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Sunbeam ALPINE I SERIES: APLINE II SERIES, Workshop Manual

The Sunbeam ALPINE I SERIES: ALPINE II SERIES Workshop Manual is a comprehensive manual for servicing and repairing your Sunbeam vehicle. Users can download this manual for free from our website to ensure they have all the necessary information for maintaining their car in top condition.

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WSM.124 

Section E (Gearbox & Overdrive) 

GEARBOX  AND  OVERDRIVE 

SECTION  E 

CONTENTS 

GEARBOX 

Page 

OVERDRIVE 

Gearbox 

unit 

Working principles 

-to remove and refit 

2 

The hydraulic 

system 

Clutch  housing 

-to  remove ... 

4 

Control of 

overdrive 

Top cover 

Lubrication and maintenance 

-to remove and refit 

3 

-to dismantle and reassemble 

Diagnosis offaults  .... 

Rear cover 

Adjustment of controls 

-to remove and refit 

5 

Selector shafts and forks 

Isolator switch-to adjust 

-to remove  and refit 

5 

Operating  valve 

Front cover 

Relief valve 

-to  remove and refit 

7 

-to dismantle and reassemble ... 

7 

Pump valve 

Mainshaft 

To remove from car 

-to remove and refit 

8 

-to dismantle and reassemble ... 

9 

To remove from 

gearbox 

Layshaft 

To refit to gearbox 

-to remove and refit 

11 

Reverse wheel 

Overhauling instructions ... 

-to remove and refit 

11 

Testing  hydraulic  pressure 

Rear bearing 

.:..,_to remove 

11 

Dimensions and tolerances 

Gearbox 

Additional  information 

-to  reassemble 

11 

Adjustment of  controls 

4th 

re-issue 

Page  1 

Page 

13 

13 

15 

15 

15 

16 

17 

19 

19 

19 

20 

20 
20 

21 

19 

27 

29 

Summary of Contents for ALPINE I SERIES: APLINE II SERIES

Page 1: ......

Page 2: ...R Series Ill to IV and ALP INE Series I to IV Issued by ROOTES SERVICE DIVISION COVENTRY ENGLAND Part No 6601102 PRINTED IN ENGLAND World Exporters ROOTES LIMITED PICCADILLY LON oN Copyright reserved...

Page 3: ...5th re issue NOTE The Manufacturers reserve the right ta alter specifications at any time without notice J...

Page 4: ...el System Clutch Propeller Shaft Gearbox Overdrive Front Suspension Rear Axle Rear Suspension Steering Brakes Wheels and Tyres Electrical System B_ody Lubrication Oil Seals and Bearings Heating Ventil...

Page 5: ...is essential that only genuine replacement parts should be fitted Genuine replacement parts are manufactured to the same specification and are of the same quality as those orig nally fitted to the ca...

Page 6: ...manufactured by Messrs V L Churchill Co Great South West Road Bedfont Feltham Middlesex England The use of these tools Is described under the appropriate section headings DECENTRALIZED SERVICE In ord...

Page 7: ...174 5 6 Mexico City 16 S0 4 4 and 16 50 51 6024 Plymouth 5 5255 Hunter 1 0365 Regent 1 31n 8 EUROPE Rootes Belgique S A 126 Rue de Linthout BRUSSELS 4 Belgium Rootes Motors S A 6 Rend Point des Champs...

Page 8: ...m B 94100001 B 33100001 DIMENSIONS ENGINE Camshaft Connecting rod Crankshaft Cylinder block Cylinder head General Gudgeon pin Performan e Piston Table of road speed engine speed Valves ELECTRICAL SYST...

Page 9: ...p Carburettor IGNITION SYSTEM LUBRICATION SYSTEM STEERING SUSPENSION Front Rear Shock absorbers TORQUE LOADING FIGURES TRANSMISSION Clutch Gearbox Overall ratios Propeller shaft Rear axle WEIGHTS WHEE...

Page 10: ...Ill onwards Rapier Fuel tank Alpine I II Alpine Ill onwards Rapier 7ft 2 in 218 4cm 8ft 243 8 cm 4ft 3 In 129 5 cm 4ft 3 In 130 2 cm 4ft 3fln l31 4 cm 4ft 4 In 132 0 cm 4ft 1 In 126 3 cm 4ft 3fIn 131...

Page 11: ...les IIIA IV Rapier pressure Serles I Alpine Series Ill Rapier 9 1 1 8 4 1 is available in certain export territories Series II Ill IV Alpine Serles IIIA IV Rapier 9 1 1 Serles II Ill IVAlpine Serles I...

Page 12: ...2mph 32 5kph 26 0kph 23 3kph 18 6kph 10 1kph 7 7kph 5 1kph CYLINDER BLOCK Material Cast Iron Max oversize with or without liners 0 040 in 1 02 mm Linering size Series I Alpine Series Ill Rapier 3 254...

Page 13: ...2 In 30 mm Exhaust 014 In 35 mm Timing Inlet opens Inlet closes exhaust opens exhaust closes Port diameter Inlet CAMSHAFT No of bearings Exhaust Type of bearings front centre and rear End thrust Drive...

Page 14: ...painted yellow Big end end float 8753 in 8752 in 22 233 22 230 mm 9379 93nln 23 822 23 820mm 8752 In 8751 In 22 230 22 228 mm 9378 93nin 23 820 23 817 mm 8751 in 8750 in 22 228 22 225 mm 93n 9376 in...

Page 15: ...1081n 81 5 81 554mm E 3 1104 3 1108In 79 004 79 014mm For Service use F 3 1108 3 1I llin 79 01 4 79 024mm For Service use E 3 2104 3 21081n 81 5 81 55 4mm For Service use E 3 2108 3 2112 in 81 55 4 81...

Page 16: ...used if 7 mm radius pump cam Is fitted Where this cam and jet is used there is a 50 leak hole in the accelerator pump suction valve Altitude settings differences above 4 000ft 1219 m 4000ft 1219 m 75...

Page 17: ...WIA 3 carburettor is fitted tLater model are fitted with a dry paper element air clearer Altitude settings differences above 4 000 ft 1219 m 4000ft 1219 m to 7500ft 2288 m Main jet Series Ill Serles I...

Page 18: ...with distributor decelerating on test rig Despatch No 40942A Ignition vacuum advance all distributors 7 lbs in 2 9 lbs ln 2 4 lbs in 2 9 lbs in 2 3 1 in 375 In 400 37 25 In 162 F 176 F 185 F 199 F 18...

Page 19: ...Number ofcover springs Alpine II Ill Rapier IIIA Colour ofdriven plate springs Number ofdriven plate springs Driven plate compressed thickness Lever tip Height Alpine I Rapier Ill Height Alpine II Il...

Page 20: ...IA O d 5031066 K 25632 12 teeth 5 teeth Series IIIA O d 5031066 K 25632 12 teeth 5 teeth Serles IV std P 113464 1207201 17 teeth 5 teeth Series IV 0 d 5031066 K 25632 12 teeth 5 teeth 1 39 I A models...

Page 21: ...l drive ratio Alpine Series I II Rapier Spiral bevel axlesJ Rapier Hypold bevel axles Alpine all Series Ill Rapier Serles IV Semi floating 3 89 I 4 55 I 4 22 I 3 89 I 3 89 I 4 22 Iwith Overdrive 4 78...

Page 22: ...ing off car 950 lbs 430 91 kgs Free length U P s e 6289 11 175 in 28 38 cm Free length J e 11 65 in 29 59 cm Spring Alpine IV Outslde diameter 4 47 in 11 35 cm Static laden length 7 55 in 19 17 cm Sta...

Page 23: ...Rubber 8 4 1 25 In 3 1 cm negative centre line of rear axle in boot 165 lbs 75 kg Ser es ti Serles Ill Semi elliptic Semi elliptic 44 in 111 76 cm 43 5 in I I0 49 cm 2 25 In 5 72 cm 2 25 in 5 72 cm 1...

Page 24: ...all 3 3 15 14 5 I 16 4 I from B3303416R H B 3304752 L H 65 74 Shims 0015 in 038 mm Shims 004 008 In 10 20 mm BRAKES for torque loading figures see table at end of section Make Alpine Rapier Typeof sys...

Page 25: ...usly near maximum speed we strongly recommend the use of 5 90xl3 Road Speed tyres with minimum pressures of 28 lbs per sq in Front and 30 lbs per sq in Rear 1 97 and 2 11 kg fem For prolonged tourinf...

Page 26: ...Specific gravity reading Coil and Distributor See Ignition System CONTROL BOX Make and type Make and type Alpine IV GENERATOR Make Type Drive Control of output Brush spring tension new Cutting in spe...

Page 27: ...Rear flashing signals Rear number plate Speedometer Direction indicator pilot lamp Interior lamp where fitted Revolution indicator where fitted Map lamp where fitted Side Lamp Alpine IV capless OTHER...

Page 28: ...RS 1 000 1 1 392 1 2 1 40 I 3 353 1 3 569 1 3i pints 4 2 U S pints 1 9 litres 4 pints 5 4 U S pints 2 5 litres Standard gearbox only both Alpine and Rapier Overdrive Is not affected PINION WHEEL REVS...

Page 29: ...pin housing to link Shock absorber to spring pan Crossmember to frame Road wheel nut REAR SUSPENSION Rear spring U bolts Alpine Rapier STEERING Box to frame Relay lever to frame Steering crosstube ba...

Page 30: ...adaptor Steering arm to carrier and adaptor Adaptor to carrier BRAKES Rear Backplate to casing Wheel cyllnder to backplate 38 lbs ft 5 2 kg m 52 lbs ft 7 1 kg m 38 lbs ft 5 2 kg m 60 lbs ft 8 2 kg m 3...

Page 31: ...S Without using anti freez e Using anti freez e Heaters COOLING SYSTEM To clean THERMOSTAT To remove and refit To test RADIATOR To remove and refit WATER TEMPERATURE GAUGE To remove element To remove...

Page 32: ...al working temperature and It Is desirable that this should be brought about as quickly as possible after starting the engine from cold To accomplish this a thermostatically operated valve Is located...

Page 33: ...n cold weather the bottom of the radiator should be blanked off so that its bottom tank keeps warm because it is here that freezing commences Using anti freeze To avoid the possibility of the cooling...

Page 34: ...portant to drain off the cleansing solution directly It hos been used for Its recommended period WSM 12 4 Section A Cooling System Finally flush the system thoroughly with running water by means of a...

Page 35: ...element terminal Unscrew and remove element 3rd re issue Pages It is most important that the interconnecting cable between the gauge and the temperature element should not be shorted to earth when the...

Page 36: ...eaning fluid as these would enter the bearing and destroy the lubricant Cleaning of the pump body should be left until the pump Is dismantled The pump should be dismantled In the following manner I Re...

Page 37: ...o reassemble 1 Place the bearing unit in the pump body with the larger diameter of the spindle to the front of the housing lining up the locating hole In the bearing with the threaded hole in the pump...

Page 38: ...In Fig 2 It should be noted that a clearance of 040 1 01 mm should exist between the outer face of the lmpellor and WSM 124 Section A Cooling System cover plate This clearance can be checked with fee...

