bristol type 407 car -...
TRANSCRIPT
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THE
BRISTOL TYPE 407 CAR
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INSTRUCTION
MANUAL
BRISTOL CARS
F I LT 0 N, BR 1ST 0 l , EN G l AND
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MAINT E NANC E CHART
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MA INT ENANC E AND SERVICING
WEEKLY
1$0\ fTERY
~ADIATOR
l'YRES
ENGINE
TRANSMISSION
Check level and t OP up if necessary
Check leve l and tOp up if ne cessary
Chec k pressu r es a nd wear
Check 01 1 leve I
Check oil level
P ERIODICALLY
C heck d isc br ake f r" iction pads for we a r" pe r"missib le .
Che c k va lve in r adiator cap for f r eedom .
Inspect w ate r s y s tem hoses for condit ion.
Chec k water s y s te m JOintS for le akage .
C hec k a nd rectify oil leaks .
C hec k battery for condition .
inch nunimum
At 10.000 mile intenals, o r evcq' G mont hs. whicheve r occu r s fir st, c heck t he condition of the brake vacuum hose s and the servo air" fi lte r ,
NO 1 E, Checkin g r:r ont Su s penSIOn and Stee ring Joint s
The r ubbe r se als on a l l s uspe ns ion and s t eering Joints should be checked a t intervals of 10,000 milesto ensure that t he seals a r e intac t and wate r proof. A da m a ged seal. i f neglec ted, ca n le ad to rapid wear of the Joint .
Whi lst e xamll'T lng t he condit ion of t he seals a c hec k s hou ld be m ad e to ensu r e t hat the- ingr ess of dirt o r water ha s not caused wea r, pa rucularl y at the tOP a nd bottom Joint s of t he s t ub ax le earne r.
Till S can be bt:st be done b y J3eklngup eac h f rom whee l In t urn under it s sp r ing pan. u s ingabox suit ably pl aced under t he d iagona lly opposite r ear co r ner of the c ha SSIS f r ame t o I'ca e t against the- weight t ra nsfer and all ow (he fron t whee l t o lift free from t he floo r.
Wit h the ma in spring load removed f r om the lowe r iHlSpen sion Joint and WIt h the wheel re mov ed , (he s t ub axl e 68scmbly can be shaken todet ermine If slac kne s s is p r e st:nt.
Should thc e h>:c k Ind ic ate slackness at e ithcr t Op o r bmtol1l Joine , a s t rip e xa m ination of the s uspecr JClnt s hou ld h@ made to dete r mine Its cond ition .
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dashboard see F ig.4 , when i t wi ll op.:n sufficientl y at the fron t fo r the fi nge r s to be inserted and the s afety catch rel eased. It can the n be raised partially o r to it s full e xtent and is sel f supporting in any positi on .
To close , lower the bonnet and press the front to lock.
BOOT
Th e boot lid with its own key . the lid.
!s se lf supporting and is externally loc ked The press button of the lock will release
A light , in circu it with the sid e lamps. is provided beneath the tool s he lf fo r loading and unl oad ing at n ight.
Front Seat Adjustment
Both front s eats arc adjusta ble fo r leg reach and back r est.
To adjust for leg r e ac h, m ove outwa rds the lever at the f r ont of the inner seat slide . This will r elea se the seat f r om its location s lot and the r e quired position can then be selected.
The squab or backrest of the seat i s fairly heavil y spring loaded forwa rds. To select a position , l ift the small knobbed lever on the inner seat hinge and press firmly backwards to the r e quiremen t. To bri ng forward, lift th e leve r. and hold the backres t firmly against the spring pressure unt i l the desired posi t ion is obtained .
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Maintain the pressures as a regu lar routine check. using a pressure gauge of known accuraty wi en che tyre s are cold . Pressures can increase considerably m heat and with hard driving. but thi? normally needs no adjustment.
It is recommended that at every 2000 miles the wheels complete with the tyres are changed round and the spare wheel brought into us e to promote even tyre wear. This is best achieved, for example. by ellchanging the left front with the spare and fitting the left front to die right rear, that removed from the right rear now becomes the spare. ,Exchange the right front and the left rear.
Replace worn tyres in pairs. and a rrange the wheels so that both front tyres are evenly paired. Oddly worn tyres on the front can affect stee ring accuracy. while one new and one well worn tyre at the rear tends to keep the differential in constant achon .
lnve.stigate immediately any uneven wear on either from tyre. sinc!! this may be caused by some misalignment o r slackness in the front suspension. front hubs or steering.
Fitting new Tyres
When new tyres and/or tubes are to be fitted. correctl y align any manufacturers markings and see that the complete wheel and tyre IS correctly balanced. The recommended tyres to fit are:-
Avon Turbospeed .......... Mk.4 .......... 16 x 6.000.
Tyre Pressures
Normal C r ui.sing ................. Front and Rea r . . .......... 28 p.s.i. SUStained High Speed ............ Front and Rear ............ 33 p.s.i.
BONNET
The Bonnet has spring balanced hinges at the rear edge and can be released by pulling the knob located beneath the
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e nga ge the l ip of the Jac k bod y beneath the l ifting pin on the cha ssis br ac ket.
To fit the Spare Wheel
To fit the s pare wheel m th e s hortest t ime , use th e following procedure . If possible. se t the car on leve l ground and apply the handbrake securel y.
Remove the spare wh eel . whee l brace and jack from the L.H. wing valance and a screwd river from the too l kit.
With the sc r ewdriver. prise off the s nap.on-capfrom the whee l to be c hanged . and loosen the five whe e l nuts wit h the wheel brace •
Rem ove the relevam Jacking point cover . inse rt the jack and r aise the side of th e ca r.
Remove the wh ee l nuts and take off the wheel. F i t the spare wh eel and sc r e w on the five wh ee l nuts firmly bu t not tight.
Lowe r the car to the ground then t ighte n alternate wheel nut s wit h the b rac e uno l the y are all secu r e.
Replace the s nap_ an _c ap.
Rem ove the jack and replace the cover plat e .
Stow the jac k firs t into the wing c ompartment, then S l O W
the removed wheel . secu r e with the clamp, fit the whee l br ace into the cl ips and loc k the compartment.
Tyres
The correct maintenance of tyres is an extremely important factor in a c ar of high pe rfo rmance . Incorrect pressure , od d pressures and wheel s oul of balance. g r ea tl y impair th e s afety of high s peed travel and se ri ous ly effect tyr e life , stee rmg accuracy and l":en erlll r oadwo rthines s . Toobta in the mos t e ffi c ienC I r oad pe rformance from the T ype 407 car the recommended ty re s and pressures s hou ld be used wh e rev e r possible.
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remove the spa r e wheel. Ta ke out the Jac k which is stowed behind the spa r e wheel.
Jacking
Two jacking points are provided in a central position on each side of the car.
Referring to F ig.3D lift the carpet at the s ide of the fr ont seat , and thiiO will expose a circu lar dished plate with a cross
Fig.30 Car Jacking Position
handle release s pring . Pull on the sprin g, which will release the pinte. Insert the baseofthe jack through the aperture, th en
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CONTENTS
FACTORY SERVICE AND SP ARES
L UBRICANTS AND CAP ACITIES
INS TRUMENTS AND CONT ROLS - R. H. VIEW
INSTRUMENTS AND CONTROLS _ L.H. VIEW
ST ANDARD TOOL KIT AND STOWAGE
&lGINE SPECIFICATION
ENGINE AND T RANSMISSION _ R.H. VIEW
ENGINE AND TRANS MISSION - L. H. VIEW
START ING THE ENGINE. COOLING FANS. RUNNING IN.
ENGINE LUBRICA nON Checking the oil level Oil Filter Oil Filler Pipe Cap Air Cleaner Oil Pressure Gauge
TORQUE _FLITE TRANSMISSION Flat Battery Driving the car T owing the car Gearchange Pattenl Summary Chart Lubrication of Torque-Flite Transmission Checking Fluid Level T ransmission Dipstick/ Filler T ube and
Drain positions Procedure for Checking Fluid Level Transmission Drain and Refill
IGNITION SYSTEM Ignition and Generato r Warning Light Coil
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2
6 & 7
8 & 9
10
II
12 & 13
14 & 15
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18 18 18 19 19
20 21 21 24 25 25 26
26 26 26
28 28 28
CONTENTS (Continued)
IGNITION SYSTEM (Com'd. ) Spark ing Pl ugs Firing orde r Dist r ibulO r Contac t B reaker Points Gene r ator Belt Adj ustment Gene r ator Be lt
ENGINE COOLING SYSTEM Water Te mpe rature Cooling Fans Radiato r Filling the Sys te m Anti-Free2e Spring and Summe r Rust Additive Radiato r Cap Draining the Sy ste m Flus hing Wate r Pu mp Thermostat Water P ump Belt Adjustment
FUEL SYSTEM F ue l Gauge C arbu r e n o r F uel Pu mp F ue l Filter Air Clean e r Man ifold Heat Control Val ve
F RON r SUSPENS ION Front Sus pe ns ion Illustration Front Hub and Stub Axle
REAR SUSPENSION Rea r Suspens ion Illu s tration Rear Axle
P ROP ELLO R. SJl AF I
P AGE
28 30 30 30 32 33 33
34 34 34 34 34 35 35 35 36 36 37 37
38 38 38 3. 3. 3. 40
43 42 44
44 45 44
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ROAD WHEELS AND TYRES
Changing a Wheel
The s pa r e whe e l, jack and wheel brace a r e all hous ed in the L.H. Win g Ba y.
