Reliant Rebel 700 1967 Workshop Manual Download Page 82 | Manualshive

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Page 82

Figure 2 Bonnet assembly

1.

Lock

15.

Bracket

29.

Backing plate

2.

Set screw

16.

Grommet

30.

Packing washer

3.

Set screw

17.

Washer

31.

Packing washer

4.

Lock washer

18.

Split pin

32.

Nut

5.

Striker

19.

Retainer

33.

Lock washer

6.

Backing plate

20.

Bracket

34.

Washer

7.

Rivet

21.

Split Pin

35.

Badge

8.

Set screw

22.

Rivet

36.

Clip

9.

Washer

23.

Safety catch

37.

Data plate

10.

Lock washer

24.

Screw

38.

Rivet

11.

Stop plate, safety catch

25.

Lock washer

39.

Buffer

12.

Set screw

26.

Washer

40.

Key

13.

Washer

27.

Hinge RH

41.

Private bonnet lock

14.

Bonnet support rod

28.

Hinge LH

42.

Wing mirror

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Summary of Contents for Rebel 700 1967

Page 1: ...Page 1 Saloon Estate and Van Workshop Manual The Reliant Motor Company Limited July 1967 Remastered June 2012 by Atodini RELIANT REBEL 700 750 ...

Page 2: ...Tamworth 4151 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 90264 General Specification pages3 4 Lubrication and Maintenance pages5 7 Section A Chassis Frame pages8 9 B Front Suspension pages10 11 C Rear Suspension page12 D Steering pages13 17 E Cooling ...

Page 3: ...3 000 rpm 4 98 kg m 36 lb ft at 3 000 rpm Lubrication System 700cc 750cc Pump Submerged eccentric rotor type Filter External full flow type Oil Pressure 3 16 kg sq cm 45 lb sq in Ignition System 12 Volt battery and coil Negative Earth Contact breaker gap 0 38 mm 0 015 in Sparking Plugs Type Motocraft AG42 Gap 0 64 mm 0 025 in Firing Order 1 3 4 2 Ignition Timing 10 BTDC Cooling System Pressurised ...

Page 4: ...ata Wheelbase 2260 6 mm 89 in Track front 1219 2 mm 48 in Rear 177 8 mm 46 625 in Ground clearance fully laden 140 0 mm 5 5 in Wheels and tyres Road wheels 350J x 12 5 50 x 12 in tubeless cross ply Capacities Engine including filter 3 13 litres 5 50 pints Gearbox 700cc 0 85 litres 1 50 pints 750cc 0 99 litres 1 75 pints Rear axle 1 13 litres 2 00 pints Steering box 0 19 litres 0 33 pints Cooling s...

Page 5: ...or dipstick filler plug Oil 3 Generator rear bearing Oil 4 Steering idler box Oil 5 Steering Box Oil 6 Oil Filler Engine Oil 7 Front Hubs Grease 8 Front suspension plugs Grease 9 Oil Filter Replace 10 Master Cylinder s Brake fluid 11 Rear leaf springs Spray oil 12 Handbrake compensator Grease ...

Page 6: ... up master cylinder s fluid levels if necessary Oil or grease all lubrication points Adjustments Check and adjust brakes Check and adjust clutch Check tyre pressures and security of wheel nuts General Check level of electrolyte in battery Every 5 000 miles 8 000 km Lubrication Change engine oil and fit new filter Change gearbox oil Oil or grease all lubrication points Check steering box oil and to...

Page 7: ... Oil GX 80 Gear Oil SAE 80EP Spirax 80 EP Pontonic MP SAE 80 Hypoid 80 Multigear EP 80 Rear Axle Mobilube GX 90 Castrol Hypoy Esso Gear Oil GX 80 140 Gear Oil SAE 90 EP Spirax 90 EP Pontonic MP SAE 90 Hypoid 90 Multigear EP 90 Steering Box Mobilube GX 80 Castrol Hypoy Light Esso Gear Oil GX 80 Gear Oil SAE 80 EP Spirax 80 EP Pontonic MP SAE 80 Hypoid 80 Multigear EP 80 Front Hub Mobilgrease MP LM ...

Page 8: ...Page 8 Section A Chassis Frame ...

Page 9: ...Page 9 ...

Page 10: ...y 33 Lower trunnion RH 56 Nut 10 Gaiter 34 Distance piece 57 Pivot pin 11 Gaiter clip 35 Bearing 58 Washer 12 Nut 36 Cover 59 Nut 13 Washer 37 Seal 60 Damper unit assembly 14 Tie rod RH 38 Inner water shield 61 Rubber bush top 15 Bolt 2 125 long 39 Outer water shield 62 Rubber bush bottom 16 Nut 40 Seal 63 Spring 17 Set screw 1 long 41 Lower wishbone bracket 64 Spring retaining collet 18 Set screw...

