a r e f u ln o t t o o v e r h e a tt h e d l o o e s w h e n s o l d e r i n g ;h o l d t h e d i o d e p i n s w i t h a p a i r o f l o n g _ n o s e d p l i e r st o a b s o r b t h e h e a t a n d w o r k a s q u i c k l y a s possble. i A r r a n g et h e c o n n e c t i o n s s s h o w n i n F I G 1 1 : 6 a n o a s e c u r ew i t h a s u i t a b l eh e a t - r e s i s t i n q d h e s i v e . a Renew bearingswhich ure *oin or damaqed The n e e d l er o l l e rb e a r i n ga n d t h e s l r p r i n g e n d c o v e rs h o u l o o e renewed as an assembly. T h e b a l l b e a r i n gi s r e p l a c e d a s f o l l o w s : R e m o v e t h e screws, rivets or circlip securing the bearing retainrng plate. Pressthe bearing from the bracket. pack the new b e a r i n gw i t h h i g h m e l t i n g p o i n t g r e a s ea n d p r e s si t f u r r y i n t o t h e h o u s i n g .R e f i tt h e b e a r i n gr e t a i n i n g l a t e , e c u r i n g p s i t w i t h a n e w c i r c l i p .s c r e w s o r r i v e t s . Reassembly: T h i s i s a r e v e r s a o f t h e d i s m a n t l i n gp r o c e d u r e , a k i n g l t c a r e t o r e p l a c e h e p a r t si n t h e s a m e p o s i t i o n s s t n d i c a t e d t a b y t h e m a r k i n g sm a d e e a r l i e r Warning light control: This is connectedto the centre point of one pair of d i o d e sa n d o p e r a t e s h e l a m p i n d r c a t r n g h a t t h e a l t e r n a t o r t t i s n o t c h a r g i n gw h e n r u n n i n g a t n o r m a l s p e e d l f t h e u n i t i s f o u n d t o b e f a u l t y i t m u s t b e r e n e w e d ,b u t take care not to confuse it with the directionindicator f l a s h e r .T o d i s t i n g u i s hi t t h e w a r n i n g l i g h t c o n t r o l h a s a greenlabel. 11 :5 The starter motor Testing: l f t r o u b l ei s e x p e r i e n c e d i t h t h e s t a r t e r c h e c kf i r s tt h a t w , t h e b a t t e r yi s f u l l y c h a r g e d a n d t h a t t h e w i i l n g a n d c o n n e c t r o n sa r e r n g o o d c o n d i t i o n S w i t c h o n t h e l i q h t s a n d

F I G 11 : 5

Testing the diodes

FIG 1l:6 The heat sink diode internalconnections w i t h s e c u r i n gp o i n t s a r r o w e d o p e r a t e t h e s t a r t e rc o n t r o l ; i f t h e I i g h t s g o d i m b u t t h e S t a r t e rd o e s n o t t u r n , e i t h e r t h e s t a r t e r i s f a u l t y o r h a s jammed in mesh. If rhe lighrs do not dim, check the s t a r t e rc o n t r o l a n d i t s w i r i n g . A s t a r t e rt h a t h a s j a m m e d m a y u s u a l l y b e f r e e d b y a p p l y r n ga s p a n n e rt o t h e s q u a r e de n d o f t h e s t a r t e rs h a f t or by rocking the car backwardsand forwards with a oear e n g a g e d ( a n d t h e r g n i t r o n w r l c h e do f f ) . l t t h e s t a r t e r " s t i l l s wrll not work. removeit for examination. Dismantling: D i s c o n n e c tt h e b a t t e r y . R e m o v e t h e d i s t r i b u t o r ( s e e _ C h a p t e r 3 ) . R e l e a s eh e e l e c t r i c u p p l y c a b l e a n d r e m o v e t s the top securing bolt. Remove the dirt deflector from below and the bottom securing bolt. Lift off the starter towards the front. R e m o v et h e c o v e r b a n d ( s e eF I G 1 1 : 7 ) a n d w i t h d r a w 4 t h e b r u s h e sf r o m t h e r r h o l d e r s ,n o t i n g t h a t d a m a q e d o r w o r n b r u s h e sl e s s t h a n * i n c h l o n g m u s t b e r e n e w e d .

1 1 0 0M k 2 1 3 0 0

"L i;10\)o
8

flf- R rzAafiT\il fr\rti ^ L-L-ty v/l/l#TJHrHrH HHl

12
FIG 11 :7

lE/+'\5 t3 14 t5

Y \ t6 t7

Components of M35G tVpe starter moror

Key to Fig 11 :7 1 Termrna nuls and washers 2 Brushspring 3 Through-bolt 4 Band cover 5 T e r m i n a lp o s t ; Bedlng 6 Bearrng ush b 8 Bruqhes 9 Yo,e 1 O A r m a t u r es h a f t 1 1 D r r v i n ge n d b r a c k e t 1 2 P r n i o na s s e m b l v 1 3 S . e e v e 1 4 l m p a c t w d s h e r 1 5 M a , n : p r r n q 1 6 S p r i n gc u p 17 Circlrp

FIG

The starter brush connections A Brushes B T a p p r n go n t i e l d c o i l s

Key to Fig 11 :8

FIG 11 :9

Commutator end bracket 1 T e r m r n a ie y e 2 Brushholder

K e vt o F i g 1 1: 9

U n s c r e wt h e t e r m i n a ln u t s 1 . R e m o v et h e t w o t h r o u g h b o l t s 3 a n d t a k e o f f t h e c o m m u t a t o re n d b r a c k e t .R e m o v e t h e d r i v e e n d b r a c k e t t o g e t h e r w i t h t h e a r m a t u r ea n d p i n i o n d r i v ea s s e m b l y 1 t o 1 7 , 1 T h e c o m m u t a t o rm u s t b e s m o o t h a n d f r e e f r o m b u r n s a n d s h o u l d b e c l e a n e d w i t h a p e t r o l m o i s t e n e dc l o t h . l f t h i s d o e s n o t g i v e a s a t i s f a c t o r fyi n i s h ,v e r y f r n eg l a s s p a p e r m a y b e u s e d .l f t h e s u r f a c ei s b a d l y b u r n t i t m a y b e n e c e s s a r y t o u s e a h i g h - s p e e dl a t h ea n d a s h a r pt o o l , l a k i n g o f f a s l i t t l e m e t a l a s p o s s i b l e . o n o t u n d e r c u tt h e s e g m e n t s . D T e s t t h e b r u s h s p r i n g s w i t h a b a l a n c e .T h e c o r r e c t t e n s i o n i s 1 5 o z l o r w o r n o r 2 5 o z f o r n e w b r u s h e sa n d a n e w s p n n g s h o u l d b e f i t t e d i f t h e t e n s r o ni s l o w . T h e b r u s hc o n n e c t i o n s r e s h o w n i n F I G S 1 1 : 8 a n d a 1 1 : 9 . T o r e n e w b r u s h e su n s o l d e rt h e m o n e a t a t i m e a n d s e c u r ee a c h b r u s h t a k i n g c a r e n o t t o l e t t h e s o l d e r r u n a l o n g t h e l e a d s .T h e b r u s h e sa r e p r e f o r m e da n d w i l l n o t n e e db e d d i n g - i n . The field coils are tested by connecting a 12-volt b a t t e r ya n d b u l b i n s e r i e sb e t w e e n t h e p o i n t s o n t h e c o i l s t o w h i c h t h e b r u s h e sa r e s o l d e r e da n d t h e f i e l d t e r m i n a l p o s t ( 5 i n F I G 1 1 : 7 ) . l f t h e b u l b d o e s n o r l i g h t r h e r er s a b r e a ki n t h e w i n d i n g s . C h e c k n e x t f o r e a r t h i n go f t h e c o i l b y r e m o v l n qt h e ! e a d f r o m t h e b r u s h c o n n e c t o ra n d c o n n e c t i n qi t t o t h e s t a r t e r b o d y . l f t h e b u l b l i g h t sa n d t h e f i e l d c o i l s a r e e a r t h e d t h e c u r e i n e a c h c a s e i s n e w c o i l sa n d a s e r v i c e t a t i o ns h o u l d s be consulted. The bearrng bush should be renewed if tt shows e x c e s s i v e i g n so f w e a r . l t m a y b e w i t h d r a w n b y s c r e w i n g s in a tap and pulling on the tap. A new bush should be i m m e r s e di n e n g r n e o i l t o r 2 4 h o u r s b e f o r e f i t t i n g a n d a f t e r p r e s s r n g n t o p l a c e i t m u s t n o t b e r e a m e dt o a d l u s t r the srze. T h e n r o s t f r e q u e n tc a u s e so f t r o u b l e w i t h t h e s t a r t e r d r i v e a r e d i r t o n t h e m o v i n g p a r t s o r a b r o k e n s p r i n g .T o d i s m a n t l e t h e d r i v e c o m p r e s st h e s p r i n g 1 5 a n d r e m o v et h e c i r c l i p 1 7 . T h e r e m a i n i n gp a r t sm a y t h e n b e p u l l e d o f f a n d

tlo

t h e s l e e v e 1 3 u n s c r e w e d f r o m t h e p i n i o n a s s e m b l y1 2 . A n V w o r n o r b r o k e n p a r t s s h o u l d b e r e n e w e d ,b u t n o l e t n a t i f e t t h e rt h e s l e e v eo r t h e p i n i o n a s s e m b l y s d e f e c t i v e t i r r s n e c e s s a r yt o r e n e w b o t h i t e n r s . W h e n r e a s s e m b l r n g ,o n o t u s e l u b r i c a n o n t h e s c r e w e o d t s l e e v ea s t h i s m a y c a u s e d i r t t o a d h e r e t o t h e r u n n i n o su r f a c e s . Reassembly: T h e s t a r t e r i s r e a s s e m b l e da n d r e f i t t e d b y r e v e r s i n gr n e aDove procedUre. 11 :6 The c.ontrol box T h e R B . 3 4 0 c o n t r o lb o x , w h i c h i s s h o w n i n F I G 1 1 : 1 0 . c o m p n s e s t h r e e u n i t s , t h e c u t _ o u t 3 , c u r r e n t r e q u l a t o r4 a n d v o l t a g e r e g u l a t o r6 a l l o f w h i c h a r e a d j u s t a b l eb y meansof the cams 1 using the tool 2.
FIG 11 :10 Control box type RB.34O

Checking the charging circuit: I n t h e e v e n t o f u n s a t i s f a c t o r y h a r g i n g ,b e f o r e a d j u s t r n g c the settings in the control box certain checks should first be made: Checkthat the drivingbelt is not slipping. M a k e s u r e t h a t t h e b a t t e r yi s i n g o o d c o n d i t i o n . C h e c k t h e g e n e r a t o ra s d e t a i l e di n S e c t i o n 1 1 : 3 . C h e c k a l l t h e w i r i n g b e t w e e n t h e g e n e r a t o r ,c o n r r o l oox and ammeter. Check all earlhconnections. l f t h e r e s u l t so f t h e s e t e s t s i n d i c a t e a f a u l t y c o n t r o l b o x t h e f o l l o w i n g t e s t s a n d a d j u s t m e n t sm a y b e m a d e : Adjusting voltage regulator : B e m o v e t h e c a b l e s f r o m t h e t e r m i n a l sB . C o n n e c t a r e l i a b l e0 t o 2 0 m o v i n g c o i l v o l t m e t e r b e t w e e n t e r m i n a l D and earth. Join the ignition and battery feeds wlth a s u i t a b l ew i r e t o e n a b l e t h e e n g i n e t o b e s t a r t e d .S t a r t u o a n d r u n t h e g e n e r a t o ra t 3 0 0 0 r e v l m i n , a t w h i c h s p e e d the voltmeter should be steady at the following readings: Ambient temperature Voltmeter readino 1 0 o Co r 5 0 o F 1 4 . 9t o 15 . 5 20oC or 6BoF 1 4 . 1t o 1 5 . 3 30oC or 86oF 145to15.1 An unsteady needle may be caused bv dirtv contacrs w h i c h m a y b e c l e a n e dw i t h a f i n e c a r b o r u n d u m t o n e a n d s w i p e d w i t h m e t h y l a t e ds p i r i t s .l f t h e n e e d l ei s s t e a d y o u t g i v e s a r e a d i n g o u t s i d e t h e s e l i m i t s , t h e r e g u l a t o rm a y b e adjusted as follows: Stop the engine and remove the control box cover. R e s t a r ta n d r u n t h e g e n e r a t o ra t 3 0 0 0 r e v . / m i n ,o b s e r v et h e voltmeter readingand, using the tool, turn the cam on the vottage regulator until the correct reading is obtaineo. T u r n i n g t h e t o o l c l o c k w i s e w i l l r r a i s et h e r e a d i n q a n o anticlockwise ill lower it.Always checkby stoppiig tne w e n g i n ea n d r e s t a r t i n g n d r u n n i n gu p a g a i nt o t h e r e q u i r e d a s p e e d . T h e s e a d j u s t m e n t ss h o u l d b e c o m p l e t e d a s q u i c l < r y as possible to avoid errorsdue to overheatino. W h e n c o m p l e t e d r e fi t t h e c o v e r a n d r . " r t o r . i h . c o n n e c _ tions. Adjusting current regulators : F i x t h e c l i p 8 r o h o l d r h e c o n t a c t s 7 t o g e t h e r ,t h u s m a k i n g t h e v o l t a g e r e g u l a t o ri n o p e r a t i v e a n d w i t h d r a w , t h e c a b l e s f r o m t e r m i n a l sB . C o n n e c t a 0 t o 4 0 m o v r n o

Key to Fig 11 :10 1 Adjustingcams 2 S e t r i n gt o o l 3 Cut-out relay 4 C u r r e n tr e g u l a t o r 5 Current,eg-ulator contacts 6 Voltage regulator 7 Voltage regulator contacts 8 Clip

F I G 11 : 11 C o n t r o l b o x a n d f u s e s .I n s e ts h o w s t h e p i l o t andtail lightfuse Key to Fig 11:11 1 C o n t r ob o x 2 A U X f u s e( 3 5 a m p ) l 3 Fuse lock b 4 A U X I G N f u s e( 3 5 a m p ) b S p a r eu s e s f corl ammeter between these cables and terminals B. $ w i t c h o n a l l l i g h t s a n d a c c e s s o r i e s ,t a r t t h e e n g i n e a n d s r u n t h e g e n e r a t o r p t o 4 5 0 0 r e v / m i n .T h e a m m e t e r h o u l d u s show a steady 21 to 23 amps and if it is outside these l i m r t si t s h o u l d b e a d j u s t e da s f o l l o w s : U s i n g t h e s p e c i a lt o o l t u r n t h e a d j u s t m e n t a m u n t i l t h e c correct readrngis obtained. Clockwise rotation will rarse the setting and vice versa. Stop the engine. restorethe o r i g i n a l c o n n e c t i o n sa n d r e p l a c et h e c o v e r . Adjusting the cut-out: T h i s o p e r a t i o nm u s t b e c o m p l e t e d a s q u i c k l y a s p o s s i o t e t o a v o i d e r r o r sd u e t o o v e r h e a t i n g . Connect the voltmeter between terminal D and eartn. S w i t c h o n a l o a d s u c h a s t h e h e a d l a m p s s t a r tt h e e n g i n e , a n d g r a d u a l l y i n c r e a s et h e s p e e d . T h e i n d i c a t e d v o l i a g e s h o u l d r i s e s t e a d i l ya n d t h e n d r o p s l i g h t l ya t t h e m o m e n r t h e c o n t a c t s c l o s e .T h i s c u t I n v o l t a g e s h o u l d b e b e t w e e n 1 2 . 7 a n d 1 3 . 3 v o l t s a n d i f i t i s o u t s i d e t h e s e l i m r t sr n e

1100Mk21300

127

FIG 11 :12

Components of the horn and wiper mechanisms

K e . yt o _ F i g 1 1 : 1 2 1 Horn 2 Screw 3 Washer 4 Nut 5 Horn push 6 R e t a i n i n gr i n g 7 Contact (upper) 8-Motil spring 9 Coverand contact 11 Motii 12 Slip ring and rotor 13 Brushgear tq grusn 15 Brushspring 16 Armature 1 7 F i e l dc o i l 18 Switch 19 Shaftand ge;r 20 Stud 21 Mbunring bracket 22 Bracket screw 2 3 P l a i nw a s h e r 24 Springwasher 25 Wheelbox 2 6 S p i n d l ea n d g e a r 2 7 C r o s s , h e a da n d r a c k 28 Molor to box d r i v e - c a s i n g 2 9 W h e e l b o xd n v e c a s i n g 3 0 E n d d r r v ec a s i n g 31 Ferrule 32 Grommel 33 Wrperarm 34 Wiper blade 35 Rubber

setting of the cut-out relay3 must be adjusted by turning t h e s e t t i n g t o o l c l o c k w i s e t o r a i s et h e s e t t i n g o r a n t i c l o c k w i s e t o l o w e r i t . S t o p t h e e n g i n e a n d r e s t o r et h e c o n n e c t io n s . H a v i n g a d . j u s t e dh e c u t t i n g - i n , t h e d r o p - o f f s e t t i n g m u s t t b e c h e c k e d . R e m o v e t h e c a b l e s f r o m t e r n r i n a lB a n d j o i n t the ignition and battery feeds so that the engine may be

started. Connect the voltmeter between terminal B and e a r t h . s t a r t t h e e n g i n e a n d r u n u p t o a p p r o x i m a t e l y3 0 0 0 rev/min. Allow the speed to fall and observe the meter needle. The openrng of the contacts, indicated by the needle dropping to zero, should occur between 9.5 and 11 volts. lf the drop-off occurs outside these limits,adjust as follows: Stop the engine and remove the control box cover. Adjust the setting by carefully bending the fixed contact bracket. Beducing the gap will raisethe drop-off voltage a n d v i c e v e r s a . R e t e s ta n d , i f n e c e s s a r y , e a d j u s tt o o b t a i n r t h e c o r r e c t s e t t i n g . R e s t o r et h e c o n n e c t i o n s a n d r e p l a c e the cover. Adjustment of air gap settings: These are accurately set in manufacture and should r e q u i r e n o a t t e n t i o n u n l e s st h e o r i g i n a l s e t t i n g s h a v e b e e n d i s t ur b e d . Armature-to-bobbin current regulators: core gaps of voltage and

F I G 1 1: 1 3 F i t t i n g a w i p e r a r m K e yt o F i g 1 1: 1 3
i R e t a i n i n gc l i p 2 S p l i n e dd r i v e

Disconnect the battery and with the special tool turn the cam of the regulator being adjusted to the point giving minimum lift to the armature tensioning spring ( fu l l y a n t i c l o c k w i s e ) .

128

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FIG 11 :14 Components of two-speed windscreen wtper motor KeytoFig 11:14 1 Gearboxcover 2 s c r e w f o r c - 9 -e r a r b o x " c o n n e c t i n g _ r o d -o v be 3 4 c i r-c Il i p i 5 plainwashers 6 cross head and rack 7 Shaft and gear e oiJJ*isner j"tj"i?"*"ro, rimir switch Limit iwrtcn assembry 12 Brushgear 13 screw for brush"gear lt i;;;;;," yoke botls ts yoke assemorv'-'io 1 7 A r m a t u r er h r u s t s c r e w

Slacken the contact locknut and unscrew the codtacr. I n s e r ta f e e l e r g a u g e o f . 5 6 i n c h b e t w e e n t h e a r m a t u r ea n d the regulator head as far back as the two rivets on the u n d e r s i d e o f t h e a r m a t u r e .W i t h t h e g a u g e i n t h i s p o s i t r o n press down squarely on the armature and screw in the c o n t a c t u n t i l i t j u s t t o u c h e s t h e a r m a t u r ec o n t a c t . T i q h r e n t h e l o c k n u t a n d w i t h d r a w t h e g a u g e . R e p e a tt h e o p " i r t , o n o n t h e o t h e r r e g u l a t o r .C a r r y o u t t h e e l e c t r i c a ls e t t i n q p r o c e d u r e sj u s t d e s c r i b e d . Contact'follow through' and armature-to_bobbin core gap of cut-out relay: P r e s st h e a r m a t u r e s q u a r e l y d o w n a g a t n s t t h e c o p p e r separation on the core face. Adjust the fixed contact b r a c k e tt o g i v e a ' f o l l o w t h r o u g h ' o r b l a d e d e f l e c t i o n o f t h e m o v r n g c o n t a c t o f . 0 10 t o . 0 2 0 i n c h . A d j u s t t h e a r m a t u r eb a c k s t o p t o g r v e a c o r e g a p o f . 0 3 5 to .045 inch. Check the cut-in and drop-off voltage settings as previouslydescribed.

