This manual was printed on paper of a fairly good quality,
and has extremely small print at several places.
Therefore the individual pages are provided in medium and
in large size, but both will be substantially bigger
than the pages are on other places on this web site,
because they require more dots per inch to stay readable on a display.
Especially the large pages may be difficult
to handle on low resolution displays.
The following table of contents follows the sequence of pages in the manual.
Because the individual page-files are big, and thus require much download time,
the table of contents has been made especially detailed.
Every chapter consists of a handful to a few dozen pages,
numbered consecutively.
But the chapter numbers themselves are not consecutive,
so the list given here below really covers the entire manual,
even though it suggests the contrary.
INTRODUCTION |
1-2 |
Abbreviations 1-4 |
GENERAL SPECIFICATION DATA |
4-1 |
Final Drive, Gearbox, Cooling 4-1 |
Fuel injection, Carburetters, Fuel Pumps 4-1 |
Braking system, suspension, steering 4-2 |
Battery, Alternator 4-2 |
Starter motor, Distributor 4-3 |
Windscreen wiper motor, Tyre data 4-3 |
Bulb chart 4-4 |
ENGINE TUNING AND DATA |
5-1 |
Valve clearances, Spark plugs 5-1 |
Ignition coil, Distributor, Ignition timing 5-1 |
Spark plug leads, Fuel injection 5-2 |
Exhaust emission, Compression 5-2 |
General data, Cylinder block & head 5-3 |
Crankshaft, Connecting rods 5-3 |
Pistons, Piston rings, Gudgeon pins 5-4 |
Camshafts, Valves, Valve guides & seats 5-4 |
Tappets, Lubricating system, Timing chains & sprockets 5-5 |
GENERAL FITTING INSTRUCTIONS |
7-1 |
Safety Precautions 7-1 |
Ball & roller bearings, Oil seals 7-2 |
Joints & joint faces, Flex hydraulic pipes 7-3 |
Hoses, Metric bolts & nuts 7-3 |
Hydraulic fittings (incl. metrification) 7-4 |
Keys and keyways, Split pins, Tab washers 7-5 |
Nuts, Locking wire, Screw threads 7-5 |
Unified Thread identification bolts & nuts 7-6 |
Studs, Brake rods 7-6 |
Taper roller bearing: fault diagnosis 7-7 |
LIFTING, JACKING AND TOWING |
8-1 |
Towed recovery (towing) 8-2 |
LUBRICANTS, FLUIDS, CAPACITIES, DIMENSIONS |
9-1 |
Engine oil, Various oils & greases 9-1 |
Cooling system, Various capacities (fluids) 9-2 |
Car dimensions 9-2 |
Weights, Fuel requirements, Hydraulic fluid 9-3 |
MAINTENANCE |
10-1 |
Maintenance schedules (ex. North America) 10-1 |
Maintenance schedules (North America) 10-3 |
ENGINE |
12-1 |
Torque wrench settings 12-3 |
Engine description 12-3 |
Cylinder pressures 12-4 |
General fault finding 12-4 |
Camshaft 12-5 |
Crankshaft damper and pulley 12-5 |
Crankshaft front oil seal 12-6 |
Main bearings 12-6 |
Camshaft cover and seals 12-7 |
Connecting rod bearings 12-7 |
Valve clearances 12-8 |
Oil filter assembly 12-8 |
Oil pressure relief valve & switch 12-9 |
Timing chain adjust 12-10 |
Engine mounting 12-10 |
Engine and gearbox assembly 12-11 |
Cylinder head 12-12 |
Cylinder head gasket 12-13 |
Oil sump 12-13 |
Oil pump 12-14 |
Timing cover, timing chain renew 12-15 |
Timing chain tensioner 12-16 |
Drive plate 12-17 |
Piston and connecting rod 12-17 |
Piston and connecting rod (overhaul) 12-18 |
Cylinder head (overhaul) 12-19 |
Oil pump (overhaul) 12-22 |
Engine dismantle & overhaul 12-23 |
FUEL SYSTEM |
19-1 |