To open , insert th e s qua r ed 'T' ke y, s upplied with the car 100 1 kit, m to th e esc ut cheon on the lowe l" edge of the wing valve and turn it to r e lease the loc k. T he door will onl y ope n a s far as the s afe ty ca tch.
In sert the fingers through the lowe r r e a r cnd of th e slightl y rai sed doo r , s e e Fig .2 9, and lift th e c atc h all OWing th e door to be rai sed to its full e xt ent.
F fg.29 Opening the Wing Hay
Remove the wh e e l b r a c e fro m it s clip Oil the fac e of the whee l cl am p, ul1!-oc r c w th e bo lt reta in ing th e wh e el c la mp an d
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Boot Lamp Lucas Mode! 474 Part No.052477 Bulb _ Rival 12v.6w. Switch _ Lucas Model 94 Part No .035436D
This lamp is m ou nted centrally beneath the tool compartments and is wired in circuit with the side lamps. A switch situa ted under the hlOge on the R.H. side ope r ates the light automatically when the boot door is opened and the side lamps a r c on.
Direction Indicator Flasher
Flasher Unit - Lucas Model FL.5. Part No.35020L.
The Flasher lamps are controlled by the indlcator switch positioned on the left hand side of the steering column, the flasher unit being housed inside the car behind the dashboard .
When the indicator switch is in operation - UP for right turn. OOWN for left rum _ a warnlng light AMBER embodied into the revolution counter will continue to flash unt il the lever automatically retut-ns to us neutral posi ti on .
Glove Box Lamp Lucas Model L,550 Part No.52325B Lucas Bulb 987 12v. 2.2w.
Thls light embodied in to the top front of the glove box is operated by i t s own push bunon switch adjacent to the light . It is wired in circuit with the side lamps .
Radio
The radio installation is classed ·as an optional e xtra. The front s peaker is situated in the roof over the d ashboard and the second speaker lS fitted inro the rear squab shelf.
The balancing of the speakers is controlled by a rotary switch. See Fig.4. to the right of the radio controls . By rotating the switch fully clockwise the rear speaker becomes non-operative , and similarly b y rot<lting the s witch fully antic lockwise the front speake r becomes non-operative .
If a radio is not installed at the Wor ks a dUlnTny panel rakes it S place on the dashboa r d. t he speaker grilll' in th e roof a nd rear squab are fitted but not the speakers. The roof aer ial is not fitted but the lead-in from the roof to the dashboa r d is In position .
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CONTENTS (Continued)
STEERING Steering Wheel Steering Gear
BRAKE SYST EM Brake System Illustration Bleeding the brakes Brake Adjustment Renewing the Friction Pads Handbrake Master Cylinder
T RICO WINDSCREEN WASHER
HEAT AND VENTILATING SYST EM
ELECTRICAL SYS T EM Battery Trickle Charge r Socket Generator Brushes Voltage and Current Regulator Fuse Box Windscreen Wipers Horns Lamps Instrument Panel Illumination Courtesy Lamp Boot Lamp Direction Indicator Flasher Glove box lamp Radio Wiring Diagram
ROAD WHEELS AND TYRES Changing the Wheel Jacking T o fit a Spare Wheel Tyres Fitting new Tyres fyre Pressures
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47 47 47
49 48 49 51 51 52 54
57
59
61 61 61 62 62 62 63 63 64 65 65 66 66 66 66 67
69 69 70 71 7 1 72 72
CONTENTS (Continued)
BONNET
BOOT
FRONT SE AT ADJUST MENT
MAINTENANCE AND SER VICING
PAGE
72
73
73
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Reverse Lamp Lucas Model LA88 Parr No.52246 B Lucas Bulb No .382 12v. 21w.
Rear Numbe r Plate Lamp.
Lucas Model L.534 . Part No .535 18. Os ram Bul b . 12v. 4w.
Instrument Panel Illumination
The instruments are illuminated as follows:- one bulb in the speedometer. one bulb in the r evolut ion counter, and two bulbs behind the panel serve to light the fuel gauge . ammeter, water temperature gauge and o il pressure gauge.
The bulbs are Lucas 987 12v. 2.2w.
The clock has its Own bul b and the gear selector push buttons are illuminated by two bulbs.
The bulbs are Phill ips 12829 12v. 2w.
The panel lights are controlled. in unison. by the rheostat control knob. marked 'p'. on the dashboard and are wi r ed in circuit with the side lamps .
In addition the speedometer and revolution counter have two bul bs each for the WARNING LIGHTS.
The bulbs are Lucas 987 12v. 2.2w.
Courtesy (Interior) Roof Lamp
Festoon Bulb 12v. 6w .
Door Shut Switch - Lucas Model 94 P art No.31175F .
This light is cont r olled by a switch in both front door pillars and the light comes on when a door is opened. and automatically switches off when the doors are clol'lcd .
A switch marked 'C' on the dashboard operates the light when the doors are closed.
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The push button In the centre of the IS teering wheel operates a solenoid "d a y s witch Lucas 6. RA.Parr No.33188A situated in th e vicinity of the right hand horn.
The ho rns sho uld g i\'e a long pe r iod of s e rvice without attention. but should they become unsati s fac tOr y. check for any loose connections or loose attachment bolts befo r e rej ecting the horn itse lf.
LAMPS
Headlamps
Home Lucas Model F. 700 Light Unlt (Home)
MK.X. P a rr No.58S18. Lucas 7002 SO/45W .
This I S a s e aled beam unit and in the event of a bulb fail ure the com plete light unit must be changed . A high beam warning light - RED - is incorporated into the speedome ter. When the foot opera ted headlamp DIPPER SWITCH. See F igA. i s dep r essed. i t a lte rnat ively switches the headlamp bulb from the lowe r power filament to the higher powerfilament . at which stage the RED headlamp warning light is ON. In the dipped posltlon the light i s OUT.
F og Lamp. Lucas Model SFT.57S. Part No.55128. Lucas Bulb No.soO (Yellow) 12v.48w.
Spot Lamp. Lucas Model SLR.57S. Pa rt No.55 132. Lucas Bulb No. 185 12v. 48w.
Front Side Lu cas Modd L539. Part No .52333 Lamp and Lucas bulb No .380 12v. Twin Fi lament 2116w. F lashe r (Clea r)
Rea r Side. Stop Lucas Model L551. Part No.533 77A and combined Lucas bulb No .3ao 12v. Twin Filament 2l/Sw. Reflector Lamp (REDJ
Rear Flasher Lamp (Ambe d
Lucas Model L539. Part No .52272 . Lucas Bulb 382 12v.21w.
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FACTORY
SERVICE AND SPARES
BRISTOL CARS LIMITED FILTON BRISTOL ENGLAND
TELEPHONE TELEGRAMS TELEX
FOR SE RVICING
FOR SPARES ...
BRISTOL 693831. A VIA TION. BRISTOL. 44163
T E LEPHONE EXTENSIONS 45 and 112
TELEPHONE EXTENSIONS 84 and 117
TO SA VE TIME AND DELA Y IN CORRESPONDENCE OR WHEN ORDE RING PARTS ALWAYS QUOTE THE CHASSIS NUM BER I.E. 40716001.
THE CHASSIS IDENTIFICATION PLATE IS ATTACHED TO THE TOP LEFT HAND OF THE CHASSIS F RAME WITHIN TIlE ENGINE BAY.
FOR CONVENIENCE ULA RS,
FILL IN THE FOLLOWING P ARTlC-
CAR CHASSIS NUMBER
IGNITION AND r::x::>OJ{ KEY NUMBER
PETROL FI LLER KEY NUMBE R
BOOT DOOR KE Y NUM BER
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407/
ENGINE AND CHASSIS RECOMMENDED
LUBRICANTS AND CAPACITIES
ENGINE CAP AClTY
Including tho: Oil Filter 10 pints Omp. )
010t includmg the Oil Filter 8 pints (Imp.) (4.55 Litres)
Above 320 F
ENGINE LUBRICATION
Mobiloi l SpectHl IOW/30 EssoExtra MotorOil 20W /30 Energol SAE . 30
o r Energol Visco Static Shell X-lOO-3U
or Shell X-IUU Multigrade lOW /30 Castrolltt: Advanced J-Iavoline lOW /3D
or Advanced Havoline 30
Mobiloil Special l OW/3D Esso Extra Motor Oil 20W /3 0 Encrgol SAE 20W
or Encrgol Visco Static Shell X-lOO 20/20W
o r Shcll X-l OO Mulngrade lOW/3D Castrolirc Advanced Havoline l OW/3D
Mobiloil Special 10W/3 0 Esso Extra Motor Oil 20 \, /30 Enc rgol SAE IOW
or E nergol Visco Static Shell X_lOO_lOW
or Shell X-lOO Multigracie 10W/30 Castr olite Adv anced Ha volinc 10W/30
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All accessOries protected by a fuse will be inoperative if that fuse is blown.
CAUTION: Never replace a blown fuse with one of higher value, as this will only result in damage to accessories if a short circuit occurs.
The volt age /current regulator controls the output of the generator according to the load on the battery and its state of charge. When the battery is in a low state of charge the generatOr output is h igh, and this is shown on the ammeter.
WINDSCREEN WIPERS
WIPER ARM - Lucas Part No. 54711438
WIPER BLADE - Lucas Part No . 54711283
The windscreen wiper motor is m ounted in the right hand wing bay. The cable transmits motion to the twO wheelboxes beneath the windscreen, which operate the wiper anus and blades.
No ad justment or lubrication is normally necessary as all parts are packed with lubricant on assembly.
The windscreen wipe r control knob , marked WIPER, on the dashboard has three operating positions as given on page 57.
