Volkswagen Transporter 1600 (1968) Bedienungsanleitung

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Zur Seite of

Richtige Gebrauchsanleitung

Die Vorschriften verpflichten den Verkäufer zur Übertragung der Gebrauchsanleitung Volkswagen Transporter 1600 (1968) an den Erwerber, zusammen mit der Ware. Eine fehlende Anleitung oder falsche Informationen, die dem Verbraucher übertragen werden, bilden eine Grundlage für eine Reklamation aufgrund Unstimmigkeit des Geräts mit dem Vertrag. Rechtsmäßig lässt man das Anfügen einer Gebrauchsanleitung in anderer Form als Papierform zu, was letztens sehr oft genutzt wird, indem man eine grafische oder elektronische Anleitung von Volkswagen Transporter 1600 (1968), sowie Anleitungsvideos für Nutzer beifügt. Die Bedingung ist, dass ihre Form leserlich und verständlich ist.

Was ist eine Gebrauchsanleitung?

Das Wort kommt vom lateinischen „instructio”, d.h. ordnen. Demnach kann man in der Anleitung Volkswagen Transporter 1600 (1968) die Beschreibung der Etappen der Vorgehensweisen finden. Das Ziel der Anleitung ist die Belehrung, Vereinfachung des Starts, der Nutzung des Geräts oder auch der Ausführung bestimmter Tätigkeiten. Die Anleitung ist eine Sammlung von Informationen über ein Gegenstand/eine Dienstleistung, ein Hinweis.

Leider widmen nicht viele Nutzer ihre Zeit der Gebrauchsanleitung Volkswagen Transporter 1600 (1968). Eine gute Gebrauchsanleitung erlaubt nicht nur eine Reihe zusätzlicher Funktionen des gekauften Geräts kennenzulernen, sondern hilft dabei viele Fehler zu vermeiden.

Was sollte also eine ideale Gebrauchsanleitung beinhalten?

Die Gebrauchsanleitung Volkswagen Transporter 1600 (1968) sollte vor allem folgendes enthalten:
- Informationen über technische Daten des Geräts Volkswagen Transporter 1600 (1968)
- Den Namen des Produzenten und das Produktionsjahr des Geräts Volkswagen Transporter 1600 (1968)
- Grundsätze der Bedienung, Regulierung und Wartung des Geräts Volkswagen Transporter 1600 (1968)
- Sicherheitszeichen und Zertifikate, die die Übereinstimmung mit entsprechenden Normen bestätigen

Warum lesen wir keine Gebrauchsanleitungen?

Der Grund dafür ist die fehlende Zeit und die Sicherheit, was die bestimmten Funktionen der gekauften Geräte angeht. Leider ist das Anschließen und Starten von Volkswagen Transporter 1600 (1968) zu wenig. Eine Anleitung beinhaltet eine Reihe von Hinweisen bezüglich bestimmter Funktionen, Sicherheitsgrundsätze, Wartungsarten (sogar das, welche Mittel man benutzen sollte), eventueller Fehler von Volkswagen Transporter 1600 (1968) und Lösungsarten für Probleme, die während der Nutzung auftreten könnten. Immerhin kann man in der Gebrauchsanleitung die Kontaktnummer zum Service Volkswagen finden, wenn die vorgeschlagenen Lösungen nicht wirksam sind. Aktuell erfreuen sich Anleitungen in Form von interessanten Animationen oder Videoanleitungen an Popularität, die den Nutzer besser ansprechen als eine Broschüre. Diese Art von Anleitung gibt garantiert, dass der Nutzer sich das ganze Video anschaut, ohne die spezifizierten und komplizierten technischen Beschreibungen von Volkswagen Transporter 1600 (1968) zu überspringen, wie es bei der Papierform passiert.

Warum sollte man Gebrauchsanleitungen lesen?

In der Gebrauchsanleitung finden wir vor allem die Antwort über den Bau sowie die Möglichkeiten des Geräts Volkswagen Transporter 1600 (1968), über die Nutzung bestimmter Accessoires und eine Reihe von Informationen, die erlauben, jegliche Funktionen und Bequemlichkeiten zu nutzen.

Nach dem gelungenen Kauf des Geräts, sollte man einige Zeit für das Kennenlernen jedes Teils der Anleitung von Volkswagen Transporter 1600 (1968) widmen. Aktuell sind sie genau vorbereitet oder übersetzt, damit sie nicht nur verständlich für die Nutzer sind, aber auch ihre grundliegende Hilfs-Informations-Funktion erfüllen.

Inhaltsverzeichnis der Gebrauchsanleitungen

  • Seite 1

    Owner s Worksho p Manua l[...]

  • Seite 2

    V W Transporte r 160 0 Owner s Worksho p Manua l b y J H Hayne s Membe r o f the.Guil d o f Motorin g Writer s an d D H Stea d Model s covered : Al l Volkswage n Transporte r 160 0 model s wit h 158 4 c c (96. 7 c u in ) engin e Does not cover the alternative bodies and conversions produced by specialist manufacturers ISB N 0 8569 6 66 0 6 © Hayne[...]

  • Seite 3

    Acknowledgement s Thank s ar e du e t o th e V W organisatio n fo r th e suppl y o f technica l informatio n an d certai n illustrations . Castro l Limite d provide d lubricatio n detail s an d th e Champio n Sparkin g Plu g Compan y supplie d th e illustration s showin g th e variou s spar k Abou t thi s manua l plu g conditions . , Lastly , thank[...]

  • Seite 4

    Content s Acknowledgement s Abou t thi s manua l Introductio n Tool s an d workin g facilitie s Recommende d lubricant s an d fluid s Vehicl e identificatio n an d spar e part s Routin e maintenanc e (also see Chapter 12, page 194) Chapte r 1 Engin e (also see Chapter 12, page 194) Chapte r 2 Cooling , heatin g an d exhaus t system s (also see Chap[...]

  • Seite 5

    Tool s an d workin g facilitie s Introduction A selectio n o f goo d tool s i s a fundamenta l requiremen t fo r anyon e contemplatin g th e maintenanc e an d repai r o f a moto r vehicle . Fo r th e owne r wh o doe s no t posses s any , thei r purchas e wil l prov e a considerabl e expense , offsettin g som e o f th e saving s mad e b y doing-it-y[...]

  • Seite 6

    produce d b y th e vehicl e manufacture r specificall y to r it s deale r network . Yo u wil l fin d occasiona l reference s t o thes e manufac - turers ' specia l tool s i n th e tex t o f thi s manual . Generally , a n alternativ e metho d o f doin g th e jo b withou t th e vehicl e manu - facturers ' specia l too l i s given . However [...]

  • Seite 7

    Recommende d lubricant s an d fluid s Componen t o r syste m Lubrican t typ e o r specificatio n Castro l produc t Engin e (1 ) Transmissio n (2 ) Transmissio n wit h limite d sli p differentia l (2 ) Whee l bearing s (3 ) Brak e hydrauli c flui d Driv e shaf t C V joint s SA E 3 0 o r 4 0 o r SA E 20W/5 0 SA E 9 0 Hypoi d SA E 9 0 Hypoi d L S NGL [...]

  • Seite 8

    Vehicl e identificatio n an d spar e part s Althoug h man y individua l parts , an d i n som e cases , su b assemblie s suc h a s distributors , fi t a variet y o f V W model s i t i s dangerou s t o assum e tha t jus t becaus e the y loo k th e sam e tha t the y ar e th e same . Difference s ar e sometime s no t visuall y detect - abl e a t all (e[...]

  • Seite 9

    Routin e maintenanc e For modifications, see Supplement at end of manual Introductio n Becaus e o f th e inheren t toughnes s an d reputatio n fo r reliabilit y an d lon g lif e ther e i s a tendenc y fo r owne r s t o b e a bi t sketch y o n V W maintenanc e - particularl y wit h vehicle s no t i n th e firs t flus h o f youth . Th e V W wil l pu [...]

  • Seite 10

    Th e windscree n washe r reservoi r i s mounte d o n th e vertica l pane l i n th e fron t o f th e ca b jus t belo w th e brak e flui d reservoir . Engin e oi l dipstick . t o th e fron t pane l o f th e ca b jus t belo w th e hydrauli c flui d reservoir . I t ha s a protectiv e cove r an d tucke d insid e i s a tub e wit h a n ordinar y tyr e val[...]

  • Seite 11

    Routin e maintenanc e 1 1 1 i n th e centr e o f th e botto m o f th e crankcase . Befor e starting , yo u mus t obtai n tw o ne w gasket s fo r it , an d i t i s als o desirabl e t o ge t si x ne w coppe r washer s fo r th e stu d nuts . Firs t drai n th e oi l b y removin g th e centr e plu g an d the n remov e th e cove r plate . Tak e car e whe[...]

  • Seite 12

    Genera l descriptio n an d typ e identificatio n .. . .. . .. . 1 Repai r an d maintenanc e procedure s - dismantlin g .. . .. . 2 Engin e remova l - preparatio n .. . .. . .. . .. . .. . 3 Engin e - remova l .. . .. . .. . .. . .. . .. . 4 Engin e dismantlin g - genera l .. . .. . .. . .. . .. . 5 Engin e ancilliarie s - remova l .. . .. . .. . ..[...]

  • Seite 13

    Chapte r 1/Engin e 1 3[...]

  • Seite 14

    1 Genera l descriptio n an d typ e identificatio n Th e 160 0 versio n o f th e establishe d 'Beetle ' engin e wa s introduce d int o th e transporte r rang e i n 1967 . Th e basi c con - figuratio n o f th e 'Beetle ' engin e i s unchange d - th e coolin g syste m incorporatin g th e superimpose d typ e o f fa n an d housing . [...]

  • Seite 15

    1 Crankcase - right half 2 Generator pedestal 3 Gasket 4 Camshaft bearing - shell - rear 5 Oil selec tor pipe FIG.1. 1 ENGIN E STATI C PART S • EXPLODE D VIE W 6 Camshaft bearing shell- front gasket centre 8 Cylinder head stud 10 Cylinder barrel 7 Camshaft bearing shell - front 9 Cylinder base sealing 11 Cylinder head 12 Rocket cover gasket 13 Ro[...]

  • Seite 16

    1 6 Chapte r 1/Engin e cylinde r design . Th e shor t crankshaf t run s i n aluminiu m allo y shel l bearing s locate d betwee n th e tw o halve s o f a magnesiu m allo y crankcas e whic h joi n vertically . Th e camshaf t run s centrall y belo w th e crankshaf t an d i s gea r drive n fro m th e rea r en d o f th e crankshaft . Th e camshaf t i s [...]

  • Seite 17

    4. 1 Ope n th e engin e cove r an d hav e a goo d loo k round . 4. 6 Removin g th e cros s pane l (earl y models T 4.1 2 Suppor t th e gearbo x wit h a piec e o f rop e o r cha. n Not e t h woode n packin g piece . 4.1 6 V,e w o f th e bumpe r wit h bumpe r an d c r 4.18 A Removin g th e engin e o n a trolle y jac k 4.18 B Engin e lowere d t o th e[...]

  • Seite 18

    1 8 Chapte r 1 /Engin e plu g i t wit h a penci l o r punch . Fue l i s gravit y fed . 9 Pul l of f th e heate r pip e connection hoses . 1 0 Disconnec t th e heate r fla p cables . 1 1 Pul l th e accelerato r cabl e throug h th e fa n housing . 1 2 Suppor t th e gearbo x wit h a piec e o f rope , wir e o r chai n slun g fro m th e bod y sid e memb[...]

  • Seite 19

    4.1 4 Remov e th e engin e securin g nut s 4.1 7 Removin g on e o f th e lowe r engin e mountin g bolt s - d o no t forge t th e othe r on e 6. 1 Removin g engin e rea r suppor t bea m 8. 1 Und o stubbor n oi l pressur e regulato r 8. 4 Th e relie f valv e sprin g i s longe r tha n 8.6 a Replacin g th e relie f valv e pisto n plug s wit h a n impro[...]

  • Seite 20

    2 0 Chapte r 1 /Engin e pulle y whe n undoin g o r tightenin g th e bol t pus h a suitabl e articl e throug h on e o f th e hole s i n th e pulle y an d ja m i t agains t th e crankcas e flange . 3 If , whe n th e nu t ha s bee n removed , th e pulle y i s a ver y tigh t fit , d o no t appl y forc e a t th e edge s o r yo u ar e likel y t o distor [...]

  • Seite 21

    7 Crankshaft 2 Crankshaft gear 3 Woodruff key 4 Spacer 5 Distributor drive 6 Securing ring 7 Distributor drive FIG.1. 2 ENGIN E RUNNIN G PART S - EXPLODE D VIE W shaft 8 Spring 9 Washer 10 Oil baffle washer 11 Oil seal 12 Key for pulley 13 Crankshaft pulley 14 Washer 15 Bolt 16 Flywheel 17 Dowel 18 Spacer 19 Locking washer 20 Locking washer 21 Holl[...]

  • Seite 22

    2 2 Chapte r 1/Engin e o f sever e burnin g a t th e sealin g are a i n th e hea d the n th e cylinde r ca n b e lightl y groun d i n wit h carborundu m paste . However , i t shoul d b e understoo d tha t th e dept h t o th e matin g fac e fo r eac h cylinde r shoul d b e equa l (giv e o r tak e 3 t o 4 thousandth s o f a n inch ) otherwis e th e h[...]

