Reliant Kitten Estate Page 138 Workshop Manual Download

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138

Drive shaft

Universal joint flange to axle/gearbox

5/16" UNF

3.46-4.15 kg/m

25-30 lb/ft

Rear axle

Axle case nuts

5/16" UNF

2.77-3.46 kg/m

20-25 lb/ft

Hub to half shaft nut

5/8" UNF

13.8-15.2 kg/m

100-110 lb/ft

Coupling flange pinion nut

5/8" UNF

9.67-11.75 kg/m

70-85 lb/ft

Axle filler/level plug

3/4" BSP

2.07-2.76 kg/m

15-20 lb/ft

Brakes

Front backplate to vertical link

5/16" UNF

2.50-3.18 kg/m

18-23 lb/ft

Rear backplate to axle

5/16" UNF

2.50-2.77 kg/m

18-20 lb/ft

Master cylinder mountings

5/16" UNF

2.50-3,18 kg/m

18-23 lb/ft

Road wheels

Wheel nuts

3/8" UNF

4.15-4.84 kg/m

30-35 lb/ft

Electrical

Alternator pivot bolts

5/16" UNF

2.08-2.77 kg/m

15-20 lb/ft

Alternator adjusting bolt

1.11-1.38 kg/m

8-10 lb/ft

Starter motor bolts

3/8" UNF

4.15-4.84 kg/m

30-35 lb/ft

Summary of Contents for Kitten Estate

Page 1: ...Page 1 Kitten Saloon and Estate Workshop Manual Incorporating the Factory supplement pack The Reliant Motor Company Limited July 1975 Remastered January 2011 by Atodini...

Page 2: ...151 Telegrams Reliant Tamworth 4151 Telex 341501 Parts Supply Department The Reliant Motor Company Limited Lynn Lane Shenstone Staffordshire WS14 0ED Telephone Shenstone 480671 Original R Part No 9104...

Page 3: ...rder 1 3 4 2 Ignition Timing 10 BTDC Cooling System Pressurised radiator pump assisted circulation and four bladed fan driven by a V belt from engine pulley Radiator cap pressure 0 492 kg sq cm 7 lbs...

Page 4: ...sill rear door aperture rear door aperture Load height maximum aperture 457 2 mm 19 in 749 3 mm 29 5 in 749 3 mm 29 5 in tailgate aperture height rear door aperture rear door aperture Load height maxi...

Page 5: ...p up rear axle oil X X X X X X Clean oil filler cap and connecting hose X X X X X X X Oil or grease all lubrication points X X X X X X X Lubricate throttle linkage and top up carburettor damper X X X...

Page 6: ...w dipstick Wipe clean and replace remove again and note oil level indicated by trace of oil to the full mark on the dipstick 2 If necessary top up with a recommended grade of oil to the full mark on t...

Page 7: ...level indicator visible in the filler neck Replace the filler cap Check leaks from cooling and heater system 1 Check hose connections and tightness of clips 2 Check radiator drain plug if fitted 3 Ch...

Page 8: ...k plugs 1 Remove each spark plug in turn from engine 2 Clean the electrodes with a wire brush or plug cleaner 3 Using a 0 64 mm 0 025 in feeler gauge check the gap and adjust if necessary by bending t...

Page 9: ...justing screw 3 Lock nut 5 refit the element or replace with a new element ensuring the plastic ends of the element are smeared with petroleum jelly or grease to facilitate sealing 6 Replace the body...

Page 10: ...of front mounting bolt 2 1 to 2 7 kg m 15 to 20 lb ft 2 Check alternator to strap locking screw 1 1 to 1 3 kg m 8 to 18 lb ft Check security of engine mountings The engine and gearbox assembly is sec...

Page 11: ...not kinked or strained when the steering is turned from lock to lock Examine the run of the fuel line from tank to carburettor and ensure that at no point is it chafing against the body or fouling co...

Page 12: ...d Saloon Estate Front 1 41 kg cm 20 lb in Rear 1 99 kg cm 28 lb in Van Rear 2 11 kg cm 30 lb in Check and adjust headlamp beam alignment The front grill bezel has two screwdriver holes for adjustment...

