Triumph TR2 (1961) manual

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Complete Service Manuals published by Robert Bentley, Inc. Volkswagen Beetle and Karmann Ghia Official Service Manual Type 1, Model Years 1966-1969. Volkswagen of America, Inc. Volkswagen Super Beetle, Beetle and Karmann Ghia Official Service Manual Type 1, Model Years 1970-1976. Volkswagen of America, Inc. Volkswagen Station WagonIBus Official Ser[...]

del Years Comprising the official driver's instruct ion book service instruct ion manual Robert Bentley, Inc. 872 Massachusetts Avenue Cam bridge, Mass. 02139[...]

Library of Congress Catalog Card Number 75-42893 ISBN 0-8376-0125-8 Manufactured in the United States of America Copyright Q 1976 Robert Bentley, Inc. All rights in this book are reserved. No responsibility accepted for the accuracy of the contents.[...]

Taken as a whole, the Triumph TR2s and TR3s represent one of the most successful sports car designs in history; so suc- cessful that, by the early nineteen-sixties, they had helped to make Standard Triumph the second-best selling imported car marque in the United States. During the late nineteen-fifties and early nineteen-sixties, countless fledgli[...]

Note on the Table of Contents Both the Driver's Instruction Book and the Service In- struction Manual are presented here exactly as originally published by the Standard Motor Co.-including the original page numbers. (The small numbers in the center at the bottom of each page are the original page numbers.) We have added the large, bold page nu[...]

Contents ............................................... Preface 5 1 OFFICIAL TRIUMPH TR2 & TR3 DRIVER'S INSTRUCTION BOOK GENERAL DATA .......................................................... 12 Spare parts service, Licence data, General specification, Road speed data MANAGEMENT OF THE CAR ...................................... 16 Contro[...]

ing clutch operating shaft, Adjusting clutch, Adjusting master cylinder, Adjusting slave cylinder, To remove flexible hose, To fit flexible hose, Removal of slave cylinder (with fork-rod assembly), To replace slave cylinder, Dismantling slave cylinder, Assembly of slave cylinder, To remove release bearing and clutch operating shaft, To replace clut[...]

needle, Centralization of jet, To assemble carburetor(s), To adjust fuel level in float chamber, Carburetor tuning, Carburetor defects (pistons sticking, eccentricity of jet and needle, flooding from float chamber or mouth of jet, leakage from bottom of jet adjacent to adjustment nut, dirt in carburetor, failure of fuel supply to float chamber, sti[...]

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Issued by STANDARD-TRIUMPH SALES LTD.[...]

THE TRIUMPH TR3 SPORTS CAR[...]

FOREWORD The vehicle has been designed so that a minimum of attention is required to keep it in satisfactory running order. There are, however, certain maintenance operations which must be undertaken regularly, and the object of this instruction book is to assist even the non-technical owner to understand the various operations required, and so ens[...]

LICENCE DATA ..... ...... Car number (Commission number) ...... Plate on dash ...... Engine number ........................ On cylinder block (Both numbers are to be seen by lifting the bonnet). .................. ...... Cnbic capacity ...... 121.5 cu, in. (1991 CL.) GENERAL SPECIFICATION ...... ...... ...... ...... ............ Number of cylinders[...]

GENERAL SPECIFICATION VALVE TIMING. [With valve-rocker clearance set at 0.015" (0.38 mm.)]. Inlet valve opens 15" before top dead centre. Exhaust valve closes 15" after top dead centre. (15" before or after T.D.C. is equivalent to 0.08 1" piston travel or 1 S" (3.81 cm.) measured round the flywheel adjacent to the star[...]

MANAGEMENT OF CAR CONTROLS, SWITCHES AND INSTRUMENTS The position of the controls, switches and instruments will readily be understood by reference to Fig. l. Scuttle Ventilator Control. Instrument Panel Light Switch. Direction Indi- cator Warning Light. Oil Pressure Gauge. Water Tempera- ture Gauge. Speedometer. Direction Indi- cator Switch. Tacho[...]

MANAGEMENT OF CAR-Controls, Switches and Instruments Choke Control. See page 9 for full instructions. Gear Lever. See Fig. 2 for gear positions. Overdrive Control. See page 42. Handbrake. Pull to operate rear wheel brakes. The lever will be held in any position by pressing Petrol Tap. This is situated on the left-hand side of thc frame adjacent to [...]

MANAGEMENT OF CAR-Controls, Switches and Instruments Windscreen Wiper. Pull to operate wipers ; they will only function when the ignition is switched on. Push to stop when arms are in the desired parking position. Heater Switch. See page 42. INSTRUMENTS Ammeter. Indicates the flow of current into or out of the battery. Fuel Gauge. Registers the amo[...]

MANAGEMENT OF CAR. DRIVING THE CAR TO START THE ENGINE IMPORTANT-When starting the engine at any time : If the engine does not start when the starter is operated, do not re- operate until both starter motor and engine have come to rest. This is to avoid damage to the starter pinion. Starting when Engine is Cold Place the gear lever in the neutral p[...]

DRIVING THE CAR-The Engine DRIVING Gear Changing For a smooth gear change into a synchronised gear (4th, 3rd & 2nd) the movement should be slow and deliberate. The gear lever must always be moved right home to secure full engagement. First and reverse gears are not synchromesh, gear engagement being achieved by sliding the respective gear into [...]

GENERAL UPKEEP REGULAR INSPECTION Every 250 miles (400 km.) the oil level should be checked when the engine is cold, and topped up if necessary. Withdraw dipstick ((F) Fig. 3) and wipe clean, then insert and push fully home before withdrawing for reading. Should the level be at the lower mark on the dipstick, 4 pints (2.2 litres) of oil will be req[...]

GENERAL UPKEEP-Cooling System and Lubrication COOLING SYSTEM Filling (see page 11). Draining For the purpose of draining, taps are provided in the bottom tank of the radiator and at the rear of the cylinder block on the right-hand side. As the cooling system is pressurised it will be necessary, when draining, to remove the radiator cap (E), Fig. 3.[...]

GENERAL UPKEEP-Lubrication Draining To drain the engine, gearbox and rear axle, remove the plug provided beneath each unit. This process is assisted by opening the filler to allow ingress of air and by draining when the oil is hot, i.e., immediately after a run. ENGINE Only first quality oils are recommended for use in the engine sump. These are ea[...]

GENERAL UPKEEP-Lubrication Carburettors Every 6,000 miles (10,000 km.) unscrew the brass hexagon plug in the top of each of the carbur- ettors and top up with current engine oil to the level of the inner hollow shaft. Apply oil also to the throttle linkages on the engine, do not oil the bear- ings of the transverse rod at- tached to the scuttle as [...]

GENERAL UPKEEP-Lubrication The container should not be disturbed until cartridge renewal is required ; as the accumulated dirt on the outside of the container may fall inside and thus be carried into the bearings when the engine is re-started. Ignition Distributor (see Fig. 5) Every 6,000 miles (10,000 km.), the cam (B) should be smeared lightly wi[...]

GENERAL UPKEEP-Lubrication Dynamo and Starter The dynamo front bearing is packed with grease before leaving the works, and after a considerable mileage the dynamo should be removed for clean- ing, adjustment and repacking of the bearing with grease. This should be done preferably by the nearest Triumph or Lucas Service Depot. Every 12,000 miles (20[...]

GENERAL UPKEEP-Lubrication It is advisable to have the oil level checked during this period, and especially after the first 1,000 miles, and replenish if necessary to level with the bottom of the threads in the filler orifice. Should a top-up be necessary, investigate the cause of oil loss. The filler plug is accessible from underneath the car, bei[...]

GENERAL UPKEEP-Lubrication Handbrake Cable Conduit A grease nipple is fitted in the conduit, as shown in the lubrication chart, to which the grease gun should be applied every 6,000 miles (10,000 km.). During the winter months it is very important to keep the cable regularly lubricated, as this prevents the entry of water which on cold nights will [...]

GENERAL UPKEEP-Lubrication and the steering slave drop arm pivot. Do not lubricate the joints attached to the drop arms as they contain rubber. The inner bushes of the wish-bones on early models also contains rubber. Later models have nylon bushes which should be lubricated with oil occasionally. A pronounced squeak develops should these bushes bec[...]

GENERAL UPKEEP-Lubrication PROPELLER SHAFT The universal joints are of the needle roller bearing type and together with the splines should be lubricated every 6,000 miles (10,000 km.). The nipple (B) at each end of the shaft should be supplied with oil for the bearings and the nipple (A) with grease for the splines. REAR ROAD SPRINGS The spring bla[...]

GENERAL UPKEEP-Tyres TYRES The maintenance of correct tyre pressure is a large factor in tyre life and the steering and suspension of the car. Examine the tyres occasionally for flints or other road matter which may have become embedded in the tread. Clean off any oil which may have got on the tyres by using fuel sparingly. Driving into or over sha[...]

GENERAL UPKEEP-Tyres Changing Position of Tyres It is recommended that front tyres be interchanged with rear tyres at least every 3,000 miles (5,000 km.). Diagonal interchanging between left front and right rear and between right front and left rear provides the most satisfactory first change, because it reverses the direction of rotation and keeps[...]

Dust may be removed from the exterior using a soft cloth only, but if it has been wet at any time it is advisable to use a sponge and water. Always use water when removing mud and when the car is clean finally wipe over with an almost dry chamois leather. Washing alone will not keep up the brilliance of the paintwork ofer an indefinite period and i[...]

BODYWORK Fig. 13. "Tenax" soft top fasteners. It may be found advantageous when removing the fasteners from the screen, to relieve the tension on the fasteners by applying a slight hand pressure, in the forward direction, to the corrier of the soft top where it passes over its supports. SPARE WHEEL AND TOOL STOWAGE The spare wheel is hous[...]

RUNNING ADJUSTMENTS Various adjustments are necessary from time to time in order to keep the mechanism in efficient running order. The periods between depend largely upon the manner in which the car is used and no definite time can be given here for carrying out these corrections. The car should be examined however every 6,000 miles (10,000 km.) an[...]

RUNNING ADJUSTMENTS-Engine A new gasket must be fitted each time the cylinder head is removed. The plain side of the gasket must be downwards against the cylinder block and should be coated on both sides with cc WELLSEAL" or similar non-setting sealing compound. When replacing the cylinder head nuts, tighten them gradually in the sequence show[...]

RUNNING AD JUSTMENTS-Engine Adjustment Remove the roeker cover and turn the engine crank with the aid of the starting handle for half a revolution after the valve to be adjusted has closed. It is easier to do this if the sparking plugs are removed. This also provides an opportunity for inspecting and checking the sparking plug gaps. Slacken the loc[...]

RUNNING AD JUSTMENTS-Engine Sparking Plugs The sparking plugs were adopted for original equipment after lengthy tests and as sparking plug types vary in suitability for different engines, it is important that the correct type of plug be fitted when making replacements, this is : Champion No. LlOS-$" reach. In countries where the octane rating [...]

Adjustment As the needle size is determined during engine development, adjustment of the carburettors is confined to correct idling adjustment. Remove the air cleaners and run the engine until it has attained its normal running temperature slacken one of the clamping bolts (B) on the throttle spindle connection and disconnect the mixture control li[...]

RUNNING AD JUSTMENTS-Engine if the float chamber is not already full, under which condition a slight pumping resistance is felt before the lever reaches its stop. This resistance ceases when the chamber is full. Fig. 18. Fuel pump. The glass bowl acts as a sediment chamber for the petrol passing to the pump. The foreign matter collects on the under[...]

RUNNING ADJUSTMENTS-Clutch CLUTCH A Borg & Beck single dry plate hydraulically operated clutch is fitted and as it is correctly set before leaving the works, it will be some considerable time before it requires re-adjustment. The hydraulic master cylinder for the clutch has a conamon filler with the brake system. (See arrow (B) Fig. 3, page 11.[...]

RUNNING AD JUSTMENTS-Brakes See page 17 for checking level of fluid in reservoir. If it is found to be par- ticularly low, it is an indication that a leak has developed somewhere in the system and it should be traced and rectified without delay. It must be remembered that the presence of oil, grease or sidar foreign matter on a drum brake shoe will[...]

RUNNING AD JUSTMENTS-Brakes The following procedure should be followed to correctly adjust the brakes: 1. Apply the brakes hard, with the car stationary, to position the shoes in the drum, then release brake. 2. Jack up the car, remove the nave plates and road wheels. 3. Rotate hub until hole provided in the brake drum coincides with screwdriver sl[...]

RUNNING ADJUSTMENTS Handbrake Adjustment (both makes) Adjustment of the rear brake shoes as previously described automatically readjusts the handbrake mechanism. The cables are correctly set before leaving the works, and only maladjustment will result from tampering with the mechanism. Bleeding the Brake and Clutch Hydraulic System If a pipe joint [...]

RUNNING ADJUSTMENTS The front telescopic dampers fitted do not require any adjustment or topping up. If the dampers are removed, or for some reason new ones are fitted, it is advisable to hold them the right way up (in the case of the rear dampers check the level of the fluid and replenish if necessary), then pump the pistons to each end of the str[...]

ELECTRICAL SYSTEM A 12 volt earth return (or one wire) lighting and starting set is fitted. One cable should be disconnected from the battery terminal before removing any electrical unit, otherwise there is a risk of a serious " short." A list of the maker's numbers and descriptions of all electrical equipment will be found on page 4[...]

ELECTRICAL SYSTEM-Dynamo, Control Box and Fuses current for a discharged battery and a low trickle charge for a battery in the fully charged state. The cut-out, operated by dynamo voltage, prevents discharge of the battery through the dynamo when the dynamo is not charging, in which condition the ignition warning light will be glowing. Belt Tightne[...]

ELECTRICAL SYSTEM-Dynamo, Control Box and Fuses current for a discharged battery and a low trickle charge for a battery in the fully charged state. The cut-out, operated by dynamo voltage, prevents discharge of the battery through the dynamo when the dynamo is not charging, in which condition the ignition warning light will be glowing. Belt Tightne[...]

ELECTRICAL SYSTEM-Lamp To CHECK AND ADJUST ALIGNMENT Park the car in front of a garage door or wall and square to it. The car must stand on level ground and the front of the lamps should be approx- irnztely 25 ft. (7.5 m.) from the " screen." The car should be unladen and the tyres at the correct pressures. A paint should be marked on the[...]

ELECTRICAL SY STEM-Lamps, etc. If adjustment is necessary, proceed as follows : Withdraw the front rim after removing the securing screw. Remove the dust-excluding rubber. This will reveal three screws (see arrows, Fig. 24), which can be adjusted to align the reflector correctly. When the correct alignment has been obtained, replace the rubber and [...]

ELECTRICAL SYSTEM-Spedication ELECTRICAL COMPONENT SPECIFICATION Battery ...... Control Box Coil ...... Dynamo ...... Distributor Starter ...... Fuse Box ...... Flasher Unit Horns ...... Windscreen Wiper Motor 1 Model Service ~ucas 1 volt- 1 I No. No. age Watt. --- l GTW9A/2 4011557 Head Lamps B12 type L (home model) 1 RB106/2 1 37182 Left-hand dip[...]

RADIO For operating instructions, see the radio leaflet provided with the set. The set is protected against possible electrical damage due to a short by a 5 amp. fuse housed in the main lead union. The aerial mast should always be lowered when the set is not operating. HEATER The heater is of the re-circulating type, with a combined rheostat and ON[...]

Fig. 25 Engine cross section. 43 SPORTS CAR[...]

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SPORTS CAR[...]

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710 9N19N3 80 37XV XVXX (170 HLIA LNI[...]

RECOMMENDED LUBRICANTS-BRITISH ISLES MOBIL Mobiloil A WAKEFIELD I B.P. Esso ENGINE Summer 3uckham's NOL " Thirty Castrol Energol XL I S.A.E. 30 Shell X-100 30 Esso Extra Motor Oil 2owi30 Winter Duckham's NPL " Twenty Mobiloil Arctic Mobil Upperlube Castrolite I Energol S.A.E.20W Shell X-100 20/20w Esso U.C.L. Upper Cylinder Lubr[...]

TRIUMPH TR2 & TR3 SERVICE INSTRUCTION MANUAL PART 2 Issued by STANDARD-TRIUMPH SALES LTD.[...]

This Manual has been prepared with a view to assisting Standard Distributors and Dealers, at Home and Over- seas, to give an efficient repair and maintenance service to owners of this Model. The book is divided into seventeen sections, which are separately indexed and indicated alphabetically. These sections deal with the main components, equipment[...]

NDE General Dat ... Front Suspension an Steering ... Bend back pages to disclose black indicators in line with markers. SECTION PAGE 63 81 141 155 173 25 255 265 275 281 297 33 357 385 411. 417[...]

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Service Instruction AI Manual GENERAL DATA SECTION A[...]