A thermostatic cut-out switch is built into the wiper motOr to prevent ove rheating. However. in order to avoid excessive load, the fast s peed should only be used in heavy rain. Never use it in snow or on a drying windscreen without the use of the screenwash,
HORNS
High Note Low Note
Lucas WT.618 Lucas WT.618
Part No . 69090 Part No . 69087
Dual Windtone horns are fitted beneath the bonnet on each side of the engine valance.
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[or the running time H-' permit 0 fully m ainta ined ch.:l ,·gf' (e.g. short run s III wtnter Il' •• mrh s uS ing lamps. starter etc. )
GENERATOR BRUSHES
Bru .. hes should be exammed at 10,000 mih:s , agam at 20,000 m iles , and at 5,000 miles the reafter.
Brushes th at are worn s hort, o r arc covered wlth 011. s hould be replaced to prevent damage to armature, commuta to t· and windings.
VOLTAGE AND CURRENT REGULATOR - Chry s ler 1889944
FUSE BOX - LUCAS MODE L 4FJ. PART No. 033283L.
The voltage/current regu lator and cut-out are housed In the right hand wing bay.
Two fuses are contained in the fuse block posITioned immed ia tel y below the regulato r. The positions of th e fuses are c learly marked AI.A2. (Auxiliary fuse) and A3,A4 (Aux ilia ry ignition) and they protec t certain accessones as foll ows: .
Independent of the Controll ed by the ignition s witch ignition swi tch
Head, Side. Tail . Bout Igniti on and Ignttio'l and Numbe r Plate Wa rning L ight. Petrol Lamp. Headlamp Reserve Wanllng L ight Wa rn ing Light. Panel and all Acc esso rie s Lights. Amm eter. connected to A3 .A4 Horns. Radi o . C lock . Fuse.
ProteCted by Trickle Cha rger Al,A2 Fuse Socket. Fog Lamp. 35 Amp . Spot Lamp. Cigar
Lighter. Inte ri o r Light Horns . Radio , C loc k.
Protec ted by Stop Lamp. P el ,'ol I A3.A4 Fu se Gauge. r:la ~ht:I' Indlc· 35 Amp. ators, Flas h..: r \\ armng
Light. Blowe r Un It. Revers e Lamp. Petro l Rescrvl:' Warmng f.ight . Windscreen Wiper Motor. Brake 1";]Uld
Level Wa rllll1g Ll!.l;ht.
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Mooiloil Special SAW sW Esso Ext ra Motor Oil 5W / 20 Energol SAE SW Shell X-lOO Multigrade SW 120 Ca ~troli tc Havoline l llW/30
AUTOMATIC TRANSMISSION CAPACITY
AUTOMATIC TRANSMISSION LUBRICATION
16, pints (Imp.) (9.38 Litres)
REAR AXLE CAPACITY
3 pintS <Imp.) 0.7 Litres)
STEERING BOX CAPACITY
i pint (Imp.) (0.28 Litres)
Mobilfluid 200 Esso Automatic Transmission
F luid Automatic tran. F luide Type A She ll Donax T6 Castr oi TQ Texamatic F luid.
REAR AXLE LUBRICATION
Mobilube GX .90 Esso Gear Oil GP.90/ 140
(Above _10°F) Esso Gear Oil GP . BO
(Below _10°F') Gear oil SAE 90 EP Shell Sfirax 90 EP Castro Hypoy Multigear Lubricant EP90
STEERING BOX. HANDBRAKE CABLE LUBRICATION,
Mobilube GX .90 ES50 Gear Oil GP.90/140 Gear oil SAE 90 EP, Spirax 90 EP. Cas trol Hypoy Multigear Lubricant EP90
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BRAKE FLUID.
POINTS NOT REQUIRING LUBRICATION SERVICE.
DISTRIBUTOR AND GENERATOR LUBRICATION
Mobil As cngine Esso As engine B.P. As engine Shell As engine Cas tro l Everyman Oil Regent Havoline 20/ 20W
EXHAUST MANIFOLD HEAT CONTROL VALVE LUBRICATION
Graphited Kerosene
FRONT WHEEL HUBS. REAR SUSPENSION UNITS. PRO-PELLOR SHAFT JOINTS. HANDBRAKE COMPENSATOR. REAR AXLE HUBS.
Mobilgrease M.P. Esso Multi-purpose Grease H. Energrease L.2. Shell Retinax A Castrolease LM Regent M a rfak Multi-purpose
Grease 2
Dunlop Disc Brake Fluid. Spec ification SAE 70Rl and SAE 70R3
ENGINE
Water Pump. Starter Motor Bearings. Automa tic Choke Linkage. Fan Belt Id ler Pulle y.
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ELECTRICAL SYSTEM
This is a Lucas 12 vol! system . Cu rrent is supplied by a large c apac ity a i r cooled gene ra tor In conjunction with a voltage and cu rre nt r egulato r with automatic cu t- out and a 12 volt 72 ampere battery.
BATTERY, Lucas BT.1lA 4016437
The barre r y is housed in the offside wing bay. To open see page 69.
Alwa ys keep th e tOP of the barrc r yclean and dry. 'Topping up' the battery is a r outine matter and means that the plates In the battery shou ld always be just c overed by adding distilled water to the cells by removing the filler plugs. Va rious commercial appliances and methods are used for this procedure. but it is important nOI to overfill. Never use a naked l ight to examine the l eve ls as the gas given out is inflammable.
No particular perIod can be given for the 'topping up' of the battery as hm weather and th e conditions of use of the car must be taken 'inro consideration. It is better to examine [he levels frequently.
See that the bartery is level and firmly clamped into position. The positive and negative connections are of diff erent sizes and I[ is not no rmall y poss ible to incorr ectly a ttach them. Keep the battery connections clean, and smear the term inals wHh vase line or pe troleum jelly before attaching the leads, to prevent corrosion.
Trickle Charger Socket
An electric supply /feed socket is mounted on the right hand valanc e . in the engine ba y, beneath the bonnet. Since it is direct electrical contac t with the battery , current may be drawn from the battery 0 1' s upplied to it from a tnck le charger.
The object of the tri Ckle charge r IS [Q maintain the banery in a fully c harged s tat e wh en the car is not in use for lengthy periods . o r when th e output from the battery is toO g r eat
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BLOWER SWITCH
UP ... OFF pos iti on .
HORIZONTAL BLOWER HALF SPEED
OOWN ... BLOWER F ULL SPEED
Thus, the system can be used normally, with the blower switch OFF, boosted to a second stage with the blower switch horizontaL and boosted further to a third stage with the blower s witch down.
The use of the opening rear quarter lights in conjunction with the heater and ventilating system is recommended, wherever possible, for air circulation .
-60 -
• •
• •
CHASSIS
• Steering Joints. • Fronr.;:iuspension Top and Bot
tom Joints. Wishbone Bushes. Steering Idler Box Bushes. Brake Pedal Bushes. Steering Column Bushes. Rear Suspension Arms. Watts Linkage_RearSuspension. P ropellor Shaft. Front Joint RegentMarfak HD2 Rear Joint Regent Marfak 0
• See Maintenance Chart
-5-
• • • ;;
'" " • ] c oS ~
li !J c • ~ • c -M .. 0:
•
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HEATER - VENTILATING SYSTEM
ThIs built in sys tem IS comroll~d by twO rotating c omrol knobs on the dash board, s ec F 'g.4 , with a blowe r switc h pos Itioned cemrall y between them.
Air enters the heate r through the gri lle . r ea r of the bonnet . and bel ow the windscre en.
The vari ou s pos llions of th e rOla r y knobs are given In F ig.2 7 and the y can be us ed as fo llo ws :
C 8 09
F1&.27 lIeater ConCl'Ol s
HEAT and VENTILATION CONTROL KNOB
From OFF position. [urn clockwise progressively to COLD. WARM and HOT.
WrNDSCREE N DE-MIST CONTROL
From O F F p OSiti On ,
DEMIST AND DEFROST. turn clock Wi se progressively t o
- 59-
T he jets Fig.26 c a n be cle aned as follows:
Unscrew the knurled nut 1 turn ; do not r em ove. With the e ngine r unning, ope r a t e the system a nd allow wate r to fl ow freely throuQ'h the loos e iet to rem ove anv pa rticles o r g r i t.
JET I
KNURLED NUT TRICD 81153·1C
PLASTI C WASHER TRICD 81635
Fi,.26 Windscreen Wasber Jet
Re ti ghten the knu rled nut, t a king c a re not to damage o r lose the pl ast ic wa s her . Re peat t he a bove procedure fo r the o ther jet. Do no t cl ean both je ts at the s a me t ime.
-58 -
• •
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1.
INSTRUMENTS & CONTROLS
R.H. VIEW
Speedometer m.p.h . - Smiths SN .6153 / 74 Speedometer k.p.h . - Smiths SN.61 53/75 lncor-pora t ing Ignition and H eadlamp Warning Lights.
2 . Fuel Gauge _ Smiths FG .2530/67 .
3. Water T emperature Gauge - Smiths TG .1 503/8 4.
4. Clock - Smiths 3103/02
5 . Ammete r - Lucas 36288
6 . Brake Fluid Warni ng Light
7 . Push Button Gea r Selectors
8. Horn Push - Lucas 32 756
9 . Oil Pres.,;ure Gauge - PG 1502/02
10 . Revolution Co unter - Smiths RV1. 2810100
lncor-pora t ing F uel and Di r ection Indicator Wa r ning Lights .
11. Igni t ion and Sta r te r (Ke y) Switch _ Lucas 31953
. 7 .