11 :7 Fuses The fuse unit is located on the righthand wing valance a n d i s i l l u s t r a t e dn F I G 1 1 : 1 1 . l t w i l l b e s e e n t h a t t h e r e i are two 35-amp fuses and two spares.The fuse across terminals 1 and 2 protects those circuits which are

2
Cleaning the cut-out contact points: These points are soft and must not be cleaned with carborundum or emerypaper. Use only fine glasspaper and wipe off with methylatedspirits.
FIG 11:15

2
The brush gear assembly

K e - y _o F i g 1 1 : 1 5 t 1 Soldered brush box connections 2 Main brushes 3 F a s r - s p e e db r ; ; h i ; i ; ; ; ; i i " . ) g e a r a s s e m b t ys e c u r r n g s c r e w s RG Red ;iri ;;r"" .4,^B.,grl Y u Ye l l o w w t t h g r e e n U G B l u e , a r t hq r e e n

11 0 0t \ 4 k 1 3 0 0 2

129

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h

/' '':_'a!?ain-, 1-

Switch on the tgnition and check with a voltmeter b e t w e e n t h e f l a s h e ru n i t t e r m i n a lB ( o r + ) a n d e a r t h t h a t . b a t l e r yv o l t a g e i s p r e s e n t J o i n t h e u n i t t e r m i n a l sB a n d L a n d o p e r a t et h e d i r e c t i o ni n d i c a t o rs w i t c h . l f t h e f l a s h e r u n i t i s d e f e c t i v ea n d m u s t b e r e n e w e d T h e s e u n i t s c a n f n o t b e d i s m a n t l e d o r s e r v i c i n ga n d c a r e s h o u l d b e t a k e n t h a t t h e c o n n e c t i o n sa r e m a d e t o t h e n e w u n i t i n t h e s a m e p o s i t i o n sa s t o t h e o r i g i n a l . lf, after long use, the flashers are not switched off when returning the steering to the straight ahead t p o s i t i o n ,i t m a y b e p o s s r b l e o c u r e t h e f a u l t b y a d j u s t i n g the operatingcam. Slackenoff the locknut and rotate d t h e c a m s l i g h t l y i n a n a n t i c l o c k w i s e i r e c t i o n ,t o r e s t o r e n o r m a lo p e r a t t o n . 11 :9 Windscreen wiPers T h e e a r l i e rc a r s o f t h o s e d e s c r i b e di n t h i s m a n u a l a r e f i t t e d w i t h a L u c a s t v p e 3 W A m o t o r a s i l l u s t r a t e di n F I G 1 1 : 1 2 , w h i l e l a t e rc a r s h a v e a t y p e 1 4 W w h i c h m a y b e i n e i t h e rs i n g l e o r t w o - s p e e d f o r m .

crankpin 3 adjacent to the ramP 2

Maintenance: T h e r u b b e r b l a d e s s h o u l d b e r e g u l a r l ye x a m i n e d f o r wear or damage and the windscreen cleaned wlth m e t h v l a t e ds p i r i t s t o r e m o v e o i l , t a r a n d a n y t r a c e so f w a x t p o l i s h w h i c h i n a d d i t i o nt o s m e a r i n g h e g l a s sa l s o h a v e a d e t e r i m e n t a le f f e c t o n t h e r u b b e r . T h e r u b b e r g r o m m e t r o u n d t h e g e a r b o x s p i n d l e s h o u l d b e l u b r i c a t e dw i t h a f e w d r o p s o f g l y c e r i n e .T h e g e a r b o x a n d t h e c a b l e r a c k are packed with greaseand need no further attentlon Setting the limit switch: y l f t h e w i p e r f a i l s t o w o r k s a t i s f a c t o r i lt h e l i m i t s w i t c h i n t h e g e a r b o x c o v e r 1 8 s h o u l d b e c h e c k e d S l a c k e nt h e four screws securing the gearbox cover and rotate the d o m e d c o v e r u n t i l t h e s e t t i n gp i p o n t o p o f t h e d o m e i s i n l i n e w i t h t h e c e n t r a lg r o o v e .T h i s m a y b e e i t h e ro n t h e s i d e nearestto or furthest from the groove depending upon w h i c h s i d e t h e b l a d e sa r e t o b e p a r k e d Checking current consumPtion : C o n n e c ta 0 t o 1 5 a m p a m m e t e ri n t h e w i p e r c i r c u i ta n d n o t e t h e c u r r e n tb e i n g s u p p l i e dt o t h e m o t o r ' T h e n o r m a l r u n n i n g d e m a n d ss h o u l d b e 2 . 7 t o 3 4 a m p s .

FIG 11:17 screws

S e a l e db e a m u n i t , s h o w i n g t h e a d j u s t m e n t

i n d e p e n d e n to f t h e i g n i t i o n s w r t c h , a n d t h e o t h e r f u s e across terminals 3 and 4 protects those circuits such as t h e f u e l g a u g e , w i p e r m o t o r a n d f l a s h e r sw h i c h o p e r a t e o n l y w h e n t h e i g n i t i o ni s s w i t c h e d o n f T h e s e p a r a t e u s e f o r t h e p i l o t a n d t a i l l i E h t si s r e m o v e d from its tubular holder by pushing the tube inwards, t w r s t i n g a n d P u l l i n ga P a r t . 1 ' l : 8 F l a s h e ru n i t r T h e F L 8 t y p e f l a s h e ru n i t i s i n a s m a l l r e c t a n g u l a c o n t a i n e ri n t h e w i r i n g l o o m b e h r n dt h e f a c i aa n d i s a c c e s s i b l e f r o m i n s i d e t h e c a r v i a t h e p a r c e lt r a y l t i s r e m o v e d b y p u l l i n g i t a w a y f r o m t h e t w o L u c a rc o n n e c t o r s T h e w a r n i n g l a m p ( s ) o n t h e p a n e ls e r v et o i n d i c a t et h a t a t h e f l a s h e ru n i t i s w o r k t n g c o r r e c t l y n d a l s o g i v e w a r n i n g o f a n i n d i c a t o rl a m P f a i l u r e . Faulty operation of f lashers: s l r r t h e e v e n t o f t r o u b l et h e f o l l o w i n g p r o c e d u r e h o u l d b e a d o p t e d :C h e c k t h e b u l b s f o r b r o k e n f i l a m e n t s R e f e r t o t h e a p p r o p r i a t ew i r i n g d i a g r a m a n d c h e c k a l l f l a s h e t . c i r c u i tw i r i n g a n d c o n n e c t i o n s C h e c k t h e f u s e

Wioer takes no current: C h e c k t h e f u s e ,a n d i f t h i s i s b l o w n c h e c k a l l t h e w i r i n g protected by the fuse. lf the wiring is in order, renew the 'wiper takes abnormallyhigh fuse and proceed as for f u s e r s i n t a c t ,e x a m i n et h e w i r i n g f o r b r e a k s current' lf the and check the operation of the control switch. Wiper takes abnormally low current: c h e c k t h e s t a t e o f t h e b a t t e r y .R e m o v e t h e c o m m u t a t o r ' e n d b r a c k e ta n d e x a m i n et h e b r u s h g e a r R e n e w a n y w o r n b r u s h e so r w e a k s p r i n g sa n d e n s u r et h a t t h e b r u s h l e v e r s move freely on thelr pivots. Clean the commutator'A s u s p e c t a r m a t u r ea s s e m b l ys h o u l d b e c h e c k e d b y s u b stitutron.

130

Wiper takes abnormally high current: T h i s m a y b e d u e t o e x c e s s i v e o a d o n t h e d r r v i n qs h a f t . l T h e s t a l l c u r r e n to f t h e m o t o r i s 1 4 a m p s w h e n c o ] d o r g a m p s w h e n h o t a n d i f t h e r e i s n o o b v i o u sf a u l t s u c h a s a s t i c k i n g w i p e r b l a d e ,c h e c k t h e g e a r b o x . R e m o v e t h e g e a r b o x c o v e r a n d c h e c k t h e a r m a t u r ee n o f l o a t .T h i s s h o u l d b e . 0 0 8 t o . 0 1 2 i n c h , a n d i f n e c e s s a r y may be adjusted by the end float adjusting screw. Check also that there is no undue frictionin thednve c a s i n g t u b e s d u e - t o o b s t r u c t i o n s o r e x c e s s i v ec u r v a r u r e . C h e c k t h e w h e e l 6 ' o x e sf o r a l i g n m e n t . Removing the'motor and gearbox:

+
I

D i s c o n n e c tt h e e l e c t r i c a c o n n e c t i o n sa n d r e m o v e t h e l wiper arms,the outer gearbox housing and the screws s e c u r i n g t h e m o t o r t o t h e r a d i a t o r v a l a n c e .W i t h d r a w t h e motor and the innercable rack. R e f i t t i n g i s a r e v e r s a lo f t h e a b o v e , b u t i t m a y a l s o b e n e c e s s a r yt o t w t s t t h e c a b l e i n o r d e r t o e n g a g e t h e r a c k with the worm in the gearbox. Removing wheelboxes. R e m o v e t h e m o t o r a n d g e a r b o x a s j u s t d e s c r i b e da n o r e m o v et h e f a c i a p a n e l ( s e e C h a p t e r 1 2 ) a n d t h e c e n t r a l f a c i as u p p o r t a f t e r l o w e n n g t h e s t e e r i n gc o l u m n . R e m o v e t h e d e m i s t e rd u c t s , t h e r e t a i n i n gn u t s f r o m t h e w h e e t b o x d r i v i n gs p i n d l e ,t h e b u l k h e a dg r o m m e t a n d l i f t t h e w h e e r ooxes away complete with the outer casinqs. R e f i t t i n g i s t h e r e v e r s eo f t h e a b o v e , e n J u r i n q t h a t t h e wheelboxes are correctly aligned and that the clble rack has been fully engaged with the gear and spindre assemblies. Dismantling the wiper motor and gearbox: Remove the gearbox coverand the end cover by u n s c r e w i n gt h e t h r o u g h - b o l t s .L i f t o f f t h e c o v e r 1 3 . T h e brushgear is removed complete, but mark it to ensure c o r r e c t r e p l a c e m e n to f t h e b r u s h e s .C l e a n t h e c o m m u t a t o r and see that thereare no carbon particles hortcircuitinq s the segments. t - T o d i s m a n t l e h e g e a r i n gr e m o v et h e c i r c l i pa n d w a s h e r f r o m t h e l i n k p i n a n d l i f t o f f t h e l i n k a n d i n n e r c a b l er a c k , R e m o v e t h e c r r c l i pf r o m t h e f i n a l g e a r s h a f t .R e m o v e b u r r s f r o m t h e s h a f t a n d l i f t o u t t h e g e a r .T h e a r m a t u r ea n d w o r m d r i v e 1 6 c a n n o w b e w i t h d r a w n . E x a m i n e l l t h e p a r t sa n o a renew where necessary. Reassembly of the wiper motor and gearbox: T h i s i s t h e r e v e r s eo f t h e d i s m a n t l in g s e q u e n c e ,e n s u r in g t h a t t h e f o l l o w i n g p o i n t s a r e a d e q u a t e l vl u b r i c a t e d : b s ^ _ A r m a t u r e e a r i n g s h o u l d b e i m m e r s e di n e n g i n eo i l f o r 24 hours before assembly. A r m a t u r es h a f t w i t h e n g i n e o i l a t t h e c o m m u t a t o re n d . F e l t l u b r i c a t o r n g e a r b o xw i t h S A E . 2 0 e n q i n e o i l . i F i n a l g e a r b e a r i n g s ,c r o s s - h e a d a n d g u - l d ec h a n n e l , c o n n e c t t n gl i n k , l i n k p i n a n d g e a r sw i t h g r e a s e . Wiper arms (see Fig 11 :13) : T o r e m o v e a w i p e r a r m f r o m t h e s p i n d l e , r e l e a s et h e r e t a r n i n g l i p 1 a n d p u l l t h e h e a d p i e c e u t w a r d sa n d a w a y c o f r o m t h e s p l i n e ds p i n d l e d r u m . R e f i t b y r e v e r s i n gt h e a b o v e , n o t i n g t h a t t h e p o s i t i o n o f

FIG 11:18 circuit

The

bi-metal

resistance instrumentataon

Key to Fig 11 :18 2 Controlbox 3 B a t t e r y( 1 2 - v o l t ) 4 S t a r t e rs o i e n o i d 19 Fuse-(43-44) 3 + i u e lCg a ua n r - Joi ge 35 Fueltank unit 3 8 l g n i t i o ns w i t i h +O tempraturegauge 47 Coolant temperaturetransmirrer 6 4 V o l t a g es t a b i l i z e r

FIG 11 :19 lmpulse tachometer circuit. Inset shows the symmetrical loop of the pulse lead Key to Fig 11 :19 2 C o n r r o lb o x 3 B a t t e r y( 1 2 _ v o t 1 ) 4 S t a n e rs o l e n o i d 19 Fuse-A3-A4 3 g l q n r i r o n-i - ' r t c n w 39 lgnitioncoir 40 Drstnbulor 95 TachJmerer

the arm reiative to the spindle is adjusted by removing the arm and re-engaging it on the splines in the deiireo position. Do not attempl to turn the arm whilst in position.

Type 14W wiper motor: T h i s m o t o r i s s h o w n i n t h e e x p l o d e dv i e w o { F I G 1 1 : 1 4 a n d m o s t o f t h e i n s t r u c l i o n sg i v e n f o r t h e e a r l i e r t y p e apply equally to the type 14W. lf after test it is necessarv t o d i s m a n t l e t h e m o t o r t h e f o l l o w i n g p r o c e d u r es h o u l d b e adooted: Remove the gearbox cover 1 by unscrewing the four r e t a t n i n gs c r e w s 2 . R e m o v e t h e c i r c l i p 4 a n d w a s h e r 5 t o releasethe connecting rod 3 from the crankpin, notrng

1 10 0 M k 2 13 0 0

131

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14

15
ff1rr{

16
h,

g'--R
tl-F \_ssreY, l v
FIG 11 :20
t ,

n.^t .filrllr\ lla\., -tl , vu,su],fllltu \y]

Components of M35J type starter motor

5 Yoke^ 6 Polescrew 3 Brush.sprrngs 4 Brushes 2 Bush housing 1 C o n r m u i a t o re n d b f a c k e t Key to Fig 11 i20 12 Pinionand barrel 11 Armalure b g F r e t dc o r s 10 Br"ush ox moulding 9 Dr ve end bracket 7 pole shoe 1 8 D r i v e e n d b r a c k e tb o l t 17 circlip 1 6 S p r r n gc u p 15 Marn sprrng l 4 B u f fe r r v a s h e r 13 Screwedsleeve

t h e l o w e r w a s h e r .R e m o v et h e c i r c l r pa n d w a s h e rs e c u r l n g a t h e s h a f ta n d g e a r 7 . S m o o t ht h e g e a r s h a f t n d w i t h d r a w tr w t h e g e a rn o t i n gt h e d r s h e d a s h e r8 . U n s c r e r nh e t w o b o l t s 1 a 1 6 a n d r e m o v et h e y o k e 1 5 a n d a r m a t u r e s s e m b l y 4 . a f t e rm a r k i n gt o e n s u r ec o r r e c tr e p l a c e m e n tC l e a no f f a n y m e t a l l i c p a r t i c l e sa n d d u s t . R e n r o v et h e s c r e w s s e c u r i n g 1 t h e b r u s h g e a r 2 a n d t h e s w i t c h a s s e m b l y1 1 a n d l i f t o f f Servicing the brushes: a , T h e b r u s h g e a r s s e m b l yw h i c h i s s h o w n c l e a r l yi n F I G 1 1 : 1 5 , m u s t b e r e n e w e db e t o r ee i t h e ro f t h e m a i n b r u s h e s are worn down to -f, inch, or the narrow section of the t h i r d b r u s h o n t w o - s p e e d m o d e l sd o w n t o t h e f u l l w i d t h of the brush C h e c k t h a t t h e b r u s h e sm o v e f r e e l y i r i t h e i r b o x e s a n d i 5 t h a t t h e b r u s h s p r i n g p r e s s u r es b e t w e e r r a n d 7 o z w h e n o m e a s u r e do r r a p u s h - t y p e g a u g e w i t h t h e b o i t o n . r t t h e b r u s h l e v e lw r t h t h e e n d o f t h e s l o t i n t h e b o x R e r r e wt h e a b r u s h g e a r s s e m b l yi s t h e s p r i n g sa r e n o t s a t i s f a c t o r y Reassembly: T h i s i s t h e r e v e r s eo f t h e d r s m a n t l i n gs e q u e n c e ,w i t h u c a r e f l a t t e n t t o nt o t h e f o l l o w t n g : l f e i t h e r t h e b r u s h g e a ro r s w i t c h a s s e m b l y i s t o b e r e n e w e d t h e m o t o r s u p p l y l e a d s a r e u n s o l d e r e da t t h e b r u s h b o x e sl.t a n e w s w i t c h i s t o b e f i t t e dt o a s r n g l e - s p e e d m o t o r r e m o v et h e Y G w i r e a t t h e s w i t c h t e r m i n a l R e s o l d e r t h e l e a d s a s s h o w n a n d e n s u r et h a t t h e y a r e w i t h i n t h e r e c e s si n t h e s w i t c h m o u l d i n g w h e n r e f i t t i n g i t t o t h e g e ar b o x . T h e g e a r w h e e lt e e t h a n d c a m , w o r m g e a r , c o n n e c t l n g r o d a n d p i n , c r o s s h e a d s l i d e ,c a b l e r a c k a n d w h e e l b o x G L w g e a r w h e e l s r ea l l l u b r i c a t e d i t h R a g o s i n e i s t a t e r e a s e a g s a T h e b e a r i n gb u s h e s , r m a t u r e h a { tj o u r n a l s , e a r w h e e l s h a f t a n d c r a n k p r na n d w h e e l b o x s p i n d l e sa r e l u b r i c a t e d with ShellTurbo 41 oil, and the felt washer in the yoke b e a r i n gs h o u l d b e t h o r o u g h l ys o a k e d i n t h e s a m e o i l T h e y o k e f i x i n g b o l t s a r e t i g h t e n e dt o a t o r q u e o f 1 4 l b

lf a new gearwheel is being fitted ensure that the correct type is obtained for either right or lefthand drive cars (see FIG 11 :16). When fitting the connecting rod 3 to the crankpin ensure that the larger of the two flat washers 5 is fitted u n d e r t h e c o n n e c t l n gr o d . Armature end f loat adjustment: T i g h t e n t h e s c r e w 1 7 u n t i l e n d f l o a t i s J u s te l i m i n a t e d then turn it back until the end float is between 002 and . 0 0 8 i n c h . U s e a f e e l e rg a u g e t o m e a s u r et h e g a p u n d e r t h e h e a d o f t h e t h r u s t s c r e w , f i t a s u i t a b l es h i m i n p l a c e and f ully tightenthe screw 11 :10 The headlamps i T h e s e a l e db e a m h e a d l a m pi s i l l u s t r a t e dn F I G 1 1 : 1 7 a n d m a y b e s e r v i c e do n l y a s a n a s s e m b l y . T o r e n r o v ea u n i t t a k e o u t t h e r e t a i n i n gs c r e w a t t h e bottom of the rrm and lift off the rim.Take out the inner s e c u n n g s c r e w s , p u l l t h e u n i t f o r w a r d a n d r e l e a s et h e t h r e e p r n s o c k e l a 1t h e r e a r o W h e n r e f i t t i n g ,e n g a g e t h e m o u l d e d r e g i s t e r s n t h e b a c k e d g e w i t h t h e s l o t s i n t h e s h e l l . P r e s st h e r e a r t o p e d g e i n p l a c e f i r s t , t h e n p r e s s d o w n w ' a r d sa n d i n w a r d s a n d r e fi t t h e r e t a i n i n gs c r e w s . Beam setting: I t i s r e c o m m e n d e dt h a t t h e b e a m s b e s e t a t a s e r v i c e station with an optical type beam setter,but if this is not i c o n v e n t i e n t t m a y b e d o n e b y p o i n t i n gt h e c a r a t a w a l l o n w h i c h t w o a i m i n g m a r k s h a v e b e e n p a l n t e da t t h e s a m e height as the lamps and the same dlstanceapart and t u r n i n gt h e a d j u s t i n gs c r e w so f o n e l a m p a t a t i m e u n t i l t h e beams are parallel to the road surface. The top screw a r r o w e d a dj u s t s t h e v e r t i c a ls e t t i n g , w h i l e t h e l o w e r s c r e w l a d j u s t sl h e d i r e c t i o n a s e t t i n g . 11 :11 The horn c lf a horn failsto function satisfactorilyheck that the a w i r i n g ,c o n n e c t i o n s n d m o u n t i n gb o l t sa r e i n o r d e rb e f o r e , r e m o v i n gi t . T h e h o r n c a n n o t n o r m a l l yb e d i s m a n t l e d a n d the slottedcentralcore and locknut must not be disturbed. A s m a l l s e r r a t e ds c r e w i s p r o v i d e d t o t a k e u p w e a r i n t h e

fr.
r f t S l a c k e n h e e n d f l o a ts c r e wb e f o r e i t t in g a n e w a r m a t u e , a n d a d l u s t a s w i l l b e d e s c r i b e dl a t e r ' The dished washer B is fitted with its concave srde towardsthe gearwheels.

l5z

m o v i n g p a r t s ;t t d o e s n o t a l t e r t h e p i t c h o f t h e n o t e . l f t w o h o r n s a r e f i t t e d ,d i s c o n n e c to n e w h i l e a d j u s t i n gt h e o t h e r . T u r n t h i s s c r e w a n t i c l o c k w i s e n t i l t h e h o r n l u s t f a i l st o u sound, then turn the screw back one quarter of a turn. C o m p l e t et h i s a d j u s t m e n ta s q u i c k l y a s p o s s i b l et o a v o r d b l o w i n g t h e f u s e , o r i f d e s i r e dt h e f u s e m a y b e r e m o v e da n o r e p l a c e dw i t h a w i r e l i n k . T h e h o r n p u s h i s l e v e r e do u t o f t h e s t e e r i n qw h e e l w i t h a screwdnver.