Page 39: ...tion timing and distributor Decarbonising and grinding in valves Engine To remove To refit CAMSHAFT AND TIMING GEAR Camshaft To remove and refit Camshaft bearings To remove and refit Timing cover To r...

Page 40: ...e To refit Inlet and exhaust manifold To remove and refit ELECTRICAL See also Section N Distributor To remove and refit Generator To adjust belt tension Ignition timing and distributor lsnitlon To tim...

Page 41: ...xamination of valves springs guides etc Push rods To remove and refit Valve rocker adjustment Rocker cover To remove and refit Rocker shaft assemblies To remove To dismantle To reassemble To refit Tap...

Page 42: ...1st issue Page4 0 WSM 114 Section B Engine Fig I En1lne lon11tudinal section l494c c enrlne shown J...

Page 43: ...WSM 12 t Section B Engine OIL FEED TO VALVE ROCKER GEAR OIL FEED FROM PUMP Fl1 2 Engine Cross section 1494 c c engine shown 3rd re issue Pages...

Page 44: ...3rd re Issue Page 6 Fl1 3 Cylinder block and associated parts 494 c c enrine shown WSM 124 Section B Engine...

Page 45: ...WSM 124 Section B Engine view o working parts 494 Fis 4 Exploded f 7397 c c engine shown 6th re Issue Page7...

Page 46: ...xhaust manifolds From chassis number B 3053209 B 9106448 HC B 9107189 LC and B 9106535 ME A non return ball valve was titted In the timing chain oil feed pipe union to ensure rapid building up of oil...

Page 47: ...g plugs are cleaned thoroughly at 3 000 mile 4 800km intervals OIL FOULING is usually identified by wet sludge deposits traceable to excessive oil entering the combustion chamber through worn rings an...

Page 48: ...ING AND DISTRIBUTOR The modern high compression engine is very sensitive to ignition timing In the following paragraphs detailed instructions are given of the various methods that can be used to obtai...

Page 49: ...to three crankshaft degrees and one vernier division shown In the inlet of Fig 12 to four crankshaft degrees TO TIME IGNITION 3rd re Issue Page II Static Ignition settings are given In the Data Secti...

Page 50: ...to the midway position 2 divisions showing on scale See Fig 12 top illustration Remove the distributor cap and connect a 12 v bulb between the L T terminal of the distributor and a good earth With the...

Page 51: ...ankshaft speed of 1 000 r p m to the static ignition setting The centrifugal advance angle Ist re issue Page 13 for this engine speed on Alpine and Rapier engines is 3 crankshaft degrees BTDC Example...

Page 52: ...iously described a road performance test can be made by taking stop watch readings of the time taken to accelerate in top gear from 20 to 50 m p h 32 to 80 k p h under full throttle conditions on a st...

Page 53: ...ct valve clearances are given In the Data Section To adjust clearance slacken lock nut and turn screw with screwdriver until correct clearance Is obtained Tighten lock nut and re check clearance Check...

Page 54: ...e engine is HOT TAPPETS To remove Remove rocker cover rocker shaft assemblies and push rods No 4 exhaust is adjusted when No I exhaust Is fully open No 3 inlet is adjusted when No 2 inlet is fully ope...

Page 55: ...from theshaftshoulder To obtain the valve timing shown in Fig 17 flt chain to crankshaft wheel and camshaft wheel so that the dots on the camshaft and crankshaft wheels are in line See Fig 16 Turn ca...

Page 56: ...onable accuracy by attempting to rotate the valve spring cap with the first finger and thumb Directly the valve leaves its seat it is possible to slightly twist the valve and this movement will be see...

Page 57: ...ol and fuel feed pipes Remove clamps long bolt and nuts holding the manifold assembly to the cylinder head Lift off manifolds leaving the carburettors on the inlet manifold to save disturbing the thro...

Page 58: ...ng the exhaust pipe at its flange joint WSM 124 Section B Engine Remove eight bolts and two nuts and washers securing cylinder head to cylinder block and lift off cylinder head Cylinder head gasket Al...

Page 59: ...the combustion chambers in the cylinder head and also from the valve ports With a suitable scraper clean out the inside of the exhaust manifold Place clean rag in the exposed area of the tappet chamb...

Page 60: ...1 025 mm less In diameter than the valve cap end diameter Guides These may be checked for wear by using a new valve as a gauge The valve stem should be a free sliding fit In the guide without excessiv...

Page 61: ...e seating and revolving the valve In place not more than about i 3 mm In each direction A complete circle of marking should appear on both valve face and seating Indicating a good seal VALVE GUIDES To...

Page 62: ...lve guides into the cylinder head The sharp edge of the top end of the valve guide must not be damaged as this edge is used to scrape excess oil from the valve stem After fitting the valve guides shou...

Page 63: ...refacing of valves must not leave too thin an edge above the valve head seating This applies particularly to exhaust valves which must be renewed If much refacing is needed A valve which has been refa...

Page 64: ...been uniformly heated to 200 C 390 F The equipment previously described under VALVE GUIDES TO RENEW should be used Inserts cannot be extracted from a cold cylinder head as they are fitted 010 to 032...

Page 65: ...diameter pipe which is supplied with oil from the front main bearing oil feed The oil pipe end passes through a hole in the cylinder block and oil supplied in excess of the chain s requirements Is re...

Page 66: ...ing chain oil feed pipe 2 11 3 WSM 124 Section B Engine 5 6 8 I 11 I l i l l t J i I 11 I 10 9 Oil gallery and feed from filter 10 Cross section through camshaft centre journal showing drilling In Jou...

Page 67: ...is recognised by its colour dyed ends Where the thin joints are used the front and rear main bearing caps have a casting recess or cast protrusions as shown in Fig 32 by the letter C The identificatio...

Page 68: ...Into a groove formed in the top ofthe filter body All oil passing Into the element casing flows through the element from Its outside surface through the WSM 12 4 Section B Engine element up from the...

Page 69: ...34 Remove centre bolt Take out the element and renew White arrows show direction of oil flow Run engine and carefully check for o 1 leaks I st re issue Page 31 Examine sump level after running engine...

Page 70: ...the pump must be refitted as described below Ensure that the engine is at T D C top dead centre with piston of No I cylinder In firing position Replace the oil pump so that the distributor driving sl...

Page 71: ...he following reasons Low oil level in sump Pressure relief valve not working properly due to particles of foreign matter lodged between valve and seating 11 lJJj J I 11111 I I 4 796 rr J Fig 37 Checki...

Page 72: ...used In certain export territories where the normal high octane fuels are not available Fitting clearances are the same for both pistons WSM 124 Section B Engine To remove pistons and connecting rods...

Page 73: ...s are given In the General Data section under Gudgeon Pin 003 076 mm oversize gudgeon pins are available for service use Delapena Precision Honing Machine This honing machine illustrated in Fig 39 is...

Page 74: ...g gauge previously described is used to determine when the boss bores are to within ooos 012 mm of the required size Connecting Rod Alignment After fitting and honing or reaming a new connect ing rod...

Page 75: ...bedding In This treatment leaves It a dull grey and faintly red colour Second Compression Ring See Fig 43 To provide more rapid running in and also to assist In oil control a stepped periphery compres...

Page 76: ...cking piston ring side clearance 1494 c c piston shown 3 minutes each cylinder at the same time rotating It first one way and then the other until the entire cylinder wall is covered with crisscrossed...

Page 77: ...be followed I Check the cylinder bore diameter with a Mercer or other dial type bore measuring gauge after setting its zero reading to a suitable size ring gauge see Section S 3rd re issue Pa1e 39 2 F...

Page 78: ...h liners during production and these should be dealt with as described under CYLINDER LINERS To renew If the fitting of liners is to prove really successful a high degree of skill on the part of the o...

Page 79: ...KSHAFT Identification For purposes of Identification the letters and figures E N 16 are embossed on both crank webs connecting No 1 and No 2 crankpins and No 3 and No 4 crankpins see Fig 48 Crankshaft...

Page 80: ...hat It Is free The correct torque wrench figure for the main bearing bolts is given In the Data Section under Crank shaft Crankshaft end thrust Crankshaft end thrust is taken by two semi circular stee...

Page 81: ...thrust face at the ends of the crankshaft centre journal FLYWHEEL To remove and refit Remove gearbox and bell housing See Section E Remove clutch See Section D Knock flywheel tabwashers clear of setb...

Page 82: ...e new gear ring by suspending It from wire hooks in a container of clean engine oil which has been heated to 220 C 428 F until the ring has attained the same temperature as the oil See Fig 51 WSM 124...

Page 83: ...in the Owners Handbook Page 4S Oil pressure relief valve See Fig 53 A piston type relief valve situated in compartment C in the filter adaptor casting opens to return all excess oil delivered by the...

Page 84: ...Screw the filter 7 into position until it just touches the joint face on the adaptor casting THEN SCREW THE FILTER A FURTHER ONE THIRD OF A TURN BY HAND ONLY Run the engine and check for oil leaks Top...

Page 85: ...and the valve opening spring 8 The flame trap 3 was not fitted to the first arrange ment of this system which had a direct hose connection from the oil filter tube on the rocker cover to the ventilati...

Page 86: ...ection B Engine I Check that the engine idles correctly When idling It should be possible to push the valve 7 hard against Its seat with a suitable rod without affecting the slow running performance 2...

Page 87: ...ion of parts To reassemble fuel pump To test fuel pump after assembly To refit pump to engine Excessive fuel pump pressure Exploded view and list of parts CARBURETTOR Type Twin Zenith 36 WIP and 36 WI...

Page 88: ...ttle fast idle for starting Accelerator pump stroke Fuel level Choke control Dismantling for cleaning Inspection and cleaning Reassembly Exploded view List of parts Carburettor settings AIR CLEANERS U...

Page 89: ...8 which pulls the pullrod 11 together with the diaphragm 13 downwards against spring pressure 16 15 13 II 10 9 8 12 thus creating a depression In the pump chamber 15 Fuel drawn from the tank enters th...

Page 90: ...chamber or pump bowl has become empty A few pulls upwards of the hand primer on these occasions will till the float chamber with fuel and ensure easy starting without prolonged use of the starter and...

Page 91: ...Page 5 over by hand tools after correctly locating the various components All badly worn parts must be renewed and very little wear may be tolerated on the rocker arm pin holes and engagement slot in...

Page 92: ...the dotted outline The sub assemblies of the pump are now ready for fitting together and this Is carried out as follows Push the rocker arm towards the pump until the diaphragm is level with the body...

Page 93: ...itioned After refitting the pump the engine should be run for a short time and pipe unions and pump examined for any signs of fuel leakage Ist re issue Page 7 EXCESSIVE FUEL PUMP PRESSURE As explained...

Page 94: ...ner Screw No 10 U N F Washer w spring Pull rod and diaphragm Spring diaphragm Priming lever Washer oil seal Retainer oil seal Washer rocker pin Link Return spring rocker arm Rocker arm Pin rocker arm...

Page 95: ...ettor is given in Fig 18 and the names of the various parts on the adjoining page A heat insulating joint of 5 mm thickness is used between the throttle spindle body and the main body to reduce heat f...