...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ,..,.. ...... ...... ...... ...... ...... ...... Tyres ...... ...... ...... ...... ......[...]

GENERAL DATA GENERAL DATA Summaries of dimensions and tolerances, relative to various components are given at the commencement of the respective sections to which they refer. Whlst data given, in some instances, in ths section appears elsewhere in the body of ths manual, such information being frequently required, it is considered desirable that it[...]

GENERAL DATA Camshaft Bearings ...... Lubricating System ...... OilPump ...... ...... Oil Pressure ...... ...... Oil Cleaner ...... ...... Carburettors ...... Valve Timing ...... Cooling System ...... Pressurised Radiator Radiator Temperature Front Bearing--cast iron sleeve ; 2nd, 3rd and 4th direct in crankcase. After Engine No. TS 9095E engines w[...]

GENERAL DATA Rear Axle Ratio ...... Wheels ...... Suspension Brakes ...... ...... Steering ...... Battery ...... Steel Disc Type with chrome nave plates (wire wheels op- tional extra.). ...... Coil springs for in- dependent front sus- pension with tele- scopic dampers Wide semi-elliptic springs at rear, controlled by piston type dampers. ...... Loc[...]

GENERAL DATA R. l? M. Fig. I Power Curve. 4[...]

GENERAL DATA Fig. 2 Body Dimensions. Body Dimensions (See Fig. 2). Hood erect ...... ...... Top of Windscreen ...... Top of Steering Wheel Road to Top of Scuttle ...... Pedal to squab." ...... Seat to Hood ...... Squab to Steering Wheel ...... ...... Seat to Steering Wheel ...... ...... Seat to Floor ...... Squab Height ...... ...... Sidescree[...]

GENERAL DATA Car Weight Complete Car with Tools, Fuel and Water 18 cwts. 3 qrs. 7 lbs. Shipping Weight 17 cwts. 2 qrs. 21 lbs. Tyre Sizes and Pressure ...... Tyre Size ...... 5.50"-15". Tvre Pressures Although no particular skill is required in their application, an elementary know- ledge of the correct way to fit them is necessary. It is[...]

GENERAIL DATA ARBOX NUMBER - REAR AXLE NUMBER ' COMM!SSION NUMBER[...]

GENERAL DATA MENDED LU RICANTS BRITISH ISLES SHELL Esso DUCKHAM'S VACL'UM l ENGINE Summer Shell X-100 Essolube Duckham's 1 Mobiloil 1 NOL 1 30 " Thirty " ' I A Castrol XL Energol S.A.E. 30 Shell X-100 Essolnbe Duckham's l Mobiloil NOL 20/20W 20 " Twenty " Arctic Energol S.A.E. 20 Castrolite Winter Upper [...]

GENERAL DATA RECOMMENDED LUBR OVERSEAS COUNTRIES Esso Energol Motor Oil S.A.E. 40 Shell X-100 40 Essolube 40 ENGINE Air Temp. "F. Ducf?lam's NOL Over 70' . 1 Forty '' Mobiloil Castrol " AF " l XXL 40" to 70" .... Du$ham's NOL ) Thirty" Mobiloil Castrol Energol Motor Oil S.A.E. 30 Shell X-100 30[...]

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- Ref A GENERAL DATA ITEMS 1 DETAILS Steering Swivels ...... . (4 nipples) I Outer Tie Rod Ball Joints ............ ...... (4 nipples) Steering Slave Drop Amt Pivot (1 nipple) I STROKES Lower Wishbone Outer Bushes (4 nipples) ( ........... Cable ...... (! nipple) Handbrake Compensator ...... (2 nipples) Clutch Shaft Bearings ........... (2 nipples)[...]

GENERAL DATA ENGINE NUT TIGHTENING TORQUES Operation I CONNECTING ROD CAPS I 1'," UNF Bolt 1 105312 1 55-60 1 CYLINDER HEAD 1 MAIN BEARING CAPS / 4" X 13 NC Setscrew 1 57121 1 85-90 1 Description I FLYWHEEL ATTACHMENT P CRANKSHAFT / 3" :: 24 NF Setscrew 1006 1 4246 1 4'' UNF and UNC Stud I TIMING CHAIN WHEEL TO CAM- SH[...]

GENERAL DATA NUT TIGHTENING TORQUES (continued) Specified Torque Range Ib./ft. Operation Description GEARBOX Detail No. Remarks I FRONT COVER TO GEARBOX I A" X 18 NC Setscrew I EXTENSION TO GEARBOX I X 18 UNC Bolt TOP COVER TO GEARBOX A" X 18 Bolts and Setscrews / ATTACHMENT OF ENGINE TO ha X l8 NC and NF GEARBOX / Bolt and Stud I REAR MO[...]

GENERAL DATA NUT TIGHTENING TORQUES (continued) Operation REAR COVER ATTACHMENT I BACKING PLATE ATTACHMENT / 3" X 24 UNF Setscrew / HU.0908 / 26-28 1 I SPRING FRONT END TO FRAME 1 4" X 20 UNF Bolt / 106251 ) 28-30 1 I HUB TO AXLE SHAFT REAR SUSPENSION I ROAD SPRING TO REAR AXLE Nyloc Nut #" X 24 UNF 8" X 18 UNF Nut-Slotted SPRIN[...]

GENERAL DATA FRACTIONAL AND METRICAL EQUIVALENTS Inches Frac. Dec. mm. Inches Frac. Dec. mm. Inches Frac. Dec. mm. STAND MEASURE AND METRIC EQUIVaLENTS English to Metric (linear) l inch = 2.54 centimetres l foot = 30.4799 centimetres 1 yard = 0.914399 metre 1 mile = 1.6093 kilometre 10 miles = 16.093 kilometres Metric to English (linear) 1 centimet[...]

GENERAL DATA English to Metric (cubic measure) 1 cubic inch = 16.387 cubic centimetres 1 cubic foot = 28.317 litres l gallon (0.1605 cu. ft.) = 4.546 litres Metric to English (cubic measure) 1 litre = 0.22 gallons, or (1,000 cu. cms.) 1.7598 pints 1 cubic centimetre = 0.61 cubic inches English to Metric (weight) 1 pound (Avoirdupois) = 0.45359 kilo[...]

Service Instruction Manual ENGINE SECTION B[...]

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...... Engine Dimensions ...... General Description ...... The Cylinder Block ...... The Cylinder Sleeves ...... The Connecting Rods Aeroflex compensating Pistons ...... The Crankshaft ...... ...... ...... The Valves ...... ...... The Camshaft ...... The Cooling System ...... The Fuel System ...... The Hobourn Eaton Oil Pump ...... ...... Coil Igni[...]

ENGINE ILLUSTRATIONS Fig. 1 Fig. 2 Fig. 3 Fig. 4 Fig. 5 Fig. 6 Fig. 7 Fig. 8 Fig. 9 Fig. 10 Fig. l1 Fig. 12 Fig. 13 Fig. 14 Fig. 15 Fig. 16 Fig. 17 Fig. 18 Fig. 19 Fig. 20 Fig. 21 Fig. 22 Fig. 23 Fig. 24 Page Page Longitudinal view of Engine ...... 6 Fig. 25 The TR2 Valve Timing Diagram 23 ...... Cross section view of Engine 7 Fig. 26 Plug Lead Att[...]

ENGINE-Dimensions and Tolerances -- - PART AND DESCRIPTION DIMENSIONS CLEARANCE REMARKS NEW NEW Crankshaft Journal diameter Bearing Internal Diameter 2.4815" 2.4805" Bearing Housing Internal 2.6255" Diameter 2.6250" Undersize bearings are available in the following sizes :-.010", -.020", --.030", -.040". Cran[...]

ENGINE-Dimensions and Tolerances PART AND DESCRIPTION DIMENSIONS CLEARANCE REMARKS NEW NEW Small End Bore for Bush Bush External Diameter Internal Diameter of Bush Gudgeon Pin Diameter 1 .OOOO" .995OU Press Fit in Con. Rod. 1.0005" .995" Piston Rings Compression Ring Width Groove Width Scraper Ring Width Groove Width Ring Gap in Cyli[...]

ENGINE-Dimensions and Tolerances PART AND DESCRIPTION DIMENSIONS CLEARANCE REMARKS NEW NEW Height of Cylinder Sleeves above face of Cylinder Block Pistons are available in the following oversizes : +.020", + 030", $040". Camshaft Front Journal Diameter Front Journal Bearing Bore External Diameter of Front 2.2498" Push Fit in Bea[...]

ENGINE-Dimensions and Tolerances PART AND DESCRIPTION DIMENSIONS CLEARANCE REMARKS NEW NEW Exhaust Valve Head Diameter Width of Exhaust Valve Seating .0469" approx. Oil Pump Outer Rotor Outside Diameter Housing Internal Diameter Depth of Rotor Housing Depth Bush in Cylinder Block Distributor Driving Shaft End Float of Distributor and Tachomete[...]

ENGINE-Dimensions and Tolerances PART AND DESCRIPTION DIMENSIONS CLEARANCE REMARKS NEW NEW iete 1.560" 38 lbs. 1.980" 1.140" 10 lbs.[...]

ENGINE Fig. I Longitudinal view of Engine. For illustration purposes the sump oil filter has been omitted.[...]

ENGINE Fig. 2 Cross section view of Engine. For illustration purposes the sump oil filter has been omitted.[...]

ENGINE I. GENERAL DESCRIPTION (Figs. I and 2) The Engine has four cylinders and the overhead valves are push rod operated, the 83 mm. bore and 92 mm. stroke give a capacity of 1,991 cubic centimetres. The compression is 8.5 to 1. A low compression kit (see page 27) is available and reduces the com- pression ratio to 7.5 to 1. The Cylinder Block is [...]

ENGINE Fig. 5 Checking Cylinder Sleeve projection above Cylinder Block. Fig. 6 The Piston and Connecting Rod Assembly in exploded form. (d) The Connecting Rods (Fig. 6) are molybdenum manganese steel stamp- ings being provided with phosphor bronze small end bushes and pre- cision type big end bearings. The rod is drilled from the big end bearing en[...]

ENGINE Aeroflex Compensating Pistons (Fig 6) are employed, which are made from a special aluminium alloy and each provided with two compression rings and one oil scraper ring. The pistons are graded F, G or H (dimensions on page 2) and this symbol is stamped on the crowns. The piston skirt has a & " slot on the non-pressure side and is fit[...]

ENGINE these bearings will be that three set- screws retaining the three rearmost bearings will clearly be seen on theleft- hand side of the cylinder block. The front bearing is pressed into the front bearing sleeve. The camshaft operates directly on flat based hollow cylindrical chilled cast iron tappets which in turn engage hardened spherical-end[...]

ENGINE carried out whilst the flywheel is still cold. The ring should be immersed in boiling water or its temperature raised by sQme other means ; a temperature higher than boiling water is not re- commended for the heat properties of the ring may be destroyed. The ring must be fitted with the leading edges of the teeth toward the starter motor. Sh[...]

ENG filter incorporated in it, should be h petrol and drained on each asion when t e engine oil is 2. into the cylinder block, and is provided The oil is prevented from escaping by the rocker cover and after lubricating the valve springs and ball pins, returns down- wards through the push rod tubes lubri- cating the push rod tappets before entering[...]

ENGINE Fig. 12 Longitudinal view of Oil Circulation.[...]

ENGINE Fig. I3 Cross section view of Oil Circulation.[...]

Fig. 14 Exploded view of Oil Pump. distributor drive shaft. From this annular space oil is circulated round the engine as described in 'Tngine Lubrication." To Remove Oil Pump from t Engine (i) Drain the oil from the sump (preferably when the engine is warm) and jack up the car. (ii) Remove the sump securing bolts and, lowering it at the [...]

ENG Fig. 15 Exploded view of Distributor and Tacho- meter Drive Details. The main bearings are of the precision type, bi-metal steel backed. No hand fitting is required and in no circumstances should the bearing caps be filed with a view to taking up wear. The mng of bearing caps will make them unserviceable for future use when new bearings are ult[...]

ENGINE Fig. 17 Measuring Crankshaft End Float. This operation can be carried out with a Dial Test Indicator. and although this may rarely happen, oversize thrust washers + .OO5" may be obtained by a special order on the Spares Department under their normal detail number specifying that the over- size thrust washers are required. 5. CONNECTING [...]

ENGINE PISTON ASSEMBLY AND CYLIN- DER SLEEVES The piston and cylinder bore dimensions are given on page 2. As indicated in this list of tolerances and limits, three sizes of pistons are used in conjunction with suitable bore dimensions. The three sizes of pistons and cylinder sleeves are indicated by the stamping of F, G or H on the crown of each p[...]

the cylinder block and a routine check should be made whenever the combustion head is removed. Should the cylinder sleeve(s) be below the specified limits new figure of eight joints should be fitted. NG GEARS The camshaft is of cast iron, having chilled faces for the cams and journals. With the camshaft a cast iron fanged front bearing is used, the[...]

ENGINE sleeve retainers (Churchill Tool No. S.138) should be applied as shown in Fig. 22. In the event of sleeve movement, new figure of eight washers should be fitted. Remove push rods and tappets. (c) Disconnect tachometer drive. Remove distributor assembly complete with pedestal by removing the two securing nuts at the crankcase. Do not slacken [...]

ENGINE helical gear when the shaft will engage with the oil pump. (c) Having refitted the cylinder head and rocker shaft it. is advisable to apply oil to the ground surfaces where the rockers contact the valves, as these points do not immediately receive a supply of oil. 11. TO SET VALVE CLEARANCES I l I All adjustments should be made when the engi[...]

ENGINE (2.06 mm.) piston travel or 1.5" T.R.2. VALVE TIMING DIAGRAM[...]

If the timing is correct the two sions will be identical. Having hally proved the valve timing, the chainwheel locking tabs may be turned up. (i) The timing gears are now marked with a scribe line as shown in Fig. 21. (j> Fit the timing chain tensioner and with plain washer and split pin. e timing cover. (L) The rocker clearances are now set to [...]

casting stresses to resolve themselves and permits the consequent valve seat dis- tortion ro be counteracted by valve Failure to carry out this init grinding is a frequent cause of excessive petrol consumption of new cars. Sub- sequent attention will not normally be required until further considerable amount of running has been one-normally afier a[...]

ENGINE arises, it is important that the valve guides are concentric with the seats themselves. Where a valve guide is badly worn it should be replaced before the seat is recut. While refacing valves, only remove suffi- cient metal to clean up the face, otherwise if too much is removed the edge will tend to curl up in service. Where valve seats are [...]

cylinder sleeves may be disturbed because of their adherence to the gasket. When refitting the cylinder head nuts, tighlen them gradually in the sequence shown in Fig. 28 in order to produce an even pressure on the gasket and prevent undue strain in the cylinder block casting. It will be necessary to recheck the nut tightness when cold to 100-105 l[...]

to ensure maximum filtration. To renew the element proceed as follows :- (a) Clean the outside of the filter casing. (b) Unscrew the centre bolt and remove the filter casing and element. NOTE-The paper element, its perforated outer cover and element tube forms a complete element assem- bly. Ensure that the to^ seal is re- tained in position & t[...]

and the second situate ee the rubber gear lever grommet by and exhaust manifold e removal of three self-tapping block. screws from the gearbox cover pressing e oil from the en gearbox. Disconnect the hea cables at their snap connectors. Re- move the bolts fiom the top brackets and the bolt in the centre of the this holds the bonnet lock connecting [...]

DIS It is sound policy to clean the exterior of the engine and gearbox before commencing to Qsmmtle. (i) Detach gearbox by removing the nine nuts and bolts from the clutch bell housing. (ii) Remove the clutch from the flywheel by withdrawing the six searing bolts. (E) Remove the flywheel by unlocking the tab washers and withdrawing the four - - (vi[...]

ENGINE of ten nuts and washers and lift out the push rods and tappets. (xix) The camshaft can be withdrawn by first removing two bolts securing the front bearing, then the bearing and finally the camshaft. (xx) Remove the nineteen sump securing bolts and remove the sump. Care should be taken not to damage the oil pump filter. (xxi) Remove oil pump [...]

ENG position. Fit the lower halves of the main s to the bearing caps, and top halves of the thrust side of the centre main earing between the cra cylinder block. It is essential that the white metal lightly secure with the two bolts and lock washers to cylinder bloc block with two bolts and ashers each. e front of the engine, tighten the bearings c[...]

either side of the rear main bearing cap with the aid of a &" square brass drift (Fig. 35). Two lengths about 9" long are necessary. Completely fill the groove and cut the felt off hi' proud of the cylinder block face. It is suggested that the felt strip is cut into approxi- mately $" lengths for easy insertion. Check the co[...]

