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Reliant Kitten Saloon Workshop Manual

Incorporating the factory supplement pack
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Table of Contents

Kitten Saloon and Estate
Workshop Manual
Incorporating the Factory supplement pack
©The Reliant Motor Company Limited July 1975
Remastered January 2011 by Atodini
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Summary of Contents for Reliant Kitten Saloon

  • Page 1 Kitten Saloon and Estate Workshop Manual Incorporating the Factory supplement pack ©The Reliant Motor Company Limited July 1975 Remastered January 2011 by Atodini Page 1...
  • Page 2 Introduction Contents This Workshop Manual contains all the General Specification pages3-4 relevant information to assist Reliant Dealers to service and maintain the Kitten Saloon, Estate and Van Lubrication and Maintenance pages5-14 Models. Section A Chassis Frame page15 Dismantling, assembly and adjustment...

  • Page 3: General Specification

    177.8 x 31.25 mm (7 in x 1.25 in) Handbrake Lever type operating rear brakes mechanically by cable linkage Suspension Front Reliant independent - wishbones, coil springs, damper units and anti roll Rear Reliant - progressive rate leaf spring, telescopic damper units. Page 3...
  • Page 4 Steering Type Rack and pinion Turning Circle 7.32 m (24 ft) Castor 12° Camber 1° positive Toe-in Zero King pin inclination 9° Conforming to European Safety Regulations Chassis Data Type Box section with tubular cross members and channrel section diagonal cross bracing.

  • Page 5: Lubrication And Maintenance

    "Key to service" booklet. safety and reliability under most operating conditions. However, if Presentation of this service booklet to any Reliant dealer will ensure your operating conditions are severe, you cover a very low annual proper completion of the maintenance operations.

  • Page 6: Road Test

    Operation Check door operation, locks and hinges Top-up battery, check connections Top up radiator coolant Check for oil and water leaks Check all controls, lights, horn, instruments etc. Check headlamp alignment Check washer reservoir and top-up Check external condition of exhaust system Check and if necessary renew windscreen wiper blades Road test...
  • Page 7 otherwise oil leaks may result. refit the plug and screw in tightly. Check leaks from cooling and heater system Check hose connections and tightness of clips. Refill the sump via the oil filler cap with the recommended grade Check radiator drain plug (if fitted). of oil.
  • Page 8 engine oil, SAE 20 or 20/50 grade and refit the hexagon plug and Using a 0.64 mm (0.025 in) feeler gauge, check the gap and piston assembly adjust if necessary by bending the side electrode towards or away from the central electrode as necessary. Discard plugs which have badly burned electrodes or cracked ceramic insulators.
  • Page 9 Clean air filter element Clean the outside of the air filter body and release the two clips retaining the body to the base plate. (figure 8) Carefully withdraw the element from the base plate. Clean the base plate and body interior Clean between folds of the element using a low pressure air line or soft brush.
  • Page 10 Adjust and check condition of the fan belt Ensure the fast idling screw is clear of the choke cam. Adjust idling screw to achieve an idling speed of The fan belt should be sufficiently tight to drive the alternator and approximately 800 to 850 rpm.
  • Page 11 Wipe clean and refit level plug. Tighten to a torque of 2.07 Check exhaust system for leakage and security to 2.76 kg/m (15 to 20 lb/ft) Check security of the exhaust connections and manifold bolt tightness. Examine the system for corrosion and deterioration. Check and top up level of rear axle oil Place the vehicle on ramp or over pit.
  • Page 12 Routine maintenance - exterior Check and adjust headlamp beam alignment The front grill/bezel has two screwdriver holes for adjustment of the Adjust front hubs headlamp beam setting screws. Refer to Section B Beam aiming can best be accomplished using equipment such as a "Lucas beam setter"...
  • Page 13 Routine maintenance - road test carburettor or ignition timing. Note: Specialist equipment is needed to ensure that carburation adjustment does not result in the vehicle infringing the emission regulations. Road test car and check brake function. Carry out any remedial work required indicated by the road test e.g.
  • Page 14 Lubrication chart (not listed in order of preference) (British Isles) Mobil Castrol Esso Shell Petrofina Duckhams Texaco Mobiloil super Castrolite Esso Extra BP Super Shell Fina Q20-50 Havoline Engine or mobiloil Castrol Motor Oil Viscostatic Super Multigrade Motor Oil motor oil special 20w50 10w30 or...
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  • Page 16: Front Suspension