Page 96: ...SUNBEAM 5093 AIR OR VACUUM r _ u AIR FUEL MIXTURE FUEL Fig 5 Zenith WIP 36 carburettor Arrangement of channels Section C Fuel System EKTERNAL AIR INLET TO FLOAT CHAMBER AIR SUl PLY CHANNEL TO ACCELERA...

Page 97: ...ON HOLES VOLUME CONTROL SCREW SLOW RUNNING MIXTURE OUTLET AIR OR VACUUM AIR FUEL MIXTURE FUEL SUNBEAM c _ Fig 6 Zenith WIA 36 carburettor Arrangement of channels Page 11 EXTERNAL AIR INLET TO FLOAT CH...

Page 98: ...NG FLOAT FLOAT NEEDLE SEATING FLOAT NEEDLE mechanism opening the throttle to the correct starting position when the choke control is pulled out to start the engine When starting under cold conditions...

Page 99: ...or action when starting in Fig 7 INTERCONNECTING ROD THROTTLE TO STAANGLER STR NGLEP V LVE Page 13 Slow running See Fig 9 With the throttle in the idling position the mixture is supplied by the idle j...

Page 100: ...OW RUNNING AIR BLEED HOLE SLOW RUNNING CHANNEL MAIN DISCHARGE JET STRANGLER FULLY OPEN IDLING ORIFICE To weaken the mixture the screw should be turned clockwise conversely it must be unscrewed to make...

Page 101: ...gh the large venturi to the induction system On the WIP carburettor the discharge characteristic of the main discharge jet is such that a correct STRANGLER FULLY OPEN MAIN METERING THROTTLE VALVE JET...

Page 102: ...EEDING TO MAIN DISCHARGE JET HAIN METERING JET BY PASS VALVE OPEN BY PASS JET WSM 124 Section C Fuel System tight compartment that Is connected by a passage way to the engine side of the throttle valv...

Page 103: ...pring must not be altered in any way DIAPHRAGM RETURN SPRING DIAPHRAGM PLUNGER ACCELERATOR PUMP OPERATING PLUNGER The accelerator pump See Figs 12 and 13 To ensure immediate acceleration when the thro...

Page 104: ...s fed into the nozzle centre and discharged under ACCELERATOR PUMP DISCHARGE NOZZLE the pressure exerted by the fuel pump through a small calibrated hole into a space In the nozzle This space is in co...

Page 105: ...Illustrations A and B Over the latter part of the throttle open ing shown in B and C no accelerator pump action takes place Movement of the accelerator pump operating arm Into the hole L shown in the...

Page 106: ...are permissible Fuel system 6 Ensure that an adequate fuel supply is being delivered to float chamber WSM 12 4 Section C Fuel System 2 Examine induction manifold and carburettor flange for air leaks 3...

Page 107: ...nd if the engine is run at a high speed no fuel should come from the nozzle after completion of the accelerator pump stroke g Check that the fuel level In the float chamber is correct Page 21 Insuffic...

Page 108: ...lose effectively and that the assembly is screwed tightly Into the base of the float chamber d Two settings are available for the pump stroke by using one of the two holes in the pump out side operati...

Page 109: ...t idle speed to be held when moved out a short distance and released If the choke control cable Is too free In operation so that it falls or creeps back when released it can be stiffened up by slightl...

Page 110: ...fiitted ifitem 4 is used 2 Slow running speed adjustment screw 3 Coupling yoke clamp bolt WSM 12 C Section C Fuel System 4 Slow running air adjustment screw not fitted If item I is used Fig 15 Synchro...

Page 111: ...final check of the slow running should be made after replacing the air cleaners 3rd re Issue Page 2S 9 After the slow running is correct a check must be made to ensure that under full throttle con dit...

Page 112: ...Disconnect the fuel pump delivery pipe and connect a reliable pressure gauge or mercury manometer to this point 2 Fit up a small tank of fuel a quart oil tin to feed fuel to both carburettors through...

Page 113: ...3 Lift out float The float needle is attached to the float by a clip Page 27 4 Remove four cheese headed screws holding throttle body to carburettor body and lift out venturi after removing its locat...

Page 114: ...UPPLY fig 17 Parts visible with top of carburettor removed WSM 124 Section C Fuel System ACCELERATOR PUMP DISCHARGE NOZZLE AIR FEED PASSAGE TO DISCHARGE NOZZLE ACCELERATOR PUMP DISCHARGE NOZZLE FIXING...

Page 115: ...tal cup on the top of the diaphragm when replacing the cover 4 The small gasket below the accelerator pump discharge nozzle should be renewed 5 The synthetic rubber ring fitted In the groove Ist re is...

Page 116: ...Page 30 68 I WSM 124 Section C Fuel System _ 46 5095 Fig 18 Exploded view ofcarburettor Items 76 to 80 shown n Inset are only usedon the WIA carburettor __ 2 26 IIC l 27 21 J...

Page 117: ...ttor throttle body 41 Slow running volume control screw spring 42 Slow running volume control screw Ist re issue Page 31 AA S _t_ B S F 1 Throttle body 43 Washer spring Tl crew 4 X b d cheese head to...

Page 118: ...roughly 4 Clean out the oil bath and refill with clean engine oil up to the level mark WSM 12A Section C Fuel System 5 Replace the oil bath container refit the filter cover with gauze and tighten thum...

Page 119: ...pressure plate assembly Staking locknuts Diaphragm Clutch To Remove and Refit Release Bearing To Adjust Rapier IV and Alpine IV HYDRAULIC SYSTEM Master cylinder Alpine Rapier Ill and I A Master cylind...

Page 120: ...der See item 40 Fig 3 Adjustment Alpine Serles I and Rapier Series Ill Cars The only external adjustment Is to the operating piston rod attached to the clutch withdrawal lever Adjustment between pedal...

Page 121: ...nder barrel and the clevis pin 73 from the clutch pedal Remove the fixing bolts and detach __ 4th re issue Pagel the cylinder and push rod Unscrew the filler cap and drain the fluid into a clean conta...

Page 122: ...reservoir with clean hydraulic fluid and test the master cylinder by pushing the piston Inwards and allowing It to return unassisted after a few applica tions fluid should flow from the outlet connect...

Page 123: ...bore Alpine Series I and Rapier Serles Ill cars Apply a LOW air pressure to the fluid connection to expel the Internal parts To assemble Flt the spring 36 in the cup filler 35 and insert 9 Piston Wuh...

Page 124: ...r pin In the hole D In the pedal stanchion Slide the bracket backwards or forwards as appro priate in order to achieve 2 to 25 5 mm to 6 3 mm offset of the spring axis to the rear of the pedal fulcrum...

Page 125: ...tween the release levers and the clutch cover These are painted red and are fitted to enable a clutch unit to be fitted to a flywheel without the necessity of compressing the springs In the cover Into...

Page 126: ...hree holes in the cover and the spider securing screws 1 Fig 5 Unscrew the cover clamping bolts evenly and lift off the cover Note the position and colour of the thrust springs Fig 8 Clamping clutch u...

Page 127: ...uts onto the eyebolts until they are flush Alternative method Assembly of the component parts Is the same as described In the preceding paragraph using the press and blocks In the same manner as when...

Page 128: ...t is enclosed within the rear end of the gearbox Later cars are fitted either with a needle roller WSM 124 Sec D Clutch Prop Shaft bearing rear universal joint Incorporating a bonded rubber vibration...

Page 129: ...niversal joint at the rear end these also do not require lubricating see inset B of Fig 12 The journal and needle bearing assemblies are the only parts subject to wear after prolonged service and when...

Page 130: ...rear universal Joint Is dismantled In exactly the same way as the front joint after removing the coupling For cars which are fitted with a metal to rubber WSM 124 Sec D Clutch Prop Shaft universal joi...

Page 131: ...cover strap drive bolts The diaphragm spring is pinched between two fulcrum rings 3 which are secured to the cover by special rivets 8 A release plate assembly 5 is attached to the cover 9 by three sp...

Page 132: ...op Shaft Under no circumstances must the clutch be lifted or pulled by means of the thrust plate or the straps will be bent and the alignment of the thrust plate destroyed Clutch Driven Plate To Remov...

Page 133: ...clearance and should remain undisturbed as far as possible Before removing the stop if necessary mark the position and recheck the clutch and brake pedal clearance after refitting the stop in the pos...

Page 134: ...is properly seated Assemble the WSM 124 Section D Clutch Prop Shaft retainer 7 on the smaller end of the return spring and Insert the assembly into the cylinder Insert the main cup 8 Into the cylinde...

Page 135: ...d forks Isolator switch to adjust to remove and refit 5 Operating valve Front cover Relief valve to remove and refit 7 to dismantle and reassemble 7 Pump valve Mainshaft To remove from car to remove a...

Page 136: ...box crossmember Remove starter and upper bellhouslng bolts Withdraw gearbox and bellhouslng rearwards and downwards Rapier Place the car on a ramp or over a pit Disconnect positive lead from battery D...

Page 137: ...pring 3rd re issue Page_l retaining cap to the extension casting and take off the cap spring and cupped washer Lift out the gear lever Note the spring loaded ball at the lower end of the lever This is...

Page 138: ...and spring located In the cover The safety latch selector lever and washers will now have become detached and may be removed Care must be taken when refitting that the washers are inserted in their c...

Page 139: ...or shaft 4 Circlip pliers V L C 7065 C and A points 5 Socket spanner RG 317 for malnshaft front nut SELECTOR SHAFTS AND FORKS To remove and refit Figs 2 and 3 It Is Imperative that these are removed R...

Page 140: ...EARLy ALPINE p COVER S A TO RLy CARS ER MAINSHAFT MAINSHAFT EA E PIECE SOME LAT B D DISTANC CIRCLIP AN SPEEDO DRIVE C R MOUNTING AND D REA fiearbox Exploded view o Fl1 3 6360 I I I I I...

Page 141: ...ynchrohub 30 In order to maintain efficient functioning of the synchronising mechanism it is advisable to correlate each baulk ring to Its mating cone by some form of identification e g using a sharp...

Page 142: ...to the following WSM 124 Section E Gearbox Overdrive Fig Sb Removing mainsha t Oil the inner surface of the second speed baulking ring 17 and secure it to its mating cone by light hand pressure in or...

Page 143: ...emove three shifting plates short 31 Remove two synchro clrcllps 32 from synchrohub Dismantle the second speed synchrohub as follows Remove first speed wheel 23 from hub 24 Detach the three long shift...

Page 144: ...fting plates and with the plain ends of the clrcllps pointing In opposite directions to each other The second speed synchro hub clrcllps must be assembled In exactly the same way as for a third and fo...

Page 145: ...washers 42 and 43 Replacement is a reversal of the preceding operation with particular attention to the followlng End float of the layshaft cluster between the thrust washers should be 0061n 008in 15...

Page 146: ...plete with dummy shaft into the casing and then fit the rear floating steel thrust washer 5 Pass the first and second synchrohub and second speed wheel assembly through the top of the casing with beve...

Page 147: ...embly with the drain hole in the six o clock position Page Ila 8 Invert gearbox and insert layshaft spindle through rear of casing ensuring that the thrust washers at each end are correctly positioned...

Page 148: ...7 shows the unit in overdrive The cone clutch Is held forward by hydraulic pressure so that the outer friction band of the clutch is locked to the stationary brake ring As the cone clutch is splined...