Page 13: ...unction Carry out any remedial work required indicated by the road test e g adjustment of brakes carburettor or ignition timing Note Specialist equipment is needed to ensure that carburation adjustmen...

Page 14: ...il SAE 80EP Spirax 80 EP Pontonic MP SAE 80 Hypoid 80 Multigear EP 80 Rear Axle Mobilube HD 90 Castrol Hypoy Esso Gear Oil GX 90 140 Gear Oil SAE 90 EP Spirax 90 EP Pontonic MP SAE 90 Hypoid 90 Multig...

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Page 16: ...d two retaining cups Note Access to the fixing on the r h side of the vehicle can be facilitated by the removal of the heater flexible hose 6 Remove the bottom wishbone to pivot bracket fixings to fac...

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Page 18: ...hank of the ball joint from the vertical link and remove the ball joint and pivot bracket assembly replace in the reverse order tightening the castellated nut to 4 29 to 4 98 kb m 31 to 36 lb ft and r...

Page 19: ...off the hub cap and wipe grease from stub axle end 5 Remove split pin castellated nut and washer from stub axle 6 Withdraw the hub complete with bearings and felt oil seal 7 Ease out the inner cone an...

Page 20: ...slacken the nut off half a flay equivalent to 30 degrees figure 6 Note The importance of the correct end float cannot be over emphasised Over tightening the bearings will cause overheating and subseq...

Page 21: ...he chassis frame Allow the jack to support the axle 2 remove the road wheel 3 Remove the nuts and lock nuts from the U bolts clamping the axle to the leaf spring remove U bolts and clamping plate 4 Re...

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Page 23: ...o the ends of the rack transmit this movement to the steering arms and thus the road wheels to turn The track rod inner ball joints attached to the rack are protected by convoluted rubber gaiters and...

Page 24: ...he upper wishbone pivot brackets as detailed in Operation 2 Operation 4 Steering wheel removal Removal Figure 2 1 Prise off the steering wheel crash pad 2 Disengage the steering lock Scribe a line on...

Page 25: ...nd damper 5 Assemble the damper to the rack and fit the anti knock pad Do Not fit the spring or shim pack Fit the cover plate and tighten the bolts evenly until the anti knock pad is just nipped 6 Usi...

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Page 27: ...eply 2 Screw the ball housing off the end of the rack shaft 3 Remove the spring and ball seat from the recess in the end of the rack and discard 4 Examine the ball housing and the ball formed on the e...

Page 28: ...rse the rack as necessary to assist the flow of oil 9 Fit the remaining gaiter in position and secure with the screw clips so that the track rod is capable of accommodating full movement from lock to...

Page 29: ...orrectly adjusted Anti freeze mixture In the winter months an anti freeze must be added to the coolant in the radiator to prevent damage to the cylinder block or radiator caused by freezing Before ref...

Page 30: ...em and flush through by inserting a hose pipe in the radiator filler orifice and allowing water to flow through the system until clean Note It is advisable to leave an indication within the vehicle th...

Page 31: ...er pump and thermostat housing 3 Remove the four set screws and washers securing the radiator to the support brackets located on each side of the radiator attached to the body 4 Remove the radiator 5...

Page 32: ...on and water flow is restricted within the engine by means of a by pass hose system through the heater matrix and the inlet manifold heat exchanger Coolant flowing through the by pass returns to the w...

Page 33: ...13 mm in total free movement Water pump Type Centrifugal Pulley ratio 1 172 1 Anti freeze quantities Volume In water Fluid Down to C F Solidifies At C F Amount of Anti freeze required Specific gravit...

Page 34: ...rear cover and oil seal replacement with sump removed Operation 6 Timing chain cover oil seal and gasket replacement without engine removed Operation 7 Timing chain replacement with front cover remove...

Page 35: ...e hole cleaned out The engine and gearbox assembly is removed from the vehicle by lifting it through the bonnet aperture This operation will be greatly facilitated by the use of a hoist bracket that l...