    Section B Front Suspension Contents Remove the damper bottom fixing nut and withdraw bolt from damper bush. Routine maintenance From inside the engine compartment, remove the damper top fixings, comprising nut and locknut, rubber spacer and two Operation 1 Front suspension assembly - removal and retaining cups.
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  • Page 18 Figure 2 Upper wishbone ball Figure 3 Lower fulcrum - lubricator joint lubricator Bleed screw Ball joint - grease nipple Lower fulcrum - grease nipple Operation 4 Upper ball joint - removal and replacement Operation 6 Upper wishbone - bush replacement To remove (figure 1) To remove (figure 1) Place vehicle on ramp or support on suitable chassis stands.
  • Page 19 Remove split pin, castellated nut and washer from stub axle. Withdraw the hub complete with bearings and felt oil seal. Reassemble in reverse order, renewing stub axle split pin. Bleed brakes and adjust. Operation 9 Front hub - overhaul Place vehicle on ramp or jack up. Remove front wheel.
  • Page 20 Slacken the nut back until a bearing float of between 0.05 to 0.15 mm is obtained. A dial gauge is preferable for this operation but if one is not available, slacken the nut off half a flay, equivalent to 30 degrees (figure 6). Note: The importance of the correct end float cannot be over emphasised.
  • Page 21 Section C Rear suspension Contents Bump Rubber - Van Description A bump rubber, separate to the damper unit, was fitted to early Kitten vans to limit the rear suspension bump travel. Routine maintenance The bump rubber is secured to a bracket on the rear chassis upsweep above the axle.
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  • Page 23 Section D Steering Contents Description The rack and pinion steering gear is mounted in rubber insulators Description attached to the front cross member. Movement of the steering wheel is transmitted by the steering shaft Routine maintenance through a flexible coupling to the helically toothed pinion. Rotation of Operation 1 Toe-in adjustment, front wheel alignment the pinion causes the rack to move laterally and the track rods,...
  • Page 24 Operation 4 Steering wheel removal The lock stops are built in to the steering gear and no adjustments are possible. Removal (Figure 2) Prise off the steering wheel crash pad. Routine maintenance Disengage the steering lock. Scribe a line on the crash pad retaining ring and the top of the steering column to ensure correct At the 1,000 miles (1,500 km) free service the toe-in and rear wheel alignment on re-assembly.
  • Page 25 Remove the nuts securing the track rod ends to the steering Assemble the damper to the rack and fit the anti-knock pad. arms. Do Not fit the spring or shim pack. Fit the cover plate and tighten the Using a suitable tool, free the tapers on the track rod ends. bolts evenly until the anti-knock pad is just "nipped".
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  • Page 27 To overhaul (Figure 3) Operation 9 Steering rack pinion preload adjustment Remove the pinion cover plate complete with shim pack Carefully mount the steering rack into a vice so that the and gasket. pinion cover plate is uppermost. Withdraw the pinion and one of the pinion bearing Remove the two bolts securing the pinion bearing preload assemblies.
  • Page 28 Replace the rack assembly in the vehicle and check the tracking, Secure the outer end of the gaiter to the track rod end with a clip. adjusting if necessary. Tighten the lock nuts securing the track rod end Refit the locknut and ball joint to the track rod, screwing ball joints.