  • Seite 23

    2 3 FIG.1. 3 LUBRICATIO N SYSTE M - DIAGRAMMATI C DRAWIN G FIG.1. 4 MEASURIN G OI L PUM P GEA R EN D CLEARANC E (Se c 10 ) FIG.1. 5 CRANKSHAF T PULLE Y WHEE L - CROS S SECTIO N (Se c 9 ) 1 Pulley 2 Oil return scroll 3 Woodruff key 4 Securing bolt 5 Lock washer 6 Oil thrower disc[...]

  • Seite 24

    2 4 Chapte r 1/Engin e i f yo u ar e goin g t o d o s o anywa y i t wil l b e simple r t o tak e th e connectin g rod s of f th e crankshaf t afterwards . Star t wit h No . 1 and , usin g a socke t wit h a n extension , slacke n th e tw o connect - in g ro d ca p nut s b y insertin g th e extensio n int o th e crankcase : I t i s importan t t o hav[...]

  • Seite 25

    FIG.1. 6 CAMSHAF T AN D VALVES - EXPLODE D VIE W (Se c 15 ) 1 Camshaft and gear assembly 2 Pushrod 3 Tappet 4 Pushrod tube 5 Pushrod tube seal 6 Rocker shaft 7 Shaft support bracket 8 Thrust washer 9 Corrugated washer 10 Securing clip 11 Rocker arm 12 Sealing ring 13 Tappet adjusting screw 14 Locknut 15 Inlet valve 16 Exhaust valve 17 Oil wiper 18 [...]

  • Seite 26

    2 6 Chapte r 1 /Engin e poin t o f th e too l use d mus t no t b e allowe d t o di g int o th e crankcase . 3 Whe n th e oi l sea l i s remove d a numbe r o f shim s whic h fi t betwee n th e flywhee l hu b an d th e flang e o n th e fron t mai n bearin g wil l b e observed . Ther e shoul d b e thre e o f the m normal - ly . Thes e gover n th e amo[...]

  • Seite 27

    2 7 FIG.1. 9 ENGIN E - CROS S SECTIO N VIEW S 1 Fan housing 2 Coil 3 Oil cover 4 Inlet manifold 5 Fuel pump 6 Distributor 7 Oil pressure switch 8 Valve 9 Cylinder 10 Piston 11 Oil pressure relief valve 12 Fan 13 Oil filler 14 Intake manifold preheater pipe 15 Connecting rod 16 Spark plug 17 Cylinder head 18 Thermostat 19 Rotor arm 20 Push rod 21 He[...]

  • Seite 28

    2 8 Chapte r 1 /Engin e 2 0 Crankcas e - examinatio n an d renovatio n Th e crankcas e shoul d b e fre e fro m crack s o r an y othe r for m o f damag e an d th e tw o matin g edge s mus t b e quit e fre e fro m dents , scratche s an d burr s whic h coul d i n an y wa y affec t thei r precis e alignmen t whe n bot h ar e clampe d together . Th e cr[...]

  • Seite 29

    [...]

  • Seite 30

    3 0 Chapte r 1 /Engin e shell s t o a n un-regroun d crankshaf t thi s i s possible . I f ver y noticeabl e however , i t indicate s tha t th e journa l i s ou t o f round . I f rod s o n a regroun d crankshaf t ar e slightl y tigh t th e engin e wil l nee d running-in . I f ver y tigh t the n th e regrindin g tolerance s ar e wron g an d i t shoul[...]

  • Seite 31

    23.3 a Th e connectin g ro d an d ca p hav e matchin g number s 23.3 b an d a forg e mar k whic h mus t 23.3 c Fi t th e bearin g shel l int o th e cap . b e uppermos t o n installation . 23.3 d Pu t th e ro d int o positio n o n th e 23.3 e an d matc h u p th e cap . journa l 23. 5 Tighte n all th e ca p nut s FIG.1.1 0 CRANKCASE ' CRANKSHAF [...]

  • Seite 32

    3 2 Chapte r 1/Engin e 1 9 Tighte n th e larg e nut s progressivel y t o a torqu e o f 2 0 f t lb s an d the n t o 2 5 f t lbs . Finall y tighte n th e smalle r nut s t o 1 4 f t lb s (photo) . 2 0 No w rotat e th e crankshaf t - i t shoul d revolv e smoothl y withou t an y stiffness . I f ther e i s stiffnes s however , slacke n al l th e crankcas[...]

  • Seite 33

    24.4 a Compar e ne w tappe t flang e thick - nesse s wit h th e ol d 24.4 b Pu t th e tappet s int o th e crankcas e 24.4 c Chec k th e ca m lob e clearance s 24. 5 N o 1 mai n bearin g i s flanged . Th e dowe l pe g hol e goe s toward s th e fly - whee l 24. 6 Th e onl y spli t mai n bearin g i s N o 2 . Fi t eac h hal f int o th e crankcas e halv[...]

  • Seite 34

    25. 4 Positio n th e pisto n ove r th e connec - tin g ro d smal l en d 25.5 a Th e maker s pu t a n arro w o n th e pisto n crow n pointin g toward s th e fly - wheel . Note th e arro w pointin g upward s an d th e pisto n N o 1 scratche d o n th e crow n a s wel l 25.5 b Fittin g a circli p fo r a V W pisto n 26.2 a Grindin g th e cylinder s int [...]

  • Seite 35

    27.3 a Insertin g a n exhaus t valv e int o th e hea d 27.3 b Fittin g th e sprin g an d retaine r 27.4 a Th e sprin g compresso r need s elon - gate d end s 27.4 b o r us e a piec e o f tub e wit h a hol e i n i t 27.6 a Us e greas e t o hol d th e collet s o n replacemen t 27.6 b Collet s i n positio n 28.1 a Stretchin g th e pushro d tube s 28. [...]

  • Seite 36

    3 6 Chapte r 1/Engin e valv e ste m an d the n th e sprin g an d sprin g collar . Not e tha t th e clos e coil s o f th e sprin g g o agains t th e hea d (photo) . 4 Nex t arrang e th e valv e sprin g compresso r wit h th e space r tub e fitte d i f require d an d carefull y compres s th e sprin g (photos) . Watc h tha t ther e i s n o likelihoo d [...]

  • Seite 37

    29.2 a Fi t ne w rocke r shaf t mountin g stu d 29.2 b Replac e th e rocke r shaf t assembly.. . 29. 3 makin g sur e th e pushrod s ar e seal s seate d correctl y 30. 2 Crankshaf t en d floa t shim s bein g assemble d 30. 3 Replacin g th e oi l sea l 31. 3 Flywheel/crankshaf t dowe l peg s i n positio n 31. 5 Offe r u p th e flywhee l 31. 8 Apiec e[...]

  • Seite 38

    3 8 Chapte r 1 /Engin e T o d o thi s a dia l gaug e micromete r i s use d agains t th e fac e o f th e flywheel . Th e crankshaf t i s the n move d i n an d ou t an d th e floa t measured . Th e thicknes s o f th e thir d shi m i s th e measure d floa t les s 0.1 0 mm . An y thre e shim s wil l d o o f cours e provide d the y ad d u p i n tota l t[...]

  • Seite 39

    32.5 c Th e oi l pum p complet e goe s o n 33.2 a Oi l coole r seal s o n th e mountin g las t bracket 33.2 b Fittin g th e oi l coole r t o th e bracke t 33.2 c Th e smal l seale r plat e goe s o n th e 33.3 a Oi l coole r seal s o n th e crankcas e bracke t stud s 33.3 b Fittin g th e coole r assembl y t o th e crankcas e 3 3 3 c Tighte n th e oi[...]

  • Seite 40

    4 0 Chapte r 1/Engin e housing . Als o ensur e tha t th e accelerato r cabl e i s i n a positio n wher e i t wil l no t ge t trappe d o r kinked . 4 Wit h th e rea r o f th e vehicl e raise d mov e th e engin e int o positio n underneat h s o tha t i t ca n b e lifted . Ideall y i t wil l b e raise d o n a trolle y jack . 5 Ther e is littl e for e [...]

  • Seite 41

    Chapte r 1 /Engin e 4 1 3 7 Faul t findin g Whe n investigatin g startin g an d uneve n runnin g fault s d o no t b e tempte d int o sna p diagnosis . Star t fro m th e beginnin g o f th e chec k procedur e an d follo w i t through . I t wil l tak e les s tim e i n th e lon g run . Poo r performanc e fro m a n engin e i n term s o f powe r an d eco[...]

  • Seite 42

    Chapte r 2 Cooling , heatin g an d exhaus t system s For extra information, see Supplement at end of manual Content s Genera l descriptio n Remova l o f component s - genera l Fa n bel t - adjustment , remova l an d replacemen t Fa n an d dynam o - remova l an d replacemen t .. . Fa n housin g - remova l an d replacemen t Hea t exchanger s - remova[...]

  • Seite 43

    2 6 2 5 2 7 2 4 2 3 2 2 2 1 2 0 1 9 1 8 1 7 1 2 1 3 1 6 1 5 1 4 1 0 1 1 8 9 1 0 7 6 5 4 3 1 3 2 3 3 3 0 3 6 3 7 3 5 3 4 4 1 k FIG.2. 1 FAN , FA N HOUSIN G AN D THERMOSTA T 17 Outer fan cover 18 Reinforcement flange 19 Inner fan cover 20 Lockwasher 21 Nut 22 Fan hub 23 Shim 24 Fan 25 Lockwasher 26 Special nut 27 Fan housing 28 Washer 29 Cheese head [...]

  • Seite 44

    4 4 FIG.2. 2 SPLI T PULLE Y FO R FA N BEL T SHOWIN G SPACER S WHIC H MA Y B E MOVE D T O ADJUS T BEL T TENSIO N FIG.2. 3 FA N ASSEMBL Y - CROS S SECTIO N / Spacer washers 7 Fan 2 Fan hub 8 Fan cover, inner 3 Woodruff key 9 Flange 4 Retaining nut 10 Fan cover, outer 5 Generator shaft a = 2 mm (0.08 in) 6 Shaped washer[...]

  • Seite 45

    3. 2 Positionin g pulle y spacer s 3. 3 Checkin g fa n bel t tensio n 3. 4 Fittin g th e oute r hal f o f th e fa n pulle y 4. 3 Disconnectin g th e dynam o lead s 4. 1 O a Fittin g th e fa n oute r cove r t o th e dynam o 4.10 b an d th e stiffenin g plate .[...]

  • Seite 46

    4 6 Chapte r 2/Cooling , heatin g an d exhaus t system s tensio n pulley . Th e pulle y o n th e generato r i s spli t int o tw o an d th e ga p betwee n th e tw o halve s govern s th e effectiv e diameter . Th e ga p i s regulate d b y space r ring s (photo) . I f th e bel t i s to o slac k th e ga p betwee n th e tw o halve s i s decrease d b y r[...]

  • Seite 47

    4.10 c Fi t th e inne r cove r plat e 4. 1 O d Not e th e space r o n th e dynam o shaf t 4. 1 O e Fi t th e fa n hu b an d shim s 4. 1 O f ... . followe d b y th e fan . 4. 1 O g Secur e wit h th e lockwashe r an d nu t 5. 6 Removin g th e uppe r par t o f th e oi l coole r duc t[...]

  • Seite 48

    4 8 Chapte r 2/Cooling , heatin g an d exhaus t system s (th e whol e manifol d o n earlie r models) , shoul d firs t b e posi - tioned . I t canno t b e manoeuvre d betwee n th e housin g an d th e generato r pedesta l afterwards . 1 2 Continu e wit h reassembl y b y carefull y lowerin g th e fa n housin g ove r th e oi l cooler . Th e pul l ro d [...]

  • Seite 49

    5.7 a Removin g th e lowe r hal f o f th e oi l coole r duc t 5.7 b Liftin g th e duc t fro m th e vertica l plat e 5. 8 Lookin g a t th e undersid e o f th e fa n housin g showin g th e ther - mostaticall y controlle d ai r baffl e plate s 5.1 2 Guidin g th e thermosta t ro d throug h th e cylinder s 5.1 4 Tightenin g th e fa n housin g sid e scre[...]

  • Seite 50

    5.16 a Replac e th e connectin g ro d fo r th e fa n housin g baffl e plate s 5.16 b Securin g th e specia l clip s 5.16 c an d retur n sprin g 6. 4 Unclampin g th e hea t exchange r contro l cable s 6. 6 Undoin g th e hea t exchange r sleev e cli p 6. 7 Drawin g th e hea t exchange r of f th e fron t stud s[...]

  • Seite 51

    7. 2 Slacke n th e thermosta t bellow s mountin g scre w 8. 4 Th e heate r contro l leve r showin g plasti c plu g 9.7 a Th e lowe r stu d als o carrie s th e war m ai r intak e pip e bracket 9.7 b D o no t us e an y pr e heate r gaske t wit h a smal l hole , fo r th e carburetto r ai r cleane r[...]

  • Seite 52

    5 2 Chapte r 2/Cooling , heatin g an d exhaus t system s th e ca b o r let s i t continu e t o th e tw o inne r slot s a t th e bas e o f th e windscreen . Th e heate r outpu t i s therefor e controlle d b y us e o f th e tw o lever s an d th e ho t ai r directio n ca n b e balance d betwee n floo r an d screen . 8 Passenge r carryin g model s hav [...]

