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British Leyland Triumph Toledo, Repair Manual

The British Leyland Triumph Toledo Repair Manual is a comprehensive user guide that provides step-by-step instructions and detailed information for maintaining and repairing your Toledo model. Download this manual for free from manualshive.com, ensuring you have the essential resource to keep your vehicle running smoothly.

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ENGINE

12.  Check the  small end  bushes  for wear,  and  if neces­

sary renew using a suitable hand press to remove the 
old bush and fit new. Ensure that the oil hole in the 
bush  corresponds  with  the  hole  in  the  connecting 
rod.  Ream  the  new  bush  to  size—see  Data.  When 
assembled  dry,  the  gudgeon  pin  is  a  thumb  push- 
fit  at  68°F  room  temperature.  If  the  gudgeon  pin 

passes  through  the  bore  under  its  own  weight,  it is 
too  slack.

13.  Check  the  connecting  rods  for  bend  and  twist. 

Use tools 335, and arbor adaptor S336-4—see Data. 
Rods  that  exceed  the  tolerances  in  both  conditions 
should  be renewed  or re-aligned.

Refitting

14.  Reverse instructions 2 to  5:

a

.  Fitting oversize pistons  as  necessary.

b.

  Fitting  the  piston  rings  with  care  and  in  the 

following  order:  (A)  expander  ring into  bottom 

groove,  ensure  that  ends  are  butting  but  not 
overlapping,  (B)  bottom  rail  of expander  from 
bottom of piston, (C) top rail from top of piston, 
(D)  scraper  ring—step  uppermost  to  second 
groove,  (E)  compression ring to top groove.

c.

  Separating  the  ring  gaps  equally  on  the  non­

thrust side  of piston.

15.  Refit the connecting rods and pistons.  12.17.01.

DATA
Pistons

Bore  size:  Grade  F 

.................................................

Grade  G 

.. 

.....................................

Piston  top  diameter:  Grade  F  ..

Grade  G  ..

Piston  bottom diameter:  Grade  F

Grade  G 

.........................

Pistons  a v a ilab le ............................................................
Groove  width:  b o t t o m ................................... .

centre and t o p .....................................

Ring width:  bottom (oil control)  3-part 

centre and top (compression)

Rings  a v a i l a b l e ............................................................

Connecting rods

Small  end bush (fitted)  i.dia............................................
Gudgeon pin diameter
Connecting rod bend not to  e x c e e d .........................
Connecting rod twist not to e x c e e d .........................

Connecting rod  and piston assemblies 

Weight variation between heaviest and lightest assembly

2*899  to 2*900 in  (73*64 to  73*66 mm)
2*9010  to 2*9005  in (73*86 to  73*67  mm)
2*875  to 2*880 in (73*03  to 73*15  mm)
2*875 to 2*880 in (73*03  to  73*15  mm)
2*8976 to 2*8981  in (73*59  to  73*61  mm)
2*8982 to 2*8987 in (73*617 to  73*620 mm)
0*020 in (0*52 mm)  oversize 
0*1578  to 0*1588  in (3*99  to 4*01  mm)
0*064 to 0*065 in (1*625  to  1*650 mm)
0*1540 to 0*1560 in (3*90 to  3*96 mm)
0*0620 to 0*0625 in (1*575  to  1*5787 mm)
0*010, 0*020.  0*030 in  (0*25,  0*51,  0*76 mm)  oversize

0-8126 to 0*8129 in (20*64 to 20-65  mm)

0-8123 to 0*8125 in (20*63 to 20-64 mm)
0-0015 in (0*04 mm)
0-0045 in (0*114 mm)

Max 4 drams

Triumph Toledo Manual.  Part N o.  545168.  Issue  1

12.17.03

12.17.13  Sheet 2

Summary of Contents for Triumph Toledo

Page 1: ...ce Engine Fuel System Cooling System Manifold and Exhaust System C l u t p h Gearbox Propeller Shafts Rear Axle and Final Drive Steering Front Suspension w r Rear Suspension Brakes Wheels and Tyres Body Heating and Ventilation Windscreen Wipers and Washers Electrical Instrum ents Service Tools Triumph Toledo Manual Part No S4S168 Issue 2 ...

Page 2: ...ts use An illustrated list of all necessary tools is included in section 99 References References to the left or right hand side in the manual are made when viewing from the rear With the engine and gearbox assembly removed the timing cover end of the engine is referred to as the front A key to abbreviations and symbols is given on page 01 5 Amendments Revised and additional procedures resulting f...

Page 3: ...teering L H Stg Left hand thread L H Thd Low compression lx Low tension l t Maximum max Metres m Microfarad mfd Midget Edison Screw MES Miles per gallon m p g Miles per hour m p h Millimetres mm Millimetres of mercury mmHg Minimum min Minus of tolerance Minute of angle Negative electrical Newton metres Nm Number No Ohms ohm Ounces force ozf Ounces mass oz Ounce inch torque ozf in Outside diameter ...

Page 4: ...so bears code symbols for identification of the vehicle s exterior colour trim material and trim colour Refer to page 04 6 The Engine Number is stamped on a flange on the left hand side ofthe cylinder block adjacent to the distributor The significance of Engine Numbers and Suffix Letters is as follows DG or alternative this prefix denotes the model range using the last two digits of the Commission...

Page 5: ... 2 04 1 1 04 1 2 19 20 07 1 19 20 07 2 04 3 1 04 3 2 19 40 19 1 19 40 19 2 04 6 i 04 6 2 19 45 08 1 19 45 08 2 05 1 1 05 1 2 26 10 01 26 10 01 A 26 40 01 2 06 1 1 06 1 2 26 40 01 1 2 06 3 37 12 19 1 37 12 19 2 09 1 1 09 1 2 37 20 04 Sheet 3 1 37 20 04 Sheet 3 2 10 00 02 1 10 00 02 2 47 15 01 1 47 15 01 2 10 00 06 1 10 00 06 2 51 10 01 Sheet 2 1 51 10 01 Sheet 2 2 10 00 07 1 10 00 07 2 51 15 07 She...

Page 6: ...2 1 86 40 02 2 86 65 02 1 86 40 86 1 86 40 86 2 6 73 01 8 3 01 8 4 2 73 01 2 1 01 2 2 01 9 i 01 6 1 01 6 2 05 1 3 05 1 4 01 8 01 8 06 2 2 06 2 3 3 3 12 17 01 2 12 17 01 3 04 1 2 04 1 3 12 17 16 1 12 17 16 2 04 3 2 04 3 3 12 21 33 Sheet 2 2 12 21 33 Sheet 2 3 04 6 3 04 6 4 12 29 18 Sheet 2 2 12 29 18 Sheet 2 3 05 1 2 05 1 3 19 15 17 Sheet 2 1 19 15 17 Sheet 2 2 06 1 2 06 2 2 37 20 04 Sheet 1 2 37 2...

Page 7: ...12 3 3 12 3 4 12 17 01 3 12 17 01 4 12 21 01 4 12 21 01 5 12 29 57 1 12 29 57 2 12 53 07 2 12 53 07 3 33 10 01 1 33 10 01 2 57 35 09 1 57 35 09 2 57 65 01 2 57 65 01 3 64 20 01 1 64 20 01 2 64 35 02 2 64 35 02 3 76 81 01 1 76 81 01 2 86 65 51 1 86 65 51 2 01 9 2 01 9 3 09 1 3 09 1 4 12 29 10 1 12 29 10 2 12 60 56 1 12 60 56 2 30 10 01 1 30 10 01 2 76 31 01 1 76 31 01 2 76 31 46 1 76 31 46 2 Issue ...

Page 8: ......

Page 9: ...alent to 132 lbf in2 b m e p 970 lbf in at 2 700 rev min equivalent to 134 lbf in2 b m e p 967 lbf in at 3 300 rev min equivalent to 133 5 lbf in2 b m e p 945 Ibf in at 3 500 rev min equivalent to 130 lbf in2 b m e p 3 main bearings Solid skirt 4 bearing chain driven O H V push rod operated High capacity internal gear rotor Full flow replaceable element Separate inlet and exhaust water heater inle...

Page 10: ... m o d els 3 turns lock to lock Later models 3 turns lock to lock Steering column Incorporating anti theft locking device Turning circle 29 ft 9 in 9 1 m between kerbs BRAKES Front 1300 1500 2 door pre 1973 models 1500 4 door and all 1973 models Rear 1300 1500 2 door 1500 4 door Front lining area Front swept area Rear lining area Rear swept area Total lining area Total swept area Front lining area...

Page 11: ...1568 mm 4 ft 6 in 1372 mm 4 ft 5 in 1346 mm 4 ft 2 in 1270 mm 4i in 108 mm 0 to fa in 1 58 mm toe in WEIGHTS o Dry excluding extra equipment Basic kerb includes tools fuel oil and water Gross vehicle weight maximum 1300 1500 2 Door 16 cwt 815 kg 17 cwt 865 kg 24 cwt 1230 kg 1300 4 Door 16J cwt 825 kg 17 cwt 875 kg 24 cwt 1240 kg 1500 4 Door TC Dry excluding extra equipment 16J cwt 850 kg Basic ker...

Page 12: ...GENERAL SPECIFICATION DATA W 04 4 Triumph Toledo Manual Part N o 545168 Issue MTO 3 6 4 ...

Page 13: ... depth 18 0 457 E Overall width 61 75 1568 Q Head room from rear seat to cushion 33 5 852 F Overall height 54 0 1372 R Rear leg room Max 30 5 775 G Front seat height floor to cushion 13 0 330 Min 24 5 622 H Front seat depth 17 5 445 T Luggage compartment depth J Head room from front seat cushion 36 0 914 Max 33 0 837 K Front squab to clutch pedal Min 26 0 660 Max 39 0 991 U Luggage compartment hei...

Page 14: ...d shade 3rd shade 4th shade 5th shade 7th shade 6th shade 8th shade 9th shade 10th shade 11th shade 12th shade Black 01 11 Red 02 12 Matador 22 Cherry 32 Signal 42 Burgundy 52 Scarlet 62 Inca Red 72 Pimiento 82 Carmine 92 Magenta Brown 03 13 Light Tan 23 Sienna 33 New Tan 43 Saddle Tan 53 Dark Brown 63 Chestnut 73 Maple Yellow 04 14 Jonquil j 24 Wimpey 34 Jasmine 44 Beige 54 Saffron 64 Mimosa Gree...

Page 15: ...pulley and timing chain cover After Engine No Before Engine No DG 25001 DM 5001 DS 5001 10 R T D C 10 B T D C 10 B T D C See 86 35 00 Lucas 25D4 Anti clockwise 60 3 0 20 mfd See 86 35 00 See 86 35 00 0 014 to 0 016 DG 25001 DM 5001 DS 5001 9 B T D C 9 B T D C 5 B T D C in 0 36 to 0 41 mm Champion N 9Y 0 025 in 0 64 mm Lucas 16C6 1 43 to 1 58 ohms BALLAST RESISTOR Make type Resistance CARBURETTER r...

Page 16: ...C H 8 Alternator to mounting bracket and front engine plate ir U N F 2 8 20 Alternator to adjusting link U N C 2 8 20 Bearing caps to block U N F 9 0 65 Clutch to flywheel F U N F 1 5 11 tCylinder head to b lo c k F U N F 6 4 46 Crankshaft n u t l x 16 T P I 20 7 150 Exhaust manifold to head U N F 1 9 14 Flywheel to crankshaft fParkarized 6 2 45 U N Fl c a d plated 5 5 40 Gearbox and rear engine p...

Page 17: ...er wishbone to fulcrum shaft fc U N F nyloc nut 5 2 38 Wheel to hub U N F 6 6 48 Rear Suspension Damper assembly to body U N F 1 1 8 Damper assembly to lower link U N F 5 2 38 Lower link to axle U N F 5 2 38 Lower link to body U N F 6 6 48 Rear damper detail i U N F 1 1 8 Rear suspension mounting bracket forward fixing U N F 2 8 20 Upper link to axle U N F 5 2 38 Upper link to body bracket U N F 5...

Page 18: ...plate U N F 2 8 20 Clutch pipe to slave and master cylinder F U N F 1 0 7 Pipe bent double ended unit to rear hose F U N F 1 2 9 Pipe bent four way to R H front hose F U N F 1 0 7 Pipe bent four way to L H front hose F U N F 1 0 7 Pipe bent rear hose to R H wheel cylinder F 1 2 9 Pipe bent R H wheel cylinder to L H wheel cylinder 1 0 7 Union double ended 1 2 9 Body Exhaust System Radiator Fuel Tan...

Page 19: ...e or Castrol GTZ Q 10 40 Esso Extra Motor Oil 10W 30 Mobiloil Super 10W 50 Fina Super grade Motor OU 10W 40 Havoline 10W 30 below 2 0 below 4 SD or SE Castrol 5W 20 Q 5 30 Esso Extra Motor Oil 5W 20 Mobiloil 5W 20 Fina Supergrade 5W 30 r Havoline 5W 20 Gearbox and Rear Axle over 0 over 30 GL4 BP Gear Oil S A E 90 EP Castrol Hypoy Duckhams Hypoid 90 Esso Gear Oil GX 90 Mobilube HD 90 Fina Pontonic ...

Page 20: ...COOLANT AT 15 5 C 60 F 1 039 1 048 1 054 1 076 ANTI FREEZE QUANTITY PINTS IMP 2 2 2 6 3 0 4 25 PINTS U S A 2 6 3 1 3 6 5 1 LITRES 1 2 1 4 1 7 2 4 DEGREE OF PROTECTION Complete Car may be driven away immediately from cold 12 C 10 F 16 C 3 F 20 C 4 F 36 C 33 F Safe Limit Coolant in mushy state Engine may be started and driven away after short warm up period 18 C 0 F 22 C 8 F 28 C 18 F l 1 Lower Prot...

Page 21: ...outine Maintenance Operations 1 000 miles 1 600 km Free Service 3 000 miles 5 000 km Service 6 000 miles 10 000 km Service 12 000 miles 20 000 km Service Summary C h a r t 10 00 01 10 10 01 10 10 03 10 10 06 10 10 12 10 10 24 10 00 02 Triumph Toledo Manual Part No 545168 Issue 1 10 1 ...

Page 22: ...CONTROL LINKAGE Lubricate oil can 5 DISTRIBUTOR Lubricate oil can 6 STEERING RACK AND PINION Lubricate grease gun 7 HAND BRAKE LINKAGE Lubricate grease gun 8 BATTERY Vaseline connections 9 GEARBOX Top up oil level 10 FINAL DRIVE Top up oil level 11 PROPELLER SHAFT SLIDING YOKE Lubricate grease gun 12 WATER PUMP Lubricate grease gun early models only n n Triumph Toledo Manual Part No 545168 Issue 1...

Page 23: ... conditi 22 Check security of starter m 23 Check security of engine m 24 Check adjust carburetter se 25 Lubricate accelerator linkaj 26 Check battery condition cl 27 Check report oil fuel fluid 1 28 Check report leaks from cc UNDERBODY 29 Check top up level of gearl 30 Check top up level of final 31 Lubricate steering rack and 32 Lubricate oroneller shaft cr element s X ier element X ion of drivin...

Page 24: ...gs X X X X X ordance with specificationf X X X tyre fabric exposure of ply or cord and tread deptht X X X X i including spare X X X X piment gnment X X X X twindscreen wiper blades X X X and hand brake operation adjust if X 52 Check report brake pedal t 53 Check operation of windov 54 Check function of all electr 55 Lubricate clutch and brake 56 Lubricate all locks door hi 57 Check report conditio...

Page 25: ...radiator filler plug and top up as necessary Replace the filler plug and half fill the expansion tank 3 Check and top up brake fluid reservoir 1 Wipe clean the reservoir cap and surrounding area and remove cap Examine the fluid level and top up to level mark on side of reservoir Investigate any sudden appreciable drop in the level On vehicles which have translucent brake fluid reservoirs there is ...

Page 26: ...f necessary with distilled water until the filling tubes are full and 3 The trough is just covered 7 Top up carburetter piston damper o 1 Unscrew and withdraw plug from top of the suction chamber 2 Note the oil level which when correct is i in 13 mm above the top of the hollow piston rod Top up if necessary and refit hexagon plug 8 Drain engine oil and refill This operation is best carried out whe...

Page 27: ...re not to damage non return valve Finally remove sediment with air line L H drawing Reverse 1 to 4 to reassemble 11 Lubricate distributor and check automatic advance Lubricate 1 Remove distributor cap 2 Lift off rotor arm 3 Apply a few drops of oil to centre of rotor spindle 4 Apply oil to advance and retard mechanism 5 Lightly grease the cam surface 6 Wipe away surplus oil and grease 7 Refit roto...

Page 28: ...data See 86 35 15 14 Clean and adjust spark plugs 1 Remove each spark plug in turn from engine 2 Clean the electrodes with a wire brush or plug cleaning machine 3 Using a 0 025 in 0 60 mm feeler gauge check the gap and adjust if necessary by bending the side electrode towards or away from the central electrode as necessary 4 Discard plugs which have badly burnt or worn electrodes or cracked cerami...

Page 29: ...ing h t leads in correct sequence 6 Refit rocker cover renewing gasket if necessary and secure with nuts and washers tighten to 1 to 2 lbf ft 0 14 to 0 3 kgf m 18 Clean engine oil filler cap 1 Remove cap and wash in clean fuel dry and refit u 19 Clean air cleaner element s Single carburetter models 1 Release two bolts securing air cleaner to carburetter intake flange and withdraw air cleaner from ...