  • Page 29: Cooling System

    Note: During summer months, if no anti-freeze is used a solution of The quantities of anti-freeze for various degrees of protection are water plus 3.35 fluid oz of Reliant Coolant Inhibitor "R" part number given in a table at the end of this section.
  • Page 30 Operation 1 Draining the cooling system Drain plugs are provided, one on the left hand side of the cylinder cooling system has been drained should the vehicle be left standing. block (Figure 1) and one in the base of the radiator (Figure 2). Running the engine without coolant can lead to severe internal damage.
  • Page 31 radiator to the support brackets located on each side of the radiator, Start the engine and run up to normal operating temperature with the radiator cap removed to clear any air-locks in attached to the body. the system. Stop engine and check coolant level, topping up if Remove the radiator.
  • Page 32 Remove the four nuts and lock washers and withdraw the pump assembly from the studs on the cylinder block, including the gasket. To replace Clean the faces of the water pump and cylinder block and fit a new gasket. Fit the pump assembly over the studs and secure it to the face of the cylinder block with four nuts and lock washers, tightening to a torque of 1.66 to 2.07 kg/m (12 to 15 lb/ft).
  • Page 33 Cooling system specification Anti-freeze quantities Cooling system Volume Fluid Solidifies Amount of Specific Capacity including heater 3.69 litres (6.5 pints) In water Down to Anti-freeze gravity °C (°F) °C (°F) required Radiator 0.37 litres Cap pressure 0.492kg/cm² (7 lb/in²) -4 (+25) -8 (+17) (0.65 pints) 1.016...
  • Page 34 Section F Contents Operation 6 Timing chain cover, oil seal and gasket replacement (without engine removed) Description Operation 7 Timing chain replacement (with front cover Routine maintenance removed) Engine service operations, engine removal, hoist bracket Operation 8 Camshaft sprocket alignment (timing chain cover and timing chain removed) Operation 1 Engine removal...
  • Page 35 Operation 12 Crankshaft removal and installation (with sump, front cover, flywheel, rear seal cove, connecting rods and crankshaft sprocket removed Operation 13 Camshaft removal and installation (with timing chain and sprocket removed) Operation 14 Camshaft bearing removal and replacement (with camshaft removed) Operation 15 Cylinder liner replacement Operation 16...
  • Page 36 Refit the centre console and secure with four screws. Push Disconnect the lead from the temperature gauge sender on the thermostat housing. the gear lever gaiter over the lever and locate in the aperture in the Disconnect the speedometer cable at the gearbox. centre console.
  • Page 37 wear is evident then knock the old one out and fit a new one using special tool no. RT 7485 (Figure 2). Needle roller bearings have been used as an alternative to the phosphor bronze bush and care must be taken when replacing these.
  • Page 38 Figure 4 Engine, cylinder block - exploded Page 38...
  • Page 39 Figure 6 Oil pump drive shaft shims Drift out the pin securing the thrust muff to the distributor/oil pump driveshaft which can then be withdrawn upwards through the distributor housing. Inspect the oil pump and drive shaft assemblies for wear or damage and renew if required.
  • Page 40 Figure 7 Replacing rear cover oil seal Figure 9 Extracting front cover oil seal Figure 8 Fitting rear cover Figure 10 Replacing front cover oil seal Slacken alternator mountings and remove fan belt. Operation 7 Timing chain replacement (with front cover Unscrew four nuts and lock washers and remove the water removed) pump from the cylinder block.
  • Page 41 Disconnect the choke cable from the carburettor. Disconnect the heat exchanger hoses from the exchanger. Disconnect the advance/retard pipe and flame trap (if fitted) from the carburettor. Disconnect the accelerator return spring from the carburettor. Remove the nut securing the carburettor abutment bracket to the carburettor.
  • Page 42 Figure 13 Cylinder head and manifolds - exploded view Cylinder head Rocker cover Manifold nut Stud Rocker cover gasket Lock washer Stud "P" clip Stud Stud Support bracket Washer Stud Washer Gasket Drip tray Oil way plug Oil filler cap Heat exchanger Core plug "O"...
  • Page 43 Figure 14 Cylinder head nuts Figure 15 Valve guide removal and tightening sequence replacement Valve guide removal Valve guide replacement Valve guide protection sleeve Clean the face of the cylinder head and remove all trace of Release the tab washers, unscrew the bolts and remove the carbon and high spots.
  • Page 44 Locate the upper half of the thrust washer in the register on the inside face of the crankshaft main bearing bore in the crankcase. Position the front main bearing cap and locate the lower half of the thrust washer in the register on the cap inside face. Note: The thrust washer is fitted so that the thrust face, identified by oil grooves, bears against the crankshaft ground face.
  • Page 45 Figure 17 Engine, crankshaft and camshaft - exploded view Crankshaft Pulley Rocker LH Flywheel assembly Rocker RH Flywheel Spacer Rocker shaft Flywheel ring gear Bolt Bracket Dowel Washer Bracket Spigot bearing Lock washer Screw Flywheel tab washer Main bearing shell Washer Set screw Camshaft...