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11 :12 Fuel and temperature gauges T h e c i r c u i t o f t h e b i - m e t a l r e s i s t a n c en s t r u m e n t a t i o n i i s g i v e n i n F I G 1 1 : 1 8 . E a c h t r a n s m i t t eirs w i r e d t o a n i n d i c a t o rh e a d a n d t o a c o m m o n v o l t a g es t a b i l i z e w h i c h r e n s u r e sa c o n s t a n ts u p p l y o f 1 0 v o l t s . Checking battery voltage : C o n n e c ta v o l t m e t e r o c o n t r o lb o x t e r m i n a lB a n d e a r t h . t T h e m e t e rs h o u l d r e a d1 2 v o l t s w i t h t h e e n g i n es t a t i o n a r y . W i t h t h e e n g i n e r u n n i n ga t 1 0 0 0 r e v / m i n a n d t h e i q n i t i o n w a r n i n g l i g h t o u t t h e r e a d i n gs h o u l d b e a b o u t 1 i t o 1 3 votls. Checking wiring: C h e c k f o r c o n t i n u i t yb e t w e e n e a c h u n i t a n d c h e c k t h a t there is no Ieak to earth.Check for shortcircuitsn the i w r r i n gt o e a c ht r a n s m i t t e rC h e c kt h a t t h e v o l t a g es t a b i l r z e r . a n d t h e t r a n s m i t t e r sa r e e a r t h e d . Voltage stabilizer: D i s c o n n e c tt h e l e a d f r o m t h e s t a b i l i z e t o t h e g a u g e a t r t h e g a u g e a n d c o n n e c ti t t o t h e ' l ' t e r m i n a l o f a S m i t h s A u t o m o t i v e I n s t r u m e n T e s t e r , h e e a r t ht e r m t n a lo f w h i c h t t i s c o n n e c t e d t o t h e c h a s s i s .A f t e r t w o m i n u t e s w i t h t h e r g n i t i o ns w i t c h e d o n t h e r e a d i n gs h o u l d b e 1 0 v o l t s .l f t h e v o l t a g es t a b i l i z eirs f a u l t y ,r e p l a c e t w i t h a n e w u n i t m a k i n g i surethat it is fitted with terminalsB and E upoermostand n o t m o r e t h a n 2 0 d e g r e e sf r o m t h e v e r t i c a l . Transmitters: C h e c kf o r c o n t i n u i t yb e t w e e nt e r m i n a a n d c a s ew i t h t h e l l e a d d i s c o n n e c t e d . u b s t i t u t ea f a u l t y t r a n s m i t t e r i t h a S w new unit. 11 :13 lmpulse tachometer T h i s e q u i p m e n t c o n s i s t so f a n i n d i c a t o r h e a d a n o a p u l s e l e a d , w h i c h i s c o n n e c t e d i n s e r r e sb e t w e e n t n e i g n i t i o ns w i t c h a n d t h e i g n i t i o nc o i l a n d t r a n s m i t s o l t a g e v p u l s e st o t h e i n d i c a t o rh e a o . In the event of faulty operation, test the wiring to the i n d i c a t o rh e a d a n d c i r c u i t c o n r i n u i t y ( s e e F I G 1 1 : 1 g ) . T h e p u l s el e a ds h o u l d f o r m a s y m m e t r i c al o o p a s s h o w r r r n t h e r n s e ta n d n o t b e t i g h t a g a i n s tt h e p l a s t i cf o r m s 11 : 14 Starter motor type M35J. inertia drive Certain later cars are fitted with thts tvpe of starter m o t o r w h i c h i s i l l u s t r a t e di n t h e e x p l o d e d v i e w o f F I G '1 1 : 2 0 . M o s t o f t h e i n s t r u c t i o n sf o r t h e r e m o v a l a n d s e r v i c i n go f t h e s t a r t e rg r v e n e a r l i e ri n t h i s c l r a p t e ra p p l y e q u a l l y t o t h e t y p e M 3 5 J , w i t h t h e f e w e x c e p t i o n sa s follows. B rushgear : Any brush worn down to t inch must be renewed, r e f e r e n c e o F I G 1 1 : 2 1 w i l l a s s i s ti n t h i s o p e r a t i o n . t T o r e n e w t h e e n d b r a c k e t b r u s h e s ,c u t t h e b r u s h l e a d s from the terminalpost.slot the head of the post to accomm o d a t e t h e n e w l e a d sa n d s o l d e r . T o r e n e w t h e f i e l dw i n d i n g b r u s h e sc u t t h e b r u s hl e a d s , { i n c h f r o m t h e f i e l d w i n d i n g j u n c t i o n a n d s o l d e rt h e n e w l e a d st o t h e s t u m p s m a k i n gs u r et h a t t h e i n s u l a t i o n l e e v e s s are adequate. Commutator: T h i s m a y b e s e r v i c e di n t h e n o r m a l m a n n e r t a k i n g c a r e n o t t o r e m o v em o r e m e t a lt h a n i s n e c e s s a r y n d r e m e m b e r a i n g n o t t o u n d e r c u tt h e i n s u l a t i o nb e t w e e nt h e s e g m e n t s . Armature: T h e r n s u l a t i o n f t h e w i n d i n g s i s t e s t e dw i t h a 1 ' 1 - v o l t o 0 'l A C s u p p l y a n d a 5 w a t t t e s t l a m p c o n n e c t e di n s e r i e s b e t w e e n t h e a r m a t u r es h a f t a n d t h e c o m m u t a t o r .l f t h e l a m p l i g h t s t h e a r m a t u r em u s t b e r e n e w e d . Check the shaft for distortion, but do not attempt to r e c t i f ya { a u l t .T h e a r m a t u r em u s t b e r e n e w e d .

FiG 11 :21 Key to Fig 11 i 21 end bracket

Brush gear and connections 1 Short brush flextble, ommuraror c 2 L o n g b r u s h - f l e x i b l ec o m m u t a t o r e n d ,

bracket 3 L o n gb r u s h - f l e x i b f ee l dw i n d i n g li , 4 S h o r tb r u s hf e x i b l ef.i e l dw r n d r n g 5 y o k e i n s u l a t i op r e c e n j 6 F i e l d i n d i n g u n c ro n w 7 T e r m i n a lo s t p

Dismantling: '1 Remove the bolts 8 securing the drive end bracket 9 a n d r e m o v ec o m p l e t ew t t h t h e a r m a t u r e n d d r i v e .R e m o v e a the thrust washer from the commutator end of the a r m at u r e . Remove the screws securing the commutator end b r a c k e t1 , d e t a c h t h e b r a c k e tf r o m t h e y o k e 5 , d i s e n g a g e t h e f i e l d b r u s h e s f r o m t h e b r u s h g e a ra n d r e m o v e t h e bracket. lf necessary the drive assembly can be removed by c o m p r e s s r n gt h e s p r i n g , r e m o v i n g t h e j u m p r i n g a n d withdrawingthe drivefrom the shaft.

1100Mk21300

Field windings: Disconnectthe windings from their rivetedconnection with the yoke, and using the 110-volt AC, 15-watt test lamp between the yoke and each of the brushes in turn l c h e c k t h e i n s u l a t i o n . f t h e l a m p l i g h t st h e w i n d i n g s m u s t be renewed. T e s t f o r c o n t i n u i t y w i t h a 1 2 - v o l t b a t t e r ya n d b u l b c o n nected between each of the field brushes and the yoke. The lamp will light if the wiring is satisfactory. Bearings: l f t h e r e i s e x c e s s i v es i d e p l a y o f t h e a r m a t u r e s h a f t t h e b e a r r n g sm u s t b e r e n e w e d a s f o l l o w s : Commutator end bracket : D r i l l o u t t h e r i v e t ss e c u r i n g t h e b r u s h b o x m o u l d i n g a n d r e m o v e t h e m o u l d i n g , b e a r i n gs e a l r e t a i n i n gp l a t e a n d { e l t w a s h e r s e a l .S c r e w i n a j i n c h t a p a n d p u l l o u t t h e b e a r i n g bush. Drive end bracket: Support the bracket and pressout the bush. New bushes may be pressed into position, using a suitable mandrel, after allowing the bush to lie immersed in engine oil for 24 hours before fitting. R e a s s e m b l ya n d r e fi t t i n g i s t h e r e v e r s eo f t h e d t s m a n t l ing procedure.

(f ) Alternator output low or nil 1 C h e c k1 , 2 , 3 5 a n d 7 i n ( e ) 2 Slip ring face dirty 3 Open circuitin dtode assembly 4 R o t o r o r s t a t o rw l n d i n g s b r o k e n (g) Starter motor lacks power or will not operate 1 2 3 4 5 6 7 B a t t e r yd i s c h a r g e d l, o o s e c a b l e c o n n e c t i o n s S t a r t e rp i n i o n t a m m e d i n f l y w h e e l g e a r S t a r t e rs w i t c h f a u l t y B r u s h e sw o r n o r s t i c k i n g ,l e a d sd e t a c h e do r s h o r t t n g C o m m u t a t o rd i r t y o r w o r n Startershaft bent E n g i n ea b n o r m a l l ys t i f f, p e r h a p sd u e t o r e b o r e

(h) Starter motor runs but does not turn engine 1 P i n i o n s t i c k i n g o n s c r e w e ds l e e v e 2 B r o k e nt e e t h o n p i n i o n o r f l y w h e e l g e a r s (j) Noisy starter pinion when engine is running s 1 R e s t r a i n i n g p r i n gw e a k o r b r o k e n (k) Starter motor inoperative 1 C h e c k1 a n d 4 i n ( g ) 2 A r m a t u r eo r f i e l d c o i l s f a u l t Y (t) Starter motor rough or noisY 1 Mounting bolts loose 2 D a m a g e dp i n i o n o r f l y w h e e l g e a r t e e t h 3 Main pinion springbroken (m) Lamps inoperative or erratic

11 :15 Alternator type 16ACR 'l This is similar to tvpe 1 AC described earlier but includes a built-in voltage regulator. Note that battery p o l a r i t yi s N E G A T I V EE A R T H .

11 :16 Fault diagnosis (a) Battery discharged 1 Terminal connections loose or dlrty 2 Shorts in lighting circuit 3 G e n e r a t o r o r a l t e r n a t o rn o t c h a r g i n g 4 Regulatoror cut-out units not functioning correctly 5 B a t t e r v i n t e r n a l l yd e f e c t i v e (b) Insufficient charging current 1 Check 1 in (a) 2 Drivingbelt slipping (c) 1 2 3 Battery will not hold charge Low electrolvtelevel Battery plates sulPhated E l e c t r o l y t el e a k a g e f r o m c r a c k e d c a s e o r t o p s e a l r n g compound 4 P l a t e s e p a r a t o r sd e f e c t i v e 1 Battery low, bulbs burned out 2 F a u l t ye a r t h i n go f l a m p s o r b a t t e r y 3 Lighting switch faulty, loose or broken connecttons (n) Wiper motor sluggish, taking high current 1 2 3 4 F a u l t ya r m a t u r e B e a r i n g so u t o f a l i g n m e n t C o m m u t a t o rd i r t y o r s h o r t c i r c u t t e d Wheelbox spindle binding, cable rack tight in outer c a s ln g 5 Lack of lubricatton 6 N o e n d f l o a t t o a r m a t u r es h a f t

(o) Wiper motor runs but does not drive arms 1 W h e e l b o x g e a r a n d s p i n d l ew o r n 2 C a b l e r a c kf a u l t y 3 Gearbox components worn (p) Fuel or temperature gauges do not work 1 Checkwirrng for contrnuity r 2 V o l t a g es t a b i l i z e f a u l t , f a 3 C h e c k i n s t r u m e n t s n d t r a n s m i t t e r so r c o n t i n u i t y (q) Faulty impulse type tachometer 1 C h e c k w i r i n g a n d c o n n e c t i o n st o i n d i c a t o rh e a d 2 P u l s e l e a d i n c o r r e c t l yf i t t e d

(d) Battery overcharged 1 R e g u l a t o r sn e e d a d j u s t i n g (e) Generator output low or nil 1 Belt brokenor slipping 2 R e g u l a t o ru n i t o u t o f a d i u s t m e n t 3 W o r n b e a r i n g s ,l o o s e p o l e p i e c e s 4 Commutator worn, burned or shorted 5 Armature shaft bent or worn 6 I n s u l a t i o np r o u d b e t w e e n c o m m u t a t o rs e g m e n t s 7 B r u s h e ss t i c k t n g ,s p r i n g sw e a k o r b r o k e n 8 F i e l d c o i l w i n d i n g s b r o k e n ,s h o r t e do r b u r n e d

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CHAPTER 12 THE BODYWORK

12 : 1 12:2 12 : 3 12:4 Removing door trim Servicing door locks The windows and winding mechanism Luggage compartment lock 12:5 12 :6 12 : 7 12 :8 Seat belts Removing facia, instruments and switches The heater Air-conditioning

12 : 1 Removing door trim Austin, Morris, Wolseley, Riley and MG (see Fig 12:1): Before the door trim pad can be removed it is frrst n e c e s s a r yt o r e m o v e t h e w i n d o w r e g u l a t o r h a n d l e , t h e i n t e r i o r o o r h a n d l ea n d t h e d o o r p u l l o r a r m r e s t T h e t w o d . f o r m e r r t e m s a r e r e l e a s e db y r e m o v i n g t h e c e n t r e s c r e w and spring washer; two screws are used to secure the a r m r e s to r p u l l . O n t w o - d o o r M k 2 a n d 1 3 0 0 m o d e l st h e a n t i b u r s tl o c r r e m o t e c o n t r o l r e t a i n e rm u s t b e r e m o v e d . Remove the screws securing the door map pocket and leverthe trim pad away with a screwdriver.

12:2 Servicing door locks Early type (see Fig 12 :2): T o r e m o v e t h e l o c k i t i s f i r s t n e c e s s a r yt o r e m o v e t h e i n n e rd o o r h a n d l e ,d o o r p u l l a n d w i n d o w r e g u l a t o r a n d l e h as previously described. Remove the door trim pad. R e m o v et h e c o n n e c t i n gl i n k 5 f r o m t h e l e v e r2 b y r e m o v i n g t h e s p r i n g c l r p a n d w a v y w a s h e r . R e m o v e t h e s e t s c r e w sg a n d r e m o v et h e l o c k a s s e m b l y . To removethe outer door handle take out the screws 6. R e f i t t i n g i s t h e r e v e r s eo f t h e r e m o v a l s e q u e n c e . Later type (see Fig 12 :3): T h e s ea n t i - b u r s tl o c k sa r ef i t t e dr o t w o d o o r 1 1 0 0 M k 2 a n d 1 3 0 0 m o d e l sa n d m a y b e s e e ni n p o s i t i o ni n F I G 1 2 : 4 . They {it flush with the door and can be locked from rne inside by pulling the safety latch rearwards. To remove the lock, remove the window regulator h a n d l e , t h e a r m r e s t , t h e r e m o t e c o n t r o l r e t a i n e r ,t h e t r i m p a d a n d t h e g r e y d o o r l i n e r s . R e l e a s et h e c l i p s 10 , p u l l o f f l h e t w o a n t i - r a t t l e l i p s 1 3 , r e m o v et h e f o u r s c r e w s1 4 a n o c withdraw the remote control assembly 7. Remove the clips 3 and 5 and withdraw the push button assemblv6.

Princess: R e m o v e t h e d o o r l o c k a n d w i n d o w r e g u l a t o rh a n d l e s a n d t h e d r i v e s c r e w ss e c u r i n gt h e c h r o m e d o o r p u l l t o t h e armrest. Remove the screws securing the armrest to the map pocket and remove the pocket. Remove the screws s e c u r i n gt h e t r i m p a n e l a n d l e v e r i t a w a y f r o m t h e d o o r . Remove the drive screws and lift off the door finishers. O n a l l m o d e l s r e f i t t i n g .i s t h e r e v e r s eo f r e m o v a l .

11 0 0 M k 2 1 3 0 0

135

Window

regulators, two-door

models :

, R e f e rt o F I G 1 2 : 4 R e m o v et h e i n n e r h a n d l e s d o o r p u l Jo r a r m r e s t , h e d o o r l o c k r e m o t e c o n t r o l r e t a i n e r t, h e t t n m p a d a n d l i n e r . R e m o v et h e s c r e w s 4 , a n d t h e g l a s s s t o p a n d l o w e r t h e g l a s st o t h e b o t t o m o f t h e d o o r . L e v e r o f f t h e o u t e r w e a t h e r s t r i pa n d t h e t n n e r d o o r s w a r s t r a r l .R e m o v et h e v e n t i l a t o r c r e w 3 , t h e s c r e w o n t h e toD edqe of the door and lift out the fixed quarter-light a s s e n r b l v C e n t r et h e b o t t o m c o n t r o l c h a n n e l t h e n t w i s t t h e g l a s sf o r w a r d sa n d u p w a r d st o r e m o v ei t . R e m o v et e n t s c r e ' r v 2 s e c u r L n gh e w i n d i n g m e c h a n i s ma n d w r t h d r a w s

R e m o v i n g d o o r g l a s s .f o u r - d o o r m o d e l s :
FIG 12 :1 The door assembly

B C h e c kl t n k A H i n g es c r e w s Key to Fig 12 :1 D D o o r h a n d l ea n d w i n d o w C Door map pocketscrews r e g u l a t o rs c r e w s

i R e m o v et h e I n t e f o r f t t t t n g sa n d t r l m . L e v e ro f f t h e w a i s t t t f i n i s h e r t r l p se n d r e i e a s eh e g l a s sc h a n n e la t t a c h e d o t h e s r e g u l a t o ra s s e m b l y R e m o v e t h e g l a s s s t o p b y m e a n s o f s c r e w s D a n d l o w e r t h e g l a s st o t h e b o t t o m o f t h e d o o r . a R e m o v et h e r e g u l a t o r r c f r o n r t h e r e g u l a t o lc h a n n e la t E . R e m o v e t h e t o p a n d v e r t t c a lf e l t c h a n n e l s . R e l e a s et h e v e n t i l a t o rs e c u n n g s c r e w s C a n d r e m o v e t h e a s s e m b l y . The glassmay now be lifted out through the top of the door panel. Removing door glass, two-door models:

R e f e r t o t h e i n s t r u c t i o n sf o r t h e r e m o v a l o f t h e w i n d o w regulator. Removing ventilators: P r o c e e d a s i n t h e p r e v i o u s i n s t r u c t i o n sw r t h o u t r e m o v i n g t h e w i n d o w g l a s s a n d t h e v e n t i l a t o r sm a y b e l i f t e d o u t . Removing rear side windows. Traveller: Countryman and

m . L o c km e c h a n i s mF o u r - d o o r o d e l s ' l I n n e r o o rh a n d l e e t a i n i ns c r e w r g d Key to Fig 12:2 c l e 3 R e m o t e o n t r o1 od o o rr e t a i n l n g 2 L o c ko p e r a t i n lg v e r i 5 C o n n e c t i nlgn k sc 4 Sel{-tapping rew screws 7 K e yo p e r a t i n a r m g r g d 6 O u t e r o o rh a n d l e e t a i n i ns c r e w s d o o rr e t a l n i n s c r e w s g 9 L o c kt o 8 L o c kf r a m e r 1 1 L o c kc o n t a c t o r 1 0 P u s h - b u t t op l u n g e b o l t n '1 Chldren's atety atch c 3 12 Locknut e g 14 S l r i k e tro d o o rp r l l a r e t a i n i n s c r e w s 15 A n t i - r a t t lc l r p FIG 12:2 R e m o v e t h e s c r e w s B a n d p u l l t h e l o c k a s s e m b l yo u t wards. o R e f i t t i n gi s t h e r e v e r s e f t h e s e i n s t r u c t l o n s . Rear door locks, Countryrran and Traveller: T o r e m o v et h e l o c k a n d r e m o t e c o n t r o l ,r e m o v et h e s l x s c r e w s w i t h t h e f l a t a n d s p r i n g w a s h e r sf r o m t h e l o c k , t remotecontrol and link bar and lift away. Reverse hese instructionso reftt. t T o r e m o v et h e o u t e r d o o r h a n d l e l e v e ro t f t h e t r i m p a d , r e m o v e t w o 2 B A n u t s a n d w a s h e r sf r o m t h e o u t e r s t u d s and lift off the handle. 12:3 The windows and winding mechanism Window regulators, four-door models : R e f e r t o F I G 1 2 1 5 . R e m o v e t h e i n t e r i o rh a n d l e s a n d t f l m p a d , R e m o v e t h e s e v e n s c r e w s B . R e l e a s et h e r e g u l a t o ra r c E f r o m t h e b o t t o m o f t h e g l a s s . L r f t t h e g l a s s u p t o c l e a r t h e r e g u l a t o ra n d r e m o v e t h e r e g u l a t o ra n d b r a c k e t a s s e m b l y . R e f i t i n t h e r e v e r s eo r d e r .

U n s c r e w a n d r e m o v e t h e t w o w i n d o w c a t c h e s .R e m o v e the two closing clips and detach the inner and outer finishers, Remove the eight clips retaining the inner f inisher.Drill out the five rivets holding the glass channel

9 l0 F I G1 2 : 3

tt

The anti-burst door lock

2 Door lock 1 Door stilkef Key to Fig 12 :3 3 D o o r p u s h t o o p e r a l i n gl e v e r c l i p mechanrsm push relarning lip 5 Dccr c 4 D o o r r e l e a s eo p e r a t i n gl e v e r 7 D o o r r e l e a s em e c h a n i s m 6 Door push 9 Door striker retaining screw 8 Door lock mechanism 11 Door release perating o 1 0 O p e r a t i n gr o d r e t a i nn g c l i p s 13 A n t i r a l t l e c l i p 12 Door lock operatrng rod rod (two off) 1 4 O p e r a t i n gm e c h a n i s ms c r e w

lJCl

r e t a i n e t o t h e b o d y . R e m o v et h e a s s e m b l y y l e v e r i n g h e r b t g l a s s c h a n n e l r e t a i n e ru p a n d o u t f r o m t h e b o t t o m . T o r e m o v e t h e g l a s s f r o m t h e a s s e m b l yc a r e f u l l yf l e x t h e s p r i n g s t e e l c h a n n e l r e t a i n e ra n d l i f t o u t t h e c l a s s . When replacingthe window seal it Into tne tody aperture with Glasticon Dum Dum putty, part No. 9 1 H . 2 7 2 7 ,t a k i n g c a r e n o t t o s e a l o v e r t h e w a t e r o u t l e r s . Two-door saloon (see Fig 12:6): Remove the screws securing the catch 6 to the body a n d o p e n t h e w i r i d o w s l i g h t l y .G r i p t h e t o p a n d b o t t o m f i r m l y a n d p u l l t h e g l a s sa n d f r a m e o u t o f t h e b o d y r u b b e r g l a z i n g .R e f i t b y r e v e r s i n g h e a b o v e p r o c e d u r e . t 12:4 Luggage compartment lock Refer to FIG 12:7. On no account should the luggage compartment lid be closed while the lock mechanism is being removed or refitted. R e m o v et h e n o t c h e d l o c k i n g r i n g 1 a n d w i t h d r a w t h e p u s h b u t t o n a s s e m b l y .U n h o o k t h e c o n n e c t j n g l i n k 3 , r e m o v et h e s c r e w s 2 a n d w i t h d r a w t h e c a t c h a s s e m b l y . R e f i t t i n g i s t h e r e v e r s eo f t h e a b o v e . 12 :5 Seat belts T h e a t t a c h m e n tp o i n t s a n d f i t t i n g sf o r t h e s e a t b e l t sa r e s h o w n i n F I G 1 2 : 8 a n d t h i s d r a g r a m h o u l d b e u s e dw h e n s fitting Fitting to centre pillar:

F I G1 2 : 5 Door interior. Four-door models KeytoFig 12:5 A D o o r l o c k r e m o t ec o n t r o l B W r n d o w r e g u l a t o ra n d b r a c k e ts c r e w s C Ventilator crew s D Door stop screws E G l a s sr e g u l a t o ra r c

T h e t o p f i x i n g h o l e m a y b e b e h i n dt h e t r i m o r c o n c e a t e d b y a s n a p b u t t o n . C u t a h o l e i n t h e t n m t o c o i n c i d ew i t h

,,/

n
7<l '\.,
-'l tii;,
a

i
'e4 =1

I I
F I G 12 : 6 Rear quarterlight

;, ;=.i \:-,/'l

Key to Fig 12:6 1 F r a m e s s e m b l( r e a r i g h t h a r r o / a y 2 F r a m e s s e m b l( f r o n tr r g h t h a n d ) a y 3 G l a z i n gu b b e r r 4 Screw 5 Glass 6 Catch ssembly 7 Rivei a t h e h o l e i n t h e p i l l a r ,n o t r n g t h a t o n V a n d e n P l a s m o d e l s t h e h o l e i n t h e h a r d b o a r d i n e rm u s t a i s o c o i n c i d ew i t h t h e l p i l l a rh o l e . F i t t h e b r a c k e t ,a w a v e d w a s h e r a n d a s h o u l d e r e d d i s t a n c e p i e c e ( t h e s m a l l e r d i a m e t e ro f w h i c h w i l l s l o t I n t h e b r a c k e t )o n a + i n c h b o l t a n d s c r e w t h e b o l t i n t o t h e h o l e i n t h e p i l l a r ,m a k i n g s u r e t h a t n o f a b r i c i n t e r f e r e s w i t h a m e t a lt o m e t a lc o n t a c t b e t w e e nd i s t a n c ep i e c ea n d p i l l a r( s e e i n s e t1 ) . Sill f ixing for static belts (see inset 2) :

-'ti[H I :llP6),

/ I

r'[ i
,
FIG 12:4

2 3
models

Door interior. Two-door

K e y t o F i g 12 : 4 1 Door lock remotecontrol 2 W i n d o w r e g u l a t o ra n d b r a c k e t s c f e w s 3 Ventilator crew s 4 Door stop screws 5 D o o r g l a s s r e g u l a t o ra r c 6 A n t i r a t t l ec l i p s

C u t t h e c a r p e to v e r t h e f i x r n g h o l e t o e n s u r ea m e t a l t o m e t a l c o n t a c t . F i t t h e b r a c k e t ,a w a v e d w a s h e r a n d a s h o u l d e r e d r s t a n c e i e c e ( t h e s m a l l e rd i a m e t e ro f w h i c h p d s l o t s i n t o t h e b r a c k e t )o n a 1 f i n c h b o l t a n d s c r e w i n t o t h e holein the sill.

