Reliant ROBIN 850 Workshop Manual Download

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Summary of Contents for ROBIN 850

Page 1: ......

Page 2: ...fication Lubrication and maintenance Frame Front suspension Rear suspension Steering Cooling system Engine Gearbox Clutch Driveshaft Rear axle Brakes Road wheels Exhaust system Fuel system Body Interior Heater Electrics Windscreen washer Optional extras Tightening torques ...

Page 3: ...t prin d on coloured paper is intended to be read in conjunction with the existing Workshop Manual R Part No 90293 A comprehensive stock of spare parts are available from Reliant Dealers A spare parts list is available for use when ordering Only genuine Reliant R Parts should be used R Part Number 91769 ROBIN850 Workshop Manual Suppl ement Service Department Reliant Motor Company Limited Two Gates...

Page 4: ... 1 Rear axle Type Ratio Brakes System Size front rear Handbrake Ignition 12 volt battery and coil Contact breaker gap Spark plugs type gap Firing order Ignition timing Cooling system 3rd 1 320 1 2nd 2 050 1 1st 3 880 1 Reverse 3 250 1 Spiral bevel gear semi floating 3 23 1 Hydraulically operated internal expanding to all wheels 177 8 x 38 1 mm 7 x 1 50in 177 8 x 31 75mm 7 x 1 25in Lever type opera...

Page 5: ...el Van 3327 4 mm 131 0 in 1422 4mm 56 0in 1371 6 mm 54 0 in 533 4mm 21 0in Ground to van floor 850 9mm 33 5in Rear door aperture 762 0mm 30 0in Rear door aperture 889 0mm 35 0in 93 1 mm 26 5 in Load floor width behind rear seat 965 2 mm 38 0in 1168 4mm 46 0in 1219 2mm 49 0in 965 2mm 38 0in Load capacities Saloon Capacity of boot area rear seat up spare wheel in position below tonneau cover 0 2306c...

Page 6: ...ons listed below should be carried out at the mileages shown or at the equivalent monthly intervals whichever occur first l ubrication Check and top up engine oil level Change engine oil Check and top up gearbox oil level Change gearbox oil Check and top up rear axle oil Check and top up steering box oil level Oil or grease all lubrication points 2 cD cD X 6 Front suspension swivel pin 7 Oil filte...

Page 7: ...X Remove and clean carburettor X X X Clean and adjust sparking plugs X X X Renew sparking plugs v Check hydraulic system bleed and top up master cylinder as necessary X X X X Check and top up master cylinder S necessary X X X Inspect brake system for leaks and hoses for chafing X X X X X X Examine brake linings for wear blow out X X X X Adjust brakes X X X X X X Check and adjust clutch X X X X X X...

Page 8: ...creen wiper etc X X X X X Check headlamp alignment X K X Check windscreen washer reservoir X Road test Adjust carburettor and ignition as necessary X X X X X X Check brake function X X X X X X Every 36 000 miles 60 000km the hydraulic braking system should be overhauled checking all bundy pipes and replace all flexible hoses Replace brake wheel and master cylinder seals or replace the units Change...

Page 9: ... EP 80 EP Pontonic Lubricant CD Light MP SAE 80 EP 80 Rear axle Mobilube CastroI Esso Gear Gear Oil Spirax Fina Hypoid 90 Multigear GX 90 Hypoy Oil GX SAE 90 EP 90 EP Pontonic Lubricant 90 140 MP SAE 90 EP 90 Steering box Mobilube Castrol Esso Gear Gear Oil Spirax Fina Hypoid 80 Multigear GX 80 Hypoy Oil GX 80 SAE 80 EP 80 EP Pontonic Lubricant Light MP SAE 80 EP 80 Front hub Mobilgrease CastroI E...

Page 10: ...Section A The frame Checking for squareness 2 ...

Page 11: ...The frame Section A 249 0mm 250 0m 9 80 9 85 1 291 0mm 11 45 292 mm 11 50 Figure 1 Frame checking dimensions Figure 2 Frame checking diagram 173 0mm 6 81 114 0mm 6 85 0 8 B 1 D ...

Page 12: ... each other on the datum line Chassis distortion is always assessed by the amount and direction of any transverse or diagonal lines from the datum line Severe damage to the chassis frame is readily apparent In some cases however lesser damage may cause distortion of the frame which may not be easily detected by visual inspection Even when the vehicle has suffered only superficial damage it is poss...

Page 13: ...Section B Front Suspension Routine maintenance 2 Front hubs 2 Stub axle assembly 3 Damper unit 4 Radius arm assembly 5 ...

Page 14: ... Taper pin 15 Lubricator swivel pin 16 Bush swivel pin top 17 Bush swivel pin bottom 18 Thrust washer swivel pin 19 Peg thrust washer 20 Thrust washer stub axle 21 Welch plug swivel pin 22 Front hub 23 Wheel stud 24 Retaining washer hub 25 Nut front hub 26 Split pin nut 27 Locking device hub nut 28 Cap front hub 29 Bearing front hub outer 30 Bearing front hub inner 31 Felt oil seal 32 Retainer CD ...

Page 15: ...rings and oil seal 6 Remove outer taper bearing and then tap out bearing track from hub using a suitable drift 7 Using the same drift from inside the hub tap out the inner bearing track complete with bearing and oil seal 8 Check components for wear and replace if necessary for subsequent reassembly To reassemble 1 Locate inner bearing track in its housing in the hub and ensure it is firmly and squ...

Page 16: ...ng bracket Figure 4 Swivel pin removal 6 Remove two set screws and lockwashers and then slide the brake plate assembly back onto the radius arm 7 Drill a small hole in the two welch plugs which are located in the top and bottom of the swivel pin housing of the stub axle The plugs can then be prised free 8 Tap out the taper pin securing the swivel pin in position using a suitable drift 9 Using MCA ...

Page 17: ...en secure steering arm to stub axle and brake back plate with long and short fs UNF bolts and lockwashers 9 Reconnect steering arm to track rod with i UNF nut and plain washer 4 10 Reconnect flexible brake hose at mounting plate 11 Refit front hub assembly as described earlier in this section Refit brake drum and road wheel and readjust brakes 12 Jack down the vehicle remove stands and bleed the b...

Page 18: ... damper unit from its housing on the the radius arm 5 Remove i UN F set screws nuts and lockwashers and detach the two caps and rubber bushes securing the radius arm assembly to the lower chassis cross member 6 The radius arm assembly complete with stub axle and hub assembly can be withdrawn from the vehicle and dismantled as required 7 Replace in reverse order remove stands jack down the vehicle ...

Page 19: ...Section C Rear Suspension Routine maintenance 1 Leaf spring 1 Damper unit Anti roll bar 2 Bump stop 2 ...

Page 20: ...ride Leaf spring To remove see Figure 1 1 Jack up the vehicle under the axle differential fit suitable stands under the chassis and remove road wheel 2 Unscrew four i UNF nuts and locknuts remove the two u bolts securing axle to leaf spring 3 Remove UNF bolts and self locking nuts securing leaf spring to rear shackle and chassis mounting 25 Bolt damper to axle 26 Nut damper to axle 3 Bolt 4 Nut 15...

Page 21: ...he damper spacer is located between damper and axle mounting bracket Anti roll bar To remove see Figure 1 1 Remove 1 7 6 UNF nut complete with lockwasher and detach R H anti roll bar link from mounting bracket on top of leaf spring Repeat operation for L H link 2 Unscrew four l UNF sets screws complete with lockwashers and remove the two anti roll bar fixing clamps and rubber bushes from the chass...

Page 22: ...Section D Steering Routine maintenance 1 Steering box assembly and steering column 1 ...

Page 23: ...or cam from column 5 Remove two i UN F screws hexagon nuts plain washers and lockwashers from outer steering column clamping bracket Pull the clamping bracket with ignition switch attached to one side with multi switch to facilitate next operation 6 Remove i UNF set screw and self locking nut and disconnect outer column from support bracket secured to the body 7 Unscrew h UNF bolt and self locking...

Page 24: ... Nut column to bracket 34 Washer track rod 7 Bearing upper worm 21 Coachwasher bracket to body 35 Steenng arm 8 Bearing lower worm 22 Nut bracket to body 36 Bolt steering arm 9 Oil seal rocker shaft 23 Grommet 37 Bolt steering arm 10 Oil seal upper 24 Clamp bush 38 Steenng wheel 11 Oil seal lower 25 Bracket column to fascia 39 Crash pad 12 Drop arm 26 Screw bracket to fascia 40 Cam multi switch 13...

Page 25: ...er outer column if removed during dismantling 3 Carefully insert the top of the upper column into outer column Check that the nylon bushes of outer column have not been disturbed 4 Fit a new rockershaft bush in steering box housing positioning flush with oil seal seating face 5 Locate new rockershaft oil seal in steering box housing with metal ring facing inwards 6 Fit upper bearing track using a ...

Page 26: ...wo No 10 set screws and lockwashers secure cover to multiswitch 12 Ensuring the front road wheel is in the straight ahead position secure steering wheel on upper column spline with 1 9 6 UNF nut and plain washer Note The steering wheel should be fitted with spokes in an inverted Y position 13 Press crash pad onto the centre boss of steering wheel 14 The steering mechanism should then be checked to...

Page 27: ... its chassis mo nting bracket To replace Replace in reverse order Steering from chassis No 6E2 12208749 On all Robin 850 veliicles from the above chassis number a double universal joint steering column arrangement was introduced This arrangement incorporates an additional lower steering column connecting the upper inner column to the steering box inner column and worm The new lower steering column...