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= ..; I • ] c 0 U ~
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TRICO WINDSC REEN WASHER
T he purpose of th is sys te m I S to allo w the wipers to gi ve a cl e ar vIS io n when the windsc ree n is o thl! rwlse dry.
The sys te m I S operated by induCti on depression. and therefo re can onl y be operated fo r any length of time when the engine 1 s running.
iI IS operat ed by lhe sca l loped knob o n the da s hboard marked WIPE /{. See Flg.4 .
TO OPERATE TH E SPRAY
Press Ih e kno b WIPER and rele a se. If fu rther s praying IS
requ ired press agalO and rel e a se . Do not keep the knob held do wn.
SLOW WIN DSC REEN WIPE Turn WIPER kno b clockwis e into fir s t pos it ion.
FAST WINDSCREEN WIPE
TO PARK WIPE RS
Turn WI P ER knob further cloc kwi se IntO sec o nd pos i t ion.
Rerurn the knob to ltS onglnal pOS ltl o n.
Th e wate r s upply is contain ed in a gla s s Jar on the le ft side . r ear of th e e ngIne. beneath the bonne t. and a s WIng co ver on th e li d o f the jar allo ws ftllin g to take place in Sit U .
it IS recomm e nd ed that Tnco Wlnd sc r een Washer Sol ve n t XAW_ 30 is used Ln the wat e r s uppl y. a s u :
(11 P rotec ts the Ja r from cracking In cold we ather. and s a ves e mpt Ying the Jar.
(2) It c an be used In Summ e r and Wint e r and helps to cl e an the Windsc r ee n.
Do not use Anti-Free ze In the J1l r .
-5 7 -
Refe rring to F ig .2 5 slacken and screw back the fork e nd locknut A and the pedal s top B.
With the foO[ bl"itke leve r pressed , by hand, fully down a gainst the carpet C1 djust the push rod C, by hand, until the maste r cylinder pi s ton is at the bot tom of its stroke . Tighten the fork cnd lockou t A. a t the same tim e adJ ust the pedal stop B hard against face D. Release the lever , unscrew the pedal s tOP a further complete turn , and lock securely.
Slacken the pedal cradle securing bolts adj acent to the r ear stop E, and set thi s stop to gi ve 1/3 2 i~c h o f cle arance a t F. T ighten the cradle securing bolts to secure the r e a r stop, and check the return s pring G to ensure a small amount of tension . • •
• •
INSTRUMENTS & CONTROLS
L.H. VIEW
1. Cigar L ighter.
2. Heater Controls.
3. Radio Controls.
4. Radio Speaker Balance Control Knob .
5. Courtesy (Interior) Light Switch - Lucas 31828.
6. Dipper Switch - Lucas 31800L.
7. Panel Light Rheostat - Lucas 78343L.
8. F og Lamp Switch - Lucas 31828 .
9. Brake Pedal.
10. Accelerator Pedal.
11. Main Lighting Switch - Lucas 31788.
12. Heater & Ventilator Blower Switch - Lucas 31788 .
13. Spotlight Switch - Lucas 31828.
14. Windscreen Wiper Switch - Lucas 31847 .
15. Bonnet Release Knob.
16. Petrol Reserve Switch - Lucas 31828.
17. Speedometer Trip Reset Knob.
18. Direction Indicator Switch - Lucas 34389.
19. Handbrake Lever.
- 56- -9-
STANDARD TOOL KIT & STOWAGE
TOOL ROLL Containing:-
SPANNER 118" x 3/16" WHIT.
SPANNER 114" x 5/16" WHIT.
SPANNER 3/8" x 7/16" WHIT.
SPANNER 3/8" x 7/ 16" A/F.
SPANNER 112" x 9/16" A / F.
SPANNER 5/8" x 3/4" A/F.
PLIERS.
SCREWDRIVER.
SOCKET 14 m / m with RUBBER INSERT.
SOC KET HANDLE.
RUBBER BLEEDER T UBE (IN TINJ.
BLEEDER WRENCH.
SET OF FEELER GAUG ES.
BEVELlFT JACK
IN BOOT
LH. WING BAY.
WHEELBRACE
SQUARED TEE KEY FOR WING BAY
CUPPED IN L.H. WING BA Y.
IN DRIVERS DOOR POCKET.
- 10-
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brake pedal. and at a ratio proportionate to the load applied. provides the hydraulic pressure ne cessary [Q operate the brakes.
A check should periodically be taken to ensure that when the brake pedal is in the OFF position there is no preloading of the master cylinder pi ston. The piston controlled by the push rod should have a free fore and aft movement of 1/3 2 inch.
If necessary. and also if changing an yof rhe part s , adjust to the following procedure .
FIC.2~ Brake Master Cylinder
-55-
then slacken back 1/ 3 turn. Thi s s hould allow the wheel to r otate by hand .
HANDSI1AKE Ao.JusnNG SCREW
Fi&:.24 Rear Disc Brake
&lEED SCREW W ITH REMOVED
Repea t thi s procedure on the othe r r ear wheel , lowe r the car on to it s wheel s and c heck the handb rake travel.
Master Cylinder
The mas ter cylinde r is mechanicall y Bnked to the foot
-54-
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ENGINE SPECIFICATION
Canadian manufacture by Chrys le r, spec ia l for B n srol Cars. E ight cylinder 900 Vee with ove rheadpushrad operated valves and m echanical tappe ts .
Bor e 3.88 inch (98. 55 m / m!' Stroke 3.31 in . (84.07 m / m). Capacity 313 cu.in. (5130cc . ). Compress ion Rati o 9.0 to 1. Po we r Output 250 BHP at 44 00 rpm. Maximum To rque 340 Ib.fL at 2800 rpm.
Ca st iron cylinder bloc k and cylinder heads. Specia l high lift camshaft, chain driven , and suppo rted in five ma in bearings .
Aluminium pistons and fo rged stee l connecting l·adS. F o rged s teel crankshaft. s tatica ll y and dynamically ba lanced . supported in five main bearings.
Lubrication system by r otary type oil pump with integral relief valve and shunt type oi l filt e r.
Carter 4 choke downdraught ca r bu r e n or with automatic c hoke fo r cold starting and manifold heat control val ve for rapid warm up.
Pressurised cooling system 14 p.s.i. by centrifugal wate r pump circulation thermos tatically controll ed. There i s no engine fan. Twin electric fans are mounted in front of the engi ne, operated by thermostat control, to ensure maximum cooling Irrespec ti ve of engine speeds.
Ca rte r mechanical Fuel Pump .
Battery and coil, posidve earth 12 volt ignition system. Centrifugall y and vac uum cont r o lled advance and reta rd. 14 m / m sparking plugs, c oi l and distribulOr.
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A grease nipple is also provided on the brake compensating lever Fig .23 .
Ftg.23 Lubricatin g Brake Compensating Lever
The correct handbrake travel. from the fully off, to the fully on position . is 4 to 5 teeth on the ratchet. On no account attempt to correct excessive [ravel by adjusting the cable rods. as these a r e set correctly by the manufacturers.
or
With the disc brakes, the handbr ake pads are completely separate to the footbrake pads, see F ig .24 and they can be set to correct the handbrake travel as follows:
J ack up the r e ar of the car in order to spin the wheel, or wheels . and set the handbrake [ever in the fully of position. Insert a screwdriver through any hole in the road wheel opposite to the handbrake adJusting screw and tighten sufficien tly to prevent the wheel from spinning .
-53_
Replace the keep plate and secure it with the bolt, washer and nut.
Tighten the bleed screw, remove the tube and Jar, and replace the bleeder rubber cap .
Operate the foot pedal normally to give the correct automatic adjustment and clearance for the pads .
T op up the master cylinder (see Bleeding the brakes).
Repeat this procedure for all brakes as necessary .
Handbrake
The handbrake is a normal push button release lever operating via a cable and rods to the rear wheels only . At periods, lubricate the brake cable through the grease nipple on the rear conduit Fig.22 .
F ig.22 Lubricating Handbrake Cable
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R.H. VIEW OF ENGINE & TRANSMISSION
KEY TO FIC. 5
1. Cod .
2 . Carburet tor.
3. Carburettor Air Cleaner .
4. Engine Dipstick .
5. Gene ra tor Belt Adjustment Strap.
6. Wate r P ump.
7. Id le r Pu ll ey Adj ustment Br acket.
8. Idler Pulley .
9. Fuel Pump.
10. Fuel F i lter.
11. E ngine Mounting .
12 . Oil F i lte r.
13. T r ansmission Dra in Pl ug .
14. E xha ust Manifold .
15. Man ifo ld Hea t Cont r ol Va lve .
16. Transm ission Dipstick and Oil F ille r Tu be .
17. Spa r kmg Plugs and Leads .
t 8. Smog Pack.
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With all bleeder screws tightened and with th e protective caps fitted . finally top up the ma ste rcylinderand conneCt the fluid indicator wire .
BRAKE ADJUSTMENT
Brake adjus un ent is autom ati c during the wearing li fe of the fric tion pads. Wi th the road wheels removed. the pads s hould be c hecked for wear at frequent inte r va ls by visual observation and meas urement. When wear has reduced the pads to a minimum permissible thickness of i (.2 50) inch. the pad assemblies (complete with securing plate s) must be rene wed. If this checking is neglected the need to r ene w the pads will be indicated by a loss of Drake effiCiency.
RENEWING THE FRICTION PADS
Remove the road whee l.
C lean around the brake, open the bleed screw, and connect the bleed tube with the other end in a clean jar (a s for bleeding).
a nd
Block the foot brake pedal in the down posi tion .
Remove the nut, washe r and bolt secu r ing the kee p plate withdraw the plate .