Page 11: ... available slacken off the retaining nut half a flat equivalent of 30 See Figure 2 If the split pin hole in the stub axle shaft does not line up with the castellated nut slacken the nut a little further until it does 5 Mark the position by centre punching the nut and stub axle see Figure 3 6 Remove the hub assembly and pack the bearing assembly with the recommended grease Note it is essential when...

Page 12: ...o support the axle Disconnect the damper by removing the UNF lower securing nut bolt and washer 4 Unscrew four 3 8 UNF locknuts and four hexagon nuts from the two U bolts securing the leaf springs to the axle Remove the U bolts Rear suspension 5 Remove UNF lower shackle nut and bolt and lower the rear of the leaf spring to the ground 6 Unscrew UNF nut and bolt securing the front eye of the leaf sp...

Page 13: ...head at the same time lifting the steering box clear of the engine compartment enabling the complete assembly to be withdrawn from the front of the vehicle 11 Replace in reverse order taking note of the following point The split location dowel is fitted in production to lock the steering column at the correct angle When replacing with a new steering box however the dowel is not required as the sup...

Page 14: ...Page 14 ...

Page 15: ...y to chassis bracket 8 Check steering geometry as described in the following text Steering measurements and adjustments Before carrying out measurements and adjustments of the steering and front suspension position the vehicle on a smooth and level surface Inflate the tyres to the correct pressures and place a load of 150lb 68kg on each seat to represent the average weight for each occupant Also e...

Page 16: ... small departure of the gauge from absolute vertical will not affect the reading Adjust dial A until bubble in level D is central read camber out or in from the scale in dial A The amount of camber should be 0 to 1 2 If this reading is not obtained shims should be added or deleted equally to both the right and left hand fulcrum fixing bolts until the correct camber angle is achieved To measure cas...

Page 17: ...ate Using template when turntables are not available Place template against one of the front wheels and draw a line on the ground parallel to the wheel Then place the template on the floor with its base along the line and draw lines P Q and X Y Figure 8 Attach the clamp Figure 6 and fit the Dunlop CG 5 gauge as previously explained Steer the wheel 20 In as previously explained This can be checked ...

Page 18: ...le with modern anti freeze formulation to leave the anti freeze solution in the cooling system throughout the year provided that the protection afforded at the onset of Winter has not been reduced by routine topping up of the coolant water during the summer months Note During summer months if no anti freeze is used a solution of water plus 3 35 fluid oz of Reliant Coolant Inhibitor R part number 1...

Page 19: ...Page 19 ...

Page 20: ... on the right of the pump body A fabricated pulley is pressed on to the front of the spindle to which is bolted a fan either two or four bladed depending on engine size figures 4 5 To remove 1 Drain the cooling system and remove the radiator 2 Slacken the upper and lower dynamo alternator fixing bolts 3 Pivot the dynamo generator towards the engine and remove the fan belt 4 Slacken the hose clips ...

Page 21: ...ery could result There is provision for fan belt adjustment by pivoting the dynamo alternator on its mountings It is vital that this adjustment is released when a new belt is fitted otherwise any attempt to strain the belt over the pulleys can easily damage the belt To adjust belt tension The correct tension of the fan belt is such that if the belt is deflected at a point midway between the dynamo...

Page 22: ...en the thermostat is open full flow takes place through the engine and radiator To remove 1 Drain the cooling system as previously described and remove the top hose 2 Unscrew the three bolts from the thermostat housing and remove with lock washers Lift off the thermostat housing and remove the thermostat Section F Testing the thermostat If it is suspected that the thermostat is malfunctioning it c...

Page 23: ...otal free movement Water pump Type Centrifugal Pulley ratio 1 172 1 If faulty readings are suspected check the unit as follows With the ignition on disconnect the wire from the sender unit located on the side of the thermostat housing The gauge should read cold Now earth the sender wire to the engine and the needle should move to hot This proves the gauge is correctly working so would indicate tha...

Page 24: ...Page 24 Section F Engine ...

Page 25: ...nd to avoid dirt ingress Remove the clutch return spring 12 Remove the engine stabiliser rod from the rear engine plate and chassis Note position of rubber grommets 700cc engines only 13 Remove exhaust downpipe from manifold 14 Disconnect the centre tie rod from the steering drop arms 15 Remove the nut and washer securing the exhaust support bracket to the bell housing allowing the exhaust system ...

