Volkswagen Transporter 1600 (1977) Bedienungsanleitung

Owner s Worksho p Manua l[...]

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[...]

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[...]

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[...]

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[...]

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 [...]

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 [...]

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[...]

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 [...]

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[...]

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[...]

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 .. . .. . .. . ..[...]

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

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 . [...]

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[...]

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 [...]

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[...]

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[...]

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[...]

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 [...]

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[...]

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[...]

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[...]

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[...]

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 [...]

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[...]

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[...]

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[...]

[...]

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[...]

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 [...]

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[...]

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[...]

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 [...]

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. [...]

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 [...]

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[...]

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[...]

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[...]

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 [...]

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[...]

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[...]

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 [...]

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[...]

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 .[...]

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[...]

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[...]

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 [...]

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[...]

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[...]

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[...]

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 [...]

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 [...]

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 [...]

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[...]

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[...]

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[...]

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[...]

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 [...]

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[...]

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[...]

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 [...]

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[...]

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[...]

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[...]

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 [...]

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[...]

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 [...]

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[...]

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[...]

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[...]

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.[...]

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 [...]

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 .. . .. . .. . .. . [...]

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[...]

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 [...]

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[...]

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[...]

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 [...]

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[...]

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[...]

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 .. . .. . .. . .. . .. .[...]

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[...]

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[...]

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)[...]

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[...]

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[...]

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[...]

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[...]

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[...]

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[...]

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[...]

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 [...]

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[...]

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 [...]

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[...]

[...]

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 [...]

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 [...]

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[...]

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 [...]

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[...]

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[...]

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[...]

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[...]

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[...]

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[...]

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 [...]

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 [...]

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[...]

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.. .[...]

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[...]

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[...]

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 [...]

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[...]

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 [...]

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[...]

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/[...]

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 [...]

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 )[...]

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[...]

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[...]

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[...]

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[...]

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 [...]

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[...]

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[...]

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[...]

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[...]

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[...]

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[...]

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 [...]

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[...]

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[...]

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[...]

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[...]

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 .. . .. . .. . .. . .. .[...]

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[...]

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 [...]

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[...]

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[...]

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[...]

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[...]

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 [...]

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[...]

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 [...]

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[...]

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 [...]

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[...]

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[...]

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[...]

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[...]

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 ,[...]

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 [...]

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[...]

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 [...]

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 [...]

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[...]

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 [...]

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

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[...]

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

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[...]

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[...]

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 [...]

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[...]

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[...]

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[...]

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[...]

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 [...]

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[...]

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 [...]

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 [...]

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[...]

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[...]

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[...]

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 [...]

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[...]

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[...]

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[...]

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 .. . .[...]

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[...]

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[...]

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[...]

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[...]

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[...]

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[...]

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 [...]

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 [...]

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[...]

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 [...]

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 [...]

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 [...]

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[...]

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[...]

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[...]

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[...]

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[...]

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[...]

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[...]

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[...]

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[...]

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[...]

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[...]

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 [...]

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[...]

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[...]

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[...]

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[...]

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 [...]

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 [...]

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 [...]

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[...]

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[...]

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[...]

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[...]

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 [...]

^ [...]

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 [...]

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[...]

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[...]

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[...]