  • Page 46 To Replace Te-assemble in the reverse order, fitting new gaskets where applicable. Note: When refitting the distributor drive shaft, ensure the large "D" of the driving gear offset dog is facing towards the block at No. 1 piston, i.e. slot in a "5 minutes past 7 o'clock" position. Take the opportunity of checking the camshaft end-float which should be within 0.64 to 0.16 mm (0.0025 to 0.0065 in).
  • Page 47 Figure 24 Replacing camshaft centre bearing Figure 21 Removing camshaft front bearing Pilot Horseshoe Bearing Mandrel Mandrel Bearing Small "D" washer Pilot Horseshoe Figure 25 Replacing camshaft front bearing Figure 23 Replacing camshaft rear bearing Horseshoe Pilot Large "D" washer Mandrel Bearing Bearing...
  • Page 48 Figure 28 Fitting cylinder liners Using a tool similar to that shown in Figure 28, insert the liners in to the block and ensure that they stand 0.050 to 0.152 mm (0.002 to 0.006 in) proud of the cylinder block face. Check that there is 0.381 mm (0.015 in) clearance between liners.
  • Page 49 Figure 29 Valve clearance - tappet Figure 30 Tappet adjustment tool adjustment Feeler gauge Adjusting screw Lock nut Refit front engine plate with a new gasket, to the engine block and secure with three nuts and washers. Fit the crankshaft outer thrust washers with the oil slots facing forward, followed by the steel thrust washer with its countersunk aperture facing rearwards.
  • Page 50 To adjust When adjustment is made the valve must be in the fully closed Remove rocker cover. position (figure 29). Remove spark plugs. Turn engine in normal running direction in order to open Refit spark plugs and reconnect HT leads in the correct and close the valves and check in the following order: order.
  • Page 51 Oversize rings available Compression ring top 0.254 mm (0.010 in) Compression ring bottom 0.254 mm (0.010 in) Oil scraper ring 0.254 mm (0.010 in) Gudgeon pin Diameter 14.283-14.288 mm (0.5623-0.5625 in) Small end bush Bore 14.292-14.298 mm (0.562-0.563 in) Camshaft Bearing diameter 38.66-38.67 mm (1.521-1.522 in) Bearing clearances...
  • Page 52 Section G Gearbox Contents Repeat for the right-hand clamp and lower the anti-roll bar down, away from the chassis. Description Disconnect the speedometer cable. Disconnect the clutch cable from the trunnion, remove the Routine maintenance lock nut and withdraw the cable from the trunnion. Pull the cable outer sleeve from the retaining hole in the engine back plate.
  • Page 53 Operation 2 Dismantling the gearbox Tap out the mills pin from the reverse selector lever and (Figure 1 & 2) withdraw the selector shaft through the bell housing. Drain the gearbox oil. Lift out the selector forks and tilt the gearbox to remove the Remove the clutch fork and lever assembly (Section H) two interlock balls from the cross drilling in the bell housing end of the Unscrew eight set screws, with lock washers and remove...
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  • Page 56 Slide first/second synchro sleeve over synchro body leaving Lift out the laygear assembly and the two thrust washers. Withdraw the reverse gear shaft through the rear of the sufficient room to enable fitment of thrust blocks and balls. Ensure gearbox and lift out the reverse gear. the teeth of the synchro sleeve are facing forward.
  • Page 57 Note: Drive carefully in to position until the bearing retaining ring is flush with the case. feed in the mainshaft assembly, taking great care not to dislodge the synchro thrust blocks and balls. Refit the rear cover with a new gasket to within 6.35 mm (¼...
  • Page 58 Section H Clutch Contents Description Routine maintenance Operation 1 Clutch adjustment Operation 2 Clutch assembly - removal Operation 3 Clutch operating fork, lever & thrust pad Operation 4 Pedal assembly - removal & dismantling Operation 5 Pedal assembly - re-assembly & replacement Operation 6 Clutch cable - removal &...
  • Page 59 Figure 3 Centralising the clutch Tap the pressure plate assembly with a hide mallet to ensure it is correctly seated on the flywheel. Check the clutch run-out does not exceed 0.381 mm (0.015 in) on the steel thrust disc. Operation 3 Clutch operating fork, lever and thrust pad Removal and replacement The operating fork is pinned into position on the shaft of the clutch...
  • Page 60 Release the locking springs and remove the thrust pad from Operation 5 Pedal assembly - re-assemble the operating fork. and replacement To re-assemble Inspect the thrust pad for wear and renew if the bearing face has worn below a depth of 1.58 mm (0.060 in) or shows any signs Refit the brake light switch with a lock nut on either side of of scoring or distortion.
  • Page 61 Figure 4 Pedal bracket assembly - exploded view Pedal mounting bracket Clutch pedal assembly Throttle pedal Clutch pedal pivot bush Throttle pedal pivot moulding Lock washer Pedal rubber Adjuster bolt Coach washer Clevis pin Lock nut Bolt Split pin Adjusting bolt Lock washer Brake pedal assembly Lock nut...