Page 26: ...ubber grommets correctly 16 Reconnect clutch rod and adjust clutch 700cc Reconnect clutch hydraulic pipe and bleed system 750cc 17 Reconnect starter motor dynamo alternator oil and water temperature sensors coil high and low tension leads 18 Reconnect fuel pipe to pump 19 Reconnect throttle and choke cables 20 Reconnect battery and test ...

Page 27: ...e flywheel assembly 1 Clean the mating face between the flywheel and the end of the crankshaft Check that the locating dowel is undamaged and ensure that the spigot bush needle bearing on 750cc is in place Check the bush for wear If wear is evident then knock the old one out and fit a new one using special tool no RT 7485 Figure 2 Needle roller bearings have been used as an alternative to the phos...

Page 28: ...amage and renew if required Note In production it has sometimes been necessary to fit one or two 0 127 mm 0 005 in shims between the oil pump driveshaft bush and the cylinder block Figure 7 It is not necessary when dismantling the pump to remove the drive bush or shim if fitted However if the bush and shim are removed it is essential that they are both replaced when re assembling failure to do thi...

Page 29: ...ock washers and detach the timing cover from the cylinder block 7 Extract the oil seal from the cover using special tool no RT 7480 and drive handle part no 550 Figure 10 8 Fit new oil seal using special tool no RT 7480 and drive handle locating as shown in Figure 11 9 With the aid of centralising tool no RT 7481 fit the timing chain cover with a new gasket to the cylinder block securing with the ...

Page 30: ...om the carburettor plug to avoid dirt ingress Remove the pipe from the clip on the side of cylinder head and tie back clear of the engine to improve access 13 Disconnect the lead from the temperature gauge sender on the thermostat housing 14 Disconnect the accelerator cable from the bracket on the carburettor and pull clear 15 Disconnect the choke cable from the carburettor 16 Disconnect the heat ...

Page 31: ...he 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 Figure 14 Cylinder head and manifolds exploded view 1 Cylinder head 17 Rocker cover 33 Manifold nut 2 Stud 18 Rocker cover gasket 34 Lock washer 3 Stud 19 P clip 35 Stud 4 Stud 20 Support bracket 36...

Page 32: ...ssary Figure 16 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 bearing caps complete with shells 5 Push the piston con rod assemblies out through the top and carefully withdraw keeping the end caps with their respective con rods Overhaul 1 Immerse the pistons and ...

Page 33: ... 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 cap and block Ensure that the oil grooves face forwards b Position the steel countersunk thrust washer against the bi metal thrust washer halves with its countersunk aperture facing rearwards c Refit crankshaft sprocket spacer and...

Page 34: ...earing 53 Rocker 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 36 Sprocket 58 Inlet valve 15 Compression ring 37 Plate 59 Valve seat 16 Taper ring 38 Screw 60 Valve spring 17 Oil Scraper ring 39 Timing chain 61 Valve spring cup 18 Gudgeon pin 41 Ca...

Page 35: ...l 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 plug and prise from the cylinder block 4 Press out the rear centre and front camshaft bearings using general tool 18G 124A and tool No 7482 Figure 19 as follows a Insert general tool and position pil...

Page 36: ...ifferent 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 the crown with the appropriate letter i e H high M mean L low The grade of the cylinder liner is marked on the outside wall with the appropriate letter Figure 27 Pistons and liners are available fro...

Page 37: ...described in operation 11 Compress the rings for installation using a compression tool similar to that shown in Figure 17 6 Fit new big end bearings in the connecting rods and caps Ensure that the correct sizes of bearing are used see engine data 7 Check crankshaft main bearing journals see engine data 8 Fit new main bearings to crankcase and main bearing caps 9 Fit new thrust washers to the crank...

Page 38: ...bolts two nuts and lock washers Figure 12 24 Replace crankshaft pulley 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 pump and distributor drive shaft 26 Fit a new gasket and then fit the sump pan tightening the fifteen set screws and spacers evenly...

Page 39: ... mm 0 040 in Cylinder Block Material Forged aluminium alloy Crankshaft Material Forged high tensile steel Main bearing journals 44 44 to 44 45 mm 1 7495 to 1 75 inches Crankpin journals 33 07 to 33 08 mm 1 312 to 1 3025 inches End float 0 0254 mm 0 001 in minimum 0 1524 mm 0 006 in maximum Crankshaft regrinding size 1st undersize 0 254 mm 0 010 in Main bearing journals 44 18 44 19 mm 1 7395 1 740 ...

Page 40: ...Exhaust 1 397 1 524 mm 0 055 0 060 in Valve lift 7 34 mm 0 289 in Valve guide lengths inlet and exhaust 41 4 41 66 mm 1 63 1 64 in Valve guide clearance 0 0381 0 0889 mm 0 0015 0 0035 in Valve springs Free length 700cc 40 46 mm 1 593 in 750cc 38 0 mm 1 496 in Fitted length and load 34 11 mm 1 343 in at 17 01 kg 37 5 lbs Length and load valve open 28 6mm 1 125 in at 39 6 kg 87 3 lbs Flywheel Materi...