With a sui table hooked imple m ent inserted into the hole In the lug of the pad securing plate. withdraw the worn pad .
Thoroughly clean the s urrounding area of the c alipe r . insert the forked end of a special Dunlop Piston resetting lever in to the space of the removed pad. with the fork astride the projecting pi ston spigot and its convex face bearing on the piston plate. Fit the spigot of the lever into the keep plate bolt hole and lever back the piston . This will cause a d isplacement of fluid which will go into the jar.
Insert a new friction pad assembly and repeat the operation for the othe r pad .
-5 1_
Do nOt reconn ect the wire at t h l b .. tag'; .
Jack up the car and remo\e ch e nearSide rear road wheel. Remove the rubber protecti ve cap from rhe bleed screw and attach the J'ubber bleeder tube, s upplied wi th the tool kit, imme r s e the othe r end of th e cube in a small quantlfy of fluid contained In a clean glass Ja r. Slacken the bleede r screw with the spanner su pplied with the too l kit, and pump the foO[ brake peda l smal-ti y until fl Uid pumped in to the jar IS r easona bly free f r om all' bubbles .
"K:r~'N PADS
KEEP
F lg.21 Front Disc Brake
~LEED SCREW WITH COVER
Taking care to keep rhe mas ter cy l inder suppli ed with fluid , bleed a ll brake s in turn ,
When all the brakes have been treated , r epea t the p rocess with the engin e r unning , to bri ng the servo into operat ion.
-50-
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L.H. VIEW OF ENGINE & TRANSMISSION
KE Y TO FIG. 6
I. Generato r .
2. Oil Filler Pipe Cap Air C le aner.
3. Dis tnbuto r.
•• Sparking P lugs and Leads .
5. Transmiss ion Unit.
6. Exhaus t Manifolii.
7. Starte r MOlo r.
8. Engi ne Mounting.
9 . v iI P an (Sum pJ.
- 15_
STARTING THE ENGINE
An automatic choke prov ides the prOpel" fuel for surring. regardles& of the season of the year.
mixture
The following sta rring p r ocedure is recommended ir respec ti ve of whether th e cngine is hot or cold.
lal
Ibl
lel
Idl
lel
Push the se lector button marked 'N' in. The starter motor will not operate if any of the o thcr buttons are pressed in or already engaged. This is a safety feature to prevent the car from being started in gear.
Dep r ess the accele rator pedal s lowly to approximately i of its full travel and ho ld it in this positi on . Do no t pump the accelerator pedal (sec 'e' ).
Turn the ignition switch key to tne right (cl ock wise) to
the igniti on 'on' position .
Turn the ignition ke y further to the extreme ri ght (clockwise) to operate the s tartc r motor. When the engine starts , relea se the key and it will automatically return to the 'on' or driving pos ition .
Pumping the accele r ator redal will 'flood' the engine and a strong s mell of petro will be not iceable.
If the engine is flooded with petrol. depress the accelerator pedal s lowly to the car floor so that the throttle will be wide open. Holding thisposition , operate the starter at inte r vals of about 15 seconds until the engine s tarts, and relea se the accelerator pedal to
prevent the engine racing .
lr is important that the accelerator pedal is depressed i of its travel in o rder to obtain the fast idling speed which readjust s itself as the engine warms up . If the accelerator pedal is not depressed the engine will not automati cally 'fast' idl e .
_1 6 _
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Tht: brake caltpc r type dISC
a foot operatt'd Se r\'O "Hill.
BRAKE SYSTEM. FIG.20
SYF;(('rn cons is ts of front and n:ar Dunlop brako.:s , hydrauilcally operated by means of
l. (,c khced master cy lInder and a Lockhced
A vac uu m tank manHams thc vacuu m supp ly from (h e engLn !:: .
A between
pn~ss button rdeast: tho.: front seats .
handbrake lever IS situated
~rov.ding that the brake flUid In the master cyli nder i s mamtalned, the br ake sys tem should on ly need the mlntmum of ancnllon. A brake flUid level warntng "ght I S fined to the da shboard, Flg.3 and a red light will ind,cate that flUid should be added to the Master Cylinder.
The specified brake fluid i:; given 10 the list of reco mmended ods , and should an altenlati ve fluid be used It s hould completely fill "the sys tem, as it IS not advisable to tOP up the ma s ter cyl inder onl y, and so cause a mixture of flUids.
Bleeding the Brake System
The inclUSIOn of aIr in the brake system is indlcat t:d by sluggish rt:.'sponst' of the brakes and spongy action of the b r'a ke pedal.
ThiS inclUS ion ma y be due tu a loose connection somewh ('!"c In rhe :; ys tcnl or by a llow.ng the riuld In the master cyltnder tu fall to a low le vel. These defec ts must be Immediately corTcered and the com plete system bled as follows:
Check aB c onneC lIon s and hlccd scr..:w.s 10 ensure that nu It·aking c an occur, and lighten where necessary.
l{efernnR to r. g.25 dl.sconncCI th e w.re connection frum the brake flu.d IndlCatol' , and unscre w this unll fl'om {he master c yllndcl'. Top up th e master cylinder WIth "ecomrnended flUId and screw th e una .n securely.
- 4 9-
, J
r------~
/ /
I ,
I /
E !i • ~ • ~ " !l .. ;:
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Cooling Fans
The tWO cooling fans in f r ont of the engine are electricall y ope rat ed and thermostatically controlled by a switch embodied into the radiator header tank . They will a utomatically switch on and off and there is no manual control.
Running in
Avoid high engine r evolutions and lim it them to 1250 r.p.m. in any gear until the engine is warmed up. Thi S I S
eguival e nt t o 30 m .p .h. in tOP gear.
The oil which is added to the engine at the time of assembl y should onl y be used for the first 1000 mi les of ope ration. at which tim e the engine should be drained and refilled with an oil 8S r ec ommended and li s ted in this book.
This may be carried out by the Agent, who sold the car, at the 1000 mile Free Service.
During the first 300 miles stopping and staning the engine should also be kept waminimum. The maximum s peed for running in is 50 m.p .h. and this is best carried out on a road giving variations in speed rather than maintaining a stead y speed.
Afte r 300 miles che speeds should be increased graduall y until a 1000 miles have been covered.
Unde r all conditions, whether the engine I S run In o r otherwise , full throttle acc e le ration and high s peeds should be avoided until the engine is thoroughly warmed up .
_17 _
ENGINE LUBRICATION
As previously s tated the oil added to the engine at the factory shou ld only be reta ined for the fir s t 1000 miles. topping up if and when necessary . From then onwa r ds. oil s hould be changed r egu larly for best engine operation and l ife . The o i ,r change period can vary widel y on the type of operation. weather conditions and other operating vari ables . but as a gene ral {'ule the ave rage driver would be recommended to change the oil every 2 000 miles .
Checking the Oil Level
The oil f iller and the dip s tick positions are s hown in F ig. 5.
Never check the oil leve l with the engine running. if the engine ha s been running allow time for the oil to drain to the sump. When taking a dipst ick reading see that the ca r is r easonably level . wipe the dipstick and make certain that it is fully inserted .
O il need not be added until the level drops to the ' add oil' mark on the dipsti ck . at which t ime onl y 2 pints s hould be added.
Oil Filter
Thi s unit is pos it ioned as shown in Fig. 5.
The o il filter element s hould be replaced afte r the fi r st 2000 mile s and thereafter every 4000 miles. pre ferabl y to coincide with an engine oil c hange. Opera t ions in d usty areas wi ll r equi r e mo re f req uent fi lter c hanges.
T o r eplace the filter e lement p roceed as follows:
From beneath the car. un screw the centre tu be bole and lift away the complete s hell whic h is partially fi lled with oi L ,At the same time. take a way the rubber joim ring s ituated between the filter s hell and the cy linde r block . Drain the oil .
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TWO OUNCES spread evenly throughout the work ing surface s. DO NOT OYERFILL. Replace the join t be tween flange and cover. if nece ssary. and replace the cove r. Bend the tabs to tighten in place .
At the rear end. release the roller and bus hing assem _ blies, freely grease them and re -assemble .
N.B. Special greases should be used. see Recommended Lubric ants .
STEERING
Steering Wheel
The two s poke 17 inch diameter s ceerLngwheel locates on a serrated shaft. and is made adjustable by a circular nut which is part of the s tee ring wheel. Us inga r ing s panne r this can be released and tightened when the de s ired pos ition is obtained.
Circlips on the shaft determine the amount of travel and also prevent the steering wheel from s liding comple tely off of the steering col umn,
MARLES STEERING GEAR
This unit does not norma lly require periodical serv icing except for inspection of the oil le ve l and topping up when necessary. A squared filler plug is situa ted at the top of the steering bOl( which can be reasil y removed to chec k the leve l.
used Unde r no circumstances must grease or solid ified oils be in the steering bOl(. The correct gr ade of oil is SAE.90,
A universal joint is fined between the lower end of the stee ring column ' and the stee ring box. T his is a pre -packed asse mbly and should not require a ttention be twee n long periods of se r vicing.
Steering track rods are fined with nylon Ilned ball jOints and no lubric a tion maintenance is required. but examination every 10,000 miles as instructed in ' the Maintenance Chart should be made.
-47-
A gr.::a s e nippl e is fi tt ed at rhe end of each axle , see Fig.1 9 and th..: hubs s hould be g/"eased at the r ecommended intcrval s .
Fig. 19 Grease Nipple - Rear .4-xle Casin g
Ax le locat ion is by Watrs linkage which is fitted th rough out with rubber bus hes and lubrication is not necessary.