Page 36: ...Refit the exhaust pipe to the manifold with a new gasket and secure with new brass nuts 13 Refit the exhaust support bracket to the bell housing 14 Remove the engine hoist bracket and replace the hea...

Page 37: ...input shaft from a spare gearbox replace the clutch disc and pressure plate assembly on to the flywheel securing evenly with six set screws and lock washers to a torque of 1 66 to 2 07 kg m 12 to 15...

Page 38: ...Page 38 Figure 4 Engine cylinder block exploded...

Page 39: ...replaced when re assembling failure to do this will allow excessive end float of the distributor driveshaft resulting in poor meshing of the oil pump drive gear with resultant engine noise The backla...

Page 40: ...y water pump and fan belt Secure and tighten alternator 11 Refit the radiator reconnect the hoses and refill the cooling system Figure 9 Extracting front cover oil seal Figure 10 Replacing front cover...

Page 41: ...e from the bracket on the carburettor and pull clear 15 Disconnect the choke cable from the carburettor 16 Disconnect the heat exchanger hoses from the exchanger 17 Disconnect the advance retard pipe...

Page 42: ...e valve springs for length to the dimensions given in the data at the end of this section 9 Remove carbon deposits from the combustion chambers and ports using a hardwood scraper Polish with wire wool...

Page 43: ...ary Figure 15 Valve guide removal and replacement 1 Valve guide removal 2 Valve guide replacement 3 Valve guide protection sleeve 4 Release the tab washers unscrew the bolts and remove the big end bea...

Page 44: ...rs and tighten to a torque of 3 31 kg m 24 lb ft Check the crankshaft end float as follows a Assemble the two halves of the outer thrust washer in the register on the outside face of the front bearing...

Page 45: ...er shaft spring 10 Small end bearing 32 Core plug 54 Rocker shaft end spring 11 Big end bearing shell 33 Plate 55 Washer 12 Bolt 34 Bolt 56 Split pin 13 Plate 35 Lock washer 57 Plug 14 Piston assembly...

Page 46: ...and replacement with camshaft removed Removal 1 Remove flywheel see operation 2 2 Unscrew four set screws and remove the rear engine plate from the cylinder block 3 Drill a hole in the camshaft core...

Page 47: ...fferent grade sizes and are graded as high low or mean Pistons are similarly graded and it is important that a piston and cylinder liner must be of the same grade The grade of the piston is stamped on...

Page 48: ...correctly as described in operation 11 Compress the rings for installation using a compression tool similar to that shown in Figure 16 6 Fit new big end bearings in the connecting rods and caps Ensur...

Page 49: ...and secure with bolt plain washer and lock washer 25 Locate a new gasket and fit the oil pump assembly complete with strainer securing to the cylinder block with two nuts and lock washers Refit oil p...

Page 50: ...inder Block Material Forged aluminium alloy Crankshaft Material Forged high tensile steel Main bearing journals 50 787 to 50 8 mm 1 995 to 2 0 inches Crankpin journals 33 07 to 33 08 mm 1 312 to 1 302...

Page 51: ...Seat angle 45 45 30 Seat width Inlet 1 397 1 524 mm 0 055 0 060 in Exhaust 1 397 1 524 mm 0 055 0 060 in Valve lift 25 42 mm 1 00 in Valve guide lengths inlet and exhaust 41 4 41 66 mm 1 63 1 64 in Va...

Page 52: ...ecuring the drive shaft to the rear axle flange lower the drive shaft to facilitate access to the gearbox flange and remove the front nuts lock washers and bolts followed by the drive shaft 12 Support...

Page 53: ...of the interlock pin in the end of the shaft 7 Tap out the mills pin from the reverse selector lever and withdraw the selector shaft through the bell housing 8 Lift out the selector forks and tilt th...

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Page 56: ...e third fourth synchro sleeve along the synchro body until it clicks in to position Note Ensure that the sleeve is not pushed in too far otherwise the synchro balls and thrust blocks will be disturbed...

Page 57: ...f the box Note The tang end of the layshaft must be at the front 7 Position the tang end of the reverse shaft to engage with the horizontal slot in the rear cover then bolt the rear cover fully home 8...