Page 28: ...pring 39 Pinch bolt onwards 66 Nut wheel to column 13 Adjuster screw 40 Nut 67 Washer wheel to column 14 Nut 41 Grommet column 68 Steering column upper Chassis No 16 Tabwasher 42 Cam multi switch 5J 8N1001 16 Oil plug 43 Outer column 69 Bolt 5J 8N1151 17 Washer ball peg 44 Bush column 70 Nut 5J3 13201 152 18 Washer bail peg 45 Bracket column support 607 13307805 19 Circlip ball peg 46 Set screw 71...

Page 29: ...Section E Cooling system Routine maintenance 1 Anti freeze 1 Radiator 2 Water pump 2 Fan belt 4 Thermostat 4 Temperature gauge and sender unit 4 ...

Page 30: ...the anti freeze with water in a separate container before refilling the cooling system The percentage of anti freeze solution in the cooling system will determine the degree of protection and it is advisable to allow a margin of safety in cases where lower temperatures than normal may be encountered The quantities of anti freeze for various degrees of protection are given in the table at the end o...

Page 31: ...gaskets should always be fitted and fixing nuts tightened to the correct torque to prevent possible ingress of water to the oil system Radiator Description The radiator comprising an upper and lower tank connected by a matrix is mounted to the body by two support brackets An overflow pipe drains surplus coolant to the road should the system be overfilled To remove see Figure 3 1 Drain the cooling ...

Page 32: ... impellor spindle seal If the latter is the case a new pump available as an assembly only will have to be fitted To remove 1 Drain the cooling system and remove radiator 2 Slacken alternator adjuster and mounting bolts pivot alternator towards the engine and remove fan belt 3 Slacken hose clips and disconnect heater hose and by pass hose from thermostat housing 4 Remove four h UNF nuts and J ockwa...

Page 33: ... is restricted within the engine by means of the by pass hose Coolant flowing through the by pass hose returns to the water pump When the thermostat is fully open complete circulation through the block cylinder head and radiator takes place To remove 1 Drain the cooling system as previously described and disconnect the hose pipe at the thermostat 2 Unscrew three set screws complete with lockwasher...

Page 34: ...tem capacity inc heater 2 84 litres 5 pints Radiator Cap pressure Thermostat Type Starts to open Fully open Opening distance Fan Fan diameter 3 blade Belt tension Water pump Type Pulley ratio Anti freeze quantities Volume in Fluid down water tO C F 10 4 25 15 7 20 20 9 15 25 13 9 30 16 3 40 25 13 50 37 34 Solidifies at C F 8 17 14 17 19 3 29 20 39 38 48 54 58 72 0 492kg sq em 71b sq in Wax 86 89 C...

Page 35: ...t housing to the water pump is deleted and replaced by a hose connected from the thermostat housing to the manifold adaptor and a hose connected from the manifold adaptor to the water pump To drain the cooling system Some 850 vehicles may have a radiator not fitted with a drain plug To drain a radiator of this type it is necessary to remove the bottom hose Take the opportunity to check the conditi...

Page 36: ... 4 Oil pump 5 Crankshaft rear cover removal and replacement 6 Timing chain cover 6 Timing chain 7 Camshaft sprocket 7 Cylinder head removal 7 Cylinder head decarbonise 9 Pistons and con rods 11 Crankshaft removal11 9amshaft removal 12 Camshaft bearings 14 Cylinder liner replacement 15 Tappet adjustment 17 Stud removal 18 Specification 18 ...

Page 37: ...nd the hole cleaned out Operation 1 Engine removal and installation The engine should be removed complete with gearbox To remove 1 Disconnect battery 2 Drain cooling system 3 Drain engine oil 4 Disconnect alternator lead and remove alternator 5 Disconnect starter motor lead 6 Disconnect temperature gauge sender unit lead at thermostat housing 7 Disconnect oil pressure indicator lead at cylinder bl...

Page 38: ... T1 0 c m l 0 l D D X 0 P 10 14 r C D C D J co J C D CJ C D 0 J T1 N ...

Page 39: ...to driveshaft tunnel with two No 8 screws 12 Replace gear lever knob and check that the rubber gaiter is correctly seated 13 Fit locking nuts and press choke and heater knobs onto control cables on centre console 14 Reconnect speedometer cable at gearbox rear cover 15 Refit starter motor to gearbox casing 16 Reconnect exhaust downpipe to manifold 17 Reconnect heater hose at water pump 18 Reconnect...

Page 40: ...a 0 038mm 0 0015in feeler gauge check that no clearance exists between ring gear and flywheel over the complete circumference 7 Check the flywheel needle bearing for wear If wear is evident knock out bearing and fit a new one using tool No RT7485 see Figure 2 8 Secure flywheel assembly to crankshaft with three i UNF set screws and tab washer tightening to a torque of 4 03kg m 291b ft The tabs of t...

Page 41: ...spacers and lockwashers evenly 5 Operation 4 Oil pump removal and replacement with sump removed 1 Rotate engine until on TDC see page 3 Section T 2 Remove distributor 3 Unscrew two h UNF nuts complete with lockwashers and remove oil pump assembly including filter from the cylinder block see Figure 4 4 Drift out the pin securing thrust muff to distributor oil pump drive shaft which can then be with...

Page 42: ...g 3 Carefully press a new oil seal into the rear cover To ensure the seal is seated firmly and squarely use a press tool similar to that shown in Figure 6 4 Locate the two dowels of the rear cover in the cylinder block and then secure cover with six i UNC set screws and lockwashers see Figure 7 Operation 6 Timing chain cover oil seal and gasket 1 Drain the cooling system Figure 6 Replacing rear co...

Page 43: ...ew timing chain to crankshaft and camshaft sprocket which can be secured to the camshaft using the locking plate and h UNC bolts 7 3 Check valve timing ensuring that the timing mark on the camshaft sprocket aligns with the Woodruff key and on the crankshaft see Figure 11 4 Check the timing chain tensioner for wear and replace if necessary Figure 11 Alignment of camshaft sprocket and Woodruff key O...

Page 44: ...rocker shaft bracket 18 Screw clip to bracket 31 Stud exhaust downpipe 6 Gasket cylinder head 19 Rocker cover 32 Nut manifold 7 Plug ollway end 20 Gasket rocker cover 33 Lockwasher manifold 8 Core plug 21 Washer cover to head 34 Stud manifold 9 Connection by pass hose 22 Nut cover to head 36 Nut manifold 10 Temperature transmitter 23 Cap oil filler 36 Washer manifold 11 Thermostat 24 Seal cap 37 G...

Page 45: ...er and lockwasher securing distributor Do not disturb clamping bolt securing distributor unless the ignition timing is to be adjusted on reassembly 14 Remove twelve i UNF and three UNF nuts and washers from cylinder head 15 Withdraw the push rods keeping them in their correct order 16 Carefully lift cylinder head from the cylinder block 17 Replace in reverse order after cleaning the cylinder head ...

Page 46: ...ft 10 Small end bearing 32 Core plug 54 Spring rocker shaft end 11 Big end bearing 33 Plate camshaft 55 Washer spring 12 Bolt connecting rod 34 Bolt plate 56 Split pm spring 13 Plate connecting rod 35 Lockwasher plate 57 Plug rocker shalt 14 Piston assembly 36 Sprocl et camshaft 58 Valve inlet 15 Compression ring 37 Plate sprocket 59 Insert inlet valve 16 Taper ring 38 Screw sprocket 60 Spring val...

Page 47: ...he connecting rods securing in position with the gudgeon pins and circlips It may be necessary to heat the pistons in hot water to facilitate the operation Ensure the front mark on the piston crowns are facing forward 10 Before fitting the piston rings position in appropriate liners for gapping which should be 0 17 0 30mm 0 007 0 012in 11 11 Fit the piston rings fitting the scraper ring first foll...

Page 48: ... m 24 lb ft 11 Permitted end float of crankshaft is 0 0254 0 1524mm 0 001 0 006in 12 12 Replace components in reverse order taking note of the following When refitting front and rear bridge pieces care should be taken to ensure that their faces mate flush with the cylinder block face Operation 13 Camshaft removal and installation with timing chain and sprocket removed 1 Remove engine assembly see ...

Page 49: ...aft Figure 18 Removing camshaft rear bearing 1 Pilot 3 Mandrel 2 Bearing 4 Horseshoe Figure 19 Removing camshaft centre bearing 11 Replace in reverse order fitting new gaskets where applicable 13 Not e When refitting distributor drive shaft ensure the large o of the driving gear offset dog is facing towards the block at No 1 piston The camshaft retaining plate fitted as original equipment is 4 621...

Page 50: ...ft front bearing 1 Horseshoe 3 Bearing 2 Mandrel 4 Pilot Figure 21 Replacing camshaft rear bearing 1 Pilot 3 Bearing 2 Mandrel 4 Small o washer 3 Drill a hole in the camshaft core plug and prise from cylinder block 14 4 Press out the rear centre and front camshaft bearings using general tool No 18G 124A and Tool No 7482 see Figure 17 as follows a Insert general tool and position pilot mandrel and ...

Page 51: ...d To replace camshaft bearings position general tool and components as shown in Figure 22 Replacing camshaft centre bearing 1 Horseshoe 2 Large o washer 3 Bearing 4 Mandrel Figure 23 Replacing camshaft front bearing 15 Figures 21 22 and 23 Ensure the oil holes in the bearings correspond to those in the cylinder block Operation 15 Cylinder liner rebore replacement 1 Carry out operations 1 14 and th...