PROPELLER SHAFT
Thi s unit s hould be s erviced eve ry 10,000 mile s . From bcneath the car it should be completely rem oved by taking out the bolts at the front end, and rel easing the clamp caps at the I"ear cnd.
I\t th e forward e nd relea s e the cover by bending back th e tabs . The tota l am ount of grea se this joint s hould contain i s
-46-
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•
then lift out and discard the element. Ta ke the rubber wa s her' off of the centre tube bo lt and bft OUI the combined s pring and rubber washe r seatin g. Ta ke ou t th e centre tube bolt. C lean thc parts and th e she ll thor oughl y. F II a new fi br e washc /" (suppl ied with clementl benea th the head of the centre tube bolt, fit the bolr , spri ng and seat lllg and new r ubbe r' washer (suppl ied with the elemend to the s hell. F it a new eleme nt, ei ther way up, lightl y grease a new fiher to c ylinder block ga s ket ( s upplied with e lement> and f l( H into Ihe reces s in the cylinder block . Re place the s hell assembl y, check that I( i s seating co r rectly and tighten centre bolt securely . (To rqu e loadin g 30ft / lbs . ) Run the engine to f ill th e oi l filter. Chec k for o i r leak s . All ow oil [Q senlc . chec k od level and r epleni s h if necessary.
Oil Filler Pipe Cap Air Cleaner . Fig.6
Th is cleaner s hou ld be wa s hed in kerosene. drained and r e-oiled with SAE 30 ,[l[ eac h engi ne oil c hange.
ou Pressure Gauge
Oil pressure i s tak en from the rear top face of thc cylinder bl oc k 10 an inst rum en t on the dashboard. and rhe normal oil pressu rc is 45 to 65 p. s .i. ·at 2000 engine Lp.m.
No oil tempera ture gauge is fitted.
- 19-
TORQUE - FLITE TRANSMISSION
With the rorque -flite t ransmi ss ion, [h e clu tch pedal has been eliminated from the car controls , and push button gear selectors located on the instrument panel provide the
Ft,.7 Push Button Gear Selectors
d rivi ng control. The drive r simply pu s hes the desired button and applies the cngine power by means ofthe accelerator peda l for comple te contl'ol of car directi on and applica t ion of the driving power.
GEAR RATIOS (Overall)
1 st. ........................ 8.1 2nd ......................... 4.8 Top ..... .. .... ..... ....... .. 3.31 (dil'ecr)
Revel'se ....... . ................. 7.2B
With the (D) or dnve button pu s hed in, three fOl'ward s pe eds are available.
With the (2) button pu s hed in , two fo r wa l'd s peeds are
_20_
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_45 _
Front Hub and Stub Axle . Fig.17
Each front wheel hub i s mounted on two tape r r oller bearings. and has an oil seal at its inner end . No attention other than packing with g r ease as given in the Maintenance Schedule is necessa ry .
Packing with g rease should be carried out by complete ly r emoving the hub and packing rhe grease be tween the bearings. The hexagon dust cap should not be loaded with grease.
REAR SUSPENSION. Fig.1S
To rsion bars are fined to the rea r s us pension. They are marked left and right hand (L and R) re s pective ly, on the rear face and they are not interchangeable. The f,'ont serrations of the tors ion bars are located in adjusters. while the rear serrations locate in the suspension unit main arm.
The suspension uni ts are packed with grease and normall y do not require attention .
The suspens ion arm assemblies fitt ed between the suspension units and the rear axle casing are rubber mounted. and do not need lubrication maintenance .
Telescopic shock absorbers are fitted be tween the axle casing and the cha ssi s frame.
Rear Axle
The rear axle and differenti a l assembly is a combined unit of Salisbury manufacture . The ratio is 3.3 1 to 1.
The rear axle oil check and o il change should be in acc ordance with the Maintenance Schedule .
Tw o oil seals are fitted w each end of the ax le cas ing. th e inner seal r etaining the oil for the differe ntial assembly , and the oute r seal which retains the bearing g rease.
-44 -
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a~aj(able . . BO.th speeds of the (2) bUtton are gear speeds and direct drive IS not obtained unless the car is dri ven above 70 m:p.h. The change up to direct drive at thi s s peed is provld~d as a sa fety measure to prevent e ngi ne damage by exc.esslve speed. Te~t s have also shown this speed to be the ~pum.um from a max im um perfo rmance viewpo int. ThiS range I S SUitable for heavy city traffic where the driver may desire part throttl e second gear for more precise s peed control. It ma~ also be used on long downhill run s where additional engine braking is needed.
~ith the. (1) button pushed in, a low or first position range IS o.btamed. In this gear the transmission will nOt chanfe .up mto any othe r gear. This button should be pushed to o . tam steady pow~r fo r climbing s teep gradients. or for brakmg when descending s teep gradients . Thi s gear ma y also be used to advantage ove r roads of deep mud, s and or snow.
To prevent ove rspeeding the en~ine do not drive the ca r above 40 .m .p.h . with the button (1) pushed in. If maximum acceleratIOn performanct' through the gears is rC<juired the (D) button should be pushed in and the accelerator ~edal press ed to the floor.
Stall tests
. . For sa fet r easons and to revent d am a e to the trans. ml s.s ton o. en thro ttle stall tests 0 erat ions (i .e . with t e engine pull mg hard aEainst the brakes) should not e attempted.
Flat Battery
In the case of an engine fa iling (0 s tart due to a flat batte r y, an auxiliary battery and leads should be used. The ca~ s hould n~~ be tow started. si nce the transmission will not drive the engme until approx imate ly 25 m.p.h. i s reached .
Driving the car
Keep the foot brake lighly applied when holding the car in gear on closed thro ttle and when changing to forward or reverse
-21 _
gears from a standing sta rt. Th is is especially important when che engine is cold and che automatic choke increases the idling s peed .
IMPORTANT Push in the (N) neutral button when it is necessary to idle the engine fo r an extended period or when parking . Operation of the to rque converter coupling fo r a prol6nged period when the car l S stationary will cause excessive heat to develop.
Warm the engi ne so that it is rUQning smoothly . Lightly apply the footb r ake and rele ase che handbrake. Push in selector button marked (D) which will give che drive range. To start the car in motion. release the foocbrake and dep r ess the accelerator redal to whatever car speed desired. The automatic contra s will take care of a ll gear changing when rC<juired , and the d ri ve r need only use the accelerator peda l to appl y engine power or to maintain speed. and the brake pedal to ,retard speed or stop the car.
T he Torque -Flire transmission is designed to provide trouble free m otoring for m any miles. However. as in any mechanical unit, va riou s parts may require slight adjustment after several hundred mile s of operation. If. for instance. the engine seems to run too fast in relation to the road speed of the car, the operati ng bands in the transmission ma y r equi re adjustment. Do not c ontin ue to drive the car if this condition exists have the matter attended to Immediately, by an approved Agent.
Accelerating
Should quick acceleration be required for emergency passing while driving at s peeds below a pproximately 29 m.p.h. with (2) second gear o r (d) drive pus h button e ngaged . press the accelerator to the floo r stOp. See Flg.8. The transmission will au tom aticalJ y change down to a lower gear.
At s peeds in excess of approxima tely 29 m.p.h. but not faster than approximately 60 m.p.h. in the (D) drive range, the act ion of pressing the accelerator pedal to the floor stop will cause the transmission [0 change down into s econd gear and provide increased accele r a tion.
•
•
•
•
FRONT SUSPENSION
The front suspension is independent. with c oil springs and telescopic shock abso rbers to the general arrangement as shown in F ig .16 .
A torsional anti r o ll bar is fined .
Inne r wishbone JOInts a r e rubbe r m ounted. while the outer are nylon lmed ball joints and no lubrication m-aintenance is reQui r ed .
"" """"'" JOINt >'t"== "o"
Ftl .n Front Hub and Stub Axle
- 4 3-
-42 -
'\ !
- , , )
• •
• •
T he transmission will change back intO the higher gear if the accelerator ped al p'r essure is released. or the speeds shown in the GEARCHANGE PATTERN SUMMARY CHART are r eached.
The (2) button may be se lec ted when the (D) button is engaged , or the (D) buc ton may be selected when the (2) button IS engaged. These changes s hould be m ade at road speeds below 70 m.p .h.
Fig.S Accelerator Pedal
Changes can a lso be made from ,(Dl drive [0 01 or 0 ) [0
(D) when the car is operating at low s peed', Do nor make th i S change from (01 o r (2) to (1 ) when the ca r s peed is above 40 m.p.h.
Reverse
T o obtain r everse , lightly apply rhe foO!brak c pedal. push the (R) button in , release th e brake a nd slowly accdenue the engine s peed. If the car is moving above a predetermined speed , any attempt to r everse the dlrecll on by pushIng the re verse or a fo rward button will cause the transmission gearing to automatically shift to neu tral. This Il'> a ~arety measure to
-23-
prevent damage lO rhe gears and in s uch case it will be necessa r y 10 rc - engage the gears uSing [he button s elected to agam place the ca r in m Oll on.
Rocki ng the car
To free the car from mud , soft sand or snow where it is des il'able lO obtain a forward and then a backward movement, this can be done by pushing buttons (R) to (i) and from (i) to (R) and accelerat ing the e ngme s peed with each gear change .
Towing the car
(I) With transmission inoperative.
When the transmission i s not operating properly , the car s hould be towed with the rear whee ls raised off of the road or with the propellor shaft disconnected and secured .
(ill Transmission operating prope rl y .
When the transmission is opera ting properl y, the c ar ma y be towed s afe l y in t he ( N ) neu tral posi flon for distances up to 100 nlLl es a t s peeds nOl exceed ing 35 m .p .h.