Page 30: ...driving belt The fan belt should be sufficiently tight to drive the alternator and water pump without loading the bearings unduly The adjustment is correct when the belt can be moved laterally in 20 mm at the mid point of its longest run Should adjustment be required proceed as follows 1 Slacken alternator pivot bolt nut 2 Loosen nut securing alternator to adjustment bracket 3 Pivot alternator awa...

Page 31: ...dicated by temperature gauge and push the choke control fully home 1 Remove air cleaner and ensure fast idling screws are clear of cams 2 Adjust the throttle adjusting screws to give an idling speed of approximately 800 to 850 rev min 3 Using an air flow meter compare the carburetter air intake intensity on both carburetters and alter the throttle adjusting screws until the air flow is the same 4 ...

Page 32: ...el fluid leaks Examine the engine gearbox and rear axle for oil leaks Examine the fuel system pipes and carburetter s and fuel pump for fuel leaks Examine clutch system for leaks of hydraulic fluid 28 Check report leaks from cooling and heater systems 1 Check hose connections and tightness of clips 2 Examine water pump 3 Check radiator drain tap where fitted 4 Check cylinder block drain tap where ...

Page 33: ...th a recommended lubricant give five strokes only Remove surplus grease 32 Lubricate propeller shaft 1 Place car on ramp or over pit 2 Using a grease gun charged with a recommended lubricant apply grease via the nipple located at the gearbox end of the front propeller shaft 33 Lubricate hand brake linkage and cable guides 1 Place car on ramp or over pit 2 Smear grease around hand brake compensator...

Page 34: ...Check tightness of suspension fixings tie rod levers steering unit attachments and steering universal coupling bolts and check gaiters for damage Rear suspension 1 Check tightness of nut and bolt securing forward end of lower link to body bracket 2 Check tightness of nut and bolt securing rear end of lower link to axle casing bracket 3 Check tightness of nut and bolt securing forward end of upper ...

Page 35: ...or Data 43 Inspect brake pads for wear and discs for condition disc brakes only 1 Apply hand brake jack up front of car remove nave plates and road wheels 2 Remove spring clips securing pad retaining pins 3 Withdraw pad retaining pins 4 Withdraw damper shims 5 Lift out friction pads 6 Report pad condition if the thickness has been reduced to 0 125 in 3 mm or if there is insufficient material to pr...

Page 36: ...uctions 1 and 2 to refit brake drum and road wheel 4 45 Check tightness of road wheel retaining nuts 1 Remove nave plate with tool provided in tool kit 2 Check tightness of wheel retaining nuts 38 to 45 lbf ft 5 2 to 6 2 kgfm 3 Refit nave plate by placing inner edge over wheel projections and giving the plate a sharp tap with the hand to spring into position 4 Repeat instructions 1 to 3 on remaini...

Page 37: ... aiming to be carried out without removing the rim Beam aiming can best be accomplished using equipment such as Lucas Beamsetter or Lev L Lite 1 beam in horizontal plane 2 Adjust beam in vertical plane 50 Check and if necessary replace windscreen wiper blades Replace wiper blades when vision is impaired due to unsatisfactory clearance of water from windscreen To remove wiper blades 1 Lift wiper ar...

Page 38: ...m is just free to revolve 4 Repeat instructions 2 and 3 with second adjuster 5 Repeat instructions 2 3 and 4 on opposite brake 6 Lower jack Rear brake adjustment 1 Release hand brake chock front wheels and jack up rear of car 2 Turn adjuster clockwise whilst spinning the wheel until the shoes have locked the drum 3 Turn adjuster anti clockwise one notch at a time until the drum is just free to rot...

Page 39: ...on Ijpts smear grease around the catch mechanism of the bonnet 57 Check and report condition and security of seats and seat belts 1 Move seat adjuster towards the door and push seat back to its fullest extent 2 Check tightness of front bolts securing seat runner to floor 3 Move seat adjuster towards door and push seat forward to its fullest extent 4 Check tightness of rear bolts securing seat runn...

Page 40: ...haft rear oil seal remove and refit Crankshaft spigot bush remove and refit Cylinder block drain tap remove and r e f i t Cylinder block front mounting plate gasket remove and refit Cylinder block r e b o r e Cylinder head overhaul remove and refit renew casting Cylinder head gasket remove and refit Cylinder head nuts tighten Cylinder pressures check Decarbonize reface all valves and seats grind i...

Page 41: ...lean fuel pump filter road t e s t 12 49 02 Exhaust valve seats remove and r e f it 12 29 77 Flywheel remove and refit Gudgeon pin bush each remove and refit Inlet valve seat remove and refit 12 53 07 12 17 13 12 29 76 Main bearing centre and rear remove and refit front remove and refit set remove and refit 12 21 42 12 21 41 12 21 39 Oil filter assembly remove and refit Oil pick up strainer remove...

Page 42: ...g cover oil seal remove and refit Timing chain cover remove and refit Valve clearance check and adjust alve guides exhaust remove and refit inlet remove and refit Valve timing check Valves exhaust remove and refit inlet and exhaust remove and refit inlet remove and refit Valve seats exhaust remove and refit inlet remove and refit 12 29 59 12 29 56 12 29 42 12 29 55 12 29 54 12 53 19 12 65 14 12 65...

Page 43: ...a over the drive shaft below the gear 6 Insert the shaft assembly and washer into position in the bush ensuring that the oil pump drive is mated with the shaft NOTE Use a screwdriver to turn the oil pump drive try the drive gear in a different position in order to be sure that it is down correctly 7 Fit the distributor pedestal into position without gasket s 8 Measure the gap between the pedestal ...

Page 44: ...s with the camshaft gear and ensuring that it engages with the oil pump drive dog 12 The gear is correctly positioned when the offset slot is nearest to the cylinder block and in line with the thread hole for the oil filter attachment 13 Fit the pedestal and selected gasket s 14 Fit and tighten the nuts and washers 15 Fit the distributor 86 35 20 DATA Drive gear end float 0 003 to 0 007 in 0 08 to...

Page 45: ...ront of the engine with a jack 11 Remove the front R H engine mounting bolts 12 Remove the front L H engine mounting bolts 13 Jack up the front of the engine sufficiently to withdraw the camshaft through the grille aperture 14 Withdraw the camshaft Refitting 15 Reverse instructions 1 to 14 and in addition a Check the camshaft end float and reduce if necessary by fitting a new camshaft location pla...

Page 46: ...4 cfankpins at B D C and lubricate them with clean engine oil 14 Smear the pistons and cylinder bores with clean engine oil 15 Carefully insert the connecting rods and pistons into the bores ensuring that the arrow thus A is pointing to the front of the engine 16 Ensure that the open face of the big end bearing is towards the non thrust side of the cylinder bore 17 Stagger the piston ring gaps avo...

Page 47: ...7 01 2 Remove the circlips from the pistons 3 Remove the gudgeon pin 4 Remove the piston from the connecting rod 5 Remove the piston rings with the expander tool and clean 6 Clean the pistons removing all carbon deposits particularly from the piston ring grooves 7 Remove the big end bearing shells 8 Examine the gudgeon pin and check for wear see Data 9 Check the piston dimensions to grade and bore...

Page 48: ...n the non thrust side of piston 15 Refit the connecting rods and pistons 12 17 01 DATA Pistons Bore size Grade F Grade G Piston top diameter Grade F Grade G Piston bottom diameter Grade F Grade G Pistons available Groove width b o tto m centre and t o p Ring width bottom oil control 3 part centre and top compression Rings a v a ila b le Connecting rods Small end bush fitted i dia Gudgeon pin diame...

Page 49: ...the piston higher than T D C or the top piston ring may be released necessitating removal of the cylinder head 7 Remove the upper shell bearing Refitting 8 Insert the shell bearing in the connection rod big end 9 Lubricate the crankpin with clean engine oil 10 Pull the connecting rod onto the crankpin 11 Fit the shell bearing to the bearing cap and fit to the connecting rod NOTE When fitting the b...

Page 50: ...il seal housing 3 Remove the seven bolts holding the oil seal housing to the crankcase noting that the top centre bolt has a copper washer 4 Withdraw the oil seal and housing complete taking care not to tear the sump gasket 5 Press out the oil seal from the housing Refitting 6 Smear the outside diameter of the replacement oil seal with grease and press into housing lip face to crankshaft 7 Clean t...

Page 51: ... in the opposite direction and note the gauge reading which should indicate an end float of0 006 to 0 014 in 0 1524 to 0 3556 mm 5 If necessary adjust the end float by removing the rear main bearing cap and existing thrust washers and renewing with different washers of suitable thickness ensuring a Thrust washers are fitted so that the thrust faces identified by oil grooves bear against the cranks...

Page 52: ...aft pulley 10 Remove the timing chain cover 12 65 01 instruc tions 5 and 6 11 Remove the oil thrower 12 Remove the timing chain sprocket and shims 13 Remove the two bolts securing the camshaft location plate and remove the plate 14 Remove the front mounting plate 12 25 10 instruc tions 9 to 12 15 Remove thedipstick 16 Remove the sump 17 Remove the oil strainer 12 60 20 18 Remove the front sealing ...

Page 53: ... c e Main bearings and big end bearings are available in the following undersizes 35 Fit the front mounting plate and gasket ensuring that a All traces of old gasket and jointing compound are removed from the cylinder block joint face b The cylinder block face of the new gasket is smeared with jointing compound c The mounting plate is located correctly over the dowels d The retaining bolts and scr...

Page 54: ...e sealing block 6 Remove the front main bearing cap bolts and withdraw the cap complete with lower shell Remove the upper shell and check that the cap is marked for reassembly 7 Remove the centre main bearing bolts and with draw the cap and lower shell Check identification marks for reassembly and withdraw the upper shell 8 Remove the rear main bearing cap bolts and with draw the cap and lower she...

Page 55: ...on marks coincide 12 Check and adjust if necessary the crankshaft end float 12 21 26 13 Smear the front sealing block gaskets with jointing compound and fit to the crankcase loosely tighten ing the screws 14 Drive wedges into the slots 15 Align the face of the sealing block with the crank case and tighten the retaining screws 16 Trim the protruding ends of the wedges flush with the crankcase do no...

Page 56: ...2 CYLINDER PRESSURES Check 12 25 01 1 Run the engine until normal temperature is attained as indicated by the temperature gauge 2 Remove the spark plugs 3 Fit a compression gauge to No 1 cylinder 4 Turn the engine over with the starter motor with the throttle wide open 5 Note and record the gauge reading 6 Repeat on the remaining cylinders NOTE All cylinders should have pressures within 10 lb in2 ...

Page 57: ...wo each side securing the L H and R H engine mounting bolts to the sub frame 9 Remove the three bolts securing the mounting plate to the cylinder block 10 Remove the two screws securing the mounting plate to the sealing block 11 Remove the front mounting plate complete with mounting rubbers 12 Remove the front mounting plate gasket Refitting 13 Remove all traces of old jointing compound from the c...

Page 58: ... the cylinder bore with 3 to 4 tonrmaximum pressure until flush with top face of cylinder block NQTE When pressing liners in with a screw typefpress there is a tendency for it to creep slightly in the same direction as the rotation of the press It is therefore necessary to set the liner back about in 0 7937 mm when lining up the liner prior to pressing home True up connecting rods slot with a file...

Page 59: ...assembly in the corresponding cam followers 7 Remove the water pump housing 26 50 03 1 to 7 8 Remove the alternator 86 10 07 Refitting 12 Reverse instructions 1 to 11 ensuring a Cylinder head and cylinder block faces are clean b New cylinder head gasket is fitted c Cylinder head nuts are tightened to the correct torque figure and in the correct sequence d All gaskets are renewed 13 Adjust the valv...

Page 60: ...tool on the combustion chamber face and pull the replacement guide in and the old one out Ensure that the guide protrusion above the cylinder head top face is correct see Data 6 Examine the valve seats for pitting and wear Reface where necessary removing the minimum of material 7 Fit valve seat inserts where the seats cannot be restored by refacing Machine the cylinder head to the dimensions given...

Page 61: ...pe A Type B Type C Valve Springs internal diameter Working coils Load at length Free length Solid length Rate 0 795 in 20 193 mm 3 1 36 in 2 7 to 30 1b 34 54 mm 12 25 to 13 61 kg 1 61 in 40 9 mm 0 93 in 23 6 mm 150 lb in 2679 kg m 0 795 in 20 193 mm 34 1 074 in 105 to 115 lb 27 28 mm 47 3 to 52 2 kg 1 59 in 40 4 mm 0 96 in 24 4 mm 235 lb in 4196 kg m 0 795 in 20 193 mm H 0 989 i n 123 to 133 lb 25...

Page 62: ...on falling into the bores and cover the cam follower apertures 11 Carefully without scoring the piston crown re move carbon deposits leaving a band of carbon round the periphery of the piston crown Avoid carbon particles falling into the cylinder block water ways 12 Repeat instructions 9 to 1I on Nos 2 and 3cylinders 1 3 Clean the cylinder block face removing all traces x of carbon and high spots ...

Page 63: ...he fastener bracket single carburetter R H Stg only 2 Disconnect the servo hose from the inlet manifold and throttle cable twin carburetter L H Stg only 3 Disconnect the engine breather hose from the carburetter 4 Remove the two nuts complete with plain and fibre washers securing the rocker cover to the cylinder head 5 Lift off the rocker pover complete with gasket Refitting 6 Reverse instructions...

Page 64: ...ust the remaining valve clearances in the following sequence Adjust Nos 5 and 2 valves with Nos 4 and 7 valves open Adjust Nos 8 and 6 valves with Nos 1 and 3 valves open Adjust Nos 4 and 7 valves with Nos 5 and 2 valves open Refitting 8 Reverse instructions 1 to 3 K J ROCKER SHAFT Remove and refit 12 29 54 Removing 1 Remove the rocker cover 12 29 42 2 Remove the four nuts complete with washers se...

Page 65: ...1 to 5 observing a Renew all worn components The grinding of worn rocker pads is not recommended b Ensure that oil ways in rockers and shaft are clear c Ensure that the rear pedestal locating screw engages properly in the rocker shaft 7 Adjust the valve clearances 12 29 48 ROCKER ADJUSTING SCREWS SET Remove and refit 12 29 56 Removing 1 Remove the rocker shaft assembly 12 29 54 2 Remove the rocker...

Page 66: ...re assembly Refitting 4 Reverse instructions 1 to 3 ensuring a Push rods with worn or pitted cup and ball ends and bent shafts are renewed b Ball and cup ends are lubricated c Cup ends are located correctly in the rocker adjusting screw ball and ball ends are seated properly in the cam follower 5 Adjust the valve clearances 12 29 48 Valves inlet and exhaust remove and refit 12 29 62 Valves inlet r...

Page 67: ...ug end to prevent fuel siphoning or dirt entering the system 18 Disconnect propeller shaft at gearbox raise one rear wheel to turn shaft 47 15 02 19 Disconnect gear lever at rear of extension 20 Remove nut securing rear mounting to sub frame 12 45 08 21 Remove nut and bolt securing exhaust pipe clip to support arm 22 Disconnect speedometer drive cable 88 30 06 23 Remove two bolts securing clutch s...

Page 68: ...move the oil filter 12 60 01 11 Remove the starter motor 12 Remove the fuel pump 13 Remove the clutch housing complete with gearbox 14 Remove the clutch unit 15 Remove the engine mounting rubbers 16 Remove the oil filler cap 17 If the engine is to be returned for reconditioning seal off all ports and apertures Refitting 18 Reverse instructions 1 to 16 ensuring a New gaskets and seals are fitted wh...

Page 69: ... instruc tions 5 and 6 v 10 Remove the timing chain and sprockets 12 65 12 instructions 2 and 5 ignoring reference to moving the crankshaft and camshaft 11 Remove the distributor pedestal and drive gear 12 10 22 instructions 2 to 4 12 Remove the two bolts securing the camshaft locating plate to the cylinder block Remove the plate and withdraw the camshaft 13 Remove the cylinder block front mountin...

Page 70: ...ar main bearing cap bolts 31 Withdraw the main bearing caps complete with lower shells Check identification marks for reassembly DO NOT MIX 32 Lift out the crankshaft 33 Remove the upper bearing shells and thrust washers from the rear main bearing Rebuilding Overhaul all sub assemblies Clean and degrease all components before assembly Lubricate all parts with clean engine oil before assembly unles...

Page 71: ...cation over the studs and dowels and that the arrow is at the top Evenly tighten the retaining bolts 50 Fit the crankshaft spigot bush which should be a loose fit in the crankshaft 51 Fit the flywheel 12 53 07 instructions 5 to 8 52 Coat the cylinder block face of a new front mounting plate gasket with jointing compound and place it in position on the joint face 53 Fit the mounting plate in positi...

Page 72: ...ker shaft assembly ensuring that the rocker adjusting screw balls locate in the push rod cups 63 Tighten the rocker shaft pedestal nuts evenly to 26 to 34 lbf ft 3 6 to 4 7 kgf m 64 Adjust the valve clearances of Nos 7 and 8 valves only to 0 050 in 0 397 mm to give a working clearance 12 29 48 instructions 6 and 7 65 Turn the camshaft until Nos 7 and 8 valves are on the rock i e inlet valve about ...

Page 73: ...sprocket o n 68 Check the sprockets for alignment 12 65 12 69 Fit a new camshaft sprocket lock plate and tighten the bolts and bend over the tabs 70 Fit the oil thrower to the crankshaft ensuring that the dished periphery faces the timing cover 71 Fit the timing chain cover complete with a new gasket 12 65 01 72 Fit the crankshaft pulley and tighten the retaining nut to 120 to 150 lbf ft 16 6 to 2...