Page 41: ...Page 41 Section G Early Models prior to Chassis No 941001 3 Synchro Gearbox ...

Page 42: ...t the clutch 11 Remove the stands and lower the vehicle 12 Reconnect the battery Gearbox dismantling removed from vehicle To separate extension and remote control assembly from gearbox 1 Unscrew 8 x set screws complete with lock washers securing top cover to gearbox Remove the dip stick if fitted 2 Remove single set screw and lock washer securing remote housing to support bracket extension 3 Caref...

Page 43: ...Page 43 ...

Page 44: ...e the circlip and spacer washer and press off the bearing Note that there is a retaining clip on the front of the primary bearing Ensure that it is fitted when the bearing is replaced 2 Using a suitable extractor remove the primary bush 3 Replace all worn parts as required and refit primary gear assembly to gearbox Note that if a little gentle heat is used at the bell housing this will assist it t...

Page 45: ... if necessary using tool No RT 7488 Figure 3 2 Fit a new gasket and secure front cover to gearbox case with seven UNF nuts and washers Note To prevent the primary gear damaging the oil seal when fitting front cover use a sleeve as shown Figure 4 Clutch operating fork 1 Position the operating fork in its support bracket and secure with 5 16 UNF nut and bolt 2 Refit the rubber gaiter over the fork a...

Page 46: ...ed with the all synchromesh gearbox On these vehicles the gear lever is mounted directly to the gearbox top cover All synchromesh gearbox from chassis No 941001 Gearbox removal and refitting Figures 5 6 To remove 1 Disconnect battery leads 2 Remove gear lever gaiter 3 Jack up the vehicle and place securely on axle stands 4 Drain gearbox oil 5 Disconnect speedometer cable 6 Unscrew rear gearbox mou...

Page 47: ...Page 47 ...

Page 48: ...aft from the primary gear shaft the needle roller pilot bearing may remain on the mainshaft 12 Lift out the laygear assembly and the two thrust washers 13 Withdraw the reverse gear shaft through the rear of the gearbox and lift out the reverse gear 14 Remove the rear cover from the mainshaft assembly Mainshaft dismantling and re assembly To dismantle 1 Remove the first speed gear bush and bush key...

Page 49: ...cond synchro body Note Handle mainshaft cluster with care to prevent synchro sleeves etc from being disturbed 26 Using tool No RT 7490 press the rear cover on to the mainshaft Primary gear assembly dismantling and re assembly To dismantle 1 Prise the primary gear front seal from the gear shaft 2 Using circlip pliers Tool No 7066 remove circlip securing the front bearing to the primary gear 3 Remov...

Page 50: ...y home 8 Return the gearbox to an upright position and insert the reverse 1st 2nd and 3rd 4th selector forks on to the shafts 9 Replace the two interlock balls in to the cross drilling in the bell housing locating in position with grease 10 Line up the reverse selector shaft in the selector fork and drive home the mills retaining pins 11 Ensuring the interlock pin is in position replace the1st 2nd...

Page 51: ... part assembly comprising of cover disc and release bearing To replace 1 Using tool No RT 7485 as a centraliser or a primary shaft from a gearbox position the clutch disc and pressure plate assembly on the flywheel securing evenly with the six set screws and lock washers to a torque of 1 66 to 2 07 kg m 12 to 15 lb ft Figure 0 Release operating fork The operating fork is secured within the bell ho...

Page 52: ...Page 52 ...

Page 53: ...tion in the reservoir leading to incorrect operation Bleeding the clutch hydraulic system 1 Clean the area surrounding the bleed screw on the slave cylinder and remove the rubber dust cap from the bleed screw Figure 4 2 Fit a suitable tube on the bleed screw and put the free end of the tube into a container containing clean brake fluid Ensure that the end remains immersed in the fluid throughout t...

Page 54: ...nent failure As with master cylinders it is recommended that a failed slave cylinder be renewed should it fail To remove slave cylinder 1 Unscrew the union and remove the fluid pipe Plug the end of the pipe to avoid fluid loss or dirt ingress 2 Unhook the return spring from the clutch fork to the rear engine plate 3 Remove two 5 16 UNF set screws nuts and lock washers and withdraw the slave cylind...

Page 55: ...Page 55 ...