Page 52: ...e connecting rods securing in position with the gudgeon pins and circlips To facilitate this operation heat the pistons in hot water Ensure the front mark on the piston crowns are facing forward 8 Before fitting the piston rings position in appropriate liners for gapping which should be 0 17 0 30mm 0 007 0 012in 9 Fit the piston rings the scraper ring first followed by the lower and then the upper...

Page 53: ...r renewing if necessary and locate on the lug in the timing chain cover 28 Fit timing chain cover and new gasket to front engine plate using centralising tool No RT7481 and secure with seven UNC bolts two UNC nuts and lockwashers see Figure 10 17 29 Replace crankshaft pulley and secure with UNF bolt plain washer and lockwasher 30 Locate a new gasket and then fit the oil pump assembly complete with...

Page 54: ...luminium alloy with cast iron liners Forged high tensile steel 44 44 44 45mm 1 7495 1 7500in 33 32 33 33mm 1 3120 1 3125in 0 0254mm 0 001 in Min 1524mm 0 006in Max 1st undersize 0 254mm 0 01 Oin Main bearing journals 44 18 44 19 mm 1 7395 1 7400in Crankpin journals 33 07 33 08mm 1 3020 1 3025in 2nd undersize 0 508mm 0 020in Main bearing journals 43 93 43 94mm 1 7295 1 7300in Crankpin journals 32 8...

Page 55: ...e 0 17 0 30mm 0 007 0 012in 1 245 1 250mm 0 049 0 050in Groove clearance 0 038 0 089mm 0 0015 0 0035in 3 150 3 175mm 0 124 0 125in Groove clearance 0 038 0 089mm 0 0015 0 0035in 14 283 14 288mm 0 5623 0 5625in 14 22 14 298mm 0 5627 0 5630in 39 673 39 674mm 1 562 1 5625in 0 012 0 051 mm 0 0005 0 002in 0 064 0 16mm 0 0025 0 0065in 9 525mm 0 375in 50 45 1 397 1 524mm 0 055 0 060in 1 397 1 524mm 0 055...

Page 56: ...s The forged steel crankshaft is mounted on three steel backed main bearings Routine maintenance The engine oil level should be checked weekly and topped up if necessary to keep the oil capacity at 3 13 litres 5 50 pints It is important that this capacity is kept constant for any appreciable drop in the level will result in poor lubrication and possible engine damage To ensure the lubrication syst...

Page 57: ...unit lead at thermostat housing 11 Disconnect the oil pressure warning light lead from the sender on the cylinder block or disconnect the oil pressure pipe if a gauge is fitted The engine 12 Disconnect high and low tension leads from the coil 13 Remove air cleaner 14 Disconnect the acceleratbr cable from the carburettor bracket and release cable from trunnion 15 Disconnect the choke cable at the c...

Page 58: ...nt chassis mounting bracket 5 Raise the gearbox and position gearbox support brack et in line with its chassis mounting and secure with three set screws and self locking nuts Note Secure earthing braid at one fixing point 3 6 Reconnect driveshaft to gearbox rear coupling with four bolts nuts and lockwashers 7 Secure engine front mounting rubbers to chassis with two self locking nuts and washers No...

Page 59: ... and a scribed line midway between the root diameter and the inside diameter of the ring gear Ensure that the hole is not drilled through the ring gear into the flywheel as this will interfere with the subsequent balance of the flywheel The engine 2 Hold the flywheel assembly in a soft jawed vice 3 Place a cloth of heavy material over the ring gear as a protection against flying fragments Warning ...

Page 60: ...peration 3 Sump removal and replacement 1 Drain engine oil 2 Unscrew fifteen set screws and remove spacers lockwashers sump and gasket 3 Clean the sump and its seating on the cylinder block face 4 To eliminate possible oil leakage the two centre front and rear fixing screw threads should be thoroughly cleaned with petrol and coated with Hylomar sealant before refitting 5 Fit new gasket replace sum...

Page 61: ...asket 53 Gasket 4 Stud 29 Oil seal cover 54 Set screw 5 Stud 30 Bolt 55 Set screw 6 Stud water pump 31 Bolt 56 Washer 7 Stud alternator strap 32 Bolt 57 Lockwasher 8 Stud fuel pump 33 Lockwasher 58 Dowel 9 Stud main bearing housmg cap 34 Nut 59 Sump 10 Washer 35 Oil filter 60 Plug sump dram 11 Nut 36 Adaptor oil filter 61 Washer 12 Core plug camshaft 37 Plug 62 Gasket 13 Bridge piece front 38 Swit...

Page 62: ...al from the rear cover Note Do not use a screwdriver as this will damage the oil seal seating 3 Carefully press a new oil seal into the rear cover To ensure the seal is seated firmly and squarely use a press tool similar to that shown in Figure 6 4 Locate the two dowels of the rear cover in the cylinder block and then secure the cover with six set screws and lockwashers see Figure 7 Operation 6 Ti...

Page 63: ...ng with seven bolts two nuts and lockwashers see Figure 10 10 Replace crankshaft pulley water pump refit fan belt and secure alternator Figure 8 Extracting front cover oil seal The engine Figure 9 Replacing front cover oil seal 11 Replace radiator reconnect hoses and refill the cooling system Operation 7 Timing chain replacement with front cover removed 1 Release locking plate unscrew two bolts re...

Page 64: ...Operation 9 Cylinder head removal w ithout engine removed 1 Disconnect battery 2 Remove blower motor air hose 3 Drain cooling system 9 4 Release the two retaining clips and remove the air cleaner body from its base plate 5 Remove two bolts securing the air cleaner base plate to the carburettor 8 Remove the oil filler cap disconnecting the engine ventilation pipe from the carburettor 7 Disconnect t...

Page 65: ...iller cap 24 o ring cap 25 Breather pipe 26 Gasket exhaust manifold 27 Manifold exhaust 28 Stud downpipe 29 Nut manifold 30 Washer manifold 19 Remove the nut securing the carburettor abutment bracket to the carburettor 20 Remove the remaining nut securing the carburettor to the manifold Remove carburettor complete with gasket 34 Loclcwasher manifold 35 Stud 36 Washer 37 Nut 38 Orip tray 39 Manifol...

Page 66: ...uence shown in F1gure 13 The three nuts fitted to the spark plug side of the cylinder head should be tightened to a torque of 2 07kgm 15 1 bft Figure 13 Cylinder head nut tightening sequence 11 Operation 10 Cylinder head decarbonise with cylinder head removed 1 Remove the spark plugs 2 amove the nuts and lockwashers securing the mlet and exhaust manifolds to the cylinder head Remove the manifolds ...

Page 67: ...ps complete with the lower half bearing shells The engine 5 Push the connecting rods and pistons upwards and carefully withdraw identifying for reassembly 6 Match up the top and bottom bearing shells and caps with their respective connecting rods and piston assemblies Overhaul 1 Immerse piston and con rod assemblies in hot water for a few minutes then release the gudgeon pin retaining circlips 2 U...

Page 68: ...plete with bearing shells and refit rear and centre bearing caps 4 Locate the upper half of the thrust washer in the register on the inside face of the crankshaft bearing bore in the crank case 13 Figure 1 Compressing rings for refitting pistons 5 Position the front bearing cap and locate the lower half of the thrust washer in the register in the cap inside face Note The thrust washer is fitted so...

Page 69: ...onnecting rod 10 Small end bearing 11 Big end bearing 12 Bolt 13 Plate 14 Piston assembly 16 Compression ring 16 Taper ring 17 Scraper ring 18 Gudgeon pin 35 Lockwasher 19 Circllp 36 Sprocket 20 Thrust washer crankshaft 37 Plate 21 Thrust washer crankshaft 38 Screw 22 Sprocket 39 T1ming chain 23 Pulley 40 Tens1oner timing cha1n 24 Key 41 Tappet 25 Spacer 42 Push rod 26 Bolt 43 Screw 27 Washer 44 L...

Page 70: ...thdraw the camshaft To replace Replace in reverse order fitting new gaskets where applicable 15 Note When refitting the distributor driveshaft ensure the large D of the driving gear offset dog is facing towards the block at No 1 piston i e slot in a 5 minutes past 7 o clock position Take the opportunity of checking the camshaft end float which should be within 0 064 0 16mm 0 0025 0 0065in Pull the...

Page 71: ...ure 19 Removing camshaft centre bearing Figure 20 Removing camshaft front bearing The engine b Applying firm pressure rotate the general tool handle until the camshaft rear bearing is removed completely from its location c To remove centre and front camshaft bearings position the general tool and components as shown in Figure 19 and Figure 20 1 P1lot 2 Beanng 3 Mandrel 4 Horseshoe 1 Horseshoe 2 M ...

Page 72: ...cing camshaft rear bearing Figure 22 Replacing camshaft centre bearing Figure 23 Replacing camshaft front bearing Note Ensure that the oil holes in the bearing shells correspond to those in the cylinder block 1 Pilot 2 Mandrel 3 Bearing 4 Small o washer 5 Horseshoe 1 Pilot 2 Bearing 3 Mandrel 4 Small o washer 5 Horseshoe 1 Horseshoe 2 Large o washer 3 Bearing 4 Mandrel 5 Pilot 17 ...

Page 73: ...the piston with the appropriate grade letter i e H High L Low M Mean The grade of the cylinder liner is marked on the outside wall with the appropriate letter see Figure 26 Pistons and cylinder liners are available from the Spares Department of your Dealer in matched pairs It should be noted that if pistons or cylinder liners available separately are fitted the appropriate part number with a suffi...

Page 74: ...ew oil seal into the rear cover position a new gasket and secure the rear cover to the cylinder block ensuring the dowels are firmly seated in their locations 12 Fit front and rear bridge pieces with cork packing ensuring the end faces are flush with the cylinder block and secure with the four screws 13 Replace the rear engine plate fixing with four set screws and lockwashers 14 Fit flywheel assem...