1100Mk21300

137

Tunnel f ixing (see inset 3); L i f t t h e c a r p e t a n d r e m o v et h e t w o p l u g s i n t h a t s i d e o f t h e t u n n e l n e a r e s tt o t h e s e a t b e i n g f i t t e d . H o l d t h e t a p p i n g p l a t e i n p o s i t i o n u n d e r n e a t ht h e f l o o r p a n e l , e n s u r i n gt h a t n o p i p e l i n e s r e t r a p p e d .S e c u r et h e b r a c k e t a of the short belt to the plate from underneaththe carpet w i t h t h e s c r e w s a n d l o c k w a s h e r s ,m a k i n g a s l i t i n t h e c a r p e t a n d f e l t f o r t h e b e l t t o p a s s t h r o u g h .T h e l o c a t i o n f o r t h i s s l i t c a n b e d e t e r m i n e db y b u c k l i n g t h e b e l t i n t h e wearing position.

Testing automatic belts :

v
I

I I

I
FIG '12:7 Luggage compartment lock Key to Fig 12:7 2 P h i l l i p ss c r e w s 1 N o t c h e dl o c k i n gr r n g 3 C o n n e c t i n gl i n k

The reel will only lock under conditions of sharp o d e c e l e r a t i o n r w h e n i n c l i n e dt o a n a n g l e o f 4 5 d e g r e e s . After fitting, test the action of the reel by sublecting the c a r t o h a r d b r a k i n ga n d s h a r p c o r n e r i n g . T o u n l o c k t h e r e e l ,a p p l y s l i g h t f o r w a r d b o d y p r e s s u r e a g a i n s tt h e b e l t a n d t h e n r e l e a s e y a r e a r w a r dm o v e m e n t b of the body. Under no circumstances must the reel end be removed. 12:6 Removing facia, instrumentsand switches

Austin/Morris Deluxe: T o r e m o v et h e f a c i aa n d t h e r o c k e rs w i t c h e s . i s c o n n e c t d t h e b a t t e r ye a r t hl e a d ,r e m o v et h e f o u r s c r e w s h o l d i n g t h e p a n e l t o t h e p a r c e lt r a y t r i m a n d p u l l i t f o r w a r d c o m p l e t e w i t h l i g h t i n g a n d w i p e r s w i t c h e s . D i s c o n n e c tt h e L u c a r f a s t e n e r sa n d p u s h t h e s w i t c h e s a w a y f r o m t h e p a n e l . T h e s p e e d o m e t e rw a s h e l d b y t h e f o u r f a c i a p a n e l screws and mav now be oulled forwardsto disconnect the drive cable,the earth wire and the warning lights. R e m o v e t h e i n s t r u m e n ta s s e m b l y . T h e s t a r t e r / i g n i t i o s w i t c h i s n e x t r e m o v e db y u n s c r e w n i n g t h e b e z e ln u t , p u s h i n gi t r e a r w a r d sh r o u g ht h e s p e e d o t m e t e r a p e r t u r ea n d d i s c o n n e c t i n g h e w i r e s . t Unscrewing the bezel nut securing the windscreen washer pump, pull it f rom behind the panelthrough the a s p e e d o m e t e r p e r t u r ea n d r e l e a s e h e n y l o n p r p e s . t T o r e m o v e t h e h e a t e rc o n t r o l s w r t c h o n l a t e r m o d e l s , d i s c o n n e c t t h e b a t t e r y ,u n s c r e w t h e b e z e l n u t f r o m t h e s w r t c h a n d r e m o v e i t f r o m b e n e a t ht h e o a r c e lt r a v . D i s c o n n e c tt h e L u c a rf a s t e n e r s . T h e p a r c e lt r a y a s s e m b l ym a y b e r e m o v e d ,a ft e r r e m o v i n g t h e f a c i a p a n e l a n d a l l t h e c o n t r o l s J u s t m e n t i o n e d ,b y removing the seven screws securing its lower edge to the body. Bend down the top edges of the tray to clear the paddedtoD railand lift out. R e fi t i n t h e r e v e r s e r d e r b u t n o t e t h e f o l l o w i n g :W h e n o r e f i t t i n gt h e p a r c e l t r a y p u s h t h e t o p e d g e s u n d e r t h e p a d d e dt o p r a i ls t a r t i n g t t h e i n s i d ea n d w o r k i n g o u t w a r d s . a Feed all the switches or wire through their respective h o l e s b e f o r e f i t t i n g t h e s p e e d o m e t e r .D o n o t o m i t t h e r u b b e r r i n g r o u n d t h e s p e e d o m e t e rb e f o r e r e f i t t i n g t h e facia panel. Austin/Morris Super Deluxe: r T o r e m o v et h e f a c i a ,d i s c o n n e c t h e b a t t e r y , e m o v et h e f o u r s c r e w s h o l d i n g t h e t o p r a i l r n p o s i t i o na f t e r b e n d i n g back the hinged metal caps from the two outer screws and lift off the rail. R e m o v e t h e s i x s c r e w s s e c u r i n gt h e f a c i a , e a s e b a c k t h e a d i a c e n td o o r t r i m a n d p u l l i t f o r w a r d . D i s c o n n e c t h e

FIG 12:8

S e a t b e l t a t t a c h m e n tp o i n t sa n d f i t t i n g s 3 Tunnel

Key to Fig 12:8 1 P i l l a r 2 S i l l( s r a t i c e l r ) b c 4 S i l l ( a u t o m a t ib e l t )

Sill f ixing for automatic belts (see inset 4) : C u t t h e c o v e r i n go v e r t h e f i x i n g h o l e i n t h e s i l l . F i t t h e b e l t b r a c k e t ,a w a v e d w a s h e r a n d s h o u l d e r e dd i s t a n c e p i e c e ( t h e s m a l l e r d i a m e t e ro f w h i c h w i l l s l o t i n t o t h e b r a c k e t ) ,t h e r e e l f i x r n g b r a c k e ta n d d i s t a n c ep i e c e o n a r f i n c h b o l t a n d s c r e w i n t o t h e h o l e . D r i l l h o l e si n t h e s i l l t h r o u g h t h e + i n c h h o l e s i n t h e b r a c k e ta n d s e c u r ew i t h the self tappingscrews. S e c u r et h e r e e l t o t h e b r a c k e ts o t h a t t h e b e l t w i l l u n wind on the pillar side. The base of the reel must be m o u n t e d i n a h o r i z o n l a lp o s r t r o n o e n s u r ec o r r e c to p e r a l tion.

138

'B-46 42 45 6

-@

FIG 12 :9

Facia panel components. Wolseley, Riley and MG

KeytoFigl2:9lRighthandfaciapanelassembly2Leflhandfaciapanelassembly3Centrefaciapanelassembly 4 S c r e w , w a s h e r ,n y l o n n u t 5 Bracket 6 Bracket 7 Screw 8 Screw 9 I n s t r u m e n tp a n e l a s s e m b l y( a i l W o l s e l e ya n d M G 1 1 0 0 a n d 1 3 0 0 ) 9 A I n s t r u m e n tp a n e l a s s e m b l y( a l l R i l e y a n d M G 1 3 0 0 M k 2 ) ' l0 I n s t r u m e n tp a n e l { i n i s h e r ' 1 1 I n s t r u m e n t 'l bezel2 Screw1 4 G l - o v e b o xi d a s s e m b l y l 15 Outer hinge 16 Innerhinge 17 Screw 1 8 G l o v e b o xl i d s u p p o r t 1 9 S c r e w 2 0 H a n d l e 2 1 S c r e w 2 2 M a g n e t i c l o c k 2 3 M a g n e t i c l o c k k e e p e r 2 4 P l u g 2 5 A s h t r a ya s s e m b l y 2 6 A s h i r a y c a s e a s s e m b l y 2 6 4 W i n g n u t 2 7 A s h t r a y r e t a i n i n gs t r a p 2 8 D e m i s t e rs l o t f i n i s h e r 2 9 P u s h , o n f i x 3 O F a c i a t r a y 3 1 S c r e w 32 Washer 33 Nut 34 Bracket 35 Rivet 36 Bracket 37 Rivet 38 Rivet 40 Suooort rail 39 Washer 41 Bivet 42 Sray 43 Screw 44 Plain washer 45 Nut 46 Screw 47 Stay 48 Screw 49 Screw 50 Nylon nut -All W o l s e l e ya n d M G 1 1 0 0 a n d 1 3 0 0 T h e r o u n d h o l e s s h o w n a s d o t t e d l i n e s i n t h e i n s t r u m e n tp a n e l s a r e f o r t h e t o g g l e - t y p e switches fitted to earliermodels

c h o k e c a b l e a t t h e c a r b u f e t t e rp u l l t h e L u c a r c o n n e c t o r s , f r o m t h e s w i t c h e sa n d r e m o v et h e d r i v e c a b l e a n d e a r t h lead from the speedometer. Ltft the facia panel away comolete with switches. When refitting the facia, first feed the choke cabte t h r o u g h t h e b u l k h e a d t h e n r e v e r s et h e a b o v e p r o c e d u r e . The speedometer is removed after removing the top r a r la s j u s t d e s c r i b e d n d r e l e a s i n gw i t h o u t r e m o v i n g , h e , a t f a c i a p a n e l . D i s c o n n e c ta l l L u c a r c o n n e c t o r s ,e a r t h w i r e a n d s p e e d o m e t e rc a b l e . U n d o t h e t w o t o p s e c u r i n g s c r e w s a n d p u l l o u t t h e s p e e d o m e t e rt o r e l e a s et h e b o t t o m c l i p s . R e f i t i n t h e r e v e r s eo r d e r . - T o r e m o v e t h e p a r c e l t r a y , r e m o v e t h e s t e e r i n gc o l u m n a s d e s c r i b e d i n C h a p t e r 9 . R e l e a s et h e h e a t e r c o n t r o l panel. Unscrew the parcel tray securing screws and lift out. The washer pump is removed by unscrewing the bezel n u t a n d p u l l i n g i t o u t f r o m b e h i n d t h e f a c i a b e f o r ed i s c o n n e c t i n gt h e n y l o n p i p e s .

Wolseley, Riley and MG (see Fig 12:9) : D i s c o n n e c t t h e b a t t e r y .R e m o v e t h e a c c e s sp l u g i n s i d e t h e g l o v e b o x a n d r e m o v e t h e w i n g n u t 2 6 4 a n d b r a c k e t2 7 . Disconnect the ashtray bulb holder and remove the a s s e m b l y .R e m o v e t h e e s c u t c h e o nf o r t h e i g n i t i o n k e y a n d the direction switch and cowling which may be left hangingon its lead. Disconnect the steering column support bracket and t h e c h o k e c o n t r o l f r o m t h e c a r b u r e t t e r .P u l l t h e i n s t r u m e n t p a n e l f o r w a r d a n d d i s c o n n e c tt h e p i p e sf o r t h e w i n d s c r e e n w a s h e r ,t h e s p e e d o m e t e r . d r i vc a b l e , t h e o i l g a u g e p i p e e ( R i l e y o n l y ) a n d a l l e l e c t r i c a lc o n n e c t i o n sa f t e r m a r k i n g them to ensure correct replacement. At this point the operator is warned to handle the facia c o m p o n e n t s w i t h c a r e i n v i e w o f t h e f i b r e g l a s si n t e r l o c k construction. Removethe panel f ixing screws from inside the glovebox and the screws located beneaththe box ano lift rt away. Remove the fixing screws located below the centre section and lift off the assemblv.

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Facia panel components, Princess FIG 12:10 6 Plainwasher 4 Shakeproofwasher 5 Screw 3 Plainwasher 1 Faciasurround 2 Screw 12:10 KeytoFig plate 12 Hinge 11 Facia board 10 Plain washer 9 Nut 8 Screw - 1 ^ 3- S t u d a n d i-dn"L"p,'ooi *u.t"t 20 Magneliccatch ptiin washer L o c k s t r i k e rp l a t e 19 17 Springwasher^_ 18 Lock 16 i+-siuJ'ana ptate 1b Wingn;i 2 6 P a n _ eill l u m i n a t i o n l i g h t c a s l n g 25 Blankrng plug 24 Switch pan6l 23 Box 22 C)uadtanr' 21 Knob 32 Plain washer 31 Screw 30 Mixture control bracket 29 Fresh aii hose 38 Fresh air louvre 2; inriru."nt surround 38 Push-on fix Demisterfinisher slot S O n i f r t r a y c l i p a n d ,t r a y 3S Aint,iy case 3 4 A s h r r a'y 0 33 Nut 4 . _37 45 Finisher'A post,righthand 44 Finrsher'A 43 Screw 42 Nui 41 ptainwasher Screw ig fuii..upptn.ruy

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Princess: T h e c o m o o n e n t s o f t h e P r i n c e s sf a c i a p a n e l a r e s h o w n i n F I G 1 2 : 1 0 . D i s c o n n e c tt h e b a t t e r y a n d t h e m i x t u r e c o n t r o l c a b l e , r e m o v e t h e b e z e l sa n d p u s h o u t t h e i g n i t i o n / starter and wiper/wash switches. R e m o v et h e w i n g n u t b e l o w a n d b e h i n d t h e a i r d u c t o n t h e d r i v e r ' ss i d e . R e m o v e t h e g l o v e b o x l i d a n d t h e s c r e w s s e c u r i n gt h e b o x t o t h e f a c i a .R e m o v et h r e ew i n g n u t s ,o n e b e l o w t h e a i r d u c t o n t h e p a s s e n g e r ' ss i d e a n d t w o f r o m t h e c e n t r e o f t h e f a c i a . D i s c o n n e c tt h e s l e e r i n gc o l u m n to-body crossmember bracket, or, on later models, extract the horizontal shear screw clamptng the outer c o l u m n a n d r e m o v e t h e s t e e r i n gc o l u m n P u l l t h e f a c i a board 11 forward at the bottom and ltft away. Disconnect all instruments and swrtches, marking all electrical cables for later replacement, and remove the { a c i a b o a r d t o g e t h e r w i t h i n s t r u m e n t sa n d s w i t c h e s Remove the screws securing the facia surround 1 'A' post finishers44 and 45 and lift off the Remove the s u r r o un d . Mk 3 and later GT models: The components of the facia panel assemblyfitted to these models are shown in FIG 12:11. Remove the shear bolts and the steering column as described in Chapter 9.

Disconnect the choke inner cable at the carburetter a n d p u l l a l l t h e e l e c t r i c a lc o n n e c t i o n s f r o m t h e b a c k s o f t h e i r i n s t r u m e n t sa n d s w t t c h e s . Remove the two capped screws from either end of the top face of the facia surround. Below the surround there are also two screws in the centre flange and two at each end. Pull the surround forward, unscrew the speedometer drive and Iift out the facia panel and surround as a complete assembly. Unscrew the wing nuts at either side of the ash tray and from behind each air vent on either side of the facia. Remove each screw from the bottom flange of the oanel and the two screws retainingthe catch from above the glove box. The facia panel may now be separated from the surround complete with instruments and swltcnes.

lnstruments and switches: T h e s e c a n b e r e m o v e dw i t h t h e f a c i a p a n e l i n s i t u . A n i n s t r u m e n ti s r e m o v e d b y s l a c k e n i n gt h e k n u r l e d n u t s b e l o w t h e p a n e l t o r e l e a s et h e s e c u r i n g c l a m p s , p u l l i n g t h e i n s t r u m e n tf o r w a r d a n d r e m o v i n g t h e c o n n e c t io n s . To remove a switch, pull off the connecting wires, p r e s s d o w n t h e r e t a i n t n g t o n g u e s w i t h a s c r e w d r i v e ra n d push the switch forward from behind

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Facia panel components. Mk 3 and later GT models

KeytoFigl2:11 1 F a c i a p a n e l s u r r o u n d2 F a c i a p a n e l ( M k 3 t y p e s h o w n ) 3 F a c i a s e c u r i n g w a s h e r , s p r i n g w a s h e r , a n d w i n g nut (4 off) 4 Facia securing lower screws (2 off) 5 Glovebox catch (facia securing upper screws) 6 Faciasurround lower securing screw and washer 7 Anti-rattle bush 8 Surround side securing screw and washers 9 Surround upper securing screws withdomedcaps 10 Faciavent 1 1 F a c i a v e n t b u t t e r f l y 1 2 F a c t av e n t s e c u r i n g r i n g 13 Ashtray 14 Ashtraysecuringclip 15 Ashtray case 16 Ashtray clamp 17 Wing nut and washer 18 Glovebox 19 Glovebox lid 20 Glovebox lid catch 21 Gloxbox lid handle 23 Ouadrant 24 Supplementary panel (when fitted) 25 Blank 26 Demisterfinisher slot

2 7 P u s h - o nf a s t e n e r

2 8 F a c i a u p p o r ts t a y s

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FIG 12:12

The components of the heater

KeytoFigl2:12 1 Healer-unitassembly 2 Screw 5 Screw 3 Heateranddemistercontrol 4 Controlleverknob 11 Bulb holder 7 Shakeproof washer 10 Bulb 6 Screw 8 Air control escutcheon 9 Temperaturecontrol escutcheon 17 Heater switch 12 Air Ilap control cable 13 Water valve control cable 15 Screw 16 Grommet 14 Cable trunnion 18 Water valve 19 Joint washer 23 Hose 24 Hose clip 25 Grommet 20 Hose 21 Hose clip 22 Pipe assembly 26 Hose clip 27 Screw 28 Hose 29 Clip 30 Demister tube (righthand) 31 Demistertube (lefthand) 32 Ducl assembly (righthand) 33 Duct assembly (lefthand) 35 Nut 36 Heater instructjon plate 34 Screw

Refitting is a reversal of the above operations, but note the following points: Always use new domed caps to the screws on the upper surround. Ensure that the steering column has been properly a l i g n e da n d t h a t a l l c o m p o n e n t sa r e f u n c t i o n i n gc o r r e c t l y before fully tightening the column support shear screws which must of course be renewed. Refitting (all models) : T h i s i s a r e v e r s a lo f t h e r e m o v a l p r o c e d u r e .O n P r i n c e s s c a r st h e f a c i a p a n e l m u s t b e f i t t e d w i t h t h e b o a r d - s e c u r i n g cliDs located in the facia surround.