ENGINE factured special retainers for this pur- pose (Fig. 22) and it is suggested that these are employed. Until this is done the piston assemblies must not be moved, for any movement will be transferred to the sleeve and damage the figure of eight washers. If damage is undetected, water leakage will result. An alternate method is to insert the cy[...]

which aligns with L.H. rubber mount- ing attachment nut. The machined faces on the combustion head and the upper flanges of the cylinder sleeves; which contact the combustion head gasket, should be lightly coated with " Wellseal " sealing compound. A substitute compound, which retains its plasticity, may be used if " Wellseal" i[...]

ENGINE secure with the extension bolt. Shims are placed behind the head of this bolt, whch incorporates the starting handle dogs, to provide the correct relation with the starting handle and the engine compressions. This position is obtained with Nos. 1 and 4 pistons at T.D.C. and the dog faces corresponding to "10 minutes to 4 o'clock&ap[...]

ENG tighten to 20-24 Ibs. ft. Finally tighten the two nuts attaching the inlet to the exhaust manifold to 16-18 lbs. ft.. Fit the Purolator oil filter with packing to left-hand side of cylinder block. It is located by a tubular stud and secured by three bolts with lock washers. The tubular stud accommodates the oil pressure gauge pipe. This part is[...]

ENGINE The important thing is for the petrol consumption to be improved. If plugs show suitability for further use, proceed to clean and test. In preparing for cleaning, remove plug gaskets, and in doing so ascertain their means of the copper gasket between the plug and the cylinder head. Plugs not down tight can be easily over- heated, throwing th[...]

ENGINE Fig. 41 Sparking Plug Gaskets in various con- ditions. sumption. It may be, however, that a plug of a " colder " type is required. After cleaning, examine plugs for cracked insulators or insulator nose worn away through continued pre- vious cleaning. In this case we should recommend that the plugs have passed their point of useful [...]

ENG plugs. However, the strains of intense evidence of your careful handling of heat, pressure, mechanical shock, elec- the plugs. trical and chemical action, during miles of service, wreak suck havoc on ) The top half of the insulator is often the electrodes that molecular con- responsible for causes of poor plug struction is affected. Plues reach[...]

a gap of .032", the C 4" reach plug being specified for normal road work, the LllS for high speed work. The normal efficient life of a sparking plug is 10,000 miles, after which, if full efficiency and economy is desired, the plugs should be replaced by new ones of the type specified. Fig. 47 Sparking Plugs in various conditions. The dist[...]

ENGINE LIST OF DISTRIBUTORS BEING SERVICED FROM SPARK PLUG COMPANY, TOLEDO, 1, OHIO, U.S.A. SPARK PLUG COMPANY OF CANADA LTD., WINDSOR, ONTARIO. SPARKING PLUG CO. LTD., FELTHAM, MIDDLESEX, ENGLAND. CHAhIPION CHAMPION CHAMPION ADEN PROTECTORATE Victoria Riddoch Motors Ltd., P.O. Box 40, Amsha, Tanganyika. Cowasjee Dinshaw & Brothers, Steamer Poi[...]

ENGINE CYPRUS FRENCH MOROCCO Auto-Hall, Boulevard de Marseille, Casablanca, French Morocco. CANARY ISLANDS Representative : Francisco Flores, Espinardo, Murcia, Spain. Nicos D. Solomonides & Co. Ltd., P.O. Box 210, Limassol, Cyprus. DENMARK F. Bulow & Co., I'olititorvet, Copenhagen, Denmark. Branch at : Odense. FRENCH SOMALILAND Maison[...]

ONG KONG Representative : Dodge & Seymour Ltd., 318, Prince's Building, P.O. Box 77, Mong Kong. Kokusai Kogyo Co. Ltd., 3-3 Makicho, Chuo-Ku, Tokyo, Japan. Maison Barrau, Nournea, New Caledonia. NEW ZEAL J. Qsawa & Co., Sanjo Kaboshi, Kyoto, Japan. Hope Gibbons Ltd., P.O. Box 2197, Wellington C.1, New Zealand. ICELAN The Central Automo[...]

G. & A. Baker Limited, Prevuayans Han Tahtakale, Postbox 468, Istanbul, Turkey Square Auto Supply Co., 625, Juan Luna, Manila, Philippine Islands. S. Cohen Ltd., P.O. Box 215, Windhoek, S-W. Africa. PORTUGAL C. Santos Lda., 2941, Avenida da Liberdade, Lisbon, Portugal. SPAIN Francisco Flores, Espinardo, Murcia, Spain. Branch at : Bilbao. UNION [...]

ENGINE 23. ENGINE NOISES Main Bearing Knock This knock can usually be identified by its dully heavy metallic note which increases with frequency as the engine speed and load rises. A main bearing knock is particularly noticeable when the engine is running very slowly and consequently unevenly, it is more pronounced with advanced ignition. When this[...]

ENGINE hock (piston slap) and should there- fore be examined. (i) Excessive clearance between piston and cylinder sleeve due to fair usage or to an unsuitable replace- ment part. (ii) Pistons or rings striking ridge at the top of the sleeve after fitting a replacement. Such ridges should be removed before replacement parts are fitted. (iii) Collaps[...]

ENGINE (iv) Incorrect valve timing. (v) Poor quality fuel. (vi) Mixture is too weak or excessively rich. (vii) Pre-ignition due to various causes. (viii) Air leak into induction system giving rise to a weak mixture. (ix) Valves, particularly inlet, not seating correctly. (X) Defective cylinder head gasket. Excessive Oil Consumption Excessive oil co[...]

ENGINE (vi) Oil release valve in exterior oil filter head out of adjustment, dirt on valve seating. broken or weak (ix) Worn engine bearings and/or crankshaft journals and pins. release valve sGing. Filter loose on bracket, damaged joint packing, (k) High Oil Pressure poor joint faces. (i) Using too heavy a grade of oil. (vii) Loose connections on [...]

ENGINE Fig. 49 Jbploded view of Engine. Cylinder Block Details. SO[...]

ENGINE NOTATION FOR FIG. 49 Exploded view of Cylinder Block Details Ref. No. Description Cylinder Block. Front Bearing Cap. Rear Bearing Cap. Rear Bearing Cap Felt Packing. Bearing Cap Bolts. Spring Washer for Bearing Cap Bolts. Oil Pump Drive Bush. Oil Gallery Blanking Screw. Washer for Blanking Screws. Drain Tap. Washer for Drain Tap. Combustion [...]

ENGINE Fig. so. Exploded view of Engine. Crankshaft Details. 52[...]

ENGINE NOTATION FOR FIG. go Exploded View of Crankshaft Details. Ref. No. Description Crankshaft. Crankshaft Main Bearings. Top Thrust Washers. Lower Thrust Washers. Sprocket Locating Shims. Crankshaft Sprocket (Timing Chain). Oil Deflector. Fan Pulley Hub. Woodruffe Keys. Rear Half of Fan Pulley. Front Half of Fan Pulley. Fan Pulley Hub Extension.[...]

ENGINE SYMPTOM. Difficulty in Starting Engine. Stalling Engine Lack of Power. FAULT LOCATION CAUSE. 1. Fault in fuel supply. 2. Sluggish starter motor. 3. Failure of starter pinion to engage with flywheel. 4. Faulty ignition. 1. Incorrect carburation. 2. Incorrect ignition timing. 3. Poor compression. -- l. Choked silencer and/or tail pipe. 2. Bind[...]

ENGINE SYMPTOM Engine Misfiring. FAULT LOCATION (CONTINUED) CAUSE 4. Incorrect ignition settings. 5. Incorrect tappet clearance. 6. Poor compression. 1. Faulty carburation. 2. Faulty ignition. 3. Valve condition. REMEDY Check type of plug and spark gap, distributor gap, condenser, seized automatic advance mech- anism. Incorrect timing. Adjust tappe[...]

[...]

Service Instruction Manual COOLING SYSTEM SECTION C[...]

INDEX ...... Description ...... ...... ...... ...... ...... To Drain the System ...... ...... ...... ...... ...... Fan Belt Adjustment ...... ...... ...... ...... ...... The Thermostat ...... ...... To remove ~hermosta;"klousin~ (with ~hermosta;)" To replace Thermostat Housing (with Thermostat) .. To rehove Thermostat only ...... ...... T[...]

ESCRIPTION The cooling system is pressurised and thermostatically controlled, with an impel- ler pump to ensure efficient circulation of water at all times. The capacity is 13 pints or 14 when a heater is fitted. Careful con- sideration has been given to points where adequate cooling is necessary, such as sparking plugs and valve guides, etc. To as[...]

COOLING SYSTEM from the lower pan of the radiator. The thermostat is fully open at 197°F. (92°C.) THERMO CLOSED and at this stage the by-pass is sealed off, this sealing off avoids loss of cooling efficiency when it is most required (Fig. 4). THERMO OPEN FULLY OPEN Fig. q Circulation when the Thermostat is open. The radiator temperature for norma[...]

COOLING SYSTEM Fig. 5 Exploded details of Thermostat Housings (the housing in the insert is that fitted to current production cars). Cooling System hoses are also shown. 3 145[...]

(f) The thermostat can be removed from housing by removing the remainder of the front cover nuts (already loosened in para. c) but after the removal of the joint washer. TO REPLACE IPMOSTAT HOUSING The replacement is the reversal of the re- moval but care should be taken concerning the following points. (a) That the contact surfaces of the house- i[...]

COOLING SYSTEM The instrument is not adjustable or repair- 14. TO REPLACE RADIATOR able and when a test shows inaccuracies or The replacement of the radiator is the damage on inspection it will be necessary to reversal of the removal. replace the complete instrument. 12. THE RADIATOR The radiator is of the finned pipe type and is secured to the cha[...]

COOLING SYSTEM Fig. 7 Exploded details of Water Pump Housing Assembly. I NOTATION FOR WATER PUMP HOUSING ASSEMBLY (Fig. 7) 1 g: Description Ref. No. Description Water Pum~ Body. Bearing ~obsin~ ~ttachment Stud. Plug (removed when heater is fitted). Bearing Housing. Grease Nipple. a a Spindle. Water Pum~ Seal. Impeller. Synthetic Rubber Spinner. Abu[...]

COOLING SYSTEM (c) It will be noted that the bolt is trapped between the bearing housing and the pulley. Mark the position of the bolt on the bearing housing so that during assembly it can be returned to its orig- inal position. IS. TO REPLACE THE WATER PUMP BEARING HOUSING (a) The replacement of this assembly is the reversal of the removal, but th[...]

COOLING SYSTEM solder run round the end face to ensure a water-tight joint (Fig. 10). Fig. 21. xo Showing the correct clearance between Water Pump Impeller and Bearing Housing. RECUTTING THE WATER PUMP SEALING FACE When servicing the water pump it is some- times necessary to re-cut the water seal abutment face. The ChurchiU Tool No. 6300 and bush S[...]

COOLING SYSTEM balance. Only when replacement parts are 26. fitted will it be necessary to re-balance the unit. The hub extension is attached to the hub, the latter being keyed to the crankshaft by six nyloc nuts and bolts and the whole assembly is secured to the crankshaft by the extension bolt, the head of which acts as the starting handle dog an[...]

COOLING SYSTEM (a) Place the two pulley pressings together, the flatter one with the drilled hole uppermost and the second pressing on top; feed the hub through the pressings with its keyway lowermost. It is neces- sary that this procedure is followed for it ensures a visual check of setting the engine at T.D.C. on Nos. 1 and 4 cylinders. (b) Posit[...]

COOLING SYSTEM SERVICE DIAGNOSIS. OVERHEATING. This difficulty may arise owing to one or more of the causes listed below :- CAUSE Ignition timing too late or auto advance and retard mechanism or suction not operating correctly. Fan belt slipping. Insufficient water in cooling system. Radiator and/or cylinder block restricted by the accumulation of [...]

[...]

rvice Instr LUT SECTION D[...]

CLUTCH INDEX ...... .... General Data ...... ...... ...... ...... - .-... ...... ...... ...... Clutch Operation ...... ...... ...... ...... ...... Twin Bore Master cylinder .......... ...... ...... ...... Clutch Slave Cylinder ...... ...... ...... ...... The Clutch Operating Shaft ...... ...... ...... ...... ...... ...... ...... The Release Bearing[...]

CLUTCH I. GENERAL DATA Model A 6 G 9". Hydraulically operated from twin bore master cylinder which incorporates the brake master cylinder. Ball bearing release bearing. Clearance between ball bearing release bear- ing and release levers-.0625". Nine, 120--130 lb. cream thrust springs. Single dry plate with six springs. All six springs cus[...]

CLUTCH cylinder and plate upper attachment by means of a jam nut and a nyIoc nut. The lower attachment being effected by nut and bolt with washer. A return spring is fitted to a plate on the clevis pin of the fork assembly to the lower portion of the support plate. The inner assembly of the slave cylinder is made up of a coil spring, cup filler, ru[...]

CLUTCH G, Fig. 9. 2 Exploded details of Clutch Assembly with Slave Cylinder. Struts are interposed between the lugs on 10. NTENANCE the pressure plate and the outer ends of the release levers. Anti-rattle springs are It is essential that the master cylinder is at fitted between the release levers and the least half full of Lockheed Brake Fluid at c[...]

CLUTCH BLEEDING THE HYDRAULIC SYSTEM Bleeding is only necessary when a portion of the system has been disconnected or if the level of the fluid has been allowed to fall so low that air has been allowed to enter the system. If bleeding is carried out for the latter reason the brake system will need to be bled also, as they share the same reservoir. [...]

CLUTC (d) Screw the rod together with the jam nut to the fork and lock. Check by moving the fork assembly and readjust if necessary. Fig. 3 The Slave Cylinder and support bracket. TO REMOVE T Drain the hydraulic system. Holding the hexagon of the flexible hose, withdraw the Bundy tubing by first removing the union nut. Still holding the hexagon of [...]

CLUTCH Fig. 20. 4 Sectional View of Slave Cylinder. I Spring. 2 Cup Filler. 3 Rubber Cup. 4 Piston. 5 Rubber Boot. 6 Fork assembly. DISMANTLING THE SLAVE CYLINDER (Fig. 4) (a) Remove the slave cylinder assembly from its mounting as described on page 5. Remove bleeder screw. (b) Remove the wire circlip from the rub- ber boot and ease the rubber boot[...]

'CH (f) Holding the clutch operating fork with- draw the shaft from the left. (g) Remove spring and grease nipple with fibre washer from lever end of shaft. NOTE-To effect the removal of the shaft from cars prior to Commission No. TS. 4 1 1, there is no necessity to remove the grease nipple (operation d) and the shaft locating bolt (operation [...]

Clutch Assembly Fixture (Churchill Tool No. yjA) as used with g" clutch. Determine from the code card in the Churchill Fixture No. 99A, the reference numbers of the adapter, the spacers, and the spacers position letter on the Churchill base plate. For this clutch they are 7,3 and D respectively. Clean the top of the base plate and place the th[...]

CLUTCH Lift up inner end of release lever and disengage the strut. Repeat procedure for 2nd and 3rd levers. Gripping the tip of the release lever and the eye bolt lift out the assembly from the pressure plate. Repeat procedure for 2nd and 3rd levers. Remove the eye bolts from release levers and take out pins. Remove the struts from pressure plate. [...]

CLUTCH (1) Secure pillar firmly into centre of base plate. Place on No. 7 adapter, recessed side downward, followed by gauge finger. (m) Screw the adjusting nuts to raise or lower the release levers sufficiently to just contact the finger gauge (Fig. 13). Adjusting the release levers. Exchange the finger gauge and pillar for the actuator and operat[...]

CLUTCH end of the strut push outwards to the periphery of the pressure plate. Offer up the lever assembly, first engaging the eye bolt shank within the hole in the pressure plate, then locate the strut in the groove of the release lever. Fit the remaining levers in a similar manner. (b) Place the pressure plate on the wooden blocks on the base of t[...]

CLUTCH assembly on the flywheel so that 32. the ground lands of the gauge plate are situated under the release levers. (ii) Turn the adjusting nuts to bring the release lever tips to contact a short straight edge resting upon the boss of the gauge plate. (iii) Having made prehnary setting, operate the mechanism several times in order to settle the [...]

CLUTC the clutch facings, but providing the polish on the facing remains such that the grain of the material can be clearly distinguished, it has very little effect on clutch performance. Should increased quantities of oil or grease attain access to the facings, one or two conditions or a combination of the two, may arise, depending on the nature o[...]

CLUTCH SERVICE DIAGNOSIS. SYMPTOM 1. Drag or Spin. 2. Fierce- ness or Snatch. 3. Slip. 4. Judder. CAUSE (a) Oil or grease on the driven plate facings. (b) Misalignment between the en- gine and gearbox shaft. (c) Improper pedal adjustment not allowing full movement to release bearing. (d) Warped or damaged pressure plate or clutch cover. (e) Driven [...]