Page 56: ...n the yoke bearings are staked in to position These shafts are sealed and cannot be overhauled and a new shaft assembly complete will need to be procured and fitted It may be necessary to clean rust and paint from the yokes to enable the circlips to be removed Prop Shaft Drive Shaft 2 Tap the radius of the yoke with a hide mallet to release the yoke bearings Should this prove difficult then the be...

Page 57: ...Page 57 Section K Rear Axle ...

Page 58: ...le To refit 1 Support the rear axle and move it in to position beneath the vehicle 2 Carefully raise the axle on a jack until the unit is in its correct position 3 Raise both rear springs and secure to rear shackles with UNF nuts and bolts 4 Fit the U bolts over the axle position the lower damper brackets and secure springs to axle using 3 8 UNF nuts and lock nuts 5 Refit the dampers to the lower ...

Page 59: ... is free to move when the back plate screws are tightened Figure 3 Hub puller sleeve axle removed 1 Sleeve Figure 4 Hub puller in use axle removed 5 Clean the half shaft taper of all grease and foreign matter 6 If the wheel studs are damaged they should be pressed out and replaced 7 Position the hub key in its slot and fit the hub to the half shaft 8 Secure the hub to the shaft with the nut and wa...

Page 60: ... Locking nut 7 Remove the pinion flange nyloc nut and washer and withdraw the flange Tap the pinion assembly in to centre of the axle and remove 8 Using hand press tool No 47 and pinion bearing remover tool RT 8765 follow the same procedure as the differential unit and remove the pinion bearing Figure 7 Note the value of the spacing washer thickness next to the pinion head plus any additional shim...

Page 61: ...r on the dummy pinion RT 8730 followed by the taper bearing cone 3 Locate the dummy pinion in the pinion housing placing the outer bearing cone in position followed by the flange and the dummy pinion nut and tighten to give the running preload thus setting the rollers 4 Place the mandrel RT 8730 in the differential side bearing bore With a dial gauge torque wrench check the torque required to turn...

Page 62: ... wheel by wedging it in between the pinion flange and the bolt heads 4 Rock the pinion flange and read off the backlash readings This should measure 0 006 to 0 008 in 5 Screw in the left hand side until a stop is felt screw up right hand side until contact is made Measure minimum backlash Unscrew left hand rod and tighten right hand rod at approximately half turn intervals until the correct backla...

Page 63: ...ange is 0 265 to 0 334 kg m 23 to 29 lb in 8 Locate the right hand back plate and brake assembly to the axle end positioning the back plate spacer and insert against the back plate Align the holes and secure with the three set screws and lock washers Ensure that the insert is free to move in the spacer aperture 9 Clean the taper of all grease and foreign matter 10 Position the hub key in its locat...

Page 64: ...t be allowed to wear below 1 5 mm 1 16 in in thickness Riveted linings should be changed when the material wears within 0 75 mm 1 32 in of the rivet heads 6 If the linings are serviceable refit the brake drum locating the larger stud hole over the stud with a collar on it this is to preserve the balance of the hub drum assembly 7 Replace the road wheel and adjust as follows Turn the adjuster of on...

Page 65: ... stroke followed by three short rapid strokes and the pedal should be allowed to return quickly to its stop with the foot right off 4 Repeat this operation until the fluid expelled is free from air bubbles Tighten the bleed nipple during a down stroke of the brake pedal 5 Remove the bleed tube from the nipple and replace the dust cover The above procedure must be carried out on all wheels in the o...

Page 66: ... 4 Remove the steady posts Prise the tongue of the shoe from the wheel cylinder piston groove adjacent to the handbrake operating lever 5 Lift the other end of the shoe from the slot in the adjuster 6 Lever the second shoe from the piston and adjuster disengaging the shoe from the handbrake lever 7 Remove both shoes complete with springs and put a rubber band around the wheel cylinder to hold the ...

Page 67: ... 3 Unscrew the nuts bolts and lock washers securing the master cylinder to the chassis and remove the master cylinder Replace in reverse order Bleed the brakes Brake pedal assembly Figure 7 Remove split pin clevis pin and washer and disconnect from the master cylinder Remove pedal return spring Pull the brake pedal lever down and remove the countersunk screws securing the pedal to the lever Unscre...

Page 68: ...Page 68 ...

Page 69: ... the spare at the recommended pressures as follows Cross ply tyres Tyre pressures saloon and estate Normal load Saloon Front 1 26 kg cm 18lb in Rear 1 26 kg cm 18 lb in Estate Van Front 1 41 kg cm 20 lb in Rear 1 69 kg cm 24 lb in Full load Saloon Front 1 54 kg cm 22 lb in Rear 1 54 kg cm 22 lb in Estate Van Front 1 69 kg cm 24 lb in Rear 1 97 kg cm 28 lb in Radial ply tyres Tyre pressures saloon ...