12 : 7 T h e h e a t e r T h e c o m p o n e n t s o f t h e h e a t e ra r e s h o w n i n F I G 1 2 : 1 2 , w h i l e t h e h e a t e rc o n t r o l s a r e s h o w n i n F I G 1 2 : 1 3 . T h e Iefthand lever regulates the quantity of air delivered to either the screen or the car interior,the righthand lever c o n t r o l s t h e t e m p e r a t u r eo f t h e a i r . l f r e q u i r e d t h e r a t e o f air flow can be boosted by a two-speed blower. Since the air is heated by the water in the engine's

FIG 12:13 The hoater controls. Position 1 for OFF. Position 2 for maximum interior heating. The lower diagram shows the settings for windscreen demisting

FIG 12:14

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FIG 12:15^ -The compressor belt is adjusted at points AdJust at 2 for the generator, alternator

c o o l r n gs y s t e m i t w i l l b e s e e n t h a t n o h e a t i n qi s a v a i l a b l e u n t i l t h e e n g i n e h a s r e a c h e d w o r k i n g t e m p e r a t u r ef o r ; t h i s r e a s o nt h e a i r c o n t r o l s h o u l d b e O F F u n t i l t h e e n q r n e has warmed up during cold weather. F o r w i n d s c r e e nd e f r o s t i n gt h e a r r c o n t r o l s h o u l d b e a t S C R E E Na n d t h e t e m p e r a t u r e o n t r o l a t M A X . c F o r w i n d s c r e e nd e m i s t i n g a n d m a x j m u m w a r m a i r t o t h e c a r i n t e r i o r , e t t h e a i r c o n t r o l b e t w e e n S C R E E Na n o s C A R a n d t h e t e m p e r a t u r eA T M A X . F o r c o o l i n g p u r p o s e ss e t t h e a i r c o n t r o l t o C A R a n d t h e t e m p e r a t u r ec o n t r o l a t M l N , a l t h o u g h t h e a i r c o n t r o l t o S C R E E N u n d e r t h e s e c o n d i t i o n sw i l l p r o v i d e e x t r a c o o l air at headlevel. O n P r i n c e s s a r s t h e b a l l - m o u n t e dd u c t s o n e i t h e rs r d e c o f t h e f a c i a p a n e l w i l l d i r e c t a i r i n a n y d e s i r e dd i r e c t i o n e x c e p t o u t w a r d s , i n , r y h i c hp o s i t i o n t h e a i r f l o w i s c u t o f f . 12 :8 Air-conditioning The layout of the system employed in these cars rs s h o w n i n F l G 1 2 . 1 4 . T h e c o m p r e s s o 8 i s d r i v e nb y a b e l t r f r o m t h e c r a n k s h a f p u l l e yw t t h a n e l e c t r o - m a g n e t ic l u l c h t c 7 incorporated in the drive. The lrquid refrigerant is condensed in the heat exchanger9 provided with an e l e c t r i c a n 1 1 . T h e I i q u i d i s s t o r e di n t h e r e c e i v e 6 a n d t h e f r h i g h - p r e s s u r s w i t c h c o n t r o l st h e c l u t c h i n t h e c o m p r e s s o r e d r i v e . A s e c o n d h i g h p r e s s u r es w i t c h 1 0 c o n t r o l s t n e condenser pressure. A glasssectronin the pipework at 4 permitsinspection o f t h e r e f r i g e r a nc h a r g e A t 2 a n d 3 a r e t w o e x o a n s i o n t v a l v e s .T h e e l e c t r o - m a g n e t r c l u t c h s o l e n o i di s e n e r q r z e o t h r o u g h t h e r e l a y 1 2 . T h e e v a p o r a r o ru n t t I t s t h e a r r c o n d i t i o n i n gc o m p o n e n t r n t h e s y s t e m a n d i s m o u n t e d b e l o w t h e f a c i a . T h e r e a r e f o u r s w i t c h e s c o n t r o l l i n qt h e e v a p o r a t o u n i t ,O F F ,L O W , M E D a n d H l G H . A n e l e c t r i c a l t y r d n v e n f a n i s a l s o i n c l u d e d , a t e m p e r a t u r ep h i a l a n d a t e m p e r a t u r e e n s i n gs w i t c h . s When the engine is running at or above a fast-idling s p e e d a n d a n y o n e o f t h e f o u r f a n c o n t r o ls u r i t c h e s s O N . i t h e r e l a ye n e r g i z e sh e c l u t c h s o l e n o i da n d t h e c o m p r e s s o r t r s s t a r t e d T h e f a n t h e n c i r c u l a t e sh e a t r i n r h e c a r t h r o u g h . t t h e e v a p o r a t o ru n i t w h e r e i t p a s s e st h r o u g h t h e c o o l i n g matrix before being returned to the car interior. The vaponzed refrigerant, having absorbed heat from the p a s s i n ga i r , i s d r a w n i n t o t h e c o m p r e s s o ra n d p a s s e du n d e r

FIG 12:16 system

Wiring diagram of the air-conditioning

K e y t o F i g 12 : 16 1 F a nm o t o r 2 H i g hp r e s s u rc u t - i n e 3 Fanmotor 4 R e s i s t oa s s e m b l y r 5 Clutch 6 C o n t r o ls w i t c h 7 T e m p e r a t u rs e n s i n q w i t c h e s 8 F u s e ( i g n i t i o n o n t r o l l ea c c e s s o r i e s ) 9 T e r m i i a lD o n 3 d '1 c c o n t r o lb o x 0 L i n el u s e 11 R e l a y 12 H i g h p r e s s u r e CUI-OUT C a b l ec o l o u r c o d e : N Y B r o w n / y e l l o w N p B r o w n / p u r p l e G Green U Blue B Black W h e n a c a b l eh a s t w o c o l o u rc o d e l e t t e r st,h e f i r s td e n o t e s n e r m a i nc o l o u r .a n d t h e s e c o n dd e n o t e s h e t r a c ec o l o u r . t pressure Into the condenser where it is returned to its liquid state and passed on to the receiver where it is stored until required by the evaporatorunit. T o a c h i e v er a p i d i n t e r i o rc o o l i n g t h e w i n d o w s s h o u l d b e c l o s e d , t h e H I G H s p e e d s w i t c h b u t t o n d e o r e s s e da n o the enginerun at approximately 500 revlmin. 1 W h e n t h e a i r - c o n d i t i o n i n gs y s t e m i s n o t r e q u i r e d i t s h o u l d b e r u n f o r a b o u t 1 5 m i n u t e se v e r vw e e k .

Servicing: There is very little that the home operator can do by w a y o f s e r v i c i n g h i s e q u i p m e n ta s m o s t f a u l t sw h i c h m a y t d e v e l o p r e q u i r e t h e e v a c u a t i o n o f t h e r e f r i g e r a n tb e { o r e w o r k c a n b e s t a r t e d a n d r e c h a r g i n g w h e n t h e r e p a i r sa r e completed. T h e d r i v i n g b e l t s h o u l d b e e x a m i n e dp e r i o d i c a l l y n d a t h e t e n s i o n a d j u s t e di f n e c e s s a r y F I G 1 2 : 1 S s h o w s r n e . layout of the belt drive and the adjusting points; the correct tenston rs obtained when there is + to * inch movement In the centre of the longest run between pullevs. T h e w r r i n g d i a g r a mg i v e n i n F t G 1 2 : 1 6 w i l l b e f o u n o u s e f u l i n c h e c k i n g f o r f a u l t s i n t h e e l e c t n c a lc i r c u i t s . Defective components must be replaced rather than r e p a i r e da n d t h i s w i l l n o t p r e s e n tg r e a t d i f f i c u l t v . I n c a s e o f t r o u b l e i n t h e s y s t e m ,c h e c k t h e l i n e f u s e 1 0 a n d t h e f u s e 8 f o r t h e i g n i t i o nc o n t r o l l e d c c e s s o n e r n t h e a s f u s e b o x ,c h e c ka l l c a b l e s o r c o n t i n u i t ya n d a l l c o n n e c t i o n s f for security. Check the generator output with a moving coil voltmeter and confirm that it is not less than g volts w i t h t h e e n g i n er u n n i n ga t 15 0 0 r e v l m i n .

1 1 0 CM k 2 1 3 0 0

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APPENDIX
TECHNICALDATA Engrne Clutc h Brakes Cooling system Tra smission n E l e c t r i c a lq u r p m e n t e lgnition Fuelsystem system Suspension Steering Capacities Dimensions

Torque wrench settings

WIRING DIAGRAMS F I G 1 3 : ' l A u s t i n / M o r r i11 0 0 M k 2 a n d 1 3 0 0 ( 1 9 6 7 - 7 1 s ) ( F I G 1 3 : 2 A u s t i nA m e r i c a 1 9 6 8 - 6 9 ) F I G 1 3 : 3 R i l e yK e s t r eM k 2 a n d 1 3 0 0 ( 1 9 6 7 - 6 8 ) l , F I G 1 3 : 4 R i l e y 3 0 0M k 2 ( 1 9 6 8 - 6 9 )M G 1 3 0 0M k 2 ( 1 9 6 8 - 7 1 ) 1 F I G 1 3 : 5 W o l s e l e a n d M G 11 0 0 M k 2 a n d 1 3 0 0 ( 1 9 6 7 - 6 8 ) y F I G 1 3 : 6 V a n d e n l a sP r i n c e s1 1 0 0 M k 2 a n d 1 3 0 0 ( 1 9 6 7 - 7 1 ) P s F I G 1 3 : 7 W o l s e l e y 3 0 0M k 2 ( 1 9 6 8 - 7 1 1 ) ( F I G 1 3 : 8 A u s t i nA m e r i c a 1 9 6 9 - 7 1 ) F I G 1 3 : 9 A u s t i na n d M o r r i s1 3 0 0G T ( 1 9 6 9 - 7 1 ) F I G 1 3 : 1 0 A u s t r n n d M o r r i s1 1 0 0 a n d 1 3 0 0 M k 3 ( 1 9 7 1o n w a r d s ) a F I G 1 3 : 1 1 A u s t i n1 3 0 0 G T ( l 9 7 1 o n w a r d s ) F I G 1 3 : 1 2 VandenPlas1300 ('l971 onwards) F I G 1 3 : 1 3 W o l s e l e y 3 0 0 M k 2 ( 1 9 7 1o n w a r d s ) 1 F I G 1 3 : 1 4 Hazardwarningsystem(to be used in conjunction with the appropriate w i r i n gd i a g r a m ) A HINTSON MAINTENANCE ND OVERHAUL GLOSSARY F TERMS O INDEX

1 1 0 0 k2 1 3 0 0 M

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TECHNICALDATA
(Dimensions are in inches unless otherwise stated)

ENGINE Bore and stroke t 0 9 8 c c , ( t V p e 1 O A M W . 0 c R , 1 0 V ,1 0 H ) s 1 1 2 7 5 c c ( t y p e s1 2 c , 1 2 H ) 1 2 7 5 c c ( t y p e s1 2 H 1 5 7a n d 1 2 H 1 8 5A u s t r n Americaonly) C o m p r e s s i o nr a t i o ( l o w ) 10 9 B c c ( s i n g l e a r b u r e t t e r ) c 1098 cc (twin carburetters) 1 2 7 5 c c( n o t A u s t i nA m e r i c a ) . . . C o m p r e s s i o nr a t i o ( h i g h ) 1098cc (singlecarburerter) 1098cc (twin carburetters) 1098cc (automatic transmission, type 1OAG . . . ) 1275cc 1 2 7 5 c c( 1 3 0 0 G T ) Crankshaft l M a i nj o u r n a d i a m e t e r : 1098 cc 1275cc Mainbearings: 1 O 9 8 c ca n d 1 2 7 5 c c M a i nb e a r i n g a t e r i a l : m 1098cc 1275cc D i a m e t r i c a l e a r a n c e. . c . Undersizes: 1098 cc 1275cc Endfloat j C r a n k p i no u r n a l i a m e t e r : d 1098 cc .. 1275cc .. Crankpin inimum egrind iameter: m r d 1098cc Connecting rods Lengthbetweencentres: 1098 cc 1275cc Big-endbearings ... ... :.: :.. Big-end earing aterial: b m 10 9 8c c 12 7 5c c B i g - e n db e a r i n g i a m e t r i c a l e a r a n c e . d c B i g - e n d n df l o a t : e 1098 cc 1275cc Pistons Type C l e a r a n c( t o p o f s k i r t ) : e 1098 cc 1275cc 6 4 . 5 8x 8 3 . 7 2m m 7 0 . 6 1x 8 1 . 2 8m m 7 0 . 6 1x 8 1 . 2 8m m 7.5.1 8.1:1 8.0:1 8.5:1 8.9:1 8.9:1 8.8:1 9.75:1 1 . 7 5 0 5o 1 . 7 5 1 t 2 . 0 0 0 5t o 2 . 0 0 1 0 Threethinwall,steel-backed Lead/bronze, plated lead/indium V P 3 ,l e a d / i n d i u m t N F M / 3 8 a .001 to .0027 -.01 0, -.020, -.030, - .040 -.020 and -.040 .002 to .003 1.6254to 1.6259 1. 7 5 0 4t o 1. 7 5 0 9 1.5854 5.75 5 . 7 4 8r o 5 . 7 9 2 T h i n w a l ls t e e-lb a c k e d , Lead/bronze, plated lead/indium pl C o p p e r / l e a d / i n d i u ma t e d .001 to .0025 . 0 0 8t o . 0 1 2 . 0 0 6t o . 0 1 0 A l u m i n i u ms o l i ds k i r t , .0021to .0037 .0029to .0037

r 100Mk 2 1300

(bottomof skirt) Clearance 1098cc 1275cc Suitable boresize (standard) 1098 cc 1275cc Oversizes available Pistonrings
Top ring

. 0 0 0 5t o . 0 0 1 1 . 0 0 1 5t o . 0 0 2 1 64.567to 64.595 mm (seetext) 10.622to 70.655mm (seetext) + . 0 1 0a n d+ . 0 2 0 one Threecompression, oil control I nternally chamfered, chrome-faced Tapered Slottedscraper Duaflex 1 or Apex 6 .062 to .0625 . 0 6 1 5t o . 0 6 2 5 . 0 6 1 5t o . 0 6 2 5 j24 to .125 007 to .012 0 11 t o . 0 1 6 O 0 Bt o . 0 1 3 007 to .012 Rails.012 to .028 . t S i d es p r i n g s' 1 1 0o . 1 5 0 . R a i l s 0 1 0t o . 0 4 0

Secondand third rings O i l c o n t r o lr i n g : 1O9B (early) cc 1098 cc (later)and 1275cc Width,top ring: 1098 cc 1275cc Width,secondand third rings: 1098 cc and 1275cc Width oil controlring 109Bccslottedscraper Fittedgap,top, secondand t h i r dr i n g : 1098 cc 1275cc top ring 1275cc secondand third rings Fittedgap, oil controlring: 1098 cc, s l o t t e d s c r a o e r 6 1098cc, D u a f l e x 1 1275 cc. Apex Ring to grooveclearance. 1 0 9 8 c c ,t o p , s e c o n d n d t h i r d a 1098 cc, slottedscraper 1 2 7 5 c c ,t o p , s e c o n d n d t h i r d a Gudgeonpin type: 1098 cc 1275cc
Gudgeonpin fit in piston: 10 9 B c c a n d 1 2 7 5 c c

.002to .004
0 0 1 5t o . 0 0 3 5 . 0 0 1 5t o . 0 3 5 F u l l yf l o a t i n g rod in Pressed connecting H a n dp u s h 2 . 8 1 2 3t o . 8 1 5 .0008to .0015interference

p Gudgeon indiameter: 1275cc p r G u d g e o n i n f i t i n c o n n e c t i n go d 1275cc Camshaft J o 'l r n a d i a m e t e r s : u l 098 cc and 1275cc (front) 1098cc and 1275cc (centre) 1 0 9 8 c c a n d 1 2 7 5 c c( r e a r ). . Endfloat Bearing type Bearing iametrical earance d c Drive Tappets d Outside iameter Length

t 1 . 6 6 5 5o 1 . 6 6 6 1.62275o 1.62325 t 1 . 3 7 2 5 o 1. 3 7 3 5 t .003 to .007 whitemetal lined Threesteel-backed, .001 to .002 C h a i n f p i t c hx 5 2 p i t c h e s ,

. 8 1 1 2 5o . 8 1 ' 1 7 5 t 1 . 4 9 5t o 1 5 0 5

148

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( a u r 6 u e u r L U / ^ a r0 2 L ) 0 O C ] u a 3r c d 9 7 o l 7
p a a d s l s a l d L u n dt t y s u r L u / ^ e r 8 l e 6 u r p e a rr a s A l e u e e 6 l s n e q x 3 09 u o r s s r L u al s n e q x f

E x h a u s te m i s s i o n E x h a u sg a s a n a l y s erre a d i n g t 8 5 0 r e v l m i n . . . t a Air pump test speed

2 t o 2 . 5 p e r c e n tC O ( 1 2 O Oe v l m i n e n g i n e ) r

C O O L I N GS Y S T E M Thermostat settings
Standard Cold climate Hot climate

B 2 o Co r 18 0 ' F 8 8 o Co r 19 0 o F J 4 o Co r 16 5 o F F U E LS Y S T E M

Carburetter(s) Type ' ' t Ogg synchromesh cc 10 9 8c c a u t o m a t i c 1275cc

1 2 7 5 c c 13 0 0 G T i S p e c i fc a t i o n : A u s t i n A m e r i c as y n c h r o m e s h A u s t i n A m e r i c aa u t o m a t i c C h o k ed i a m e t e r : 10 9 8 c c s y n c h r o m e s h ... 1 0 9 8 c c a u t o m a t i ca n d 1 2 - 7 5 c c Needle(standard):

SU
I-,IJZ

s i n g l eo r l w i n

H54single H54single H S 2t w i n A U D . 2 8 1f,i x e dn e e d l e A U D . 3 7 9 , p r i n gl-o a d e d e e d l e s n A U D 2 9 6 ,f i x e dn e e d t e A U D . 3 8 0 , p r i n g - l o a d en e e d l e s d

'll 1 2 ' l

10 9 B c cs v n c h r o m e s h 1098cc automatic 12 7 5c c 1 2 7 5 c c ,A u s t i nA m e i i c af,i x e dn e e d l e 12 7 5c c A u s t i nA m e r i c as p r i n g - l o a d e d , I n i t i a jl e t a d j u s r m e nA,u s t i nA m e r i c a t ( Needle weak): 10 9 8c c s v n c h r o m e s h

'l 098 cc automatic

AN single, 3 twin D DL DZ DZ AAR 1 3 f l a t sf r o m b r i d g e E Bs i n g l e ,G V t w i n ED H 6 s i n g l eD 6 t w i n , BO BO Red Bl u e , S U e l e c t r i cS P o r A U F . 2 0 O

1275cc ( Needlerich): 10 9 8c c s y n c h r o m e s h ... 10 9 8c c a u t o m a t i c 1275 c c P i s t o n p r i n gs i n g l e a r b u r e t t e r s s , c P i s t o n p r i n gt w i n c a r b u r e t t e r s s , Fuelpump

I G N I T I O NS Y S T E M S p a r k i n gp l u g s Type: 'l 098 cc 12 7 5c c Gap Coil A u s t i nA m e r i c a ,e a r l y A u s t i nA m e r i c a ,l a t e r

Champion 5 N Champion 9Y N 024 to .026 L u c a sL A . ' 1 2 Lucas A.12 L L u c a s A . 7w i t h 1 . 3t o 1 . 5o h m b a l l a s t B resistor

150

Distributor Type C o n t a c b r e a k eg a p . . . t r Static timino 1098 cc, m'anual, singlecarburetter manual, twin carburetter a u t o m a t i cH C e n g i n e s , , 1275 cc A . . A u s t i n ,M o r r i s1 9 6 7 o n I V I . G , i t e yW o t s e t e y , 9 6 7 _ 6 9 " n u a t . . . R , 1 m Wolseley, Vandenplas,automatic. 1967 on 19'67_69 ^ .VG, Riley,automatic, B. Wolseley, Vanden plas, after 1968; manual , t ^ M 9 , R i t e y1 9 6 8o n t y ,m a n u a . . . .. . C . M G , m a n u a t k 2 1 9 ' 6 9 _ ] 1 - -. . M R i l e ym a n u a M k 2 1 9 6 g _ 6 9 . . , l A u s t i n ,M o r r i sG T 1 9 6 9o n S t r o b o s c o p i ct i m i n g 1098 cc, manual, singlecarburetter manual, twin carburetter a u t o m a t i cL C e n g i n e s , ... automatic, distributor No. 41134 a u t o m a t i c , i s t r i b u t oN o . 4 11 g 1 d r 1275 cc A. HC engines LCengines B. HCengines .. Firing rder o automatic, engines LC

Lu-cas 25.D4 (tater45.D4) . 0 1 4t o . 0 1 . 6 3 d e g .B T D C 5 d e g .B T D C 41134) Z 9"s PIPQ (distributor 41181i I 9"s 9IPc (distributor 3 des.BTDC I d " S B T D CH C e n g r n e s 8 d e g . B T D CH C e n g i n e s 3 d e g .B T D C L C e n g r n e s 3 d e g .B T D C L C e n g r n e s deg. BTDC LC ens-ines 2 d e s .B T D C 2 d e g .B T D C 2 d e g .B T D C

H I 4 " s q T D C C" n s , n " , 7

5 deg. BTDC at 600 revlmin 7 deg. BTDC at 600 revlmin 8 d e g . B T D Ca t l O O O e v l m i n . r 1 Od e g . B T D Ca t 6 0 0 r e v l m i n B deg. BTDC at 600 revlmin

c.

t_: ""n':.:'

8 deg. BTDC at 600 revTmin 10 deg. BTDC at 600 revlmin at 9 {"S, B,TDC 1000 revlmin, 1-3-4-2 (No.1 on teft) *Denotes vacuumpipe disconnected CLUTCH

Clutch Type (earlycars) Type (lateicars)' ... Diameter plate of N u m b e r f c o i ls p r i n g s o C o l o u r f c o i ls p i i n g s. . . o C o l o u ro f d i a p h r a g rs p r i n g i Fluid F l u i d( A u s t i n m e r i c a ) A

7t

S i n g l e r y p l a t e , o i ls p r r n g s d c S i n g t e r y p t a t ed i a p h i a g r n ' s p r i n g , d

6 B l a c kw i t h w h i t es p o t Green L o c k h e e d i s c B r a k eF l u i dS e r i e s o r D 2 Series 329 Series329 TRANSMISSION

Gearbox Numberof speeds Synchromesh; 1 0 9 8c c 1275 cc 1 3 0 0m o d e l s

Fourforwardand one reverse Second, third and fourth Second, third and fourth All forwardspeeds

11 0 0M k 2 1 3 0 0 151

Overallgearbox ratios Synchromesh, 98cc: 10 T o p. . . Third Second Firs.. t Reverse S y n c h r o m e s h2 7 s c c ( e a r l y ) : 1, Top Third Second Firs.. t Reverse S y n c h r o m e s h 2 7 5c c ( l a t e r ) : 1,

4.133:1 5.83:1 8.98:1 14.99:1 14.99:1 3.44.1 4.91:1 8.3:1 13 . 1 ; 1 6 13.16:1 3.65:1 5.1 :1 6 7.92:1 13.21:1

rop ..

Third Second First.. ffeverse S y n c h r o m e s h , 0 0 m o d e l s8 . 8 : 1 c o m p r e s s i orn t i o : 13 , a Top..

Third

..