  • Seite 53

    1 Tail pipe 2 Retaining ring 3 Seal 4 Self-locking nut 5 Clamp 6 Clamp bolt 7 Silencer 8 Seal 9 Air inlet hose 10 Hose clip FJG.2. 5 EXHAUS T SYSTE M AN D MOUNTING S (fo r Dampe r pipe , tai l pip e an d fitting s se e Fig.2.6 ) 11 Grommet 12 Connecting pipe 13 Gasket - pre-heater pipe (left) 14 Gasket - pre-heater pipe (right) 15 Gasket - exhaust [...]

  • Seite 54

    5 4 Chapte r 2/Cooling , heatin g an d exhaus t system s 1 1 Faultfindin g I t i s difficul t t o detec t heatin g system s fault s i n a rea r engine d ai r coole d ca r becaus e th e tell-tal e hea d o f stea m i s no t ther e t o sho w an d n o temperatur e gauge s ar e used . Th e firs t indication s o f ove r heatin g ar e a falljn g of f i n [...]

  • Seite 55

    4 3 6 7 Heat exchanger 2 Combustion chamber 3 Electric motor 4 Blower, fresh air 5 Casing 6 Regulator (pressure) 7 Solenoid valve 8 Fuel pump 9 Fuel jet 10 Combustion air blower 11 Spark plug (2 pole) 12 Coil VR Y HEATE R - DIAGRAMMATI C SECTIO N 13 Glow plug 14 Thermo-switch 15 Overheating switch 16 Safety switch 17 Warm air duct 18 Control flap 1[...]

  • Seite 56

    56 " FIG.2. 8 SUPPLEMENTAR Y HEATE R - WIRIN G DIAGRAM S (above , t o Augus t 196 9 - below , fro m Augus t 196 9 t o 1973 ) 7 2 3 4 5 7 10 Electric motor Spark plug Breaker contact Safety switch Temperature regulating switch Glow plug Thermo switch 11 Overheating switch 17 Ignition coil 15 Fuel pump 17 Warning light 18 Fuse box 19 Fuse. 16 am[...]

  • Seite 57

    Chapte r 3 Fue l syste m an d carburatio n For modifications, and information applicable to later models, see Supplement at end of manual Content s Genera l descriptio n an d exhaus t emissio n contro l .. . .. . 1 Ai r cleane r .. . .. . .. . .. . .. . .. . .. . 2 Sole x carburetto r - descriptio n .. . .. . .. . .. . 3 Sole x carburetto r - remov[...]

  • Seite 58

    5 8 Chapte r 3/Fue l syste m an d carburatio n fu l t o humans . A s th e expor t o f VW' s t o th e State s i s a ver y significan t percentag e o f thei r tota l output , an d man y see m t o ge t t o th e Wes t Coast , i t i s natura l tha t V W activit y i n th e emissio n contro l fiel d ha s bee n intensive . A s developmen t i n thi s f[...]

  • Seite 59

    2.1 a Ai r cleane r remove d fro m vehicl e (kee p i t thi s wa y up ) 2. 1 b Th e to p hal f o f th e ai r cleane r withdraw n fo r servicin g FIG . 3.1 . DIAGRAMATI C CROS S SECTIO N O F SOLE X 3 0 PIC T CARBURETTO R WIT H AI R B Y PAS S ADJUSTMEN T 1 By pass air/fuel mixing 2 Choke tube 4 Volume control screw 5 By pass air drilling chamber 3 By [...]

  • Seite 60

    6 0 Fi g 3.2.A . CARBURETTO R SOLE X 3 0 PICT/ 2 7 Screw 2 Lockwasher 3 Upper body 4 Needle valve 5 Seal 6 Screw 7 Retaining ring 8 Spacer 9 Insert with spring and heater element 10 Cap 11 Screw 12 Cover 13 Spring 14 Vacuum diaphragm 15 Gasket 16 Accelerator cable spring 17 Main body 18 Float and pin 19 Float pin bracket 20 Air correction jet 21 Ma[...]

  • Seite 61

    6 1 Fig . 3.2B . SOLE X 3 0 PIC T - 3 CARBURETTO R (Sec . 4 ) / Top cover screw 2 Spring washer 3 Top cover 4 Needle valve washer 5 Needle valve 6 Gasket 7 Float pin retainer 8 Float 9 Air corrector jet 10 Carburettor body 11 Volume control screw 12 Nut 13 Lock washer 14 Accelerator cable spring 15 Spring washer 16 Plug 17 Plug washer 18 Main jet 1[...]

  • Seite 62

    6 2 Chapte r 3/Fue l syste m an d carburatio n mixtur e t o ai d startin g a col d engine . A t idlin g speed s th e throttl e fla p i s shu t s o tha t n o ai r an d fue l ca n ge t t o th e engin e i n th e regula r way . Fo r thi s ther e ar e separat e route s leadin g t o smal l hole s i n th e sid e o f th e chok e tube , on th e engin e sid [...]

  • Seite 63

    4. 3 Liftin g th e carburetto r of f th e manifol d 4. 4 Lowe r hal f o f carburetto r showin g gaske t • r 4. 6 Uppe r hal f o f carburettor . Not e needl e valv e an d stranqle r fla p 'B ' 4. 9 Electr o magneti c fue l cu t of f valv e unscrewe d fro m carburet - to r bod y 4. 1 3 Reassemblin g th e tw o halve s o f th e carburetto r[...]

  • Seite 64

    6 4 Fig.3.2.C . SOLE X 31/3 4 PIC T 3 CARBURETTO R - EXPLODE D VIE W Difference between the two types is in pilot jet position — angled on the 31 PICT 3 (Sec 3) 1 Cover screw 2 Spring washer 3 Top cover 4 Needle valve washer 5 Needle valve 6 Gasket 7 Float pin bracket 8 Float and pin 9 Air correction jet and emulsion tube 10 Carburettor lower hou[...]

  • Seite 65

    6 5 FIG.3. 3 CARBURETTO R ADJUSTMEN T POINT S • NO T FIG.3. 4 CARBURETTO R ADJUSTMEN T POINT S - MODIFIE D MODIFIE D FO R EXHAUS T EMISSIO N CONTRO L REQUIRE - FO R EXHAUS T EMISSIO N CONTRO L (Se c 5 ) MENTS (Se c 5 ) 1 Throttle stop screw 1 3 1 1 1 0 2 Volume control screw 1 Air by pass serew 2 Volume control screw (sealed) 3 Throttle stop scre[...]

  • Seite 66

    6 6 Chapte r 3/Fue l syste m an d carburatio n fiv e carburettor s an d non e o r on e o f tw o type s o f throttl e valv e positioner . * Befor e attemptin g an y adjustmen t mak e sur e yo u kno w whic h on e yo u ar e dealin g with . Throttl e valv e positioner s ar e describe d i n Sectio n 11 , an d nee d adjustmen t afte r firs t settin g th [...]

  • Seite 67

    6 7 FIG.3. 6 FUE L PUM P (EARL Y TYPE ) COMPONENT S (Se c 8 ) 1 Cover screw 2 Washer 3 Cover 4 Gasket 5 Filter screen 6 Body screw 7 Washer 8 Pump body,upper 9 Diaphragm assembly 10 Pump body,lower 18 Gasket,pump to flange 19 Intermediate flange 20 Gasket flange to crankcase 21 Push rod[...]

  • Seite 68

    6 8 Chapte r 3/Fue l syste m an d carburatio n late r version s thi s cut-of f valv e wa s incorporate d int o th e bod y o f th e pump . 2 T o clea n th e filte r scree n remov e th e to p cove r securin g scre w an d carefull y lif t of f th e cove r an d gaske t (photo) . Th e gaske t ma y b e re-use d provide d i t remain s unbroken . Carefull [...]

  • Seite 69

    6. 2 Removin g th e fue l pum p cove r (late r types ) t o clea n th e filte r 7. 2 Removin g th e fue l pum p 7.3 a Th e fue l pum p actuatin g ro d 7.3 b Th e fue l pum p intermediat e flang e 7. 6 Fue l pum p an d externa l cu t of f valv e connection s 'A ' fro m th e fue l tan k an d 'B ' t o th e carburetto r 9. 1 Fue l ta[...]

  • Seite 70

    7 0 Chapte r 3/Fue l syste m an d carburatio n cylinde r an d th e pi n take n ou t o f th e cylinde r s o a s t o releas e th e floa t inside . 1 0 Fue l tan k - ventilatio n an d activate d carbo n filte r uni t 1 Ther e ma y b e on e o r mor e ven t pipe s o n th e fue l tan k t o cop e wit h expansio n du e t o hea t an d t o preven t spillag e[...]

  • Seite 71

    12.4 a Inle t manifol d aluminiu m gaske t 12.4 b Inle t manifol d centr e sectio n bein g positione d 12.4 c Th e section s o f th e inle t manifol d ar e joine d b y rubbe r boot s an d clips . 12.4 d Whic h mus t b e carefull y positione d 12.4 e Th e manifol d oute r section s ar e hel d b y th e cylinde r hea d stud s[...]

  • Seite 72

    7 2 FIG . 3.7 . SCHEMATI C DRAWIN G O F FUE L TAN K VENTILA - TIO N WIT H ACTIVATE D CARBO N FILTE R UNI T (Sec . 10 ) / Expansion chamberdncorporated in fuel tank design) 2 Breather line 3 Pressure line from fan housing 4 Suction line from air cleaner 5 Crankcase breather hose 1 2 / Pull rod 2 Pull rod diaphragm 3 Vacuum hose to carburettor FIG.3.[...]

  • Seite 73

    Chapte r 3/Fue l syste m an d carburatio n 7 3 1 3 Faul t diagnosi s I n additio n t o th e mor e basi c fault s whic h ma y occu r i n an y vehicl e fue l syste m ther e ar e som e peculiaritie s a s a resul t i n th e change s an d modification s neede d i n connectio n wit h exhaus t emissio n contro l - whic h wer e mad e t o th e carburetto r [...]

  • Seite 74

    Chapte r 4 Ignitio n syste m For information applicable to later models, see Supplement at end of manual Content s Genera l descriptio n .. . .. . .. . .. . .. . .. . 1 Contac t point s - adjustment , remova l an d replacemen t .. . 2 Distributo r - remova l an d replacemen t .. . .. . .. . 3 Condense r - testin g an d renewa l .. . .. . .. . .. . [...]

  • Seite 75

    7 6 FIG.4. 2 DISTRIBUTO R WIT H CENTRIFUGA L AN D VACUU M ADVANC E EXPLODE D VIE W - (Se c 5 ) FIG.4. 2 DISTRIBUTO R WIT H CENTRIFUGA L AN D VACUU M ADVANC E EXPLODE D VIE W - (Se c 5 1 1 2 3 4 5 6 7 a 9 Mounting clamp bracket Cap Rotor Contacts securing screw Contact points Clip screw Clip retainer Clip retainer Cap clip 10 Contact points mounting[...]

  • Seite 76

    Chapte r 4/lgnitio n syste m 7 7 2 Contac t point s - adjustment , remova l an d replacemen t 1 Volkswage n servic e procedure s chec k th e contac t point s b y measurin g th e ca m dwel l wit h specia l equipment . Al l els e bein g equa l th e correc t ca m dwel l give s a point s ga p o f . 4 mm/.O1 6 ins . T o chec k th e gap , firs t remov e [...]

  • Seite 77

    2.1 a Removin g th e distributo r ca p 2.1 b an d roto r 2. 3 Contac t point s read y fo r ga p chec k 2. 4 Checkin g th e point s ga p wit h a feele r blad e an d undoin g th e clam p scre w t o enabl e th e fixe d poin t t o b e move d 1 2. 5 Disconnectin g th e point s lea d 2. 7 Liftin g th e point s assembl y fro m th e pivo t pos t[...]

  • Seite 78

    Chapte r 4/lgnitio n syste m 7 9 a s describe d earlier . 4 Th e nex t jo b i s t o remov e th e drivin g colla r fro m th e botto m o f th e shaf t bu t befor e doin g thi s i t i s importan t t o not e whic h wa y i t i s fitted . Se e whic h wa y th e drivin g dog s ar e offse t i n relatio n t o th e roto r ar m notc h i n th e to p o f th e sh[...]

  • Seite 79

    6. 5 Fittin g th e distributo r driv e shaf t thrus t washe r ove r a suitabl e 6.8 a Replacin g th e distributo r driv e shaft . Not e th e fue l pum p guid e ro d driv e ca m o n th e shaf t FIG.4. 3 DISTRIBUTO R DRIV E SHAF T (Se c 6 ) 7 Spacer spring 2 Fuel pump drive cam 3 Thrust washer 6.8 b Replacin g th e thrus t sprin g FI G 4. 4 CORREC T [...]

  • Seite 80

    Chapte r 4/lgnitio n syste m 8 1 spee d wil l alte r s o i f i t fall s outsid e th e specifie d limit s adjus t th e by-pas s ai r scre w o n th e carburetto r unti l i t i s onc e mor e correct . The n chec k wit h th e stroboscop e again . 1 4 Whe n th e mar k line s u p wit h th e crankcas e joint , clam p u p th e distributor . Reconnec t th e[...]

  • Seite 81

    8 2 Chapte r 4/lgnitio n syste m circumstanc e wher e th e ignitio n i s bein g checke d fo r correc t operation . D o no t by-pas s an y par t o f thi s procedur e unles s th e faul t i s particularl y obviou s an d rectificatio n solve s th e problem . Suc h obviou s fault s woul d b e broke n o r detache d wires . I t i s assume d tha t th e bat[...]