Page 74: ...ove the mounting s Refitting 6 Reverse 1 to 5 ENGINE MOUNTING REAR Remove and refit 12 45 08 Removing 1 Employ a jack to take the weight at the rear of the gearbox extension 2 Remove the nut securing the mounting to the sub frame 3 Remove the two nuts and bolts securing the mounting to the gearbox attachment bracket 4 Raise the jack slightly 5 Remove the mounting Refitting 6 Reverse 1 to 5 noting ...

Page 75: ...ry 86 35 16 4 Tune the carburetter s 19 15 01 or 19 15 02 5 Clean the fuel pump filter 19 45 02 n ENGINE REAR GEARBOX ADAPTOR PLATE Remove and refit 12 53 03 o Removing 1 Remove the flywheel 12 53 07 2 Remove the seven bolts securing the adaptor plate to the cylinder block 3 Remove the adaptor plate Refitting 4 Reverse instructions 1 to 3 ensuring a The adaptor plate is located correctly over the ...

Page 76: ...rankshaft 7 Tighten the flywheel retaining bolts CAUTION Two types of flywheel retaining bolts are used in sets It is most important to identify and to tighten to the correct torque figures given below Type A Cadmium plated coloured Silver 35 to 40 lbf ft 4 8 to 5 5 kgf m Type B Parkerized Black 40 to 45 lbf ft 5 5 to 6 2 kgf m 8 Using a dial indicator gauge check the flywheel for run out not to e...

Page 77: ...lit 6 Place a cold chisel immediately above the centre line of the drilled hole and strike sharply to split the ring gear Refitting 7 Heat the replacement starter ring gear uniformly to a maximum of 200 C 8 Place the flywheel on a flat surface clutch face side uppermost and clean the ring gear locating register 9 Locate the ring gear and hold in position until it contracts sufficiently to grip the...

Page 78: ...lter turning clockwise and tighten 7 Reconnect the battery 8 Start the engine and check for oil leaks between the cylinder block and filter OIL PICK UP STRAINER Remove clean and refit 12 60 20 Removing 1 Remove the sump 12 60 44 2 Release the oil strainer locknut 3 Unscrew the oil strainer and remove it 4 Wash the oil strainer in petrol and dry it before refitting Refitting 5 Reverse instructions ...

Page 79: ... drive shaft engages correctly into the drive gear shaft b The securing bolts are evenly tightened c Absolute cleanliness is observed n OIL PUMP Overhaul 12 60 32 n 1 Isolate the battery 2 Remove the oil pump from the crankcase 12 60 26 3 Remove the cover plate complete with strainer 4 Remove the inner rotor and shaft assembly 5 Remove the outer rotor 6 Clean oil from the body and rotors and reass...

Page 80: ...0 25 mm c Check the clearance between the outer rotor and body This must not exceed 0 008 in 0 2 mm 8 Check the cover plate for scoring and test on a surface plate for distortion Renew if necessary 9 Check the pump spindle bearing surface in the pump body for excessive wear 10 Reassemble the pump fitting any new parts neces sary to satisfy the above quoted tolerances Renew the complete pump if a s...

Page 81: ...g 8 Reverse instructions 1 to 7 noting a Clean the crankcase and sump faces b Fit a new gasket c The longer bolts are fitted at the rear of the sump d Tighten the retaining bolts to 15 to 20 Ibf ft 2 1 to 2 8 kgf m OIL PRESSURE RELIEF VALVE Remove and refit 12 60 56 n Removing 1 Unscrew the relief valve body from the cylinder block 2 Remove the washer 3 Take out the plunger 4 Remove the spring Ref...

Page 82: ...s the chain tensioner with a suitable bent length of rod taking care not to damage the gasket when withdrawing the rod c The cover and gasket locate on dowels TIMING CHAIN COVER OIL SEAL Remove and refit 12 65 05 Removing 1 Remove the timing chain cover 12 65 01 2 Carefully remove the oil seal avoiding damage to the timing covet Refitting NOTE The latest type of oil seal has a spiral groove formed...

Page 83: ...7 and 8 valves are the same Oscillate the crankshaft to achieve this condition but ensure that when the rocker clearances are the same the conditions in instructions 3 and 4 are maintained within a few degrees NOTE The actual valve clearance does not matter providing the clearances are the same 6 Should the valve timing prove to be incorrect retiming will be necessary 12 41 05 instructions 59 to 6...

Page 84: ...should be at 12 o clock 4 Bend back the lock plate tabs and remove the two bolts securing the sprocket to the camshaft 5 Taking care not to turn the crankshaft or camshaft remove both sprockets together with the timing chain Refitting 6 Remove the crankshaft drive key 7 Temporarily refit both sprockets 8 Check the alignment of the sprockets by placing a straight edge across the teeth of both sproc...

Page 85: ...w the chain 15 Fit a new camshaft sprocket lock plate refit the bolts and bend the tabs 16 Refit the oil thrower with the dished periphery to wards the timing chain cover 12 41 05 17 Refit the timing chain cover 12 65 01 NOTE If new sprockets are fitted see instructions 67 and 68 12 41 05 TIMING CHAIN TENSIONER Remove and refit 12 65 28 Removing 1 Remove the timing chain cover 12 65 01 2 Prise ope...

Page 86: ...9 15 11 19 15 02 19 15 24 Fuel pump clean filter overhaul remove and refit test on vehicle 19 45 05 19 45 15 19 45 08 19 45 01 Fuel tank remove and refit 19 55 01 Hose filler to tank remove and re fit Mixture control cable remove and refit o Petrol pipe engine end section remove and refit main line complete assembly remove and refit Piston and suction chamber remove clean and refit Throttle cable ...

Page 87: ...ove and refit 19 10 02 Removing 1 Remove the four bolts securing the air cleaner assembly to the carburetter intakes 2 Disconnect the fuel link pipe 3 Remove the air cleaner assembly complete with gaskets Refitting 4 Reverse instructions 1 to 3 renewing the gaskets AIR CLEANER TWIN RENEW ELEMENTS Remove and refit 19 10 09 Removing 1 Remove the air cleaner assembly 19 10 02 2 Remove the bolt securi...

Page 88: ...ckwise to decrease b Should the engine not idle smoothly at the correct speed check the mixture setting 6 Switch off the engine and raise the carburetter piston with the lifting pin Release the pin and check that the piston falls freely on to the carburetter bridge indicated by a soft metallic click If the piston does not fall freely refer to 19 15 17 7 Start the engine and turn the jet adjusting ...

Page 89: ... to fall freely refer to 19 15 18 7 Start the engine and check the idling speed with the tachometer which should be 750 800 rev min a If the reading is not correct continue with instructions 8 to 11 and 15 and 16 b If the idle speed is correct but is not consistent with smooth running continue with instructions 8 to 21 8 Slacken both throttle interconnection clamp nuts 9 Slacken both jet control i...

Page 90: ...r arm of the forks 16 Insert feeler gauges to the value of 0 030 to 0 035 in 0 76 to 0 89 mm between the heel of the fulcrum plate and the machined surface of the manifold and tighten the clamping nuts while holding the lever pins on the lower arm of the fork Following this instruction a clearance should exist between the lever pins and the bottom arm of the forks The actual clearance is not impor...

Page 91: ...9 15 11 Removing 1 Pull off the breather pipes from the carburetters 2 Disconnect the chok cable at the trunnion 3 Disconnect the link rod between the cable linkage and throttle interconnection shaft lever 4 Disconnect the two throttle return springs 5 Disconnect the vacuum pipe 6 Disconnect the main fuel feed pipe 7 Remove the four carburetter flange to manifold nuts two per carburetter complete ...

Page 92: ... not to bend the needle Withdraw the needle from the guide and remove the spring from the needle 9 Push the piston lifting pin upwards detach its securing circlip and withdraw the pin and spring downwards 10 Release the pick up lever return spring from its retaining lug 11 Support the plastic moulded base of the jet and remove the screw retaining the jet pick up link and link bracket when fitted 1...

Page 93: ...imit valve 23 Unscrew the disc retaining screws open the throttle and ease the disc from its slot in the throttle spindle Store the disc in a safe place until required for assembly 24 Tap back the tabs of the lock washer securing the spindle nut remove the nut and detach the lever arm washer and throttle spindle note the location of the lever arm in relation to the spindle and carburetter body Ins...

Page 94: ...entralize it in the bore of the carburetter 29 Fit new disc retaining screws but do not fully tighten check that the disc closes fully and adjust its position as necessary Tighten the screws fully and spread their split ends just enough to prevent them turning 30 Screw the seating into the float chamber do not overtighten Insert the needle coned end first into the seating 31 Refit the float to the...

Page 95: ...Renew the assembly if the time taken is still not within these limits INC 204 37 Fit the spring and guide to the needle and insert the assembly into the piston ensuring a The lower edge of the guide is flush with the face of the piston b The guide is positioned so that the etched locating mark on its lower face is adjacent to and in line with the centre line between the two piston transfer holes c...

Page 96: ... end of the moulded jet and tighten the securing screw 45 Screw the jet adjusting nut down two complete turns 12 flats to provide the initial setting 46 Refit the carburetter s 19 10 09 or 19 15 11 47 Tune the carburetter s 19 15 01 or 19 15 02 u FLOAT CHAMBER NEEDLE AND SEAT Remove and refit 19 15 24 Removing 1 Disconnect the fuel hose from the float chamber 2 Mark the lid and float chamber for a...

Page 97: ...es with rubber plugs or Plasticine and insert the piston fully into the suction chamber b Secure a large flat washer to one of the fixing holes with a screw and nut so that it overlaps the bore c With the assembly upside down hold the piston and check the time taken for the suction chamber to fall the full extent of its travel The time taken should be five to seven seconds if this time is exceeded...

Page 98: ...he cable clip is correctly positioned so that the inner cable is gripped and cannot slip out THROTTLE CABLE Single Carburetter Remove and refit 19 20 06 Removing 1 Remove the cable retaining clip from the pedal 19 20 01 2 Withdraw the exposed throttle inner cable from the fork end of the throttle pedal 3 Remove the outer cable complete with inner cable from the bulkhead by squeezing ears of ferrul...

Page 99: ...tly fitted so that the cable will not slip out of the fork b The c ble is not kinked or subjected to sharp bends c Cable tension is adjusted so that the heel of the fulcrum plate is just touching the machined face of the manifold y MTO 596 THROTTLE LINKAGE Single Carburetter Remove and refit 19 20 07 Removing 1 Slacken the throttle inner cable clamp bolt 2 Squeeze between the thumb and finger the ...

Page 100: ...move the ferrule securing the outer cable to the control panel 4 Remove the outer cable from the control panel 5 Separate the carburetter end section of the outer cable from the control panel end section at the connector 6 Drop the outer cable below the control panel and pull the cable through the bulkhead grommets into the interior of the car and remove Refitting 7 Feed the control panel end of t...

Page 101: ...itting 6 Reverse instructions 1 to 5 ensuring a New rubber connectors linking each pipe section are renewed if cracked or damaged b The connecting ends of each pipe section are not fitted so that there is any strain on the rubber connectors c Pipes are not chafing or fouling body or com ponents PETROL PIPE MAIN LINE ENGINE END SECTION Remove and refit 19 40 04 Removing 1 Drain fuel tank 19 40 01 2...

Page 102: ...igh it may be reduced by fitting extra paper washers between the pump and cylinder block Where pressure is too low overhaul the pump 19 45 15 or renew 19 45 08 u FUEL PUMP Clean filter 19 45 05 Note Two alternative fuel pumps are illustrated 1 Remove the screw in the top of the pump 2 Lift off the dome cover 3 Lift off the cover sealing ring 4 Lift out the filter 5 Use clean lint free cloth and so...

Page 103: ...ed Dismantling 1 Remove screw complete with plain washer securing dome cover to upper body Remove dome cover Remove sealing ring Lift out filter Mark for reassembly the relationship between upper and lower body of pump Remove five screws complete with spring washers securing upper body to lower body Lift off upper part of body Mark for reassembly the relationship of diaphragm to lower body Turn di...

Page 104: ...g all seals and washers FUEL TANH Remove and refit 19 55 01 Removing 1 Isolate the battery and extinguish all naked lights 2 Remove the petrol tank drain plug and drain the tank 19 40 01 3 Disconnect the main line fuel pipe from the tank outlet pipe and clamp the rubber connector to prevent fuel linkage from the main line pipe 4 Remove the luggage compartment carpet and spare wheel cover and spare...

Page 105: ...diator drain tap remove and refit 26 10 01 26 20 07 26 15 01 26 25 06 26 25 01 26 40 01 26 40 10 Radiator hoses bottom hose remove and r e f i t 26 30 07 expansion tank hose remove and r e f i t 26 30 37 top hose remove and refit 26 30 01 Thermostat remove and refit 26 45 01 test 26 45 10 Water pump remove and refit 26 50 01 Water pump housing remove and refit 26 50 03 n Triumph Toledo Manual Part...

Page 106: ...nk with soft water 7 Fill the cooling system with soft water via the radia tor filler plug 8 Fit the filler plug and expansion tank cap 9 Run the engine at fast idle speed for three minutes 10 Top up the system and replace the plug n EXPANSION TANK Remove and refit 26 15 01 Removing 1 Disconnect the radiator connecting hose at the expansion tank 2 Disconnect the overflow hose 3 Remove the two bolt...

Page 107: ...gine No DG 1605 only Remove and refit 26 25 01 Removing 1 Remove the fan blades 26 25 06 2 Remove the water pump complete with pulley i 26 50 01 jJiff NOTE Water pump complete with pulley is only serviced as a complete assembly Not available as separate items Refitting 3 Reverse instructions 1 to 2 ensuring that a new water pump to housing gasket is fitted with com pound FAN BLADES Remove and refi...

Page 108: ...fitting C 0 4 Fit the belt over the pulleys and adjust 86 10 05 RADIATOR HOSES Remove and refit Top hose Bottom hose Radiator to expansion tank hose 26 30 01 26 30 07 26 30 37 Removing 1 Drain coolant from the system 26 10 01 2 Slacken the wire clip at each end of the hose 3 Remove the hose Refitting 4 Reverse 1 to 3 MT2101 fn Triumph Toledo Manual Part No 545168 Issue 1 26 20 07 26 30 37 ...

Page 109: ...ts 4 Lift out the radiator NOTE It may be more convenient to remove the bolt securing each mounting bracket to the body disconnecting the hoses and lifting the radiator and horns out together Refitting 5 Reverse 1 to 4 RADIATOR DRAIN TAP when fitted Remove and refit 26 40 10 Removing 1 Drain the coolant 26 10 01 2 Unscrew the tap assembly from the radiator block Refitting 3 Reverse 1 and 2 UIVLAIM...

Page 110: ...ct opening temperature b A new water elbow gasket is fitted c The radiator coolant is replenished with the correct anti freeze concentration THERMOSTAT Test 26 45 10 Removing 1 Remove the thermostat 26 45 01 2 Determine the opening temperature of the thermo stat stamped on the flange or base 3 Immerse the thermostat in water heated to the opening temperature of the thermostat 4 If the thermostat d...

Page 111: ...ect the Lucar connector from the temper ature transmitter 5 Remove the two bolts securing the thermostat housing to the water pump housing 26 45 01 6 Slacken the alternator mountings and remove the belt 26 20 07 7 Disconnect the heater by pass pipe union 8 Remove the three bolts securing the water pump housing to the cylinder block 9 Remove the fuel feed pipe and vacuum pipe 10 Remove the water pu...

Page 112: ...system complete remove and r e f i t Front pipe single or left hand remove and r e f i t Induction or exhaust manifold remove and refit Intermediate pipe remove and r e f i t Tail pipe or silencer remove and refit 30 10 26 30 10 01 30 10 09 30 15 01 30 10 11 30 10 22 n o Triumph Toledo Manual Part No 545168 Issue 1 30 1 ...

Page 113: ...J V ...

Page 114: ... n Refitting NOTE An exhaust pipe sealant such as Holts Fire Gum Sealer should be used at the exhaust pipe joints 8 Align front pipe and intermediate pipe in the correct position 9 Refit and tighten the three nuts holding the front pipe to the manifold 10 Refit and tighten bolt holding front pipe to the supporting bracket 11 Replace flexible mounting on intermediate pipe 12 Align and slide tail pi...

Page 115: ...ve and refit 30 10 11 Removing 1 Release clip holding tail pipe to intermediate pipe 2 Remove rubber mounting on tail pipe 3 Remove tail pipe 4 Release clip holding intermediate pipe to front pipe 5 Remove rubber mounting on intermediate pipe 6 Remove intermediate pipe and silencer Refitting NOTE An exhaust pipe sealant such as Holts Fire Gum Sealer should be used at the exhaust pipe joints 7 Slid...

Page 116: ... Tighten the clip around the tail pipe and intermediate pipe n DOWN PIPE FLANGE PACKING Remove and refit 30 10 26 Removing 1 Remove three nuts holding the front pipe to manifold 2 Remove nut and bolt holding front pipe to support bracket 3 Pull down front pipe and remove flange packing n Refitting 4 5 6 Pull front pipe down and replace packing Refit front pipe and tighten manifold stud nuts Refit ...