  • Page 62: Drive Shaft

    Section J Drive shaft Contents Description Routine maintenance Operation 1 Drive shaft - removal Operation 2 Checking the drive shaft for wear Operation 3 Drive shaft - dismantling & re-assembly Operation 4 Drive shaft - refitting Description The drive shaft (or prop shaft) comprises two sections incorporating a sliding spline and universal joints to allow fore and aft movement of the rear axle.
  • Page 63 Operation 1 Drive shaft removal Similarly separate the yoke and journals at the opposite end Place the vehicle on a ramp, or on axle stands under the of the drive shaft. Unscrew the dust cap to separate the two sections of the chassis.

  • Page 64: Rear Axle

    Section K Rear axle Contents Remove the drive (prop) shaft see Section J. Disconnect the handbrake cables from the operating levers Description on the brake back plates by removing the split pins and washer and Routine maintenance withdrawing the clevis pins. Disconnect the cables from the stop brackets on the axle tubes.
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  • Page 67 Figure 2 Rear axle oil level/filler plug Figure 3 Hub puller sleeve (axle removed) Level/filler plug Sleeve Figure 4 Hub puller in use (axle removed) Figure 3 Slackening the half shaft nut (axle shown removed) that the spacer insert is free to move when the back plate screws are Remove the hub key and press off the half shaft bearing tightened.
  • Page 68 Figure 6 Removing half shaft using slide hammer Figure 8 Removal of pinion bearing using collars and hand press (axle shown removed from vehicle Adapter Collars Slide hammer Figure 7 Removal of differential bearing using collars, adapters Figure 9 Removal of axle bearing cones from outer housing and hand press Collars Puller tool...
  • Page 69 Figure 11 Measuring the torque to turn the pinion using dummy Figure 10 Determining overall differential end float using Pinion tool gauging tool Pinion setting tool Gauging nut Locking nut of the operator as they face the axle and referred to as the left-hand Remove the pinion flange nyloc nut and washer and side throughout these instructions.
  • Page 70 Figure 14 Determining pinion to crown wheel backlash using a Figure 12 Determining pinion mounting distance using dummy dial gauge pinion Using a torque wrench, progressively collapse the spacer starting at 6.91 kg/m (50 lb/ft). Preload begins when end float is eliminated at approximately 11.06 kg/m (80 lb/ft).
  • Page 71 Figure 15 Replacing the differential bearing using special tool and universal handle Figure 16 Modification of gauging tool RT 8732 Replacer tool Universal handle Place the differential unit in to the differential case housing. Measure the gap between the gauge nut and the disc and Replace the left-hand half shaft to assist in supporting the record the figure.
  • Page 72 Section L Brakes Contents Description Routine maintenance and adjustments Operation 1 Check front brake lining and adjustment Operation 2 Check rear brake lining and adjustment Operation 3 Handbrake adjustment Handbrake cable lubrication The hydraulic system Operation 4 Bleeding the hydraulic system Operation 5 Front brakes - fitting new shoes Operation 6...
  • Page 73 Operation 5 Front brakes - fitting new shoes may be damaged causing brake failure. Ensure that the breather hole Always fit Reliant replacement shoes, including a new set of return in the filler cap is clear before replacing the cap. springs.
  • Page 74 To replace Operation 6 Front wheel cylinders - removal & replacement A leaking wheel cylinder will cause fluid loss and may lead to excessive Attach new return springs to the new shoes, ensuring the springs are correctly located and positioned such as they are between pedal movement and contamination of the brake shoe linings, The the shoe webs and the brake plate on assembly (Figure 4) vehicle may also show a tendency to pull or veer under braking.
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  • Page 76 Operation 9 Master cylinder - removal & replacement Operation 7 Rear brakes - fitting new shoes to remove (Figure 5) A faulty master cylinder can be diagnosed by excessive pedal Jack up the rear of the vehicle and secure on stands. movement or signs of leakage around the rubber sealing gaiter and push rod.
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  • Page 78 Figure 7 Handbrake lever - after chassis no: 6F7/14701001 - saloon, 6F7/14801002 - estate, 6H1/14901043 - van. Handbrake lever Mounting bracket Set screw Lock washer Coach washer Handbrake cable Compensator pulley Clevis Clevis bolt lock nut Clevis pin Washer Split pin Clevis pin Washer Split pin...
  • Page 79 Dual circuit braking system The hydraulic system pressure reducing valve is fitted to stop the rear A dual line braking system was fitted to later cars. A tandem master wheels locking prematurely under heavy braking. In the event of front cylinder is fitted for use with the dual line system.

