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4th 

re-issue 

Page  2 

WSM.12,t 

Section  E  (Gearbox &  Overdrive) 

GEARBOX 

GENERAL  DESCRIPTION 

A four-speed gearbox  is  fitted  having synchromesh 

on  the  upper  three  ratios.  Of  these,  second  and 

third employ helical gears, and are in constant mesh. 

The synchronised gears are engaged by dog-clutches, 

whereas first has sliding gear engagement.  Reverse 

is  engaged  by  a  sliding  idler  pinion.  Top  gear  ls 

direct drive. 

The synchromesh is  of  baulking ring  type.  Spring­

loaded  shifting  plates  locate  the  baulking  ring 
relative  to  the  sliding  sleeve.  The  baulking  ring 
impinges on  a cone machined on  the gear. 
Overdrive  is  available  as  factory  fitted  optional 
equipment.  It  is  engaged  by a  switch  mounted  on 
the steering column  and  controlled  by  an  isolator 
switch  mounted  in  the  gearbox  top  cover.  The 
isolator switch permits engagement of overdrive In 
third and top gears only. 

GEARBOX-To  remove and  refit  (see Over­

drive  Section  where  applicable.) 

Alpine 

Place car on  ramp or over a  pit. 

Disconnect positive  lead from  battery. 
Drain radiator. 

Drain gearbox.  Replace plug. 

Remove top water hose. 

Remove floor cover and gear lever. 
Disconnect throttle linkage. 
Disconnect exhaust system from branch pipes and 

remove. 

Place  jack  under  rear  of  engine  and  detach  rear 

cross-member from underframe. 

Disconnect speedometer cable and hydraulic clutch 
pipe. 

Remove lower bellhouslng  bolts. 
Disconnect clutch slave cylinder from bellhouslng. 
Lower engine and remove gearbox 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. 

Drain  radiator. 

Drain  gearbox.  Replace  plug. 

Undo  clip  and  remove  top  hose. 

Remove  rocker  cover.  (It  may  be  necessary  to 

remove  rocker  shaft  complete  if  heater  is  fitted). 

Disconnect accelerator control linkage. 

Remove engine rear lifting  brackets. 

Disconnect  exhaust flange from manifold. 
Disconnect  front  exhaust  hanger  bracket. 
Remove  propeller  shaft  rear  coupling  bolts,  dis­

connect  coupling  and  remove  shaft  rearwards. 

Rapier  IV.  Unscrew gear-lever  knob.  Remove  ashtray. 
From  behind  and  above  blower  switch,  remove 

wing 

nut  �xing which retains upper 

edge 

of 

console 

to 

lower 

edge  of  foe/a. 

Remove  single  screw  from  ashtray 

aperture.  Remove front and rea; gearbox  tunnel covers. 

Jack  up engine at  rear. 

Remove  bolts  securing  engine  rear  mounting 

bracket  to frame. 

Disconnect speedometer cable. 

Disconnect  clutch  slave  cylinder  from  bellhouslng. 
Disconnect starter cable and remove starter motor. 
Remove gear lever. 
Disconnect wires from overdrive solenoid and gear­
box isolator switch  (If overdrive fitted). 

Lower rear of engine. 

Remove  nuts  and  bolts  securing  bellhouslng  to 

engine. 

Remove  gearbox  and  bellhouslng  rearwards  and 

downwards. 

Reverse the above procedure for refitting. 

Check oil level. 

Bleed  clutch  hydraulic  system.  (See  Section  D, 

"Bleeding the System"). 

Check  that  the  clutch_  Is  operating  and  adjusted 
correctly. 

Note:-Do  not  In  any way  tilt  the gearbox  when 

removing  or  refitting,  as  a  great  strain  Is thus 
Imposed on the clutch driven plate. 

Содержание ALPINE I SERIES: APLINE II SERIES

Страница 1: ......

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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