Page 117: ...der head 5 Pull manifold clear of studs and remove from engine 6 Remove induction and exhaust manifold gasket Refitting 7 Renew and refit the manifold gasket up to cylinder head 8 Refit the manifold onto the head studs 9 Tighten nuts holding manifold to head 10 Renew down pipe flange packing and fit over studs 11 Replace and tighten three nuts holding down pipe in position 12 Refit carburetter and...

Page 118: ...d refit Fluid pipe remove and refit Hydraulic system b leed Master cylinder overhaul remove and refit Release bearing assembly remove and refit Slave cylinder overhaul remove and refit 33 25 17 33 10 01 33 30 02 33 30 07 33 30 03 33 15 09 33 15 01 33 20 07 33 20 01 33 25 12 33 35 07 33 35 01 n o v Triumph Toledo Manual Part No 545168 Issue 2 33 1 ...

Page 119: ...e that the reservoir is topped up to from the top 2 Remove the gearbox cover 3 Wipe the bleed nipple clean 4 Attach a piece of small bore tubing to the nipple and let it hang in a container partially filled with hydraulic fluid 5 Unscrew the bleed nipple one complete turn NOTE During bleeding care should be taken to ensure that the reservoir does not become empty resulting in air being drawn into ...

Page 120: ...leed hydraulic system 33 15 01 11 Lower car on ramp u MASTER CYLINDER in Remove and refit 33 20 01 Removing 1 Drain the fluid system 2 Disconnect the fluid pipe at the master cylinder 3 Remove the cotter pin from top of pedal 4 Remove two nuts securing master cylinder to body 5 Remove master cylinder from car Refitting 6 Hold master cylinder in place in engine compart ment 7 Renew two nuts securin...

Page 121: ...thimble to the valve stem 10 Remove the seal from the piston and fit a new seal seal lip towards the spring 11 Engage the spring thimble on the piston and care fully depress the thimble prong 12 Lubricate the bore of the master cylinder with clean brake fluid and insert the seal assembly spring and piston 13 Fit a new rubber to the push rod 14 Fit the push rod and washer to the master cylinder and...

Page 122: ...l return spring 4 Remove the pedal pivot bolt and nut 5 Withdraw the clutch pedal complete with bushes and pivot sleeve Refitting 6 Reverse instructions 1 to 5 u CLUTCH PEDAL RETURN SPRING Remove and refit 33 30 03 Removing 1 Remove cotter pin washer and split pin securing pedal to master cylinder 2 Remove nut and carefully slide out bolt holding pedal 3 Remove spring from pedal Refitting 4 Renew ...

Page 123: ...olt nut and washer 5 Pull slave cylinder clear of housing Refitting 6 Centralize push rod in housing 7 Push slave cylinder into housing 8 Line up groove with hole and place bolt in through hole and tighten nut 9 Line up hydraulic pipe and tighten nut up in slave cylinder 10 Bleed the system O SLAVE CYLINDER Overhaul 33 35 07 n 1 Remove slave cylinder from car 33 35 01 2 Remove dust cover retainer ...

Page 124: ...mbly o v e r h a u l Rear extension overhaul remove and refit Rear oil seal remove and r e f it Speedometer drive gear remove and refit Speedometer drive gear pinion remove and refit Synchronizer assemblies overhaul Top cover overhaul remove and refit Top cover extension overhaul remove and refit 37 12 07 37 20 34 37 10 01 37 20 04 37 20 01 37 16 01 37 16 10 37 16 04 37 16 05 37 20 29 37 12 04 37 ...

Page 125: ...SYNCHROMESH GEARBOX Section Through Gearbox Assembly ...

Page 126: ...er the sump using a ramp jack interpose a piece of wood between the jack head and sump to spread the load 6 Disconnect the exhaust support bracket from the front pipe 7 Remove the gearbox mounting assembly 8 Disconnect the speedometer cable from the rear extension 9 Remove the bolts and spring washers 10 Withdraw the rear extension assembly joint washer and mainshaft washer Refitting 11 Locate the...

Page 127: ...ten the peg bolt and washer 10 Refit the rear extension 37 12 01 or 37 20 04 u CLUTCH HOUSING Remove and refit 37 12 07 1 Remove the gearbox assembly 37 20 01 Removing 2 Remove the clutch release mechanism 33 35 12 operation 2 3 Unscrew and remove the bolts 4 Remove the clutch housing and joint washer Refitting 5 Replace the clutch housing and a new joint washer 6 Fit and tighten the bolts ensure ...

Page 128: ...g 1 Remove the top cover extension 37 12 10 2 Remove the cap 3 Lift off the steel and nylon cups 4 Remove the spring 5 Release the lever from the operating shaft 6 Withdraw the lever 7 Remove the circlip 8 Take off the spring 9 Remove the nylon sphere 10 Unscrew the stop bolt and locknut 11 Drill out the two rivets 12 Remove the reverse stop plate 13 Unscrew the taper locking pin 14 Withdraw the s...

Page 129: ...he stop bolt and locknut to the lever 36 Fit the nylon sphere to the lever 37 Fit the reverse baulk spring 38 Secure the circlip 39 Fit the lever assembly into the extension 40 Secure the lever to the shaft 41 Fit the spring 42 Refit the nylon and steel cups 43 Refit the cap 44 Refit the top cover extension and adjust the reverse stop bolt 37 12 13 and 37 16 01 TOP COVER Remove and refit 37 12 16 ...

Page 130: ...lector shaft through the rear end of the top cover and through the reverse actuator 18 Fit the spring and detent plunger into the top cover and push the selector shaft into the neutral position 2nd detent 19 Place the 3rd top selector fork into the top cover 20 Slide the 3rd top selector shaft through the rear end of the top cover and through the 3rd top fork 21 Fit the spring and detent plunger i...

Page 131: ...et 37 16 05 Removing 3 Remove the fabric washer if fitted 4 Raise the ramp 5 Working from below the vehicle unscrew the nut 6 Remove the bolt and washer 7 Lower the ramp 8 Working from the passenger compartment release the cap 9 Remove the steel and nylon cups 10 Remove the spring 11 Withdraw the gear change lever Refitting 12 Fit the gear change lever into the extension 13 Replace the spring 14 R...

Page 132: ...Overhaul 37 16 10 n Dismantling 1 Remove the gear change lever 37 16 04 2 Take out the pinch sleeve 3 Remove the bushes and washers 4 Slacken and remove the locknut and unscrew the stop bolt 5 Remove the snap ring 6 Take off the spring 7 Remove the nylon sphere O Reassembling 8 Fit a new nylon sphere to the lever 9 Fit a new spring 10 Fit a new snap ring 11 Screw a new reverse stop bolt into the l...

Page 133: ...emove it from the vehicle Refitting 16 Check that the clutch driven plate is centralized 17 Fit the gearbox in position ensuring that the constant pinion shaft is not allowed to hang on the clutch plate splines 18 Fit the dowel bolt and nut 19 Fit and tighten the nuts and washers 20 Secure the upper bell housing bolts and nuts 21 Refit the gearbox mounting assembly 22 Fit and tighten the bolts 23 ...

Page 134: ...e reverse idler spindle and distance tube 11 Insert the needle roller retaining tube correspond ing to the dimensions given and eject the layshaft spindle to the rear Allow the layshaft cluster to drop to the bottom of the gearbox 12 Using Tool No S4235A 2 withdraw the constant pinion assembly 13 Remove the top gear baulk ring 14 Remove the circlip retaining the speedometer drive gear 15 Remove th...

Page 135: ... u 39 43 MT0598 Reassembling 41 Screw the pivot pin into the reverse actuator until one full thread protrudes through the lever boss 42 Fit the actuator and pivot pin into the gear casing 43 Fit the plain washer and tighten the nut 44 Smear the front face of the layshaft front thrust washer with grease and stick it in position in the gear casing Insert the end of the layshaft spindle through the c...

Page 136: ...the mainshaft 63 Fit the 1st speed gear 64 Fit the thrust washer 65 Fit a discarded bearing inner race or distance tube 18 99 to 19 05 mm 0 748 to 0 750 in long 66 Measure the thickness of the circlip washer and assemble to the shaft 67 Fit a discarded half circlip 68 Measure the 1st speed gear end float and determine the thickness of the circlip washer required to provide an end float of 0 00 to ...

Page 137: ...rrectly located 94 Invert the gearbox and align the layshaft cluster and thrust washers 95 Insert the layshaft spindle from the rear and eject the needle roller retaining tube 96 Position the reverse idler gear and fit the spindle and distance tube Fit the locating bolt 97 Locate the washer on the end of the mainshaft 98 Refit the rear extension assembly and a new joint washer 99 Fit the bolts and...

Page 138: ...prings and balls to the synchro hub and retain them in position with petroleum jelly 5 Carefully press the sleeve onto the hub 6 Using the spring balance and adaptor check the axial release loads which should be lst 2nd 8 6 to 9 5 kg 19 to 21 lb 3rd top 8 6 to 9 5 kg 19 to 21 lb If the release loads differ from the specified figures fit new springs and or add shims under the springs until the corr...

Page 139: ...needle rollers 3 Prise out the retaining rings Reassembling 6 Using a shouldered mandrel drive the retaining rings into the end bores of the layshaft cluster to the depth shown 7 Using heavy grease to retain them refit the needle rollers 8 Insert the needle roller retaining tube 9 Refit the layshaft cluster 37 20 04 10 Refit the gearbox 37 20 01 u O Triumph Toledo Manual Part No 545168 37 20 29 ...

Page 140: ... thrower is correctly located 11 Replace the washer 12 Refit the circlip 13 Refit the snap ring 14 Replace the roller bearing 15 Refit the constant pinion 37 20 04 operation 93 16 Refit the gearbox 37 20 01 n REAR OIL SEAL Remove and refit 37 23 01 Removing 1 Remove the propeller shaft assembly 2 Remove the gearbox drive flange 37 10 01 3 Prise out the seal Refitting __ 4 Drive a new seal into the...

Page 141: ...IVE GEAR PINION Remove and refit 37 25 05 Removing 1 Drive the vehicle onto a ramp Raise the ramp 2 Disconnect the speedometer cable from the gearbox 3 Unscrew and remove the peg bolt and washer 4 Withdraw the speedometer pinion and housing 5 Withdraw the pinion from the housing 6 Remove the O rings 7 Prise out the seal Refitting 8 Fit a new seal into the housing 9 Fit new O rings 10 Fit the pinio...

Page 142: ...entre bearing overhaul Propeller shaft assembly remove and refit 47 15 39 47 15 01 Propeller shaft front remove and refit 47 15 02 rear remove and refit 47 15 03 Universal joint overhaul 47 15 18 n D Triumph Toledo Manual Part No 545168 Issue 1 47 1 ...

Page 143: ...ted on earlier models only 4 Remove the nuts bolts and washers securing the centre bearing housing to the support brackets 5 Support the propeller shaft and disconnect it from the gearbox and rear axle flanges 6 Remove the propeller shaft from the vehicle Refitting 7 Attach the propeller shaft to the gearbox and axle flanges 8 Loosely secure the centre bearing housing to the support brackets 9 Ref...

Page 144: ... to the rear shaft noting the marks made in 4 Attach the shaft flange to the gearbox drive flange 9 Secure the strap to the floor using the nut bolt and washer earlier models only 10 Move the centre bearing to align the shafts and tighten the nuts and bolts 7 8 PROPELLER SHAFT REAR Remove and refit 47 15 03 Removing 1 Drive the vehicle onto a ramp Select neutral chock the wheels but do not apply t...

Page 145: ...n position 8 Fit the spider to the propeller shaft yoke 9 Engage the spider trunnion in the bearing cup and insert the cup into yoke 10 Fit the opposite bearing cup to the yoke and care fully press both cups into position ensuring that the spider trunnion engages the cups and that the needle bearings are not displaced 11 Using two flat faced adaptors of slightly smaller diameter than the bearing c...

Page 146: ...ing and housing assembly from the shaft 7 Remove the wire circlips 8 Separate the bearing and housing Reassembling 9 Fit the bearing into the housing 10 Refit the wire circlips 11 Fit the assembly onto the shaft 12 Ensure that the key and keyways are free from burrs and fit the key 13 Refit the drive flange 14 Fit and tighten the nut 15 Replace the split pin 47 15 39 Triumph Toledo Manual Part No ...

Page 147: ... overhaul remove and refit Half shaft bearing and oil seal remove and refit Pinion oil seal remove and refit Rear axle assembly remove and r e f i t Rear axle casing remove and refit 51 15 07 51 15 01 51 10 01 51 20 01 51 25 01 51 25 04 Triumph Toledo Manual Part No 545168 Issue 1 51 1 ...

Page 148: ...nect the brake pipe s from the wheel cylinder 8 Remove the nuts spring washers and bolts retaining the brake backplate to the axle casing 9 Remove the oil catcher 10 Remove the backplate assembly 11 Remove the rear hub oil seal and housing assembly 12 Remove the oil seal from the housing 13 Remove the axle shaft key CAUTION Place a container directly beneath the end of the axle casing to collect t...

Page 149: ...earing to threaded end of axle s h a f t 2 84 in 69 94 mm U DIFFERENTIAL ASSEMBLY Remove and refit 51 15 01 Removing 1 Remove both half shafts 51 10 01 2 Mark the differential pinion and propeller shaft drive flange to ensure correct re alignment 3 Remove the four nuts and bolts from the drive flange 4 Remove the nuts and washers retaining the differen tial assembly unit to the axle casing NOTE Pl...

Page 150: ...move the bearing cap retaining bolts and spring washers and remove the bearing caps n 4 Assemble the spreader S101 and adaptor S101 1 to the casing 5 Stretch the unit case by tightening the turnbuckle three to four flats until the differential carrier can be levered out and the bearing shims and caps removed IMPORTANT To avoid damaging the case do not spread any more than is necessary Each flat on...

Page 151: ... 11 Turn the differential gear wheels by hand until the differential pinions are opposite the openings in the differential gear case remove the differential pinions and their selective thrust washers 12 Remove the differential gear wheels and their thrust washers 7 13 Remove the drive flange nut split pin 14 Retain the drive flange using RG421 or S337 and remove the drive flange nut 15 Remove the ...

Page 152: ...l 21 Drift out the pinion inner bearing cup n Inspection 22 Clean all components 23 Renew all worn or damaged parts 24 The crown wheel and pinion must only be replaced as a matched pair The pair number is etched on the outer face of the crown wheel and the forward face of the pinion 25 If one differential bearing is defective replace both differential bearings If one pinion bearing is defective re...

Page 153: ... the pinion pin 31 Press each pinion in turn firmly into mesh with the differential gears and assess the required pinion thrust washer thickness 32 Remove the pinion pin and the two pinions 33 Select a thrust washer of the thickness required for each pinion Eight thrust washers are available in 0 002 in 0 05 mm steps from 0 027 in to 0 041 in 0 685 mm to 1 03 mm 34 By selection from the above rang...

Page 154: ...Remove the bearing caps 42 Press the differential bearings cups onto the bearings and move the carrier assembly to one side of the case Zero the dial gauge and move the carrier assembly fully in the opposite direction The indi cated movement which should be noted is the Total side float and is referred to as Dimension A 43 Remove the differential assembly from the case Setting th epinionposition 4...

Page 155: ...rements figures and divide by two 51 Twenty two pinion head washers are available ranging in size from 0 075 to 0 096 in 1 91 to 2 44 mm 52 Remove the dummy pinion 18G 191 M 53 Remove the inner bearing from the dummy pinion Calculating pinii Example Sum of each bore measurement divided by two Plus dummy pinion washer allowance from 18G 191 M Required size of pinion head washer head washer size 0 0...

Page 156: ...ging in size from 0 003 to 0 030 in 0 076 to 0 076 mm Note 0 001 shim thickness equals approximately 4 lbf in 0 046 kgf m pre load 63 Remove the drive flange nut washer and flange 64 Soak the new oil seal in oil for one hour and fit the seal 65 Fit the drive flange washer and flange nut 66 Tighten the drive flange nut to 90 lbf ft 12 4 kgf m using RG421 or S337 to retain the flange 67 Lock the nut...

Page 157: ...le 0 003 in 0 76 mm 0 005 in 0 127 mm 0 010 in 0 25 mm 0 20 in 0 50 mm 74 Fit the differential assembly to the case and fit the shim packs Slacken S101 and remove 75 Refit the bearing caps as originally marked and secure using the bolts and spring washers 76 Rotate the pinion to settle the differential bearings Position dial gauge service tool 18G 191 on the adaptor plate and position the foot on ...

Page 158: ...8 in 0 002 in 0 05 mm steps 0 027 in 0 685 mm 0 029 in 0 737 mm 0 031 in 0 787 mm 0 033 in 0 838 mm Max 0 003 in 0 076 mm 0 004 to 0 006 in 0 102 to 0 152 mm 0 005 0 127 mm 15 to 18 lbf in 0 17 to 0 21 kgf m 0 035 in 0 889 mm 0 037 in 0 940 mm 0 039 in 0 991 mm 0 043 in 1 092 mm 0 077 in 1 956 mm 0 082 in 2 083 mm 0 0825 in 2 095 mm 0 083 in 2 108 mm 0 084 in 2 134 mm 0 085 in 1 259 mm 0 0855 in 2...

Page 159: ...using S337 or RG421 and remove the nut and washer CAUTION Place a container directly beneath the driving flange to collect the spillage of oil when the driving flange and oil seal are removed 6 Remove the driving flange 7 Remove the oil seal Refitting 8 Reverse 1 to 7 noting a Immerse the new seal in light oil for one hour before fitting b Fit the new seal with the lip of the seal facing inwards c...