Page 58: ...rivet heads or if any of the above conditions are apparent the disc must be renewed Check the condition of the pressure plate and the thrust pad surfaces Should any sign of scarring or overheating be...

Page 59: ...hrough the top of the gearbox bell housing To ensure that the thrust pad moved in the correct plane it is pivoted in the operating fork and held firm by lock springs Figure 2 To remove 1 remove gearbo...

Page 60: ...rake stop light switch to the mounting bracket and remove the switch Operation 5 Pedal assembly re assemble and replacement To re assemble 1 Refit the brake light switch with a lock nut on either side...

Page 61: ...dal lever with the clevis pin and fit the washer and a new split pin 6 Underneath the vehicle insert the threaded end of the cable through the trunnion and fit the adjuster nut 7 Adjust the clutch see...

Page 62: ...ns incorporating a sliding spline and universal joints to allow fore and aft movement of the rear axle Each universal joint consists of a centre spider four needle bearings and two yokes Routine maint...

Page 63: ...the yoke Withdraw the bearing cups and disengage the journal from the yoke 3 Repeat the sequence 1 and 2 on the remaining bearings removing the journal from the yoke on the drive shaft 4 Similarly se...

Page 64: ...connect the cables from the stop brackets on the axle tubes 4 Disconnect the hydraulic flexible pipe from the three way connector on the axle tube and plug both this and the three way adapter to stop...

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Page 67: ...and adapter refit the half shaft 4 Secure the back brake plate with three set screws and lock washers Ensure that the back plate spacer is correctly positioned and Figure 3 Hub puller sleeve axle remo...

Page 68: ...e axle case Remove the right hand axle housing and withdraw the differential unit Figure 8 Removal of pinion bearing using collars and hand press 1 Collars Figure 9 Removal of axle bearing cones from...

Page 69: ...to turn the pinion using dummy Pinion tool 1 Pinion setting tool of the operator as they face the axle and referred to as the left hand side throughout these instructions 5 Unscrew the right hand sid...

Page 70: ...in Operation 7 Re assembly determining the correct backlash crown wheel to pinion 1 Replace the differential assembly complete with the dummy bearings into the differential housing and secure the two...

Page 71: ...ct shims on the differential unit Using a hide mallet and tool number RT 550 1 and universal handle 550 replace the differential unit bearing Figure 18 Figure 16 Modification of gauging tool RT 8732 3...

Page 72: ...is clear of the ground Brakes Front brake adjusters 1 Adjuster 3 Remove the road wheel and fully slacken off the brake adjusters 4 Remove the front brake drum 5 Check the lining material thickness Li...

Page 73: ...e on the nearside rear wheel brake back plate Figure 2 Remove the dust cover and fit the rubber tube over the nipple Immerse the other end of the tube in the brake fluid in the glass jar Figure 3 Hand...

Page 74: ...nged in axle sets Repeat for the opposite front wheel 8 Lower the vehicle and road test to check braking performance Operation 6 Front wheel cylinders removal replacement A leaking wheel cylinder will...

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Page 76: ...laced On no account try to clean contaminants from brake shoe linings Operation 9 Master cylinder removal replacement A faulty master cylinder can be diagnosed by excessive pedal movement or signs of...

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Page 78: ...6H1 14901043 van 1 Handbrake lever 2 Mounting bracket 3 Set screw 4 Lock washer 5 Coach washer 6 Handbrake cable 7 Compensator pulley 8 Clevis 9 Clevis bolt 10 lock nut 11 Clevis pin 12 Washer 13 Spli...

Page 79: ...e exception of the pressure release valve not fitted to the earlier cars The hydraulic system pressure reducing valve is fitted to stop the rear wheels locking prematurely under heavy braking In the e...

Page 80: ...r 1 55 kg cm 22 lb in Van Rear 1 69 kg cm 24 lb in Full load Saloon Estate Front 1 41 kg cm 20 lb in Rear 1 99 kg cm 28 lb in Van Rear 2 11 kg cm 30 lb in Repairs A puncture must be repaired either wi...

