Reliant Kitten Estate, Руководство по ремонту

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Page 96
8. Disconnect the speedo cable from the gearbox.
9.
Disconnect the throttle cable at the carburettor.
10.
Disconnect the choke cable at the carburettor.
11. Disconnect the clutch cable at the bell housing
12. Disconnect the handbrake cable from the rear axle.
13. Drain and remove the radiator.
14. Disconnect the heater hoses ant the bulkhead.
15. Disconnect the steering column lower universal joint.
16. Remove the gear lever gaiter and gear lever.
17. Disconnect the exhaust downpipe at the manifold.
18. Disconnect the brake bundy tube from the master cylinder
at the four-way connector.
19. Remove the seat belt fixings from the transmission tunnel.
20. Remove the seat belt lower mountst.
21. Disconnect the earth lead from the fuel tank support.
22. Remove the front seats complete with runners.
23. Remove five screws from the rear of the body locating to
tapped inserts in the chassis.
24. Remove the carpets followed by the two screws on the
right-hand side and one on the left-hand side securing the floor to the
chassis.
25. Remove two screws holding the body to the front support
bracket and the single screw fixing the air ducts to the front support
bracket on the left-hand side.
26. Remove the screws, lock washers and washers securing the
"A" post hinge support brackets to the chassis outriggers.
27. Remove the four nuts, bolts and washers securing the roll-
over bar to the chassis adjacent to the "B" post.
The body is now free to be manoeuvred over the engine and lifted
from the chassis.
Operation 13 Tread plate (side door) removal & replacement
To remove
1. Using a 3.175 mm (1/8 in) drill, remove the heads from the
eight rivets securing the tread plate to the door sill.
2.
Tap out the rivets and remove the tread plate. Replace in
reverse order with eight 3.87 x 9.4 mm (0.150 x 0.37 in) rivets.
Operation 14 Kick plate, (estate rear door) - removal &
replacement
To remove
1. Drill the heads off the six retaining rivets using a 5.56 mm
(7/32 in) diameter drill. Tap out the rivet shafts and remove the kick
plate.
Replace in reverse order using six 4.76 x 10.16 mm (0.181 x 0.4 in)
rivets and plain washers.
Operation 15 Front grill/headlamp bezel - removal
& replacement
To remove
1. Remove the four screws and cup washers securing the grille
to the headlamp bezel moulding. Remove the grille.
2. Remove the two screws and cup washers at each end of the
headlamp bezel, securing the bezel to the body. The bezel can now be
removed.
Replace in reverse order.
Operation 16 Exterior mirror - removal & replacement
The exterior rear view mirrors mounted on each door are secured by
two countersink screws in nylon inserts. The nylon inserts should
remain captive in the door skin when the screws are removed.
Operation 17 Windscreen - removal & replacement
To remove
1. Remove the windscreen wiper arms and blades.
2. Cover the bonnet with a suitable cloth to avoid damage to
paintwork.
3.
Using a screwdriver with all the sharp edges removed, ease
the ends of the locking strip from the windscreen rubber. pull out the
locking strip
4. With the aid of an assistant working outside the vehicle,
apply hand pressure to the inside of the screen whilst easing down the
lip of the windscreen rubber to release the screen.
5. Lift the windscreen clear, placing it on a blanket or similar
to avoid scratching the class.
6. Examine the windscreen rubber for damage/perishing and
renew if necessary.
To replace
1. Fit the windscreen rubber to the windscreen aperture,
positioning the joint half way up one of the "A" pillars.
Note:
If a new rubber is being fitted it should be cut approximately
25.4 mm (1 in) oversize. The ends of the rubber can be forced back so
a tight butt joint is formed.
2. The windscreen can now be fitted by inserting a corner
onto the rubber and progressively easing the lip over the glass using a
suitable tool or a soft tapered piece of dowelling.
3. Using a suitable tool the locking strip can now be inserted
with the join at the opposite "A" pillar. If the old locking strip is to be
re-used it should be lightly stretched before inserting.
Operation 18 Rear quarter light (saloon & estate) - removal
& replacement
To remove
1. Apply firm pressure to the glass from inside the vehicle
adjacent to the "B" pillar whilst easing the lip of the rubber away from
the flange. The quarter glass should now lift out, leaving the plastic air
vent cover attached to the body by four rivets.
To replace
1. Fit the weather strip rubber to the quarter glass.
2. Run a draw cord around the rubber to body groove with the
overlap of approximately 152 mm (6 in) at the bottom edge of the
glass.
3. Whilst an assistant applies firm pressure to the outside of
the glass, pull the draw cord out springing the rubber lip over the
flange.
4. Check for good sealing paying special attention to the area
of the air vent moulding.
Operation 19 Rear window (saloon) - removal & replacement
To remove (Figure 6)
1. Raise the rear window.
2. Disconnect the heated rear window (if fitted) at the bullet
connectors.
3. Remove the domed nut and lock washer securing the
window stay to the window.
4.
Whilst supporting the glass, remove the domed nuts, coach
washers and insulating washers from both hinges.
5. Carefully remove the glass, taking care to retain the hinge
gaskets.
6. The locking release handle is secured to the glass by the
lock retaining nut.
7. The hinges are each secured to the body by two domed
nuts, lock washers and backing plates.
Replace components in reverse order.
Rear Window (Estate) - Removal & refitting
Follow the procedure as for the saloon and estate rear quarter light
glass
(Operation 18)