Page 160: ...spension arms to the axle 10 Raise the axle and remove rearwards to clear the suspension arms 11 Withdraw the axle from the car Refitting 12 Position the axle below the car and support on a jack 13 Raise the jack engage the rear ends of the radius rods through the axle brackets and fit the bushes washers nuts and pins 14 Engage the rear ends of the suspension arms in the axle casing brackets and f...

Page 161: ... 51 15 01 3 Remove the rear axle assembly 51 25 01 4 Remove the brake pipe 5 a Pull the breather cap from the breather assembly b On later model breather assemblies remove the insert c Unscrew the stem from the axle case H Remove the combined filler level plug Refitting 7 Reverse 1 to 6 o u u 51 25 04 Triumph Toledo Manual Part No 545168 Issue 2 ...

Page 162: ... 05 mast remove and refit 57 40 06 remove and refit 57 40 01 upper column remove and refit 57 40 02 Steering geometry check Steering lock ignition switch remove and refit Steering rack damper adjust damper remove and refit gaiter remove and refit overhaul remove and refit 57 65 02 57 40 31 57 57 35 10 57 25 02 57 25 07 57 25 01 Steering wheel pad remove and refit 57 60 03 remove and refit 57 60 01...

Page 163: ...draw the rack from the car n Refitting 9 Carefully guide the rack into position on the car 10 Engage the pinion shaft splines in the intermediate shaft flexible coupling ensuring that the previously marked scribe lines are aligned If no scribe marks are present it will be necessary to centralize the rack shaft locate the rack in its fitted position and ensure that the steering wheel spokes are hor...

Page 164: ...along the tie rod into position on the rack 10 With the rack centralized fit the inner clip to the gaiter and rack housing 11 Position the outer end of the gaiter on the tie rod so that it is caablpe of accommodating movement of the tie rod from lock to lock 12 Secure the outer end of the gaiter to the tie rod end with a clip 13 Fit the locknut to the tie rod locating it as near as possible to its...

Page 165: ... the plug 9 Remove the circlip securing the ball race to the pinion shaft and withdraw the ball race Tie rods and rack shaft 10 Release the clips securing the gaiters to the rack housing and tie rods and slide the gaiters clear of the rack 11 Slide the pinion end of the rack housing towards its adjacent tie rod inner ball joint 12 Grip the exposed rack shaft in protected vice jaws 13 Slacken the l...

Page 166: ...80 lbf ft 11 06 kgf m 25 Fit the rack shaft to the rack housing ensuring that the toothed end of the shaft is located at the pinion housing 26 Fit the locknut and tie rod assembly to the pinion end of the rack shaft and tighten the locknut to 80 lbf ft 11 06 kgf m Pinion 27 Fit the ball race to the pinion and secure it with the circlip 28 Fit a new internal O ring to the pinion end plug 29 Positio...

Page 167: ...nion housing and the underside of the damper plug flange check the clearance existing 5e To the thickness of the feeler gauge pack add the rack side movement required 0 006 in 0 154 mm This gives the thickness of shims to be fitted under the damper plug flange 5 Remove the damper plug and fit the required shim pack Tighten the damper plug 6 Ensure that the rack shaft is adequately lubricated and f...

Page 168: ...ring column clamp bracket to the column upper support bracket 7 Detach the clamp bracket and spring clips 8 Remove the pinch bolt and nut securing the lower end of the column to the intermediate shaft universal joint 9 Withdraw the steering column complete Refitting 10 Locate the steering column assembly in position and engage the lower end of the column in the bottom bush fitted to the scuttle 11...

Page 169: ...d an Easiout type extractor 9 Remove the steering column bracket and spring clip 10 Withdraw the steering column complete Refitting 11 Locate the steering column assembly in position and engage the lower end of the column in the bottom bush fitted to the scuttle 12 Fit the nylon washer to the lower end of the column and with the road wheels straight ahead and the steering wheel spokes horizontal e...

Page 170: ...lumn btishes Refitting 10 Enter the upper steering column in the tubular housing and carefully engage the lower steering column 11 Align the milled flat in the lower column with the slot in the upper column and fit the safety clamp but do not tighten the securing bolts 12 Slide the tubular housing downward until the safety clamp butts against the edge of the slot in the upper column and the collap...

Page 171: ...ng the column bushes Refitting 11 Enter the upper steering column in the tubular housing and carefully engage the lower steering column 12 Align the milled flat in the lower column with the slot in the upper column and fit the safety clamp but do not tighten the securing bolts 13 Slide the tubular housing downward until the safety clamp butts against the edge of the slot in the upper column and th...

Page 172: ...umn 6 Enter the lower column in the upper column ensuring that the nylon washer is located below the tubular housing 7 Align the slot in the upper column with the milled flat in the lower column and fit the safety clamp Do not tighten the securing bolts 8 Telescope the upper and lower columns to reduce their combined overall length as far as possible but do not apply force 9 Ensure that turning cl...

Page 173: ... models 2 Remove the steering wheel 57 60 01 3 Remove the trafficator switch cancelling clip 4 Prise off the end cap from the lower end of the tubular housing 5 Remove the circlip and slide off the washer 6 Release the steering lock and withdraw the steering mast n Refitting 7 Reverse instructions 1 to 6 Triumph Toledo Manual Part No 545168 Issue 1 57 40 06 ...

Page 174: ...using and withdraw the upper bush 4 Withdraw the end cap from the tubular housing and repeat instruction 3 for the lower bush Refitting 5 Insert the upper and lower bushes into the tubular housing ensuring that the rubber dowels engage the holes in the housing 6 Fit the end cap to the tubular housing 7 Install the upper and lower columns where applic able or the single column in the tubular housin...

Page 175: ...ersal joint to the column and the flexible joint to the rack pinion 7 Fit the U bolts to the rack and tighten 8 Fit the pinch bolts to the universal joint and flexible coupling INTERMEDIATE SHAFT FLEXIBLE COUPLING Remove and refit 57 40 25 Removing 1 Remove the intermediate shaft 57 40 22 2 Remove the pinch bolt securing the flexible coupling to the intermediate shaft and withdraw the flexible cou...

Page 176: ...es 7 Fit two new shear head bolts and tighten evenly until both heads shear 8 Connect the plug in connector for the ignition switch 9 Fit the nacelle o u TIE ROD BALL JOINT OUTER Remove and refit 57 55 02 Removing 1 Slacken the locknut securing the tie rod to the outer ball joint 2 Remove the nut and washer securing the ball joint to the steering arm 3 Release the ball joint from the steering arm ...

Page 177: ...adaptor torque 80 lbf ft 11 06 kgf m and check the ball end for end float and articulation End float should be within 0 0005 to 0 003 in 0 0127 to 0 0762 mm There must be no tight spots in articulation Adjust by adding or removing shims as necessary Shims available are 0 002 0 004 and 0 010 in 0 0508 0 1016 and 0 254 mm 12 If end float and articulation are satisfactory bend over the lock washer ta...

Page 178: ...the steering wheel from the steering mast Refitting 8 Engage the steering wheel hub on the steering column ensuring that the scribe marks are aligned If no markings are present set the road wheels in the straight ahead position with the steering wheel spokes horizontal 9 Fit the washer and nut to the steering column and tighten with the steering lock disengaged 10 Fit the nacelle halves and secure...

Page 179: ...obtain the required setting 0 to in 0 to 1 59 mm toe in 6 Tighten the locknuts at the tie rod outer ball jbints 7 Tighten the gaiter outer clips STEERING GEOMETRY Check 57 65 02 n Only two adjustments are possible Camber 57 65 05 and toe in 57 65 01 DATA Kerb condition A B Camber angle Castor angle King pin inclination Wheel alignment cpositive4 1 1 positive 1 l positive l 2i l 2 1 2i l 6i i 5 r 5...

Page 180: ...n stands 2 Slacken the four bolts and nuts 3 top 1 bottom securing the front suspension bracket to the sub frame 3 Remove shim s between the top of the bracket and the sub frame for negative adjustment add shim s for positive adjustment One shim equals approximately 1 degree camber angle 4 Tighten the suspension bracket bolts and nuts and remove the body stands ...

Page 181: ...st 60 25 13 bearings remove and refit 1 60 25 14 oil seals remove and refit 1 60 25 15 overhaul 60 25 07 remove and refit t 60 25 01 stub axle remove and refit 1 60 25 22 vkeel stud remove and refit 60 25 29 Radius rod remove and refit i 60 10 16 Road spring remove and refit Vertical link remove and refit Wishbone lower overhaul lower remove and refit upper remove and refit 60 20 01 60 25 23 60 35...

Page 182: ...n n n ...

Page 183: ... towards the outer rubber bush and nut 9 Fit the rear end o f the radius rod to the lower wishbone and secure it with the bolt and Nyloc nut Torque 50 to 65 lbf ft 7 0 to 9 0 kgf m 10 Tighten the nut at the front of the radius rod to 30 to 38 lbf ft 7 0 to 9 0 kgf m and insert the hairpin cotter 11 Remove the jack BALL JOINT UPPER n Remove and refit 60 15 02 Removing 1 Jack up the car support the ...

Page 184: ...using 5 Using a suitable chisel remove the plastic upper seat taking care to avoid damaging the housing Reassembling 6 Using the ball pin and vice carefully press the new upper seat into position 7 Fit the ball pin lower seat and circlip and check the ball pin for freedom of movement and end float The ball bearing should articulate freely and have a maximum end float of 0 004 in 0 1016 mm Three al...

Page 185: ...ve the lower seat 6 Clean all components and renew as necessary Reassembling 7 Fit the lower ball seat 8 Lubricate the ball with clean grease and insert it in the housing 9 Fit the upper ball seat 10 Fit the disc spring concave adjacent to ball seat 11 Fit the top cover circlip and sealing cap 12 Partially fill the rubber boot with clean grease and fit it to the housing Triumph Toledo Manual Part ...

Page 186: ... of the damper from the wishbone 6 Withdraw the damper and spring assembly from the turret 7 Remove the spacing washers from the mounting flange studs 8 Using tool S4221A and adaptors S4221A 5 and S4221A 18 compress the road spring until the upper mounting flange can be rotated freely 9 Remove the locknut and nut securing the upper mounting flange to the damper rod 10 Withdraw the mounting flange ...

Page 187: ...flange 17 Fit the insulating ring to the spring engaging the lip inside the coils 18 Fit the mounting flange to the damper rod ensuring that the centre of the flange engages the collar of the lower bush washer 19 Fit the lower washer of the upper rubber bush engaging the collar in the mounting flange 20 Fit the rubber bush and upper washer 21 Fit and tighten the damper rod nut 22 Fit and tighten t...

Page 188: ...b end float of 0 002 to 0 005 in 0 0508 to 0 1270 mm 10 Fit a new cotter pin to the slotted nut 11 Partially fill the hub cap with fresh grease and fit the cap to the hub 12 Fit the brake drum drum brakes only or disc brakes only 12a Fit the calliper to the vertical link 12b Fit the hose support bracket to the upper ball joint 13 Fit the road wheel and remove the jack FRONT HUB Overhaul 60 25 07 D...

Page 189: ... axle 6 Remove the cotter pin 7 Tighten or slacken the slotted nut as necessary to obtain 0 002 to 0 008 in 0 0508 to 0 2032 mm end float 8 Fit a new cotter pin 9 Clean the hub cap and partially fill it with fresh grease 10 Fit the hub cap 11 Fit the brake drum if removed and adjust the front brakes drum brakes only or disc brakes only 11a Fit the brake pads 12 Fit the front road wheel and remove ...

Page 190: ... 60 25 01 4 Remove the four bolts and spring washers securing the brake backplate to the vertical link drum brakes only 5 Remove the disc upper shield disc brakes only 6 Detach the backplate and suspend it on string or wire ensuring that the brake hose is relieved of stress drum brakes only 7 Remove the Nyloc nut washers and brake hose bracket from die upper wishbone ball joint 8 Detach the upper ...

Page 191: ...ng the front damper road spring assembly to the front suspension turret 4 Remove the nut and bolt securing the lower end of the damper to the wishbone 5 Slacken the two bolts securing the damper mounting plates to the wishbone and ball joint 6 Release the lower end of the damper from the wishbone and withdraw the damper and spring assembly from the turret Refitting 7 Ensure that the three spacing ...

Page 192: ...he lower wishbone from the bracket 4 Remove the two bolts and nuts securing the upper wishbone to the ball joint and damper 5 Detach the ball joint from the wishbone 6 Using string or wire support the hub assembly to the road spring to prevent strain being applied to the brake hose 7 Remove the four bolts and nuts three upper one lower securing the wishbone bracket to the sub frame 8 Withdraw the ...

Page 193: ...wishbone bracket and shim s to the sub frame and secure with the four bolts and nuts Fit the lower wishbone to the wishbone bracket and secure with the bolt and nut Do not tighten at this stage Engage the ball joint in the upper wishbone and insert the triangular plates Fit the two bolts and nuts to the wishbone arms plates and ball joint stem Fit the lower end of the damper to the wishbone and se...

Page 194: ... wishbone to the inner bracket 6 Remove the nut and bolt securing the radius rod to the wishbone 7 Withdraw the wishbone Refitting 8 Reverse instructions 1 to 7 Do not tighten the bolt and nut securing the wishbone to the inner bracket until the vehicle is resting on its wheels SUSPENSION WISHBONE LOWER Overhaul 60 35 09 1 Remove the lower wishbone from the car 60 35 02 2 Press out the wishbone ru...

Page 195: ...fit Rear hub oil seal remove and r e f i t remove and refit wheel studs remove and refit Road sprin g insulating ring remove and r e f i t remove and refit Suspension arm bushes remove and refit remove and refit 64 30 15 64 35 29 64 35 28 64 30 01 64 15 15 64 15 01 64 15 26 64 20 17 64 20 01 64 35 05 64 35 02 n Triumph Toledo Manual Part No 545168 Issue 1 64 1 ...

Page 196: ...ve the hub from the half shaft O Refit ing 6 7 8 9 Install the hub on the half shaft and fit the washer and nut If a new key is fitted it is essential to ensure that it does not prevent the half shaft from fully entering the hub Tighten the hub nut To prevent stress being trans mitted to the crown wheel and pinion teeth a tyre lever should be positioned across the wheel studs to resist tightening ...

Page 197: ... 64 15 26 Removing 1 Remove the rear wheel 2 Remove the brake drum 3 Tap out the wheel studs towards the brake back plate The removal of wheel studs is not recom mended unless for purposes of renewal Refitting 4 Enter the stud squarely in the hub flange ensuring that the countersunk faces on both the stud and the rear of hub flange are clean 5 Using suitable packing e g a short length of tubing an...

Page 198: ...mper eye bush and upper spring location plate The finishing tip of the upper coil of the spring should be located away from the car i e nearest the wheel to avoid adverse side loading on the damper spindle which may cause the spindle bearing to bind Fit the washers and lower rubber bush to the dam per rod ensuring that the collar of the upper washer is positioned to engage the mounting flange Fit ...

Page 199: ...e suspension arm from the body and lift out the damper Refitting 6 Reverse instructions 1 to 6 NOTE Where there is a depression in the spring cup it is fitted towards the rear of the car Do not fully tighten the bolt and nut securing the rear suspension arm to the body until the weight of the car is supported on the road wheels u u BUMP STOP Remove and refit 64 30 15 Removing 1 Remove the two bolt...

Page 200: ...e axle bracket Fit the retaining bolt and nut 7 Engage the lower end of the damper in the suspen sion arm Fit the retaining bolt and nut 8 Engage the front end of the suspension arm in the body bracket and fit the retaining bolt and nut 9 Remove the body stands and jack 10 Tighten the attachment bolts at the damper axle bracket and body bracket SUSPENSION ARM BUSHES Remove and refit 64 35 05 Remov...

Page 201: ... Fit the dished washer s to the screwed end of the radius rod ensuring that the curved peripheral rims of the washer s are inclined towards the bushed eye of the radius rod 7 Fit the inner rubber bush plain face of bush against washer s 8 Enter the screwed end of the radius rod in the axle bracket and engage the bushed end in the body bracket 9 Fit the bolt and nut to the body bracket 10 Fit the n...

Page 202: ... brake disc calliper remove and refit calliper seals remove and refit disc remove and refit disc shield lower remove and refit disc shield upper remove and refit pads remove and refit o Hand brake cable remove and refit cables adjust lever assembly remove and refit lever pawl and ratchet remove and refit 70 35 16 70 35 10 70 35 08 70 35 09 Hydraulic pipes 70 20 00 Master cylinder overhaul 70 30 02...

Page 203: ...just the brakes if previously slackened off 9 Fit the road wheel and remove the jack REAR BRAKE DRUM Remove and refit 70 10 03 n Removing 1 Jack up the car and remove the rear wheel 2 Release the hand brake 3 Remove the two countersunk screws securing the brake drum to the hub 4 Withdraw the brake drum Refitting 5 Align the countersunk holes in the drum with the tapped holes in the hub 6 Engage th...

Page 204: ...c to the stub axle 11 Adjust the bearing end float and fit the hub cap 60 25 01 12 Fit brake hose bracket to upper ball joint 13 Fit the calliper assembly 14 Fit the road wheel and remove the jack FRONT DISC SHIELD UPPER Remove and refit 70 10 18 Removing 1 Remove the upper bolt and spring washer securing the calliper to the vertical link 2 Remove the two bolts and spring washers securing the disc...

