Daimler DS420 Service Manual E1021/1 (1969 est.)

 

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This manual E1021/1 (estimated year of publication: 1969) is the oldest of three different Service Manual editions for the DS420. The year of publication has been estimated via the resemblance of the publication number E1021/1 with the publication number E1017/1 of one of the owner's manuals elsewhere on this site.

For younger cars you may consult newer editions of the service manual, such as AKM3978 (1977). or AKM9135 (1985).

To browse through this manual (300 pp.) from the first page on, start Here

    titlepage (24.4kB)

The following table of contents follows the sequence of pages in the manual.

ENGINE A-1
Description & data   A-5
Routine maintenance   A-9
Recommended lubricants   A-11
Exploded view drawing   A-12
Cylinder head removal   A-14
Cylinder head dismantling   A-15
Cylinder head assembling   A-16
Pistons and gudgeon pins   A-20
Connecting rods and bearings   A-23
Oil pump   A-24
Oil filter   A-27
Oil sump   A-27
Inlet manifold   A-28
Crankshaft damper   A-28
Timing gear   A-29
Engine mountings   A-31
Engine stabiliser   A-32
Engine removal & refitting   A-32
Cylinder block exploded view drawing   A-33
Engine dismantling   A-35
Crankshaft   A-35
Cylinder block   A-38
Engine rebuilding   A-39
Sparking plug inserts   A-39
CARBURETTERS & FUEL SYSTEM B-1
Description, idling, data   B-3
Exploded view drawing   B-4
Routine maintenance   B-6
Carburetters, removal   B-7
Cleaning suction chamber & piston   B-7
Carburetter tuning   B-8
Centring the jet   B-8
Auxiliary starting carburetter   B-9
Throttle control linkage   B-11
Petrol pump description   B-12
Petrol pump removal, refitting   B-13
Petrol pump dismantling   B-13
Petrol tanks   B-18
COOLING SYSTEM C-1
Description & data   C-3
Routine maintenance   C-4
Frost precautions   C-5
Radiator   C-5
Fan, fan belt   C-7
Thermostat   C-7
Water pump   C-8
Water temperature gauge   C-10
Pressure testing   C-10
AUTOMATIC TRANSMISSION D-1
General data   D-3
Description & operation   D-5
Control system   D-9
Maintenance   D-18
Road test, fault diagnosis   D-19
Service adjustments   D-23
Transmission removal & refitting   D-26
Transmission dismantling   D-26
Transmission assembling   D-46
Converter & converter housing   D-51
Steering wheel controls, exploded view   D-53
Exploded view drawing of the BW-8 unit   D-54
PROPELLER SHAFTS E-1
Description & routine maintenance   E-3
Front & rear propeller shafts: removal   E-3
Centre bearing   E-4
Alignment in horizontal & vertical plane   E-4
Adjustment of the engine stabiliser   E-5
Universal joints   E-5
FINAL DRIVE UNIT F-1
Description   F-3
Thornton Powr-Lok differential   F-4
Data   F-5
Service tools, routine maintenance   F-6
Final drive unit, removal & refitting   F-6
Dismantling   F-7
Assembling   F-9
Drive gear adjustment   F-13
Final assembly   F-14
Exploded view drawing   F-15
POWER ASSISTED STEERING G-1
Description, data, operation   G-3
Routine maintenance   G-5
Adjustments in car   G-6
Checking the hydraulic system   G-7
Steering box   G-8
Examination of components   G-11
Assembling   G-11
Adjustment of rebuilt gear   G-13
Refitting   G-14
Replacement of external/internal seals   G-14
Pressure pump   G-14
Steering wheel   G-18
Steering column (upper)   G-18
Steering column (lower)   G-21
Steering idler assembly   G-21
Centre track rod   G-22
Steering lock stops   G-22
Front wheel alignment   G-22
Fault finding charts   G-23
Accidental damage assessment   G-26
Special tools   G-26
FRONT SUSPENSION H-1
Description, data, routine maintenance   H-3
Front suspension assembly   H-3
Hydraulic dampers   H-4
Coil springs   H-5
Wheel hubs   H-6