Carburetter description 19-2 |
Carburetter tune & adjust 19-3 |
Mixture controle adjust 19-4 |
Fuel supply system, description 19-7 |
Fuel pump description 19-8 |
Fuel pump overhaul 19-9 |
Petrol tanks 19-13 |
Carburetter removal 19-14 |
Carburetter overhaul 19-15 |
Automatic Enrichment Device 19-17 |
Automatic Enrichment Device diaphragm 19-17 |
Automatic Enrichment Device needle valve 19-18 |
Automatic Enrichment Device filter 19-18 |
Hot air pick up unit 19-18 |
Hot air delivery pipe 19-18 |
Hot air filter 19-19 |
Mixture control (choke) cable 19-19 |
COOLING SYSTEM |
26-1 |
Torque wrench settings 26-2 |
Cooling system fault diagnosis 26-2 |
Cooling system description 26-3 |
Cooling system drain and refill 26-3 |
Cooling system pressure test 26-4 |
Pressure cap 26-4 |
Thermostat test 26-4 |
Fan steering pump belt 26-5 |
Torquatrol unit 26-5 |
Fan blades 26-5 |
Thermostat renew 26-6 |
Water pump renew 26-6 |
Water pump overhaul 26-7 |
Expansion tank 26-8 |
Hose set 26-8 |
Radiator block 26-8 |
MANIFOLD AND EXHAUST SYSTEM |
30-1 |
Exhaust & induction manifolds 30-2 |
Front, centre & rear mounting 30-3 |
Exhaust system renew 30-4 |
Down pipe 30-4 |
Branch pipe 30-5 |
Silencer assembly 30-5 |
Intermediate pipe 30-5 |
Tail pipe and silencer 30-5 |
AUTOMATIC TRANSMISSION GM400 |
44-1 |
Overall view / cutaway drawing 44-3 |
Description & glossary of terms 44-4 |
Clutch & band application chart 44-5 |
Clutch plate identification 44-5 |
Shift speeds 44-6 |
Valve spring identification chart 44-6 |
Torque wrench settings 44-7 |
Service tools 44-7 |
Transmission fluid level 44-7 |
Transmission fluid - recommended 44-7 |
Ranges & overrun braking 44-8 |
Governor assembly 44-8 |
Stall speed test 44-8 |
Road test 44-9 |
Fault finding & diagnosis, step by step 44-10 |
Selector lever assembly 44-20 |
Starter inhibitor switch 44-20 |
Rear extension housing 44-21 |
Oil/fluid pan & oil filter 44-22 |
Selector cable adjust 44-23 |
Kick-down switch 44-23 |
Band apply pin - selection check 44-23 |
Front unit end-float 44-24 |
Rear unit end-float 44-25 |
Speedometer drive pinion 44-25 |
Valve body assembly 44-25 |
Transmission assembly - renew 44-25 |
Transmission assembly - overhaul 44-26 |
Valve block - overhaul 44-28 |
Front & rear servo assembly 44-30 |
Oil pump 44-31 |
Forward clutch assembly 44-32 |
Direct clutch & intermediate roller 44-34 |
Planet gear carrier / Output shaft assembly 44-35 |
Centre support & intermediate clutch 44-36 |
Gearbox assembly 44-37 |
PROPELLOR AND DRIVE SHAFTS |
47-1 |
Torque wrench settings, Service tools 47-2 |
Drive shaft 47-2 |
Propeller shaft 47-4 |
FINAL DRIVE |
51-1 |
Rear axle: cross section drawing 51-2 |
Torque wrench settings, Service tools 51-3 |
Description 51-3 |
Tooth contact pattern check 51-4 |
Fault diagnosis 51-5 |
Drive pinion shaft oil seal 51-6 |
Final drive - rear cover gasket 51-7 |
Output shaft assembly & bearings 51-8 |
Output shaft oil seal 51-10 |
Final drive unit renew 51-12 |
Final drive unit overhaul 51-14 |
STEERING |
57-1 |
Steering description & data 57-2 |
Steering column (upper) - description 57-2 |
Fault finding 57-3 |
Steering wheel pad 57-5 |
Tie rod outer 57-5 |
Tie rod end inner & outer 57-5 |
Steering column universal joint 57-6 |
Steering column (lower) 57-6 |
Steering lock assembly 57-7 |