Page 205: ...l and remove the jack REAR BRAKE BACKPLATE Remove and refit 70 10 26 Removing 1 Jack up the car remove the rear wheel and release the hand brake 2 Remove the rear hub 64 15 01 3 Disconnect the hand brake cable at the rear of the backplate 4 Disconnect the fluid feed pipe union at the wheel cylinder left hand side only or Disconnect the fluid feed and transfer pipe unions at the wheel cylinder righ...

Page 206: ...s 1 to 3 Ensure that the hose is neither kinked nor twisted when installed 5 Bleed the brakes BRAKE HOSE REAR Remove and refit 70 15 17 Removing 1 Disconnect the brake pipes and unions from the forward and rearward ends of the flexible hose 2 Using two spanners remove the locknuts and washers securing the hose to the body and rear axle brackets Do not twist the hose 3 Remove the hose from the brac...

Page 207: ... brake pipe unions to the con nector 4 Bleed the brakes CONNECTOR 4 WAY Remove and refit 70 15 35 Removing 1 Clean the connector and unions 2 Disconnect the brake pipe unions from the con nector 3 Remove the bolt securing the connector to the scuttle Refitting 4 Reverse instructions 2 and 3 5 Bleed the brakes MTO 509 Triumph Toledo Manual Part No 545168 Issue 70 15 32 70 15 35 ...

Page 208: ...ector to R H front hose remove and refit 70 20 03 Pipe L H front hose to calliper wheel cylinder remove and refit 70 20 04 Pipe R H front hose to calliper wheel cylinder remove and refit 70 20 05 Pipe wheel cylinder to wheel cylinder front remove and refit 70 20 08 Pipe 4 way connector to 2 way connector remove and refit 70 20 14 Pipe R H rear cylinder to L H cylinder remove and refit 70 20 17 Pip...

Page 209: ...epeat the procedure on the right hand front wheel 9 Adjust the brakes m BRAKES Bleed Disc and drum 70 25 02 Do not allow the fluid level in the reservoir to fall below half capacity When topping up during the bleed ing process do not use aerated fluid exhausted from the system Do not bleed the system with the servo in operation engine running 1 Release the hand brake 2 Attach the bleed tube to the...

Page 210: ...tly to lock a road wheel it is indicative of extensively worn liners 6 Remove the jack Rear A single wedge type adjuster with a square ended shank is provided on the rear backplates 7 Jack up the rear of the car and release the hand brake 8 Rotate the adjuster clockwise viewed from the rear of the backplate until the wheel is locked 9 Rotate the adjuster anti clockwise until the wheel can be turne...

Page 211: ...tle 5 Withdraw the master cylinder n Refitting 6 Reverse instructions 1 to 5 7 Top up the reservoir with clean fluid 8 Bleed the brakes MASTER CYLINDER Remove and refit Servo only 70 30 01 Removing 1 2 3 Disconnect the brake pipe at the master cylinder Plug the master cylinder to prevent fluid discharge from the reservoir Seal the brake pipe to prevent ingress of foreign matter Remove the bolt sec...

Page 212: ... a new seal 9 Assemble the spacer spring and thimble to the valve stem 10 Remove the seal from the piston and fit a new seal seal lip towards the spring 11 Engage the sprihg thimble on the piston and care V v fully depress the thimble prong 12 Lubricate the bore of the master cylinder with clean brake fluid and insert the seal assembly spring and piston 13 Fit a new boot to the push rod 14 Fit the...

Page 213: ...the pedal 3 Remove the pedal bushes 4 Fit new bushes lubricate and insert new sleeve 5 Remove and renew the pedal pad rubber 6 Fit the pedal to the car 70 35 01 BRAKE PEDAL AND BRACKET Remove and refit 70 35 05 n Removing 1 Remove the fascia 2 Remove the windscreen wiper linkage 3 Remove the clevis pin securing the brake pedal to the master cylinder rod 4 Disconnect the pedal return spring 5 Remov...

Page 214: ...2 Remove the link gaiter and lower plate 3 Remove the nut and fulcrum pin from the hand brake mounting bracket 4 Withdraw the ratchet and bushes from the hand brake lever 5 Drill or file the riveted end of the pawl fulcrum pin until the end of the pin is flush with the hand brake lever 6 Depress the hand brake button and retain it in this position with tape 7 Remove the pawl fulcrum pin and withdr...

Page 215: ...le casing 5 Withdraw the cable fork through the bracket on the axle casing 6 Remove the pinch bolt nut and plain washers from the cable sheath front bracket 7 Withdraw the cable sheath rearwards clear of the front bracket and ease the cable wire downwards 8 Release the nipple on the front end of the cable from the hand brake compensator and withdraw the cable Triumph Toledo Manual Part No 545168 I...

Page 216: ...ying pressure to the piston and at the same time opening the calliper bleed nipple Close the nipple when the piston has moved the required amount and repeat on the opposite piston in the calliper Subsequent bleeding is not usually neces sary 6 Remove dust and clean the brake pad locations in the calliper 7 Fit brake pads complete with damping shims to the calliper Ensure that the angled edge of th...

Page 217: ...n spring 6 Withdraw the shoe 7 Repeat instructions 4 to 6 on the rear shoe Refitting 8 Offer up the bottom shoe to the backplate ensuring that the pointed end of the shoe web is adjacent to the front piston 9 Connect the return spring to the backplate and shoe web 10 Engage the rear end of the shoe trailing end in the rear cylinder 11 Engage the front end of the shoe in the front cylinder 12 Fit t...

Page 218: ... the rear shoe to the rear of the wheel cylinder slotted end of the front shoe to the front of the adjuster 9 Engage the upper spring ends in the holes in the shoe webs spring fitted inboard 10 Offer up both shoes to the backplate and engage the shoe ends in the adjuster 11 Engage the bottom end of the rear shoe in the hand brake lever and rear of the wheel cylinder 12 Fit the lower spring install...

Page 219: ...remove the brake shoes Refitting 8 9 10 11 12 13 14 15 16 Arrange the shoes in the manner in which they will be offered to the backplate Engage the upper spring ends in the shoe webs spring fitted inboard Offer up both shoes to the backplate and engage the shoe ends in the anchor plate Fit the lower spring ends to the shoe webs spring fitted inboard Engage the trailing shoe in the hand brake opera...

Page 220: ...of foreign matter 4 Remove the bolt securing the earth wires and the front end of the master cylinder bracket to the valance 5 Remove the two nuts and shakeproof washers securing the bracket and master cylinder to the servo and withdraw the bracket and master cylinder 6 Remove the four nuts and spring washers securing the servo to the scuttle and withdraw the master cylinder Refitting 7 Fit the se...

Page 221: ... disconnect the hose 3 Withdraw the non return valve from the servo Refitting 4 Renew the sealing rubber as necessary and press the non return valve into position in the servo 5 Connect the vacuum hose to the non return valve and tighten the hose clip BRAKE SERVO Renewing filter 70 50 25 n 1 Remove the servo from the car 70 50 01 2 Slide the rubber boot and end cap along the push rod 3 Remove the ...

Page 222: ...by using a low pressure air line Do not interchange the pistons 7 Prise out the cylinder seals taking care not to damage the cylinder bore 8 Thoroughly clean the caliper and pistons using brake fluid or methylated spirit If either pistons or bores are scored or corroded a new caliper must be obtained Reassembling 9 Carefully install new seals in the cylinder bores CAUTION Two types of caliper pist...

Page 223: ...ON To prevent water entering the brake assembly it is essential that the seal between the wheel cylinder and the back plate is in good condi tion and fitted correctly FRONT WHEEL CYLINDER Overhaul Drum brakes only 70 60 11 1 Remove the wheel cylinder 70 60 03 2 Remove the rubber boot 3 Withdraw the piston and seal 4 Thoroughly clean the cylinder and piston and examine for wear and scoring Renew th...

Page 224: ...eel cylinder complete with lever Refitting 10 Ensure that the wheel cylinder mounting faces and backplate are clean 11 Lightly smear the mounting faces on the wheel cylinder and both sides of the backplate with a zinc base grease 12 Install the lever in the wheel cylinder 13 Enter the wheel cylinder in the backplate 14 Install the spring plate from the rear of the back plate open end of plate towa...

Page 225: ...tions 1 to 9 11 Apply and release the hand brake several times to adjust the rear brakes 12 Bleed the brakes REAR WHEEL CYLINDER Manual brake adjustment Overhaul 70 60 26 1 Remove the wheel cylinder 70 16 18 Manual brake adjustment 2 Remove the clip retaining the rubber boot to the wheel cylinder body 3 Withdraw the piston complete with rubber boot and seal from the cylinder 4 Examine the piston a...

Page 226: ...d examine the cylinder and piston and renew as necessary 7 Check that the adjusting wheel rotates freely on the screwed rod 8 Smear the cylinder bore with clean brake fluid 9 Renew the piston seal and rubber boot and insert the piston in the cylinder 10 Fit the clip to the rubber boot 11 Insert the adjuster wheel and screwed rod in the cylinder ensuring that the adjustment is fully slackened off 1...

Page 227: ...EEL AND TYRE OPERATIONS Nave plate remove and refit Tyres general Wheel and tyre b a la n c e Wheels general remove and refit 74 20 02 74 10 00 74 15 00 74 20 00 74 20 01 n Triumph Toledo Manual Part No 545168 Issue 1 74 1 ...

Page 228: ...yres on the same axle 2 Do not fit radial ply tyres to the front wheels and cross ply to the rear wheels 3 With suitable tyre pressure adjustments it may be possible to obtain acceptable handling with cross ply tyres on the front wheels and radial ply tyres on the rear wheels but this combination is not recom mended Size type pressures The pressures recommended see chart provide optimum ride and h...

Page 229: ...ny oil or grease which may get onto the tyres should be cleaned off by using fuel sparingly Do not use paraffin kerosene which has a detrimental effect on rubber Repairs Tubeless tyres A temporary repair can be made to tubeless tyres using a special kit provided the puncturing hole is small and confined to the central tread area The following precautions must however be observed 1 Do not use more ...

Page 230: ...tre provide location for stainless steel nave plate Wheel location and retention on hubs by four f in U N F studs and nuts tightened to 38 to 45 lbf ft 5 2 to 6 2 kgf m Wheel tolerances 1 Wobble The lateral variation measured on the vertical inside face of a flange must not exceed 0 045 in 1 143 mm 2 Lift On a truly mounted and revolving wheel the difference between the high and low points measure...

Page 231: ... that wheel retaining nuts are refitted with chamfered ends inboard NAVE PLATE Remove and refit 74 20 02 Removing 1 Using special tool in tool kit insert hooked end between inner edge of nave plate and wheel 2 Holding nave plate at a point diametrically opposite to the tool lever the nave plate off the wheel location lugs Refitting 3 Place nave plate over two of the three retaining lugs on wheel a...

Page 232: ...Door handle front remove and refit Door handle rear remove and refit Door hinges front remove and refit Door hinges rear remove and refit Door lock front remove and refit Door lock rear remove and refit Door lock striker front remove and refit Door lock striker rear remove and refit Door lock remote control remove and refit Door private lock remove and refit Door push button remove and refit Door ...

Page 233: ... and refit Private lock remove and refit 76 67 01 76 67 06 76 37 39 Quarter light rear remove and refit Quarter vent remove and refit 76 31 31 76 31 28 Rear quarter trim pad remove and refit 76 13 03 Seat front driver remove and refit Seat front passenger remove and refit Seat belts front static remove and refit Seat belts rear static remove and refit Seat cushion rear remove and refit Seat cushio...

Page 234: ...ling holes in the floor side member Raise the rear of the car by jacking on a wooden beam placed under the front edge of the luggage compartment floor The beam must pass under the fyll width of the car and be notched to accept the exhaust and fuel feed pipes etc Support the rear suspension arms remove the for ward pivot bolts and fit transverse member No 2 Fit brackets S700 27 1 L H and S700 27 2 ...

Page 235: ...o 4 16 Fit brackets S700 49 1 L H and 700 49 2 R H locating the outer bracket bolt in hole C with the brackets located on the sub frame rear mounting tubes 17 Remove the adaptors S700 15 4 from transverse member assembly No 1 and fit adaptors S700 15 3 locating them in the sub frame front mounting tubes For rear end repairs proceed as follows 18 Fit transverse member No 1with the rear mounting hol...

Page 236: ...BODY n n Triumph Toledo Manual Part No 545168 Issue 1 76 10 01 Sheet 3 ...

Page 237: ... 1 3 57 0 060 90 68 1 53 2 3 19 0 030 81 03 0 76 3 l 47 0 030 37 3 0 76 4 6 256 0 010 158 9 0 25 5 1 72 0 060 43 69 l 53 6 30 20 0 030 767 1 0 76 7 23 06 0 060 585 7 l 53 8 11 53 0 030 292 9 0 76 9 26 50 0 060 673 1 1 53 10 5 01 127 2 11 6 95 176 5 76 10 04 Triumph Toledo Manual Part No 545168 Issue 1 ...

Page 238: ... radius rods from the sub frame and support the suspension units 5 Remove the nut and washer from the gearbox mounting rubber 6 Remove the four nuts and bolts from the engine mounting rubbers 7 Remove the steering rack 57 25 01 8 Support the sub frame 9 Remove the two nuts bolts and plain washers and the four retainers and mounting rubbers 10 Remove the two nuts bolts plain washers and retainers a...

Page 239: ...3 Pull the trim pad edges from the body flanges and detach Refitting 4 Reverse 1 to 3 using Dunlop SP758 adhesive on the trim pad and body flanges BONNET Remove and refit 76 16 01 Removing 1 Remove the four bolts spring washers and two location plates Lift off the bonnet Refitting 2 Reverse 1 ensuring correct alignment BONNET STAY Remove and refit 76 16 14 1 Remove the split pin washers and clevis...

Page 240: ...nd refit 76 16 29 Removing 1 Remove the trunnion 2 Slacken the pinch bolt 3 Pull the cable and clip from the catch plate 4 Unscrew the nut 5 Pull the cable out CAUTION Do not close the bonnet with the cable removed or loose Refitting 6 Reverse 1 to 5 n BONNET CATCH Remove and refit 76 16 34 Removing 1 Remove the two nuts spring washers and plain washers Remove the catch from the bonnet Refitting 2...

Page 241: ...al from the trunk lid using a suitably blunt tool if necessary Refitting 2 Fit the seal using Dunlop 758 LUGGAGE COMPARTMENT LID HINGES Remove and refit 76 19 07 Removing 1 Remove the lid 76 19 01 2 Disconnect the lead from the switch and pull it clear of the hinge 3 Remove the four nuts spring and plain washers 4 Remove one nut bolt plain washer and spring washer L H hinge only 5 Pull the hinges ...

Page 242: ...ve the three bolts spring washers and plain washers and lift off the latch 2 Disengage the retaining spring by tapping the spindle lightly with a hide hammer Withdraw the lock n Refitting 3 Locate the lock in the lock aperture slots and press firmly to engage the retaining spring 4 Reverse 1 MT2066 LUGGAGE COMPARTMENT LOCK STRIKER Remove and refit 76 19 12 Removing 1 Remove the three bolts spring ...

Page 243: ...ured by bolts passing through the body brackets into captive nuts behind the bumper rail BUMPER REAR Remove and refit 76 22 15 Removing Earlier 2 door models Instructions 3 and 4 only Other models Instructions 1 to 4 1 Remove the luggage compartment side trim pads 4 screws and washers 2 Remove the fuel tank 19 55 01 3 Remove two bolts spring washers plain washers and spacers 4 Remove the four bolt...

Page 244: ...gear lever grommet 37 16 05 5 Pull off the hand brake lever grip 6 Remove the 15 bolts 7 Remove the four nuts set screws on earlier cars 8 Break the seal between the tunnel cover and the floor and carefully lift out the tunnel cover over the gear lever Refitting 9 Reverse 1 to 8 Apply Seelastik to the mating surfaces of seal tunnel cover and floor Ensure that the seal retainers are correctly locat...

Page 245: ...olts and spring washers Refitting 6 Reverse 1 to 5 Check the door closing action and adjust if necessary DOOR REAR Remove and refit 76 28 02 Removing 1 Disconnect the battery 2 Remove the two bolts and spring washers 3 Support tl e door and remove the six bolts and spring washers Refitting 4 Reverse 1 to 3 Check the door closing action and adjust if necessary 76 28 01 76 28 02 Triumph Toledo Manua...

Page 246: ...3 Removing 1 Remove the door 76 28 02 2 Remove the hinges six bolts and spring washers MT 2078 Refitting 3 Reverse 1 and 2 DOOR GLASS FRONT Remove and refit 76 31 01 Removing 1 Remove the trim pad 76 34 01 2 Remove the glass stop three screws 3 Remove the anti drum stiffener three screws earlier models only 4 Wind the glass fully down and detach the regulator arm from the channel 5 Remove one bolt...

Page 247: ...egulator arm from the channel 4 Remove one bolt and plain washer 5 Drill out the rivet and pull the channel away from the quarter light glass 6 Detach the inner and outer door waist seals from the clips 7 Turn the glass sideways and lift it clear NOTE Avoid scratching the glass on the seal clips during removal Refitting 8 Reverse 1 to 7 u w 76 31 02 Triumph Toledo Manual Part No 545168 Issue 2 ...

Page 248: ...GHT REAR 4 door Remove and refit 76 31 31 Removing 1 Follow instructions 1 to 6 operation 76 31 02 2 Break the weatherstrip seal using a suitable blunt tool 3 Pull the glass out of the door frame Refitting 4 Reverse 1 to 3 using a new weatherstrip if neces sary and applying Seelastik to the mating surfaces before fitting REGULATOR DOOR GLASS Remove and refit front 76 31 45 rear 76 31 46 Removing 1...