Page 149: ...orcing the pistons forward When the overdrive control is moved to the disengaged position the spring plunger pushes the ball on to Its seat and the valve falls away from the ball Oil from the cylinder...

Page 150: ...tem It must be emphasised that any hydraulically controlled transmission must have clean oil at all times and great care must be taken to avoid the entry of dirt whenever any part ofthe case Is opened...

Page 151: ...Fl1 10 Scoring operatlni valve ball seat WSH 124 Section E Gearbox Overdrive holding it centrally give a light tap indenting two grooves in the seating Alternatively score the seating with a sharp poi...

Page 152: ...ch on the ignition but do not start the engine 2 Move the overdrive facla swltch to OVERDRIVE 3 Engage third or top gear the safety latch will move over to the left pressing on the switch plunger The...

Page 153: ...arbox Overdrive A Q WARNING OVERDRIVE II LIGHT SWITCH 1 Yellow Green j 1 t LIGHTING __c 1 Yellow SWffCH Yellow Blue w white Y RELAY Yellow GEARBOX SWITCH A rl To FUSE UNIT A3 OVERDRIVE 7315 White SOLE...

Page 154: ...g at the top of the valve Near the bottom of the valve will be seen a small hole breaking through to the centre drilling This js the jet for restricting the exhaust of oil from the operating cylinders...

Page 155: ...ttached to the front housing by eight w studs The unit can be drawn off the main shaft leaving the front cover plate In position To refit to gearbox Before the ov_erdrlve unit Is fitted to the gearbox...

Page 156: ...withdraw the operating pistons by gripping their spigots with pliers Disconnect the balance pipe if fitted Loosen and progressively remove the eight nuts around the centre flange of the casing This wi...

Page 157: ...collapse Inspect the teeth of the gear train for damage If the sunwheel bush is worn the gear will have to be replaced since it is not possible to fit a new bush In service because it has to be bored...

Page 158: ...010530 Washer Alpine B 9009213 Filter Rubber joint Filter Filter cover plate Filter cover place 1asket Set screw securin1 fllter cover plate Wuher Solenoid and joint to casina Set screw Solenoid to ca...

Page 159: ...slotted nut Fit the annulus assembly into the rear casing and fit the circlip into the bearing outer track Ensure that the rear bearing circllp is located against the rear face of the casing The rear...

Page 160: ...tting second cage 3rd re issue Page 25 Fit the planet carrier pass the sunwheel splines into the open ends of the cone clutch member and fit the small clrclip at the forward end of the sunwheel Press...

Page 161: ...embly ensuring that the lower operating plunger engages with the small cam on the operating shaft If the pump body has been removed rarely neces sary Insert Its small end Into the casing In the middle...

Page 162: ...05 mm Valve spring load Pin for roller 3 15 lbs at r long 1 428 kgs at 14 29 mm Bore for pin In roller Gearbox Mainshaft Shaft diameter at sunwheel bush Sunwheel bush internal Shaft diameter at rear s...

Page 163: ...valve spring free length 1 328 33 73 mm I 182 30 02 mm ws 124 Section E Gearbox Overdrive Introduction points First production to 32 1450 7781 32 1450 n82 to 32 1536 1843 32 1536 1844 to 25 3013 1965...

Page 164: ...he solenoid plunger D touching the fork E screw in the stop pad F until the inner face of the recess in the pad F makes contact with the end of the adjusting nut C Then screw the stop pad F back three...

Page 165: ...lever and steering arms To check 9 34 9 13 14 34 TO REMOVE AND REFIT UNIT TO DISMANTLE AND REASSEMBLE UNIT To dismantle and reassemble front hubs Front hubs To adjust Stub axles To remove and refit St...

Page 166: ...n and lower link Thrust is taken via a nut and thrust washer to the lower face of the stub axle swivel This design obviates the necessity for a separate stub axle carrier thus affording a saving in un...

Page 167: ...nder these conditions gives rise to excessive tyre wear and tyre squeal when cornering 6 Ball pin heights These are o The dimensions between the lower link outer fulcrum pin centre and the centre of t...

Page 168: ...ame amount of wear 3 For checking the front wheel track the car should be in a normally laden condition 4 Both front wheels must be checked for run out To do this spin each wheel holding a piece of ch...

Page 169: ...nto Its sheath and retain it there with the damping screw under the dial head See Fig 6 Loosen knobs B and C Fig 5 so that the gauge can be adjusted to the width of the car Place the gauge in front of...

Page 170: ...ee movement of the gauge Take the reading on the dial See Fig 6 If correct retract the dial pointer and remove the gauge To adjust track toe in setting Leave the gauge In position Slacken the locknuts...

Page 171: ...vertical position Setting of outer track rods If new track rods are being fitted after accident damage or if excessive tyre wear is present the following procedure should be observed to ensure correct...

Page 172: ...11 4 Section F Front Suspension It is recommended that the ball joint alignment Is checked as a routine measure during the 12 000 miles 19 200 km service Ackerman angles toe out on turn When the front...

Page 173: ...et the front wheels In the straight ahead position on two turntable gauges Move the right hand front wheel through a 24 turn to the left Adjust the lock stop located on the top face of the lower link...

Page 174: ...lnf a typical readlnf of 0 positive camber Camber is POSITIVE if the bubble is in black figures and NEGATIVE if In red figures For the correct camber angle see General Data Section Reading castor and...

Page 175: ...g sure that the contact points of 2nd re Issue Page 11 the gauge to the tyre are clear of the normal bulge of the tyre above the contact area of tyre to ground Turn the scale of the gauge on its pilla...

Page 176: ...mber readings the indicator carrier may be used either side of the main pillar of the gauge I e 180 apart Regardless of which side of the main pillar the Indicator happens to be the camber reading wil...

Page 177: ...road wheel and will meas ure the angle through which the stub axle moves downwards from the straight ahead position on each 20 lock Turn the road wheels to 20 in the left hand lock 3rd re issue Page 1...

Page 178: ...ring ball pin heights After accident damage or in a case of excessive tyre wear these dimensions should be checked If they are outside of the limits shown In Fig 23 the wheels will not remain In track...

Page 179: ...ossible to check the steer ing arm dimension without plugging its taper hole TO REMOVE AND REFIT UNIT See Fig 14 Raise the car by placing a jack with a block of wood or other suitable packing under th...

Page 180: ...prevents lubricant from the hub getting on to the brake disc WSM 124 Section F Front Suspension RemovethediscbrakecalIper SeeSectionK Brakes Remove the hub cap 2 Remove the split pin from the castell...

Page 181: ...en the hub nut using a torque spanner to obtain a reading of15 20 lbs ft 2 07 2 76 kg m Release the nut 1 to 1 flats in order to provide end float and to line up one of the two split pin holes in the...

Page 182: ...d nut 18 until the two nuts 18 and 19 are locked together and fit a new split pin Flt the rubber seal around the adjusting nut 19 and thrust washer 20 Remove the spring compressor but do not fit the s...

Page 183: ...rms of the link are not stressed by spreading The locknut 29 must be fitted before the castel lated nut and tightened very securely at the same time holding the eye bolt 25 from turning The castellate...

Page 184: ...pin should project 3 27 3 26 83 82 8 mm This dimension is important and should be checked 6 Remove assembly from press and remove jack 7 Fit and tighten one locknut Fit second locknut and tighten TO...

Page 185: ...ing compressor tool and compress the road spring sufficiently to take the load of the spring 31 2nd re issue Page 21 Remove lower link eyebolt 25 Disconnect stabilizer bar and remove four bolts securi...

Page 186: ...ed to the lower link and prevents raure plate fromfallini over ALPINE I 745 44 32 MM f 755 11 44 58MM RAPIER 2 24 5 57 02MM 2 255 11 57 28MM _____ 31 II R 2 AD 9cM MATERIAL 5 mm MILD STEEL Fl1 18 Deta...

Page 187: ...ce ____ front of lllllt car 4505 Fig 19 Rear gap gauge Rapier Ist re issue Page 23 This item should be made from 1 25mm thickness hardwood by glueing a carefully made tracing of this illustration to t...

Page 188: ...nt Suspension X This end to __ __ face __ rear of car This item should be made from 1 25mm thickness hardwood by glueing a carefully made tracing of this illustration to the wood It can then be cut to...

Page 189: ...Fis 21 Ball pin heirht checkinr fixture in position Details of items 1 to 4 In Fig 22...

Page 190: ...ANGLE IRON 6 t 16c 111 IMPORTANT ITEM No J jTHIS LINE TO BE DEEPLY SCRIB ONTO BACK OF C ENTRE AFTER WELDING CENTRE INTO POSITION THE LINE MUST 8E THE AC TUAL CENTRE POINT HEIGHT ABOVE ANO PARALLEL TO...

Page 191: ...mm 5 83 148 08 mm This plate Is moved over to take dimension 8 A Swing lever 6 00 152 40 mm 5 86 148 8 4 mm Fl1 23 Ball pin heifht checking fixture in use Adaptor used to find centre of large end of t...

Page 192: ...mm 490 12 45mm 375 9 5mm 4 A j SOO DIA WSM ll4 Section F Front Suspension i i 560 DIA 1 tt t B S F 1 4 U N F 400 10 2mm 560 1 4 2mm 210 6 9mm 435 11 0mm 100 2 5mm 460 11 7mm 750 19 1 mm 550 13 95mm Fi...

Page 193: ...in turn Is housed In the outer tube This piston rod guide forms a bearing for the piston rod holds the rebound valve and drain tubes In position and contains the spring loaded piston rod seal D The cy...

Page 194: ...e lower spindle between two pieces of wood WSM 124 Section F Front Suspension Grip the dirt shield firmly with the hands and prime the shock absorber by working It up and down several times to expel t...

Page 195: ...OD D PISTON ROD SEAL E PIS TON ROD GUIDE F PORTS K ANTI FROTHING BAFFLE LREBOUNO r VALVE TUBE MPISTON VALVE ir m _ N ANTI FROTHING BAFFLE OREBOUNO VALVE p LOWER CYLINDER Q RESERVOIR 5096 R BASE VALVE...

Page 196: ...g changes All lubrication nipples have been eliminated by the fitting of metal and rubber bonded bushes to the innet ends of the top and bottom links pre packed upper and lower swivel bearings togethe...

Page 197: ...e eye type attach ments at their lower ends with rubber bushes Inserted into the eye and a horizontal bolt secures the shock absorber to a bracket which In turn Is attached to the underside of the bot...

Page 198: ...ts and washers remove the brakecaliper from the stub axle by withdrawing the remaining bolt and washer suspend the brake caliper nearby without straining the flexible hose Remove the brake disc and hu...

Page 199: ...lcrum pin A workshop press is used In conjunction with the special tool RG 319 which consists of Drive tool ii Support tool iii Replacing tool The top link and camber shims are removed from the crossm...

Page 200: ...axle by removing the nut from the tapered ball pin and using a suitable extractor RG 191A support the stub axle and hub assembly by positioning a block of wood between the rebound rubber and Its abut...

Page 201: ...RS To remove and refit A change has been made to the shock absorber attachment to the bottom link but can be removed from the crossmember In a similar manner to that Page 37 described under Stub axle...