Steering unit - centralisation 57-7 |
Steering wheel 57-7 |
Steering idler assembly renew 57-8 |
Camber angle 57-8 |
Castor angle 57-9 |
Front wheel alignment 57-10 |
Centre track (rod) 57-10 |
Hydraulic system 57-11 |
Pump blow-off pressure 57-11 |
Rack 57-11 |
Sector shaft 57-12 |
Steering idler - overhaul 57-13 |
Steering box internal seals 57-14 |
Steering box sector shaft seal 57-14 |
Steering box input shaft seal 57-14 |
Steering column (upper, 2 models) renew & overhaul 57-15 |
Steering box 57-18 |
Inspection of components 57-21 |
Steering box cutaway drawing 57-25 |
Pressure pump 57-27 |
FRONT SUSPENSION |
60-1 |
Torque wrench settings, Description 60-2 |
Accidental damage 60-3 |
Anti-roll bar 60-4 |
Wheel hubs 60-5 |
Front hub bearing end float, stub axle 60-5 |
Ball joint (upper), wishbone (upper) 60-6 |
Ball joint (lower) 60-7 |
Wishbone (lower) 60-8 |
Front suspension assembly 60-9 |
Front damper, damper safety 60-10 |
Front spring 60-11 |
REAR SUSPENSION |
64-1 |
Torque wrench settings 64-2 |
Dimensional data 64-2 |
Description 64-3 |
Key to exploded view drawing 64-4 |
Exploded view of rear suspension 64-5 |
Rear suspension height check 64-6 |
Camber angle 64-6 |
Hub bearing end-float 64-7 |
Hub and carrier assembly 64-8 |
Hub bearing end-float 64-9 |
Fulcrum shaft bearings 64-10 |
Radius arm & arm bushes 64-12 |
Road spring & damper units 64-13 |
Rear suspension assembly renew 64-13 |
Wishbone - Inner fulcrum mounting bracket 64-14 |
Rear suspension mountings 64-16 |
Bump stop 64-16 |
BRAKES |
70-1 |
Torque wrench settings 70-3 |
Data 70-3 |
Cleaning solvents 70-3 |
Brake fluid 70-3 |
Hoses & pipes - general fitting 70-3 |
Operation of brake system - description 70-4 |
Symptom & diagnosis chart 70-5 |
Brake servo test procedure 70-6 |
Brake servo bleeding 70-6 |
Brake system drain & flush 70-7 |
Front disc 70-8 |
Rear disc 70-9 |
Disk shields, front 70-11 |
Fluid reservoir 70-11 |
Tandem master cylinder renew 70-11 |
Tandem master cylinder overhaul 70-12 |
Reservac tank 70-13 |
Non return valve 70-13 |
Pedal box 70-14 |
Handbrake lever assembly 70-15 |
Handbrake cable 70-15 |
Handbrake mechanism renew 70-16 |
Brake pads, handbrake 70-16 |
Three way connector, rear 70-16 |
Brake pads front & rear 70-17 |
Servo assembly 70-18 |
Brake caliper, front 70-19 |
Brake caliper, rear 70-20 |
WHEELS AND TYRES |
74-1 |
General description & data 74-2 |
Tyres & tyre pressure 74-2 |
Wear, damage, heat 74-3 |
Tyre repairs 74-4 |
Valves 74-4 |
USA gradings for tyres 74-4 |
Wheel alignment & road camber effects 74-5 |
Alignment precautions 74-5 |
Tyre and wheel balance, static 74-6 |
Tyre and wheel balance, dynamic 74-7 |
BODY |
76-1 |
Bonnet 76-3 |
Boot lid and hinges 76-3 |
Boot lid lock assembly 76-4 |
Fuel filler flaps, flap locks 76-4 |
Front & rear bumper 76-5 |
Radiator grille 76-6 |
Windscreen front 76-7 |
Windscreen rear 76-8 |
Fascia veneer panels & crash roll 76-9 |
Glove box lock (early type) 76-9 |
Glove box 76-10 |
Front & rear door and hinges 76-11 |
Door glas regulator handle, early type 76-11 |
Door glass regulator handles 76-11 |
Door inside handle (early type) 76-11 |
Door inside handles 76-11 |
Door outside handles 76-12 |
Door glass regulators 76-12 |
Door locks, outer units 76-12 |
Private lock, front & rear 76-12 |