  • Page 80: Wheels And Tyres

    Section M Wheels and tyres Contents Description Tyre pressures and care of tyres Tyre pressures - saloon and estate Repairs Tyre rotation Jacking positions Wheel removal and inspection Valves and caps Wheel and tyre balance Description Wheels fitted as standard equipment are pressed steel type with polished wheel nave/hub caps which spring over projections on the wheel.
  • Page 81 Wheel removal and inspection Remove the nave/hub caps and wheel trims and loosen the wheel nuts. Jack up the vehicle until the wheel is clear of the ground. Remove the wheel. Examine the wheel carefully for damage. Use a wire brush to clear any corrosion.

  • Page 82: Exhaust System

    Section N Exhaust system Contents Operation 1 Exhaust system - removal and replacement To remove (Figure 1) Description Remove the two brass nuts securing the downpipe to the exhaust manifold. Routine maintenance Slacken the nut securing the support bracket to the bell housing.

  • Page 83: Fuel System

    Section P Fuel system Contents Description Routine maintenance Operation 1 Fuel tank - removal and replacement Operation 2 Fuel tank sender unit - removal and replacement Operation 3 Fuel pump - Check function, removal, replacement and overhaul Exhaust emissions Carburettor Operation 4 Adjusting - idling or slow running Operation 5...
  • Page 84 Figure 2 Fuel tank and pipes Fuel tank Hose Pipe, pump to carburettor Sender unit Clip Clip Sealing ring Breather hose "P" clip Locking ring Clip In-line petrol filter Drain plug Grommet Pipe Washer Pipe, pump to filter Sleeve washer Olive Clip Clip...
  • Page 85 Locate the pump on the studs. Insert the rocker arm Note: Ensure the tab on the diaphragm aligns with the mating mark through the aperture in the cylinder block wall so the arm rests on the on the lower body. camshaft eccentric.