Page 249: ...n washers and remove the arm rest 2 Refit in reverse order DOOR LOCK Remove and refit front rear 76 37 12 76 37 13 Removing 1 Remove the trim pad 76 34 01 76 34 04 2 Remove the water curtain 3 Release the linkages 4 Remove the four screws and pull the lock clear Refitting 5 Reverse 1 to 4 DOOR LOCK STRIKER Remove and refit front 76 37 23 rear 76 37 24 Removing 1 Remove the two screws and lift off ...

Page 250: ...3 PRIVATE LOCK FRONT DOOR Remove and refit Removing 1 Remove the trim pad 76 34 01 2 Remove the water curtain 3 Release the linkage 4 Remove the clip 5 Push the lock out Refitting 6 Reverse 1 to 5 76 37 39 j MT 2032 DOOR SEAL Remove and refit front rear 76 40 01 76 40 02 1 Pull the seal from the door using a suitable blunt tool 2 Ensure correct location in the channel when refitting Triumph Toledo...

Page 251: ...e the check strap Refitting 5 Reverse instructions 1 to 4 EXTERIOR MOULDINGS Remove and refit 76 43 06 The exterior mouldings fitted to the doors rear roof tonneau and luggage compartment lid are secured to the body by clips and retainers Removing 1 Starting at one end pull the moulding firmly and progressively away from the panel Refitting 2 Renew worn or damaged clips or retainers if any and rev...

Page 252: ...gage the speedometer drive 7 Disconnect the harness plugs 8 Remove the five screws and fix nuts 9 Remove the demister grille six screws 10 Remove one screw and washer 11 Remove two brackets screws and washers 12 Pull the hoses off the vents 13 Remove the speedometer 88 30 01 14 Remove the four nuts plain washers and spring washers 15 Lift the two centre studs and pull the fascia clear Refitting 16...

Page 253: ...g 5 Reverse 1 to 4 U CARPET GEARBOX COVER Remove and refit 76 49 01 1 Remove the gear lever knob and locknut 2 Remove the carpet 3 Refit in reverse order CARPET REAR Remove and refit 76 49 03 Removing 1 Remove the front seats 76 70 04 05 2 Remove the front seat belts buckle unit 76 73 05 3 Disconnect the four fasteners at the front and lift the carpet clear of the hand brake lever o Refitting 4 Re...

Page 254: ...et one screw and washer 2 Withdraw the lock Refitting 3 Reverse 1 and 2 FRONT GRILLE Remove and refit 76 55 03 Removing 1 Remove the four nuts bolts and plain washers On later models the four nuts and studs are re placed by nylon fix nuts and self tapping screws 2 Withdraw the grille and rim NOTE A separate grille and rim are fitted on early models The grille is additionally secured by two rivets ...

Page 255: ...age from the lock 4 Remove the two nuts spring washers and plain washers and remove the handle Refitting 5 Reverse 1 to 4 u DOOR PUSH BUTTON Remove and refit 76 58 12 Removing 1 Remove the door handle 76 58 01 76 58 02 2 Remove the two nuts and detach the push button Refitting 3 Reverse 1 and 2 76 58 01 76 58 12 Triumph Toledo Manual Part No 545168 Issue 1 ...

Page 256: ...draught welts 12 Remove the safety harness top bolts 13 Remove the B post trims 76 13 08 14 Pull the lining edges away from the body flanges 15 Detach the listing rails and remove the headlining Refitting 16 Apply a two inch border of Dunlop SP758 adhesive to the headlining around the roof light aperture and on the body flanges Allow 10 minutes for the adhesive to become tacky 17 Reverse 1 to 15 c...

Page 257: ...lts nuts and washers 7 Remove the strap two screws and washers 8 Pull the parcel shelf clear Refitting 9 Reverse 1 to 8 PARCEL SHELF REAR Remove and refit 76 67 06 1 From inside the luggage compartment remove the four screws and plain washers securing the under side of the shelf to the squab support 2 Lift out the shelf 3 Refit in reverse order i j ASHTRAY Remove and refit front 76 67 13 rear 76 6...

Page 258: ...moving 1 Remove the seat s 76 70 04 76 70 05 2 Remove the squab cover 13 clips Refitting 3 Reverse 1 and 2 SEATS FRONT Remove and refit Driver s seat Passenger s seat 76 70 04 76 70 05 Removing 1 Move the seat fully forward 2 Remove the two bolts 3 Move the seat fully rearwards 4 Remove the two bolts 5 Lift out the seat complete with runners Refitting 6 Ensure that the packing washers are correctl...

Page 259: ... off the clip and detach the cable 3 Pull off the knob 4 Remove the escutcheon two screws 5 Remove the squab cover 76 70 03 6 Remove one bolt 7 Pull off the clip remove the cable and lever assembly SEAT CUSHION REAR Remove and refit 76 70 37 SEAT SQUAB REAR Remove and refit 76 70 38 Removing 1 Raise the cushion front clear of the spring clip 2 Lift out the cushion 3 Remove the two screws 4 Lift ou...

Page 260: ...and bolt to sill 5 Remove the bolt and spring washer from the tunnel then refit together with the buckle unit SEAT BELT STATIC REAR Fitting 76 73 17 n 1 Remove the rear seat cushion 76 70 37 2 Remove the plugs 3 Prise up the rear deck trim panel to reveal the fixing points Cut through the trim above these points shoulder strap type belts only 4 Fit the seat belt in accordance with the manu facture...

Page 261: ...nly and weatherstrip noting positions for refitting Refitting 5 Reverse 4 using new weatherstrip if necessary and applying Seelastik to the glass channel before fitting 6 Insert a strong cord into the weatherstrip inner channel allowing the ends to protrude from the lower edge 7 Have an assistant position the glass centrally in the aperture and maintain a steady pressure whilst the cord ends are p...

Page 262: ...20 17 80 10 22 Heater unit control assembly remove and refit fan switch remove and refit remove and refit water valve remove and refit 80 10 02 80 10 22 80 20 01 80 10 16 Heating and ventilation d e scrip tio n 80 00 00 Pipe water pump to heater hose remove and re fit 80 25 16 Swivelling cold air vent L H remove and refit R H remove and refit 80 15 22 80 15 23 Water hose engine to heater remove an...

Page 263: ... thewatervalve sothat the heater is no longer effective Cold air ventilation Move the right hand lever to the cold position and set the left hand lever to screen or screen and car as required Place the central lever in its midway position Further movement of the lever will operate the blower to provide greater air flow if needed The left hand lever operates the bottom flap F which when moved to it...

Page 264: ...elftrim panel into the luggage compartment From there it passes up through the side tonneau panels into the roof and out through the louvres over the back light Flap valves are located in the louvres preventing air entering the car but allowing stale air to flow out CONTROL ASSEMBLY Remove and refit 80 10 02 Removing 1 Remove the fascia 76 46 01 2 Follow instructions 3 to 5 inclusive operation 80 ...

Page 265: ...2 Slacken the screw and remove the retainer 3 Withdraw the valve assembly Refitting 4 Reverse 1 to 3 ensuring that the control rod is positioned to allow free movement of the valve MT 2 164 FAN SWITCH Remove and refit 80 10 22 Removing la Later models Where the heater control knobs are secured by clips pull off the knobs or 1b Earlier models Remove the three grub screws and pull off the heater con...

Page 266: ...is secured to the fan motor by three screws SWIVELLING COLD AIR VENT Remove and refit L H 80 15 22 R H 80 15 23 Removing 1 Remove the cold air hose 2 Remove the two nuts spring washers and plain washers 3 Withdraw the vent from behind the fascia Refitting 4 Reverse instructions 1 to 3 ...

Page 267: ... matrix n Refitting 10 Reverse 1 to 9 applying Seelastik S R 51 to the dash seals and rear fixing brackets FAN MOTOR Remove and refit 80 20 15 Removing 1 Remove the screen washer bottle R H Stg only 2 Disconnect the three leads 3 Slacken the trunnion bolt detach the cable and clip 4 Remove the air tube two clips 5 Remove the fan motor three bolts spring washers and plain washers Refitting 6 Revers...

Page 268: ...d refit Feed hose 80 25 07 Return hose 80 25 10 The heater water hoses are each secured by two clips Drain the cooling system before removal PIPE WATER PUMP TO HEATER HOSE U Remove and refit 80 25 16 The pipe is secured to the water pump by a tubular nut and is also retained by the rear manifold fixing stud 80 20 17 80 25 16 Triumph Toledo Manual Part No 545168 ...

Page 269: ...voir remove and refit switch remove and refit 84 10 09 84 10 21 84 10 24 84 10 21 84 10 01 refer to 86 65 41 Windscreen wiper system data and description linkage remove and refit motor overhaul motor remove and refit switch remove and refit wiper arm remove and refit wiper blade remove and refit 84 15 00 84 15 26 84 15 18 84 15 12 84 65 38 84 15 01 84 15 05 n Triumph Toledo Manual Part No 545168 I...

Page 270: ...84 10 09 Removing 1 Remove the two screws and washers 2 Pull the pipe from the jet Refitting n 3 Reverse 1 to 2 4 Close the bonnet and operate the pump to check the jet aim Thejet must pass unobstructed through a bonnet air intake louvre and provide satisfactory windscreen washing 5 If necessary adjust the jet aim by slight bending of the jet tube bracket or slackening the two screws and repositio...

Page 271: ...y Remove and refit 84 10 21 Removing 1 Disconnect two Lucar connectors 2 Remove the cover Pull off the outlet pipe and withdraw it from the cover Refit the cover 3 Manoeuvre the unit upwards from the carrier Refitting 4 Reverse instructions 1 to 3 To ensure that the motor runs in the correct direction observe polarity Connect the Lucar connectors as follows Light green black wire to the positive t...

Page 272: ... interior of the pump as detailed below but no individual Stanpart spare parts are available Dismantle 1 Rotate the cover anti clockwise to release the bayonet fitting Lift the pump and cover assembly from the reservoir 2 Remove two screws 3 Lift off the pump housing 4 Carefully withdraw the rotor and rotor drive plate 5 Lift out the rubber O ring 6 Lift off the seal housing 7 Withdraw the seal fr...

Page 273: ...cted the positive supply is transferred from the normal speed brush to the high speed brush A switching feature stops the blades in the park position irrespective of their position when the fascia switch is selected off This is effected by a two stage switch unit in the gearbox Two static contacts are swept by a slip ring arrangement on the final gear When the fascia switch is selected off the mot...

Page 274: ...to 3 Used when two speed wiper motor and electric washer pump are fitted to vehicle PARK 1 to 2 NORMAL SPEED 2 to 3 HIGH SPEED 3 to 4 2 Normal supply brush 3 High speed brush Two speed wiper motor only 4 Permanent magnet 5 Earth brush 6 Final gear slip ring arrange ment 7 Static contacts Triumph Toledo Manual Part No 545168 Issue 1 84 15 00 Sheet 2 ...

Page 275: ... against the spring to adopt its service position 6 Locate the splines for a suitable park position Push on to engage the clip to the spindle groove 7 Lower the wiper arm to the screen WINDSCREEN WIPER BLADE Remove and refit 84 15 05 Removing 1 Lift the wiper arm and blade from the screen so that it falls into its service position 2 Simultaneously lift the clip A tilt cage B and gently pull the wi...

Page 276: ...e the battery 2 Remove the motor shaft nut and withdraw the crank 3 Remove the three screws and lift off the motor 4 Disconnect the four Lucar connectors from the motor 5 Collect the six washers and three spacers Refitting 6 Reverse 1 to 5 n r Triumph Toledo Manual Part No 545168 Issue 1 84 15 12 ...

Page 277: ...emperature water resistant grease 17 Reverse 12 to 15 18 Reverse 5 to 9 19 Ensure that earth brush is not hidden under brush plate 20 Ensure that brushes are not contaminated with grease 21 Fit two springs and brushes and retain deep in brushbox using slave clips locally made from paper clips or similar wire as shown 22 Carefully insert armature shaft through bearing screwing in as required to eng...

Page 278: ...WINDSCREEN WIPERS AND WASHERS ...

Page 279: ...he two buttons to release the millboard cover 6 Remove the six bolts 7 Remove the two wiper arms 84 15 01 8 Remove the two spindle nuts and rubber washers 9 Withdraw the linkage and motor assembly from the vehicle 10 Remove the motor shaft nut and withdraw the crank 11 Remove the three screws and lift off the motor 12 Collect the six washers and three spacers Refitting 13 Reverse 1 to 12 84 15 26 ...

Page 280: ...y remove and refit contact gap adjust data and description ignition timing adjust lu b ric a tio n overhaul remove and refit 86 35 13 86 35 14 86 35 00 86 35 15 86 35 18 86 35 26 86 35 20 Lamps front parking and flasher lamp remove and refit headlamp beam a i m i n g headlamp remove and refit plate illumination lamp remove and refit rear tail stop and flasher lamp remove and refit roof lamp remove...

Page 281: ...t steering column combination switch remove and refit stop lamp switch remove and refit windscreen wiper switch remove and refit 86 65 00 86 65 14 80 10 22 86 65 02 86 65 22 86 65 09 86 65 30 86 45 02 86 65 55 86 65 51 86 65 38 Wiring diagram left hand steer maximum equipment condition left hand steer minimum equipment condition right hand steer 1970 to 1972 models right hand steer 1973 model 86 0...

Page 282: ...89 59467 Front flasher lamps 21 382 GLB382 502379 Rear flasher lamps 21 382 GLB382 502379 Tail stop l a m p s 5 21 380 GLB380 502287 Plate illumination la m p s 5 501 GLB501 514797 Luggage boot illumination 2 2 987 GLB987 59492 Roof la m p 6 254 GLB254 59897 Instrument illum ination 2 2 987 GLB987 59492 Warning lights 2 2 987 GLB987 59492 Sealed beam light unit o Triumph Toledo Manual Part No 5451...

Page 283: ...WIRING DIAGRAM TOLEDO RIGHT HAND STEER 1970 TO 1972 MODELS ELECTRICAL L 094 ...

Page 284: ...uggage boot lamp 41 Stop lamp 8 Ballast resistor 25 Luggage boot lamp switch 42 Turn signal flasher unit 9 Ignition coil 6 volt 26 Roof lamp 43 Turn signal switch 10 Ignition distributor 27 Door switch 44 L H front flasher lamp 11 Connector block 28 Voltage stabilizer 45 L H rear flasher lamp 12 Master light switch 29 Temperature indicator 46 L H turn signal warning light 13 Main dip flash switch ...

Page 285: ...Triumph Toledo Manual Part No 545168 86 00 04 ...

Page 286: ...ing to both wiring diagrams service personnel should be able to obtain total wiring diagram information for any specific vehicle The primary electrical equipment variations are as follows MINIMUM EQUIPMENT CONDITION MAXIMUM EQUIPMENT CONDITION Starter motor with conventional inertia drive Starter motor with pre engage drive for cold climate markets Single speed windscreen wiper motor Two speed win...

Page 287: ...Triumph Toledo Manual Part N o 545168 Issue 1 oo 8 8 WIRING DIAGRAM TOLEDO LEFT HAND STEER MINIMUM EQUIPMENT CONDITION Please see page 86 00 05 ELECTRICAL ...

Page 288: ...er motor 24 Luggage boot lamp 41 Stop lamp 8 Ballast resistor 25 Luggage boot lamp switch 42 Turn signal flasher unit 9 Ignition coil 6 volt 26 Roof lamp 43 Turn signal switch 10 Ignition distributor 27 Door switch 44 L H front flasher lamp 11 Connector block 28 Voltage stabilizer 45 L H rear flasher lamp 12 Master light switch 29 Temperature indicator 46 L H turn signal warning light 13 Main dip ...

Page 289: ...Triumph Toledo Manual Part N o 545168 Issue 1 WIRING DIAGRAM TOLEDO LEFT HAND STEER MAXIMUM EQUIPMENT CONDITION OO as o o OO Please see page 86 00 05 ELECTRICAL ...

Page 290: ...ight switch 31 Fuel indicator 50 13 Main dip flash switch 32 Fuel tank unit 51 14 Main beam warning light 33 Heater motor 52 15 Main beam 34 Heater resistor 53 16 Dip beam 35 Heater switch 54 17 Front parking lamp 36 Stop lamp switch 55 o o ON 18 Plate illumination lamp 37 Stop lamp 56 W b VO 19 Tail lamp 38 Windscreen wiper switch 57 Windscreen wiper motor Windscreen washer pump Windscreen washer...

Page 291: ...ELECTRICAL O ...

Page 292: ...boot lamp switch 48 L H rear flasher lamp 10 Ignition distributor 30 Voltage stabilizer 49 L H front flasher lamp 11 Connector block 31 Temperature indicator 50 L H turn signal warning light 12 Master light switch 32 Temperature transmitter 51 R H front flasher lamp 13 Main dip flash switch 33 Fuel indicator 52 R H rear flasher lamp 14 Main beam warning light 34 Fuel transmitter 53 R H turn signal...

Page 293: ...ELECTRICAL ALTERNATOR WIRING DIAGRAM Manufacturer Lucas Type 15ACR k 86 10 00 Sheet 1 Triumph Toledo Manual Part No 545168 Issue ...