CLUTCH SYMPTOM 5. Rattle. 6. Tick or Knock. 7. Fracture of Driven Plate. 1 8. Abnormal Facing Wear. CAUSE (c) Pressure plate out of parallel with flywheel face in excess of of permissible tolerance. (d) Contact area of friction facings not evenly distributed. Note that friction facing surface will not show 100% contact until the clutch has been in [...]

[...]

[...]

GEARBOX INDEX Dimensions and Tolerances ...... Notation for Fig . l ...... . Notation for Fig 2 ...... Description ...... ...... ...... Operation ...... ...... Ratios ...... ...... ...... Bearings ...... ...... Mounting ...... ...... ...... ...... ...... ...... Oil Capacity ...... ...... ...... ...... ...... ...... Nut and Bolt Data ...... ...... T[...]

Fig. 1 Fig. 2 Fig. 3 Fig. 4 Fig. 5 Fig. 6 Fig. 7 Fig. 8 Fig. 9 Fig. 10 Fig. 11 Fig. 12 Fig. 13 Fig. 14 Fig. 15 Fig. 16 Fig. 17 Fig. 18 Fig. 19 Fig. 20 Fig. 21 GEARBOX ILLUSTRATIONS P Exploded view of Gearbox Casing, Extension housing ...... ...... Exploded view of Gears ...... Sectional view of Gearbox ...... Gearbox ready for withdrawal ...... Ali[...]

[...]

.494" -492" Crankshaft Bush Internal Diameter -4998" ternd Diameter to eter of Constant ,6887" .6880" 1.162" 1.160" n to H five assembly.[...]

GEARBOX Dimensions and Tolerances PARTS AND DESCRIPTION DIMENSIONS CLEARANCE REMARKS NEW Countershaft External Diameter of Countershaft Internal Diameter of Countershaft Gear Needle Roller Diameter .l 19" Countershaft Gear End Float Internal Width of Casing 6.771" 6.769" AfFected Length of 1st Countershafi Gear Width of Constant Gear[...]

GEARBOX Dimensions and Tolerances PARTS AND DESCRIPTION DIMENSIONS CLEARANCE REMARKS NEW Gearbox Top Cover Selector Shaft External Diameter Bore in Cover for Selector Shaft. Gear Synchronisation and Loading Details 2nd Speed Synchro Axial Load for Release 25 to 27 lbs. 3rd and Top Synchro Axial Load for Release 19 to 21 lbs. Gap between Baulk Ring [...]

[...]

GEARBOX lef. To. Description 1 Clutch and Gearbox Casing. 2 Bush for Clutch Shaft. 3 Bush for Clutch Shaft. 4 Drain Plug. 5 Front End Cover. 6 Oil Seal. 7 Joint Washer. 8 Setscrew for Cover. 9 Plain Washer for 8. .O Countershaft Cover. i l Joint Washer. 12 Setscrew. 13 Plain Washer. L4 Gearbox Extension. L5 Oil Seal. 16 Joint Washer. 17 Extension A[...]

GEARBOX V Fig. 2. Exploded view of Gears. 182 6[...]

GEARBOX Ref. No. Description 1 Mainshaft. 2 Triangular Washer. 3 Centre Bearing (Interchangeable with 36). 4 Outer Circlip for Centre Bearing (Inter- changeable with 37). 5 Circlip for Centre Bearing. 6 Washer for Centre Bearing. 7 Washer for Rear Bearing. 8 Rear Bearing. 9 Driving Flange. 10 Slotted Nut. 1 1 Plain Washer. 12 Split Pin. 13 1st Gear[...]

[...]

GEARBOX Description Four forward speeds with gear synchronisation on 2nd, 3rd and Top and one Reverse ratio actuated by a compound gear which is disengaged when in Neutral or in any of the forward gears. OPERATION A remote control lever is carried in a turret formed in the rear end of the top cover, which is at a point approximately~ha~ay down the [...]

GEARBOX (h) Disconnect the two wires from their terminals on the solenoid if an Over- drive is fitted. (i) Remove gearbox mounting after the withdrawal of two nuts by jacking up the unit, using a block of wood between jack and sump to avoid damage. (j) Remove starter motor bolts and slide starter motor forwards clear of the bell housing. (k) Remove[...]

GEARBOX (h) Withdraw the countershaft locating setscrew as shown in Fig. 7. Fig. 7 (9 Countershaft and Reverse Locating Set- screw partially withdrawn. After removal of the countershaft front end cover plate which is secured by two wired setscrews, plain washers and lead linger drive out the counter- shaft using a suitable tube as shown in Fig. 8, [...]

(1) Tap the mainshafi towards the rear with a sofi metal drift, as shown in Fig. 11, sufficiently to clear the bearing Fig. 11 Driving Mainshaft to rear with Tool No. ~oSMI to free Centre Main Bearing. from the casing. Next tilt the shaft sufficiently to enable the third and top synchro unit to be withdrawn as shown in Fig. 12. Note the position Fi[...]

Removing Mainshaft Centre Bearing with Press No. Sqazn an from Set No. S4615. e reverse pinion (compound gear) after tapping out its spindle through the rear of the casing, the *. g sets having been re- in a ous operation (h). The countershaft assembly can now lifted out of the casing with the needle roller retaining tube still locating the 24 roll[...]

GEARBOX (g) (i) Install the triangular washer on (ii) The 3rd speed constant gear float its splines on the mainshaft. on its bush (.004"-.006"). (i) is (ii) Press ball race on to mainshaft checked as in Fig. 17, and (ii) as with Churchill fixture as shown in in Fig. 18. Fig. 16. Then fit the thrust washer Fig. 18 Checking Third Gear Mains[...]

GEARBOX (iv) Axial release loading of 2nd speed synchro unit 25-27 lbs. (v) Axial release loading of 3rd and top speed synchro unit 19-21 lbs. (iv) and (v) can be checked as shown in Fig. 20. If it is found to be in- Fig. 21 Fitting Mainshaft Circlip with Churchill Tool No. zoSM. 46. TO SPRING BALANCE Fixture which can be readily manu- factured to [...]

this position with the correct thrust washer fitted, the small seeger circlip fits properly into its recess. When passing dis circlip along the ground portion of the constant pinion shaft, take care not to score the shaft as such amage may cause subsequent leakage of oil. Fit larger circlip into the annular groove in the outer ring of the ball race[...]

GEARBOX Fit countershaft front end cover plate (t) Install speedometer driving gear and and paper joint securing with two set- accommodating bush, securing with screws . .. and washers using lead linger special setscrew. and wiring as necessary. Assemble gearbox extension and paper joint, securing with six setscrews and washers, using lead linger a[...]

GEARBOX (v) Assemble clutch throw-out bearing and sleeve and install with clutch operating shaft coil spring and clutch operating fork, positioning both with special securing setscrews, wire locking the latter. Install grease nipple with fibre washer into R.H. end of clutch operating shaft. (W) Fit top cover assembly with selector mechanism, paper [...]

GEARBOX INSTALLATION OF OVERDRIVE I. DISMANTLING Remove the detachable floor pressing from around the gearbox. Remove the four bolts connecting the propeller shaft to the gear- box flange. Disconnect the speedometer drive from the gearbox. Remove the bottom nuts of rear mounting and jack up engine sufficiently to allow removal of rear mounting. Rem[...]

GEARBOX The end float can then be checked with a set of feeler gauges as shown in Fig. 30. The correct float should be between .007" and .012". Remove the mainshaft details remain- ing on the shaft and begin the final assembly. Feed the shaft into the casing and assemble the 2nd gear synchro unit, the hardened steel thrust washer whlch mu[...]

e cam. The 6uts are Remo?~e e-.e coves plate by -p4--- LiAAl.,C cheese he%$& :;airs, Slzckec 03 the e S=,* ck.arct~jL?g bolt on l>e SQJ~~~~ZI. lever, A C *, . ~ Xc:~;[~ the vake seteng levey nn~$ 1-CS 3.'' <. 16 - // e. &gixgf:ej: :lccje cc~lc~~~~~ &l7> & &a- .- m . mets~ :~~2fi 23 :,he cafb~.-- Icselt a"[...]

GEARBOX 6. FITTING THE ISOLATOR SWITCH On the lid of the gearbox, and situated near the dipstick, is a plug with a 16 mm. dia. thread. This plug should be removed and replaced by an isolator switch type SS 1011, which is supplied (see Fig. 36). See page 24 for multi-gear overdrive. Fig. 37 Showing the position of the Overdrive Control. the " l[...]

GEARBOX WHITE FEED SIDE. 7 1 SWITCH. SWITCH RELAY CONTACTS -%--l the gearbox lid. A second feed wire is connected from the negative side of the meter to " C1 " on the relay. To complete the wiring, a wire is connected from " C2 " on the relay through a snap connecter to the solenoid. Built into the solenoid are two coils, a clos[...]

GEARBOX SUPPLEMENTARY INSTRUCTIONS FOR INCOR ORATING OVERDRIVE ON Cc SECOND" AND "T IRD" GEARS I. The incorporation of Overdrive on 3. GEARBOX TOP COVER ASSEMBLY " Second " and " Third " gears has Fig. 41 necessitated the following engineering alterations :- To ~ermit the selection of overdrive in (a) Increasing t[...]

GEARBOX SUPPLEMENTARY INSTRUCTIONS FOR INCORPORATING OVERDRIVE ON cSECOND" AND "THIRD" GEARS Fin. 40 Ghost view of Top Cover AssembIy. - - (iii) Withdrawing the pivot bolt (3) (f) Remove 1st and 2nd speed selector to enable the change speed lever shaft retaining screw (6), spring and assembly to be withdrawn. $" locking ball and[...]

GEARBOX SUPPLEMENTARY INSTRUCTIONS FOR INCORPORATING OVE VE ON SECOND" ccTHIRD " GEARS NOTE. It is important that no attempt is made to move more than one selector shaft at a time otherwise damage will be caused to the bores of the top cover and difficulty will be experienced in removing the shafts. Finally shake out the interlock balls f[...]

GEARBOX SUPPLEMENTAIRY INSTRUCTIONS FOR INCORPORATING OVERDRIVE ON '"SECOND" AND "THIRD" GEARS (d) Measure with feeler gauges the gap Wiring. The switches are wired in between the switch and boss, that is, parallel (Fig. 43) and the necessary link the amount the switch would have to lead from switch to switch is obtainable [...]

[...]

ervice Instr EAR AXLE SECTION F[...]

INDEX Notation for Fig . 2 ...... ...... ...... ...... Data ...... ...... ...... ...... ...... ...... General description ...... ...... ...... To remove hubs ...... ...... ...... ...... To revlace hubs ...... ...... ...... ...... To rgmove hubs ...... TO replace hubs C entre lock type To remove axle shaft ...... ...... ...... To replace axle shaft [...]

Fig. X Axle arrangement. (For Notes I and 2 See page 4).[...]

REAR AXLE[...]

REAR AXLE NOTATION FOR REAR AXLE EXPLODED VIEW (FIG. 2) Ref. No. Description Axle casing assembly Breather. Fibre washer. Drain plug. Grease nipple. Bearing cap. Bearing cap setscrew. Tab washer. Differential bearing. Shims. Differential casing. Sun gear. Thrust washer. Planet gear. Thrust washer. Cross pin. Locating pin. (See note 1 page, 4). Crow[...]

AXLE between the " head" bearing outer ring and the casing. %reloading of bearings is adjusted by means of skims between the spacer and tail bearing. The differential casing contains two sun and two planet wheels and also carries the crown wheel, which is bolted in position by ten bolts passing through the casing and into tapped holes in [...]

AR AXLE 4. TO REMOVE HUBS (Centre lock tates the severing of the hand brake type) (Fig* 35) and hydraulic connections and re- (a) Jack up the car and remove the hub moving the brake backing plate. cap by-tapping the lugs with a copper faced mallet. Remove the road wheel. 5. TO REPLACE HUBS (Centre lock tyI?e> (Fig* 35) (b) Remove the split pin t[...]

REAR AXLE (e) Remove the four bolts and nyloc nuts 7. TO REPLACE AXLE SHAFT which secure the brake backing plate and the bearing housing to the axle The replacement of the axle shaft is the flange. reversal of their removal. However the following points should be noted. (f) Withdraw the axle shaft assemblv from the axle casing together with th; bra[...]

On later production cars the axle shaft e replacement necessary to bleed the brakes. e axle has to be 'Jack up car and remove roa nyloc nuts. this can be effected by inserting the blade of a screwdriver into the split to expand the ring which can then be First disconnect the Bundy Tubing and the hand brake cables at the wheel cylinders and the[...]

g. TO REPLACE T the axle is going to be completely If a replacement axle is being fitted it will dismantled the hubs can be removed at be necessary to remove the complete brake a later stage, which means that the assemblies at the axle ends. half shafts, hubs, brake backing plates, etc., must be removed as an assembly. It is not necessary to remove[...]

AR AXLE (g) Remove axle centre casing cover and joint after withdrawal ofeight setscrews. ) Remove the differential bearing caps, noting the markings stamped on the top of these and the correspondingly abutt- ing portions of the casing. The exis relation between the caps and casing must be retained when re-assembling. Fig. 12 shows example of marki[...]

REAR AXLE assembly can be removed from the axle casing and dismantled as follows : (i) Drive out the cross pin locating pin and withdraw the cross pin. (ii) Rotate the sun wheels which will in turn rotate the planet wheels until the planet wheels with their respective thrust washers are op- posite the cut away portions of the crown wheel carrier fr[...]

REAR AXLE Fig. 18 Fitting pinion bearings outer rings utilis- ing Churchill Tool No. M70. (ii) Fie the dummy pinion (M.84), the pinion bearing inner cones and install into the axle centre casing ; tightening the flange nut progressively until the correct pinion pre-load of 15-18in. lbs. is obtained. (iii) Install the pinion setting gauge in the axl[...]

(iv) Although the packing shims are sup- plied to nominal thicknesses, the dimen- sions should be measured with a micrometer gauge. It is important that no damaged shims are used and that they are thoroughly cleaned before measurement. (Fig. 2 1 .) (v) Remove the pinion setting gauge, dummy pinion and pinion bearing outer rings. (vi) Insert the mea[...]

AR AXLE Fig. 25 Testing the pre-load of the pinion bearing utilising the Churchill Tool No. mSM. 98 Note : The oil seal is not fitted at this juncture. (xi) The fixture shown in Fig. 25 is now applied and the pre-load of the bearings checked. The correct pre-load should fall between 15-18 in.lbs. If the pre- Fig. 27 Fitting differential utllislnb t[...]

REAR AXLE levered in the opposite direction until the taper roller bearings go hard home. The reading on the dial gauge (.062" for example) will indicate the total side float of the crown wheel carrier and should be noted for later reference. (xv) The crown wheel carrier is now re- moved from the axle centre casing so that the sun gears, plane[...]

REAR AXLE To obtain the thickness of the shims required between the other differential bearing and casing, the figure arrived at in previous operation, i.e., .040", should be subtracted from the total side float measured in operation (xiv), plus an allowance of .005" to provide the necessary degree of bearing pre-load. This gives a total [...]

REAR AXLE the same overall total. Should the back- lash be insufficient, then the reverse procedure must be adopted. A tooth marking test should now be carried out, and to enable this to be done a few teeth should be painted with a suitable marking compound. The pinion should be rotated backwards and forwards by the driving flange, over the marked [...]

"Knock on " type hub. I. Axle casing. 5. 2. Hub bearing. 6. 7. 3. Axle shaft. 4. Oil seal. CAUSE I. Axle Noise Seal and Bearing Housing. Brake assembly. Fixing bolts for brake backing plate and seal / bearing housing. Inadequate or improper lubrication. Teeth broken o Contact of crown wheel and pinion not correctly adjusted. (a) Leakage i[...]

[...]

ON U AND N[...]

FRONT SUSPENSION AND STEERING FRONT SUSPENSION INDEX Front Suspension Data ...... ...... ...... ...... Description ...... ...... ...... ...... ...... ...... Notation for Fig . 2 ...... ...... ...... ...... Maintenance ...... ...... ...... ...... ...... ...... Front Wheel Alignment ...... ...... ...... To adjust Front Wheel ~li~nment""&quo[...]

FRONT SUSPENSION AND STEERING ILLUSTRATIONS Fig. 1 Fig. 2 Fig. 3 Fig. 4 Fig. 5 Fig. 6 Fig. 7 Fig. 8 Fig. 9 Fig. 10 Fig. 11 Page Front Suspension arrangement 1 Exploded details of Front Suspen- ...... ...... sion Unit ...... ...... 4 Outer Tie-rod assembly ...... 6 Showing use of Wheel Turning Measure for setting wheel lock. V. L. Churchill Tool No.[...]