  • Seite 82

    Chapte r 5 Clutc h an d operatin g mechanis m Content s Genera l descriptio n .. . .. . .. . .. . .. . .. . 1 Clutc h cabl e - removal , replacemen t an d adjustmen t .. . 2 Clutc h assembl y - removal , inspectio n an d replacemen t .. . 3 Clutc h releas e operatin g mechanism - inspectio n an d repai r 4 Faul t diagnosi s .. . .. . .. . .. . .. .[...]

  • Seite 83

    2. 2 Clutc h cabl e adjustin g win g nu t 2. 5 Mak e sur e th e rubbe r dir t excludin g cap s ar e refitte d 3. 9 Replacin g th e drive n plat e an d cove r assembl y 3.10 a Centr e th e clutc h plat e o n th e flywhee l (typica l components ) 3.10 b I f th e gea r bo x i s dismantle d us e th e inpu t shaf t t o centr e th e clutc h (typica l com[...]

  • Seite 84

    8 5 FIG.5. 1 EARL Y CLUTC H UNI T - COI L SPRIN G TYP E FIG.5. 2 LATE R CLUTC H UNI T - TYPICA L DIAPHRAG M SPRIN G TYP E / Cover securing screw 2 Lock washer 3 Release ring 4 Adjusting nut 5 Pressure collar 6 Release lever 7 Spring 8 Cover plate 9 Spring cap 10 Spring (white) 11 Spring (red) 12 Spring seat 13 Spring pin 14 Pivot pin 15 Clutch plat[...]

  • Seite 85

    8 6 FIG.5. 3 COMPARISO N O F EARL Y TYP E (LEFT ) AN D LATE R VERSIO N (RIGHT ) O F TH E DIAPHRAG M SPRIN G CLUTC H COVE R FIG.5. 4 CLUTC H OPERATIN G CABL E OUTE R SLEEV E A Adjustment washer location B Bend measurement (1 - 1 % in)[...]

  • Seite 86

    Chapte r 5/Clutc h an d operatin g mechanis m 8 7 relieved . Lif t of f th e cove r an d clutc h drive n plate . 4 Th e clutc h drive n plat e shoul d b e inspecte d fo r wea r an d fo r contaminatio n b y oil . Wea r i s gauge d b y th e dept h o f th e rive t head s belo w th e surfac e o f th e frictio n material . I f thi s i s les s tha n 0.02[...]

  • Seite 87

    4. 6 Vie w o f th e bearin g attachmen t clip s 4.8 a Fittin g th e clutc h releas e shaf t bus h 4.8 b followe d b y th e shaf t 4.8 c an d bearin g sleev e an d seals . 4.8 d Mak e sur e th e bus h an d sea l d o no t com e ou t o n th e insid e lik e thi s 4.8 e Th e locatin g scre w fo r th e bus h an d sleev e[...]

  • Seite 88

    Chapte r 5/Clutc h an d operatin g mechanis m 8 9 5 Faul t diagnosi s Symptom s Reason/ s Remed y Judde r whe n takin g u p driv e Clutc h spi n (failur e t o disengage ) s o tha t gear s canno t b e meshe d Clutc h slip - (increas e i n engin e spee d doe s no t resul t i n increas e i n vehicl e spee d - especiall y o n hills ) Loos e engine/gear[...]

  • Seite 89

    FIG.5. 6 CLUTC H RELEAS E MECHANIS M - COMPONENT S 7 2 3 4 5 Clutch housing Bush - starter pinion Bush - operating shaft Oil return sleeve Oil seal • drive shaft 6 7 8 9 10 Clutch operating shaft Release bearing Retaining spring Circlip Washer 11 Rubber seal 16 Spring locating collar 12 Bush 17 Return spring 13 Sleeve 18 Clutch lever 14 Lock scre[...]

  • Seite 90

    Chapte r 6 Transmissio n an d fina l driv e For modifications, and information applicable to later models, see Supplement at end of manual Content s Genera l descriptio n .. . .. . .. . .. . .. . .. . 1 Transmissio n - remova l an d replacemen t .. . .. . .. . 2 Transmissio n - dismantlin g .. . .. . .. . .. . .. . 3 Inspectio n fo r wea r i n tran[...]

  • Seite 91

    FIG.6. 1 FINA L DRIV E AN D DIFFERENTIA L (T O AUGUS T 1968 ) (Se c 3 ) 7 Differential 4 Oil seal 2 Side covers 5 '0' ring 3 Outer race taper 6 Shim roller bearings 7 Shim 8 Cap nut 9 Spring washer 10 Joint flange 11 Spacer ring 12 Circlip 13 Sealing cap 14 Drive shaft, rear (input) 15 Stud (connecting) 16 Reverse gear sleeve 17 Circlip 1[...]

  • Seite 92

    FIG.6. 2 FINA L DRIV E AN D DIFFERENTIA L (FRO M AUGUS T 1968 ) (Se c 3 ) 1 Differential 2 Adjusting ring 3 Outer race, taper roller bearings 4 Oil seal 5 'O' Rir.j 6 Lock washer 7 Screw 8 Lock plate 9 Flange 10 Spacer washer 11 Circlip 12 Cap 13 Drive shaft - rear part (input) 14 Stud (connecting) 15 Reverse gear sleeve 16 Circlip 17 Clu[...]

  • Seite 93

    FI G 6.3 . GEARBO X AN D GEA R TRAI N (Se c 3 ) Mote : thi s drawin g i s correc t fo r gearboxe s u p t o Augus t 196 8 afte r whic h th e pinio n shaf t fastening s (8 ) wer e change d an d a pinio n retainin g nu t replace d them . Se e tex t Sectio n 3.12 . r Casing 5 ? Gear carrier 6 3 Drive shaft (mainshaft) 7 1 Drive pinion shaft 8 Shim (to [...]

  • Seite 94

    Chapte r 6/Transmissio n an d fina l driv e 9 5 ver y ba d stat e the n th e cos t o f th e componen t part s ma y wel l excee d th e cos t o f a ne w replacemen t unit . Thirdly , remembe r tha t a basi c knowledg e o f gearbo x constructio n an d functio n i s a bar e necessit y befor e tacklin g thi s one . I f yo u ar e doin g on e fo r th e fi[...]

  • Seite 95

    1. 1 Th e transmissio n fro m belo w showin g 2. 6 Und o th e squar e heade d scre w layou t an d support s 2.7 a Und o th e tw o nut s holdin g th e gear - bo x a t th e fron t mountin g 2.7 b Remov e th e eart h stra p 2.8 a Remov e th e uni t t o th e re a 2.8 b an d lowe r i t t o th e groun d 2.9 a Assembl e th e starte r moto r 2.9 b Fil l u [...]

  • Seite 96

    Chapte r 6/TransmissiO n an d fina l driv e 9 7 1 8 Th e pinio n shaf t i s a ver y tigh t fi t i n th e bal l bearin g i n th e casing . Havin g remove d th e circli p an d dishe d washe r fro m th e en d o f th e shaf t (watc h ou t tha t th e springines s o f th e washe r doe s no t caus e th e circli p t o fly ' whe n i t i s released ) th[...]

  • Seite 97

    [...]

  • Seite 98

    Chapte r 6/Transmissio n an d fina l driv e 9 9 plasti c plug s fro m th e drilling s opposite . Befor e doin g thi s mak e sur e yo u obtai n som e ne w plug s t o driv e i n whe n reassembling . Chec k th e sprin g fre e lengt h whic h shoul d b e 2 5 m m ( 1 inch) . I f les s tha n 2 2 m m the y shoul d b e changed . Th e ball s shoul d b e fre [...]

  • Seite 99

    5.B 1 Th e pinio n shaf t assembl y 5.B 4 Fittin g firs t gea r o n th e pinio n 5.B 5 Fittin g 1st/2n d gea r clutc h shaf t hu b 5.B 8 Fittin g 2n d gea r an d baul k rin g 5.B 9 Fittin g 3r d gea r an d rolle r bearin g 5.B1 0 Fi t 3r d gea r retainin g cli p 5.B1 2 Fi t th e space r ring , 4t h gea r an d th e 5.B1 3 Drivin g o n th e bearin g [...]

  • Seite 100

    Chapte r 6/Transmissio n an d fina l driv e 10 1 5 E Gea r carrie r - fittin g shaft s an d selecto r fork s 1 I t i s assume d tha t th e selecto r rail s ar e i n orde r (se e Sectio n 4 , paragrap h 7 ) an d th e fork s ar e a correc t fi t i n th e hu b sleev e groove s (Sectio n 4 , paragrap h 6) . 2 Holdin g bot h shaft s togethe r pu t the m[...]

  • Seite 101

    5E.2 A Replacin g th e shaft s i n th e bear - 5E.2 B Th e shaft s i n positio n ing s 5E.4 A Fi t th e dishe d washer s an d circli p 5b.4 B Driv e hom e th e circli p ont o th e pinio n shaf t 5E. 5 Assembl e th e selecto r fork s t o th e correc t rail s 5E.6 A Th e cros s shaf t brackets , rela y leve r an d post s fo r revers e gea r 5E.6 B D [...]

  • Seite 102

    5F.4 a Lowe r th e carrie r an d th e shaft s int o th e casin g 5F.6 b followe d b y th e circli p 5F.4 b I t ma y b e necessar y t o juggl e th e gea r wit h a screwdrive r t o ge t revers e gea r ont o it s shaf t 5F.6 a Replac e th e pinio n shim s 5F.8 a Tighte n th e nut s t o a torqu e o f 2 2 lbs/f t 5F.8 b Lug s correctl y i n positio n 5G[...]

  • Seite 103

    5H. 2 Rene w th e 'O ' ring s o n th e bearin g 5H. 4 Pu t th e differentia l assembl y int o c° ve r th e casin g 5H.5 a Replac e th e shim s .. . 5H.5 b ... . an d th e sid e bearing s 5H.5 c chec k th e mark s mad e whe n dis - mantlin g 5H. 7 replac e th e revers e gea r sleev e ont o th e inpu t shaf t 5H. 8 Fi t th e extensio n sha[...]

  • Seite 104

    FIG.6. 5 GEA R CARRIE R AN D SELECTO R LEVER S - COMPONENT S (Se c 5G ) 1 Gear carrier 2 Bearing drive shaft 3 Needle bearing - pinion shaft 4 Support - shift lever 5 Screw 6 Bracket - relay shaft 7 Relay shaft 8 Reverse lever 9 Support 10 Union nut 11 Clamp sleeve 12 Selector rail. 3rd/4th gear 13 Selector rail - reverse 14 Selector rail - 1st/2nd[...]

  • Seite 105

    10 6 FIG.6. 6 DIFFERENTIA L ASSEMBL Y (Se c 8 ) 1 Taper roller side bearing 2 Crown wheel (ring gear) 3 Differential housing 4 Shaft retaining pin 5 Thrust washer 6 Differential gear and drive shaft 7 Spacer sleeve 8 Differential pinion 9 Thrust washer 10 Pinion shaft 11 Differential gear and drive shaft,short 12 Housing end cover 13 Bolt with spri[...]

  • Seite 106

    Chapte r 6/Transmissio n an d fina l driv e 10 7 6 Synchromes h hu b assemblie s - dismantling , inspectio n an d reassembl y 1 Unles s th e transmissio n i s th e victi m o f neglec t o r misuse , o r ha s covere d ver y hig h mileages , th e synchr o hu b assemblie s d o no t normall y nee d replacement . Unti l recentl y the y coul d onl y b e r[...]

  • Seite 107

    5H.1 3 a Fi t a ne w gaske t , 5H.13 b ... . an d replac e th e clutc h housin g 6.3 b Th e indente d spline s i n th e sleev e mus t lin e u p wit h th e slidin g key s 7. 6 Drivin g a ne w sea l int o positio n 1 Housing bolt 2 Cover 3 Shaft - short 4 Friction cone FIG.6. 8 LIMITE D SLI P DIFFERENTIA L - CON E TYP E (Se c 9 ) 5 Adjusting shim 6 S[...]

  • Seite 108

    Chapte r 6/Transmissio n an d fina l driv e 10 9 Whe n th e leve r i s i n 2n d gea r gea r positio n i t shoul d b e exactl y vertica l wit h th e cranke d uppe r sectio n incline d a t abou t 30 ° t o th e rear . Sideway s movemen t measure d a t th e leve r knob , wit h a gea r engage d shoul d no t excee d 3 5 mm . I n neutra l i t shoul d no [...]

  • Seite 109

    FIG.6. 9 GEA R CHANG E / Knob 2 Gear lever 3 Bellows 4 Moun ting bracket bolt 5 Spring washer 6 Washer 7 Bracket 8 Spring 9 Stop plate 10 Guide sleeve 11 Shift rod front 12 Muff coupling LEVE R AN D ROD S - COMPONENT S (Se c 10 ) 13 Shift rod, rear 14 Bellows 15 Bush, front 16 Bush, rear 17 Self tapping screw 18 Locking cap 19 Insert 20 Housing 21 [...]

  • Seite 110

    Chapte r 7 Whee l shafts , driv e shaft s an d universa l joint s Content s Genera l descriptio n .. . .. . .. . .. . 1 Driv e shaft s - remova l an d replacemen t .. . .. . .. . 2 Constan t velocit y universa l joint s - removal , repai r an d replacemen t .. . .. . .. . .. . .. . .. . .. . 3 Rea r whee l shaft s an d bearing s - remova l an d rep[...]