Page 202: ...the lower arm of the link ensuring that the tube Is correctly located around the outside of the link bush S Position the mushroom driver between the nose cap of the press ram and the upper end of the...

Page 203: ...arm supported by the slotted tube as shown at C Ensure that the slotted tube Is properly located below the boss of the link 2 Place the link bush and driving tube in position between the nose cap of t...

Page 204: ...the link In the press with the fitted bush downwards and the threaded end of the fulcrum pin correctly located In the link bush lt will be necessary to reposition the packing blocks to clear the fulc...

Page 205: ...and refit To dismantle and reassemble To dismantle adjust and reassemble bevel pinion To adjust differential unit Measurement of differential bearings Adjustment of differential bearings To check adju...

Page 206: ...ft described in detail In this section The complete differential assembly is detachable from the axle casing after removal of the axle shafts when major attention to the unit is required The axle shaf...

Page 207: ...emove setscrew securing brake drum Remove brake drum Release brake pipe connections from rear of backIng plate Protect brake pipe connections against the ingress of foreign matter Remove nuts and bolt...

Page 208: ...Fla 3 Exploded view of rear axle Hypoid Bevel Drive...

Page 209: ...tre lock wire wheels Attach the retaining plate part of hub removing kit RG 188A to the hub by means of the set screws supplied Clamp the plate securing the shaft in the vice Remove split pin there ar...

Page 210: ...the nuts Place the whole assembly In a vice flt the nut and tighten with a torque spanner to 180 lbs ft 25 kg m It can be checked that compression has been obtained by attempting to rotate the Inner...

Page 211: ...ed 003 in 2 The tabwashers for the eight setscrews should be renewed and screwstightened to 45 55 lb ft 3 Bearing cap nuts tightened to 50 55 lb ft If bearings or crown wheel and pinion are renewed re...

Page 212: ...e ofaccuracy necessary In these adjustments VLC kit No R G 295B will be required To adjust position of pinion relative to crown wheel axis Note In Flf 6 the shims positions denoted A and 8 For this pu...

Page 213: ...measurement would be the thickness of shims to be added to the actual pinion at points Aand B toposition the pinion relative to the crown wheel axis In practice however It is found that as the bearing...

Page 214: ...s to rotate The reading on the scale should be 6 12 lbs 2 7 5 4kg for new bearings or 4 8 lbs I 8 3 6kg when the original bearings are fitted The torque loading can also be checked conveniently using...

Page 215: ...earlnf thicknesses C D and Having carried out the preceding operations re move the differential box bearings as previously described and shims In their place fit the dummy bearings without shims their...

Page 216: ...ness between the dummy bearing and the actual bearing used for each side See Measurement of bearings If the actual bearing Is thicker than the dummy bearing the amount must be subtracted from the meas...

Page 217: ...TACT heavy In the root of the drive gear tooth profile TOE CONTACT hard on the small end of the drive gear tooth HEEL CONTACT hard on the large end of the drive gear tooth Fl1 7 Specimen tooth markln1...

Page 218: ...revent loss of fluid Remove all sprlng U bolts Withdraw axle from between springs Re assembly is a reversal of the above operations Bleed brakes See Section K When refitting the axle to the springs th...

Page 219: ...per roller bearings carrying the differential housing and the bevel pinion shaft described In detail in this section The complete differential assembly is detachable from the axle casing after removal...

Page 220: ...Page 16 WSM 12 f Section G Rear Axle 0 QQ I I I I I t 0 ii 8 ts t 0 Cl 2 i J...

Page 221: ...her than the followlng Remove road wheel Remove all road dirt from brake backing plate around Its fixing to the axle tube flange Remove setscrews securing brake drum Remove brake drum 2nd re issue Pag...

Page 222: ...the following procedure should be adopted WSM 124 Section G Rear Axle Flt the split bush part ofVLC kit RG 188A 1 to the solid ring Note It Is not necessary to dismantle the tool to fit the split bush...

Page 223: ...re Issue Page 19 DIFFERENTIAL UNIT To dismantle and reassemble See Fig I 0 Remove assembly fromaxle as previously described Remove caps over bearings supporting differential assembly Lift off differe...

Page 224: ...d press RG 4221 B with the adaptor RG 4221 6 Pressure should be applied to the threaded end of the shaft A thread protector must be used Inner and outer races of bevel pinion bearings must not be rene...

Page 225: ...using the two dummy bearings and replacing the two bearing caps with the securing nuts fully tightened See Fig 13 A gap will exist betv een the end of the dummy pinion shaft and the centre jig Place t...

Page 226: ...ner end than the heel outer end of the tooth Adjustment is effected by using a WSM 124 Section G Rear Axle suitable length of tubing to drive the appropriate dummy bearing Inwards Having obtained the...

Page 227: ...tions of the crown wheel and must be 0 005 0 009 n 0 13 0 23 mm A dial indicator gauge must be used the body of which Is secured to the differential housing The reading Is then taken off the thrust si...

Page 228: ...ation To rebuild REAR SUSPENSION CONTENTS 1 4 Pas To check rear spring camber SHOCK ABSORBERS Alpine I and II Servicing Testing Topping up the fluid Rapier Servicing Construction Operation Testing Alp...

Page 229: ...s and washers from U bolts Jack up rear axle until it is parted from the spring and support it with suitable blocks of wood Remove U bolts Tap out lower shackle pin and shakeproof washer after removin...

Page 230: ...nut securing bundle clip to spring 26 Washer rear spring eye to frame 7 Rubber lining 27 Nut 8 Dowel bolt 28 Shackle 9 Dowel bolt securing nut 29 Shackle bush 10 Thrust button 30 Shackle pin ohaddetof...

Page 231: ...lip to spring 26 Washer rear spring eye to frame 7 Rubber lining 27 Nut 8 Dowel bolt 28 Shackle 9 Dowel bolt securing nut 29 Shackle bush 10 Thrust button 30 Shackle pln J 11 Dowel bolt sleeve 31 Wash...

Page 232: ...15 Clamp plate securing spring to 16 U bolt axle casing 17 Washer 18 Nyloc nut 19 Pivot pin 20 Washer 21 Washer fl OM spring eye to frame 22 Nut 23 Shackle pin 24 Washer rear spring eye to frame 25 N...

Page 233: ...20 SHACKLE PINS 4 WASHER 21 WASHERS 5 NUT 22 SHACKLE ASSEMBLY 6 CLIP 23 BUSH 7 RUBBER LINER 24 NUTS 8 BOLT 25 SHOCK ABSORBER NUT 26 BOTTOM BUSHES 10 DOWEL BOLT 27 RETAINING WASHERS II NUT 28 RUBBER B...

Page 234: ...ay result Before refitting the spring to the chassis check that the leaves are lying flush on each other Bushes may be pressed out of the spring or frame for renewal purposes The use of a suitable wit...

Page 235: ...f the cylinder Body Before carrying out the check work the shock absorber through six to eight strokes to expel any air present in the compression chamber Move the arm up and down through one complete...

Page 236: ...nting holes 8 Crank plate 9 Crank pin 10 Connecting rod 11 Compression piston 12 Piston pin 13 Recuperation valve 14 Compression or bump cylinder 15 Valve screw 16 Valve screw compression washer 17 Ru...

Page 237: ...ips act to exclude dirt etc and faces outwards Any fluid which exudes past the guide bearing is prevented from escaping further by the seal and a port below the seal allows fluid to return into the re...

Page 238: ...TON ROD OIL SEAL PISTON ROD GUIDE PRESSURE TUBE AT REST COMPRESSION I EXTENSION t Ist re issue Page II FLUID UNDER RESERVOIR PR S URE RESERVE TUBE C BASE VALVE D 376S B FLUID UNDER PRESSURE A Fl1 6 Di...

Page 239: ...working It up and down several times to expel the air Move the piston free top half up and down through one complete cycle to check the nature of the movement Moderate and even resistance throughout t...

Page 240: ...t the same time the lower part of the cylinder A is replenished with fluid as the foot valve plate 12 opens to allow recuperation from the reservoir C On slow rebound strokes fluid passes through a ca...

Page 241: ...Inward stroke should be felt If WSM 124 Section H Rear Suspension however the resistance Is slight erratic or free movement cannot be eliminated by priming then the shock absorber should be changed N...

Page 242: ...STEERING UNIT Description To remove To refit To dismantle To reassemble and adjust TELESCOPIC STEERING UNIT Steering column cowling Direction indicator switch Overdrive switch Horn ring assembly Steer...

Page 243: ...wheel hub A cancelling ring clamps around the upper end of the inner column When the steering wheel is returned to the straight ahead position a pawl on the cancelling ring operates a trip mechanism...

Page 244: ...refitting ensuring that the lower contact plate of the horn ring assembly is correctly and securely located over the key Inside the wheel boss STEERING WHEEL To remove 2nd re issue Page 3 1 Remove ho...

Page 245: ...shers 11 Damper button 4 Shims 12 Guide roller 5 Shims 13 Rocker shaft 6 Spring cap 14 Nut 7 Filler plug 15 Steel balls lower track 8 Top cover 16 Steel balls nut 17 18 19 20 21 22 23 WSM 124 Section...

Page 246: ...12 Loosen off the three bolts securing the steering unit to the front side member to enable the drop arm remover to be fitted 2nd re issue PageS 13 Remove the drop arm from Its spline using special to...

Page 247: ...Page6 WSM 124 Section J Steering N Iii it...

Page 248: ...r clip from the hanger on the bulkhead leaving the hanger itself in position 2nd re issue Page7 14 Jack up the front of the car and remove the nut and tab washer securing the drop arm to the rocker sh...

Page 249: ...steering wheel as previously described 6 Disconnect the parcel tray on the driver s side and drop It clear of the steering column WSM 124 Section J Steerin1 7 Jack up the front of the car and remove...

Page 250: ...Inner column 23 from the nut 14 and withdraw through the aperture In the upper end of the box This operation will 4th re issue Page9 release the twelve balls 20 from the upper track 21 which should b...

Page 251: ...efit the steering unit to the car as previously described WSM 12 4 Section J Steering BURMAN TELESCOPIC STEERING UNIT A Burman telescopic steering unit Is similar in design to the previous steering un...

Page 252: ...RING 8 HORN RING 9 STEERING WHEEL 10 SPLIT NYLON BUSH 11 STEERING WHEEL ADJUSTING NUT AND MOTIF Page 11 9 10 11 12 13 I I I I I I I I I l I I I I I I I I I I 6743 I _ 12 EXPANDER BOLT EXTENSION 13 SCR...

Page 253: ...ening off the pinch bolt 5 Refitting is the reverse of the removal sequence but particular attention must be given to the following points 7 BALL BEARING RACE 8 SPRING AND CIRCLIP 9 DOWEL 10 STEERING...

Page 254: ...t The three coil springs between the con tact plates returns the horn ring to the off position when pressure is removed from the horn ring To remove and refit Fig 3 1 Disconnect the battery 2 Lift the...

Page 255: ...2 The dowel re tains the splined extension piece within the inner WSM 124 Section J Steering column 2 and limits its upward and downward travel to predetermined amounts The lower end is slotted and h...

Page 256: ...ension piece 4 so the cross dowel 6 through the tapered end locates In the cuts In the end of the splined extension piece 4 and retained within byfitting the spilt nylon bush 11 onto the threaded end...