ONT SUSPENSION RUBBER FULCRUM BUSHES SECTION SFOWING RUBBER WSHES LOWER END OF DAMPERS SECTION SHOWING RUBBER BUSHES MNER FULCRUM-TOP WISHBONE. Fig. I Front Slls[...]

RUBBER BEAR1,NGS I y SECTION SHOWING RUBBER BUSHES LOWER WISHBONE-INNER FULCRUM l SECTION THRO'OUTER SHACKLEPIN- LOWER WISHBONE.[...]

[...]

FRONT SUSPENSION AND STEERING FRONT SUSPENSION DATA Track at Ground (Static Laden) 45" Castor Angle ...... ...... Nil King pin 1nclinati0h (Static Laden) ...... 7" Wheel Camber (Static Laden) .... 2" Wheel Camber (Full Bump 3") z 10 Wheel Camber (Full Rebound 2.25") ...... 1" Turning Circle ...... ...... ...... 32&apos[...]

FRONT SUSPENSION AND STEERING r-[...]

FRONT SUSPENSION AND STEERING NOTATION Ref. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. Description Inner Upper Fulcrum Pin. L.H. Front Upper Wishbone Arm. R.H. Front Upper Wishbone Arm. Rubber Bush. Plain Washer. Castellated Nut. Split Pi[...]

FRONT SUSPENSION AND STEERING As a precautionary measure it is most desirable to check that an end float of .004" to .012" in the lower outer wishbone arm attachment to the shackle pin is main- tained. Each arm is adjusted independently. Apart from damage at this point, tightness at this point can appreciably affect the ride of the car (s[...]

FRONT SUSPENSION AND STEERING 7. TO SET STEERING LOCK STOPS (a) Select a space of level ground and run the car gently forward so that the front wheels run on to the Churchill Turning measure and the back wheels on to blocks as high as the Churchill gauge (Fig. 4). This will ensure that the car maintains its level. (b) Measure the wheel movement fro[...]

FRONT SUSPENSION AND STEERING The hub bearings are now considered to be correctly adjusted and the castel- lated nut can be locked with the split pin. (f) Fit the grease retaining cap and grease nipple to hub, and grease hub. (g) Replace road wheel and nave plate. Remove lifting jack from under front of car. 10. TO REMOVE FRONT S ABSORBER (a) Jack [...]

SUSPENSION AND STEE Place the rebound rubber abutment plate in position on the lower attach- ment studs (welded to the spring pan) with the apex of the wedge pointing towards the centre of the car. Secure with nuts and lock washers. Utilising two long bolts, nuts and lock washers secure the rebound rubber and its bracket to the chassis frame. Remov[...]

FRONT SUSPENSION AND STEERING Assemble the alloy distance piece (spigot downward) on the road spring with a rubber washer interposed be- tween, and position a second rubber washer on the spring's lower extremity. The spring and distance piece assembly is offered up to the front suspension unit followed by the spring pan, the latter located on [...]

FRONT SUSPENSION AND STEERING (g) Withdraw the split pin from the castel- lated nut securing the ball joint as- sembly to the upper wishbone arm. Remove the castellated nut and with- draw the ball joint assembly from the wishbone arms, collecting the distance piece as the ball joint is moved. (h) Withdraw the split pin and remove the nut and plain [...]

SUSPENSION A Feed the locking washer and steering lock stop bush on to the steering stop securing bolt and attach to the bottom trunnion assembly. The bolt is left finger tight at this juncture. Fit two rubber bushes to the inner lower fulcrum pin situated on the upper face of the chassis frame, one to each side. Fit two thrust washers to the shack[...]

FRONT SUSPENSION A (wi) Attach the rod of the Churchill Tool No. M.50 to the spring abutment bracket and the guide rods through the centre of the lower wishbone arms. (xvii) Assemble the alloy distance piece (spigot downward) on the road spring with a rubber washer interposed, fit a second rubber washer to the lower extremity of the road spring. (x[...]

FRONT SUSPENSION AND STEERING[...]

FRONT SUSPENSION AND STEERING STEERING NOTATION FOR FIGURE 11 Ref. No. Description Outer Tube and Box Assembly. Rocker Arm Bush. Rocker Arm Oil Seal. Inner Column and Cam. Rubber Ring. Felt Bush. Inner Column Ball Cage. Ball Cage Race. End Cover. Joint Washer. Adjusting Shims. Bolt. Lock Washer. End Plate Gland Nut. Rocker Shaft Assembly. Top Cover[...]

FRO PENSION A ENANC An oil filler is provided in the form of a lug, which is locate on the steering at approximately 12" from the steering box. gh pressure oil should be used for shment. (See Lubrication Chart for The felt bush in the top of the column outer tube is graphite impregnated and should, erefore, require no additional lubrication. o[...]

FRONT SUSPENSION AND STEERING Fit the brass olive to the protruding stator tube and secure with the gland nut. Loosen nut back one turn, this is retightened in a later operation. Feed the wires from the short tube of the control head into and through the stator tube now in the steering unit. With the flasher control lever of the head at 12 o'c[...]

FRONT SUSPENSION AND STEERING Fig. 13 The Steering Unit being removed from the front of the car. For the purpose of this illustration the bumper has not been removed. Note the wrapping on the bumper bar to prevent wing damage. (R) After the removal of the steering unit the drop arm can be detached from the rocker shaft, utilising a suitable puller [...]

FRONT SUSPENSION AND STEERING Remove cover and joint washer after withdrawing the setscrews of the steer- ing box cover. Allow the oil to drain away. Withdraw the rocker shaft whilst pro- tecting the rocker shaft oil seal with a thin cylinder of shim steel. Remove the setscrews and lock washers securing the end cover to the steering box, followed b[...]

ONT SUSPENSION AND STEERING The drop arm must only be removed by a special puller, Tool No. M.91 is re- commended, a hammer must not be used since any blow would be transferred to the hardened conical pin in the rocker shaft lever which would in turn indent the cam gear and damage the unit. The drop arm should only be replaced when the mmnion brack[...]

FRONT SUSPENSION AND STEERING 16. TELESCOPIC (ADJUSTABLE) STEERING UNIT (a) Description (Fig. 15) This unit is very similar to the normal equipment apt& from three main features :- (b) Steering Unit (i) The inner column is of similar length, but its steering wheel attachment splines are of a much greater length. (ii) The outer column is shorter[...]

FRONT SUSPENSION AND STEERING 17. TO FIT THE TELESCOPIC (ADJUSTABLE) STEERING UNIT AND STEERING WHEEL With the exception of the steering wheel the fitting of this unit does not differ from that of the normal equip- ment. Follow the sequence given in "To Fit Steering Unit" (see page 18, operations (a) to (h)). Ensuring that the car is on l[...]

FRONT SUSPENSION AND STEERING 20. TO FIT CONTROL HEAD AND STATOR TUBE TO TELESCOPIC STEERING WHEEL The procedure is the same as fitting the normal equipment but it may be considered necessary to apply a smear of grease to the upper (slotted) end of the stator tube to ensure freedom of movement. It must be pointed out that over greasing at this poin[...]

SUSPENSION AND STEE ASSESSMENT OF ACCIDENTAL DAMAGE The following illustrations are necessary for the assessment of accidental damage. It is suggested that the suspect components are removed from the car as described in this Section, cleaned and laid on a surface plate for measuring. The measurements taken should be com- pared with those shown in t[...]

Fig. 20 ----L! '3'16"~~~ N C 10 T PI EFFECTIVE BA ,742 TRUNCATE TO :g$:DIA THREADS MUST BE SMOOTH CLEARANCE ON EFFECTIVE DIA. WHEN SCREWED INTO PART NO 200438 TO BE '88:. The Vertical Link.[...]

FRONT SUSPENSION AND STEERING 00'5 WITH Fig. 21 R.H. front and L.H. rear upper wishbone. Fig. 22 U U L.H. front and R.H. rear upper wishbone. Fig. 23 The R.H. front and L.H. rear Lower Wishbone. The R.H. rear and L.H. front are symmetrical but opposite handed.[...]

[...]

P4 AND 0 0 ...... Description ...... ...... ...... ...... ...... ...... Maintenance ...... ...... ...... emove or Replace ...... ...... ...... ...... ...... aintenance ...... ...... ...... To Rernove Rear Road Spring Notation for Figure 3 ............ To Fit Rear Road Spring ...... Rear Road Spring Overhaul ...... To Dismantle Rear Road Spring To A[...]

ROAD SPRINGS AND SHOCK ABSORBERS IF PER ?aN~? FOOT LENSTH SPRING DATA 11 COMPETITION RATE 380 LB~N 925 LB , ITEM WIRE DIA NUMBER OF WORKING CMLS MEAN DIA l3 CCNLS I HAND OF HELIX I RIGHT 11 SOLID LENGTH I 4.16' 4.29 MU( I DIMENSION 50"'002" 6% 3 5 ? GENERAL DATA 1 FITTED LOAD STATIC DEFLECTION MATERIAL ITEM DIMENSION 11 ITEM DI[...]

ROAD SPRINGS AND SHOCK ABSORBERS FRONT SPRING a. DESCRIPTION The low periodicity coil spring used in the fiont suspension of this car is illustrated in Fig. 1. This illustration also gives the data of both the normal road spring and the competition spring. This competition spring can easily be distinguished from the normal type, for it has a left-h[...]

A? SECCUCU3 W5 TAPERED m oq-THICK 10 Fig. 2 Raw Road S-.[...]

V Fig. 3. Exploded Rear Suspension Details. NOTATION FOR FIGURE 3. Ref. No. Description 1. Rear Road Spring 2. Silentbloc Bush. 3. Front Attachment Bolt. 4. Castellated Nut. 5. "D" Washer. 6. Svlit Pin. 7. shackle Pin and Plate Assembly. 8. Rubber Bush. 9. Shackle Plate. 10. Nut. 11. "U" Bolt. Ref. No. Description 12. Right Hand[...]

ROAD SPRINGS AND FIT REAR ROAD SPRING Press the silentbloc bush into the forward eye of the road spring and ensure that the eight split rubber bushes are in good condition. Offer up the spring, short end forward, to a position above the rear shackle bracket of the chassis frame and below the axle. Support the spring on a small jack and attach sprin[...]

OIL- SEAL ROAD SPRINGS AND I I Fig. 4 The Fmt Shock Abeorber. SHOCK ABSORBERS FRONT SHOCK ABSO A telescopic type shock absorber is fitted, utilising a stem fixing at the top with rubber bushes, large diameter steel washers and lock nuts. At the lower end it is first attached to a fulcrum pin bracket with rubber bushes interposed between shock absor[...]

volume equal to the displacement of the piston rod (D) passes through the ports (E) in the piston rod guide (F), down the anti- foam tube (G) and into the reservoir (H) by way of the rebound valve (RV). On the rebound stroke, however, the piston valve (Pv) closes and oil passes through the ports (E) in the piston rod guide (F), down the anti-foam t[...]

ROAD SPRINGS AND SHOCK ABSORBERS The unit is filled to the base of the filler plug boss which prevents over filling and main- tains the necessary air space essential to satisfactory operation. The working mech- anism is completely submerged in oil which is prevented from leaking along the spindle by means of oil seals. 2. MAINTENANCE The damper req[...]

ervice Instruction Manual FRAME UNIT SECTION J[...]

INDEX Page Description ,., -... ...... -.- ..~... ..*... .... W .....- 3 The assessment of accidental damage ...... ...... ....- - 3 Preparation of the car ...... *..... ..... e ...... .-.- - 4 Checking Side Members for "Twist" ...... ...... ...... .-.- 5 Checking Side Members for "Cradling" ...... ...... ....- ....- 5 Checking [...]

I. DESCRIPTION. Fig. n. A rigid structure is provided, the frame side members being formed by opposed steel pressings welded together, giving tubular type side members of rectangular section. ded at the front and rear ends of the members are two tubular cross mem- bers. The front tube is 19" diameter and is supported by the steering unit and i[...]

FRAME UNIT - 88 00" WHEEL BASE - 8 49' cl 8 44' I FRAME DATUM {Plan view of Frame Unit. Fig* I Side view of Frame Unit.[...]

-! MRX PERMISSABLE WRI4TIClM BETWEEN 1 /SIDEMEMBERS OVER THIS LEMCTH 9 .20" :::& TO REAR CROSS U ' MAX PERMlSSA8iE VARIATION BETWEEN SIDEMEMBERS OVER THIS LENGTH ? -10"[...]

I %' DIA. TUBE 13': DIATUBE I I d 1 AB CD E.F GH Fig. 2 The car prepared for the assessment of accidental damage, in particular the assessment of "cradling" (for clarification purposes only the chassis frame is shown). 3. PREPARATION OF CAR (Fig. 2) (a) Select a clean level floor space and jack up the car, utilising four screw j[...]

FRAME UNIT Fig. 3 Illustrating the eight points of the chassis which are generated on the floor below. JI 4. CHECKING THE SIDE MEMBERS FOR TWIST If, by adjusting the screw jacks under the chassis frame as described in "Preparation of Car" page 3 operation a-c, it is found to be an impossibility to bring the front cross member and the stra[...]

Fig. 4 Utilising the eight generated points for the assessment of frame squareness." 6. CHECKING SIDE MEMBERS FOR SQUARENESS (Fig. 4) (a) It is assumed that the car has been pre- pared and the eight points generated on the floor below. Replace the road wheel and rebound rubber bracket. The car is now moved so that the position of the markings [...]

FRAME UNIT Fig. 5 Utilising the eight generated points for the assessment of "bowing." 7. CHECKING THE SIDE MEMBERS (c) With a suitable straight edge join point FOR BOWING (Fig. 5) J to point M. (a) Having gained access to the points generated on the floor beneath the car, join the points A to B, C to D, E to F and G to H. (b) Accurately [...]

[...]

SECTION K 27[...]

PROPELLER SHAFT INDEX Page ...... ...... ...... Type and Description ...... ...... ...... ...... 1 Lubrication and Maintenance Instructions ...... ...... ...... ...... l Removal of Propeller Shaft ...... ...... ...... ...... ...... ...... 2 Dismantling Propeller Shaft ...... ...... ...... ...... ...... ...... 2 To Examine and Check for Wear ...... [...]

PROPELLER SHAFT Fig. I Propeller Shaft Details. I NOTATION FOR FIG. I Ref. No. 1 2 3 4 5 5A 6 7 I. DESCRIPTION The propeller shaft and universal joints fitted to this model are the Hardy Spicer Series 1300, the tube diameters being 2", and the overall length of the assemblies being 2' 4&". Details of these propeller shafts are as[...]

PROPELLER S is located by testing the lift in the joint by hand. Any circumfer tial movement of the shaft relative to the e yokes indicates wear in the needle roller bearings and/or the sliding splines. REMOVAL OF PROP (a) Jack up one rear wheel clear of the ground to enable the propeller shaft to be rotated. (b) Remove nuts from bolts at both flan[...]

PROPELLER S T Fig. 2. Top bearing should begin to emerge, turn joint over and finally remove with fingers as shown in Fig. 3. If necessary tap bearing race from inside with small diameter bar, as shown in Fig. 4, taking care not to damage the bearing race. This operation will destroy the oil seal and necessitate fitting replacement parts when re-as[...]

PROPELLER SHAFT Insert spider in flange yoke. Then using a soft-nosed drift about kff smaller in dia- meter than the hole in the yoke, tap the bearing into position. It is essential that bearing races are a light drive fit in the yoke holes. Repeat this operation for the other three bearings. Refit snap rings with a suitable pair of circlip pliers,[...]

Service Instruction Manu WHEELS AND TYRES SECTION L 281[...]

...... Construction of Tyre ............ ...... ...... ...... Tyre Pressures ............ ...... ...... ...... ...... ...... ...... Valve Cores and Caps ............ ...... ...... ...... Tyre Examination ...... ...... ...... ...... ...... ...... ...... Repair of Injuries ...... ...... ...... ...... ...... Factors affecting Tvre Life and Performance[...]

Fig. r Tyre Construction. Construction of Tyre ne of the principal functions of the tyres to a car is to ate high frequency vibrations. They do virtue of the fact that the unsprung mass of eac tyre-the part of the tyre in contact with the round-is very small. Tyres must be flexible and responsive. They must also be strong and to to contain the air [...]

WHEELS the recornmend~tions, the owner will obtain the best results both fmrn the tyres and the car. Tyre Pressures: Correct tyre pressures for 5.50"-15" are : Front 22 lbs. Rear 24 lbs. Mote.--Pressures should be checked when the tyres are cold, such as after standing overnight, and not when they have attained normal running temperatures[...]

a tube patch attached to the inside of the casing. This will protect the tube from possible chafing at that point. If nail holes are not clean, and par- ticularly if frayed or fractured cords are visible inside the tyre, expert advice should be sought. X. FACTORS AFFECTING TYRE LIFE AND PERFORMANCE (a) Inflation Pressures Other things being equal t[...]