  • Seite 111

    2. 1 Undoin g driv e shaf t ca p screw , oute r end . Not e spli t rubbe r boo t 2.3 a Removin g th e shaf t fro m th e gea r bo x 2.3 b Removin g th e shaf t fro m th e whee l hu b 3.1 a Fittin g a ne w boot . Firs t th e inne r circlip. . 3.1 b ...the n th e boot.. . 3.1 c pu t th e oute r circli p on.. .[...]

  • Seite 112

    3. 1 d eas e th e boo t ove r th e C. V join t an d tighte n u p 3.5 a Pris e ou t th e en d ca p 3.5 b .. . remov e th e circli p 3.5 c remov e th e C. V join t fro m th e shaf t 3.5 d Discar d th e concav e washer , i f on e i s fitted , behin d th e join t 3.7 a Examinin g a spli t boo t[...]

  • Seite 113

    3.7 b Damag e (arrowed ) o n th e join t oute r rin g 3.7 c Damag e (arrowed ) o n th e join t hu b 3. 8 Constan t velocit y join t - placin g th e hu b sectio n i n th e cag e 3. 9 Fittin g th e ball s int o th e cag e 3.1 0 Fittin g th e hub , balls , an d cag e int o th e oute r sectio n[...]

  • Seite 114

    Chapte r 7/Whee l shafts , driv e shaft s an d universa l joint s 11 5 ma y hav e gon e un-notice d fo r a lon g perio d an d le t i n wate r an d dirt , i t ma y nee d carefu l examinatio n t o decid e whethe r renewa l i s needed . Th e track s i n whic h th e ball s ru n shoul d no t b e groove d o r damage d a t th e edge s i n an y way . Th e [...]

  • Seite 115

    3.1 2 Placin g th e join t o n th e shaf t 3.13 a Placin g th e circli p ove r th e en d o t th e shaf t 3.1 3 b Drivin g th e circli p hom e 3.14 a Repac k th e C. V join t wit h greas e 3.14 b Tappin g th e boo t retaine r plat e bac k ont o th e join t j[...]

  • Seite 116

    11 7 / Split pin 2 Nut 3 Brake drum and hub 4 Back plate assembly 5 Bolt FIG.7. 1 REA R WHEE L SHAF T AN D BEARING S (T O AUGUS T 1970 ) 6 Spring washer 7 Bolt 8 Lock washer 9 Dowel pin 10 Bearing housing 11 Spacer ring 12 Grease seal 13 Ore lip 14 Roller bearing 15 Spacer sleeve 16 Ball bearing 17 Wheel shaft 1 Split pin 2 Nut 3 Bolt 4 Brake drum [...]

  • Seite 117

    Chapte r 8 Brakin g syste m For information applicable to later models, see Supplement at end of manual Content s Genera l descriptio n .. . .. . .. . .. . .. . .. . 1 Brak e adjustmen t (includin g th e han d brake ) .. . .. . 2 Fron t drum s an d brak e shoe s - inspectio n an d renewa l .. . 3 Rea r drum s an d brak e shoe s - inspectio n an a r[...]

  • Seite 118

    Chapte r 8/Brakin g syste m Serv o Boostin g facto r Torqu e wrenc h setting s Tande m maste r cylinder/suppor t screw s .. . Fron t whee l cylinde r an d backplat e o n steerin g knuckl e Dis c calipe r o n steerin g knuckl e .. . Rea r axl e shaf t (fo r brak e drum ) .. . Rea r bac k plat e bolt s 2.0 5 lbs/f t 29/3 3 40/4 3 7 2 25 3 2 5 mk g 4/[...]

  • Seite 119

    2. 7 Th e handbrak e adjuste r # & unde r th e rubbe r gromme t (earl y models ) 3. 2 Fron t dru m brak e B FIG . 8. 1 BRAK E ADJUSTMEN T - MOVEMEN T O F ADJUSTE R WHEEL S T O PU T SHOE S NEARE R THE DRUM S (Sec . 2 ) A Front drum LEFT B Front drum RIGHT viewed from drum side viewed from drum side C Rear drums viewed from either side FI G 8. 2 [...]

  • Seite 120

    9 1 5 FIG . 8. 3 FRON T WHEE L DRU M BRAK E ASSEMBL Y (SEC . 3 ) / C washer (for speedo cable only) 2 Dust cover 3 Bearing clamp nut 4 Thrust washer 5 Wheel bearing 6 Brake drum 7 Brake shoe 8 Return spring 9 Connecting line 10 Adjusting screw 11 Adjusting wheel 12 Bolt 13 Lock washer 14 Brake cylinder 15 Plug 16 Back plate 17 Steering knuckle IS )[...]

  • Seite 121

    I FIG . 8. 4 REA R WHEE L BRAK E ASSEMBL Y (DETACHABL E DRUMS ) 7 2 3 4 5 6 Split pin Nut Socket head screw Brake drum Wheel hub Slotted cup washer 7 8 9 10 11 12 Spring Steady pin Return spring Brake shoe Distance piece Return spring 13 Locating clip 14 Adjuster screw 15 Knurled adjuster 16 Plug 17 Retaining pin 18 Wheel cylinder bolt 19 Spring wa[...]

  • Seite 122

    Chapte r 8/Brakin g syste m 12 3 plat e an d se e tha t th e othe r sho e i s move d b y th e hydrauli c pisto n whe n th e brak e peda l i s depressed . D o no t le t th e pisto n com e righ t ou t o r th e syste m wil l nee d bleedin g afte r reassem - blin g it . I f eithe r pisto n wil l no t mov e i t mus t b e seized . Thi s wil l requir e ov[...]

  • Seite 123

    4.8 a Fittin g th e stead y pin , sprin g an d washe r whils t assemblin g th e righ t rea r brak e sho e assembl y 4.8 b Hookin g th e handbrak e cabl e t o th e leve r o n a righ t rea r brak e assembl y FIG . 8. 5 REA R WHEE L BRAK E ASSEMBL Y (ON E PIEC E HU B AN D BRAK E DRUM ) (SEC . 4 ) 1 Split pin 2 Nut 3 Brake drum and hub 4 Slotted cup wa[...]

  • Seite 124

    Chapte r 8/Brakin g syste m 12 5 6 I f th e pad s ar e t o b e use d agai n mar k wher e the y cam e fro m beforehan d s o the y ma y b e pu t bac k i n th e sam e position . Driv e ou t th e retainin g pin s fro m th e outsid e wit h a lon g nose d punch . Lif t of f th e sprin g plate . 7 Befor e removin g th e ol d pad s i t i s bes t t o forc e[...]

  • Seite 125

    12 6 FIG . 8. 6 FRON T WHEE L HYDRAULI C BRAK E CYLINDE R (SEC . 6 ) 1 Boot 2 Piston 3 Cup 4 Housing 5 Bleed valve 6 Dust cap 7 Adjusting nut 8 Adjusting screw FIG . 8. 7 REA R WHEE L HYDRAULI C BRAK E CYLINDE R (SEC . 6 ) 1 Boot 2 Piston 3 Seal 4 Circlip 5 Housing 6 Bleed valve 7 Dust cap FIG . B B DIS C BRAK E CALIPE R ASSEMBL Y (SEC . 7 ) / Pad [...]

  • Seite 126

    Chapte r 8/Brakin g syste m 12 7 •1 1 Fi t th e ne w oute r seal . 1 2 Repea t th e proces s fo r th e othe r piston . 1 3 Refi t th e calipe r t o th e knuckle , tightenin g th e securin g bolt s t o 7 2 I b ft/1 0 mkg . Replac e th e pisto n retaine r plate s notin g tha t the y shoul d li e flus h agains t th e pisto n an d hav e th e tw o sta[...]

  • Seite 127

    8. 4 Mountin g bol t an d union , maste r cylinde r 8. 6 Fillin g th e maste r cylinde r flui d reservoi r FIG . 8. 9 HYDRAULI C MASTE R CYLINDE R (SINGL E CIRCUIT ) CROS S SECTIO N (SEC . 9 ) 1 Piston 2 Intake port 3 Piston washer 4 Primary cup seal 5 Residual pressure valve 6 Spring 7 Compensating port 8 Secondary cup seal 9 Stop plate tO Circlip[...]

  • Seite 128

    12 9 FIG . 8.1 0 TANDE M MASTE R BRAK E CYLINDE R (SEC . 10 ) Top : Cros s Sectio n 1 Rear brake circuit piston 4 Port 2 Primary cup 5 Primary cup 3 Port I Rear brake circuit TJ Front brake circuit Centre : Tande m brak e maste r cylinde r wit h hydrauli c warnin g devic e u p t o Chassi s 21906156 7 Lower : Tande m brak e maste r cylinde r wit h e[...]

  • Seite 129

    13 0 FIG . 8.1 1 MASTE R CYLINDE R PRESSUR E DIFFERENTIA L INDICATO R PISTO N AN D WARNIN G LAM P SWITCH ; CROS S SECTIO N (SEC . 10 ) / Plug 2 Sealing washer 3 Spring 4 Connecting port 5 Piston 6 Seal cups 7 Warning lamp plunger switch / Primary piston 2 Secondary piston 3 Spring between pistons A From master cylinder FIG . 8.1 2 REA R BRAK E PRES[...]

  • Seite 130

    Chapte r 8/Brakin g syste m 13 1 9 Som e cylinder s incorporat e a pressur e differentia l warnin g system . Thi s consist s o f a singl e pisto n hel d centrall y i n balanc e b y th e equa l pressur e o f th e tw o circuits . I f unequa l pressur e betwee n th e tw o circuit s develop s th e pisto n move s on e wa y o r th e othe r an d operate s[...]

  • Seite 131

    12. 5 Flexibl e hos e mountin g bracke t an d cli p 13. 4 Blee d nippl e ca p removed , righ t han d fron t whee l 1 0 FIG . 8.1 3 BRAK E PEDA L CLUSTE R - EARL Y VERSION S R.H.D . AN D AL L VERSION S L.H.D . (SEC . 14 ) / Bolt 2 Lock washer 3 Nut 4 Seal 5 Brake pedal 6 Split pin 7 Washer 8 Pin 9 Push rod 10 Nut 11 Lock washer 12 Bolt 13 Return spr[...]

  • Seite 132

    13 3 FI G 8.1 4 TYPICA L BRAK E PRESSUR E REGULATO R (Sec . 11 ) FIG . 8.1 5 BRAK E (AN D CLUTCH ) PEDA L CLUSTE R - LAT E VERSION S R.H.D . (SEC . 14 ) 7 Split pin 2 Washer 3 Clevis pin 4 Push rod 5 Master cylinder cap 6 Pin and clip 7 Return spring 8 Nut 9 Lock washer 10 Bolt 11 Push rod 12 Seal 13 Clamp screw 14 Lock washer 15 Brake pedal lever [...]

  • Seite 133

    13 4 1 2 3 4 5 6 Roll pin Handle Ratchet bar stop Cover Screw Lock washer 7 Trim plate 8 Guide sleeve 9 Spring 10 Split pin 11 Washer 12 Pin FIG . 8.1 6 HANDBRAK E LEVE R ASSEMBL Y (SEC . 15 ) 13 Ratchet bar 14 Eye bolt 15 Screw 16 Ratchet bar bracket 17 Boot 18 Nut 19 Washer 20 Anchor pin 21 Spring clip 22 Pin 23 Handbrake lever[...]

  • Seite 134

    Chapte r 8/Brakin g syste m 13 5 th e prope r fluid , a clea n receptacl e an d a tub e whic h wil l fi t ove r th e blee d nippl e securel y an d whic h i s convenientl y lon g enough . A usefu l devic e i s th e tub e whic h i s fitte d wit h a non-retur n valve . Thi s avoid s th e necessit y o f keepin g th e othe r en d o f th e tub e submerge[...]

  • Seite 135

    13 6 732454 1 6 3 FIG . 8.1 7 MODIFICATIO N T O TANDE M BRAK E MASTE R CYLINDE R FO R SERV O ASSISTE D SYSTE M (SEC . 16 ) 15. 5 Vie w o f th e handbrak e cabl e fro m belo w 7 Seal 2 Circlip 3 Washer 5 Washer 7 Rear brake piston 1 Retaining ring 2 Circlip FIG . 8.1 8 SERV O MECHANISM . EXPLODE D VIE W (SEC . 16 ) 3 Air connection 4 Rubber dust exc[...]

  • Seite 136

    Chapte r 8/Brakin g syste m 13 7 1 7 Faul t diagnosi s an d remedie s Befor e diagnosin g fault s i n th e brak e syste m chec k tha t an y irregularitie s ar e no t cause d by : 1 Uneve n an d incorrec t tyr e pressure s 2 Incorrec t 'mix ' o f radia l an d cross-pl y tyre s 3 Wea r i n th e steerin g mechanis m 4 Defect s i n th e suspe[...]

  • Seite 137

    Chapte r 9 Electrica l syste m For modifications, and information applicable to later models, see Supplement at end of manual Content s Genera l descriptio n .. . .. . .. . .. . .. . .. . 1 Batter y - remova l an d replacemen t .. . .. . 2 Batter y - maintenanc e an d inspectio n .. . .. . .. . 3 Electrolyt e replenishmen t .. . .. . .. . .. . .. .[...]