Second First.. Reverse .:: S y n c h r o m e s h , 0 0 m o d e l s9 . 7 5 : 1c o m p r e s s i orn t i o( G T ) : 13 , a Top.. Third Second Firs.. t Reverse ... :. ... ::: ::: Automatic, 098 cc (early): 1 Top .. Third Second First. . , Reverse A u t o m a t i c1 0 9 8 c c ( l a t e r ) 3 0 0 m o d e l s : , 1 Top.. Third Second First
Reverse

3 . 6 51 : 5.22:1 1 B.0B:
.. 12.95:1 3.65:1 4.93:1 7. 5 7 : 1 12.04:1 12.22:1 4.1 5.84:1 7.38:1 10.76:1 10.76:1 .. 3.76:1 5.49:1 6.94:1 10.11:1 1 0 . 1: 1

..

D i f f e r e n t i a l ratio 1098 cc s y n c h r o m e s h 1098 cc automatic (early) (later) 1098 cc automatic 1275cc (early) 1275cc (later) Torque converter Type Ratio Converter u t p r . l tg e a r r a t t o o End float

4.133:1 3.48:1 3.27:1 3.44:1 3.65:1

Threeelement 2:1 maximum 1. 15 : 1

0035to .0065

152

STEERING Steering Type

S t e e r i n gw h e e l t u r n s l o c k t o l o c k Steering angles, static unladen condition Rackand pinion ? r * deS.positive t 1 d e g . 5j deg. positive + + d e q 1O d e g .
1 J 1 6L 1 3 2

Camber Castor

S w i v e lh u b i n c l i n a t i o n Toe-out

SUSPENSION F l u i d p r e s s u r e ,f r o n t ( u n l a d e n ) A u s t i n ,M o r r i sa n d M G 205 * MG (Normalair) 220+ Princess 230+ 1 3 0 0A u t o m a t i c n l v o 225+ V a n d e nP l a s1 3 0 0A u t o m a t i c 250 + A u s t i n ,M o r r i st w o - d o o r( a r c hr e a rs p r i n g m o d e l s ) 1 9 5 + Rearsuspension Toe-out Camber 1 deg
I

2 l b / s qi n 1 0 l b / s qi n 2 l b / s qi n 2 l b / s qi n 2 l b / s qi n 5 lblsqin positive

BRAKES Brakes Earlymodels Latermodels

Front disc brakes D i a m e t e r ,e a r l y t y p e D i a m e t e r ,l a t e r t y p e Pad liningmaterial

L o c k h e e dh y d r a u l i c , i s c f r o n t a n d d o r u mr e a r A s e a r l y y p eb u t w i t h s w i n g i n g a l i p e r t c front disc brakes I 8.4 MintexM.7BFG (U.S.A. Ferodo 2426F. FG)

M i n i m u mp a d t h i c k n e s s Reardrum brakes Diameter L i n i n gm a t e r i a.l.. Brakeluid f B r a k e l u i d ,A u s t i nAmerica f

B F e r o dA M . B . Fo r M i n t e x 7 9 o E M L o c k h e eD i s cB r a k e l u i d e r i e2 o r d F S s 329 L o c k h e eD i s cB r a k e l u i d3 2 9 o r t o d F SAE 1703a J

ELECTRICAL OUIPMENT E

Battery Type,earlymodels Type,laternrodels Capacity Earthing system Starter motor Generator

M a x i m u mo u t o u t Control box

L u c a sN 9 o r N X 9 L u c a sD 9 o r D Z 9 12-volt4Oamplhr , S e eS e c t i o n 1 1 : 1 L u c a sM . 3 5 Go r M . 3 5 J L u c a sC . 4 0 22-amp Lucas 8.340 r R8.106 R o 14.2 to 'l4.8 volts at 2OoC 69" F) ( 1 2 . 6t o 1 3 . 4 9 . 3t o 1 ' 1 . 2

Type

R e g u l a t o r p e n - o r c u i t s e t t i n ga t 1 5 O Or e v l m i n o Cut-out: C u t -i n v o l t a g e Drop-off voltage

11 0 0M k 2 1 3 0 0

Alternator N o m i n ao u t o u t l oT Resistance rotorwinding at 2b'C (68"F) Windscreenwiper

L u c a s 1 A Co r 1 6 A C R 1 43 amps 3 , 8 o h m s + 5 p e r c e n t o r 3 . 2 a m p sa t 12-volt Lucas WA or 14W 3

CAPACITIES f T r a n s m i s s i o n s i n g i,n c l u d i n gi l t e r ca n i t A u t o m a t i cr a n s m i s s i oin ,c l u d i n gi l t e r C o o l i n g y s t e mw i t h o u th e a t e r s , H e a t e.r. . F u e lt a n k H y d r o l a s t is u s p e n s i o n c 8| pints l 1 3 p i n t s( r e f i l 9 p i n t s ) 5f pints 1 pint 8 gallons 5 pints

DIMENSIONS
O v e r a l ll e n g t h Track.static and u n l a d e n Front

12 ft 2l inch 4 ft 3j inch 4 ft 2{ inch 34 ft 9 inch T O R O U EW R E N C H S E T T I N G S

Rear.. Turning ircle. c

E n g i n ea n d t r a n s m i s s i o n C y l i n d e h e a ds t u d n u t s ,1 0 9 B c c r C y l i n d e h e a ds t u d n u t s ,1 2 7 5 c c a n d M k 3 r
B i g - e n db o l t s . . . M a i n b e a r i n gb o l t s Flvwheelcentre bolt Rocker bracketnuts

T r a n s m i s s i o n s et o c r a n k c a s e ca ( C y l i n d es i d ec o v e r s e a r l y ) r
C y l i n d e r s i d e c o v e r s ( d e e p p r e s s e dt y p e )

T i m i n gc o v e rf U N F b o l t s T i m i n g o v e r , f U N Fb o l t s c W a t e rp u m p
Water outlet elbow O i l f i l t e r ( c e n t r eb o l t ) . . O i l f i l t e r ( c a r t r i d g et y p e )

Oilpump
M a n i f o l d t o c v l i n d e rh e a d Rockercover

C r a n k s h a ptu l l e yn u t . . f T r a n s m i s s i o n s es t u d s , U N C ca I T r a n s m i s s i o n s es t u d s , f U N C ca 1 T r a n s m i s s i o n s es t u d n u t s ,I U N F ca T r a n s m i s s i o n s es t u d n u t s ,* U N F ca Bottomcoversetscrews, UNC ] F i r s tm o t i o ns h a f tn u t . . . T h i r dm o t i o ns h a f tn u t F l y w h e eh o u s i n g o l t sa n d s t u d n u t s . . l b Drivengearto differential cage D r i v es h a f tf l a n g en u t s Differential housingend coverbolts

40 lb ft 50 lb ft (see text) 35 lb ft 60 lb ft 110to115lbfl 25 lb ft 6lbft 2lbft 5lbft 6lbft 14lbft 17tbft 8tbft 10to15lbft 4lbft I lb ft 15lbft 4lbft 70 lb ft Blbft 6lbft 25 lb ft 18tbft 6tbft 15lbft 1 5 0l b f t 18lbft 55 to 60 lb ft 70 lb ft 18lbft

154

Converter centrebolt . (six centralbolts) Converter C o n v e r t e rr a i np l u g s . . . d Differential drivingflangebolts Engine steadyrod Nyloc nuts . . G e a rt r a i nb e a r i n g a p s c G e a rt r a i nc a r r i es t r a p . r p G o v e r n otro a u x i l i a r y u m p h o u s i n g o l t s b
I n p u t s h a f tn u t . . . T o p a n d r e v 6 r s ec l u t c h h u b n u t

Transmission engine to securing nut D r i v es h a f fU - b o l tn u t s Distributor clamp bolt,fixed nut Distributor clamp bolt,fixed bolt S u s p e n s i o na n d s t e e r i n g Steering leverto hub bolts S t e e r i n ge v e rb a l lj o i n t n u t l S t e e r i n g n u c k l e a l l p i n o r t o mn u t k b b Steeringnuckle allpinop nut k b t Steeringnuckle allpin etainer k b r F r o n th u b n u t ( d r i v es h a f t ) R e a rs u s p e n s i oa n t i - r o l b a rf i x i n gb o l t s n l R e a rs u s p e n s i os t u b a x l en u t n F r o n ts u s p e n s i ou p p e ra r m p i v o tp i n n u t n Frontsuspension lower arm pivot pin nut
S t e e r i n gw h e e l n u t Road wheel nuts Discto hub

110to115lbft 22 to 24lb ft 1Bto 20 lb ft 40 to 45 lb ft 28 lb ft 1 2 t bt t 12lbft 10to15lbft 70 lb ft 1 5 0l b f t 12lbft 1 0 t o 1 2 . 5l b f t 4lbft 2.5 lb ft 30 to 35 lb ft 25 tb ft 35 to 40 tb ft 35 to 40 lb ft 70 lb ft 1 5 0l b f r 70 lb ft 32 to 37 lb ft 35 to 40 lb ft 35 to 40 lb ft 32 to 37 lb ft 42 tb ft 40 to 45 lb ft 45 ro 50 lb ft 65 to B0 lb in 50 lb ft 1 5l bi n 30 lb ft Sto9lbft

F r o n ts w i v e lh u b t o c a l i p e r p B r a k e a l i p e r i v o tp i n s c r e w s c
I n e r t i av a l v e e n d p l u g Pressure ailureswitch f

Pressure failureswitch end plug S t e e r i n g o l u m nc l a m pb o l t . . c Alternator T h r o u g h - b o l .t .s.

Diode heatsink fixinqs Brushbox screws

45 to 60 lb in 25 lb in 10lb in

t 1 0 0M k 2 1 3 0 0

Master key to wiring diagrams Some of the components listed in this key may not be fitted to individual models 1 Dynamooralternator 2 Controlbox(exceptwithl6ACRalternator) 3 Battery(12-volt) 4 Startersolenoid 5 Slartermotor 7 H e a d l a m pd i p s w i t c h 1 0 M a i n - b e a mw a r n i n g l a m p 6 L i g h t i n gs w i t c h 8 R i g h t h a n dh e a d l a m p I L e f t h a n dh e a d l a m p 1 ' l R i g h t h a n ds i d e l a m p 1 2 L e f t h a n ds i d e l a m p 1 3 P a n e l l a m p s s w i t c h ( w h e n l i t t e d ) 1 4 P a n e l l a m p s 1 5 N u m b e r p l a t el a m p ( s ) 1 6 R i g h t h a n ds t o p a n d t a i l l a m p 1 7 L e f t h a n ds t o p a n d t a i l l a m p 1 8 S t o p l a m p s w i t c h 1 9 F u s e u n i l ( 3 5 a m p 1 - 2 ; 3 5 a m p 3 - 4 ) 2 0 I n t e r i o rl i g h t ( s ) 2 1 R i g h t h a n dd o o r s w i t c h ( e s ) ( c o m b i n e d w i t h i g n i t i o n k e y b u z z e r - 1 9 7 0 A m e r i c a ) 2 2 L e f t h a n dd o o r 24 Horn push 25 Flasher nit u s w i t c h ( e s ) ( c o m b i n e dw i t h i g n i t i o nk e y b u z z e r - 1 9 7 0 A m e r i c a ) 23 Horn(s) 28 Righthand front flasher lamp 2 6 D i r e c t i o n i n d i c a t o r , h e a d l a m p f l a s h e r ,a n d d i p s w i t c h 27 Direction indicator warning lamp(s) 29 Lefthand tront flasher lamp 30 Righthand rear flasher lamp 3'l Lelthand rear llasher lamp 32 Heater or fresh-air motor switch" 33 Heater or fresh air motor-. 34 Fuel gauge 35 Fuel gauge tank unit 36 Windscreen wiper switch (except Princess) 39 lgnition coil 37 Windscreen wiper motor 38 lgnition/starler switch (combined with steering lock-certain models) 40 Distributor 4 1 F u e lp u m p 4 2 O i l p r e s s u r es w r t c h ( w h e n f i t t e d ) 4 3 O i l p r e s s u r eg a u g e o r w a r n i n g l a m p 44 lgnition warning lamp 45 Speedometer 46 Water temperaturegauge (except Austin/Morris De-Luxe) 47 Waler temperature transmitter (excepl Austin/Morris De-Luxe) 4 9 R e v e r s el a m p s w i t c h . . 5 0 R e v e r s el a m p ' * 48 Ammeter (Princess) 63 Fog lamp(s) switch (Princess) 56 Clock (Princess) 54 Righthand fog lamp (Princess) 55 Lefthand fog lamp (Princess) 60 Radio6 5 L u g g a g e c o m p a r t i n e n tl a m p 5 7 C i g a rl i g h t e r( P r i n c e s s ) 6 4 B i - m e t a l i n s t r u m e n lv o l l a g e s t a b i l i z e r 75 Automalic switch (Countryman/Traveller) 66 Luggage comparlment Iamp (Countryman/Traveller) 67 Line luse (35 amp) 7 7 E l e c t r i cw i n d s c r e e n w a s h e r ( P r i n c e s s ) 78 Windscreen washer 3witch (Export) transmissionsafety switch (when fitted) 84 Suction 81 Ashtrav illumination lamo 8 2 P a n e l l a m D - h e a t e rs w i t c h i l l u m i n a t i o n " 83 lnduction heater and thermostat*' 94 Oil filter swrtch (early synchromesh models) 95 Tachometer (Riley, MG 1300 Mk 2 and GT) 99 Radiaror chamber heater'* 1 0 5 O i l f i l t e r w a r n i n g l a m p ( e a r l y s y n c h r o m e s hm o d e l s ) 1 0 5 R e a r i n t e r i o rl a m p ( M k 3 C o u n t r y m a n / badge lamp (Wolseley) Traveller) 110 Righthandrepeaterflasher(exceptAmerica) 111 Lefthandrepeaterflasher(exceptAmerica) 115 Rearwinddw 118 Combined windscreen washer and wiDer switch (Princess) demisler swiich1 1 6 R e a r w i n d o w d e m i s t e ru n i t ' 1 3 1 C o m b i n e d r e v e r s es w i t c h a n d a u t o m a t i c s a f e t y s w i t c h ( w h e n f i t t e d ) 139 Alternative numberplate lamp connections for Germany 150 Rear window demist warning lamp' 153 Hazard warning switch (all Austin America) 154 Hazard warning flasher u n i t ( a l l A u s t i n A m e r i c a ) 1 5 9 B r a k e p r e s s u r ew a r n i n g l a m p a n d l a m p p u s h ( a l l A u s l i n A m e r i c a ) 1 6 0 B r a k e p r e s s u r ef a i l u r e s w i t c h ( a l l A u s t i n A m e r i c a ) 1 6 4 B a l l a s t r e s i s t a n c eo r c a b l e ( a l l A u s t i n A m e r i c a e x c e p t v e r y e a r l y m o d e l s ) 1 6 8 l g n i t i o n k e y w a r n i n g b u z z e r (1970 Austin America) 1 7 0 R i g h l h a n dl r o n t m a r k e r l a m p ( 1 9 7 0 A u s t i n A m e r i c a ) 1 7 1 L e f t h a n df r o n t m a r k e rl a m p ( 1 9 7 0 A u s t i n America) 1 7 2 R i g h t h a n dr e a r m a r k e r l a m p ( 1 9 7 0 A u s t i n A m e r i c a ) 1 7 3 L e f t h a n d r e a r m a r k e rl a m p ( 1 9 7 0 A u s t i n A m e r i c a ) . .. Optional extta Optional extra/standard some models Cablecolourcode N Brown P Purple W White U BIue G Green Y Yellow R Red LG Lightcreen B Black

When a cable has two colour code letters the fitst denotes the main colour and the second denotes the ttacer coloul

156

l
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FIG 13:1 A u s t i n / M o r r i s1 1 0 0M k 2 a n d 1 3 0 0( 1 9 6 7 - 7)1

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FIG 13 :3

Riley Kestrel Mk 2 and 1300(1957-68)

11 0 0 k 2 1 3 0 0 M

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FIG 13:4

, R i l e y1 3 0 0 M k 2 ( 1 9 6 8 - 6 9 )M G 1 3 0 0 M k 2 ( 1 9 6 8 - 7)1

FIG 13:5

W o l s e l e y n d M G 1 1 0 0 M k 2 a n d 1 3 0 0( 1 9 6 7 - 6 8 ) a

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V a n d e n P l a s P r i n c e s s1 1 0 0 M k 2 a n d 1 3 0 0 ( 1 9 6 7 - 7 1 )

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FIG 13 :7

W o l s e l e v1 3 0 0 M k 2 ( 1 9 6 8 - 7 1 )

r 1 1 0 0 v k2 1 3 0 0

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V a n d e n P l a s 13 0 0 ( 19 7 1 o n w a r d s )

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diagram) Hazard warning system (to be used in coniunction with the appropriate wiring 1 5 2 H a z a r dw a r n i n g s y s t e m p i l o t l a m p

1 g F u s e u n i r ( 1 2 3 5 a m p ) 2 5 F l a s h e ru n i r 6 7 L i n e f u s e ( 3 5 a m p ) Key to Fig 13:14 154 Hazard warning flasher unit Hazat? warning switch t5i

170

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HINTS ON MAINTENANCE AND OVERHAUL

There are few things more rewarding than the restora_ t i o n o f a v e h i c l e ' so r i g i n a lp e a k o f e f f i c i e n c ya n d s m o o t h performance. The following notes are intended to help the owner ro r e a c h t h a t s t a t e o f p e r f e c t i o n .p r o v i d i n g t h a t h e p o s s e s s e s the basic manual skills he should have no difficulty in p e r f o r m l n gm o s t o f t h e o p e r a t i o n s e t a i l e di n t h i s m a n u a r . d I t m u s t b e i s t r e s s e dh o w e v e r , t h a t w h e r e r e c o m m e n d e d i n , t h e m a n u a l ,h i g h l y - s k i l l e d p e r a t i o n s u g h t t o b e e n t r u s t e d o o t o e x p e r t s ,w h o h a v e t h e n e c e s s a r y q u i p m e n t ,t o c a r r y o u t e the work satisfactorily. Ouality of workmanship : T h e h a z a r d o u s r i v i n g c o n d i t i o n so n t h e r o a d s t o - d a y d . demand that vehicles should be as nearly perfect, mechanically,as possible. lt is therefore most important that amateur work be carried out with care, bearing in m a n d t h e o f t e n i n a d e q u a t ew o r k i n g c o n d i t i o n s ,a n d a l s o t h e i n f e r i o rt o o l s w h i c h m a y h a v e t o b e u s e d . l t i s e a s y ro c o u n s e l p e r f e c t i o ni n a l l t h i n g s , a n d w e r e c o g n i z et h a t r t may be setttng an impossibly high standard. We do, h o w e v e r , s u g g e s tt h a t e v e r yc a r e s h o u l d b e t a k e n t o e n s u r e that a vehicle is as safeto take on the road as it rs humanly p o s s i b l et o m a k e i t . Safe working conditions : E v e n t h o u g h a v e h i c l e m a y b e s t a t i o n a r V ,t j s s t i l l i p o t e n t i a l l yd a n g e r o u s i f c e r t a r ns e n s i b l ep r e c a u t t o n s are n o t t a k e n w h e n w o r k i n g o n i t w h i l e i t i s s u p p o r t e do n jacks or blocks. lt is indeed preferablenot to use Jacks alone, but to supplement them with carefullv piaced blocks, so that there will be plenty of support if ine car r o l l s o f f t h e j a c k s d u r i n g a s l r e n u o u s m a n o e u v r e .A x l e s t a n d sa r ea n e x c e l l e n t a y o f p r o v i d i n ga r i g i d b a s ew h i c h w i s n o t r e a d i l y i s t u r b e d . i l e s f b r i c k sa r ea d a n g e r o u s u b _ d P o s stitute. Be careful not to get under heavy loads on lifling t a c k l e , t h e l o a d c o u l d f a l l . l t i s p r e f e r a b l en o t t o w o r k alone when lifting an engine,or when working unoer_ n e a t h a v e h i c l e w h i c h i s s u p p o r t e dw e l l o f f t h J g r o u n o . T o b e t r a p p e d , p a r t i c u l a r l y n d e r t h e v e h i c l e ,r n r y h . u " u u n p l e a s a n r e s u l t s f h e l p i s n o t q u i c k l yf o r t h c o m i n g .M a k e t i s o m e p r o v t s t o n ,h o w e v e r h u m b l e , t o d e a l w i t h f r r e s . Always disconnect a battery if there is a likelihood ot e l d c t r i c a ls h o r t s . T h e s e m a y s t a r t a f i r e i f t h e r e i s l e a k i n g fuel about. This applies particularlyo leadswhich can t carry a heavy current, like those in the starter circuit. W h i l e o n t h e s u b j e c t o f e l e c t r i c i t y ,w e m u s t a l s o s t r e s st h e danger of using equtpmentwhich is run off the mains a n d w h i c h h a s n o e a r t ho r h a sf a u l t yw i r i n g o r c o n n e c t i o n s . So many workshops have damp floori, and electrical s h o c k s a r e o f s u c h a n a t u r e t h a t i 1i s s o m e t i m e si m p o s s i b l e t o l e t g o o f a l i v e l e a d o r p i e c e o f e q u i p m e n td u e t o t h e m u s c u l a rs p a s m sw h i c h t a k e p l a c e . Work demanding special care: T h i s i n v o l v e s t h e s e r v i c i n go f b r a k i n g ,s t e e r i n ga n d s u s p e n s i o ns y s t e m s .O n t h e r o a d , f a i l u r e o f t h e b r a k i n o s y s t e m m a y b e d i s a s t r o u s .M a k e q u i t e s u r e t h a l t h e r e c a i b e n o p o s s i b i l i t yo f f a i l u r et h r o u g h t h e b u r s t i n go f r u s t y b r a k e p i p e s o r r o t t e n h o s e s ,n o r t o a s u d d e n l o s l o f p r e s sure due to defective sealsor varves. Problems: 1 2 3 4 5 6 7 8 The chief problems which may face an ooerator are: Externadirt. l D i f fi c u l t y i n u n d o i n g t i g h t f i x i n g s D i s m a n t l i n gu n f a m i l i a rm e c n a n t s m s . Deciding in what respectparts are defective. Confusion about the correctorder for reassemblv. A d j u s t i n gr u n n i n gc l e a r a n c e s . Road testing. F i n a lt u n i n g .