Page 75: ...o a torque of 2 35 3 04kgm 17 221bft Check tappet clearance see Operation 17 31 Fit a new gasket and replace the rocker cover securing in position with the two nuts and washers 32 Replace all ancillaries 33 Install the engine and gearbox assembly see Operation 1 Operation 17 Valve clearance tappet adjustment Tappet clearances are 0 152mm 0 006 in cold 0 254 mm 0 01 Oin hot To adjuat 1 Remove rocke...

Page 76: ...oy 1 02mm 0 040in Aluminium alloy with cast iron liners Forged high tensile steel 50 787 50 800mm 1 995 2 00in 33 32 33 33mm 1 3120 1 3125in 0 0764mm 0 003in min 0 279mm 0 011 in max 1st undersize 0 254mm 0 010in Main bearing journals 50 533 50 546mm 1 988 1 989in Crankpin journals 33 07 33 08mm 1 3020 1 3025in 2nd undersize 0 508mm 0 020in Main bearing journals 50 279 50 292mm 1 978 1 979in Crank...

Page 77: ...haft identification Colour code The engine 0 17 0 30mm 0 007 0 012in 1 245 1 250mm 0 049 0 050in 0 038 0 089 mm 0 0015 0 0035 in 3 150 3 175mm 0 124 0 125in 0 038 0 089 mm 0 0015 0 0035 in 0 254mm 0 010in 0 254mm 0 010in 0 254mm 0 010in 14 283 14 288mm 0 5623 0 5625in 14 292 14 298mm 0 562 0 563in 38 66 38 67 mm 1 521 1 522 in 0 0254 0 0889 mm 0 001 0 0 0035 in 0 064 0 16 mm 0 0025 0 0065 in 9 525...

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Page 79: ...all round under the chassis 14 From underneath the vehicle disconnect starter motor lead unscrew two i UNF bolts and nuts complete with plain washers and lockwashers and remove starter motor 15 Unscrew clutch cable adjuster and withdraw cable from operating fork and trunnion which should then be removed from fork and retained 16 Disconnect speedometer cable at gearbox rear cover 17 Remove four 1 5...

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Page 81: ...elector shaft through bell housing 8 Lift out selector forks and tilt gearbox to remove interlocking balls from cross drilling in bell housing end of selector shaft bores 9 Withdraw layshaft into bell housing allowing lay gear assembly to drop into base of gearbox 10 Unscrew six l UNC set screws complete with lockwashers and withdraw rear cover and mainshaft assembly taking care not to displace fr...

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Page 83: ...e 1 Using circlip pliers General Tool No 7066 remove Circlip securing front bearing to primary gear 2 Remove spacer and front bearing from primary gear 3 Withdraw needle roller bearing from inside primary gear body This bearing may have been removed with mainshaft assembly 4 Inspect front bearing and needle roller bearing for wear renewing if necessary 5 Replace components in reverse order Figure ...

Page 84: ...p face and feed layshaft through thrust washer into laygear assembly until it mates with its bore in rear end of box Note Tang end on layshaft must be at front 6 7 Position tang of reverse shaft to engage with horizontal slot in rear cover and force rear cover fully home 8 Locate rear suppon mounting and eanhing strap to rear cover and then secure rear cover with six 1 UNC set screws and lockwashe...

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Page 86: ... the primary gear 3 Remove the spacer and front bearing from the primary gear 4 Withdraw the needle roller bearing from inside the primary gear body Note This bearing may have been removed with the mainshaft assembly 5 Inspect front bearing and needle roller bearing for wear renewing if necessary To reassemble Replace components in reverse order Care should be taken when replacing the front oil se...

Page 87: ...Section H The clutch Routine maintenance 1 Clutch assembly 1 Operating fork lever and thrust pad 2 Pedal assembly 2 Clutch cable 4 Clutch adjustment 4 Specification 5 ...

Page 88: ...eserving balance and adjustment Figure 1 Clutch 1 Driven plate 5 Lockwasher To remove see Figure 1 1 Remove gearbox see Section G 2 Unscrew six set screws complete with lockwashers and remove clutch assembly from flywheel 3 Check that the linings are secure and free from oil The disc should also be checked for excessive wear and signs of overheating If the linings are worn down to the rivet heads ...

Page 89: ...ever and shaft assembly from gearbox and remove clutch fork 5 Release locking spring and remove thrust pad from operating fork 6 Inspect thrust pad for wear and renew if the bearing face has worn below a depth of 1 588mm 0 060in or shows signs of scoring or distortion To replace 2 1 Refit thrust pad to operating fork and secure firmly in position with a new lock spring 2 Insert clutch lever shaft ...

Page 90: ...n cable to carburettor early vehicles 15 Split pin pivot 30 N9t stop screw clutch pedals 3 Rotate accelerator pedal shaft nylon pivot bushes to line up with square removal apertures in mounting 4 Prise out pivot bushes and remove accelerator pedal 5 Two metal bushes are pressed into both clutch and brake pedals and can be removed with a suitable drift if necessary 6 Inspect pedal pads for wear and...

Page 91: ...with abutment bracket from the vehicle Note The abutment bracket is press fitted onto the nylon bush of the clutch cable and should not be removed 5 When fitting a new clutch cable assembly which includes the abutment bracket two methods of securing the bracket to the footwall can be adopted a rivetting the abutment bracket to the footwall as in production or b drilling out the fixing holes in the...

Page 92: ... clutch Section H Clutch specification Clutch type Operation or Spring pressure plate assembly with 158 75mm 6 25in dia single dry plate Diaphragm assembly with 158 75mm 6 25in dia single dry plate Cable 5 ...

Page 93: ...as the effect of darkening the facings However as long as the polish on those facings remain such that the grain of material can be clearly distinguished it has very little effect on clutch performance Increased quantities of oil or grease however can give rise to harmful conditions One of two conditions may arise or even combinations of both a The oil may burn off and leave a carbon deposit havin...

Page 94: ...Section J The driveshaft Routine maintenance 1 To remove driveshaft 1 Checking driveshaft for wear 1 To replace driveshaft 2 ...

Page 95: ...als but if excessive wear is apparent on the yoke bearing seatings or drive shaft splines a new complete unit will have to be fitted Figure 1 Drive shaft To dismantle 1 Using circlip pliers General Tool No 7066 remove the four circlips from both joints It may be necessary to scrape away the paint from around the clips If removal is difficult prise the clips out with a screw driver 2 Tap the radius...

Page 96: ...shaft Section J To replace drive shaft 1 Secure drive shaft coupling flanges to gearbox and axle with four 1 5 6 UNF bolts and nuts complete with lockwashers tightening to a torque of 3 46 4 15kg m 25 301b ft 2 ...

Page 97: ...tenance 1 To remove axle unit 1 To replace axle unit 2 To fit new halfshaft bearings with axle in vehicle 2 Dismantling rear axle 3 Reassembly of rear axle 4 To fit pinion assembly in axle case 6 Determining correct backlash 6 Final assembly of axle 7 ...

Page 98: ...C tll l f 13 Key hub securing 14 Washer hub secunng 15 Nut hub securing 16 Taper bearing 17 Shim differential beanng 18 Crown wheel and pinion 19 Bolt crown wheel 20 Differential case 21 Wheel d1fferenual 22 Thrust washer 23 Pinion different al A Ts Routine maintenance Top up the rear axle oil level every 3 000 miles 5 000km if necessary The rear axle breather hole located in the LH axle tube shou...

Page 99: ...jack up the rear of the vehicle place suitable stands under the chassis and remove road wheels 2 Disconnect hydraulic brake pipes at brake backplate 3 Slacken brake adjusters remove the one countersunk screw and lever off the R H brake drum 4 Using a lever wedged between two of the studs or a plate tool similar to that shown in Figure 2 unscrew the halfshaft nut complete with washer 5 Fit hub pull...

Page 100: ...end with four UNF set screws and lockwashers 17 Clean the halfshaft taper of all grease and foreign matter 18 If the wheel hub studs have been damaged they should be pressed out and new ones fitted 19 Position the hub key in its location on the halfshaft and fit the wheel hub 20 Secure the wheel hub to halfshaft with i UN F nut and washer tightening to a torque of 12 44 13 82kgm 90 1OOib ft 21 Che...

Page 101: ... as for the differential unit and remove the pinion bearing see Figure 7 Note the value of the spacing washer thickness next to the pinion head and any added shims 9 Following previous procedure remove the L H brake assembly and L H axle halfshaft 10 Using the three legged puller tool No R T 3072 1 on slide hammer tool No 3072 remove the axle housing outer bearing cones See Figure 8 11 Should the ...

Page 102: ...erall end float 6 Separate the casings and remove the differential assembly complete with dummy Figure 9 Determining overall differential end float using tool No R T 8732 1 Gauging nut 2 Locking nut bearings but do not remove the dummy bearings from the differential carrier Instructions for setting the pinion using main tool R T 8732 1 Ensure the pinion bearing cups are seating correctly in the pi...

Page 103: ...he torque required to turn the pinion nut This should be set at 115kgm 15kgm 1 0 131bs ins Determining correct backlash 1 Replace the differential assembly complete with the dummy bearings into the differential housing and secure the two halves of the case together 2 If removed refit the push rods of the tool No RT 8732 as for setting differential end float Slacken the R H side then screw in the L...

