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 |