For long distance towing, 100 miles or more, the propellor s haft shou ld be disconnected and secured .
- 24-
• •
• •
not hold the va lve in the closed (forward) pos ition, but the va lve ope rates freely, fit a new spring.
FI ,. l~ Manifold lIeat Control Val ve
Eve r y 2000 miles the valve should be lubricated with Kerosene containing g raphite.
. Thi s.can be c.arried out beneath the car, by squirting the lubricant itberall y IOtO the s pindl e on both s ides of the exhaus t manifold and wo rking the valve backwards and forwards a fe w times . This will allow the graphite to penetrate between the spin.dle a~d the bushes and keep It lubrica ted . The li quid It self will qU ickly dry out when the manifold becomes he a ted .
-41-
00 NOT WA SH OR OIL TH E AIR FILTER ELEMENT.
Under- seve r-e dr-iving condition s it is r-ecommended clement shou ld be ser-viced mor-e fr-equently .
Fit a new element ever-y 15 ,000 miles .
Fig.14 Filter Element
Manifold Heat Control Valve
that the
The hear contr-ol valve is located in the exhaust m anifold . See Fig.5, and is comrolled by a ther-mostatic coil spr-ing and counterweight .
Should th e valve become s tuc k the e ngine pe r fo r-mance would be affected.
The coil s pring Fig .15 should hold the va lve in the closed (for-war-dl posi t ion with the m ani fol d cold . If the s pr-ing does
_40_
• •
• •
GE ARCHANGE P ATTE RN SUMMARY CHART
Ligh t to moderate thr-ottle change-up
GEARS
1s t to 2nd 2nd to Top ...
MPH
10 22 14 54
Wide open thr-ottle (Kick -down) change up
1st to 2nd 2nd to Top ...
Top to 1s t ...
Closed thrott le change down
(Approx) 37 .. . (Appro x) 70
.. . (Approx) 7
Wide open thr-o ttle ( Kick -down) limits
T op to 1s t .. . Top to 2nd .. .
(Approx) 29 ... (Approx) 60
NOTE: It mu s t be acce pted that gearchange points can vary some wha t due to prod uction tolerances . Ho weve r , the quali t y of the gearchange should be s m oo th , r esponsive, and without notice able engine runawa y.
LUBRICATION OF TORQUE - FLITE TRANSMISSION
To obtain the best performance and long life fOI' the automatic tr-ansmission, it i s r ecomm ended that it be given a r egula r sc heduled maintenance se rvice .
After the initia l 1000 mil e se r-vic e thi s maintenance shou ld be carded our after every 10,000 miles (16 ,000 km) o r one yea r , wh icheve r occu r s first.
It ma y be desirable that this service be carried out more frequently s hould rhe r egula r operatingconditionsofthecar be:
(1) Contin uous operation at h ighe r than normal loadi ng . ( 2) Prequent towing of trailers . ( 3 ) Fre quent heavy t raffic in hot weather.
-25-
Checking Fluid Level
T he fl uld leve l shou ld be ..: hecked at regular intena ls. It is des irabh.' [ha l Ihl s c heck be m ad e when the enginc te mpe r a tu l"e gauge sho ws a normal warm cond ition , indicat ing Ihal Ihe fl uid in I hl' t ran s m ission has been he ated w its norm a l ope r ati ng tempera tu re ,
Transm ission Dips tick/Filler Tube and Drain positions
The dI pstick for the tran s m ission is com ple te lysepa r a tc fr om Ihat of th e engine , a s can be s een in F ig. 5. In the ca r the transmiSSIOn di ps tick/fi lle r tube is s i tuated in the ri gh t hand side of rhe e ngine ba y at the ,"car, clos e to the bulkhe ad .
Dr"<lIning i s ca rded Out by disconnecting the lower e nd of rhe fi ll e r tube f r om th e sum p.
Procedure for checking fluid level
( 1)
(2 )
( 3)
With the handbrake on and the enr ine idlin.:, ope r ate all push bu ttons , pau s ing mom cnra r i y at each posi t ion and endin g with th e (N ) ne utra l pushed in . Stop the engine .
Check the o i l level at the transmission dipsdck. The flu id level 1:>hou ld be at the 'F' ma r k o r s lightl y below, but never above th e 'F ' mark a t i t s no r m al wa rm con dition. Add , o r If nec essa ry , rem ove fl uid to br ing it to Ihis leve l.
If it sho uld be necl!ssa ry [Q chec k rhe fl uid level whe n rhe transm iSSion IS cold. rhe flUid level sho uld be at, or s llghrl y below, the ' L' o r 'Add one pinl ' ma ,·k . If below, "dd one plllt of flu id and then r e -check the leve l.
CAUT ION: To prevcnt d i r t f l"om ente r in g th e trans mission m ake sure that th e di ps tick c ap is Reated prope rly on (he f~llcr tu be .
TRA NSMISSION - DRAIN AND REFILL
Dr ain
(1 ) Disconnect fill e r tube f,"om thc t r ansm is s ion s um p and allow 10 drain .
~ 26-
• •
• •
The ca r bureto r is no r ma ll y a ve r y dependable unit, and if set correctly, should continue to funct ion s atisfacto rily for long pe r iods , without attention . THE IDLING SPEED IS 500 RPM.
Fuel Pump. Carter M2504 S.
No se r vicmg maintenance is norm a ll y r equired fo r this uni t.
Shou ld the pum p becom e in poor c ondi tion. a replacement I S r ecom mended o r the pump c an be r emoved from the engine , di smantl ed and cle aned .
The follOWing parts s hould be r ene wed when re-assemb ~ ling .
M.20 3- 89S M.20 3-46 M.121 - 134
Diaph ragm Assembly . Oudet Airdom e Diaphragm. Fl ange Gas ke t .
Fuel Filter . Mopar 2084 258.
F o r eign pa rtic les , whic h may be present in the fuel, will be c ollected by thi s unit and i t s hould be discarded eve r y 10,000 miles . o r m o r e oft en , if thought advisable, and replaced by a new fi lte l·.
Air Cleaner
The carburettor air cl ea ner is fitted with a r ene wa ble filt e r el em ent whic h s hould r ec e ive r egular a ttention.
To obtain access to the elem ent , r emove the wmg nut froITl the cent r e of the cl ea ne r and lift off the c over. The elem ent c an then be lifted out.
Under normal operat ion, r em ove the fil terelementeve r y 5000 m iles and tap the face gently aga in s t the flat dean fac e of a fl oor or bench as s hown in F ig . 14 to reITlove any accumulation of dire .
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F UEL SYSTEM
Th is consist s of the petr ol rank , housed behind the r ear s eat s qua b, a mechanical petrol pum p, driven front th e camshaft and a 4 Chok.e downdra ught c arbu r et to r fitted with an air cleaner .
T he petrol tank IS fitted with a float unit - Sm iths F T .S301l17 and a Rese rve Uni t - Lucas 7803 7A.
A circula r h inged door fitted with its own special k.ey i s si tuated on the left hand side of the ca r above the r ear wheel. Thi s g ives access to the pe trol fi ll er.
ruE PETROL CAPACIT Y IS 18 IM P. GAL LONS (82 LITRES) INCLUDING 2 IMP. GALLONS (9 LIT RES) RESERVE.
A nylon semi rigid tube connects the pet rol tank to the rigid pipe in the engine bay.
A replaceable fuel filter shown in Fig.S i s fitted between the fuel pump and the Carburettor.
Fuel Gauge
This instrument records 16 IMP. gallons le aVing 2 IMP gallons of unl'ccorded r e serve. The switch m a rked 'R' on the d a shboa r d bri ngs the r eserve into use, and a petrol reserve warning l ight (AMBER ) embodied into the r evolution counter mdica tes th at the reserve supply is being used .
Carbur ettor . Carte r AFB.3131 S.
Se rvicing the ca r burettor should on ly be carr ied out by an e xperienced ca r burettor mechanic, and with the p roper equipTnent.
Dirt, dust , water and gummy deposi ts are some of the main causes of poor carbureHor operarion, and careful clean ing of th e carburettor and jets , and the renewal of parts where required , wilt return the carburettor to its originall y designed perfo rmance.
-38-
• •
• •
(2)
( 3)
(4)
Refill
R<;m ove the fly whee l access pla te si tuated fo rwa rd of the transmission s um p and turn the to rque converter until the drain plug c an be rem oved. This com ponent can be re volved by h and if the sparking p lugs a re rem oved , but otherwise it is necessa r y to revolve it by careful leve r ing with a sc r ewdriver or the like ,
Replace th e torque conve rter d ra in pl ug and refit the flyw heel access plate ,
Refit the trans m ission filler tube.
(1) Add 10 pi nts (5.68 li t res ) of rec ommended fluid mrough the fill e~ tube . . F ill ing i s bes t carr ied out using a fu nnel and a sU itable piece of rubber hose fitting nea tly ove r the top of the fi ll e r tube.
( 2)
( 3)
(5)
Start engine and add approximately 6 pints (3.41 li t res) mor e , with the engine idling .
Allow e ngine to idle for a t leas t 2 minutes.
With handbr ake on and engine idling, operate all push b~ttons , pa using momentari ly a t each pos it ion , end ing With the (N ) neut ral button pushed in .
Chec k the level and add o r rem ove fl uid as necessa r y. (See Checking Fl uid level ).
-2 7-
IGNITlON SYSTEM
Ignition and Generator Warnmg Light
The ignition system is of the normal battery and coil type and a warning light is em bodied into the speedometer.