Page 104: ...ers are settled by rotating before measurement The plus readings from the dummy bearing width are subtracted from the selected shims The minus readings are added to the selected shims R H Side Dummy bearing width say 71 0 Taper bearing width say 715 Actual shims required 030 005 025 Plus 002 which represents the manufacturers preload allowance Therefore total shims required 027 l H Side Dummy bear...

Page 105: ...d brake 13 Replace the axle drain plug tightening to a torque of 2 07 2 76kgm 15 20lbs ft 14 Replace the axle unit on the vehicle see previous axle unit replacement procedure 15 Reconnect the hydraulic brake pipes at the brake back plate and bleed the brakes If the vehicle is on stands leave this operation until last 16 Fit the rear road wheels Remove stands and jack down the vehicle if applicable...

Page 106: ...7 Filler plug 8 Split pin breather hole 9 Axle shaft 10 Collar shaft 11 Bearing axle end 12 Oil seal 13 Hub assembly 14 Stud 15 Key hub securing 16 Washer hub securing 17 Nut hub securing 18 Taper bearing 19 Shim differential bearing 20 Crown wheel and pinion 21 Differential case 22 Bolt crown wheel 23 Wheel differential 24 Thrust washer 25 Pinion differential 26 Thrust washer 27 Differential pin ...

Page 107: ...2 Rear axle Rear axle cutaway ...

Page 108: ... adjustment 1 Front brake adjustment 1 Rear brake adjustment 1 Handbrake adjustment 1 Bleeding the hydraulic system 2 Front brakes 2 Front wheel cylinders 3 Rear brakes 3 Rear wheel cylinders 4 Master cylinder 4 Brake pedal assembly 5 Handbrake 5 ...

Page 109: ...rum is locked then slacken back until the wheel is again sufficiently free to rotate without binding Figure 1 Front brake adjustment 1 Grease nipple 2 Bleed screw 3 Adjuster Note This adjustment must be performed accurately to obtain a minimum clearance between the linings and the drum with consequent minimum pedal travel Rear brake adjustment 1 Jack up the vehicle until rear wheels are clear of t...

Page 110: ...kes and then the pedal should be allowed to return quickly to its stop with the foot right off 4 Repeat this operation until fluid expelled is free from air bubbles Tighten the bleed nipple without excessive force ensuring that this is done during a downward stroke of the brake pedal 5 Remove the bleed tube and replace rubber dust cover 6 Repeat operation for L H rear wheel Note During the process...

Page 111: ...ve are apparent a new cylinder will have to be fitted To remove see Figure 4 1 Remove the brake shoes as previously described 2 Disconnect hydraulic fluid pipe and bridge pipe connecting the two wheel cylinders and plug to prevent loss of fluid and ingress of dirt 3 Remove the bleed screw 4 Remove two screws and lockwashers from the inboard side of the back plate and withdraw the wheel cylinder an...

Page 112: ... wheel cylinder could be the cause It is advisable to check the hydraulic system before fitting a replacement To remove see Figure 5 1 Remove brake shoes as previously described 2 Disconnect the fluid pipe from the rear of the wheel cylinder and plug to prevent loss of fluid and ingress of dirt Remove bleed screw 3 Remove dust cover prise off retaining plate and spring plate and withdraw wheel cyl...

Page 113: ...he procedure is described in Section H The Clutch Handbrake To replace handbrake cable see Figure 7 1 With the handbrake in the OFF position 15 Grommet hose 16 Clip bundy 17 Clip bundy 18 Gasket flexible hose 19 Lockw asher flexible hose 20 Locknut flexible hose 21 Bundy flexible hose 5 remove the split pins washer and clevis pin and disconnect cable clevis from R H and LH rear wheel handbrake lev...

Page 114: ... h UNF set screws lockwashers and coachwashers and remove handbrake lever from body mounting 3 Replace in reverse order and readjust handbrake cable as necessary Brake specification System Brakes front rear Master cylinder bore diameter Handbrake 13 Split pin 14 Clevis pin 15 Washer 16 Split pin Hydraulically operated internal expanding to all wheels 177 80 x 38 10mm 7 x 1 50in 177 80 x 31 75mm 7 ...

Page 115: ...Section M Wheels and tyres Tyre pressures 1 Jacking positions 1 Wheel removal and inspection 1 Valves 1 Wheel and tyre balance 2 Spare wheel and retaining bracket 2 ...

Page 116: ...ng out any servicing operation ensure the vehicle is on level ground with the handbrake applied and the wheels suitably blocked The recommended jacking points under the chassis main longitudinal frame members are indicated in Figure 1 and Figure 2 Note Do not work under the vehicle with the jack as the sole support always fit chassis stands Wheel removal and inspection Remove centre caps slacken w...

Page 117: ...rent for which no other cause can be found wheel and tyre balance should be checked statically and corrected according to instructions supplied by the manufacturer of the balancing equipment When w heels are to be re balanced it is essential that the weight of the vehicle be removed from the tyres as soon as possible after a run so that temporary flat spots do not form on the tyres Spare wheel and...

Page 118: ...e towards the wheel and tightened to a torque of 4 15 4 84kg m 30 351 bft Figure 1 Spare wheel location and fixing 1 Retaining strap 2 Hook 3 Bracket Spare wheel and retaining bracket On later 850 models the spare wheel is held in position by means of a rubber strap with hooks locating in brackets secured to the body Figure1 Section M 1 ...

Page 119: ...Section N Exhaust system ...

Page 120: ... screw coach washer and nut release the two silencer support straps from their chassis mountings and carefully withdraw exhaust system from the rear of the vehicle 3 To disconnect silencer from down pipe slacken 1 5 6 UN F clamp bolt and nut 4 Replace in reverse order fitting a new downpipe gasket to the manifold Note Periodic checks should be made to the exhaust system for tightness at all securi...

Page 121: ...er unit 2 Fuel pump 2 Carburettor 3 Adjusting slow running 5 Difficult starting with the engine cold 6 Difficult starting with the engine hot 6 Excessive fuel consumption 6 Poor acceleration 6 Loss of power 7 Accelerator pedal assembly 7 Accelerator cable 7 Air cleaner 8 ...

Page 122: ...ves the engine oil filler cap Figure 1 Fuel tank 1 Fuel tank 2 Insulation tank 3 Fuel tank unit 4 Sealing ring 5 Locking ring 9 Nut 10 Filler tube 11 Hose filler tube 12 Clip hose 13 Grommet hose Routine maintenance Periodically check the tightness of the carburettor securing nuts and at any time the gasket is replaced ensure it is seated correctly and securely Check for full traverse of choke lev...

Page 123: ...der unit is faulty and will need replacing Fuel pump Testing the fuel pump Providing there are no leaks or obstructions in the fuel line a quick check on the fuel pump efficiency can be made as follows 1 Disconnect carburettor feed pipe at the fuel pump outlet 2 Connect a slave pipe to the pump outlet and place in a clean jar 3 Crank the engine when a well defined spurt of fuel should be apparent ...

Page 124: ...ved and cleaned every 6 000 miles 1 O OOOkm All jets should be cleaned in clean petrol and blown out with an air line or tyre pump On no account use wire or anything which will enlarge the jet orifices Clean the float chamber with clean petrol and blow out To remove carburettor see Figure 3 1 Remove air cleaner 2 Disconnect fuel inlet pipe from carburettor and plug to prevent ingress of dirt 3 Dis...

Page 125: ... a c w Q CT c P1040 c en 3 en 0 J tJ ...

Page 126: ...hrottle 2 Throttle spindle 3 Screw throttle 23 Pump injector 24 Float and arm 25 Float spindle 4 Reconnect choke cable The choke control knob must be 3 0mm 0 125in away from the centre console when the choke is in the fully OFF position 5 Reconnect carburettor fuel inlet pipe 6 Replace air cleaner 7 Adjust carburettor Adjusting slow running 30 IZ carburettor When the engine has reached its normal ...

Page 127: ...ifold after switching off the engine it may be a result of excessive pressure from the fuel pump An additional washer under the needle valve may be effective in preventing flooding and could be tried before resorting to the fitting of a new pump or replacing worn parts Generally the engine can be started by gently opening the throttle to the fully or near fully open position then rotating the engi...

Page 128: ...on cylinder head withdraw accelerator cable and remove from vehicle To replace 1 Thread new cable through grommet in engine bulkhead connect to accelerator pedal and locate retaining fastener in pedal mounting bracket 2 Insert accelerator cable through support bracket locate inner cable in throttle lever trunnion and secure outer cable with retaining fastener 3 Using long nosed pliers through acce...

Page 129: ...r cleaner is serviced The cap contains a gauze element which should be washed in paraffin oil dipped then thoroughly wiped before replacing 5 Clean air cleaner base plate position new filter element refit air cleaner body and secure with single screw and washer Fuel system specification Fuel tank capacity Fuel pump Type Carburettor Type Jet sizes mm Main jet Compensating correction jet Slow runnin...

Page 130: ...ather pipe for the tank filler hose see Figure 1 The pipe is connected to a stub pipe which protrudes from_the rear of the tank adjacent to the filler tube To remove the pipe slacken off a single jubilee clip securing the breather and prise from the stub pipe The fuel tank is now secured at an additional mounting point An L shaped mounting bracket welded to the front of the tank is secured to the ...

Page 131: ...r the correct mixture has been obtained If an attempt is made to remove these shrouds the fasteners will break off However earlier vehicles built without tamper proof carburettors are still required by law to be adjusted so that the permitted level of toxic exhaust emission is not exceeded The information in this Workshop Manual Supplement includes details of slow running and fast idle choke adjus...