Page 257: ...ins and using a suitable extractor RG 191A withdraw the relay lever assembly from beneath the car 3 Refitting Is the reverse of the removal sequence but particular attention must be given to the follo...

Page 258: ...Remove the wider sealing ring bearing and P T F E washers followed by the Belleville washer pack from the upper face of the relay lever 4 As the pin is a heavy interference fit in the relay lever no...

Page 259: ...ve and dismantle the relay lever assembly see under Steering Relay Lever To remove and refit To dismantle and re assemble WSM 12 Section J Steering Series I to IIIA Models The bush bearings used in th...

Page 260: ...refit to dismantle and reassemble Handbrake anti rattle springs HYDRAULIC SYSTEM Bleeding the system Master cylinder to remove and refit to dismantle and reassemble Flexible hoses to remove and refit...

Page 261: ...n the hand brake Is correctly adjusted there Is four to six notches of handbrake movement before the wheels are locked If with the rear brakes In correct adjustment there Is excessivehandbrake free tr...

Page 262: ...tween the pistons and caliper is effected by rubber rings fitted in grooves in the caliper bores A metal splash guard Is fitted to protect the Inner face of the disc from grit On Serles I and II model...

Page 263: ...n Ing clips and pins 3 Refitting Is the reverse of the removal sequence but particular attention must be given to the following I Check the fluid level In the master cylinder reservoir to assess the p...

Page 264: ...Measurements are taken between the four machined faces inside the caliper and the disc Any off centre is corrected by positioning shims between the caliper and stub axle carrier with an equivalent thi...

Page 265: ...icle as pre viously described SPLASH GUARDS Splash guards are fitted to protect the Inner faces of the discs against grit On early Serles I models they are secured by brackets to the steering arm forw...

Page 266: ...nt approximately I in 25 4 mm from the outer edge Revolve the disc and check the indicator reading the maximum reading on the gauge should not exceed 0 004 in 0 10 mm When the disc has suffered damage...

Page 267: ...ackplate Fig 4 Rear brake assembly _rirht hand side Illustrated When hydraulic pressure is applied the piston operates the leading shoe and the cylinder body reacts by sliding on the backplate to oper...

Page 268: ...oad wheel Slacken off all available shoe adjustment by rotating the square headed adjuster anti clockwise arrowed in Fig I Remove the countersunk screw securing the brake drum to the hub and remove th...

Page 269: ...ditioned Service Unit Scheme whereby replacement brake shoe assem blies can be obtained In exchange for the old ones In territories where these facilities are not available relining may be carried out...

Page 270: ...protruding through the back plate by removing the clevis pin Disconnect the pressure pipe union from the wheel cylinder DRILL THROUGH LINING FROM THIS SIDE USING HOLE ALREADY IN BRAKE SHOE AS A PILOT...

Page 271: ...torque figures for the pipe unions are given under Maintenance Refit the brake shoes as previously described Bleed the brakes as subsequently described under 37 __ _ 85 72 MM 6290 Bleeding the system...

Page 272: ...cylinder bleed screw and fit the bleed tube Immersing the free end of the tube in a Jar containing a little clean brake fluid 2 Unscrew the bleed nipple three quarters of a turn operate the brake wit...

Page 273: ...ressure and feed pipe unions from the cylinder collecting the brake fluid In a suitable container Remove the clevis pin from pedal at push rod location Remove the two boltst passing through the master...

Page 274: ...where necessary To reassemble See Fig 8 It Is essential that all internal parts are meticulously cleaned with brake fluid before reassembly Do not use petrol paraffin trlchlorethylene or any other si...

Page 275: ...hose from rotating When fitted slide the hose locating plate onto the support bracket so the plain hole is on the feed pipe side feed the hose sleeve into the plate and bracket locating the sleeve hex...

Page 276: ...usted as follows Place chocks In front of and behind one of the front wheels to prevent the car from rolling and release the handbrake Remove the nave plates and jack up one rear wheel until It Is fre...

Page 277: ...locked See item 8 Fig 18 Before removing the filler cap to top up clean the area around the filler cap to prevent dirt entering the reservoir Ensure that the air vent In the filler cap is not choked T...

Page 278: ...re full braking power by a few light applications of the brake pedal It Is also advisable to do this after or during prolonged driving In wet weather under circumstances where the brakes are not in us...

Page 279: ...o dismantle and reassemble Special tool number RG 33 w 1 be required when carrying out this operation I Apply the handbrake jack up the front of the car and remove a road wheel 2 Undo the two bolts se...

Page 280: ...oove in the caliper bore Gently work round the seal with the fingers to ensure correct seating 12 Open the bleed screw item 3 fig 14 13 Coat the pistons 9a and b with lubricant and offer up squarely t...

Page 281: ...to press the dust seal retainer back Into position Caliper bridge bolts No attempt should be made to remove the brldfe bolts Joining the two halves of the caliper There Is no point In doing so and In...

Page 282: ...ces v When tab washers are fitted remove the hub assembly and turn the tabs of the four tab washers over the heads of the bolt and the hub refitted vi Set the hub end float see under Front hubs To adj...

Page 283: ...he efficiency of the hand brake for the same effort applied to the handbrake lever at the side of the driver s seat 8 I Micram Adjuster 2 Mask 3 Out Piston 4 S JOuter Piston S lnq t Piston 6 l iandbra...

Page 284: ...uld be fitted to the underside of the brake shoe flanges Fit the mlcram adjuster 1 and mask 2 into the slot at the toe of the leading shoe Offer up the shoes complete with pull offsprings to the backp...

Page 285: ...g to the brake shoe No attempt should be made to reline the brake pads on the front brakes WHEEL CYLINDERS See Fig 16 Each wheel cylinder consists of a die cast aluminium body 11 containing two piston...

Page 286: ...level of the brake fluid in the master cylinder reservoir has been allowed to fall so low that air has entered the system Always keep a careful check on the fluid level in the reservoir during bleedi...

Page 287: ...by unscrewing the union nut collecting any escaping fluid In a suitable container Disconnect the push rod from the brake pedal by removing the clevis pin Remove the two bolts securing the master cylin...

Page 288: ...nnermost Push the piston inwards with the end of the push rod 11 and secure the push rod by fitting clrclip 12 Make sure that the circllp beds evenly 8 WASHER 9 PISTON 10 SECONDARY CUP 11 PUSH ROD ASS...

Page 289: ...hose to the support bracket until Its other end has been secured Feed the hose sleeve Into the support bracket apply a spanner to the hexagon and set the run of the hose clear of all obstructions that...

Page 290: ...permits vacuum from the Inlet manifold to temporarily communi cate with the second side of the piston 5 In the vacuum cylinder 19 thus vacuum on both sides of the piston 5 Is equal When pressure is ap...

Page 291: ...LOW PRESSURE END 11 T SHAPED LEVER 12 AIR FILTER ASSEMBLY 13 VALVE CONTROL PISTON HIGH PRESSURE END 14 HYDRAULIC OUTLET PORT 15 END COVER PISTON BUFFER 17 TRANSFER TUBE 18 PISTON ROD 19 VACUUM CYLINDE...

Page 292: ...HE SCREW BE DISTURBED AIR FILTER The air filter element Is of a moulded cellular construction and sho uld be renewed in accord ance with the Instructions given In the Owners Instruction Book To renew...

Page 293: ...7 will push out the washer followed by the output piston 25 the latter Is then discarded WSM 124 Section K Brakes 14 Refitting Is the reverse of the removal sequence but particular attention must be g...

Page 294: ...sponge rubber backing ring 2 from the piston flange and fit the new one from the service kit Smear the spedal lubricant supplied in the kit on the leather seal 3 of the piston 5 xii Smear the piston r...

Page 295: ...et port of the air filter and the vacuum port to deter mine if there is any suction at either orifice 4 If suction can be detected it Indicates that the bores are scored or the components Incorrectly...

Page 296: ...lt Is faulty Test 5 If the brakes remain on disconnect the vacuum pipe operate the brakes to elimi nate all the vacuum in the servo unit and repeat the test If the brakes remain on the fault is not in...

Page 297: ...grommet ii Blocked filter or restricted air inlet Leak in servo vacuum Failure of seal or seals ii Scored bore WSM 124 Section K Brakes ACTION I Fit new parts from Service Kit ii Examine air filter e...

Page 298: ...edure Is as follows I With the ignition switched off pump the foot brake to destroy any vacuum in the servo unit 2 Remove the air vafve cover assembly item 19 Fig 22 by withdrawing the five securing s...

Page 299: ...Page 40 3 6 7 8 Fis 22 Se rvo unit exploded view Sect WSM 124 ion K Brakes 18 419 GZo 21...

Page 300: ...iew of the servo unit 1 4 RETURN SPRING IS BOLT 16 LOCKING PLATE 17 ABUTMENT PLATE 18 VACUUM SHELL 19 AIR VALVE COVER ASSEMBLY 20 AIR VALVE 21 AIR VALVE SPRING 22 SCREW 23 CONTROL VALVE DIAPHRAM ASSEM...

Page 301: ...creasing the hydraulic line pressure to the wheel cylinders There now exists therefore two hydraulic line pressures WSM 12 t Section K Brakes a The lower pressure line from the master cylinder to cham...

Page 302: ...NIFOLD INDU BOOSTED H DRAULIC o WHEEL PRESSURE T CYLINDERS RAULIC LINE HY MOASTER CYLINDER FROM VACUUM CONNECTION TO CTION MANIFOLD INDU D HYDRAULIC BOOSTE WHEEL PRESSURE TO CYLINDERS HYDRAULIC LINE F...

Page 303: ...5040184 should also be ob_tained The dismantling of the control valve assembly only is covered by operations 1 5 WSM 124 Section K Brakes I Remove the servo unit from the car as pre viously described...

Page 304: ...ons for which are as follows Inside diameter Outside diameter Length Page 4S 0 688 0 690 in 17 48 17 53 mm 0 9735 0 9745 in 23 73 23 75 mm 1 37 1 38 in 34 8 35 1 mm I Position the slave cylinder 26 in...

Page 305: ...the slave cylinder followed by the valve housing 24 and secure by fitting the four screws WSM 124 Section K Brakes 15 Place the control valve diaphragm assembly 23 on the valve housing 24 with the na...

Page 306: ...adjustment excessive handbrake lever travel is still experienced adjust the length of the long and short handbrake cables as follows I Chock the front wheels release the handbrake and jack up the rea...

Page 307: ...the car to the ground apply the hand brake and remove the chocks WSH 124 Section K Brakes Handbrake operation Fig 26 Early Rapier Series IV Models To improve handbrake operation on early Rapier Serie...

Page 308: ...constant depth Adjustment hand operated Fig 28 The handbrake mechanism is set during Initial assembly and will only require attention when replacement parts have been fitted or the length of the cable...

Page 309: ...the trailing shoe from the wheel cylinder body the tension of the pull off springs is released and the leading shoe can now be removed from the slot in the tappet 6 Refitting is the reverse of the re...

Page 310: ...ster wheel from the outer piston by removing the rubber band 3 Withdraw the outer piston and pressing from the wheel cylinder it will be necessary to rotate the piston a short distance to disengage th...

