| 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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