  • Page 86: Accelerator Cable

    If further servicing or adjustment is needed this can only be carried Figure 4 Slow running and fast idle screws out by an authorised Reliant Dealer. Any adjustment made without Fast idle adjustment screw the specialist equipment, or the breaking of the tamper proof shrouds...
  • Page 87 Figure 1 Accelerator mechanism Pedal mounting bracket Bearing Set screw Throttle cable Lock washer Abutment bracket Washer Pivot pin and lever assembly Star lock washer Accelerator pedal Trunnion (Solderless nipple) Pedal adjuster screw Washer Lock nut Link Accelerator pedal bearing Clip Throttle return spring Apply pressure to the lugs on the plastic fastener securing...
  • Page 88 Position the new element, refit the body and secure with the two clips. Figure 7 In-line fuel filter Filter element In-Line fuel filter - Removal and replacement Figure 6 Air cleaner Air cleaner The in-line fuel filter, situated on the rear chassis side member Paper element forward of the fuel tank, is secured to the pipes by means of spring Set screw...
  • Page 89 Section Q Body Contents Operation 1 Door window regulator mechanism- removal & replacement To remove (Figure 1 & 2) Operation 1 Door window regulator mechanism- removal Remove the single screw securing the window winder and & replacement remove the handle. Prise the plastic bezels from the door release handle.
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  • Page 91 Figure 1 Door mechanism Interior door handle Lock washer Screw Bezel Striker back plate Lock washer Insert Striker cover plate Screw Striker cover travel stop Regulator mounting plate Screw Clip Screw Washer Screw Lock washer Link, lock to handle Lock washer Screw Adjustment pin Exterior handle...
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  • Page 93 Figure 2 Door shell and trim Door Snap cap Lock washer Glass Upper hinge Coach washer Frame Lower hinge with check strap Screw Rubber silent channel Screw Coach washer Rivet lock washer Lock washer Stiffener Washer Weather strip Backing plate Shim Rivet Backing plate...
  • Page 94 To remove the striker plate first prise out the access Figure 2a Door shell and trim DL models grommet, then unscrew two countersunk screws securing the striker Door Casing board (saloon/estate) to the body. Shim (2 hole) Frame Casing board pocket Shim (1 hole) Silent channel Retaining bar...
  • Page 95 Figure 4 Estate rear door Rear door Rivet Seal Locking handle Upper hinge Backing plate Lower hinge Washer Rivet Washer Screw Screw Rear window Screw Rear door lock Weather strip Grommet Screw Link Wiper motor cover Striker Buffer Insert Backing plate Washer Screw Set screw...
  • Page 96 Disconnect the speedo cable from the gearbox. Cover the bonnet with a suitable cloth to avoid damage to Disconnect the throttle cable at the carburettor. paintwork. Disconnect the choke cable at the carburettor. Using a screwdriver with all the sharp edges removed, ease Disconnect the clutch cable at the bell housing the ends of the locking strip from the windscreen rubber.
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  • Page 98 Figure 6 Rear window - Saloon Rear window Lock washer Sealing rubber Coach bolt Buffer Locking handle Lock washer Hinge Retaining plate Washer Coach bolt Gasket Lock washer Gasket Washer Domed nut Insulation Rear window stay Screw Coach washer Bracket Lock washer Domed nut Tonneau lifting stay...
  • Page 99 Section R Interior Operation 1 Front seats - removal & replacement Contents From underneath the vehicle remove the four nuts with lock washers and coach washers securing the seat runners to the floor. Front seats - adjustment The seat can now be lifted out of the vehicle complete with the runners.
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  • Page 102 Operation 3 Rear seat - removal & replacement The two abutment brackets which support the seat squab in the raised position are secured to the body by means of screws that also retain the trim panels. The rear seat cushion is retained by press and stud fasteners at each Replace the seat and components in reverse order, securing the back end of the cushion.
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  • Page 104 Remove the bolt, lock washer and spacer from the seat belt Repeat for the left-hand side of the vehicle, again ensure catch arm and remove the arm from the drive shaft tunnel mounting. the headlining is kept taut .Trim excess material from the headlining. Carpets &...
  • Page 105 Section S Heater Contents Description Description The heater is of the fresh air type and is mounted behind the centre console on the engine bulkhead. Water from the cooling system is fed Operation 1 Heater unit - removal & replacement to the heater via hoses from the engine.
  • Page 106 Lever valves control both temperature and distribution. The Remove the four nuts, bolts and washers securing the temperature of the air is controlled by mixing warm and cold air in heater assembly to the bulkhead and withdraw the unit. proportion within the heater unit. The centre vent on the fascia, also regulated by the levers, can deliver hot or cold air as required.

  • Page 107: Ignition System

    Section T Electrics Contents GENERAL ELECTRICAL SYSTEM IGNITION SYSTEM Battery -Maintenance Distributor - Description -Testing -Lubrication Battery specification -Adjustment of contact breaker points Fuses Operation 1 Contact breaker points - removal & replacement Coil Operation 2 Condenser - removal & replacement Starter solenoid Operation 3 Distributor - removal &...
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  • Page 109 Contact breaker points has a limited arc of movement in relation to the distributor body. To adjust Distributor rotation is anti-clockwise when viewed from above. Remove the distributor cap and rotor arm. Lubrication of distributor Turn the engine so that the heel of the contact breaker is on the highest point of the cam.
  • Page 110 Figure 4 Correct replacement of points Figure 3 Contact breaker adjustment breaker points and difficult starting. Locking/adjustment screw To remove the condenser Cam spindle lubrication pad Remove the distributor cap and rotor arm. Breaker arm pivot point Remove the contact breaker assembly Terminal post Remove the cross head screw and lift the condenser from Low tension lead...

  • Page 111: Starting System

    Disconnect the vacuum tube from the distributor and plug the end of the tube with a suitable plug to stop air being drawn in. Start the engine and allow to idle at normal tick over speed. Aim the "strobe" light at the timing marks taking care not to contact the spinning fan.
  • Page 112 Bench testing fault is indicated and a replacement motor will need to be fitted. Remove the commutator end cover from the motor and check the brushes for wear and replace if necessary. Starter motor specification Measuring light running current Lock torque 0.97kg/m (7.0 lb/ft) @ 350 amps Clamp the motor in a vice and, using a 12 volt battery.
  • Page 113 It is important that the charging system be kept in good working order multi bladed fan is fitted behind the drive pulley. because the ignition, starting and lighting systems depend on it. These systems will be rendered inoperative if the battery is in an extremely The brush gear is enclosed in a moulding screwed to the slip-ring end low state of charge.
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  • Page 115 Figure 9 Alternator output test circuit Live side output diodes (3) 12 volt battery Earth side output diodes (3) 0-40 or 0-60 ammeter Field feed diodes 12 volt 2.2 watt lamp Stator winding 0-20 volt meter Field winding 0-15 ohms 35 amp variable resistor Slip-rings Link between regulator terminals "F"...
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  • Page 121: Lighting System