Page 132: ...le 47 Screw fast idle 8 Throttle spindle 28 Sleeve nut 48 Spring 9 Lockwasher 29 Float chamber 49 Screw suction chamber 10 Nut 30 Bolt float chamber 60 Guide choke cable 11 Disc 31 Lid float chamber 51 Screw 12 Screw 32 Float 62 Insen screw 13 Throttle lever 33 Hinge pin 63 Clip pick up lever 14 Cam lever and link 34 Needle and seat 64 Gasket 16 Pivot 36 Baffle plate 65 Gasket 16 Tube inner 36 Gas...

Page 133: ...eed of 2 250 rpm Push the control fully in and check that there is a clearance of 1 016 mm 0 040 in between the end of the screw and the cam The mixture control cable should have approximately 1 6 mm nin free movement before it commences to pull on the cam lever Note Any adjustment of idling or slow running must be followed by a check on the fast idle adjustment Air cleaner chassis No 5J 8A 1 001 ...

Page 134: ...tine maintenance The filter element should be checked every 6 000 miles 10 000km and replaced every 12 000 miles 20 000km on both types of air cleaner Figure 6 Air cleaner chassis No 5J 8A 1001 5J 8A 1151 5 5J3 13201152 6H3 1221 0274 1 Air cleaner 2 Element 3 Set screw cleaner to carburenor 4 Lockwasher cleaner to carburenor 6 Washer cleaner to carburenor 6 Gasket cleaner to carburenor 1 Air clean...

Page 135: ...dow frame and glass 2 Side door 3 Door window 3 Rear door Van 3 Rear door lock mechanism 4 Door seals 4 Bonnet 4 Pivot bolt backing plate 6 Tread plate side door 8 Kick plate Van rear door 8 Overriders 8 Ext rior mirror 8 Mud flaps 8 Windscreen 10 Rear quarterlight Saloon 10 Rear window Saloon 11 Rear window Van 12 ...

Page 136: ...liberally greasing window regulator channel and regulator mechanism spring 6 Detach external side door handle both locking and non locking by removing the 2BA and 1 BSF set screws and washers Figure 1 Side door mechanism 1 Remote control mechanrsm 2 Bezel remote control 3 lnsen remote conuol 4 Screw remote conuol 5 Screw remote control 6 Washer remote control 7 Remote control hnk 8 Adjustment pin ...

Page 137: ...dow fully closed prise the silent channel from the bottom of the window frame to gain access to the lower frame retaining rivets Figure 2 Side door shell and trim 1 Side door 2 Drop glass 3 Frame 4 Silent channel 5 Rivet frame to door 6 Weatherstrip Inner 7 Rivet weatherstrip to door 8 Weatherstrip outer 9 Rivet weatherstrip to door 10 Channel regulator 11 Insulation drop glass 12 Casing board 13 ...

Page 138: ...strip and secure to door casing with six 3 175 x 8 89mm 0 125 x 0 35in rivets 4 With the window fully open carefully drill the heads off the rivets securing outer weatherstrip to door 5 Push the rivet shafts through into door body and then peel weatherstrip from door 6 Remove all signs of adhesive from weatherstrip seating on door 7 Smear a light coating of adhesive on new weatherstrip and its sea...

Page 139: ...il female to body with four 4 76 x 16 51 mm 0 181 x 0 65in rivets and dovetail male to door with six 3 175 x 101 60mm 0 125 x 4 0in rivets Door seals The rubber seals are carried on a v shaped metal section clipped onto the body flanges Care should be taken not to hammer the seals onto the flange as this will cause the metal section to open up and the retaining claws will not hold A rubber mallet ...

Page 140: ...late bonnet pivot Figure 5 Body mounting plates Frame 2 Reinforcement plate 6 RIYel plate to body 6 Bolt bonnet pivot 7 Washer pivot bolt 8 Buffer bonnet lid to body 4 Re nforcement plate 6 Reinforcement plate 9 Bonnet badge 10 Clip badge to bonnet 11 Lock bonnet 12 Key 7 Reinforcement plate 5 ...

Page 141: ... cleaner 14 Drain and remove radiator 15 Disconnect heater hoses 16 Remove steering column and box 17 Remove centre console 18 Remove gear lever 19 Disconnect exhaust downpipe from manifold 20 Fold back floor carpets to gain access to the body to chassis fixing points 1 Spare wheel retainer 25 Lockwasher over rider 49 Rivet 2 Rivet retainer to body 3 Bracket spare wheel 4 Bolt 5 Washer 6 Heat shie...

Page 142: ... no b dy Sect1o The o 6 Body Saloon Figure 7 ...

Page 143: ...der 29 Finisher strip 30 Set screw 31 Washer 32 Lockwasher 33 Exterior mirror 34 Insert 35 Screw mirror 36 Mud flap rear 37 Bracket mud flap 38 Rivet 39 Washer 40 Mounting plate top 41 Set screw 42 Lockwasher 43 Nut 44 Mud flap front 45 Mounting plate 46 Rivet 47 Washer 48 Tread plate 49 Rivet plate to body 50 Motif robin 51 Motif super robin inserts secure front grille to the body see Figure 6 an...

Page 144: ...The body Section 0 9 Figure 7 Body Van ...

Page 145: ...emove windscreen from the vehicle and place on a bench protected by cloth or felt to avoid scratching the glass 7 Weatherstrip 8 Rear window van 9 Weatherstrip van rear wmdow 6 Examine the weatherstrip for signs of deterioration and renew if necessary To replace 10 1 Fit the weatherstrip to the lip of the windscreen aperture positioning the rubber so that the joint will finish half way up the A po...

Page 146: ...rawcord while an assistant applies light hand pressure to the outside of the quarterlight 5 Check the seating of the quarterlight glass in the weatherstrip Rear window saloon To remove see Figure 9 1 Raise rear window and locate support rod 2 Disconnect heated rear window if fitted at the bullet connector 21 Knob support rod 22 Catch plate 3 Buffer 4 Rear window hinge 5 Coach boll hinge 13 Handle ...

Page 147: ...e components in reverse order Rear window support rod saloon To remove see Figure 9 1 Unscrew retaining stud complete with waved washer and coachwasher and withdraw support rod from catch plate 2 The support rod catch plate and retainer bracket can be removed by drilling the heads off the retaining rivets with a 5 56mm U2 in dia drill and then tapping out the rivet shafts 3 Replace catch plate and...

Page 148: ...door 6 Stiffener door casing 7 Weatherstrip inner 8 Rivet weatherstrip to door 9 Weatherstrip outer 10 Rivet weatherstrip to door 11 Regulator channel 12 Insulation drop glass 13 Casing board 14 Tappet fuung 16 Nut1nsen 16 Screw 17 Retamer snap cap 18 Snap cap 19 Hinge upper 20 Hinge lower 21 Set screw hinge to body 22 Lockwasher hinge to body 23 Washer hinge to body 24 Backing plate hinge 26 Back...

Page 149: ...w securing the check link to the check link lug Figure 2 Rear door Van 1 Rear door 2 Seal rear door aperture 3 Hinge rear door upper 4 Hmge rear door lower 5 Washer hrnge to door and body 6 Nut hinge to door and body 7 Loclcwasher hinge to door and body 8 Hinge rear door upper 9 Hinge rear door lower 10 Washer hinge to door and body 11 Nut hinge to door and body 12 Look rear door 13 Screw lock to ...

Page 150: ... 6 Retnforcement plate 750 1 Rtvet plate ftxtng only 8 Set SCfew engtne well t frame 9 Set screw eng1ne well to frame 10 Coachwasher engtne well to frame 11 Lockwasher engtne well to frame 12 Nut engine well to frame 13 Insulation securing the body to the chassis is discontinued The Robin 850 body is now secured to the chassis using set screws lockwashers coachwashers and nut inserts There are two...

Page 151: ...et mud flap 23 Rivet bracket to flap 24 Washer bracket to flap 25 Mounting plate top 26 Screw plate fixing 27 Lockwasher plate fixing rf l 28 Nut plate fixing 29 Mud flap front 30 Bracket mud flap 31 Rivet flap securing 32 Washer flap securing 33 Tread plate 34 Rivet plate to body 35 Mounting plate solenoid 36 Rivet plate to body 37 Mounting plate coil 38 Rivet plate to body 39 Mounting plate w ip...

Page 152: ... Front grille 13 Overrider front rear 14 Finisher overrider 32 Washer flap securing 33 Tread plate 52 Mounting plate spare wheel 53 Rivet plate to body 15 Set screw overrider 16 Lockwasher overrider 17 Washer overrider 18 Exterior mirror 19 Insert mirror fixing 20 Set screw mirror fixing Rear window Saloon 34 Rivet plate to body 35 Mounting plate solenoid 36 Rivet plate to body 37 Mounting plate c...

Page 153: ...he hinges to the body 7 Replace in reverse order Rear window stay Saloon To remove 1 Remove two set screws lockwashers plain washers and spacers securing the window stay lower bracket to the body 17 Key handle 18 Stay rear window 19 Bracket stay 20 Washer bracket 21 Nut bracket 22 Coach bolt stay to glass 23 Coachwasher stay to glass 24 Washer stay to glass The body 25 Lockwasher stay to glass 26 ...

Page 154: ...Section R The interior Front seats 1 Seat be1ts 2 Rear seat 2 Carpets and interior trim 3 Headlining Saloon 5 Headlining Van 5 Fascia and centre console 6 ...

Page 155: ... 16 Cover cushion 17 Cover squab 18 Clip cover to frame 19 Clip cover to frame 20 Mounting plate seat 21 Rivet adjuster 22 Lockwasher adjuster 3 Remove rivet and retaining washer to disconnect adjustment lever from mounting plate and lift front seat from the vehicle 4 As an alternative the seat can be removed complete with mounting plate by unscrewing single UNF countersunk screw coachwasher and s...