EL§ AND TYRES are taken into account when designing the tyre and in preparing Load and Pressure Schedules. Pressures in warm tyres should not be reduced to standard pressures for cold tyres. " Bleeding " the tyres increases their deflections and causes their tem- peratures to climb still higher. The tyres will also be under-inflated when[...]

WHEELS AND TY driving and braking are greater than some areas the surface dressing is when the tyre is part worn. Higher coarser or of larger " mesh " than in tread mileages will usually be obtained others. The material may be com- if new tyres are fitted in the autumn paratively harmless rounded gravel or or winter rather than in the spr[...]

WHEELS AND TYRES Impact Fractures In order to provide adequate strength, resistance to wear, stability, road grip and other necessary qualities, a tyre has a certain thickness and stiffness. Excessive and sudden bcal distortion such a.s might result from striking a kerb, a large stone or brick, an up- standing manhole cover, or a deep pothole may f[...]

EELS A S vantage In ths respect and their pattern displacement tends to be al- ways in the same direction. Fig. l0 illustrates the basic cause of SLIP OF ROAD IN BRA RELATIVE TO TYRE howing the effect of braking and rolling resistance on Tyre Tread. " heel and toe " wear. If the tyre is assumed to be on a locked wheel and sliding forward,[...]

WHEELS AND 'NRES worn at irregular spacings round the circumference-indicates an alternat- ing " slip-grip " phenomenon but it is seldom possible to associate its origin and development with any single cause. It is preferable to check all points which may be contributory factors. The front tyre and wheel assemblies Fig. 12 Fins and F[...]

WHEELS AND TYRES TOE OUT MORE WEAR ON R H. FRONT TOE IN MORE WEAR ON L.H. FRONT WHEELS PARALLEL WEAR EQUAL c---- CAMBER DOWN Fig. 13 Exaggerated Diagram showing effect of road camber on a car's progress. As a result the car runs crab-wise, dia- grammatically illustrated in an exaggerated form in Fig. 13. The diagram shows why nearside tyres ar[...]

WHEELS AND 'IT 4. CBMBER, CASTOR A NG PIN INCLINATION These angles normally require no attention unless they have been disturbed by a severe impact or abnormal wear of front end bearings. It is always advisable to check them if steering irregularities develop. Wheel camber, usually combined with road camber, causes a wheel to try to rurn in th[...]

WHEELS AND TYRES troubles develop, and mechanical in- eccentric wheels gve the same effect. vestigation fails to disclose a possible During rotation the offset weight dis- cause, wheel and tyre balance should tribution sets up a rotating couple be suspected. which tends to steer the wheel to A Tyre Balancing Machine is marketed right and left alter[...]

WHEELS AND TYRES DYNAMIC OR COUPLE UNBALANCE EQUAL EXCESS MASSES AT 'A' AN D 'B' Fig. 17 Dynamic or Couple Unbalance. The causes may lie in road conditions, traffic conditions, driving methods and certain features of design which are essen- tial to the control, steering and driving of a car. Close attention to inflation pressure[...]

WHEELS AND TYRES Final tightening should be done pro- (c) Examination gressively and alternately by short turns of This should be done periodically every opposite nuts to ensure correct seating and 5,000 miles or at more frequent inter- to avoid distortion. vals if the car is used for competition Wheels with damaged or elongated stud driving or rac[...]

(ib) Rims All rust should be cleaned off the exterior of the rim and the affected portion protected with enamel or similar finish. When the tyres are changed the interior of the rims can be inspected for corrosion. Particular attention must be paid to the corrosion, if it is not cleaned away the tyre will become affected. (d) Wheel Building (See Fi[...]

[...]

ELECTRICAL EQUIPMENT INDEX Routine Maintenance ...... ...... ...... ...... .... Service Data ..... ...... ..... .... Specific Gravity of~lectz~te ... Servicing ........... ...... ...... .... . . ...... Recharging from an External Supply ............ ...... Preparing new unfilled, uncharged Batteries for Service Preparing GTZ " Dry-charged &quo[...]

ELECTRICAL EQUIPMENT INDEX HEADLAMPS . Page Description ...... ...... ...... ...... ...... ...... ...... 22 Bulb Replacement ...... ...... ...... .... m ...... ...... 23 ............ Ministry of Transport Lighting Regulations ...... 23 ...... Beam Setting ...... ...... ...... ...... ..... ...... 23 Renewal of Light Unit ............ ...... ...... .[...]

Fig . 1 Fig . 2 Fig . 3 Fig . 4 Fig . 5 Fig . Q Fig . 7 Fig . 8 Fig . 9 Fig . 10 Fig . 11 Fig . 12 Fig . 13 Fig . 14 Fig . 15 Fig . 16 Fig . 17 Fig . 18 Fig . 19 Fig . 20 Fig . 21 Fig . 22 Fig . 23 Fig . 24 Fig . 25 Fig . 26 Fig . 27 Fig . 28 Fig . 29 Fig . 30 Fig . 31 Fig . 32 Fig . 33 Fig . 34 Fig . 35 Fig . 36 Fig . 37 Fig . 38 Fig . 39 ELECTRIC[...]

7A/2, GTW9A,2, GT9A/2 and GTZ9A/2 I. WOU Every 1,008 miles, or monthly (weekly in hot climates) examine the level of the electrolyte in the cells, and if necessary add distilled water to bring the level up to the top of the separators. A convenient method of adding the distilled water is by means of the Lucas Banery Filler, a device which automatic[...]

ELECTRICAL EQUIPMENT (cj Maximum Permissible Electrolyte Temperature During Charge Climates normally Climates between Climates frequently 1 below 80°F. (27°C.) 1 80'-100°F. (27°-380C.) 1 above 100°F. (3RC.) Fig. I Topping up Battery. N.B.-Never use a naked light when examin- ing a battery, as the mixture of oxygen and hydrogen given off b[...]

ELECTRICAL EQUIPMENT Press the contact prongs against the exposed positive and negative ter- minals of each cell. A good cell will maintain a reading of 1.2-1.5 volts, depending on the state of charge, for at least 6 seconds. If, however, the reading rapidly falls off, the cell is probably faulty, and a new plate assembly may have to be fitted. Rec[...]

ELECTRICAL EQUIP Keep the current constant by varying the series resistance of the circuit or the generator output. This charge should not be broken by long rest periods. If, however, the temperature of any cell rises above the permissible maxi- mum quoted in Para. 2 (d), the charge must be interrupted until the tem- perature has fallen at least 10[...]

ELECTRIGAL EQUIP Filling the Cells Remove the seals from the cell filling holes and fill each cell with correct specific gravity electrolyte to the top of the separators IN ONE OPERA- TION. The temperature of the filling room, battery and electrolyte should be maintained at between 60°F. and 100°F. If the battery has been stored in a cool place i[...]

ELECTRICAL EQUIPMENT (c) Belt Adjustment Fig. 4 Checking Brush Gear. At the same time, remove the metal band cover to inspect the brushgear and commutator. Check that the brushes move freely in their holders by holding back the brush springs and pulling gently on the flexible connectors. If a brush is inclined to stick, remove it from its holder an[...]

ELECTRICAL Gradually increase the engine speed, when the voltmeter reading should rise rapidly and without fluctuation. Do not allow the voltmeter reading to reach 20 volts and do not race the engine in an attempt to increase the voltage. It is sufficient to run the generator up to a speed of 1,000 r.p.m. If there is no reading, check the brush gea[...]

ELECTRICAL EQ NT (vi) The driving end bracket, which on removal from the yoke has withdrawn with it the armature and armature shaft ball-bearing, need not be separated from the shaft unless the bearing is sus- pected and requires examination, or the armature is to be replaced ; in this event the armature should be removed from the end bracket by me[...]

ELECTRICAL EQUIPMENT (iii) Mark the yoke and pole shoes so that the latter can be fitted in their original positions. (iv) Unscrew the pole shoe retaining screws by means of the wheel- operated screwdriver. (v) Draw the pole shoes and coils out of the yoke and lift off the coils. (vi) Fit the new field coils over the pole shoes and place them in po[...]

ELECTRICAL EQUIPMENT be filled with lubricant. In cases of extreme urgency, this period may be shortened by heating the oil to 100°C. for 2 hours, then allowing to cool before removing the bear- ing bush. The ball bearing at the driving end is replaced as follows:- (i) Drill out the rivets which secure the bearing retaining plate to the end bracke[...]

ELECTRICAL EQUIPMENT petrol-moistened cloth. Replace the 4. SERVICING brush in its original position. Brushes which are worn must be replaced, see (a) Testing in Position Para. 4 (d) (i). If the motor does not operate or fails to crank the engine when the starting (b) Check the tension of the brush springs, button is used, switch on the lamps and a[...]

ELECTRICAL EQUIPMENT (b) Bench-testing (i) Removing the starting motor from the engine : Disconnect the earth terminal on the battery to avoid any danger of short circuits. Remove the heavy cable from the starting motor. Remove the mounting bolts and withdraw the starting motor from the engine. (ii) Measuring the light running current : Secure the [...]

(iv) Fault Diagnosis-(cont'd) SYMPTOM Speed, torque and current consumption low. m Speed and torque low, current consumption high. Armature does not rotate, no current con- sumption. Armature does not rotate, high current consumption. Excessive brush movement causing arcing at commutator. I Excessive arcing at the commutator. I PROBABLE FAULT [...]

ELECTRICAL EQUIPMENT (i) Brushgear Where necessary the brushes and brush-holders must be cleaned, using a fluffless petrol-moistened cloth. To prevent damage to the com- mutator, brushes must be replaced when worn to -f6-" in length. The flexible connectors can be removed by unsoldering, and the con- nectors of the new brushes secured in place[...]

ELECTRICAL EQUIPMENT Field Coils Continuity Test : Fig. 18 Testing for Open Circuit in the field coils. Connect a battery and suitable bulb in series with two pointed probes. If the lamp fails to light in the following test an open circuit in the field coils is indicated and the defective coils must be replaced. Place the probes on the brush tappin[...]

ELECTRICAL EQUIPIIENT Porous bronze bushes must not be opened out after fitting or the porosity of the bush may be impaired. NOTE: Before fitting a new porous bronze bearing bush it should be completely immersed for 24 hours in clean, thin engine oil. In cases of extreme urgency this period may be shortened by heating the oil to 100°C. for 2 hour[...]

RUBBER 9ETAINI-Ji SLEEVE CONTROL PEG PINION LOCmING UNIT ASSEMBLY RlhG L< 9 '~bb FRICTION WASHER COJ'LING RESTRA NING FRICTION LOCATING LOCAilffi PLATE SPRING WASPER NUT RING jig. 20 Exploded view of Starter Motor Drive Assembly. 4. DISMANTLING Having removed the armature as described in the section dealing with starting motors, the dr[...]

ELECTRICAL EQUIPMENT operating conditions. There is also a micrometer adjustment by means of which fine alterations in timing can be made to allow for changes in running conditions, e.g., state of carbonisation, change of fuel, etc. A completely sealed metallised paper capacitor is utilised. This has the property of being self-healing ; should the [...]

ELECTRICAL giving maximum opening, slacken the screw(s) securing the fixed contact plate and adjust its position to give the required gap. Tighten the screw(s). Recheck the setting for other positions of the engine giving maximum opening. 3. DESIGN DATA Firing angles : O', go", 180°, 270°, &l0. Closed period : 60" & 3"[...]

(b) Testing in Position to Locate Cause of Ignition Failure Spring back the clips on the distri- butor head and remove the moulded cover. Lift off the rotor, carefully levering with a screwdriver if neces- sary. Switch on the ignition and whilst the engine is slowly cranked, observe the reading on the car ammeter, or on an ammeter connected in seri[...]

ELECTRICAL EQUIPMENT assembly are freed. Take care not to lose the ratchet and coil type springs located under the micrometer nut. The complete shaft assembly, with automatic timing control and cam foot can now be removed from the dis- tributor body (see (ii) below). G> (ii) Contact Breaker TQ dismantle the assembly fur- ther, remove the nut, in[...]

ELECTRICAL E (v) Fit the capacitor into position, on earlier models the eyelet on the other end of the contact breaker earthing lead is held under the capacitor hg screw. Place the fixed contact plate in position and secure lightly with securing screw(s). One plain and one spring washer must be fitted under each of these screws. (vi) Place the insu[...]

2. BULB REPLACE Slacken the captive securing screw at the bottom of the front rim and remove the front rim and dust-excluding rubber. To remove the Light Unit assembly from the three spring-loaded screws, press the Unit inwards, turning it anti-clockwise to disengage the slotted holes in the seating rim from the setting adjustment screws. Disengage[...]

ELECTRICAL EQU'IPIMENT LOCKNUT m CV- OUT ADJUST NG , SCREW ADJUSTING SCREW SCREWS SECURING FIXU) CONTACT BRACKET Fig. 27 Control Box with Cover removed. The Regulator The regulator is set to maintain the generator terminal voltage between close limits at all speeds above the regulating point, the field strength being controlled by the automa[...]

ELECTRICAL EQUIPMENT The bi-metallic spring also compensates for effects due to increases in resistance of the copper windings from cold to working values. The Cut-out The cut-out is an electro-magnetically operated switch connected in the charging circuit between the generator and the battery. Its function is automatically to con- nect the generat[...]

Regulator Adjustment The regulator is carefully set during manufacture and, in general, it should not be necessary to make further adjustment. If, however, the battery does not keep in a charged condition, or if the generator output does not fall when the battery is fully charged, the setting should be checked and, if necessary, corrected. It is im[...]

ELECTRICAL EQUIPMENT removed, these settings should not be tampered with. If, however, the armature has been removed, the regulator will have to be reset. 0.030"-0.034" WITH ARMATURE PRESSED AGAINST WUGES l ARMATURE FKING SCREWS ED CONTACT WlTH 0.02~" GAUGE BETWEEN ARMATURE SHIM C CORE, CONTACT CAP TO BE 0~001=0~005. Fig. 31 Mechanic[...]

ELECTRICAL EQUIPMENT (E) Mechanical Setting If for any reason the cut-out armature has to be removed from the frame, care must be taken to obtain the correct air-gap settings on re-assembly (see Fig. 31). These can be obtained as follows :- Slacken the two armature fixing screws, adjusting screw F and the screw securing the fixed contact. Insert a [...]

ELECTIPICAL EQUIPMENT Inspection of Commutator ELECTRIC WINDTONE HORNS - Disconnect the wiper at its terminals and withdraw the three screws securing the cover at the commutator end. Lift off the cover. Clean the commutator, using a petrol-moistened cloth, taking care to remove any carbon dust from between the commutator segments. Inspection of Bru[...]

ELECTRICAL EQUI (ii) Adjustment Adjustment of the horn does not alter the pitch of the note, but takes up wear of the moving parts which if uncorrected, would re- sult in loss of power and rough- ness of tone. The horn must not be used re- peatedly when out of adjustment, as the resulting excessive current may damage it. The maximum current consump[...]

ELECTRICAL EQUIPMENT (iii) Steel push rod stiff or jammed in its bush. Remove the contact breaker spring and work the push rod up and down to ease it. If necessary, clean the rod and bush with petrol to remove any ac- cumulations of dirt or grease. The exposed portion of the rod should be smeared with a fairly thin grease (Duckham's H.B.B., or[...]

ELECTRICAL EQUIPMENT KEY TO CABLE COLOURS Fig. 34 Wiring Diagram. I BLUE 2 BLUE WITH RBD 3 BLUE WITH YELLOW 4 BLUE WlTH WHITE 5 BLUE WITH GREEN 6 BLUE WITH PURPLE 7 BLUE WITH BROWN 8 BLUE WITH BLACK 0 WHlTP . ----- I0 WHITE WITH RED I I WHITE WITH YELLOW I2 WHITE WITH BLUE 13 WHITB NITH GREEN I4 WHITE WlTH PURPLE IS WHITE WITH BROWN 16 WHITE WITH B[...]

CONTROL BOX. MODEL RB106-2 Later production cars were fitted with this control box, the function of which is identical to its predecessor, RB 1061 1. REGULATOR CUT-OUT ADJUST NG ADJUSTING SCREW SCREW / FIXED CONTACT - / BLADE REGULATOR SERIES WIND1 TONGUE OV l NG CONTACT v STOP-ARM . 10 ARMATURE Fig. 36 Control Box with cover removed. Automatic A[...]

CAL EQZIEP ing the registance in the generator field circuit. The con%gquent reduction in the generator field curfkt lowers the generator terminal voltage, and this, in turn, weakens the magnetic flux in the regulator core. The armature therefore returns to its original position, and the contacts closing allow the generator voltage to rise again to[...]