Practical suggestion to solve the problems: 'Prelimrnary cleaning of large parts-engines, transmtsstons, steering, suspensions, etc.,_should be carried out before removal from the car. Where roao d i r t a n d m u d a l o n e a r e p r e s e n t w a s h c l e a nw i t h a h r g n , , pressure water jet, brushing to remove stubborn a d h e s i o n s ,a n d a l l o w t o d r a i n a n d d r y . W h e r e o r r o r g r e a s e r s a l s o p r e s e n t ,w a s h d o w n w i t h a p r o p r i e t a r y compound (Gunk, Teepol etc.,) applying with a stiff b r u s h - a n o l d p a i n t b r u s hi s s u i t a b l e _ i n t o a l l c r e v i c e s . C o v e r t h e d i s r r i b u t o ra n d i g n i t i o n c o i l s w i t h a p o l y _ thene bag and then apply a strong water jet to clearthe loosened deposits. Allow ro drain and dry. The a s s e m b l i e s i l l t h e n b e s u f f i c i e n t l yc l e a n t o r e m o v e a n d w t r a n s f e rt o t h e b e n c h f o r t h e n e x t s t a g e . On the bench, further cleaning can be carried our, first wiping the parts as free as possible from grease w i t h o l d n e w s p a p e r .A v o i d u s i n g r a g o r c o t t o n w a s r e w h i c h c a n l e a v ec l o g g i n gf i b r e sb e h i n d .A n y r e m a i n i n g g r e a s ec a n b e r e m o v e d w i t h a b r u s h d i p p e d i n p a r a f f i n . lf necessary,traces of paraffin can be removed bv c a r b o n t e t r a c h l o r i d e .A v o i d u s i n g p a r a f f i n o r p e t r o l i n l a r g e q u a n t i t i e s f o r c l e a n i n g i n e n c l o s e d a r e a s ,s u c h a s g a r a g e s , n a c c o u n to f t h e h i g h f i r e r i s k . o W h e n a l l e x t e r i o r sh a v e b e e n c l e a n e d ,a n d n o t b e f o r e , d i s m a n t l r n g c a n b e c o m m e n c e d . T h i s e n s u r e st h a t d i r t will not enter rnto interiors and orifices revealed bv drsmantling. In the next phases, where components have to be cleaned, use carbon tetrachloride in Dreference to petrol and keep lhe containers covered except when in use. After the components have been cleaned, plug small holes with tapered hard wood p l u g s c u t 1 os i z ea n d b l an k o f f l a r g e ro r i fi c e s w i t h g r e a s e _ proof paper and masking tape. Do not use sofi wood plugsor matchsticks s they may break. a 2 lt is not advisable to hammer on the end of a screw thread, but if it must be done, first screw on a nut ro p r o t e c t t h e t h r e a d , a n d u s e a l e a d h a m m e r .T h i s a p p l r e s p a r t i c u l a r l yt o t h e r e m o v a l o f t a p e r e d c o t t e r s . N u t s a n d 'grow' bolts seem to together, especially in exhausr systems. lf penetrating oil does not work, trv the j u d i c i o u sa p p l i c a t i o no f h e a t , b u t b e c a r e f u l ot startino a fire. Asbestos sheet or cloth is useful to isolateheai Tight bushes or preces of tail-pipe rusted into a srtencer can be removed by splitting them with an open-ended hacksaw. Tight screws can sometimes oe startedby a tap f rom a hammer on the end of a suitabre s c r e y d r i v e r .M a n y t i g h t f i t t i n g s w i l l y i e l d t o t h e j u d i c i o u s use of a hammer, but it must be a soft-faced hammer if damage is to be avoided, use a heavy block on the opposite side to absorb shock. Any parts of tne 1

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steering system which have been damaged should be renewed, as attempts to repair them may lead to cracking and subsequenl failure, and steering ball l o i n t s s h o u l d b e d i s c o n n e c t e du s i n g a r e c o m m e n d e d tool to prevent damage. 3 l f o f t e n h a p p e n st h a t a n o w n e r i s b a f f l e d w h e n t r y i n g t o p d r s m a n t l ea n u n f a m r l i a r r e c e o f e q u i p m e n t .S o m a n y m o d e r n d e v r c e sa r e p r e s s e dt o g e t h e ro r a s s e m b l e db y s p i n n i n g - o v e rf l a n g e s ,t h a t t h e y m u s t b e s a w n a p a r t . The intention is that the whole assembly must be renewed. However, partswhich appearto be in one j p i e c e t o t h e n a k e d e y e , m a y r e v e a lc l o s e - f i t t t n g o i n t l i n e s w h e n i n s p e c t e dw i t h a m a g n l f y i n g g l a s s . a n d , t h r s m a v p r o v i d e t h e n e c e s s a r yc l u e t o d t s m a n t l t n g . L e f t - h a n d e ds c r e w t h r e a d s a r e u s e d w h e r e r o t a t i o n a l forces would tend to unscrew a righthanded screw thread. w m u B e v e r yc a r e f l w h e n d i s m a n t l i n g e c h a n i s m s h i c h m a v c o m e a p a r t s u d d e n l y .w o r k i n a n e n c l o s e ds p a c e a w h e r e t h e p a r t sw i l l b e c o n t a i n e d , n d d r a p e a p i e c e o f c l o t h o v e r t h e d e v i c e i f s p r i n g sa r e l i k e l y t o f l y i n a l l directions. Mark everything which might be reass s e m b l e di n t h e w r o n g p o s i t i o n ,s c r a t c h e d y m b o l sm a y b e u s e d o n u n s t r e s s e dp a r t s , o r a s e q u e n c e o f t i n y d o t s from a centre punch can be useful. Stressed parts s h o u l d n e v e r b e s c r a t c h e do r c e n t r e - p o p p e da s t h r s m a v l e a d t o c r a c k i n g u n d e r w o r k i n g c o n d i t i o n s .S t o r e parts which look alike In the correctorder for teas sembly Never rely upon memory to assist in the w m , a s s e m b l vo f c o m p l r c a t e d e c h a n t s m se s p e c i a l l y h e n f t h e y w i l l b e d i s m a n t l e d o r a l o n g t l m e ,b u t m a k e n o t e s , and drawings to supplement the diagrams in the m a n u a l ,a n d p u t l a b e l so n d e t a c h e dw i r e s . R u s t s t a i n s b w m a y i n d i c a t eu n l u b r i c a t e d e a r .T h i s c a n s o m e t i m e s e s e e n r o u n d t h e o u t s l d e e d g e o f a b e a r r n gc u p I n a u n i v e r s a lo i n t . L o o k f o r b r i g h t r u b b i n g m a r k so n p a r t s w h i c h n o r m a l l ys h o u l d n o t m a k e h e a v y c o n t a c t .T h e s e m i g h t p r o v e t h a t s o m e t h i n gi s b e n t o r r u n n i n g o u t o { t r u t h . F o r e x a m p l e ,t h e r e m i g h t b e b r r g h tm a r k so n o n e s i d e o f a p i s t o n , a t t h e t o p n e a r t h e r i n g g r o o v e s ,a n d o t h e r sa t t h e b o t t o m o f t h e s k i r t o n l h e o t h e r s i d e .T h i s could well be the clue to a bent connecttng rod Suspected cracks can be proved by heating Ihe com1 ponentIn a lightoil to approximately 00'C, removing, drying ofi, and dustingwith frenchchalk,if a crackis i o r e s e n t h e o r l r e t a i n e d n t h e c : a c k w r l l s t a i nt h e t r e n c h chalk. 4 I n d e t e r m i n r n gw e a r , a n d t h e d e g r e e ,a g a r n s tt h e p e r m i s s i b l e l i m r t s s e t i n t h e m a n u a l , a c c u r a t em e a s u r e ment can only be achreved y the useof a mtcromeler. b I n m a n y c a s e s .t h e w e a r i s g i v e n t o t h e f o u r t h p l a c e o f d e c i m a l s .t h a l r s I n t e n t h o u s a n d t h so f a n r n c h T h i s c a n b e r e a d b y t h e v e r n r e rs c a l e o n t h e b a r r e lo f a g o o d mrcronreter Bore dtameters are more dlfficult to l d e t e r m i n e . f , h o w e v e r ,t h e m a t c h i n gs h a t t i s a c c u r a t e l y m e a s u r e d ,t h e d e g r e e o 1 p l a y i n t h e b o r e c a n b e f e l t a s a g u i d e t o i t s s u i t a b i l i t y . n o t h e r c a s e s ,t h e s h a n k o f a I t w i s t d r i l l o f k n o w n d i a m e t e ri s a h a n d y c h e c k . M a n y m e t h o d s h a v e b e e n d e v i s e df o r d e t e r m i n i n g t h e c l e a r a n c eb e t w e e n b e a r i n g s u r f a c e s .T o - d a y t h e , b e s t a n d s i m p l e s ti s b y t h e u s e o f P l a s t i g a g eo b t a i n a b l e . t f r o m m o s t g a r a g e sA t h i n p l a s t t c h r e a di s l a t d b e t w e e n f a t h e t w o s u r f a c e s n d t h e b e a r i n gi s t i g h t e n e d . l a t t e n i n g t h e t h r e a d O n r e m o v a l ,t h e w i d t h o f t h e t h r e a d i s

c o m p a r e dw i t h a s c a l es u p p l i e dw i t h t h e t h r e a da n d t h e c l e a r a n c ei s r e a d o f f d i r e c t l y . S o m e t i m e s J o i n t f a c e s , l e a k p e r s i s t e n t l ye v e n a f t e r g a s k e t r e n e w a l .T h e f a u l t d t w r l l t h e n b e t r a c e a b l e o d i s t o r t i o n , i r t o r b u r r s .S t u d s r w h i c h a r e s c r e w e di n t o s o f t m e t a lf r e q u e n t l y a i s eb u r r s a t t h e p o i n t o f e n t r y .A q u i c k c u r e f o r t h r s i s t o c h a m f e t t h e e d g e o f t h e h o l e i n t h e p a r t w h i c h f i t s o v e rt h e s t u d Always check a replacement part with the original one before it is f itted. l f p a r t sa r e n o t m a r k e d ,a n d t h e o r d e r f o r r e a s s e m b l y i s n o t k n o w n , a l i t t l e d e t e c t i v ew o r k w i l l h e l p . L o o k f o r marks which are due to wear to see if they can be m a t e d . J o i n t f a c e s m a y n o t b e i d e n t i c a ld u e t o m a n u facturing errors, and parts which overlap may be s t a i n e d ,g i v i n g a c l u e t o t h e c o r r e c t p o s i t l o n . M o s t i f i x i n g s l e a v e i d e n t i f y i n gm a r k s e s p e c i a l l y f t h e y w e r e p a i n l e d o v e r o n a s s e m b l y .l t i s t h e n e a s l e rt o d e c i d e w h e t h e r a n u t , t o r i n s t a n c e ,h a s a p l a t n ,a s p r l n g ,o r a shakeproof washer under rt. All running surfaces 'bedded' t o g e t h e ra f t e rl o n g s p e l l so f w o r k a n d become o t i n v i m p e r f e c t i o n s n o n e p a r tw i l l b e f o u n d t o h a v el e f t c o r r e s p o n d i n gm a r k s o n t h e o t h e r . T h i s i s p a r t i c u l a r l y t r u e o f s h a f t s a n d b e a r i n g sa n d e v e n a s c o r e o n a c v l i n d e rw a l l w i l l s h o w o n t h e p t s t o n b C h e c k r n ge n d f l o a t o r r o c k e rc l e a r a n c e s y f e e l e rg a u g e m a y n o t a l w a y s g i v e a c c u r a t er e s u l t sb e c a u s eo f w e a t . F o r i n s t a n c e t, h e r o c k e r1 i pw h r c h b e a r so n a v a l v es t e m may be deeply pitted, in which case the teelerwill . s i m p l y b e b r i d g i n g a d e p r e s s i o nT h r u s t w a s h e r sm a y a l s o w e a r d e p r e s s i o n sI n o p p o s t n g f a c e s t o m a k e t a c c u r a l em e a s u r e m e nd r f { i c u l t E n d f l o a t l s t h e n e a s r e r 1 t o c h e c k b y u s i n ga d i a l g a u g e .l t i s c o m m o n p r a c t i c e 0 a d l u s t e n d p l a y i n b e a r i n ga s s e m b l i e sl.i k e f r o n t h u b s . w i t h t a p e rr o l l e r s b y d o r n g u p t h e a x l e n u t u n t r lt h e h u b b e c o m e ss t r f ft o t u r n a n d t h e n b a c k r n gr t o f f a l i t t l e .D o n o l u s e t h r s m e t h o d w i t h b a l l b e a r i n gh u b s a s t h e a s s e m b l yi s o f t e n p r e l o a d e db y t i g h t e n i n gt h e a x l e n u t t o r t s f u l l e s te x t e n l . l f t h e s p l l t p i n h o l e w t l l n o t l t n e u p , f r l et h e b a s eo f t h e n u t a l r t t l e . o a Steering ssemblies ftenwear in the straight-ahead positron.lf any part is adjusted,make sure that it r e m a i n sf r e e w h e n m o v e d f r o m l o c k t o l o c k . D o n o t b e i s u r p r i s e d f a n a s s e m b l yl i k e a s t e e r i n gg e a r b o x ,w h i c h rs known to be carefullyadlusted outside the car, b e c o m e ss t i f fw h e n i t i s b o l t e di n p l a c e .T h i s w i l l b e d u e t o d i s t o r t i o no f t h e c a s e b y t h e p u l l o f t h e m o u n t i n g b o l t s , p a r t i c u l a r i yi f t h e m o u n t i n g p o i n t s a r e n o t a l l t o u c h i n g t o g e t h e r .T h i s p r o b l e m m a y b e m e t i n o t h e r equipment and is cured by careful attentionto the a l i g n m e n to f m o u n t i n g p o i n t s . When a spanner is stamped with a size and A/F it means that the dimensionis the width between the t a w s a n d h a s n o c o n n e c t i o nw i t h A N F , w h i c h i s t h e d e s i g n a t i o nf o r t h e A m e r i c a n N a t i o n a l F i n e t h r e a d . C o a r s e t h r e a d s l i k e W h i t w o r t h a r e r a t e l Yu s e d o n c a r s t o - d a v e x c e o tf o r s t u d sw h i c h s c r e w i n t o s o f t a l u m i n i u m or cast rron. For this reason it might be found that the t o p e n d o f a c y l i n d e rh e a d s t u d h a s a f i n e t h r e a da n d t h e lower end a coarse thread to screw into the cylinder block. lf the car has mainly UNF threadsthen it is l i k e l y t h a t a n y c o a r s et h r e a d sw i l l b e U N C , w h t c h a r e n o t t h e s a m e a s W h r t w o r t h .S m a l l s i z e sh a v e t h e s a m e n u m b e r o f t h r e a d si n W h i t w o r t h a n d U N C , b u t i n t h e ! i n c h s i z e f o r e x a m p l e ,t h e r e a r e t w e l v e t h r e a d s t o t h e i n c h i n t h e f o r m e r a n d t h i r t e e ni n t h e l a t t e r .

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7 After a major overhaul, particularly rf a great deal of work has been done on the braking, steering and suspension systems, it is advisable to approach the probl"t of testing with care. lf the braking system has been overhauled, apply heavy pressureto the brake pedal and get a second operator to checK every possible source of leakage The brakes may -work w e x t r e n r e l y e l l , b u t a l e a k c o u l d c a u s ec o m p l e t ei a i l u r e after a few miles. D o n o t f i t t h e h u b c a p s u n t i l e v e r yw h e e l n u t h a s b e e n c h e c k e d f o r t i g h t n e s s ,a n d m a k e s u r e t h e t y r e p r e s s u r e s a r e c o r r e c t . C h e c k t h e l e v e l so f c o o l a n t , l u b r i c a n t s a n d h y d r a u l i c i l u i d s . B e i n g s a t i s f i e dt h a t a l l i s w e l l , t a k e t h e car on the road and test the brakesat once Check the s t e e r i n ga n d t h e a c t i o n o f t h e h a n d b r a k e D o a l l t h i s a t moderate speeds on quiet roads, and make sure there is no other vehicle behind you when you try a rapld stoo.

F i n a l l y ,r e m e m b e r t h a t m a n y p a r t s s e t t l e d o w n a f t e r a t i m e , s o c h e c k f o r t i g h t n e s so f a l l f i x i n g s a f t e r t h e c a r has been on the road for a hundred miles or so I t i s u s e l e s st o t u n e a n e n g r n e w h i c h h a s n o t r e a c h e di t s n o r m a lr u n n i n gt e m p e r a t u r el n t h e s a m e w a y t h e t u n e o f a n e n g i n e w h i c h i s s t i f f a f t e r a r e b o r ew i l l b e d i f f e r e n t t w h e n t h e e n g i n e i s a g a i n r u n n i n gf r e e . R e m e m b e r o o , t h a t r o c k e r c l e a r a n c e so n p u s h r o d o p e r a t e d v a l v e g e a r w i l l c h a n g e w h e n t h e c y l i n d e rh e a d n u t s a r e t i g h t e n e d afteran initialperiodof running with a new headgasket Trouble may not always be due to what seems the o b v i o u s c a u s e . l g n r t i o n , c a r b u r a t i o na n d m e c h a n i c a l c o n d i t i o n a r e i n t e r d e p e n d e n ta n d s p i t t i n g b a c k t h r o u g h t h e c a r b u r e t t e r ,w h i c h m i g h t b e a t t r r b u t e d t o a w e a k m i x t u r e ,c a n b e c a u s i : db y a s t r c k i n gi n l e t v a l v e F o r o n e f r n a l h i n t o n t u n i n g , n e v e ra d j u s tm o r e t h a n t o n e t h i n g a t a t i m e o r i t w i l l b e i m p o s s i b l eo t e l l w h i c h a d j u s t m e n tp r o d u c e d t h e d e s i r e dr e s u l t .

1 1 0 0M k 2 1 3 0 0

175

G T O S S A R YO F T E R M S
Allen key Alternator C r a n k e d w r e n c h o f h e x a g o n a ls e c t i o n for use with socket head screws. Electricalgeneratorproducingalterna t i n g c u r r e n t .R e c t i f i e dt o d i r e c t c u r r e n t ' for battery charging. t s u r r o u n d i n ga t m o s p h e r i c e m p e r a t u r e . U s e d i n e n g i n e e r i n gt o i n d r c a t e t h e outer ring gear of an epicyclic gear train. T h e s h a f t c a r r y i n gt h e w i n d i n g s ,w h i c h rotates in the magnetic field of a generator or startermotor. That part of a solenoidor relay which is activated b y t h e m a g n e t i cf i e l d . I n l i n e w i t h , o r p e r t a i n i n gI o , a n a x r s . PIay in meshing gears. A bar where force applied at the centre i s e q u a l l yd i v i d e db e t w e e nc o n n e c t i o n s at the ends. A x l e c a s i n gw i t h l a r g ed i a m e t e r o u s i n g h for the crownwheeland differential A s e l f - e n g a g i n ga n d s e l f - d i s e n g a g i n g drive on a startermotor shaft. A c o n i c a l s h a p e dg e a r w h e e l , e s i g n e d d to mesh with a similargear with an a x i s u s u a l l ya 19 0 d e g . t o i t s o w n . Brake horse power, measured on a dynamometer. A B r a k e m e a n e f f e c t i v ep r e s s u r e . v e r a g e p r e s s u r e n a p i s t o nd u r i n g t h e w o r k i n g o stroke. C y l i n d e r w i t h h y d r a u l i c a l l yo p e r a t e d piston(s) acting on brake shoes or p a d( s ) . Dry liner Dry sump Damper Commutator

Clevis

U-shaped forked connector used with a clevis pin, usually at handbrake connections. A type of collar, usually split and located in a groove in a snaft, and held i n p l a c e b y a r e t a i n e r .T h e a r r a n g e m e n t u s e d t o r e t a i nt h e s p r i n g ( s ) o n a v a l v e stem in most cases. Rotating segmented current distributor between armature windings and brushes in generator or motor. T h e r a t i o , o r q u a n t i t a t i v er e l a t i o n ,o f t h e total volume (oiston at bottom of stroke) to the unswept volume (piston at top of stroke) in an engine cylinder. See capacrtor. Plug for blanking o{f a manufacturing hole in a casting. Large bevel gear in rear axle, driven by a b e v e l p i n i o n a t t a c h e dt o t h e p r o p e l l e r 'ring gear'. shaft. Sometimes called a 'C' with a handle. For use on Like a screwed collars without flats, but with slots or holes. M o d e r n t e r m f o r s h o c k - a b s o r b e r ,u s e d i n v e h i c l e s u s p e n s i o n s y s t e m st o d a m p out springoscillations. The lowering of atmospheric pressure as in the inlet manifold and carburetter. Close tolerance pin, peg, tube, or bolt, which accuratelylocates mating parts. Rod connecting steering box drop arm (pitman arm) to nearest front wheel s t e e r i n ga r m i n c e r t a i n t y p e s o f s t e e r i n g systems. Thinwall tube pressed into cylinder DOre Lubrication system where all oil is s c a v e n g e df r o m t h e s u m p , a n d r e t u r n e d t o a s e p a r a t et a n k . See Generator. Terminal, part of an electricalcompo'Electrodes' nent, such as the points or o f a s p a r k i n gp l u g . I n l e a d - a c r dc a r b a t t e r i e s s o l u t i o n o f a s u l o h u r i c a c i d a n d d i s t i l l e dw a t e r . The axial movement a s s o c i a t e dp a r t s ,e n d p l a y . between

Collet

Ambient temperature Annulus

Armature

Compression ratio

Axial Backlash Balance lever

Condenser Core plug

Crbwnwheel

Banjo axle Bendix pinion Bevel pinion ' bhp bmep

'C'-spanner

Depression Dowel Drag link

Brake cylinder

B r a k e r e g u l a t o r C o n t r o l v a l v e f i t t e d i n h y d r a u l i cb r a k i n g s y s t e m w h i c h l i m i t s b r a k e p r e s s u r et o rear brakes during heavy braking to prevent rear wheel locking.

Camber Capacitor

Angle at which a wheel is tilted from the vertical. M o d e r n t e r m f o r a n e l e c t r i c a lc o n d e n s e r . P a r t o f d i s t r i b u t o r a s s e m b l y ,c o n n e c t e d across contact breaker points, acts as an interference suppressor. Top face of a nut, slotted across the flats, to take a locking splitpin. Angle at which the kingpin or swrvel pin is tilted when viewed from the side. Cubic centimetres. ngine capacityrs E arrived at by multiplying the area of the bore in sqcm by the strokein cm by the number of cylinders.