    Lighting system The lighting system comprises headlamps, front indicators, rear stop/tail/indicators, number plate lamp, battery, solenoid, light switch and multi-switch as shown in Figure 11. The condition of earth leads and earth connections is important. The main harness earth connections are on the engine front cover, the battery to engine earth lead and the gearbox to chassis earth strap.
  • Page 122 Front direction indicators Operation 7 Headlamp beam adjustment The front direction indicators lamps are actuated by the steering It is recommended that beam setting equipment is used to ensure column multi-switch and the flasher unit secured behind the dash accurate beam adjustment. Follow the manufacturer's instructions for panel on the right-hand side.
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  • Page 125 To remove (Figure 17) up must be investigated, for example the electrolyte may be "boiling Remove the bezel, glass and bulb. off" because the battery is being over charged by the alternator, in Withdraw the lamp body and disconnect the leads. which case the alternator regulator needs to be checked (page 112).
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  • Page 127 Fuses The fuse box is secured to the right-hand side of the engine protecting the unswitched battery circuit which includes headlamps, compartment by two screws and nylon inserts. hazard lamps, interior lamp and horn. the second 35 amp fuse A blown fuse will result in the failure of all dependent circuits and is protects the switched components, ignition circuit, indicators, heater blower, wiper motor and instruments.
  • Page 128 Figure 19 General electrics - components Battery Washer Clip Front securing hook Lock washer Rivet Rear securing hook Ignition coil Saddle plate Lock washer Coil bracket Washer Rivet Rivet Fuse box assembly Washer Clamping strap Fuse box cover Lock washer Insulator Fuse box body Washer...
  • Page 129 failure of the blades can also be caused by a faulty switch which should be tested by substitution. If all other electrical and mechanical components have been inspected and found to be correct the wiper motor may be faulty. These are nor serviceable so a replacement will need to be fitted.
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  • Page 132 Headlamp main beam warning light unlike the other key(s) for the vehicle, do not have a number stamped A blue lamp. To the left of the indicator warning light in the lower left- on them. This is for security/anti theft reasons. hand quadrant of the speedometer, the lamp is illuminated when the The keys are supplied with a tag on which the unique number of the lights are switched to main beam.
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  • Page 134 Instrument and switch removal Operation 10 to remove ignition switch Access to both main instrument fixings is achieved from bemeath the The ignition switch assembly is integral with the steering column lock but the switch itself can be removed as follows: fascie.

  • Page 135: Windscreen Washer

    Section U Windscreen washer Contents The washer reservoir should be checked regularly and topped up as necessary. Denatured alcohol (methylated spirit) should never be Windscreen washer/rear window washer (if fitted) mixed with the water because whilst it will help stop the fluid freezing in cold weather, it does tend to cause the paintwork to discolour.
  • Page 136 Operation2 Jet nozzle - removal & replacement Operation 3 Estate/van rear washer nozzle - removal & replacement Remove the cover from inside the door, secured by six Disconnect the supply tube from the nozzle, accessible from beneath the fascia behind the radio aperture. screws.
  • Page 137 Section V Tightening torques Front Suspension Lower ball joint (pin) 7/16" UNF 4.29-4.98kg/m 31-36 lb/ft Spring/damper unit top fixing 3/8" UNF 4.15-4.84 kg/m 30-35 lb/ft Spring/damper unit lower fixing 1/2" UNF 4.84-5.53 kg/m 35-40 lb/ft Upper ball joint (pin) 7/16" UNF 4.98-5.67 kg/m 36-41 lb/ft Upper wishbone to pivot bracket...
  • Page 138 Drive shaft Universal joint flange to axle/gearbox 5/16" UNF 3.46-4.15 kg/m 25-30 lb/ft Rear axle Axle case nuts 5/16" UNF 2.77-3.46 kg/m 20-25 lb/ft Hub to half shaft nut 5/8" UNF 13.8-15.2 kg/m 100-110 lb/ft Coupling flange pinion nut 5/8" UNF 9.67-11.75 kg/m 70-85 lb/ft Axle filler/level plug...

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