Page 70: ...ly The cap prevents the ingress of dirt and acts as an extra barrier against leakage should the valve fail New valve cores can be fitted using a valve coring tool Figure 3 When replacing a tyre a new tubeless valve complete should also be fitted Wheel and tyre balance Unbalance in wheel and tyre assemblies will be responsible for various effects such as wheel wobble abnormal war of tyres and suspe...

Page 71: ... with lock washers securing the down pipe to the manifold and remove the down pipe 7 Examine the manifold gasket and renew if necessary Replace in reverse order Exhaust System To Remove Estate Van 1 Remove the 5 16 UNF nut and lock washer securing the tail pipe to the flexible mounting 2 Unscrew the two 5 16 UNF nuts and lock washers securing the down pipe to the exhaust manifold 3 Withdraw the ex...

Page 72: ...Page 72 Section P Fuel System ...

Page 73: ...seal 4 Reconnect the sender unit electrical connectors and refit the fuel pipe connector sleeve 5 Refit the tank drain plug 6 Remove stands and lower the vehicle to the ground 7 Reconnect the battery leads Fuel Gauge Sender Unit Diagnosis If faulty or inaccurate readings are suspected on the fuel gauge check the gauge and sender unit as follows With the ignition switched on disconnect the sender w...

Page 74: ... and fit a new gasket 8 Locate the pump over the fixing studs and insert the operating arm through the aperture in the block so that the arm lies on the camshaft eccentric 9 Secure the pump with two 5 16 UNF nuts and lock washers tightening evenly to a torque of 2 07 2 49 kg m 15 18 lb ft 10 Remove the plugs and reconnect the inlet and outlet pipes 11 Run the engine and check for leaks Carburettor...

Page 75: ...Page 75 ...

Page 76: ...phragm spring and cover first locate the diaphragm on the body place the spring in the cover and bring the two parts together with the soring locating in the centre cup of the diaphragm To refit the assembly locate the gasket then position the assembly in the main body of the carburettor and replace the three screws To reassemble the carburettor Before reassembly of the unit ensure that all jets a...

Page 77: ...e screw correctly preventing it vibrating out of adjustment Adjust the throttle control screw and volume control screw so that the engine idles evenly and acceleration is clean and progressive Check that the gasket between the inlet manifold and the carburettor is sound as an air leak here will seriously affect the way the engine runs Stalling is usually due to the idling speed being too low or th...

Page 78: ... operating lever and cross shaft pivot plate 3 From inside the foot well fit both split pins to prevent lateral movement of the shaft 4 Secure the pivot bracket to the body using two UNF set screws nuts and washers 5 Using two 1 4 UNF set screws nuts and washers fit the cross shaft pivot plate to the engine bulkhead 6 Retighten the operating lever fixing bolt first ensuring that the lever is at th...

Page 79: ... torque 2 07 2 49 kg m 15 18 lb ft Carburettor Type Zenith 30IZ Jet sizes 700cc 750cc Main jet 95 105 Compensating jet 175 160 Slow running idling jet 45 50 Slow running air bleed 80 80 Accelerator pump jet 45 40 Accelerator pump back bleed 35 35 Economy jet 55 50 Needle valve 1 3 1 6 ...

Page 80: ... Rubber seal 11 Nut 35 Handle 59 Dovetail 83 Pivot vent 12 Washer 36 Escutcheon 60 Spacer 84 Catch lever 13 Lock washer 37 Winder handle 61 Backing plate 85 Wavy washer 14 Drop glass 38 Escutcheon 62 Screw 86 Pin 15 Rubber glass to regulator channel 39 Washer 63 Lock washer 87 Hinge upper 16 Bottom door glass stop 40 Screw 64 Retainer 88 Rivet 17 Set screw 41 Lock washer 65 Retainer 89 Washer 18 W...

Page 81: ...lush with the bodywork and tighten the screws 3 Carefully open the door and check that the wheel of the door lock makes a good seating on the dovetail If spacers must be added or deleted it will be necessary to completely remove the striker plat to do so The rear of this is accessible after removing a large rubber grommet Take extreme care not to allow the backing plate to drop into the body as th...

Page 82: ...t 5 Striker 19 Retainer 33 Lock washer 6 Backing plate 20 Bracket 34 Washer 7 Rivet 21 Split Pin 35 Badge 8 Set screw 22 Rivet 36 Clip 9 Washer 23 Safety catch 37 Data plate 10 Lock washer 24 Screw 38 Rivet 11 Stop plate safety catch 25 Lock washer 39 Buffer 12 Set screw 26 Washer 40 Key 13 Washer 27 Hinge RH 41 Private bonnet lock 14 Bonnet support rod 28 Hinge LH 42 Wing mirror ...