  • Seite 138

    Chapte r 9/Electrica l syste m 13 9 Fuse s N o o f fuse s No 1 N o 2 N o 3 N o 4 N o 5 N o 6 N o 7 N o 8 N o 9 No1 0 No1 1 No1 2 Identification ; Re d 1 6 amp . Whit e 8 am p 196 7 1968-8 9 197 0 1971-7 2 8 1 0 1 2 1 2 Lef t headlamp . Lo w Brak e light s Interio r ligh t Parkin g light s bea m Hor n . Righ t rea r lam p Flasher s Numbe r plat e Ri[...]

  • Seite 139

    14 0 2. 1 Disconnec t th e batter y FIG . 9. 1 DYNAM O COMPONENT S (TYPICA L LAYOUT ) (SEC . 12 ) / Through bolt 2 Lock washer 3 Spacer ring 4 Screw 5 Lock washer 6 Commutator end plate 7 Brush spring 8 Screw 9 Lock washer tO Carbon brush 11 Lock washer 12 Splash shield 13 Ball bearing 14 Splash shield 15 Thrust washer 16 Retaining plate 17 Splash [...]

  • Seite 140

    Chapte r 9/Electrica l syste m 14 1 2 A s wel l a s keepin g th e terminal s clea n an d covere d wit h petroleu m jelly , th e to p o f th e batter y an d especiall y th e to p o f th e cells , shoul d b e kep t clea n an d dry . Thi s help s preven t corrosio n an d ensure s tha t th e batter y doe s no t becom e partiall y discharge d b y leakag[...]

  • Seite 141

    14 2 FIG . 9. 2 DYNAM O AN D REGULATO R TEST S A Voltmete r connectio n fo r n o loa d regulate d voltag e chec k B Voltmete r connectio n fo r n o loa d unregulate d voltag e chec k C Ammete r connectio n fo r curren t outpu t chec k an d revers e curren t chec k[...]

  • Seite 142

    14 3 FIG . 9. 3 STARTE R MOTO R COMPONENT S (BOSCH ) 1 Nut 2 Lock washer 3 Screw 4 Rubber seal 5 Disc 6 Solenoid switch 7 Stop ring 8 Circlip 9 Screw 10 Washer 11 End cap 12 C washer 13 Shim 14 Sealing ring 15 Housing screw 16 End plate 17 Spring 18 Brush holder 19 Grommet 20 Housing 21 Insulating washer 22 Thrust washer 23 Pin 24 Nut 25 Lock washe[...]

  • Seite 143

    14 4 FIG . 9. 4 STARTE R MOTO R COMPONENT S V.W . 1 Nut and lock washer 2 Connecting strip 3 Nut and lock washer 4 Solenoid housing and winding 5 Insulating disc 6 Moulded seal 7 Insulating plate 8 Cap 9 Circlip 10 Steel washer 11 Bronze washer 12 Brush inspection cover 13 Commutator end plate 14 Brush holder and brushes 15 Screw and lock washer 16[...]

  • Seite 144

    Chapte r 9/Electrica l syste m 14 5 th e voltag e shoul d b e approximatel y 1 2 volts . A t twic e thi s spee d th e voltag e shoul d increas e t o 3 6 volts . Chec k quickl y an d switc h of f withi n a fe w seconds . I f th e voltag e i s ni l o r lo w the n th e generato r i s faulty . 1 0 Dynam o - curren t outpu t chec k an d revers e curren [...]

  • Seite 145

    10. 2 Terminal s D+an d D F o n th e generato r 11. 1 Th e regulato r i s behin d th e ai r cleane r i n th e engin e compartmen t 12.2 a Removin g th e apertur e cove r fro m th e dynam o 12.2 b Hookin g u p sprin g t o pul l th e brus h fro m th e holde r 1 2.2 c Und o th e brus h termina l ta g scre w 12. 4 Brus h an d sprin g correctl y fitte d[...]

  • Seite 146

    13. 2 Removin g th e starte r to p bolt . Not e th e bol t hea d an d ter - mina l (arrowed ) fo r th e mai n cabl e connectio n 13. 3 D o no t confus e th e tw o nut s o n th e solenoi d 14.2 a Undoin g th e connectin g stra p termina l nu t 14.2 b Removin g th e solenoi d retainin g screw s 14. 3 Unhoo k th e solenoi d fro m th e operatin g leve [...]

  • Seite 147

    14.6 a Remov e th e U cli p fro m th e en d o f th e shaf t 14.6 b an d th e shi m washer s 14.7 a Remov e th e throug h bolt s 14.7 b Tak e of f th e en d cove i 14. 8 Lif t th e yok e an d brus h holde r assembl y of f th e armatur e 14. 1 2 Refi t th e yok e s o tha t th e tongu e an d cu t ou t fi t togethe r[...]

  • Seite 148

    Chapte r 9/Electrica l syste m 14 9 holder s an d pus h the m t o on e sid e s o tha t th e pressur e i s relieved . Th e yok e complet e wit h th e brus h holde r mountin g plat e ma y the n b e draw n ,of f th e armature . Watc h ou t fo r th e washer s o n th e en d o f th e shaf t (photo) . 9 T o rene w th e brushes , tw o ma y b e detache d b [...]

  • Seite 149

    FIG . 9. 5 WINDSCREE N WIPE R SPINDL E AN D BEARIN G ASSEMBL Y 7 Cap nut (early models had clamp nuts) 2 Lock washer 3 Wiper arm 4 Bearing cover 5 Circlip 6 Nut 7 Washer 8 Seal 9 Shaft bearing 10 Spring washer 11 Brass nut 12 Spring washer 13 Wiper shaft 15. 1 Th e fus e bo x i s locate d unde r th e das h panel . 15. 4 Pr e Augus t 196 9 th e rela[...]

  • Seite 150

    Chapte r 9/Electrica l syste m 15 1 o f th e remova l procedure . Whe n refittin g th e uni t t o th e ca r mak e sur e th e spindle s ar e a t righ t angle s t o th e windscreen . Th e mountin g hol e i n th e fram e i s slotte d t o permi t adjustment . Th e earthin g stri p contac t a t th e mountin g scre w shoul d b e clean . 9 Th e sealin g w[...]

  • Seite 151

    23. 1 Th e sto p ligh t switc h i s connecte d t o th e fou r wa y distribu - to r jus t ove r th e maste r cylinde r 24. 2 Pris e ou t th e ca p fro m th e centr e o f th e steerin g whee l 24. 5 A s a las t resor t tr y movin g th e adjustin g scre w 25.1 a Tw o screw s t o remov e th e rea r lam p len s 25. 1 b Tw o screw s t o remov e th e fron[...]

  • Seite 152

    15 3 FIG . 9. 6 BRAK E LIGHT/BRAK E PRESSUR E WARNIN G SWITCHES . CIRCUI T DIAGRA M (SEC . 23 ) a. b. current feed to brake lights 1 Rim securing screw 2 Rubber washer 3 Rim FIG . 9. 7 SEALE D BEA M HEADLAMP S - COMPONENT S (SEC . 25 ) 4 Securing ring screw 5 Retaining ring screw 6 Retaining ring 7 Sealed beam unit 8 Aiming ring with 2 aiming screw[...]

  • Seite 153

    15 4 FIG . 9. 8 HEADLAM P BEA M AIMIN G DIMENSION S SEALE D BEA M UNITS . RIGH T SID E DI P A Distanc e betwee n lam p centre s (108 0 mm/42. 5 ins ) B Heigh t o f lam p centr e abov e groun d (measur e o n vehicle ) D 2. 0 ins/5 0 m m H Lam p horizonta l centr e lin e V Lam p vertica l centr e line s FIG . 9. 9 HEADLAM P BEA M AIMIN G DIMENSIONS ,[...]

  • Seite 154

    Chapte r 9/Electrica l syste m 15 5 plu g i s connecte d th e correc t wa y roun d — gre y wir e positive . 3 Al l doubl e filamen t bulb s fi t onl y on e wa y roun d becaus e th e wattag e o f eac h filamen t i s differen t - th e flashe r filamen t bein g brighter . Fo r thi s reaso n th e bayone t pin s ar e offset . Se e tha t yo u ge t the [...]

  • Seite 155

    26. 2 Eas e th e pane l forwar d an d disconnec t th e speed o cabl e 26. 3 Th e connection s a t th e rea r o f th e pane l 28.1 a Und o th e screw s holdin g th e switc h t o th e colum n (Not e steerin g whee l ha s bee n remove d t o giv e a bette r photo ) 28.1 b Disconnec t th e cable s t o tak e th e switc h of f 25. 5 Tur n th e bul b holde[...]

  • Seite 156

    Chapte r 9/Electrica l syste m 15 7 secon d perio d an d measure s to e an d cambe r an d print s ou t th e answe r i n degree s an d minutes . Th e ignitio n an d chargin g system s ar e measure d b y th e resistance s o f th e variou s circuits . I t i s importan t tha t al l connection s ar e clea n an d tha t cabl e size s ar e standard . Th e [...]

  • Seite 157

    15 8 WIRIN G DIAGRA M 196 8 T O 196 9 EXCEP T NORT H AMERICA N MODEL S A B C C 1 D L U E 1 E 2 E 6 E 9 F F 1 G H H 1 J J 1 J 3 K 1 K 2 K 3 K 4 K 5 L 1 L 2 L 6 L 7 L 8 M 1 M 2 M 3 M 4 M 5 M 6 M 7 M 8 N N 1 N 3 0 P 1 P 2 P 3 P 4 Q 1 Q 2 Q 3 Q 4 R S T T 1 V V 2 Batter y Starte r Generato r Regulato r Ignition/starte r loc k Windscree n wipe r switc h [...]

  • Seite 158

    15 9 WIRIN G DIAGRA M 196 8 T O 196 9 NORT H AMERICA N MODEL S A B C C 1 D E F G H H 1 J J 1 J 2 J 3 J 4 J 5 J 6 J 7 J 9 K 1 K 2 K 3 K 4 K 5 K 6 K 7 K 8 K 9 L 1 L 2 M l M 2 N 0 0 1 0 2 P 1 P 2 P 3 P 4 Q 1 Q 2 Q 3 Q 4 R R 1 S S 1 T 1 U 1 U 2 W X 1 X 2 Y Y 1 Z Z 1 Batter y Starte r Generato r Regulato r Ignition/starte r switc h Windshiel d wipe r sw[...]

  • Seite 159

    WIRIN G DIAGRA M 197 2 ONWARD S EXCEP T NORT H AMERICA N MODEL S O A B C C 1 D E E 1 E 2 E 3 E 6 F F 1 F 2 F 3 F 4 G G 1 H H 1 J J 2 K K 1 Batter y Starte r Generato r Regulato r Ignition/starte r loc k Windscree n wipe r switc h Lightin g switc h Tur n signa l switc h (switc h fo r han d dimme r an d headligh t flasher ) Emergenc y flashe r switc [...]

  • Seite 160

    WIRIN G DIAGRA M 197 2 ONWARD S EXCEP T NORT H AMERICA N MODEL S O )[...]

  • Seite 161

    WIRIN G DIAGRA M 197 2 ONWARD S NORT H AMERICA N MODEL S A Batter y B Starte r C Generato r C 1 Regulato r D Ignition/starte r switc h E Windshiel d wipe r moto r E 1 Lightin g switc h E 2 Tur n signa l an d headligh t dimme r switc h E 3 Emergenc y flashe r switc h E 6 Switc h fo r interio r light , rea r E 9 Fa n moto r switc h E1 5 Heate d rea r[...]

  • Seite 162

    M WIRIN G DIAGRA M 197 2 ONWARD S NORT H AMERICA N MODEL S s[...]

  • Seite 163

    H 105*1 FIG . 9.1 2 INSTRUMEN T CONSOL E (CLOC K NO T SHOWN ) Turn signal warning lights Generator warning light High beam warning light Parking light warning light Oil pressure warning light 6 Instrument illumination light 7 Warning light holder 8 Fuel gauge 9 Speedometer[...]

  • Seite 164

    Chapte r 1 0 Suspension , damper s an d steerin g For information applicable to later models, see Supplement at end of manual Contint s Specification ! Wheelbei B 2,40 0 m m (94. 5 in ) Trac k Front - dru m brake s 138 4 m m (54. S In ) Fron t - dis c brake s 138 6 m m (54. 6 in ) Rea r 142 6 m m (56. 1 in ) Turnin g circl e Kerb s 11. 3 m (37. 1 f[...]

  • Seite 165

    7 3 FIG.10. 1 FRON T AXL E ASSEMBL Y (Se c 1 an d 17 ) 7 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Caliper bolt Shouldered bolt Spring washer Caliper Hub cap Bearing nut clamp screw Bearing clamp nut Thrust washer Taper roller bearing, outer Brake drum Socket head screw Brake disc Wheel hub Backplate bolt Spring washer Front brake 17 Bolt 18 Spring washer [...]

  • Seite 166

    Chapte r 10/Suspension , damper s an d steerin g Steerin g geometr y To e i n *fron t whee l unpresse d .. . .. . .. . .. . 1571. 6 m m •fron t whee l 1 5 K g pressur e .. . .. . .. . 570. 6 m m rea r whee l t5'±10 ' *Not e to e i n variation s o f 1 571. 6 m m eithe r wa y ar e acceptabl e f Cambe r angl e Fron t whee l + 40' 1 2[...]