Bearing end-float adjustment   H-6
Stub axle carrier   H-7
Lower wishbone & ball joint   H-7
Upper wishbone   H-8
Upper wishbone ball joint   H-9
Castor angle adjustment   H-9
Camber angle adjustment   H-10
Anti-roll bar   H-11
Accidental damage assessment   H-12
REAR SUSPENSION I-1
Description & data   I-3
Routine maintenance, lubricants   I-4
Rear suspension assembly   I-4
Road spring & hydraulic damper assembly   I-5
Rear hubs   I-5
Halfshafts   I-8
Universal joints   I-9
Radius arms   I-9
Hydraulic dampers   I-9
Wishbone   I-10
Wishbone outer pivot   I-12
Inner fulcrum wishbone mounting bracket   I-13
Rear wheel camber angle   I-14
Special tools   I-15
Rear suspension exploded view drawing   I-16
BRAKES J-1
Description   J-3
Front brake exploded view drawing   J-4
Rear brake exploded view drawing   J-5
Data & Routine maintenance   J-6
Recommended brake fluids   J-7
Bleeding the brake system   J-8
Brake overhaul precautions   J-9
Flushing the system   J-9
Brake pedal shaft housing   J-9
Vacuum concentric booster   J-9
Master cylinder   J-14
Booster, master cylinder exploded view   J-15
Front & rear calipers   J-17
Front & rear brake discs   J-17
Brake disc "run-out"   J-18
Renewing the friction pads   J-18
Renewing the brake piston seals   J-19
Handbrake   J-19
Brake fluid level, Handbrake warning light   J-21
Vacuum reservoir and check valve   J-21
WHEELS AND TYRES K-1
Description, data, tyre pressure   K-3
Tyres, general information   K-4
Construction of the tyre, examination   K-4
Wheel alignment, association with road camber   K-4
Tyre and wheel balance   K-5
Tyre replacement, wheel interchanging   K-6
BODY AND EXHAUST SYSTEM L-1
Instrument panel, facia panel   L-5
Bonnet, bonnet lock   L-5
Luggage compartment, hinges, locks   L-6
Petrol filler lids   L-7
Front bumper   L-7
Front bumper overriders   L-8
Rear bumper and overriders   L-8
Windscreen   L-9
Rear glass   L-10
Front & rear door trim casings   L-11
Wooden door capping   L-11
Front door and hinges   L-11
Rear door and hinges   L-12
Front no draught ventilator   L-12
Front window regulator (manual)   L-12
Rear window regulator (manual)   L-13
Rear quarter window regulator (manual)   L-13
Rear heater unit   L-14
Door lock mechanism and latch   L-15
Refitting the lock mechanism   L-16
Exhaust system removal & refitting   L-16
Exhaust system exploded view drawing   L-17
HEATING AND WINDSCREEN WASHING M-1
Description, heater controls   M-3
Air distribution, Vacuum system   M-3
Cold & hot weather   M-4
Vacuum servo system   M-4
Scuttle ventilator servo unit   M-4
Heater tap servo unit   M-5
Vacuum supply tank   M-5
Heater unit   M-5
Heater equipment exploded view drawing   M-6
Vacuum servo system exploded view drawing   M-7
Heater matrix, fan motor   M-8
Vacuum servo unit operating scuttle ventilator   M-8
Heater control button panel   M-9
Windscreen washing equipment description   M-9
Washing equipment data, servicing, testing   M-9
Washing equipment dismantling, bench testing   M-10
Washing equipment performance testing   M-10
ELECTRICAL AND INSTRUMENTS N-1
Battery   N-5
Distributor   N-8
Alternator   N-12
Alternator control unit   N-17
Warning light control unit   N-19
Starter motor   N-20
Starter motor fault diagnosis   N-24
Lamps   N-28
Table of light bulbs   N-29
Light bulb replacement   N-31
Flasher unit, fuse units   N-34
Horns   N-35
Windscreen wiper   N-36
Wiring harness replacement   N-41
Instruments   N-41
Instrument panel components   N-44
Bi-metal resistance instrumentation (sensors)   N-45
Analysis of engine temperature gauge faults   N-48
Analysis of petrol tank gauge faults   N-48
Analysis of oil pressure gauge faults   N-49

 
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