Front quarter vent catch, glass, hinge, rubber 76-13 |
Front door glass 76-14 |
Front door waist rail 76-14 |
Front door glass stop 76-15 |
Rear door trim pad 76-15 |
Rear door glass rubber & frame 76-15 |
Rear door glass & glass stop 76-16 |
Rear door outer waist rail moulding 76-16 |
Rear quarter light catch 76-17 |
Rear quarter light veneer panels 76-17 |
Front seat 76-17 |
Front seat runners 76-18 |
Rear seat armrest, cushion, squab 76-18 |
Rear floor panel 76-18 |
Rear quarter armrest 76-19 |
Rear quarter trim pad 76-19 |
Rear quarter veneer panel 76-20 |
Rear quarter crash roll 76-20 |
Passenger compartment occasional seats 76-21 |
Front seat belts 76-21 |
Rear seat belts 76-22 |
Grab handles, rear 76-23 |
Blinds, front & rear 76-23 |
Curtains 76-24 |
Cocktail cabinet, renew 76-24 |
Centre division veneer panel 76-25 |
Sliding glass division channels 76-25 |
Sliding glass division upper channel 76-26 |
Sliding glass division 76-27 |
Electrically operated glass division 76-27 |
Electrically operated glass division, lifting cord 76-28 |
Electrically operated glass division, tension roller 76-30 |
HEATING AND VENTILATION SYSTEM |
80-1 |
Description, control buttons 80-2 |
Heater unit 80-4 |
Blower motor 80-4 |
Blower motor resistor 80-5 |
Heater matrix 80-5 |
Demist air vent 80-6 |
Temperature control assembly 80-6 |
Heater vacuum control assembly 80-6 |
Rear heater unit 80-7 |
Scuttle vent servo 80-7 |
Vacuum reservoir 80-8 |
Heater water valve 80-8 |
AIR CONDITIONING SYSTEM |
82-1 |
Description; Electronic control module 82-3 |
Temperature distribution system 82-4 |
Evaporator sensor 82-5 |
Temperature selector switch 82-5 |
Temperature differential control 82-5 |
Temperature sensors, description 82-5 |
Coolant temperature switch 82-6 |
Mode control switch 82-6 |
Blower motor speed control 82-7 |
Vacuum system 82-7 |
Compressor clutch control 82-8 |
Superheat switch & thermal fuse 82-8 |
Fault finding chart 82-9 |
Airco wiring diagram 82-10 |
Cooling control system 82-11 |
Compressor description 82-12 |
Condensor description 82-12 |
Reveiver / drier, description 82-12 |
Sight glass description 82-13 |
Evaporator description 82-13 |
Expansion valve description 82-13 |
Refrigeration cycle schematic diagram 82-14 |
Refrigeration system description 82-15 |
Safety precautions & good practice 82-16 |
Manifold gauge set 82-17 |
Manifold gauge set, connecting 82-18 |
Manifold gauge set, purging test hoses 82-19 |
Stabilising the system 82-19 |
Refrigerant adding 82-19 |
Leak test 82-20 |
Pressure - temperature relationship table 82-20 |
Fault finding with manifold gauge set 82-21 |
Depressurising the system 82-26 |
Evacuating the system 82-27 |
Flushing the system 82-28 |
Recharging the system 82-29 |
Compressor oil checking 82-30 |
Superheat switch testing 82-31 |
Compressor remove and refit 82-32 |
Compressor servicing procedure 82-33 |
Front cooler unit 82-40 |
Rear cooler unit (UK) 82-40 |
Front fan speed & temp. control unit 82-41 |
Rear fan speed & temp. control unit 82-41 |
Receiver / drier, renew 82-42 |
Rear blower motors 82-42 |
Front cooler unit cut/off solenoid valve 82-43 |
Condensor renew 82-43 |
Heater cooler unit (federal) 82-44 |
Electronic control module (federal) 82-45 |
Lower servo motor assembly (federal) 82-45 |