  • Seite 167

    1.1 a Vie w o f th e steerin g knuckle s an d bal l joint s (whee l an d dru m remove d t o giv e cleare r photo ) 1.1 b Genera l vie w o f th e fron t suspensio n an d steerin g linkag e fro m beneat h I • 2.1 a Greas e poin t i n th e centr e o f th e axl e bea m an d 2.1 b on e a t eac h en d FIG.10. 2 DIMENSION S O F SPECIA L LEVE R REQUIRE D[...]

  • Seite 168

    Chapte r 10/Suspension , damper s an d steerin g 16 9 Prio r t o 197 2 th e steerin g gea r wa s o f th e wor m an d pe g typ e bu t i n 197 2 thi s change d t o wor m an d roller . A t th e sam e tim e th e steerin g rati o wa s increase d makin g th e steerin g lighte r tha n before . Th e linkag e fro m th e steerin g gea r t o th e wheel s requ[...]

  • Seite 169

    3.7 a Bearin g packe d wit h greas e 3.7 b fi t th e oute r bearin g 3.7 c followe d b y th e thrus t washe r 3.7 d replac e th e clam p nu t t 3. 8 an d tighte n th e socke t hea d ser e 4. 1 Th e plu g ma y b e replace d b y a greas e nippl e[...]

  • Seite 170

    Chapte r 10/Suspension , damper s an d steerin g ar m the y shoul d b e renewe d b y a specialis t wit h th e correc t tools . I f yo u hav e alread y carrie d th e dismantlin g o f th e fron t axl e a considerabl e wa y i t ma y b e simples t t o disconnec t th e brake s an d steerin g gea r a s wel l an d detac h th e whol e assembl y fro m th e [...]

  • Seite 171

    17 2 1 8 1 Frame 2 Diagonal arm 3 Bearing housing 4 Spring plate 5 Torsion bar 6 Inner and outer bushes FIG.10. 3 REA R SUSPENSIO N ASSEMBL Y (Se c 9 ) 7 Cover for spring plate bearing 13 Bolt 8 Bolt 14 Washer 9 Spring washer 15 Spring washer 10 Bolt 16 Nut 11 Spring washer 17 Shock absorber 12 Bolt 18 Bolt 19 Lock washer 20 Spring washer 21 Nut 22[...]

  • Seite 172

    Chapte r 10/Suspension , damper s an d steerin g 17 3 clockwis e o n th e oute r en d b y 8 spline s (60° ) th e ne t increas e i n th e angl e wil l b e 65 ° 20 ' les s 60 ° whic h i s 5 ° 20 ' an d a s nea r a s on e ca n get . I n exampl e B B th e inne r en d o f th e ba r i s rotate d clockwis e 3 spline s (24 ° 30' ) an d [...]

  • Seite 173

    17 4 nea r suspensio n sprin g plat e angl e bod y lin e angl e FIG.10. 4 REA R SUSPENSION . SPRIN G PLAT E SETTIN G ANGL E CALCULATION - (Se c 10 ) B FI G 10. 5 ADJUSTIN G REA R WHEE L CAMBE R B Y ALTER - IN G THE TORSIO N BA R ANGLE S THROUG H ROTATIO N O F TH E DIAGONA L ARM S (Sec . 10 ) FI G 10. 6 ADJUSTIN G REA R WHEE L TOE-I N USIN G SPECIA [...]

  • Seite 174

    17 ! FIG . 10. 7 WOR M AN D PE G STEERIN G GEA R - COMPONENT S (Se c 13 ) Bolt and washer 7 Spring washer Adjusting screw and lock nut 8 Special washer Cover for gear case 9 Taper rollers Nut 10 Lever shaft Tab washer 11 Peg Washer 12 Dust seal 13 Bolt and washer 14 End cover 15 Shim 16 Retaining ring 17 Ball race 18 Steel balls 19 Steering worm 20[...]

  • Seite 175

    17 6 15. 4 Th e bal l join t betwee n th e dra g lin k an d th e dro p arm ; not e th e numbe r o f thread s visibl e befor e undoin g th e clam p FIG . 10. 8 WOR M AN D ROLLE R STEERIN G GEA R - CROS S SECTION S (Se c 13 ) 1 Roller shaft dust seal 2 Oil seal 3 Roller shaft 4 Worm shaft 5 Housing 6 Lower ball thrust bearing 7 Upper ball thrust bear[...]

  • Seite 176

    Chapte r 10/Suspension , damper s an d steerin g 1 3 Steerin g gea r - overhau l 1 Th e decisio n t o dismantl e an d rebuil d a steerin g gea r assem - bl y wil l depen d t o a larg e exten t o n th e availabilit y o f parts . I t i s inevitabl e tha t i f adjustment s fai l t o rectif y pla y adequatel y the n mos t o f th e interio r component s[...]

  • Seite 177

    17 8 FIG . 10. 9 STEERIN G COLUM N ASSEMBL Y (Se c 14 ) 1 Nut 2 Fillister head screw 3 Lock washer 4 Cancelling ring 5 Steering wheel 6 Cheese head screw 7 Spring washer 8 Plastic clamping ring 9 Cap 10 Seal 11 Screw 12 Lock plate 13 Nut 14 Flange 15 Cotter pin 16 Slotted nut 17 Spring washer 18 Screw 19 Coupling disc 20 Column shaft 21 Insulating [...]

  • Seite 178

    Chapte r 10/Suspension , damper s an d steerin g 17 9 axl e tube ) b y fittin g th e securin g bolt s an d nut s an d tightenin g the m t o th e specifie d torques . 1 7 Fron t axl e assembl y - remova l an d replacemen t 1 I f th e fron t axl e assembl y i s badl y wor n o r damage d requirin g a considerabl e amoun t o f repai r (o r tota l repla[...]

  • Seite 179

    FIG . 10.1 0 STEERIN G LINKAG E AN D BAL L JOINT S (Se c 15 ) / Screw 2 Lock washer 3 Split pin 4 Nut 5 Spring washer 6 Screw 7 Washer 8 Steering damper 9 Sleeve 10 Bush 11 Split pin 12 Nut 13 Left tie rod 14 Right tie rod 15 Nut 16 Spring washer 17 Screw 18 Clip 19 Tie rod ball joint R.H.thread 20 Tie rod ball joint L.H. thread 21 Dust seal 22 Loc[...]

  • Seite 180

    Chapte r 10/Suspension , damper s an d steerin g 18 1 2 1 Faul t diagnosi s Befor e diagnosin g fault s i n th e mechanic s o f th e suspensio n an d steerin g itself , chec k tha t an y irregularitie s ar e no t cause d by: — p Bindin g brake s Incorrec t 'mix ' o f radia l an d cross-pl y tyre s Incorrec t tyr e pressure s Misalignmen[...]

  • Seite 181

    Chapte r 1 1 Bodywor k an d underfram e For modifications, and information applicable to later models, see Supplement at end of manual Content s Genera l descriptio n .. . .. . .. . .. . .. . .. . 1 Maintenanc e - bodywor k .. . .. . .. . .. . .. . 2 Maintenanc e - upholster y an d floo r covering s .. . .. . 3 Mino r bod y damag e - repai r .. . .[...]

  • Seite 182

    Chapte r 1 1 /Bod y 18 3 th e hea d linin g clea n i n th e sam e wa y a s th e upholstery . Whe n usin g liqui d cleaner s insid e th e ca r d o no t over-we t th e surface s bein g cleaned . Excessiv e dam p coul d ge t int o th e seam s an d padde d interio r causin g stains , offensiv e odour s o r eve n rot . I f th e insid e o f th e ca r get[...]

  • Seite 183

    18 4 FIG.11. 1 FLOO R FRAM E 1 Side member, rear 2 Side member insert, rear 3 Cross tube with flange 4 Outrigger, rear 5 Outrigger, centre 6 Support, rear member 7 Heater tube 8 Side member, front 9 Outrigger, front 10 Side member insert 11 Seat box 12 Stiffener between side member inserts 13 Cross member, front 14 Front cross support FIG.11. 2 BOD[...]

  • Seite 184

    Chapte r 1 1 /Bod y 18 5 wil l ensur e tha t a ver y smoot h finis h i s imparte d t o th e fille r a t th e fina l stage . A t thi s stag e th e den t shoul d b e surrounde d b y a rin g o f bar e metal , whic h i n tur n shoul d b e encircle d b y th e finel y 'feathered ' edg e o f th e goo d paintwork . Rins e th e repai r are a wit h[...]

  • Seite 185

    9.4 a Chec k stra p lubricatio n 9.4 b Doo r hing e lubricatio n 10.1 a Remov e th e windo w winde r handl e 10. 1 b Pris e ou t th e doo r latc h finge r plat e 10.1 c Remov e th e escutcheo n retainin g scre w 10. 3 D o no t forge t th e rubbin g washe r behin d th e windo w winde r handl e[...]

  • Seite 186

    Chapte r 1 1 /Bod y 18 7 vehicl e b y fou r countersun k crosshea d screws . Ther e i s als o a doo r chec k stra p whic h i s hel d b y a pin . Th e pi n ca n b e take n ou t afte r retainin g cli p i s take n of f it s lowe r end . 2 T o slacke n th e hing e screw s a n impac t screwdrive r i s essen - tial . Similarl y fo r tightenin g the m pro[...]

  • Seite 187

    18 8 FIG . 11. 3 DOO R LATC H STRIKE R PLAT E (Se c 15 ) Slackening of screws enables plate to be moved in any direction FIG.11. 4 CA B DOO R HANDL E AN D LOC K CYLINDE R - EARL Y MODEL S (Se c 16 ) / 2 3 4 Operating pin Rotary spring Circlip Locating ring 5 6 7 Spring Lock cylinder housing Casket 8 9 10 Setscrew Seal O • ring 11 Lock cylinder 12[...]

  • Seite 188

    Chapte r 1 1 /Bod y 18 9 1 7 Slidin g doo r mechanis m - descriptio n an d adjustmen t 1 Th e slidin g doo r run s i n thre e channels . A t th e bottom , a rolle r bracke t fitte d a t th e fron t corne r support s weigh t an d guide s th e doo r i n a channe l fitte d alon g th e botto m o f th e doo r opening . I n th e centr e a rolle r bracke [...]

  • Seite 189

    19 0 FIG.11. 6 SLIDIN G DOOR-LOWE R ROLLER S AN D BRACKE T FIG.11. 7 SLIDIN G DOO R - TO P GUID E ROLLE R AN D (Se c 17 ) BRACKE T (Se c 17 ) Arrows indicate movement and shims Arrow indicates roller movement for door position adjustment. Bracket screws are loosened to move roller into channel recess. FIG.11. 8 SLIDIN G DOO R - HING E LIN K SHOWIN [...]

  • Seite 190

    FIG.11.1 1 REMOTECONTRO L LATC H (LEFT ) AN D CENTR E LATC H (RIGHT ) SHOWIN G POSITION S O F SETTIN G SCREW S O R PIN S (Se c 17 ) FIG.11.1 3 SLIDIN G DOO R - REMOVIN G TH E DOO R RETAINE R CATC H (Se c 18 ) FIG.11.1 4 SLIDIN G DOO R - CENTR E RUNNE R COVE R COMPONENT S (Se c 18 ) 7 Beading 2 Cover 3 Retaining strip FIG.11.1 5 SLIDIN G DOO R - CEN[...]

  • Seite 191

    19 2 7 Return spring 2 Hinge link 3 M6nut 4 Lock washer 5 Roller bracket 6 Guide block FIG.11.1 6 SLIDIN G DOOR - HING E LIN K ASSEMBL Y COMPONENT S (Se c 18 ) 7 Roller and bearing 8 Phillips screw 9 Spring washer 10 M 6 nut (thin) 11 Housing 12 Circlip 13 Pivot 14 Pin 15 Operating cam 16 Spring washer 17 M8 nut 18 Washer 19 Lower locking lever 20 [...]

  • Seite 192

    Chapte r 11/Bod y 19 3 4 Chec k th e hekjh t o f th e rea r en d o f th e roof . Thi s i s don e b y swingin g th e lea f spring s ou t t o on e sid e an d the n slackenin g th e hexago n loc k nu t an d screw . Mov e th e lifte r pi n i n th e elongate d hol e t o correc t th e height , (Fig.11.17) , a t th e sam e tim e th e rea r guide s ca n b [...]

  • Seite 193

    Chapte r 1 2 Supplement : Revision s an d informatio n o n late r model s Content s Introductio n .. . .. . .. . .. . .. . .. . .. . 1 Revise d routin e maintenanc e schedule s (196 8 t o 1974 ) .. . 2 Specification s .. . .. . .. . .. . .. . .. . .. . 3 Engin e .. . .. . .. . .. . .. . .. . .. . .. . 4 Pushro d tube s - remova l wit h engin e i n [...]

  • Seite 194

    Chapte r 12/Supplemen t 19 5 3 Specification s Fuel system Carburetto r (Augus t 197 5 on ) Typ e Mai n je t Ai r correctio n je t Pilo t je t Auxiliar y fue l je t Enrichmen t Needl e valv e washe r Idl e spee d C O level ' Fue l octan e Ignition system Distributo r (fro m Augus t 197 5 - Numbe r 04 3 90 5 20 5 L ) Timin g Dwel l angl e Centr[...]