Page 156: ... order taking note of the following points Before fitting the cushion padding and cover clean all traces of adhesive from the frame Apply Bostik 1GA 516 adhesive or equivalent to the cushion cover flaps The cushion and Figure 2 Seat belts squab cover flaps should be kept as taut as possible when replacing the retaining clips Seat belts 2 In accordance with present regulations all Robin vehicles ha...

Page 157: ...two No 10 UNF countersunk screws 3 2 Unhook tonneau cover from the rear of the vehicle and then release seat back retaining straps 5 Replace rear seat and components in reverse order Secure backboard hinges to the floor 3 Using a 5 56mm nin dia drill remove the heads off the rivets securing seat back board hinges to the body 4 Tap out rivet shafts and remove rear seat back assembly from the vehicl...

Page 158: ...The interior Section R 4 Figure 4 Interior trim ...

Page 159: ...side ensuring the headlining is kept taut 7 Trim excess material from headlining 8 Leave the vehicle for a few minutes to enable the adhesive to take and then remove spire clips 9 Using a light coating of adhesive refit the top of R H and L H A post and 8 post trim covers over headlining 10 Replace door seals 11 Locate rear quarter trim fillets replace rear window seal rear window and rear quarter...

Page 160: ... Replace door seals and windscreen 11 Refit sun visors interior lamp and rear view mirror 12 Reconnect battery Fascia and centre console To remove see Figure 5 1 Disconnect battery 2 Remove windscreen see Section Q 3 Press in retaining lugs remove heater and choke Knobs from centre console 4 Remove gear lever knob 5 Remove two No 8 screws securing rear of centre console to driveshaft tunnel Then l...

Page 161: ... centre console 1 Fascia 6 Centre console 2 Bolt fascsa to body 7 Screw 11 Cover multi swstch 3 Screw fascia to body 8 Insert 12 Clamp plate 4 Insert fascia to body 9 Fasica backing plato 13 Set screw 5 Screw fascia to body 10 Rivet 14 Lockwasher ...

Page 162: ... fixings can be gained by removing a black plastic grommet in the side door aperture Figure 1 Figure 1 Fascia and centre console 1 Fascia 2 Bolt fascia to body 3 Washer fasc1a to body 4 Lockwasher fascia to body 5 Washer fasc1a to body 6 Nut fascia to body 7 Blankmg grommet 8 Screw fascia to body 9 Insert fascia to body 10 Screw fascia to body 11 Centre console 12 Screw console to body 13 Insert c...

Page 163: ...SectionS Heating and ventilation system To remove heater 1 Heater control valve 2 Heater matrix 2 Heater motor and fan 2 Heater box 2 ...

Page 164: ... motor 14 Nut motor to case To remove heater see Figure 1 1 Slacken retaining clips and remove water inlet and outlet hoses from heater unit There w ill be a slight water loss during this operation 2 Disconnect footwall demister and fresh air ducting tubes from heater 3 Slacken trunnion and cable support clamp and disconnect heater control cable from water control valve 4 Disconnect heater leads 5...

Page 165: ...remove 1 Remove heater as previously described 2 Drill the head off the rivet securing heater matrix fixing clamp to the heater Tap out rivet shaft and remove clamp 3 Remove matrix from heater box 4 Replace new matrix in reverse order securing matrix fixing clamp to heater box with a suitable rivet Heater motor and fan To remove 1 Remove heater as previously described 2 Using an allen key through ...

Page 166: ...er motor 6 Charging system 7 Alternator 7 Lighting system 11 Headlamps 12 Front indicator lamps 14 Stop tail rear indicator lamps 15 Number plate lamp 15 tnt rior lamp 15 General electrics system 18 Battery 18 Fuses 20 Coil 20 Starter solenoid 20 Sparking plugs 20 Horn 20 Windscreen wiper motor 20 Instruments and switches 22 iring diagram 25 ...

Page 167: ... B y s u p LG N 0 K R Colour Red White Green Black Yellow Slate Blue Purple Light Green Brown Orange Pink Section T 2 3 Figure 1 Electrics ignition system Battery 3 Fuse unit 6 Coil 2 Starter solenoid 4 Ignition switch 6 Distributor 1 6 ...

Page 168: ...contaminates the distributor points Caution Do not over lubricate any part of the distributor The presence of dirt oil or water on the ignition points the central carbon brush or on the contact segments in the distributor cover will cause erratic running or may even prevent the engine from running at all Contact breaker points To adjust 1 Remove the distributor cap and rotor arm 2 Turn the engine ...

Page 169: ... and the breaker plate Note Dismantling of the complete distributor is not recommended as only the cover rotor arm condenser and contact set are available as spares To remove distributor from the engine 1 Disconnect spark plug leads from the plug terminals 2 Remove the high and low tension leads from the coil 3 Unscrew single i UNC bolt complete with washer and lockwasher securing distributor clam...

Page 170: ...d 2 Using a timing light 1 Connect the leads of the timing light in accordance with the manufacturers instructions 2 Check that the TDC 1 0 BTDC mark on the pulley is visible and mark with chalk or paint 3 Aim the timing light at the upper pointer on the timing cover Check that the TDC 10 BTDC pulley mark is aligned with the timing cover pointer If the pulley mark is to the left of the timing poin...

Page 171: ...ighest point of the cam It may be necessary to remove sparking plugs to eliminate the resistance cau ied by compression 3 Slacken the slotted headed screw Figure 4b in the contact plate and adjust until the gap is 0 38mm 0 015in The gap is measured with a suitable feeler gauge and pressure should be applied to the points with the feeler gauge inserted between them whilst the screw is being tighten...

Page 172: ...e contact breaker Figure 4d 2 Replace the slotted head screw and adjust the contact breaker points as previously described Not e If a new contact set is fitted set the contact gap to 0 40 to 0 45mm 0 016 to 0 018in To allow for initial bedding in of the plastic heel 3 Replace the rotor arm and distributor cap Distributor condenser The condenser is fitted in parallel to the contact breaker points A...

Page 173: ...n the distributor body See Figure 4b 5 Replace in reverse order checking that there is no possibility of a short circuit between the condenser lead terminal and the contact breaker plate Note Dismantling of the complete distributor is not recommended as only the cover rotor arm condenser and leads assembly and contact breaker set are available as spares Distributor specification Direction of rotat...

Page 174: ...Electrics Section T R 2 Figure 5 Electrics starting system Colour Codes Letter R w G B y s u p LG N 0 K Colour Red White Green Black Yellow Slate Blue Purple Light Green Brown Orange Pink 5 4 ...

Page 175: ...r pole four brush machine with inertia drive and is secured in the R H side to the rear engine plate and gearbox bell housing To remove starter motor see Figure 6 1 Disconnect battery 2 Remove oil filter 3 Disconnect starter motor lead and remove two i UNF bolts washers lockwashers and hexagon nuts securing the motor to the rear engine plate and bell housing 4 Remove starter motor from the vehicle...

Page 176: ...side 7 The only attention the alternator is likely to require is the occasional changing of the commutator bushgear Remove alternator cover unscrew two 4BA bolts and lift brushbox moulding from slip ring end bracket Check whether brushes and slip rings are free of oil or grease If necessary the brushes and springs can be cleaned with a petrol moistened cloth Check brush and spring assemblies for f...

Page 177: ... y s u p LG N 0 K Colour Red White Green Black Yellow Slate Blue Purple Light Green Brown Orange Pink 3 Figure 7 Electrics charging circuit Battery 3 Fuse Unit AlrP rnAinr 4 RAttAN r nnrUttnn inrhr Atnr 8 5 Ignition switch A f nmhinAti in trl tmAnl ...

Page 178: ...running at 6 000 rev min approximately and adjust the variable resistance until the voltmeter reads 14 0 volts The ammeter reading should then be approximately equal to the rated output Any appreciable deviation from this figure would indicate an internal fault and the alternator available as an assembly only will have to be replaced To remove alternator see Figure 8 1 Disconnect battery and alter...

Page 179: ...at 14 0 V and 6 000 rev min Max permissible rotor speed Stator phases Stator winding connection Number of rotor poles Resistance of rotor winding in ohms at 20 C Brush spring tension Negative only 12 28 amp 15 ACR 12 500 rev min 3 Star 12 4 33 5 10 255 368g 9 13oz with brush face flush with brush box housing ...

Page 180: ...d secured to the R H front engine mounting earths the complete lighting If any section of the lighting system fails to function the condition and security of the earth leads and straps described above should be checked A blown fuse could also be the cause Figure 10 Electrics lighting system 1 Battery 2 Starter solenoid 3 Fuse box 4 Switches 6 Multi switch 6 Speedometer 7 Headlamp 8 Fog and spot la...

Page 181: ...lamp unit rim is a clip on type To remove the rim press the rim upwards and lever outwards at the base of the lamp unit The rim is located by a spring clip at the base and two lugs at the top of the unit 2 Remove the three screws which secure the inner rim to the seating rim withdraw lamp unit 3 The lamp unit can now be disconnected from the cable connectors either for replacement or access to the...

Page 182: ...ehicle should be at its kerbside weight with a person in the driving position with the fuel tank approximately half full and the tyres at the correct pressure 2 Position the vehicle on level ground 1Om 32 8ft from and square to a suitably darkened screen 13 3 Measure the height from the ground to the centre of the headlamp and adjust the board so that the dividing line H marked on the board corres...