Dynamo Electrode

Electrolyte End float EP

Castellated Castor cc

E x t r e m e p r e s s u r e .I n l u b r i c a n t s ,s p e c i a l grades for heavily loaded bearing surfaces, such as gear teeth in a gearbox, or crownwheel and pinion i n a r e a ra x l e .

1100Mk21300

177

Fade Fieldcoils Fillets

First motion shaft

Of brakes. Reduced efficiency due to overheatng. i o Windingson the polepieces f motors and generators. N a r r o w f i n i s h i n g s t r i p s u s u a l l ya p p l i e d t o i n t e r i o rb o d Y w o r k . Input shaft from box. clutch to gear

Journals Kingpin

Those oarts of a shaft that are in contact with the bearings. T h e m a i n v e ( i c a l p i n w h i c h c a r r i e st h e front wheel spindle,and permits steer'steering ing movement. May be called 'swivel pin'. pin' or The shaft which carriesthe laygear in the gearbox. The laygear is driven by the first motion shaft and drives the third motion shaft according to the gear selected. Sometimes called the 'countershaft' or'second motion shaft.' A m e a s u r eo f t w i s t o r t o r q u e . A p u l l o f 10lb at a radiusof 1ft is a torque of 10 lb ft. Pounds per square inch. T h e s m a l l ,o r p i s t o n e n d o f a c o n n e c t i n g 'small-end'. r o d . S o m e t i m e sc a l l e d t h e Low Tension, The current output from the battery. Accurately manufactured bar or rod used for test or centring purposes. A pipe, duct, or chamber, with several branches. times their diameter.

Layshaft

'

Fullflow filter

F i l t e r si n w h i c h a l l t h e o i l i s p u m p e d t o the engine. lf the element becomes clogged, a bypass valve operates to p a s s u n f i l t e r e do i l t o t h e e n g i n e . Front wheel drtve. Two meshing gears in a close fitting casing. Oil is carried from the inlet round the outside of both gears in the spaces between the gear teeth and casjng to the outlet, the meshing gear teeth prevent oil passing back to the i n l e t .a n d t h e o i l i s f o r c e d t h r o u g h t h e outlet port. 'Dynamo'. When Modern term for r o t a t e d o r o d u c e s e l e c t r i c a lc u r r e n t . A r i n g o f p r o t e c t i v eo r s e a l i n g m a t e r i a l . Can be used to protect pipes or leads passingthrough bulkheads. Fulfy threaded headless screw with screwdriver slot. Used for locking, or alrgnment purposes. Shaft which connects a piston to its 'wrist c o n n e c t i n g r o d . S o m e t i m e sc a l l e d 'piston pin'. pin', or One of a pair transmitting drive from the differential. I n s p i r a lf o r m . T h e t e e t h o f h e l i c a l g e a r s a r e c u t a t a s p i r a la n g l e t o t h e s i d e f a c e s of the gearwheel. Hot area that assistsvapourisation of fuel on its way to cYlinders. Often provided by close contact between inlet and exhaust manifolds. High Tension. Applied to electrical current produced by the ignition coil for the sparki;rg plugs. A device for checking specific gravity of liquids. Used to check specific gravity of electrolyte. A form of bevel gear used in the rear axle drive gears. The bevel Pinion meshes below the centre line of the crownwheel, giving a lower propeller shaft line. A device for passing on movement. A free running gear between driving and driven gears. A lever transmitting track rod movement to a side rod In s t e e r i n gg e a r . A centrifugal pumping element. Used in water oumDs to stimulateflow.

FWD Gear pump

lb ft

lb/sq in Little-end LT Mandrel Manifold

Generator Grommet

N e e d l er o l l e r s B e a r i n g r o l l e r s w i t h a l e n g t h m a n y

Grubscrew

Oil bath

Gudgeonpin

Reservoir which lubricates parts by immersion. In air filters, a separateoil supply for wetting a wire mesh element to hold the dust. In air filters, a wire mesh element lightly oiled to trap and hold airborne dust. Period during which inlet and exhaust valves are open together. Bar connected between fixed point on chassisand another on axle to control sidewavs movement. Pivoted catch which engages in the teeth of a ratchet to permit movement in one direction onlv. T o o l w i t h p e g s , o r p a n s ,t o e n g a g e I n holes or slots in the part to be turned.

Oil wetted

H a lfshaft Helical

Overlap
Panhard rod

Hot spot

Pawl

HT Hydrometer Hypoid bevel gears

Peg spanner

Pendant pedals Pedals with levers that are pivoted at the top end.

Phillips screwdriver Pinion Piston-type damper Preloading Radial

A c r o s s - o o i n t s c r e w d r i v e rf o r u s e w i t h the cross-slotted heads of Phillips screws. A small gear, usually in relation to another gear. Shock absorber in which damPing is controlled by a piston working in a closed oil-filled cylinder. P r e s e t s t a t i c o r e s s u r eo n b a l l o r r o l l e r bearings not due to working loads. R a d i a t i n gf r o m a c e n t r e , l i k e t h e s p o k e s of a wheel.

ld ler

lmpeller

178

Radius rod Ratchet

P i v o t e da r m c o n f i n i n g m o v e m e n to f a Partto an arc of fixed radius Toothed wheel or rack which can move i n o n e d i r e c t i o no n l y , m o v e m e n t i n t h e other being prevented bY a Pawl A gear tooth ring attached to outer periphery of flywheel. Starter pinron e n g a g e sw r t h i t d u i l n g s t a r t i n g . A.orn, by which rotating Part is oul of true. Outer end of rear axle halfshaft is c a r r i e d o n b e a r r n gi n s i d e a x l e c a s i n g ' W h e e l h u b i s s e c u r e dt o e n d o f s h a f t . A hydraulic or pneumatic system for a s s i s t i n g ,o r , a u g m e n t i n g a p h y s i c a l 'Vacuum Servo'. effort. See One which is threaded for the full length of the shank. A c o u p l i n g l i n k ,u s e d i n t h e f o r m o f t w o parallel pins connected by side plates r to secure the end of the master suspension spring and absorb the effects of deflection. Thinwalledsteelshell lined with antifriction metal. Usually semi-circular ano used in Pairsfor main and bigend bearings. Rubber bush bonded to inner and outer metal sleeves. Screw with hexagonalsocket for an Allen key. A c o i l o f w i r e c r e a t i n ga m a g n e t i cf i e l d w h e n e l e c t r i cc u r r e n t p a s s e st h r o u g h i t . Used with a soft iron core to operate c o n t a c t s o r a m e c h a n i c a ld e v i c e . A g e a r w i t h t e e t h c u t a x i a l l y a c r o s st h e p e np n e r y . Short axle fixed at cne end onlY. An instrument for accurate measurement of rotatingspeed. Usually indic a t e s i n r e v o l u t i o n sP e r m i n u t e .

TDC

Top Dead Centre. The highest Pornt reached bv a piston in a cylinder,with the crank and connecting rod in line. Automatic device for regulating temDerature. Used in vehicle coolant s y s t e m st o o p e n a v a l v e w h i c h r e s t r i c t s circulation at low temPerature. Output shaft of gearbox. t O u t e r e n d o f r e a ra x l e h a l f s h a f f l a n g e d a n d b o l t e dt o w h e e l h u b . w h i c h r u n s o n bearing mounted on outside of axle c a s i n g . V e h i c l e w e i g h t i s n o t c a r r i e db y the axle shaft.

Thermostat

Ring gear

Runout

Third motion shaft Th reequarter floating axle

Semi-floating axle Servo

Setscrew

T h r u s t b e a r i n g Used to reduce frtctton in rotating p a r t s s u b y e c tt o a x i a l l o a d s . or washer 'lb ft" Turning or twisting effort. See Torque The bar(s) acrossthe vehicle which Track rod
c o n n e c t t h e s t e e r i n ga r m s a n d m a i n tain the front wheels in their correct alrgnment.

Shackte

UJ

Universal ioint. A coupling between shafts which permits angular movemen1.

Shell bearing

Unified NationalFine screw thread. UNF Vacuum servo D e v i c e u s e d i n b r a k e s Y s t e m , u s i n g

Shock absorber See'DamPer'. Silentbloc

difference between atmospheric pressure and inlet manifold depression to o p e r a t ea p i s t o n w h i c h a c t s t o a u g m e n t b r a k e p r e s s u r ea s r e q u i r e d .S e e ' S e r v o ' . o A r e s t r i c t i o n r ' c h o k e ' i n a t u b e ,a s i n a c a r b u r e t t e r ,u s e d t o i n c r e a s ev e l o c l t y t o obtain a reduction in Pressure. A sliding scale for obtaining fractional readings of the graduations of an adjacent scale. A domed thin metal disc which is partially flattened to lock in a recess Used to plug core holes in castings. Removable cylinder barrel, sealed against coolant leakage, where the coolant is in direct contact with the outer surface. A reservoirattached to the crankcase o to hold the lubricating il.

Venturi

Socket-head screw Solenoid

Vernier

Welch plug

Spur gear Stub axle Tachometer

Wet liner

Wet sump

11 0 0M k 2 1 3 0 0

179

INDEX
A A i r c o n d i t i o n i n gs e r v i c i n g Air conditioning system Air filter Air manifold testing . Air pump testing Air pump servicigg . . Alternator dismantling Alternator reassembly Alternator rem6val Alternator testing A n t i f r e e z es o l u t i o n s . . A n t i - r o l l b a r a n d a u x i l i a r ys p r i n g s . . Arch spring suspension Armature, generator Armature, starter A u t o m a t i c t r a n s m i s s i o na o j U s t m e n t. . A u t o m a t i c t r a n s m i s s i o n e s c r i p t i o n. . d A u t o m a t i c t r a n s m i s s i o na u l t d i a g n o s i s f A u t o m a t i ct r a n s m i s s i o n o w e r f l o w p A u t o m a t i c t r a n s m i s s i o nt e s t s B . B a l lj o i n t s Battery maintenance Batterytesting B e a m s e t t i n g s ,h e a d l a m p s . . B e l lj o i n t s e r v i c i n g d r i v e s h a f t s . Belt tension . . end bearings,itring f !ig 6rg-end bearings, emoval r Bleeding,brake system B l e e d i n g ,c l u t c h s y s t e m Brake adjustment B r a k ec a l i p e rs e r v i c i n g , i x e d f B r a k e c a l i p e rs e r v i c i n g , w r n g i n g s braKedtsc removal . . Brake flexible hose removal . . B r a k eI i n i n g s B r a k em a i n t e n a n c e. . Brake mastercylinder removal Brake mastercylinder servtcrng B r a k e p r e s s u r e e g u l a t i n gv a l v e r 6 r a K es h o e s . . Brushes, lternator . . a B r u s h e s ,g e n e r a t o r B r u s h e s ,J t a r t e r

..

..
,

143 143 47 31 30 30
tzl

125 124
tz3 EA

103 100 122 126 79 84 80 84 103 121 122 132 9 1 58

)1

..

'

' r1 6 ,

)1

11 9
o4

. 111 .. 112 .. 114 113,114 117 112, 16 1 111 116

t t o

111 116 124 122

. tzo

c
C a l i p e r ,f r x e d 112 Caliper, wrnging s 113 C a m b e ra n g l e 100 Camshaft drive removal 11 Camshaftdrive replacemenr 17 Camshaftend float . . 1l C a m s h a f tr e m o v a l ( a u t o m a t i ct r a n s m i s s r o n ) 23 C a m s h a f tr e m w a l ( s y n c h r o m e s n ; 17 Camshaft replacement 17 C a r b u r e t t e ra d j u s t m e n t 40, 43 C a r b u r e t t e rd a m p e r . . 38 C a r b u r e t t ed i s m a n t l i n q r 40 C a r b u r e t t e rf a u l t s 4l

C a r b u r e t t e rf l o a t l e v e l 42, 43 C a r b u r e t t e rj e t a d j u s t m e n t 45 C a r b u r e t t e lri n k a g e . . 42 C a r b u r e t t e rr e a s s - e m b l y 45 Carburettersynchronizatron.. .. 41 C a r b u r e t t etru n i n g . e x h a u s te m i s s i o nc o n t r o l 45 C a s t o ra n g l e 100 Changesp-eed hart . . c 84 C h e c k v a l v e ,e x h a u s te m i s s i o n 29 C l u t c h c o n s t r u c t i o n. . 61 C l u t c h d i a p h r a g ms p n n g ol u t u t c n d r s m a n i l t n g. . ot C l u t c h m a s t e rc y l i n d e r 62 C l u t c h o p e r a t i n gl e v e r 62 Clutch pedalclearance 62 C l u t c h p l a t ec e n t r i n g 62 Clutch platelinings . . o l Clutch reassembllng . . o l Clutch removal .. 61 C l u t c h r e p l a c e m e n t. . 62 C l u t c h s l a v ec y l i n d e r 63 Clutchthrow-out stop 64 Commutator, generator 122 C o m m u t a t o r , s t a r t e r. . tzo C o n n e c t i n gr o d r e m o v a l 19 C o n n e c t i n gr o d r e m o v a l ( j 2 7 5 c c u n g i n e l .. 26 L o n n e c t t n gr o d r e p l a c e m e n t . 19 C o n n e c t i n gr o d r e p l a c e m e n t( 1 2 7 5 c c e n g i n e ) 28 C o n t a c t b l a d e ,f u e l p u m p 37 Contact breaker 50 Control box 127 C o n v e r t e ro u t p u t g e a r a a l u s i m e n t . . )2 .. L O n v e r t e rr e m o v a l 23 C o o l i n g s y s t e mm a i n t e n a n c e C o u p l i n g s ,f l e x i b l ed r i v e C r a n k c a s e m i s s r o nc o n t r o l . e C r a n k s h a f t e a r i n g s .. b 21 Crankshaft il seal . o 19 Crankshaft ulley p 16 Crankshaft emoval . . r z l Crankshaft nd float e 1a C u r r e n tr e g u l a t o r 127 Cut-out aJjustment . . 127 C y l i n d e rb o r e g r a d i n g 'l 9 uyInoer bore ovefsizes 21 C y f i n d e rb o r e o v e r s r z e s 1 2 7 5 c c e n g i n e ) ( .. 28 h e a d t r g h t e n i n gs e q u e n c e . . 14 :yilnoer uyilnoernead removal 14 C y l i n d e rh e a d r e p l a c e m e n t 14 C y l r n d e rh e a d s e r v r c i n g 16 D Dampers, teering s D e c a r b o n i z ig n D i a p h r a g m ,f u e l p u m p D i f f e r e n t i as e r v i c i n g( a u t o m a t i c ) l D i f f e r e n t i as e r v i c i n g( s y n c h r o m e s h ) l D i s c b r a k ep a d s D r s cr e m o v a l Distributor djustment a Distributor ap c Distributor ismantling d

99
to

87 72 112
t t J

49 51 51

1100Mk21300
181

Distributor riveshaft d Distributor reassembly Distributor removal . . r Distributor eplacement Door fittings Door glasses Door locks D r i v es h a f t b e l l j o i n t s e r v i c i n g D r i v e s h a f t s l i d i n gj o i n t E E l e c t r i c as y s t e m l E l e c t r o l y t eb a t t e r y E n g i n ed e s c r i p t i o n . . E n g i n ed i s m a n t l i n g . . E n g i n er e m o v a l( a u t o m a t i c ) .. E n g i n er e m o v a l ( s y n c h r o m e s h ) E n g i n es t e a d y r o d E x h a u s te m i s s i o nc o n t r o l ,d e s c r i p t i o n r E x h a u s te m i s s i o nc o n t r o l ,c a r b u r e t t e t u n i n g E x h a u s te m i s s i o nc o n t r o l ,t e s t r n g c Expansron hamber. .

53
3 l 5 l 3 l

135 136 135 91 95

121 122 9 14 12 11
J I

H H a n d b r a k ea d l u s t m e n t H e a d l a m pb e a m s e t t i n g He a l e r a Hints on maintenance nd overhaul Horn adjustment Hub servicing H y d r a u l i cb r a k e s y s t e m H y d r a u l r cc l u t c h s y s t e m H y d r a u l i ch o s e s H y d r o l a s t i cs u s p e n s i o ns y s t e m Hydrometertest of electrolYte I l d l e r g e a r b e a r i n g( s y n c h r o m e s h ) l d l e rg e a r a d j u s t m e n t l d l e r g e a r b e a r r n gl u b r i c a t i o n( a u t o m a t i c ) lgnrtron ystem s lgnitronestrng t l g n i lg n 1 1 6 1 n 9 Inertra alve v l m p u l s et a c h o m e t e r I n h i b i t o rs w r t c h ( a u t o m a t i c ) I n s t r u m e n tp a n e l

117 132 142 173 132 99 111 61 117 98 122

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F Facia removal Fan belt adjUstment F a u l t d i a g n o s i s( a u t o m a t i ct r a n s m i s s r o n ) F a u l t d i a g n o s i s( e x h a u s te m i s s r o nc o n t r o l ) F i e l d c o i l s ,g e n e r a t o r Field coils, starter F i r i n go r d e r . . F l a s h e ru n i t Floatadjustment F l y w h e e lh o u s i n g r e m o v a l . . Flywheel servicing F r i c t i o np a d s Fronthubs . . . F r o n t s u s p e n s i o nd e s c r i p t i o n Front suspensiongeometry Fuelgauge . . Fuses Fuel pump adJustment Fuel pump dismantling Fuel pump reassembling Fullflowoil filter

138 122 84 41 123

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Jet adlustment Jet centralizing L Laygear L r m i tv a l v e . . Lock servlcing Low-tension circuit testing, distributor Luggage compartment locl( . . M Main bearings b M a s t e rc y l i n d e rs e r v i c r n g r a k e s M a s t e r c y l i n d e rs e r v a c i n gc,l u t c h t M e t r i c - c o n v e r s i o na b l e s Mixture control, carburetter M o u n t i n g s ,s u b f r a m e

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Oil controlpistonrings Oil frlter r O i l p r e s s u r e e l i e fv a l v e O i l p u m p s e r v i c i n g( a u t o m a t i c ) O i l p u m p s e r v i c i n g( s y n c h r o m e s h ). . O i l s e a l ,c r a n k s h a f t . . O i l s e a l ,h u b s P P e d a lc l e a r a n c e c l u t c h , P i s t o n ,c a r b u r e t t e r . . .. Piston oversizes ( P i s t o no v e r s i z e s 1 2 7 5 c c ) . . h P r s t o nr e m o v a l ( s y n c h r o m e s ) P i s t o nr e m o v a l ( 1 2 7 5 c c ) P i s t o nr i n g s P r i m a r yg e a r e n d f l o a t c P r e s s u r e h e c k ( a u t o m a t i c ). .

G G a s k e t ,c y l i n d e rh e a d G e a r b o xd i s m a n t l i n g( s y n c h r o m e s h ) Gearbox reassembly a G e a r c h a n g e d j u s t m e n t( a u t o m a t i c ) c Gearchange ableservicing Gearchangeremote control . . G e n e r a t o rd i s m a n t l i n g , G e n e r a t o r ,r e a s s e m b l y G e n e r a t o r ,t e s t i n g Glossary Governor adjustment (automatic) G r i n d i n g - i nv a l v e s . Gudgeonpins G u d g e o n p i n s ( 12 7 5 c c e n E i n e ) Gulp valve

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f P r e s s u r e a i l u r es w i t c h P r e s s u r er e g u l a t i n g v a l v e Pushrod removal and replacement . .

119 111 14

T T a c h o m e t e r . m p u l s et y p e i T a n d e m m a s t e rc y l i n d e r ,b r a k e s T e c h n i c a lD a t a
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R Rack, steering Radiatorremoval and replacement . . Rear brake servrclng R e a rh u b s Rearsuspension .. R e g u l a t o ru n i t R o c k e rc l e a r a n c e Rocker shaft assembly Rocker shaft assembly (1275 cc) R o c k e rs e t t i n g ,f u e l p u m p

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Thermostatestrng . T h r o t t l ed a m p e r ( 1 2 7 5 c c ) Throw-out stop,clutch Timrngchain cover Timing chain sprocket T i m i n g m a r k s ,c a m s h a f t T i m i n g m a r k s .i g n i t i o n

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Sealed beam headlamps Seat belts Selector forks and rods S l a v e c y l i n d e r ,c l u t c h S l o w - r u n n i n ga d j u s t m e n t , a r b u r e t t e r c S p a r k i n gp l u g s Specific gravity, antifreeze . . Specific gravity, electrolyte . . Stall speed check (automatrc) Startermotor servicing Startermotor testing S t a t i c i g n i t i o nt i m i n g Steering angles Steering ball joints . . Steering column removal S t e e r i n g c o l u m n r e fi t t i n g Steering lock and ignition switch Steering rack adjustment .. Steering rack servicing Steeringwheel S t r o b o s c o p i ci g n i t i o nt i m i n g Sub{rames nd mountings a Suspensionsystem,description Suspension ervicing s Swivel hub inclination Synchromeshtransmission . . Synchronizingtwin carburetters
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T o p p i n g - u p m a s t e rc y l i n d e r ,b r a k e s . . T o p p r n g - u p m a s t e rc y l i n d e r ,c l u t c h . . Torque converter Torquewrench settrngs T r a c k i n gf r o n t w h e e l s T r a n s m i s s i o n e r v i c r n g( a u t o m a t i c ). . s T r a n s m i s s i o n e r v i c i n g( s y n c h r o m e s h ) s T r i m p a d r e m o v a l .d o o r

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Vacuum servounit Vacuumtiming control V a l v es e r v i c i n g V a l v e s e r v i c i n g( 1 2 1 5 c c J V a l v e s .f u e l p u m p V a l v eg u i d e s V a l v e r o c k e ra d j u s t m e n t V a l v et i m i n g g e a r ( a u t o m a t i c ) V a l v et i m i n g g e a r ( s y n c h r o m e s h ) V e n t i l a t o rr e m o v a l V o l t a g e r e g u l a t o ra d j u s t m e n t

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W a t e r c i r c ul a t i o n s y s t e m Water pump servicing W i n d o w g l a s sr e m o v a l Window winders Wrpermotor servicing Wiring diagrams ..

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