  • Seite 195

    19 6 Chapte r 12/Supplemen t 1 0 1 1 1 2 Fuse identification Supplementar y heate r (Nort h America ) Rea r interio r lam p (u p t o 1974 ) Supplementar y heate r (Nort h America ) Heate d rea r windo w Windscree n wiper s Reversin g lamp s Fue l gaug e Kickdow n (automati c transmissio n excep t 1976 ) Directio n indicator s Generato r warnin g la[...]

  • Seite 196

    Chapte r 12/Supplemen t 19 7 4 Engin e Pushrod tubes - renewal with engine in position 1 Damage d o r leakin g pushro d tube s ca n b e renewe d withou t th e necessit y o f removin g th e engine . 2 Refe r t o Chapte r 1 an d remov e th e rocke r cover . 3 Remov e th e rocke r shaf t an d withdra w th e pushrods . 4 Usin g a screwdriver , leve r t[...]

  • Seite 197

    19 8 Chapte r 12/Supplemen t FIG.12. 5 CROS S SECTIONA L VIE W O F MODIFIE D 1ST/2N D SYNCHR O HU B GROOV E (ARROWED ) FIG.12. 6 GEARCHANG E RO D BUS H FITTIN G DIAGRA M a 43.03 in (1093 mm) 9 Hav e th e engin e a t th e norma l operatin g temperatur e an d idlin g speed . Mak e sur e tha t th e chok e i s full y OFF . 1 0 Pul l th e distributo r v[...]

  • Seite 198

    19 J FIG.12. 7 TYP E 09 1 GEARBO X FINA L DRIV E AN D BELLHOUSIN G COMPONENT S / 2 3 4 Clutch bellhousing Input shaft Circlip Reverse gear 5 6 7 8 Differential Gasket Gearcase Adjusting ring 9 10 11 12 Lockplate Plate Driving flange Thrust washer 13 14 Circlip Plastic plug[...]

  • Seite 199

    20 0 Chapte r 12/Supplemen t FIG.12. 8 REMOVIN G A N ADJUSTE R RIN G USIN G TH E SPECIA L TOO L FIG.12. 9 REMOVIN G PINIO N DRIVESHAF T RIN G NU T USIN G TH E SPECIA L TOO L nut . Mak e sur e thi s i s marke d als o befor e movin g it . Th e bracket s whic h suppor t th e revers e selecto r cros s shaft s ar e als o adjust - abl e an d mus t b e ma[...]

  • Seite 200

    FIG.12.1 0 MAINSHAF T COMPONENT S ; 2 3 4 4th speed gear Baulk ring Needle bearing Circlip 5 6 7 3rd/4th synchro assembly Circlip Baulk ring 8 9 10 11 3rd speed gear Needle bearing Mainshaft Spring 12 13 14 15 Synchro sleeve Synchro hub Sliding keys Spring[...]

  • Seite 201

    20 2 FIG.12.1 1 COMPONENT S O F TH E PINIO N DRIVESHAF T 1 3 5 6 1 Anti-rotation ring 2 1st gear needle bearing 3 Combined 1st gear needle bearing/locknut 4 Tapered roller bearing Pinion shaft Circlip 7 4th speed gear 8 Spacer spring 9 Circlip 10 3rd speed gear 11 2nd speed gear 12 2nd gear needle bearing 13 Baulk ring 14 Circlip 15 1st/2nd synchro[...]

  • Seite 202

    Chapte r 12/Supplemen t 20 3 FIG.12.1 2 REMOVIN G ANTI-ROTATIO N RIN G FRO M 1ST/2N D SYNCHR O HU B betwee n th e baul k rin g an d th e gea r teet h wit h feele r blades . Th e ga p shoul d b e withi n th e followin g limits : 1st/2nd 0.023 and 0.071 in (0.60 and 1.80 mm) 3rd/4th 0.023 and 0.075 in (0.60 and 1.9 mm) Otherwis e rene w th e componen[...]

  • Seite 203

    FIG.12.1 3 COMPONENT S O F TH E GEA R CARRIE R / 2 3 4 5 Intermediate selector lever Ball joint Link Selector lever shaft Coil springs 6 7 8 9 10 Stop Intermediate selector lever bracket 3rd'/4th selector rod Reverse selector rod 1st/2nd selector rod 11 12 13 14 15 16 Detent hole plug Detent ball Detent spring Detent sleeve Plug Pinion drivesh[...]

  • Seite 204

    20 5 FIG.12.1 5 SYNCHR O SID E T O SID E SPRIN G LOCATIO N FIG.12.1 4 3RD/4T H SYNCHR O HU B AN D SLEEV E Line on hub must be at bottom (black arrow) when groove on sleeve is uppermost (white arrow) FIG.12.1 6 1ST/2N D SYNCHR O HU B AN D SLEEV E FIG.12.1 7 SECTIONA L VIE W O F DETENT/SELECTO R SHAF T ARRANGEMEN T SHOWIN G POSITIO N O F INTERLOC K P[...]

  • Seite 205

    206 Chapte r 12/Supplemen t (shoulde r toward s 2n d gear) , circlips , space r spring , 4t h gea r (shoulde r toward s spring ) an d th e circlip , bu t not e th e followin g points . 6 9 Befor e pressin g th e 1st/2n d synchr o ont o th e driveshaft , fi t a ne w anti-rotatio n ring . 7 0 Onc e 3r d spee d gea r i s fitted , us e feele r blade s [...]

  • Seite 206

    Chapte r 12/Supplemen t 20 7 9 9 Adjus t th e unio n nu t o n th e revers e rocke r leve r suppor t unti l th e suppor t i s jus t fre e t o slid e i n an d ou t o f it s clam p sleeve . 10 0 Pus h th e revers e (middle ) selecto r shaf t unti l it s circli p contact s th e fac e o f th e gea r carrier . Han d tighte n th e unio n nut . 10 1 Withou[...]

  • Seite 207

    20 8 Chapte r 12/Supplemen t / Housing 2 Bush FIG . 12.2 4 GEARSHIF T HOUSIN G COMPONENT S 3 Inner selector lever 4 Spacer Seal 12 1 Se t th e left-han d differentia l bearin g adjustin g rin g t o it s originall y marke d positio n (se e paragrap h 54 ) b y screwin g i t i n th e tur n whic h i t wa s backe d off . 12 2 Refi t th e component s det[...]

  • Seite 208

    Chapte r 12/Supplemen t 20 9 FIG.12.2 5 GIRLIN G TYP E CALIPE R ; 2 3 Disc/hub Caliper body Bleed screw 4 5 6 Anti-rattle spring Pad retaining pin Pin securing clip 7 8 9 Piston seal Piston Dust excluder 10 11 12 Retaining ring Anti-squeal shim Friction pad o f th e calipe r together . I f flui d i s see n t o b e leakin g fro m th e joint , rene w[...]

  • Seite 209

    21 0 1 5 2 2 FIG.12.2 6 BRAK E MASTE R CYLINDE R (WITHOU T SERVO ) / 2 3 4 5 6 7 Stop lamp switch Stop lamp switch Sealing plug Master cylinder body Stop bolt Spring Support ring 8 9 10 11 12 13 14 Washer Cup seal Cup washer Secondary piston Piston seal Piston seal Stroke limiting screw 15 16 17 18 19 20 21 Stop sleeve Spring Support ring Washer Cu[...]

  • Seite 210

    21 1 FIG.12.2 7 BRAK E MASTE R CYLINDE R (WIT H SERVO ) / 2 3 4 5 6 7 Plug Stop bolt Stop lamp switch Stop lamp switch Master cylinder body Sealing ring Spring 8 9 10 11 12 13 14 Support ring Cup seal Cup washer Secondary piston Piston seal Piston seal Stroke limiting screw 15 16 17 18 19 20 21 Stop sleeve Spring Support ring Cup seal Support ring [...]

  • Seite 211

    21 2 Chapte r 12/Supplemen t FIG.12.2 8 INSTRUMEN T PANE L RETAININ G CLIP S th e pane l an d twis t th e pane l securin g clip s unti l th e pane l ca n b e draw n forwar d fa r enoug h fo r th e speedomete r cabl e t o b e disconnected . 4 Disconnec t th e wirin g havin g firs t identifie d th e wire s an d terminals . 5 Remov e th e instrumen t [...]

  • Seite 212

    Chapte r 12/Supplemen t 21 3 a - To starter b - Diagnosis leads X - Battery cut-out switch FIG. 12.3 0 ALTERNATO R TES T CIRCUI T A - Ammeter (0 to 50 amps) V - Voltmeter 10 to 18V) R - Load resistance (0.2 to 2 ohms/50 amp) Speedometer drive cable - renewal 1 1 Th e speedomete r i s drive n throug h a flexibl e cabl e fro m th e left-han d fron t [...]

  • Seite 213

    21 4 Chapte r 12/Supplemen t 2 5 Th e alternato r system s us e a negativ e earth . Car e mus t b e take n no t t o revers e th e batter y connectio n o r damag e t o th e diode s wil l b e extensive . Neve r ru n th e alternato r wit h th e outpu t wir e disconnected . 2 6 Alway s disconnec t th e batter y completel y i f a n outsid e chargin g op[...]

  • Seite 214

    1 7 FIG.12.3 2 EXPLODE D VIE W O F TH E ALTERNATO R ; 2 3 4 5 Spacer Fan end plate Bearing Bearing retainer Washer 6 7 8 9 Cover plate Regula tor/brush assembly Body Insulating plate 10 11 12 13 14 Diode assembly Stator Rotor Washer Bearing 15 16 17 Spacer Spring Drive end plate[...]

  • Seite 215

    216 FIG.12.3 3 WINDSCREE N AN D HEADLAM P WASHE R SYSTE M 1 Washer fluid reservoir 2 Headlamp washer pump 3 Headlamp washer jets 4 Windscreen washer jets 5 Windscreen washer pump FIG.12.3 4 STEERIN G COLUM N LOC K HOUSIN G SECURIN G SCREW S FIG.12.3 5 STEERIN G COLUM N LOC K (T O HOUSING ) SCREW S O N LATE R MODEL S[...]

  • Seite 216

    Chapte r 12/Supplemen t 21 7 FIG.12.3 6 STEERIN G COLUM N LOC K AN D SWITCHE S (197 5 ON ) 1 2 3 4 5 6 Direction indicator switch Wiper switch Column/switch upper trim Cover plate Spacer Switch/lock housing 7 8 9 10 Lock cylinder Lock spear head screw Ignition switch Column/switch lower trim housin g lowe r tri m t o th e bas e o f th e steerin g l[...]

  • Seite 217

    21 8 Chapte r 12/Supplemen t rolle r shaf t t o preven t the m cuttin g th e lip s o f th e oi l sea l a s i t i s fitted . 9 Appl y greas e t o th e lip s o f th e sea l an d driv e i t int o positio n usin g a piec e o f tubing . 1 0 Refi t th e dro p arm , correctl y aligned , fi t a ne w lockplat e an d tighte n th e nu t t o a torqu e wrenc h [...]

  • Seite 218

    ^ [...]

  • Seite 219

    Conversio n factor s Inche s (in ) X Fee t (ft ) X Mile s X Volume (capacity) Cubi c inche s (c u in ; in 3 ) X Imperia l pint s (Im p pt ) X Imperia l quart s (Im p qt ) X Imperia l quart s (Im p qt ) X U S quart s (U S qt ) X Imperia l gallon s (Im p gal ) X Imperia l gallon s (Im p gal ) X U S gallon s (U S gal ) X Mass (weight) Ounce s (oz ) X [...]

  • Seite 220

    Safet y first ! Professiona l moto r mechanic s ar e traine d i n saf e workin g proce - dures . Howeve r enthusiasti c yo u ma y b e abou t gettin g o n wit h th e jo b i n hand , d o tak e th e tim e t o ensur e tha t you r safet y i s no t pu t a t risk . A moment' s lac k o f attentio n ca n resul t i n a n accident , a s ca n failur e t o[...]

  • Seite 221

    Inde x Ai r cleane r 58,19 7 Ai r contro l flap s - 4 8 Alternato r adjustment - 214 descriptio n an d precautions - 21 3 driveshaft-21 4 overhau l - 214 remova l an d refittin g - 214 testin g i n positio n - 214 Auxiliar y heate r 5 2 Axle , front , remova l 17 9 Axl e shafts - 11 5 B Balljoin t steerin g - 17 7 suspensio n - 16 9 Batter y chargi[...]

  • Seite 222

    Inde x headlam p washers - 21 4 ' heate d rea r window-21 2 horn - 15 1 instrumen t pane l - 20 9 lamps - 15 1 regulato r - 14 5 speedomete r driv e cabl e - 21 3 starte r moto r - 14 5 steerin g colum n switche s - 21 4 stoplight - 15 1 warnin g buzzer - 21 2 windscree n washe r - 15 1 windscree n wiper - 149,15 1 wirin g diagram s - 157,15 9[...]

  • Seite 223

    Inde x Piston s assembl y t o conro d - 3 2 assembl y t o cylinde r - 3 2 fittin g o f ring s - 22,3 2 inspectio n - 2 2 remova l - 2 2 Points , contac t breake r - 7 8 Pum p fue l 6 6 Pum p oi l - 20 , 3 8 Pushrod s 3 6 Pushro d tube s 36, 19 7 Rea r brake s 12 3 Rea r lamp s - 15 1 Recommende d lubricant s an d fluid s - 7 Regulato r (voltage ) 1[...]