Page 83: ...assemble in reverse order Make sure that the hinge packing washers are correctly seated Rear door Estate and van Figures 5 6 To remove 1 Fully open the door and remove the single screw connecting the check link assembly lug 2 From beneath the vehicle disconnect the number plate lamp wiring at the snap connector 3 With an assistant supporting the door remove four UNF hinge to body set screws and lo...

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Page 85: ...Page 85 ...

Page 86: ... 23 Shim 45 Washer 67 Spring bracket 2 Header rail RH 24 Bonnet hinge 46 Nut 68 Stud 3 Header rail LH 25 Packing washer 47 Grommet 69 Nylon washer 4 Header rail rear 26 Packing washer 48 Check link 70 Rivet 5 Wheel arch front 27 Washer 49 Lug 71 Hinge 6 Wheel arch rear 28 Lock washer 50 Screw 72 Rivet 7 Cover panel 29 Nut 51 Rubber washer 73 Rivet 8 Master cylinder cover 30 Rear door hinge 52 Wash...

Page 87: ...washer 48 Check link 70 Rivet 5 Wheel arch front 27 Washer 49 Lug 71 Floor panel 6 Wheel arch rear 28 Lock washer 50 Screw 72 Front stiffener 7 Cover panel 29 Nut 51 Rubber washer 73 Rivet 8 Master cylinder cover 30 Rear door hinge 52 Washer 74 Support block 9 Screw 31 Washer 53 Split pin 75 Support bracket 10 Captive nut 32 Nut 54 Screw 76 Screw 11 Backing plate 33 Set screw 55 Slide plate 77 Loc...

Page 88: ...ly firm pressure on the glass and seal assembly from inside the vehicle adjacent to the B post Rear Quarter glasses To replace 1 Fit the weather strip to the glass 2 Fit a draw cord in the weather strip groove allowing an overlap of approximately 6 152mm at the bottom 3 Position the window over the aperture with the cord ends inside the vehicle 4 Pull out the cord whilst an assistant applies light...

Page 89: ...Page 89 Section R Interior ...

Page 90: ...ashers lock washers plain washers and hexagon nuts securing the front flap of the cushion to the body 4 Tilt the squab and cushion as far forward as possible to gain access to cushion hinge to body fixings 5 Remove two UNF set screws and lock washers from both hinges and lift the complete rear seat assembly from the vehicle 6 To separate the squab from the cushion remove the six countersunk screws...

Page 91: ...nnect battery Headlining Estate To remove Figure 4 1 Remove finisher strip from roof location 2 Starting from the rear carefully peel off the foam backed headlining from the vehicle roof 3 Clean the roof surface thoroughly to remove all trace of adhesive and foam To replace 1 Coat the roof area with an even coating of Bostik 1GA 516 adhesive and allow to dry until tacky 2 Starting at the front off...

Page 92: ...ith their electrical connections intact 13 Unscrew fixing screw plain washer lock washer and nut locates under the RH side of the fascia and remove the indicator flasher unit 14 Disconnect the speedometer drive cable from the rear of the instrument 1 Arm rest 20 Rear LH floor carpet 39 Listing rod 2 Retainer 21 Rear LH floor carpet 40 Front trim fillet 3 Trim panel 22 Stud fastener 41 Centre trim ...

Page 93: ...ering column and into position on the bulkhead Be sure that the steering column grommet is correctly located in the fascia 4 Secure the fascia to the bulkhead using six No 14 bolts 5 Reconnect the speedometer drive cable 6 Refit the indicator flasher unit under the RH side of the fascia with a No 10 UNF set screw plain and lock washers and hexagon nut 7 Locate the switches into their appropriate a...

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Page 95: ...Page 95 ...

Page 96: ...m see section E 2 Slacken the retaining clips and remove the water hoses from the heater unit Pull the air duct hoses off 3 Disconnect the leads from the heater motor 4 Unscrew four UNF set screws plain and lock washers and nuts and remove heater unit from vehicle 5 Replace in reverse order Heater control valve To remove the valve slacken the trunnion and clip to disconnect the control cable Unscr...

Page 97: ...anti clockwise viewed from above Whilst all distributors are physically interchangeable it is vital that the correct type is fitted or the engine will perform poorly Electrics Lubrication The cam and contact breaker pivots should be periodically lubricated with petroleum jelly The centrifugal weight spindles should be lightly oiled with engine oil every 3000 miles 5000km To lubricate the cam spind...

Page 98: ...nd the distributor cap Distributer Condenser all models The condenser is fitted in parallel to the contact breaker points to mitigate excessive arcing across the contacts A short circuit in the condenser will cause total ignition failure In such cases the condenser must be replaced An open circuit however is more difficult to diagnose without the use of specialised equipment The usual signs of thi...