Page 311: ...Wheels TYRES AND WHEELS CONTENTS TYRE EXAMINATION TYRE AND WHEEL BALANCE PRESSED STEEL WHEELS WIRE WHEELS CHANGING POSITION OF TYRES NYLON TYRES WHEEL ALIGNMENT WHEEL TRIM DISCS 2nd re issue Page 1 P...

Page 312: ...s of these balance weights as well as the position of the tyre on the wheel should be marked with chalk on the rim so that subsequent replace ment may restore the original balance as far as possible T...

Page 313: ...ound If possible the car should be run a short distance to settle the wheels on the splines and the nuts re tightened Extreme care must be taken to ensure that the O ring on the conical seat of the hu...

Page 314: ...e and vica versa The offside hubs are marked RHS and the nearside LHS NYLON TYRES WSM 124 Section L Tyres Wheels Nylon tyres may develop temporary flatting after standing for some time and cooling off...

Page 315: ...ASHER DISTRIBUTOR Maintenance Servicing FAULT FINDING FUSE UNIT GENERATOR Maintenance Servicing HORNS INSTRUMENTS AND CONTROLS LAMPS SPARKING PLUGS STARTER DRIVE Maintenance Dismantling and Reassembly...

Page 316: ...wn Into the following unlts 1 Battery 2 Generator control box and fuse unit 3 Starter and starter switch 4 Ignition system coll distributor and plugs 5 Lamps switches direction indicators windscreen w...

Page 317: ...om rust or corrosion 6 Measure the specific gravity of the electrolyte in each cell in turn with a hydrometer The reading given by each cell should be approxi mately the same if one cell differs appre...

Page 318: ...Increase over three successive hourly readings During the charge the electrolyte must be kept level WSM 124 Section N Elec Equip with the tops of the separator guard by the addition of distilled wate...

Page 319: ...the generator output This charge should not be broken by long rest 2nd re issue Page S periods If however the temperature of any cell rises above maximum quoted Climate below 90 F 32 C Climate above...

Page 320: ...tator end in a porous bronze bush ROUTINE MAINTENANCE Lubrication Inject a few drops of engine oil into hole marked Oil at the end of the C E bearing housing See Fig 2 The felt ring acts as a reservoi...

Page 321: ...re issue Page 7 3 Withdraw the commutator end bracket 1 from the yoke 6 4 Lift the driving end bracket and armature assembly from the yoke Take care not to lose the fibre thrust washer 5 from the com...

Page 322: ...with a strip of fine glass paper while rotating the armature The commutator is of moulded construction and can be re skimmed during service but care must be exercised to ensure that the finished diam...

Page 323: ...is available the field coils must be replaced To do this carry out the procedure outlined below 1 Drill out the rivet securing the field coil terminal assembly to the yoke and remove the insulated sle...

Page 324: ...c Equip 2 Press the bearing 13 out of the end bracket and remove the corrugated washer 14 and felt ring 8 3 Before fitting the replacement bearing see that it is clean and pack it with high melting po...

Page 325: ...turns to the predetermined maximum The cycle is then repeated and the armature is set into vibration As the speed of the generator rises above that at which the regulator comes into operation the am p...

Page 326: ...off voltage Reverse Current SERVICING 12 7 13 3 8 5 11 0 3 5 5 0amp Testing in position to locate fault in charging circuit If the generator and battery are In order check as follows 1 Ensure that th...

Page 327: ...d on open circuit will build up a high voltage Therefore when adjusting the regulator do not run the engine up to more than half speed or a false setting will be made 2 Mechanical Setting The mechanic...

Page 328: ...t Is well clear of the armature tension spring Slacken the two armature securing screws Press the armature squarely down against the copper sprayed core face and re tighten the armature securing screw...

Page 329: ...driving belt This should be just taut enough to drive without slipping 3 Check the generator by substitution or by disconnecting the generator cables and linking the larger generator terminal D to the...

Page 330: ...erator at 3000 r p m ROOTES MAN UAL WSM 124 Section N Elec Equipment 7 Using the correct tool turn the voltage ad justment cam until the orrect setting Is obtained turning the tool clockwise to raise...

Page 331: ...nection to terminal D is to withdraw the ignition warning light feed from control box terminal WL and to clip the voltmeter lead to the small terminal blade thus exposed this terminal being electrical...

Page 332: ...drop off occurs outside these limits an adjustment must be made In this event continue as follows 4 Stop the engine and remove the control box cover ROOTES MANUAL WSM 124 Section N Elec Equipment 5 A...

Page 333: ...and should have a polished appearance If It Is dirty clean It by pressing a fine dry cloth against It while the starter Is turned by hand by means of a spanner applied to the squared extension of the...

Page 334: ...TS AND WASHERS 2 THROUGH BOLT 3 COVER BAND 4 TERMINAL POST WSM 124 Section N Elec Equip springs and move the brush by pulling gently on its flexible connector If the movement is sluggish remove the br...

Page 335: ...a strip of fine glass paper while rotating the armature To remedy a badly worn commutator dismantle the starter drive as described under Starter Drive and remove the armature from the end bracket Now...

Page 336: ...four pole shoe retaining screws by means of the wheel operated screwdriver Draw the pole shoes and coils out of the yoke and lift off the coils Fit the new field coils over the pole shoes and place t...

Page 337: ...meshing correctly with the flywheel It may be that the drive requires cleaning The pinion and barrel assembly should move freely on the screwed sleeve if there Is any dirt or other foreign matter on t...

Page 338: ...t breaker about the cam thus advancing the spark for part throttle operating conditions The combined effects of the centrifugal and vacuum operated timing controls give added efficiency over the full...

Page 339: ...rease In roughness Having thus located the defective cylinder stop the engine and remove the cable from the sparking plug terminal Restart the engine and hold the cable end about 5 mm from the cylinde...

Page 340: ...ch Connect the voltmeter between the ignition switch terminal to which the lead from the control box is connected and a good earth No reading Indicates a faulty lead or loose connections 4 Ignition sw...

Page 341: ...to the terminals in the distributor cap remove the cap and slacken the screws on the inside of the moulding Cut the cables to the length required and push firmly home into the holes in the moulding Ti...

Page 342: ...g renewal The single long bearing bush used in this distributor can be pressed out of the shank by means of a shouldered mandrel If the bearing has been removed the distributor must be assembled with...

Page 343: ...shing fully home Refit the moulded cover Renewal of contacts If the contacts are so badly worn that renewal Is necessary they must be renewed as a pair and not individually The contact gap must be set...

Page 344: ...ired Check on the road and If necessary carry out further adjustment To remove glass and reflector assembly Refer to Fig 24 Take out the screw at the bottom of the rim with screwdriver The lamp front...

Page 345: ...lecting surface ls protected to the extent of producing continual reflective efficiency without deteriora tion fth re issue Page 27 Fig 24A Headlamp Assembly Later Models KEY TO FIG 25 I FRONT RIM 2 S...

Page 346: ...the use of an optical type beam setter can be employed providing it is of the type Lucas No 571119 If the use of neither type of beam setter is available a fair degree of accuracy can be attained by u...

Page 347: ...driver Reassembly Is a reversal of the above instructions Fig 28 Side lamp details Alpine 1 II and II 6th re issue Page 29 SIDE LAMPS AND FRONT FLASHER BULBS Alpine IV models Refer to Fig 29 To renew...

Page 348: ...ER PLATE ILLUMINATING LAMP Release the dome shaped glass by sliding the retaining clip to one side Take off the glass and renew the bulb Refit the glass and move the retaining clip into position STOP...

Page 349: ...flasher unit and circuit from the fuse box up through the steering column switch in the order named The flasher unit is located inside the car and Is plugged into a socket on the underside of the fac...

Page 350: ...hilst using either direc tion indicator CAUTION ROOTES MANUAL WSH 124 Section N Elec Equip In countries where the headlamp flasher operates on the main beam it Is Inadvisable to use the flasher contin...

Page 351: ...account is the central locknut or slotted stem to be disturbed on the 9H model horn s Maintenance If the horns suddenly fail to sound after operating normally the cause is unlikely to be in the horns...

Page 352: ...idge which mounts the contact and coll assembly These are No 69087 Model 9H ROOTES MANUAL WSM 124 Section N Elec Equipment 69090 69127 69128 69131 and 69132 Remove the cover securing screw take off th...

Page 353: ...hat of mal adjustment or the presence of foreign matter between the contact points In this Instance the adjusting screw Is to be rotated slowly in a clock wise direction for almost one half turn Shoul...

Page 354: ...under all conditions It Is essential that parts of identical pattern to the original equipment be fitted Oil tar and other stains on the windscreen may be removed by the judicious use of methylated sp...

Page 355: ...djustment GROOVE IN GEARBOX COVER Fig 35 DRJA wiper motor 4th re issue Page 37 ALIGNING PIP DR3A wiper motor Later models With the wiper arms positioned on their serrated spindles so as to provide the...

Page 356: ...ked position with the wiper blades against the screen moulding will result in noisy operation and a reduced arc of wipe Slight adjustments to the parked position of the wiper blades may be carried out...

Page 357: ...g assembly Is replaced and secured Horn Ring Assembly To dismantle Remove horn ring assembly from steering column see above Turn the assembly over and remove three 4 B A self locking nuts with washers...

Page 358: ...TER SWITCH ROOTES MAN UAL WSM 124 Section N Elec Equipment a D C voltmeter movement to which a pointer Is attached so that when the engine Is running this moves round the instrument dial which is cali...

Page 359: ...ded by a heater winding and the transmitter unit is of a resistance type The system by which the equipment functions is voltage sensitive and the voltage regulator which serves both indicators Is nece...

Page 360: ...d Charge battery either by a long period of day time running or from independent electrical supply Broken or loose connection in See that connections to battery starter starter circuit and starter swi...

Page 361: ...own by lack put when car is running steadily of power when in top gear Due to starting Hydro meter reading less Generator belt slipping Adjust belt see Section B than 1 200 Loose or broken connections...

Page 362: ...hen quickly separated by the fingers when the Ignition switch is on Dirty or pitted contacts Contact breaker out of adjust ment Turn engine until contacts are fully opened and test gap with gauge ROOT...

Page 363: ...signs of deterioration or crackin Examine the carburettor petrol supp y etc LIGHTING TROUBLE Lamps give insuffi Battery discharged Charge battery either by a long period cient illumination of daytime...

Page 364: ...NG DIAGRAM SNAP LOCATIONS COLCUlf __ff u 81 UE W 41T N cw y Yl t LOW I c tffN ltl 0 p P a LACK CONNECTOR 8 On right hand front wing valance 9 10 Behind left hand quarter trim pad Under facia In line w...

Page 365: ...l 3il C i J1 i LH ITOPLAMP CAllNW1 A MOTOR ANO IWITCH DIST UToa O IINMUYI CIR CUit Wlllll LH MAR H AS K R RH FLA Httl WAANtMG 1 IGMT GO cw AJ4 FIIONt rLASH11 11 H IIIM FLAINll 11 IMAP CONNIC IOIII TE...

Page 366: ...N W jF1TT1tul G w 7 L A5Hf q StC eLMtP L H AMP L H SNAP CONNECTOR LOCATIONS A Left hand front wing valance B Rlght hand front wing valance C Beneath facia adjacent to steering column D On bulkhead be...