Page 183: ...etain nylon spacer 4 Replace in reverse order Front direction indicator lamps The front indicator lamps are dependant on the indicator switch incorporated in the multi switch and the flasher unit secured to the R H side of the engine compartment Failure of one of these will render both front and rear indicators inoperative Access to the front indicator bulb is gained by removing two screws and lif...

Page 184: ...ws of the inserts Number plate lamp Access to the bulb is gained by removing two cross head screws securing the chrome bezel Figure 15 Stop tail indicator lamp to the body folding back the rubber flange of the body and removing the glass lens To remove see Figure 16 1 Remove bezel glass lens and bulb 15 2 Withdraw lamp body and disconnect leads from wiring harness 3 Replace in reverse order Interi...

Page 185: ...d 8 Screw lamp to body 9 Interior lamp 10 Base Voltage 12 Headlamp super models quartz halogen Pilot bulb 12 12 Stop and tail Front and rear indicator Number plate lamp Interior lamp Fog and spot lamp 12 12 12 12 12 Wattage 60 45 60 55 5 21 5 21 5 6 48 11 lens 12 Bulb 13 Terminal sleeve 14 Screw lamp to body 15 Insert lamp to body Cap type Sealed beam 16 Sealed beam or metal reflector Capless SBC ...

Page 186: ... switch 6 a Speedometer b Combined temperature fuel gauge d Battery condition indicator 8 a Hazard warning unit b Flasher unit 9 Temperature sender 17 Colour Codes Letter R w G B y s u p LG N 0 K Colour Red White Green Black Yellow Slate Blue Purple Light Green Brown Orange Pmk 15 10 Oil pressure switch 11 Wiper motor 12 Heater motor 13 Horn 14 Brake hght switch 15 lntenor light 16 Fuel gauge send...

Page 187: ...nd negative leads secured to the battery terminals by a 1 7 6 UNC nut and bolt 2 Unscrew the two wing nuts securing the battery retaining strap to the hooked bolts Remove retaining strap and rubber insulation 3 Lift the battery from the well ensuring it is kept horizontal to avoid spilling the electrolyte 4 Replace in reverse order and ensure that the negative terminal is earthed on reconnection H...

Page 188: ...Electrics Section T 19 Figure 18 General electrics components ...

Page 189: ... holding the cable about 6 0mm 0 25in from some metal part of the vehicle make and break the contact points with an electrician s screwdriver A strong and regular spark will jump the gap from the end of the cable if the coil is in order If a spark is not apparent the coil will have to be replaced Starter solenoid The starter solenoid is secured to a mounting bracket on the R H side of the engine c...

Page 190: ...ocedure being described as follows a Mechanical Badly kinked or flattened cable rack tubing will prevent the rack from turning freely thus preventing or restricting the operation of the wheelboxes and wiper arms The tubing must be reformed or replaced having a radius of no less than 228mm 9 0in Check the wheelbox spindle for freedom of rotation a seized unit or one having damaged teeth must be rep...

Page 191: ...mediate investigation The lower segment of the instrument indicates the quantity of fuel in the petrol tank When the wheelboxes and cable rack tubing It is not necessary to disconnect instruments and switches 22 5 Detach wiper arms remove wheelbox spindle retaining nuts spacers and washers and push spindles through their locations in the body 6 Slacken L H wheelbox clamping nuts and remove R H whe...

Page 192: ...re gauge 26 Screw and washer 10 Bulb 27 Sealing ring 11 Pipe oil pressure gauge 28 Sealing ring 12 Washer pipe to gauge 29 Multi switch 13 P cllp 30 Clamp 14 Ammeter 31 Screw 15 Bulb 32 lockwasher 16 Clamp speedo 33 Switch ignition 17 Clamp combined Instrument 34 Nut 23 Combined ignition and starter switch The ignition starter switch is mounted on a bracket located beneath the fascia to the right ...

Page 193: ...witch located on the right hand side of the steering column The switch has four positions thus Forward Main beam Back Flasher Up Left hand indicator Down Right hand indicator Press the button on the extreme end of the switch to operate the horn Interior light switch The interior light is situated above the interior rear view mirror and has an integral switch on the body of the lamp Instrument and ...

Page 194: ... I I HAZARD UNIT i Pn JI G I J r L t bf i __ 0 0 I G LGt 1 _ l HEATER SW HEATER MOTOR I G fu1 KJLT GETEM v o REGULAlffi GAUGE TEMP SENDER UNIT Gt J T I LGG PETRa GAUGE TANK UNIT r 1 RLG HAZARD WARNING SWITCH KEY SUPPRESSOR o PWG SOCKET JOINT SNAP CCN ECT ON EARTH CABLE I EARTH VIA FXG S ll I RGI Oil GAUGE ILL LIGHT II J R 6 1 uI G I liB c ov 1 G 1 NLG SUPER OR OPTICJ W EXTRA FOG LAMP FOG LAMP SW j...

Page 195: ...gnition advance according to engine load by vacuum control acting directly on the contact breaker plate Service recommendations and distributor specification are as for the 43 04 distributor 1 Figure 1 Distributor 1 Distributor 2 Cover 3 Rotor arm 4 Capacitor 6 Contact set 6 Bush and spring 7 Suction pipe 8 Elbow sleeve 9 Sleeve suction pipe 10 Fuel trap 11 Clip fuel trap 12 Reduction sleeve 13 Sc...

Page 196: ... gauge 37 Nut switch fix1ng 2 Grommet pipe 38 Washer switch fix1ng 13 Washer pipe to gauge 39 Bezel switch fixing 14 Clip pipe securing 40 Barrel ignition lock 15 Adaptor pipe 41 Key ignition lock 16 Ammeter 42 Switch lighting 17 Bulb Illumination 43 Switch heater motor 18 Clamp speedometer 44 Switch w iper motor 19 Clamp combined instrument 46 Switch heated rear screen 20 Knurled nut 46 Bulb illu...

Page 197: ...t lamp switch Super models only The individual fog and spot lamp switches have been replaced by a combined auxiliary lamp switch This is a two position rocker switch located in the bottom right hand corner of the main instrument panel Pressure on the switch first operates the left hand lamp Further pressure on the switch illuminates both left hand and right hand auxiliary lamps Hazard warning swit...

Page 198: ...WITCH Q T RS llAlOR GAUGE TEMP S CER I NtT G t T I l GG PETilCl G 0UGE TANK UNIT r l RLG ol NlG oJ oo 1 All KEY Sl PPRESSOR PUJG SOCKET JOINT __ _ 9IW o na mN EARTH St CABLE I E AR1 H VIA FXG S fl SUI ER 00 Colour code 1 GHT B t IJB c u c Bl I ____ G ___ _ _ _ _ ____ I FOG LAMP FOG LAMP SW j Gl SWYt lL REAR SCI UN HEATER j L __ Q _f3t ___ _ _j rYIMN r SCRE Iill W White G Green B Black Y Yellow S S...

Page 199: ...Section U Windscreen wesher ...

Page 200: ...ehicle take care not to block up the nozzles of the washer jet as this will result in inefficient and irregular cleaning of the windscreen Use a fine needle to clear the jets To remove w asher pump see Figure 1 1 Unscrew bezel securing pump to fascia 2 From underneath the fascia disconnect the inlet and outlet tubes from the pump which can then be removed from the vehicle 3 Replace in reverse orde...

Page 201: ...Section V Optional extras Radio 1 Radio suppression 2 Radio aerial 2 Tightening torques ...

Page 202: ...434 271 m North of England 276m Midlands 341m Welsh 371 m Scottish 224m Northern Ireland To remove radio 1 Disconnect battery 2 Pull off radio control knobs 3 Remove two retaining nuts plain washers and wavy washers securing radio unit bezel and packing plates to fascia 4 Detach radio bezel and front matt black packing plate 5 Push the radio back behind the fascia and manoeuvre to enable it to be ...

Page 203: ...cle LH rear quarter 4 Retract aerial remove two locking nuts chrome spacer and nylon adjuster and withdraw aerial assembly complete with cable from underneath the vehicle 5 To complete the removal of the Van aerial unscrew aerial cable adaptor complete with star washer and small retaining nut and star washer securing aerial to the L H rear of the body Access to the aerial fixings can be gained by ...

Page 204: ...e Steering box to frame Track rod to drop arm Track rod to steering arm Steering wheel to column Brakes Front backplate to hub Rear backplate to hub Master cylinder to mounting plate and body Road wheels Wheel nuts i UNF 3 46 25 1 5 6 UNF 2 07 15 1 5 6 UNF 2 90 21 i UNF 3 18 3 32 23 24 i UNF 4 03 29 1 5 6 UNF 1 66 2 07 12 15 i UNF 2 35 3 04 17 22 1 5 6 UN F 1 66 2 07 12 15 S6 UNF 1 66 2 07 12 15 1...

Page 205: ...ssis Front suspension Radius arm to frame Damper ullit to radius arm and frame Steering Steering arm to stub axle Steering box to frame Flexible coupling to upper and lower column Track rod to drop arm Track rod to steering arm Steering wheel to column i UNF 3 46 25 fa UNF 2 07 15 fa UNF 2 90 21 i UNF 3 18 3 32 23 24 i UNF 4 03 29 fa UNF 1 66 2 07 12 15 i UNF 2 35 3 04 17 22 fa UNF 1 66 2 07 12 15...

Page 206: ...es kg m lbft Brakes Front backplate to hub Rear backplate to hub Master cylinder to mounting plate and body Road wheels Wheel nuts fa UNF 2 50 3 18 18 23 fa UNF 2 50 3 18 18 23 fa UNF 2 50 3 18 18 23 UNF 4 15 4 84 30 35 ...

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Reliant ROBIN 850, Workshop Manual

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