Daimler DS420 Service Manual AKM9135 Ed. 1 (1985)

 

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This manual AKM9135 (1985) is the latest one of the three different Service Manuals for the DS420. It was published in four revisions; the earliest one (1985) of which is shown here. To see the 4th Edition (i.e. the very latest manual of all; 1990) click here.
For earlier cars you may consult an earlier edition of the service manual, such as E1021/1 (1968 est.) or AKM3978 (1977).
A remarkable feature of this manual is the large number of fault-finding procedures. Unlike the earlier manuals, which simply limit themselves to describe how you disassemble and reassemble various items, this edition has added many step by step descriptions to guide you from a symptom experienced by the driver, to the mechanical component that is likely to cause this specific problem.

To the right we show the cover of the first revision, which was supplied in a standard ringbinder with a cover of cardboard in plastic.

   binder cover AKM9135 (2.5kB)

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.

To browse through this manual (400 pp.) from the first page on, start Here

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

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