Page 294: ...tor Controls field winding earth return circuit R1 and R2 Potential divider Senses battery reference voltage ZD Zener diode Voltage sensitive component Opposes passage of current until breakdown voltage approximately 8 volts is reached Controls T1 base current direct T1 Input transistor Controls T2 base current by diverting current passing through R3 to earth when ZD is conducting Cl and R4 Capaci...

Page 295: ...may be irreparably damaged if subjected to incorrect polarity Observe polarity of alternator and battery terminals 5 Do not connect the variable resistor across the battery for longer than is necessary to perform the check 6 Run the engine 7 Gradually increase the speed At 1 500 alternator rev min 620 engine rev min the light should be extinguished 8 Hold the speed at approximately 6 000 alternato...

Page 296: ...peed At 1 500 alternator rev min 620 engine rev min the light should be extinguished Hold the speed at approximately 6 000 alternator rev min 2 480 engine rev min The voltmeter reading should now be steady at 14 0 to 14 4 volts If the voltmeter reading is not steady at the above figure and a satisfactory Check capacity to pro duce current has been performed the indication is that the control unit ...

Page 297: ... towards the engine and fit the drive belt to the pulley 9 Adjust the drive belt 86 10 05 10 Connect the multi socket connectors ALTERNATOR Drive belt adjust 86 10 05 1 Slacken the main mounting bolt assembly and the two adjustment bracket bolts 2 Carefully lever the alternator away from the engine to tension the belt CAUTION To prevent bearing damage when tensioning the belt use a lever of soft m...

Page 298: ...l to engage with the outer journal of the slip ring end bearing Employ a second operator to support the slip ring end bracket by hand Care fully tap the extractor tool to drive the bearing from the housing NOTE It may be necessary to carefully file away surplus solder from the two field winding connec tions on the slip ring moulding if the extractor tool will not pass over the moulding 10 The rubb...

Page 299: ... Ensure that the rubber O ring is fitted correctly in the slip ring end bracket bearing housing 21 Fit the slip ring end bracket by carefully pushing the bearing into the housing 22 Fit the through bolts tightening evenly 23 Ensure that the rubber locating piece is correctly fitted to the rectifier pack Position the rectifier pack and secure it with the nut 24 Position the three stator wires on re...

Page 300: ...mbly 3 Lift the battery from the vehicle n Refitting 4 Lift the battery into the tray 5 Swing up the battery retaining assembly Tighten the nuts 6 Fit the battery leads Do not hammer the terminals to the terminal posts 7 Coat the terminals with petroleum jelly Vaseline to prevent corrosion n Triumph Toledo Manual Part No 545168 Issue 86 15 01 ...

Page 301: ...tured below Data information for each unit is given on the following pages IGNITION DISTRIBUTOR APPLICABILITY CHART Power units Ignition distributor Stanpart No 1300 Single carburetter 1500 Single carburetter 1500 Twin carburetter 212292 Fitted up to Engine No DG 25000 H or L 217031 X Fitted up to Engine No DM 5000 H or L 217613 Fitted up to Engine No DS 5000 H or L 218106 Fitted from Engine No DG...

Page 302: ...Advance Check at decelerating speeds Distributor rev min Degs distributor advance Crankshaft rev min Degs crankshaft advance Minimum Maximum Minimum Maximum Below 300 No advan e to occur Below 600 No advanc 5to occur 400 0 1 0 800 0 2 550 0 5 2 5 1 100 1 5 850 3 5 5 5 1 700 7 11 1 100 6 0 8 0 2 200 12 16 1 500 6 0 8 0 3 000 12 16 n Vacuum Advance Inches of Degs distributor advance Degs crankshaft ...

Page 303: ...mfd 1 3 4 2 5 14 9 Centrifugal Advance Check at decelerating speeds Distributor rev min Degs distributor advance Crankshaft rev min Degs crankshaft advance Minimum Maximum Minimum Maximum Below 2Q0 No advan e to occur Below 400 No advanoe to occur 300 0 1 600 0 2 800 1 3 1 600 2 6 2 000 6 8 4 000 12 16 2 800 8 10 5 600 16 20 Vacuum Advance U Inches of Degs distributor advance Degs crankshaft advan...

Page 304: ...gal Advance Check at decelerating speeds Distributor rev min Degs distributor advance Crankshaft rev min Degs crankshaft advance Minimum Maximum Minimum Maximum Below 200 No adv ii e to occur Below 400 No advanoe to occur 400 0 5 2 5 800 1 5 700 5 0 7 0 1400 10 14 900 6 0 8 0 1800 12 16 2200 110 13 0 4400 22 26 3000 14 0 16 0 6000 28 32 Vacuum Advance Inches of Degs distributor advance Degs cranks...

Page 305: ...gal Advance Check at decelerating speeds Distributor rev min Degs distributor advance Crankshaft rev min Degs crankshaft advance Minimum Maximum Minimum Maximum Below 450 No advance to occur Below 900 No advancis to occur 600 0 5 2 5 1200 1 5 800 3 0 5 0 1600 6 10 1400 5 0 7 0 2800 10 14 1900 6 5 8 5 3800 13 17 2800 7 0 9 0 5600 14 18 Vacuum Advance Inches of Degs distributor advance Degs cranksha...

Page 306: ... supply to the ignition coil This unit causes a voltage drop in the circuit so that the 12 volt supply from the ignition switch may be employed to power the nominally rated 6 volt ignition coil During engine start the resistor is by passed and the battery voltage reduced from 12 volt by the starter motor load is applied to the coil direct from the starter solenoid This slight voltage overload prov...

Page 307: ...e metal nut to the nylon thread finger tight Tighten by rotating half a turn only with a spanner 11 Adjust the contact gap 86 35 14 2 10 3 9 5 7 4 8 IGNITION DISTRIBUTOR Contact gap adjust 86 35 14 1 Remove the cover and rotor 2 Rotate the crankshaft to position the contact heel on a cam peak 3 Slacken the lock screw 4 Position a 0 014 to 0 016 in 0 36 to 0 41 mm feeler gauge between the contacts ...

Page 308: ...When the timing is correct operations 8 to 10 may be ignored 8 If a small correction is required rotate the micro meter adjustment nut to advance or retard the timing 9 If a large correction is required centre the micro meter adjustment nut and slacken the clamp bolt Align the pulley notch with the 9 degree BEFORE on the scale Rotate the distributor bqdy anti clockwise past the test lamp illuminat...

Page 309: ...t 86 35 20 Removing 1 Pull off the high tension connection to the ignition coil 2 Pull off the four high tension connections to the spark plugs 3 Remove the distributor cover 4 Disconnect the low tension Lucar connector from the distributor 5 Pull off the vacuum timing control pipe 6 Remove the nut washer and bolt to release the clamp plate from the pedestal 7 Withdraw the distributor from the ped...

Page 310: ...e 12 Lubricate the cam spindle bearing and cam spindle weight pillars with Rocol Moly pad Fit the cam spindle either way round to the weights and secure it with the cam spindle screw 13 Fit the control springs exercising care not to distort the springs 14 Lubricate the shaft with Rocol Moly pad and insert it into the body Fit the thrust washer and coupling Ensure that the coupling is the correct w...

Page 311: ...ucar connectors as follows White yellow wire to positive terminal White black wire to negative terminal IGNITION COIL AND BALLAST RESISTOR Ballast resistor remove and refit 86 35 33 Removing 1 Locate the ballast resistor on the left hand engine bay valance adjacent to the ignition coil 2 Disconnect the Lucar connectors 3 Remove the screw spring washer and washer and lift out the ballast resistor k...

Page 312: ...s breakout With draw the housing assembly 6 Later vehicles only To remove the housing assembly drill out three Pop rivets Remove one screw Lift the bonnet Disconnect the appropriate connections at the harness breakout Withdraw the housing assembly Refitting 7 Reverse 1 to 6 LAMPS Headlamp beam aiming Two holes in the rim make it possible to adjust the beams without removing the grille and rim moul...

Page 313: ...boot lid 2 Remove the luggage boot floor covering 3 Right hand lamp only Remove the floor panel 4 Remove the two screws and withdraw the side trim panel 5 Disconnect the earth Lucar connector from the lamp base 6 Pull the two bulb holders from the lamp base Remove the bulbs from the bayonet fittings 7 Remove the four nuts spring washers and washers Withdraw the lamp assembly from the panel 8 Remov...

Page 314: ...battery 2 Rotate the lens until the two screws are exposed 3 Remove the screws and lower the lamp 4 Carefully remove the festoon bulb 5 Note the wire colour codes and positions 6 Disconnect the three Lucar connectors Refitting 7 Reverse 1 to 6 LAMPS Roof lamp remove and refit 86 45 02 Later vehicles only Removing 1 Isolate the battery 2 Gently squeeze the lens adjacent to the clip pro jections and...

Page 315: ...e vehicle Refitting 9 Reverse 1 to 8 Ensure that the battery lead starter motor lead and four Lucarconnectors are positioned as shown Ensure good electrical contact between the solenoid and the vehicle body B Battery lead N Brown wire WY White yellow wire N Brown wire WR White red wire SM Starter motor lead FLASHER UNIT Turn signal flasher unit remove and refit 86 55 11 Removing 1 Locate the flash...

Page 316: ...the commutator end bracket It holds four wedge shaped brushes and captive coil springs The brushes are keyed to ensure correct fitting The field winding is a continuously wound strip with no joints One end is attached to two brush flexibles while the other is attached to a single flexible which is earthed to the yoke The yoke is windowless and has no through bolts The commutator end bracket is sec...

Page 317: ... Dismantle the starter motor 86 60 13 operations 1 to 5 2 Using a suitable press compress the main spring and ease the jump ring from the shaft Churchill hand press S4221A and adaptor S4221A 14 may be employed to perform this operation 3 Withdraw the inertia drive components from the shaft Refitting 4 Lightly lubricate the drive end bracket bush with thin engine oil Position the drive end bracket ...

Page 318: ...ket armature and inertia drive assembly complete from the yoke 3 Remove the thrust washer 4 Remove the four bolts and lift aside the commutator end bracket 5 Lift out the two field winding brushes from the brush box to separate the commutator end bracket from the yoke continued n n n 86 60 13 Sheet 1 Triumph Toledo Manual Part No 545168 Issue 2 ...

Page 319: ...ze bearing bushes for wear 12 If necessary renew the commutator end bracket bush Drill out the two rivets and discard the plate and felt seal Screw a in tap squarely into the bush and withdraw Prepare the porous bronze bush by immersing it in thin engine oil for 24 hours Using a highly polished shouldered mandrel suitably dimensioned and a suitable press fit the bush Do not ream the bush after fit...

Page 320: ... the ends of the old flexible Do not attempt to solder direct to the field winding strip as the strip may be produced from aluminium Field winding 20 If necessary check the field winding insulation from the yoke as follows Drill out the rivet at the earth connection Apply the normal 110 volt a c test lamp circuit to the field winding and yoke Do not attempt to disconnect the flexible from the fiel...

Page 321: ...tion Head No connections 4 to 1 4 to 1 to 8 Steering column combination switch View on switch harness plug U to UW U to U R P to UW LG NtoGR LG N to GW PBtoB Position Head main Position Head dip Position Head flash Position L H turn signal Position R H turn signal Position Horn Windscreen wiper switch Used when single speed wiper motor isfitted to vehicle Terminal 4 is not used Position Park 1 to ...

Page 322: ...sition Position Position Position Park Normal speed High speed Wash 1 to 2 2 to 3 3 to 4 Two centre terminals connected Hazard switch Used when hazard warning system is fitted to vehicle Terminal 4 is not used Position Off 7 to 8 Position Hazard 1 to 2 to 3 n r Triumph Toledo Manual Part No S45168 Issue 1 86 65 00 Sheet 2 ...

Page 323: ... any tape holding the harnesses to the column 9 Carefully withdraw the switch harness and remove the switch unit from the vehicle Refitting 10 Reverse 1 to 9 When inserting the switch to the steering column lock assembly note the keyway and ensure that the lock shaft and switch are aligned for correct engagement SWITCHES Master light switch remove and refit 86 65 09 Removing 1 Isolate the battery ...

Page 324: ...to 4 SWITCHES Luggage boot illumination switch remove and refit 86 65 22 Removing 1 Open the luggage boot lid 2 Locate the switch mounted on the right hand hinge assembly 3 Pull the switch from the bracket 4 Disconnect the terminal end Refitting 5 Reverse 1 to 4 Ensure good electrical contact between the switch and the vehicle body n Triumph Toledo Manual Part No 545168 Issue 1 86 65 14 86 65 22 ...

Page 325: ...nderside of the knob Insert a suitable probe into the hole and while depressing pull the knob from the shaft 3 Use a suitable tool to slacken the bezel Support the switch behind the fascia and unscrew the bezel 4 Withdraw the switch from the fascia and manoeuvre it to a visible position 5 Note the wire colour codes and positions 6 Disconnect the three Lucar connectors 7 Prepare for minor water spi...

Page 326: ...pedal should be 0 60 in 15 24 mm with the brake pedal not operated 7 Switch on the ignition and perform functional check of the stop lamp circuit SWITCHES Steering column combination switch remove and refit 86 65 55 Removing 1 Isolate the battery 2 Remove the two screws and lift off nacelle upper half 3 Remove the single screw and detach nacelle lower half 4 Prise off the trim board four clips 76 ...

Page 327: ...Fuel indication Heater Reverse lamp optional extra Windscreen wiper Stop lamp Turn signal 35 White 188218 58465 FUSE SYSTEM Fuse remove and refit 86 70 02 Removing 1 Lift the bonnet and locate the fusebox on the bulkhead 2 Pull off the plastic cover 3 Identify the defective fuse 4 Carefully lever the fuse from the contacts Refitting 5 Reverse 1 to 4 86 70 00 86 70 02 Triumph Toledo Manual Part No ...

Page 328: ...d re fit Speedometer cable complete remove and refit Speedometer cable inner remove and refit Temperature indicator remove and refit Temperature transmitter remove and refit Voltage stabilizer remove and refit 88 00 01 88 25 26 88 25 32 88 30 01 88 30 06 88 30 07 88 25 14 88 25 20 88 20 26 n 88 1 Triumph Toledo Manual Part No 545168 Issue 1 ...

Page 329: ...INSTRUMENTS u 88 30 06 88 30 07 88 30 01 Triumph Toledo Manual Part No S4S168 Issue ...

Page 330: ...trument illumination 5 LG Lucar Fuel indicator 6 GB Lucar Fuel indicator 7 GR and B Bulb holder L H turn signal warning light 8 B Eyelet Earth 9 W and NY Bulb holder Ignition warning light 10 Wand WN Bulb holder Oil pressure warning light 11 UW and B Bulb holder Main beam warning light 12 R and B Bulb holder Instrument illumination 88 00 01 Triumph Toledo Manual Part No 545168 Issue 1 ...

Page 331: ... on the bulkhead above the fuse box 3 Disconnect the two Lucar connectors 4 Remove the screw to release the voltage stabilizer Refitting 5 Reverse 1 to 4 Connect the Lucar connectors as follows Green wire to terminal B Light green wire to terminal I A t Tr 88 20 26 Triumph Toledo Manual Part No 545168 Issue ...

Page 332: ...ews and lift off temper ator unit Refitting 10 Reverse 1 11 to 9 Ensure that the three bulb holders and four Lucar connectors are positioned as shown on fasciaj connections 88 00 01 Include the earth lead eyelet under the spring washer and knurled nut Switch oh the ignition and perform a functional check of jthe turn signal circuit to ensure that the left hand and right hand warning lights give co...

Page 333: ...se 1 to 9 Ensure that the three bulb holders and four Lucar connectors are positioned as shown on fascia connections 88 00 01 Include the earth lead eyelet under the spring washer and knurled nut 11 Switch on the ignition and perform a functional check of the turn signal circuit to ensure that the left hand and right hand wafning lights give side indication FUEL TANK UNIT Remove and refit 88 25 32...

Page 334: ...nsure that the catch engages in the annular groove 11 Reverse 1to 6 Ensure that the four bulb holders are positioned as shown on fascia connections 88 00 01 SPEEDOMETER CABLE COMPLETE Remove and refit 88 30 06 Removing 1 Place the vehicle on a ramp 2 Withdraw the speedometer until it is possible to obtain access to the rear 88 30 01 operations 1to 3 3 Depress the lever to release the catch from th...

Page 335: ...e boss Pull the speedometer cable from the instrument 3 Using long nosed pliers withdraw the inner cable Take care not to contaminate the upholstery or fittings with grease Refitting 4 Sparingly grease the inner cable Do not use oil 5 Feed the inner cable into the outer cable Rotate slightly to assist operation 6 Withdraw the inner cable about 8 in 200 mm and wipe off surplus grease Re insert the ...

Page 336: ... bearing remover S 101 Differential case spreader S 4221 A 17 Pinion bearing remover replacer S 108 Pinion height setting gauge S 4221 A 18 Coil spring compressor S 109 C Hub remover S 4221 A 19 Mainshaft ball race remover replacer S 144 Mainshaft circlip remover 4235 A Slide hammer S 145 Mainshaft circlip replacer S 4235 A l Axle shaft remover S 304 Hub ball bearing replacer S 4235 A 2 Constant p...

Page 337: ......

Page 338: ...SERVICE TOOLS 550 Triumph Toledo Manual Part No 545168 Issue 2 99 00 02 ...

Page 339: ...SERVICE TOOLS S 4221 A 5 S 4221 A 17 S 6118 1 Triumph Toledo Manual Part No 545168 Issue 1 99 00 03 ...

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