ELECTRICAL EQUPPMENT of the magnet on the armature is sufficient to overcome the tension of the adjusting spring. The operation of the cut-out is as follows : The shunt coil is connected across the generator. When the vehicle is starting, the speed of the engine and thus the voltage of the generator, rises until the electromagnet is sufficiently ma[...]

ELECTRICAL EQUIPMENT Withdraw the cables from control box terminals A and A1 and connect these cables together. Connect the negative lead of the voltmeter to control box terminal D, and connect the other lead to terminal E. Slowly increase the speed of the engine untd the voltmeter needle " flicks " and then steadies. This should occur at[...]

ELECTRICAL EQUIPMENT contacts by means of fine car- borundum stone or fine emery cloth. Carefully wipe away all traces of dust or other foreign matter with methylated spirits (de - natured alcohol). (c) Cut-out Adjustment (i) Electrical Setting If the regulator is correctly set but the battery is still not being charged, the cut-out may be out of a[...]

(iii) Cleaning Contacts If the cut-out contacts appear rough or burnt, place a strip of fine glass paper between the con- tacts-then, with the contacts closed by hand, draw the paper through. This should be done two or three times with the rough side towards each contact. Wipe away all dust or other foreign matter, using a clean fluffless cloth moi[...]

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BODY INDEX ...... Body Mounting Points ............ ...... ...... ...... ...... To remove Body ...... ...... ...... .... ...... To fit Body ...... ...... ...... ...... Battery Box Drain ..... To remove and Dismantle Front Bumper ...... ..... ...... To fit Front Bumper ............ To remove Rear Over-Riders and Brackets ..... To fit Rear Over-Rider[...]

BODY ATTACHMENT DETAILS PACKING5 WASHER AND B0 WASHERS 8 BOLTS (g) Front outrigger brackets. Four square pads eaqh side. (h) Along rear crucXoPm member. One strip with hole each side. (i) Rear outrigger brackets. Four square pads each side. (j) Rear of rear wheel. Wing valance to chassis frame. A metal stay secured to wing and chassis frame bracket[...]

(di) Remove carburettor &S- connecting control Remove cables from dyn starter motor. (xiv) Disconnect brake hydraulic union. (m) Loosen steering column draught excluder clip. (c) Working inside the car. (i) Remove the seat cushions followed by the seat frames. (G) Remove the carpets. (iii) Disconnect the electrical control wires for the overdri[...]

BODY Fig. 2 Illustration giving details of Battery Box Drain for modifying cars prior to Commission No. T.S. 3288. (d) The bumper can now be lifted away from its support brackets and the four metal packings and the two centre bolts collected. (e) Withdraw two bolts from each pair of support brackets and chassis frame to release the four brackets. T[...]

BODY (b) Position the distance piece in the car body. Feed the bolt through the support bracket and a plain washer and thence $p, the distance piece, follow- ing with-a second plain washer and then secure with a nut. (c) The lower attachment can now be tightened. (d) The over-rider attachment bolts are positioned in the brackets together with the p[...]

BODY 15. TO REMOVE FRONT APRON (a) Open the bonnet by releasing the locks from inside the car, or cars after Commission No. TS.4229 fitted with Dzuz fasteners at the forward corners of the bonnet lid by use of the carriage key. Prop the bonnet open and disconnect battery. (b) Remove four bolts (two each side), which secure the top apron re- enforce[...]

(d) With operators each side of the car gently ease the windscreen assembly forward allowing the draught excluder to slide over the wiper blade spindles. The windscreen can be withdrawn and lifted from the car. TO FIT WINDSC This is the reversal of the removal but the following points should be noted. (a) The stanchion guides should be greased to p[...]

BODY Fig. 3 Front Door Water Sealing. For illustration g (c) When fitting the side screen retainer brackets the correct position is only obtained by fitting them so that the heads of the locking screws face inwards. Having replaced the brackets it is a wise precaution to check the fitting of the side curtain. 26. (a) Lift out seat cushions and remo[...]

BODY (h) The tunnel can now be removed by levering up the rear end to break the wate TO FIT THG GEARBOX TUNNEL The fitting is the reversal of the removal, but the following points should be noted. (a) It is essential that sufficient compound is used around the periphery of the tunnel to effect a good water seal. (b) If the car is fitted with overdr[...]

BODY used, or a hot air blast can be directed to the lacquer. If neither oven nor hot air blast is available the component can be left undisturbed in a warm atmosphere for, 24 hours. Although reasonable sealing will be obtained by the instructions con- tained in this paragraph, the proper heat treatment at the hlgher temperature will provide the be[...]

BODY Bridge Pieces in position on Elbow Rail Channel. Reposition the canopy on the car and secure to the windscreen brackets. Secure at the rear, setting the bridge pieces so that the bolts enter them correctly and obviating any possibility of cross threading Remove canopy, rear end first. Pencil on the body protection tape lines which corres~ond t[...]

the top and rear edges fit as close to the canopy as possible. On initial fitting of the fibreglass canopy it may be necessary to remove and reposition the sidescreen retainer brackets. 34. TO REMOVE FIBREGLASS TOP CANOPY It is essential that the following instructions are carried out in the sequence mentioned, difficulty may be experienced if oper[...]

BODY TQ FIT SMLITH[S CIRCULAR HEATER C.H.S. g20/4 The following procedure for carrying out this installation is recommended :- l. Disconnect the battery lead. 2. Drain the cooling system and remove the two square headed plugs, one from the rear of the cylinder head and the other from the water pump housing. 3. Fit the taper threaded tap (28)(Fig. 1[...]

BODY It will be necessary to clear of the studs and t by slackening off the am of the "'U' (Fig. 10). Locate the de- mister nozzles (1) on the two ensuring that they are above the screen wiper drive cable "U'hhaped rod and t nuts and washers on the four studs retighten with a suitable spanner. At this point it is advisable [...]

BODY Fig. 13 Fitting Heater Hoses on water pipe connecters their respective connecters (Fig. 13), i.e., the hose on the L.H. side to the water pipe return connecter and that on the other side to the connecters for the feed hose, and secure with clips. These connecters were fitted in operation 5. Fit the two lengths of demister hose (2)&(3) to t[...]

BODY Fig. 16 Exploded view of Heater kit NOTATIONS Ref. No. Description 1. Demister Nozzle (2 off). 2. Demister Hose, R.H. 3. Demister Hose, L.H. 4. Demister Pipe "Y" shaped Air Duct. 5. Alloy Elbow Piece. 6. Elbow Piece Securing Screw. 7. Heater Unit. 8. Securing Nuts for Attachment Bracket (3 off), Spring Washers (3 off) 9. Earth Wire. [...]

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FUEL SYSTEM INDEX Notation For Fig . 1 ............ ...... Data and Description ...... ...... To remove Petrol Tank ...... ...... ...... To fit Petrol Tank ...... ...... Petrol Gauge :- ...... ...... Description ...... Precautions when carrying out tests ...... To test Dash Meter ...... To test Tank Unit ...... Fault Location for Petro1'~au~e [...]

FUEL SYSTEM Fig. I Exploded view of Petrol Tank and Pipe Lines. Petrol tank Petrol tank strap Petrol tank strap furing blot Drain plug Banjo bolt for vent pipe Fibre washer above banjo connection Fibre washer below banjo connection Vent pipe Cork washer Petrol tank gauge unit Petrol fder cap and neck assembly Upper hose clip NOTATION FOR Fig. I Rub[...]

L SYS I DATA From the petrol pump a metal pipe (a) Tank capacity passes round the front of the engine, to the twin §.U. carburettors. 12i gallons (no reserve). Each carburettor is fitted with an individual oil damped A.C. air filter. etrol Stop Tap Situated on the left-hand side of the chassis frame and is connected to the petrol pump by a flexibl[...]

SYS T PETROL T After ensuring that the tank is perfectly sound and clean, it can be replaced in the car. The recommended method of testing the tank is to clean the exterior with a wise brush, blank off the filler pipe and all but one union then connect to a compressed air line. Submerge the tank in water and slowly fill the tank with air. Faults wi[...]

FUEL SYSTEM SYMPTOM No Reading Meter reads full. FUEL GAUGE FAULT CAUSE (l) Meter supply interrupted. (2) Meter case not earthed. (3) Tank unit cable earthed. (4) Tank unit cable broken or disconnected. 8. TO REMOVE FLEXIBLE PETROL FEED PIPE In no circumstances must an attempt be made to remove this hose from the lift pump without first diconnectin[...]

FUEL SYSTEM (b) Fit the taD into the fork bracket so I that the fied to the pump is upper- most. The two flats on the tap body will assist in locating its position. Secure the tap to bracket by tightening the jam nut. (c) Position the rigid petrol feed pipe from tank into lower portion of tap and ensure that the olive is seated before the union n[...]

WX E Hand prlrning lever Fig. 3 Section view of Petrol Pump. turns passes into the lower body of the petrol pump below the diaphragm assembly and by action of the latter is pumped out by way of the breather hole. To obviate thrs condition an oil seal is fitted round the diaphragm assembly push rod and is prevented from rising with the action of the[...]

rear stud. can be removed ck, together with ) b;clach ei-Le Ehexi'bE~ ward end of the re the rigid end ) Start and run the en mOmerrls and esa for leaks.[...]

FUEL SYSTEM Fig. 5 Showing the "UE" type Fuel Pump in exploded form. (e) To remove the diaphragm assembly (10) first turn it through 90" in an anti-clockwise direction and lift out of engagement with link lever (22). Collect the diaphragm spring (1 1). No attempt should be made to separate the four layers of the diaphragm as it is a [...]

FUEL SYSTEM TO ASSEMBLE PETROL PUMP (a) Place the figure of eight gasket (3) in position on the valve ports in the upper body (1). Position the inlet valve assembly (5) in the off centre and shallower port, with the spring of the valve pointing towards diaphragm. The outlet valve (5) is positioned in the centre port with the spring of the valve ins[...]

FUEL SYS For Notation see Fig. 5. Firstly, all parts must be thoroughiy cleaned to ascertain their condition. Wash all parts in the locality of the valves in a clean paraffin bath separate for the other and unless in entirely sound condition without any signs of cracks or hardening. Upper and lower cas gs should be examined for cracks or damage, an[...]

FUEL SYSTEM DISCONNECTION OF CARB- URETTOR CONTROLS There are nine throttle or carburettor control connections and it may be necessary to disconnect one or more to make adjust- ments, to effect removal of the carburettors or madolds. (a) The folding coupling on the throttle butterfly spindle. One pinch bolt. (b) The outer Bowden cable at the front [...]

FUEL SYSTEM Fig. 7 Exploded view of R.H. and L.H.S. Accelerator Pedal Assemblies. 1 NOTATION FOR Fig. 7. Ref. No. Description R.H.S. pedal assembly. Fulcrum bracket. Double coil washer. Split pins. Plain washers. Attachment bolts. Pedal limit stop bolt. Jam nut. Shaft bearing. Bearing hc&ngs. Self tapping screw. Lever assembly. Mills pin. (e) P[...]

FUEL SYSTEM (g) The shaft can now be dismantled by drifting out the mills pin securing the lever assembly to the shaft and collecting a double coil washer and mounting bracket. The split pin locating the bracket on the shaft can also be withdrawn. 33. TO FIT ACCELERATOR PEDAL L.H.S. (Fig. 7) Position the nylon bearing between the half housings and [...]

FUEL SYSTE[...]

L SYS Ref. No. Description l Throttle butterflv and suindle. 2 Throttle butterfl? stop &d adjusting screv 3 Piston. 4 Suction chamber. 5 Jet bore. 6 Needle. 7 Needle locking screw. W 8 Spring. 9 Float chamber needle valve. 10 Float. l l Float lever. 12 Float chamber attachment bolt. expanding choke type, in which the cross sectional area of the[...]

FUEL SYSTEM boss, forming the upper part of the suction chamber casting An extremely accurate fit is provided between the spindle and the bush in the silction chamber so that the enlarged portion of the piston is held out of contact with the bore of the suction chamber, within which, nevertheless, it operates with an extremely fine clearance. Simil[...]

FUEL SYSTEM creating enough depression on the induction side to raise the piston. i'he fuel discharge required from the jet is very small under these conditions, hence the diameter of the portion of the needle now obstructing the mouth of the jet is very nearly equal to the jet bore. Initial manufacture of the complete carb- urettor assembly t[...]

interior of the spindle contains a quantity of thin engine oil, and the marked retarding effect upon the movement of the main piston assembly, occasioned by the resist- ance of the small piston, provides the momentary enrichment desirable when the throttle is abruptly opened. The damper piston is constructed to provide a one-way valve action which [...]

39. CARBURETTOR JET NEE 420 Two jet needles are available for fitting to the carburettors of the TR2. (a) FV. For normal motoring. (b) GC. For high speed motoring and competition driving. (a) Remove the air-cleaner. See page 10. (b) Remove the damping piston from the top of the suction chamber. (c) Withdraw the three suction chamber securing screws[...]

FUEL SYS[...]

FUEL SYSTEM S.U. CARBURETTOR DETAILS (Fia. 10) Ref. No. Description 1 Bodv assemblv. suchon chamber and piston assembly Damper assembly. Washer. Jet needle. Needle locking screw. Piston spring. Securing screw. Shake proof washer. Jet head. Top half jet bearing. Washer. Bottom half jet bearing. Washer. Cork gland washer. Copper gland washer. Spring [...]

SYSTEM Feed the rocker lever bolt through the double coil washer and the rocker lever so that the platform of the lever is on the left viewing the bolt head. This assembly is fitted to the front carburettor with a plain washer be- tween it and the carburettor. Ensure that the rocker lever moves freely. Fit the throttle spindle return spring anchor [...]

FUEL Select the jet lever of the front carb- urettor, identified by having two holes at the extremity of the longer arm. This is attached to the jet assembly by a clevis pin and split pin, position the second end of the lever return spring to the jet lever. Feed the upper end of the tension link through the rocker lever of the front carburettor fro[...]

FUEL SYSTEM The engine is now ready for starting and, after thoroughly warming up, the speed should be adjusted by turning each throttle adjusting screw an equal amount until the idling speed is approximately 500 R.P.M. The synchronisation of the throttle setting should now be checked by listening to the hiss of each carburettor, either directly or[...]

FUEL SYSTEM (ii) The piston is meant to be a fine clearance fit at its outer diameter in the suction chamber and a sliding fit in the central bush. The suction chamber should be removed. com~lete with piston, and the 'freedo& of movement checked after removal of the damper rod. The assembly should be washed clean and very lightly oiled whe[...]

(g) Sticking Jet Should the jet and its operating mech- anism become unduly resistant to the action of lowering and raising by means of the enrichment mechanism, the jet should be lowered to its fullest extent, and the lower part thus exposed should be smeared with petroleum jelly, or similar lubricant. Oil should be applied to the various linkage [...]

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ISED TOOLS POLICY Considerable time and care has been taken in the preparation of specialised tools for servicing our Models, as it is realised that efficient servicing is not possible without the correct tools and equipment. Messrs. V. L. Churchill & Co. Ltd. have designed and are manufacturing on our behalf and this Company has already circul[...]

SPECIALISED TOOLS GEARBOX Mainshaft Remover ...... ...... ...... Mainshaft Circlip Installer ...... ...... Front Oil Seal Protecting Sleeve ...... ...... Gearbox Extension Remover ...... ...... Constant Pinion Shaft Remover ...... ...... Countershaft Needle Roller Retainer Ring Driver ...... ...... Mainshaft Circlip Remover ...... ...... Countersha[...]

Instruction anual BRAKES SECTION R[...]

INDEX Notation for Figure 1 ...... ...... ...... Description ...... ...... ...... Routine maintenance ...... ...... Identification of linings ...... ...... Data ...... ...... ...... ...... ...... Brake Adjustment :- Front brake shoes ...... ...... Rear brake shoes ...... ...... ...... Handbrake ...... To bleed the hyd&utic system ...... Leakage[...]

NOTATION FOR Fig. I. Ref. No. Brake Operation Master cylinder to front connection pipe Two-way connection Banjo bolt Large copper gasket Small copper gasket Right to left-hand front connection pipe Front banjo connection Banjo bolt Large copper gasket Small copper gasket Stop light switch Flexible hose Hose locknut Ref. No. 14 Large shake proof was[...]

I. DESCRIPTION Lockheed Hydraulic Brakes are fitted to all four wheels. Two leading shoe type are used on the front wheels and leading and trailing shoe type on the rear wheels. A foot pedal operates the brakes hydraulic- ally on all four wheels simultaneously, whilst the handbrake operates the rear brakes only by means of a cable. The foot pedal i[...]

4. DATA Front Brakes 10" X 2&" Rear Brakes 9" X 1%'' up to Comrnision No. TS.5481. Rear Brakes 10" X 2t" after TS.5481. Transverse rear brake cable lengths : Right-hand 12.97" f .06" 12.47" 10" Left-hand 26.85" & .06" 26.35" )brakes. These lengths are measured from pin ce[...]