When the ignition i s switched on this will light up GREEN and will remain alight while the engine is idling, or ~hereabou,ts. When the engine is accderated and when the car IS traveUmg normally, the light should go out. If th~ hg~t s~op~ O?, or appears at any time whe n the car is travellmg, It will mdlcate tha t the generator is not charging and the matter should receive immediate attention.
Coil
The coil requires no routine attention other than checking the terminal connections for tightne s s and cleaning around the terminals at intervals.
Sparking Plugs 14 m/m
At intervals not exceeciing 4000 miles, after the initia l 1000 miles service, the sparking plugs should be removed, cleaned and re-gapped, or if necessary, n:placed by ne w.
T o remove the plugs, first remove the leads by pulling them from the plugs. Us ing the universal joint box spanner s upplied with the tool kit, remove the spark plugs.
If thev are to be used again they should preferably be clcam:d by ' a sand-blast type cleaner, but ,failing this t,he y sh ould have a ny deposits rem oved by scraping or brushmg: In both instances they should afterwards be thoroughl y cleanea by washing in petro l.
THE CORRECT GAP IS _ ·035 INCH and careful and accurate setting should be made by bending the s,ide electrode and checking the gap with a feel e r guuge. See Flg.B.
-28-
• •
• •
Ordinary flushing can be carried out by pouring water into the radiator, with the drain tap open and cylinder drain plugs removed, until the water is clear.
If more than this is required, any proprietary brand of flushing solution may be used to the manufacturers instructIOns.
Water Pump Thermostat
If there is evidence of overheating, the cause could be the water pump thermostat. Thi s can be removed by partially draining the system and removing the water pump outlet pipe.
Immerse the lower portion of the thermostat in h';ated water and at approximately 85°C the valve should open a minimum of ; inch.
Water Pump Belt Adjustment. Fig.12
Slacken the nut on the idler pulley bracket unti l the idler pulle y can be moved outwards until the correct belt tension is obtained.
and To remove this belt, first remove the generator
then push the idler pulley in to its full extent.
-37_
belt
hot engi ne , allo w to cool and rem ove th e filler cap s lowly to release an y s team pressu r e .
Ft&;.13 Radiator Cap
Draining the system
To drain th e system . ease o r rem ove the radiator cap to allow air to enter, open the d ra in tap at the bottom of the radiator and remove the [W O d ra in plugs from the cylinder block. These plugs are situa ted one on e ithe r side of the cylinder block behi nd the engi ne mountings. and they are onl y accessible from benea th the car.
The he ating syste m be ing on a higher level will auto· mat ica ll y drain.
Flushing
Flush the cooling sys tem at intervals. depend ent on local water condit ions and the operating conditions of the ca r. It is also important to flu s h the system after the removal of water conta ining anti - freeze , o r if the ca r ha s been id le for a considerab le pe ri od , wh e th e r drained o r othe rwi se .
- 36-
• •
• •
When the gapplng I s co rrect , see that th e seating IS clean, if necessa ry fil ne w wa s hers. Fit (he plugs InIO the spec ial
Fle.9 SeWn&; Spark Piu&; Gap
spanner, Insert them , bUI do nOI overtl ghlo:n. Do not drop the pl ugs Into their r es pective positi ons a s thi S ma y alt e r the gapplng.
CD CV CB CD
FIRING ORDER
1- 8 - 4 - 3 - 6 - 5 - 7 - 2
CD G) CD 0) DISTRIBUTOR
ENGINE c", Fie.to Firin&; Order
Shou ld the plug I(!adsbcconlemlxed r l'ferIOFlg, l O. No. l lead has a red cap allac hm ent 10 the d istribulO r for r e ady Idenl1ficat ion.
Distributor
rhe d istnbutol' s ho '.lId h.: luhn cated at n :)2u lar mtervalf.; at Ih~ following po int >;.
At every 2000 r.lI[~ s - Add 5 to 10 drop s of o d (see recommended list) [0 the cap on the outside of the dtfltrtbuto r base.
At eve r y 10,000 mde~ - Lubncate the feh pad under the rot u r with 2 to 3 dropsofrecommendedol l. Take care to keer od from the contact hreake r pOint s .
Contact Breaker Points
It IS vitally important. fo r efficient engine operation , to keep the distributor contact pa rtS clean and parallel, and gapped cor r ecdy.
THE CORRECT GAP IS ·014 TO ·0 19 INCH and ca r eful and ac cu I'atc seHing IS r ccommended.
As the servici ng of the contaCt po int s and the servICi ng of th e spa rk plugs coinCide , it considerably helps when setting the points lO ha\'e th,· plugs rem oved .
To set the pOints, 'fi r st unscrew the wing nut from the cenll'e of the air clo,;aner. and lift this unit a wa y.
'nd Sce
.nd ,he
Sl·t,
Kelease the spring clips reta ining the distributo r cap, Itfl away the cap comple te with !o,;ads. Take off the '·Oto r. Fig.l!.
/{emove the ~cr.:w and washer 'A' I'ctalnmg the contacts. s lacke n the low tens ion conneCfll\g nut 'R', and l ift aw ay
Wlt'e CDnn':Cfion. The con tact assembly will [h en tlft away.
E)I; iHT1me th e contac t POInts , and If hi.ldly pitted , fit a new
-30 _
• •
• •
Wh en com ple tel y refilling, as ag?inst toppmg up, repl ace the filler cap and a llow the engine to run (Or a short whtl e . Stop the engine and check the water levd and add if necessary .
Anti-Freeze
In Winte r condition:=;. Ethylene-Glycol ba se, permanent type anti _f r eezt' must be us ed and on no account should alcohol type anti-freezes be used .
Mobil Esso Castrol Shell B.P. Smiths Regent
Recommended Anti-Freeze
... Mobi! 'Pe r mazone'
... Esso Anti-Freeze
... Cast r ol Anti - Free7.e
... Sh~ll Ami- F ree ze
. .. B.P. 'Ami-Fros t'
... 'Blueco! '
.. . P. T . Anti-F reez<:.'
Spring and Summer Rust Resistant Additive fOr COOling System
In Summer a rust re s isting compound s hould be added to the water and the followin g a re recommended.
Shell Smi ths
Radiator Cap
... Donax C anti -Corrosion fluid
... 'Summereol'
Incorporated into the r<'ldiator cap. is a s team pressu r e rele a se and ove rflow valve which oplTates at 14 p.s.i.
It is ad~lsable to check pcriodica(Jy that the spnng loaded val ve IS free by pressing 1l open through the hole in the centre of the cap as s hown in F'ig . 13.
WARNING: Neve.r rcn:ovc the r ad iatOr cap whilc the engine is r,unmng. Since water may b.: ejected through the fdler neck under pump pressure. After stopping a
-35-
ENGINE COOLING SYSTEM
The cooling efficienc y of an engine depends large ly on its cleanliness. To remove the accumulation of rust and other deposits from the radiator and cy linder block, the cooling system should be drained and flushed at least once a year, or more freguently if the water has a rusty appearance.
Keep the radiator filled to the correc t level and check the be lt tension and ho se connections periodicall y.
NEVE R ADD WATER OR ANTI_FR EEZE IF THE SYS TEM IS OVERHEATED.
Water Temperature
T he normal running temperature is 800 e to 92°e with a
maximum pe rmissib le temperature of 100°C.
Cooling Fans. See Page 17.
Radiator
The radiator is specially constructed for the car with an oil cooler perm anentl y embodied into the bottom tank of the radiator, This tank portion also embodies an adaptor from which the cooling fans are thermostaticall y controlled.
Filling the system
THE WATE R CAPACITY OF T HE COOLING SYSTEM IS 36 PINTS (20.46 litres) including the heater,
The c orrect level of water is about i inch below the radiator header tank baffle plate thus leaving an air space at the top of the header tank , It is important to che ck the level regu larly and t o maintain a general level which can be gained by experience. In the event of overfilling, open one of t he drain t aps and allow to dra in ,
_3 4_
• •
• •
To replace o r fit a new set, see that the pillar is lightly greased , compress t he s pring of the contact , to fit into the low te n sion location , and pu s h the as,,;embly fu lly down on to th e
FELT PAD
Fig. ll Distributor
pillar , Replace the low tension wire connection <lnd tighten the s crew ' B' . Replace screw 'A' and tighten suffici e ntly for it to be moved accuratel y .
With the s parking plugs removed , turn the eng ine with the belts , or fai ling thi s . use a box spanner on th e nut in the pulley on th e front of the crankshaft , until th e rubbing block of th e point s is on the high s pOt of the cam, With a sc r e wdriver in serted between the twO V cut-outs , adjust th e po ints usi ng feeler gauges to the f' ecommended gap . The cam will m ove su ffici ently in itself across the high point to ensu re that the setting is made at the pea k. Tighte n SC r e w 'A'. Turn th e e ngine to another high s pOt and recheck .
- 3 1 -
Wh!:n satisfactory , replace the rOtor and the cap with its lead. No.1 red cap lead sho uld posit ion itself centrally forward . Replace the air cleaner .
IDLER PULLEY
Generator
CRANKSHAFT PULLEY
Fig.12 Belt Tensioning
GENERATOR
c a08
At every 2000 miles' _ Lllbricate with 5 to 10 drops of light engine oil in twO cups.
- 32-
• •
• •
Belt Adjustment
Belts adjusted toO tightly will cause rapid wear of the generator and water pump bearings, and a loose belt wil l slip and wear excessively, causing overheating and unsteady generator output.
Generator Belt. Fig.12
Slacken the generator adjusting strap and the generator bracket mounting bolts sufficiently to allow the generator to be moved outwa rd s until the belt tension is correct.
To remove this belt push the generator in to its full extent.
NOTE : A 'used' belt is one which has ope rated for a minimum of ! an hou r.
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