Page 99: ...engine and allow to idle at normal tick over speed Aim the strobe light at the timing marks taking care not to contact the spinning fan Ensure that the 10 mark is aligned with the pointer If the mark is to the left 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 ...

Page 100: ...eel ring gear which makes a distinctive sound If this is not apparent a faulty solenoid could be indicated If the components of the starting system are found to be functioning correctly this would indicate that the fault lies elsewhere in the ignition or charging systems Starter motor testing is detailed below Bench testing Remove the commutator end cover from the motor and check the brushes for w...

Page 101: ...ry is in a good state of charge 2 Ensure the fan belt is correctly tensioned 3 Check that the spade connectors on the back of the dynamo are secure and clean 4 Disconnect the two leads and link the generator terminals together with a short length of cable 5 Start the engine and run at normal idling speed 6 Clip the black lead of a 0 20 VDC moving coil volt meter to one of the terminals and connect...

Page 102: ...ed in series with the field supply diodes and is extinguished when the voltage generated in the diodes equals the supply voltage from the battery The only attention that the alternator is likely to require is the occasional checking of the brushes remove the alternator end cover unscrew two 4BA bolts and lift the brush box clear from the slip ring moulding bracket Check that they are free from oil...

Page 103: ... the following 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 terminals F and 2 Connect an exterior test circuit as shown in Figure 8 Observe carefully the polarity of the battery and alternator terminals 8 12 volt battery 9 0 40 or 0 60 ammeter 10 12 v...

Page 104: ...0 to 160 amps It is essential to use only the recommended tester A cell in good condition will maintain a constant 1 2v 1 5v reading for 10 seconds when the prongs of the tester are across the terminals Battery voltage By means of the tests already described the condition of the battery has been ascertained and also its state of charge The working voltage should then be checked With a meter across...

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Page 106: ...ove the U clamp securing the wiper motor to the body 5 Remove the motor pulling the rack from the tubing as you do so 6 Refit in reverse order Wheel boxes and rack tubing To remove 1 Remove the fascia see Section R 2 Unscrew four self tapping screws and remove the wheel box cover plates 3 Detach the wiper arms and remove the wheel box retaining nuts washers and waterproof spacers 4 Disconnect the ...

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Page 108: ...of the headlamp and adjust the board so that the dividing line H marked on the board corresponds Figure 12 4 Position the board so that the vertical dividing line corresponds to the centre line of the vehicle 5 Switch the lights on to main beam and cover the RH headlamp 6 The LH headlamp should be set until the area of concentrated light the hot spot is focused just below H on the aiming board on ...

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Page 111: ...g out the lamp lens Interior lamp Figure 19 To gain access to the bulb carefully squeeze the centre of the lamp cover and gently remove it Instruments and switches Figure 20 Access to the two main instruments is achieved through the aperture located beneath the fascia Disconnect the appropriate connections and remove the knurled nuts securing the instruments to their retaining brackets to remove t...

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Page 114: ...plunger button situated below the wiper motor switch Water is directed onto the screen from a two way jet fixed to the bonnet and linked to a reservoir with plastic tubing The reservoir is housed in a support bracket which is rivetted to the LH bulkhead near the engine manifold ...

Page 115: ... to drop arms 7 16 UNF 4 15 4 84 kg m 30 35 lb ft Cooling system Water pump fixing nuts 5 16 UNF 1 66 2 10 kg m 12 15 lb ft Engine Cylinder head nuts 3 8 UNF 3 46 kg m 25 lb ft 5 16 UNF 2 07 kg m 15 lb ft Big end bearing caps 5 16 UNF 2 90 kg m 21 lb ft Main bearing caps 3 8 UNF 3 32 kg m 24 lb ft Flywheel to crankshaft bolts 3 8 UNF 4 04 kg m 29 lb ft Rocker shaft nuts 3 8 UNF 3 04 kg m 22 lb ft ...

Page 116: ...97 kg m 5 7 lb ft Rear brake adjuster to back plate 0 55 0 69 kg m 4 5 ft lb Rear back plate to axle 5 16 UNF 2 20 2 50 kg m 16 18 lb ft Front back plate to upright 5 16 UNF 2 20 2 50 kg m 16 18 lb ft Master cylinder mountings 5 16 UNF 2 20 2 50 kg m 16 18 lb ft Road wheels Wheel nuts 3 8 UNF 4 15 4 84 kg m 30 35 lb ft Electrical Alternator dynamo pivot bolts 5 16 UNF 2 08 2 77 kg m 15 20 lb ft Al...

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