The method detailed hereafter is suitable only for the braking system ; the procedure to be adopted when bleeding the clutch is detailed in the " Clutch Section ". (a) Ensure an adequate supply of Lock- heed Brake Fluid is in the reservoir of the Master Cylinder Unit and keep the level at least half full throughout the operation. Failure [...]

BRAKES (d) Hdding the pedal limit stop screw turn the jam nut to the support bracket and tighten. NOTE: The clutch pedal is set in a similar way but it must be remembered that adjustment at the slave cylinder may also be necessary to obtain the correct free pedal movement. 12. TO REMOVE FRONT LEFT-HAND FLEXIBLE HOSE Open bonnet and disconnect batte[...]

inspect the line and ~onnections. BRAKES Hold the hexagon of the flexible hose (e) Replenish the hydraulic reservoir with at the outside of the bracket and fluid. tighten the banjo bolt, at the same time ensuring that the two-way con- (f) Bleed all four brakes as described on nection is not allowed to turn. page 3. Reconnect the Bundy tubing to the[...]

BRAKES TWIN BORE MASTER CYLINDER Description This unit consists of a body which has two identical bores, one connected to the brakes and the second to the clutch. Each of the bores accommodates a piston having a rubber cup loaded into its head by a return spring ; in order that the cup shall not tend to be drawn into the holes of the piston head, a[...]

either side of the support bracket. With the washers in place screw on nut finger tight. Connect the Bundy tubing to the master cylinder connections through the aperture at the rear of the master cylinder. The clutch operating pipe is fitted to the adapter on the left and the brake operating pipe, which is on the right, direct to the master cylinde[...]

BRAKES Fig. 3 Exploded view of Twin Bore Master Cylinder. NOTATION FOR Fig. 3 Ref. No. 1 Body 2 Cover plate 3 Joint washer 4 Filler ca and baffle P 5 Cover g ate attachment screw 6 Shake proof washer 7 Valve seat 8 Valve cup ) Brakes only 9 valvebody 10 Valve return spring main cup and piston 14 Piston 15 Piston secondary cup 16 Boot fixing phte Re[...]

Position the cover plate on the body in such a manner that is nearer the outlet port ensure the jets of fluid from the cylinder will i ge upon the plate and so avoid p e leakage through the filler cap. Ensure that the joint washer and filler c ood order and is clear. Ref.[...]

BRAKES Exploded view of Front Brake dew,[...]

25. TO FIT FRONT (a) Fit the smaller end of the coil spring (a) Mount the wheel cylinders on the over the projection in the cup filler and back plate and secure each with a insert both parts into the cylinder bolt and lock washer. body, with the spring leading. (b) Connect bridge pipe to bottom (b) Follow up with the rubber cup, lip bore of each wh[...]

Fig. Exploded view of Rear B 4 L& washer. 5 Wheel cylinder body. 6 Spring in body. 7 Cup filler.[...]

BRAKES 29. TO WEMOVE REAR WHEEL (e) Bleed the hydraulic system as described CYLINDER on page 3. Adjust the brake shoes (a) Jack up rear of car. Remove nave as described on page 3. plate, road wheel and brake drum. Slacken off micrarn adjuster. (f) Check the system for fluid leakage by applying firm pressure to the pedal (b) Drain ofi hydraulic flui[...]

Follow up with the rubber cup, lip end forward, taking care not to damage or turn back this lip. Insert hydraulic piston into body ensuring that the slot coincides with the lever slot in the cy Place the handbrake lever in position and fit pivot pin. Stretch the handbrake piston rubber seal over the handbrake piston and place with dust cover in cyl[...]

NOTATION FOR Fig. 8 Pedal shaft cover assembly. Clutch pedal. Brake pedal. Rubber pad for pedals. Pedal pivot bush. Pedal shaft. Supporting bracket for pedal shaft. Lock washer. Bolt securing brackets to shaft. return spring. washer. cylinder support bracket to bulkhead. Lockwasher. Nut securing pedal assembly and master cylinder support bracket to[...]

(c) Position the supporr brackets on the shanks of the welded bolts and allow the cut away side to drop into the recess of the revolving collar. Slight pressure may be necessary to bed this bracket. (d) Secure the bracket to the pedal shaft, utilising two bolts and lock washers, one each side. (e) Hook the return springs in the shaft of the pedals [...]

BRAKES Fig. 9 Exploded view of Hand Brake Assembly. NOTATION FOR Fig. g Ref. I Ref. No. I No. Lever assembly. Lever pivot bush. Handbrake lever grip. Pawl stop mills pin. Pawl release push rod. Pawl release spring. Plain washer between spring and lever. Push rod button. Pawl. Clevis pin, pawl to lever. Split pin. Plain washer between split pin and [...]

43. TO ASSE LE HANDBW ASSEMBLY (a) Feed the push rod into the lever from below so that its shape corres- ponds with that of the handle. (b) Attach the pawl t sh rod so that it points ream (c) Mow the push rod to protrude through the upper portion of the handle and feed on a plain washer and coil spring, followed by the button. Apply pressure to the[...]

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SECTION S[...]

EXHAUST S INDEX Page Notation for Figure 1 ...... ...... ...... ...... ...... ...... ...... 1 Description ...... ...... ...... ...... ...... ...... ...... ..*... 2 Maintenance ...... ...... ...... ...... ...... ...... ...... ...... 2 Exhaust System . To remove and dismantle ...... ...... ...... 2 Notation for Figure 3 ............ ...... ...... ...[...]

EXHAUST SYSTEM Fig. I Exploded view of Exhaust System. NOTATION FOR Fig. I. Ref. No. 1 Exhaust flange joint. 2 Front exhaust pipe. 3 Prior to Commission No. TS.4310 only : A Attachment bolt to chassis. B Flexible mounting strip. C Clamp plate. D Attachment nut. E Exhaust pipe clip (Upper half). F Clamping bolt. G Attachment nut. H Rubber and metal [...]

The manifolds are attached to one another by studs in the aluminium alloy induction manifold and lugs moulded in the cast iron exhaust m Id. There is no " hot spot "for easy starting. The exhaust system is situated on the side of the engine and passes e rear of the car through the centre of the crucifom to a position adjacent to the left-[...]

Fig. 3. anifold details. 2 Inlet manifold. 3 Joint washer. 4 Insulating washer. 5 Exhaust manifold attach 6 Carburettor attachment S Ref. No. 12 Flange joint washer.[...]

EXHAUST SYSTEM (d) Loosen the pinch bolt (or bolts) forward of the cruciform centre and withdraw the silencer rearward. (e) Remove the lower bolt attaching flexible mounting strip to chassis frame. Remove the nut and bolt, collecting 5. the rubber grommet and rubber washer securing the bracket to the chassis frame. (f) The front exhaust is detached[...]

Issaed by the SERVICE DI 1 NTRY, ENGLAND[...]

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Foreword (1976 Edition) The TR3 is a result of The Standard Motor Company's attempting to improve the ap- pearance and the performance of the TR2. The improvements consist of a more stylish grille, a one-half gallon reduction in fuel capacity, a ten-horsepower increase in engine output, and the greater potential for the application of the over[...]

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GENERAL DATA The information given in this section should be studied in conjunction wi appropriate pages of the m CAMSHAFT BEARINGS Vandervell shell bearings are fitted to the 2nd, 3rd and rear journals. CARBURETTORS Two S.U. Type H6 carburettors are fitted. The early TR3 cars were fitted with carbu- rettors having cc TD " needles, but this ne[...]

GENERAL DATA Fig. I Power Curve.[...]

ENGIN I. CYLPNDER BLOCK Vandervell replaceable shell bearings have been introduced for the 2nd, 3rd and rear camshaft journals. These pe manufactured to very fine limits, and whilsrcertain fitting precautions must be observed, line boring of the assembled bearings is unnecessary. Removal of the rear bearing will necessitate the removal of the seali[...]

ENGINE 5. ENGINE OIL FILTER In order to give the maxhum protection to the engine when subjected to high speed or rally conditions, a new filter of the " full flow " type has been introduced on the TR3 models. This type of filter ensures that all the oil in circulation passes through the filtration system. The " full flow " type [...]

CLUTCH D N PLATE ASSEMBLY An improved clutch driven plate incorpor- ating a Belleville washer friction centre was fitted after Engine No. TS.7830E. (TR2). The new driven plate can be recognised by four small tongues (or tabs) protruding through the spring retaining plates adjacent to the longer side of the splined hub and by the colour of the six c[...]

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A new rear axle assembly, Part No. 302177, bearing the Serial NO.- i3511, was intro- duced at Commission No. on all subsequent cars. The major differences inc new axle include new half shaft and hub assemblies, a thrust button mounted on the differential cross-pin an roller hub bearings, as The sectioned insert views indicate the axle arrangement f[...]

Fig. 5 Removing hub bearing inner ring. Fig. 6 Fitting hub bearing inner ring to axle shaft. brake fluid pipe and the hand- brake attachments must first be disconnected and the backing Fig. y Fitting oil seal into bearing housing. plate subsequently removed. (iv) Extract the bearing outer ring from the housing, as shown in Fig. 4, after first tappi[...]

REAR AXLE hub, plain washer and castellated nut, t~ghtening this to a torque of 125-145 lbs. ft. (17.29-19.71 kg. metres) and securing it with a split pin. (iv) Examine the inner oil seal and, if a replacement is necessary, proceed as shown in Fig. 8. Oil seal renewal is recommended in all cases of axle overhaul. (v) Replace the original shim pack [...]

REAR 5. HIGH SPEED AND COMPETITION WORK (a) Rear Axle Assembly-ratio 4.111 A rear axle of the above ratio is available for high speed and com- petition work but is only suitable for cars fitted with Overdrive. The installation and servicing procedure is the same as for standard ratio axles. Crown wheel Part No. 202579 (41 teeth) Pinion (10 teeth) P[...]

REAR AXLE Arrangement of Axle Components.[...]

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These bearings supersede the rubber bushes and were introduced kto production at car Com- mission No. TS.9121. They are as fo Nylon bearing. 4 off. Steel bush. 4 Q Sealing rings. Nylon washers. 8 off. Pressed into each wishbone arm. edge of nylon washers. Fitted each side of wishbone arms. (i) Fit the rubber sealing rings nylon washers. (G) Press t[...]

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BODY BODY SPECIFICATION Provision is made for the installation of an occasional bench seat in the luggage com- partment immediately behind the driver and passenger seats. REVEAL MOULDING AND GRILLE A chromium plated moulding is fitted to the front rim of the air intake with a grille mounted immediately behind. STAINLESS STEEL WING BEADING The stain[...]

BOD 11. TO OCCASIONAL SEATS (e) Position the occasional seat behind the (a) Slide the driver and passenger seats forward to their fullest extent. (b) Lift up the carpet at the rear of the two seats and remove the two bolts and washers so exposed. (c) Make two small holes in the carpet to gn with the tappings in the floor assembly. (d) Withdraw the [...]

BODY Description The " Hard Top " is of presse steel construc- tion, incorporating channel sections which are spot welded to the main panel. These channels By stiffen the as mbly and also ate the front an rear mounting brackets. The sides of the main panel are folded to form a "U" section which further strengthens Detail No. Des[...]

BODY 2. WINDSCREEN TOP RAlL WINDSCREEN ATTACHMENT BRACKET PROTECTION /PLATE PENCIL MARK TRANSFERED . SECURING SCREW TO CAPPING BRIDGE PIECE PENCIL MARK OPPOSITE CE OF BRIDGE P REMOVE HOOD WEBBING BY REMOVING 2 FLAT HEADED SCREWS AND 2 HOOD FASTENER SCREWS Fig. I Marking and fitting Rear Cappings. (c) Unscrew and remove the four counter- sunk screws[...]

BODY Centralise the " Hard Top " over the windscreen and temporarily secure by tightening the three attachment brackets. (Fig 3A.) (b) Mark the position of the attachment bracket holes on the underside of the windscreen top rail (Fig 3B). Slacken off the brackets then remove the Cc Hard (c) Mark the top side of the screen exactly in line [...]

BODY 6. DRIP CHANNELS-TO FIT (See Figs. 5 and 6) DRIP CHANNEL ". Fig. 7 Fitting Rear Window and Waist Rubber. Fig. 5 Fitting lower part of Drip Channel. After correctly shaping the ends of the drip channels, position the channels and draught rubbers " C " on the "Hard Top " as dustrated and secure with the screws " A &[...]

BODY 9. REAR WINDOW LIGHT-TO m manipulate the inner rubber 1.i~ into vosi- (See Fig. 7) tion. * Using a special tool (see ~ii. 7) finally secure the glass by feeding the filler Fit the rubber moulding around the glass strip into position. With the aid of a with the filler section positioned towards the " Seelastik gun ", complete the inst[...]

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FUEL S PETROL TANK The petrol tank has been modified slightly to accommodate the occasional seat, its capacity is thereby reduced to 12 gallons. FLEXIBLE FUEL PIPES A flexible fuel pipe connects the twin carburettors and is integral with a short feed line which is connected to the Bundy tubing at a point adjacent to the thermostat housing. CAlWUlWT[...]

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MASTER CYLINDERS FLUID RESERVE TANK - COMPENSATOR - GREASE NIPPLE STOP LIGHT SWITCH SLAVE CYLINDER ND BRAKE RATCHET BEFORE SETTING HAND BRAKE CABLE LOCK THE REAR SHOES UP IN THE DRUMS AND APPLY HAND BRAKE LEVER ONE NOTCH CABLE AND WIRE ROPES SHOULD BE JUST TAUT Fig. I GlRLING BRAKES ULIC CLUTC (From Chassis No. TS.q~ox) The brakes on the front whee[...]

BUST -SET BOLTS -RETAINING PLATES WASHER--. LINING SEGMENTS COVER- - DUST COVER SEALING RING PISTON / END PLUG / / PLUG RETAINER GASKET Fig. 2 Exploded arrangement of Disc Brake Caliper Assembly. Due to the simplicity of these disc brakes the only normal servicing which wd be carried out by the owner or garage wd be the replacement of worn lining s[...]

Instead of pushing the pistons to the bottom of the bore withdraw them from the caliper body, taking great care not to damage the bores. The sealing rings may then be removed by inserting a blunt tool under the seals and prising out, talung care not to damage the locating grooves. Ex- amine the bores and pistons carefully for any signs of abrasion [...]

Details of Rear Brake Assembly. g shoe rests in a slot hder body. At the adjuster end the shoe ends rest in slots in the adjuster links. The shoes are supported by platforms formed in the backplate, these being held in position by two hold-down springs fitted on each shoe with a peg passing through a hole in the backplate. The adjuster consists of [...]

(i) Jack up the vehicle, remove the isconnect the rod (3) Remove the brake d Disconnect the union from the remove the rubber rear of backplate. (iii) By using a screwdriver, prise t retaining plate apart, then tap from beneath wheel cylinder. e handbrake lever from between t e backplate and wheel cylinder. (v) Remove the spring plate and distance p[...]

BRAKES The front disc brakes are entirely self- adjusting. The rear brakes are adjusted for lining wear at the brakes themselves, and on no account should any alteration be made to the hand brake cable for this pur- pose (Fig. l). One common adjuster is provided for each brake assembly. Adjustment of both rear wheels is identical. Release the handb[...]

Disrnant Disconnect the pressu unions from the cvli the securing bolts Hnd devis pin from jaw end. Pull back cover and remove the circ pair of long nosed pliers. Th and dished washer can th removed the pl tached, W& then the plunger assembly complete. The assembly ca lihg the shouldered end of the plunger. Ease the pressure seal off the plunger[...]

SPRING l BLEED VALVE Fig. Bleeding Remove the bleed screw dust cap, open the bleed screw approximately three- quarters turn and attach a tube, h- mersing the open end into a clean receptacle containing a little GirlBng Crimson Brake and Clutch Fluid. Fill the master cylinder reservoir with genuine Girling Crhson Brake and Clutch Fluid, and by using[...]

wheel nearest the master cylinder. Always keep a careful check on the reservoir during bleeding, since it is most important that a level is maintained. Should air reach the master cylinder from the reservoir, the whole operation of bleeding must be repeated. After bleeding, top up the reservoir to its correct level of approximately three- quarters [...]

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XHAUST E UST SYSTEM The exhaust system is unchanged from the TR2 apart from the new manifold gasket fitted to the enlarged port combustion head after engine number TS.9350E.[...]

Books on the repair and maintenance of the old T riumphs are becoming more and more difficult to locate; many have been out of print for years or even decades, and good examples are increasingly hard to find at reasonable prices. Then, too, there are all the people like me who have a copy of a valuable reference book, but in rather forlorn conditio[...]