Upper servo motor assembly (federal) 82-46 |
Air flow control switch (federal) 82-46 |
Temperature switch control (federal) 82-47 |
Demister duct outlet (federal) 82-48 |
Vacuum solenoid valves 82-48 |
Expansion valve 82-49 |
WIPERS AND WASHERS |
84-1 |
Windscreen wiper motor 84-2 |
Windscreen wiper motor parking switch 84-5 |
Windscreen wiper rack, wiper wheelboxes 84-6 |
Windscreen washer tubing 84-7 |
Windscreen washer pump motor 84-8 |
Wiper switch, washer switch, delay unit 84-8 |
Main fuse box 84-9 |
ELECTRICAL SYSTEM |
86-1 |
Battery description & maintenance 86-4 |
Battery testing 86-5 |
Battery health & safety 86-6 |
Boost battery / jump lead starting 86-6 |
Battery renew, battery leads 86-7 |
Starter circuit, tests 86-8 |
Starter motor, overhaul 86-10 |
Starter motor, renew 86-13 |
Starter motor solenoid, renew 86-13 |
Starter inhibit switch 86-13 |
Starter motor solenoid, test 86-14 |
Starter relay 86-14 |
Alternator (Bosch) description 86-15 |
Alternator (Bosch) tests 86-16 |
Alternator (Lucas) description 86-18 |
Alternator (Lucas) tests 86-19 |
Alternator (Lucas) dismantle 86-22 |
Alternator (Bosch) dismantle 86-23 |
Alternator renew 86-24 |
Alternator drive belt 86-24 |
Ignition system, description 86-25 |
Ignition system, tests 86-26 |
Ignition distributor (renew) 86-28 |
Ignition distributor (maintenance & overhaul) 86-29 |
Ignition amplifier unit 86-30 |
Ignition HT coil 86-31 |
Lighting circuit diagrams 86-32 |
Headlamp beam setting 86-34 |
Front flasher 86-34 |
Headlamp dim / dip circuit 86-35 |
Headlamp (inner) assembly 86-35 |
Headlamp (outer) assembly 86-35 |
Headlamp rim embellisher 86-35 |
Pilot bulb 86-35 |
Rear lamp assembly 86-36 |
Reversing lamp 86-36 |
Gear lever illumination 86-36 |
Side marker lamp 86-37 |
Repeater flasher 86-37 |
Number plate light 86-37 |
Interior lamp circuit drawing 86-38 |
Roof lamp, courtesy lamp, reading lamp 86-39 |
Master light switch 86-40 |
Panel light switch 86-40 |
Interior light switch 86-40 |
Blower fan switch 86-40 |
Windscreen wiper switch, washer switch 86-40 |
Fuel change over switch 86-40 |
Headlamp dip switch 86-41 |
Flasher indicator switch 86-41 |
Ignition switch (steering column) 86-41 |
Rear window switch 86-42 |
Rear centre division window switch 86-42 |
Rear heat control switch 86-42 |
Rear interior light switch 86-42 |
Rear A/C fan speed switch 86-42 |
Rear A/C temperature switch 86-42 |
Stop lamp switch 86-43 |
Reversing lamp switch 86-43 |
Hazard switch & flasher assembly 86-43 |
Hazard / direction indicator circuit diagram 86-44 |
Window motor (front & rear door) 86-45 |
Centre division window lift motor 86-45 |
Door lock solenoid (front & rear door) 86-46 |
Rear door window lift motor & regulator 86-47 |
Ignition load relay 86-47 |
Heated rear window relay 86-47 |
Radio 86-47 |
Door lock circuit diagram 86-48 |
Powered windows circuit diagram 86-48 |
Fuse units 86-49 |
Fan circuit diagram 86-49 |
INSTRUMENTS |
88-1 |
Instruments description & test 88-2 |
Battery condition gauge 88-3 |
Oil pressure gauge 88-3 |
Fuel gauge 88-3 |
Coolant temperature gauge 88-3 |
Speedometer 88-4 |
Tachometer 88-4 |
Clock 88-5 |
Fuel gauge tank unit 88-5 |
Coolant temperature transmitter 88-5 |
Speedometer transducer 88-6 |
Oil pressure gauge transmitter 88-6 |
SERVICE TOOLS |
99-1 |
Tool list 99-1 |