Page 367: ...e Page 49 A Left hand front wing valance B Rlght hand front wing valance F At rear of facla adjacent to instruments G At left hand side of gearbox C Beneath facia adjacent to steering column 0 Beneath...

Page 368: ...h instruments M Adjacent to windscreen wiper motor N Left hand wing valance beneath control box Rapier Series IV Later Models A At rear of right hand tail lamp cluster B At rear of left hand tall lamp...

Page 369: ...0C1 AMP R H H AOL AMP R M MOAN6 WIRING DIAGRAM HEADLAMPI H CO OUR CMAR1 u e 1 ua W WMITE N SQOWN V IEl_LOW G GlltlrN 5 0C L AMP L M M41NMAM WA NINO LICHT uw U o 7124 WIRING OF HERDLRMPS W LfGHT F LRSH...

Page 370: ...MP H 7252 HeAOLAMP 11 H r i r MAIN BEAM W 1 IG ff HEA01 MP LH WIRING FOi Hl ADLAMP FL ASH L M O MODELS OM Y I I I I I I I I jN I I I I I I I I I I I I I I I I I I I I I r J J I Tt11 5 LE 0 9utRtEO Oi...

Page 371: ...N y y G GREE I _ _ s o o o _ J t 1 t TO R UNIT M C G scql MW1PIA SWtTC SCAt WIPER G N MOTOA 510EL 4 P A J 1 MEAOl AMP R H HFACl MICI sw F OIPPt R SWITCH I _UR MEADL AMP A 1 4 MC AQLAMPL M 5l0 LA MP L...

Page 372: ...COMPONENTS WEATHERSTRIPS WINDSCREEN BACKLIGHT INTERIOR DOOR HANDLES TRIM PADS WINDING WINDOWS QUARTER LIGHT GLASS NO DRAUGHT VENTILATOR FRONT SEAT FRONT SEAT SQUAB REAR SEAT CUSHION REAR SEAT SQUAB AR...

Page 373: ...SM 124 Page 2 Section O Body Page EXTERIOR DOOR HANDLE 19 STRIKER UNIT 19 WINDOW REGULATORS 20 BONNET 20 BONNET LOCK 21 BOOT LID 22 BOOT LID LOCK 23 GRILLE ASSEMBLY 23 BUMPERS 2 4 BODY MOULDINGS 2 4 N...

Page 374: ...13 081 M 9 5 56 1 122 C M 10 27 78 70 55 C M 11 29 44 74 77 CM 12 O ZS 0 635 c M REA l PRINC FRONT EYE LOCATION 14 13 _ 3 97 IQ 08 M 14 49 14 124 82 c M 15 43 42 110 29 C M 16 27 12 69 364 17 _0 88 2...

Page 375: ...S l5 13 081 C M 9 5 56 I 122 C M 10 24 36 61 87 C M li 74 16 1 8 36 c M 12 1 38 3 505 C M lll AII ENGINE MOUNTING REAR SPRING FRONT EYE LOCATION 13 Z 96 7 518 C IWI 14 0 34 0 863 c M 15 46 117 96 C M...

Page 376: ...film over the whole of the con tacting surfaces of the rubber and panel Bonding st re issue Page 5 A period of 15 minutes should be allowed for the adhesive to become tacky before the rubbers are mou...

Page 377: ...traces of old sealing compound from the glass and glazing rubber Fig 1 Windscreen refitting Rapier WSH 124 Section 0 Body B Fig 2 Cross section of weatherstrip Rapier Apply a coating of Seelastik to...

Page 378: ...f special tool Carefully remove any surplus sealing compound with a rag slightly dampened with petrol or white spirit WINDSCREEN To remove and refit Alpine It Is recommended that if the windscreen has...

Page 379: ...The services of two operators are needed to carry out the removal and refitting operations one work ing on the Inside and one on the outside of the car The glass is located by means of the glazing ru...

Page 380: ...ssue Page 9 The backlight is located by means of the glazing rubber around its periphery only No other fixing is used but the contacting surfaces are treated with Seelastik during assembly To remove T...

Page 381: ...In the handle shank line up with the pin the groove on the escutcheon and push the handle in towards the trim pad WSM 124 Section O Body When the pin locates with the hole in the spindle force it home...

Page 382: ...flange on the door at its upper edge The pad Is now free Fig 11 Removing o trim pad Rapier illustrated Page II Fig 12 Genera view ofdoor with trim pad removed Rapier To refit Enter the upper edge of t...

Page 383: ...ve and refit Rapier Fig 15 Remove window winding handle Remove rear seat cushion and squab The retaining screws for the squab are accessible from inside the boot Remove the trim panel from below the w...

Page 384: ...ning screws and forwards for the rear screws Upon removal of these the seat assembly is free to be removed from the car Refitting is a reversal of the above instructions FRONT SEAT Removal of trim All...

Page 385: ...Fig 16 Door glasses and mechanism Rapier Coupe 9 WINDING WINDOW FRAME 10 WINDING WINDOW I I GLASS CHANNEL ANO CAMPLATE 12 SEAL 13 GLASS RUN CHANNEL 19 20 21 22 2 4 25 26 WSM 124 Section O Body QUARTE...

Page 386: ...ING RUBBER 10 GLASS CHANNEL AND CAMPLATE 18 GLASS 3 GLASS II SEAL 19 WEATHERSTRIP DRAIN CHANNEL 12 GLASS RUN CHANNEL 20 NUT 5 WEATHERSTRIP 13 RETAINER DOOR TRIM PAD 21 SEAL OUTER FRAME 1 4 REMOTE CONT...

Page 387: ...ft the squab upwards to release Its retaining clips and remove It from the car To refit WSM 124 Section O Body Enter the clips at the top edge of the squab and push the lower edge of the squab Into po...

Page 388: ...ng A pine Page 17 door flanges and backlight aperture and allow it to become nearly dry To refit the lining reverse the removal procedure The lining when fitted must be free from creases with no saggi...

Page 389: ...olts securing the hinges to the body and moving the doors In the required direction after which the securing bolts must be re tightened In order to raise or lower the door diagonally packing pieces of...

Page 390: ...door trim Page 19 From inside the door casing remove nut at front and screw at rear Both are fitted with plain and shakeproof washers To adjust On the reverse side of the push button is a plunger hel...

Page 391: ...g retaining screws from window regulator Rapier QUARTER LIGHT GLASS REGULATOR To remove Rapier Fig 25 Remove interior trim Temporarily replace window winding handle and lower window to approximately h...

Page 392: ...ree lever 8 and take out lock To remove striker undo the locknut from above the baffle into which the unit fits and turn in an anti clockwise direction by the screwdriver slot provided Replace both st...

Page 393: ...tachment points Alpine 6 WSM 124 Section O Body L W Fi1 32 Components of the boot lid lock Rapier I LOCKING BARREL 5 SPRING 2 PUSH BUTTON 6 PUSH BUTTON ASSEMBLY 3 HOUSING 7 BRACKET 4 LOCK Replace both...

Page 394: ...Reverse the above procedure BOOT LID LOCK To remove Alpine From below the outer edge of the boot weather strip remove the two self tapping screws Remove the tv o screws from the rear of the top face o...

Page 395: ...h their washers for both the front and rear bumpers WSM 124 Sectio 1 0 Body L In the latter case remove the nuts and washers from the outer sides and the bolts and washers which also retain the overri...

Page 396: ...WSM 124 Section P Lubricants RECOMMENDED LUBRICANTS CONTENTS LIST OF RECOMMENDED LUBRICANTS 2nd re issue Page I Page No 1 3...

Page 397: ...Oil Shaft and Cam bearing Contact breaker pivot Automatic timing Spark control Engine Oil Cam Profile and shaft greaser Shell Retinax A GENERATOR BATTERY TERMINALS STEERING UNIT FRONT SUSPENSION where...

Page 398: ...x 80 E P Shell Retlnax A No attention required Shell Retlnax A Engine Oil Engine Oil Girling Fluid S A E Spec 70 R 3 5th re Issue Pagel Lockheed Super Heavy Duty Brake Fluid to S A E Spec 70 R 3 No at...

Page 399: ...SEALS AND TAPER ROLLER BEARINGS CONTENTS 3 Pac OIL SEALS Leather seals impregnated with wax Synthetic rubber seals TAPER ROLLER BEARINGS Cups Roller assemblies Cones on stationary shafts Cones on rev...

Page 400: ...t allow the assembly to rest for any length of time in an incomplete stage of fitting where It might cause the weight of the shaft or housing to be borne by the seal resulting in damage or distortion...

Page 401: ...e seating for the cup which should be assembled clean and smeared with lubricant after installation 2 Roller Assemblies Before placing in position all old grease must be scrupulously cleaned out and t...

Page 402: ...CRIPTION Rapier Series Ill and IV Alpine Series I IV ADJUSTMENTS Rapier Series Ill and IV BLOWER To remove and refit Rapier Alpine CONTROLS To remove and refit Rapier Alpine HEATER To remove and refit...

Page 403: ...open up the heater In order to carry out adjustments Fresh air enters the heater by ram effect via the blower ventilator air hose and is boosted by the action of the blower if fitted when required C...

Page 404: ...r Control Valve Is closed See also Fig 2 Car Control When the Car control lever Is _moved from the Cold positon towards Hot the Air Mixing Valve A progressively approaches the vertical position See Fi...

Page 405: ...e remains fully open The Cold Demist Valve C Fig 1 controls the amount of cold air entering the Demist Cold Air Passage F Fig 1 and Is Interconnected with the Hot Demist Valve D Fig 1 which controls t...

Page 406: ...mal and that full movement Is achieved without slack N L Adjust the cables at the heater unit end CABLE If normal function is not restored or derangement of the linkages has inadvertently occurred pro...

Page 407: ...the Screen cable at the heater end Loosen the rear throttle bracket securing screw and remove the forward one Remove the right hand heater securing screw and the two upper screws which anchor the hea...

Page 408: ...ns N and O Disconnect battery _l j Page7 Remove control lever knobs screw off Remove console and filler panel Series IV only Release the lower facia panel Release control disconnect cable and withdraw...

Page 409: ...fter refilling it may be necessary to bleed the heater See TO BLEED THE HEATER l WATER VALVE To remove and refit Set the Temperature control to HOT Max and drain the cooling system save anti freeze If...

Page 410: ...h also secures the blower earth lead and carefully withdraw the blower Page 9 Retitting is a reversal of the above operations When refitting the blower ensure that the upper sponge collar is in positi...

Page 411: ...ter Arbor 336 79mm bore engine Adaptor Collelts 2 Use with Flywheel Spigot Bearing Remover 7600 Piston ring compressor 81 5mm bore engine Adaptor Use with Con Rod Jig 335 Master Arbor 336 81 5 mm bore...

Page 412: ...Adaptor for coll spring compressor Use with RG 50D main tool RG 187 SteerIng idler lever bush remover and replacer adaptor Use with shackle pin RG 191A RG 192 RG 193 RG 194 RG 196A I RG 198A General E...

Page 413: ..._ PRINTED IN ENGLAND 9Y WREN PRINTING CQ LTD LONDON...

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