Page 81: ...lb ft Valves and caps When checking tyre pressures always ensure that the dust cap is replaced on the valve and tightened down firmly by hand only The cap prevents the ingress of dirt and acts as an e...

Page 82: ...cement To remove Figure 1 1 Remove the two brass nuts securing the downpipe to the exhaust manifold 2 Slacken the nut securing the support bracket to the bell housing 3 At the rear prise off the rubbe...

Page 83: ...er the chassis 3 Remove the drain plug and drain the contents of the fuel tank Fuel system Figure 1 Carburettor lubrication 1 Suction chamber 2 Damper 3 Fuel trap 4 Slacken the jubilee clip securing t...

Page 84: ...Note The diaphragm and pull rod assembly are riveted together and must not be dismantled 6 release the circlip and withdraw the rocker arm and extension spindle from the lower body 7 Remove the rocke...

Page 85: ...s to centralise the diaphragm then tighten the screws securely diagonally 6 Clean the pump mounting face on the cylinder block and fit a new gasket 7 Locate the pump on the studs Insert the rocker arm...

Page 86: ...to weak mixture Air leaks can be caused by split or perished hoses a worn split r missing O ring in the oil filler cap a damaged rocker cover gasket or even by the dipstick not being fully seated in...

Page 87: ...cleaner element 1 Wipe clean outside of the air cleaner and release the two clips retaining the body to the base plate 2 Remove the body then remove the element To replace 1 Clean the base plate and...

Page 88: ...line fuel filter 1 Filter element In Line fuel filter Removal and replacement The in line fuel filter situated on the rear chassis side member forward of the fuel tank is secured to the pipes by mean...

Page 89: ...curing the winder mechanism to the door and detach the mounting plate 5 Peel off the waterproof membrane from the bottom and raise enough to clear the winder mechanism 6 Lower the regulator mechanism...

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Page 91: ...er the window glass 8 Refit the regulator mechanism lock assembly waterproof membrane door card etc Operation 5 Side door weather strips removal replacement To remove and replace Figure 2 1 Remove the...

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Page 93: ...r 23 Washer 40 Nut 7 Weather strip 24 Backing plate 41 Shim 8 Rivet 25 Backing plate 42 Set screw 9 Weather strip 26 Rivet 43 Lock washer 10 Rivet 27 Screw 44 Coach washer 11 Regulator channel 28 Lock...

Page 94: ...aking note of the following Secure the dovetail female to the body with four 4 76 x 16 50 mm 3 175 x 0 65 in rivets Secure the male dovetail to the door using six 3 175 x 12 7 mm 0 125 x 0 5 in rivets...

Page 95: ...nd front support bracket Stiffening brackets located behind the A post to support door hinges are also tied to outriggers in the chassis side rails and the B post roll over bar is similarly secured to...

Page 96: ...screws are removed Operation 17 Windscreen removal replacement To remove 1 Remove the windscreen wiper arms and blades 2 Cover the bonnet with a suitable cloth to avoid damage to paintwork 3 Using a...

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Page 98: ...e rubber bumper is supported on a metal channel riveted to the body Pull the rubber from the channel section 4 The metal channels may be removed if required by drilling out the nine retaining rivets R...

Page 99: ...e order ensuing that the thick spacer washers between the runners and floor are correctly located Operation 2 Dismantling front seats 1 Remove the two retaining clips securing the pivot rivets on the...

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Page 102: ...from the back board secured by two screws The two abutment brackets which support the seat squab in the raised position are secured to the body by means of screws that also retain the trim panels Rep...

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Page 104: ...with spire clips Note The headlining should be kept as taut as possible to avoid wrinkles in the finished installation 5 Apply adhesive to the right hand edge of the cloth insert the listing rods on t...

Page 105: ...52 Coach washer 5 Air mixing valve and seal 29 Air hose ram 53 Spring washer 6 Distribution valve and seal 30 Flange pipe 54 Nut 7 Lever and spindle RH 31 Screw 55 Air distribution box 8 Lever and sp...

Page 106: ...ses from the air chamber on the top of the heater unit 8 Remove the gear lever cover secured by four self tapping screws It may be necessary to peel back the drive shaft carpet to gain full access 9 R...

Page 107: ...9 Wheel boxes cable rack removal replacement Rear window wiper Estate Wiper assembly specification Instruments switches Instrument switch removal Operation 10 Multi switch removal replacement Operatio...

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Page 109: ...ributor the presence of dirt oil or water on the points the central carbon brush or in the contact segments in the distributor cap will cause erratic running or may even prevent the engine from runnin...

Page 110: ...lure as the contact points will no longer interrupt the low tension circuit In such cases the condenser will need replacing An open circuit however cannot be readily checked without the use of special...

Page 111: ...t of the pointer the ignition is too far advanced Slacken the distributor and turn slightly anti clockwise to retard the ignition until the marks align If the mark is to the right of the pointer then...

Page 112: ...n freely with a current of 65 amps at 8000 10 0000 rpm The test only proves that the motor functions correctly when not at its normal operating load If on refitting the motor it again fails to crank t...

Page 113: ...achine and is driven by a belt from the crankshaft pulley to ventilate the interior components a multi bladed fan is fitted behind the drive pulley The brush gear is enclosed in a moulding screwed to...

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Page 115: ...ng procedure should be carried out only with the unit at normal operating temperature Alternator output test 1 Unplug the alternator connector and remove the rear cover link together the regulator ter...

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Page 121: ...r screws in the grille and two at either end of the bezel 2 The light unit is held secure by the inner rim affixed with four self tapping screws Remove these and lift off the sealing rim 3 The light a...

Page 122: ...g a piece of tissue paper to stop the fingers actually contacting the glass envelope If the glass envelope is accidentally touched it must be carefully cleaned with methylated spirit before use Failur...

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Page 125: ...to be checked page 112 If one cell needs topping up more than the others carefully inspect the battery casing for cracking If damage is found the only solution is to replace the battery The efficiency...

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Page 127: ...r slip inside the glass tube of the fuse The fuses indicated in Figure 20 show the top 35 amp fuse protecting the unswitched battery circuit which includes headlamps hazard lamps interior lamp and hor...

Page 128: ...d could be the cause but before replacing the unit check all connections and earths for cleanliness and security Figure 19 Sparking plugs Motocraft AGR 32 plugs are fitted as standard to all Kittens T...

Page 129: ...ent will need to be fitted Operation 8 To remove wiper motor Figure 21 1 Remove the wiper arms from the wheel box splines 2 Disconnect the wiring plug from the wiper motor 3 Uncouple the cable tubing...

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Page 132: ...by inserting the key pushing down and rotating it to position 1 Turning the key further to position 2 turns the ignition on Further turning the key against the pressure of a return spring to position...

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Page 134: ...lling bush on the steering column 4 Disconnect the mukti switch wiring from the main harness and withdraw the wires thriugh the grommet in the ignition switch mounting bracket Replace in reverse order...

Page 135: ...ary Denatured alcohol methylated spirit should never be mixed with the water because whilst it will help stop the fluid freezing in cold weather it does tend to cause the paintwork to discolour It is...

Page 136: ...push out the nozzle Replace in reverse order Adjust the jets for spray direction Operation 3 Estate van rear washer nozzle removal replacement 1 Remove the cover from inside the door secured by six s...

Page 137: ...F 2 76 3 46 kg m 20 25 lb ft Steering rack to chassis 5 16 UNF 2 07 2 49 kg m 15 18 lb ft Steering column universal joint pinch bolts 5 16 UNF 2 76 3 18 kg m 20 23 lb ft Steering rack damper preload c...

Page 138: ...ller level plug 3 4 BSP 2 07 2 76 kg m 15 20 lb ft Brakes Front backplate to vertical link 5 16 UNF 2 50 3 18 kg m 18 23 lb ft Rear backplate to axle 5 16 UNF 2 50 2 77 kg m 18 20 lb ft Master cylinde...

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Reliant Kitten Estate, Workshop Manual

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