Volkswagen Transporter 1600 (1979) инструкция обслуживания

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Хорошее руководство по эксплуатации

Законодательство обязывает продавца передать покупателю, вместе с товаром, руководство по эксплуатации Volkswagen Transporter 1600 (1979). Отсутствие инструкции либо неправильная информация, переданная потребителю, составляют основание для рекламации в связи с несоответствием устройства с договором. В законодательстве допускается предоставлении руководства в другой, чем бумажная форме, что, в последнее время, часто используется, предоставляя графическую или электронную форму инструкции Volkswagen Transporter 1600 (1979) или обучающее видео для пользователей. Условием остается четкая и понятная форма.

Что такое руководство?

Слово происходит от латинского "instructio", тоесть привести в порядок. Следовательно в инструкции Volkswagen Transporter 1600 (1979) можно найти описание этапов поведения. Цель инструкции заключается в облегчении запуска, использования оборудования либо выполнения определенной деятельности. Инструкция является набором информации о предмете/услуге, подсказкой.

К сожалению немного пользователей находит время для чтения инструкций Volkswagen Transporter 1600 (1979), и хорошая инструкция позволяет не только узнать ряд дополнительных функций приобретенного устройства, но и позволяет избежать возникновения большинства поломок.

Из чего должно состоять идеальное руководство по эксплуатации?

Прежде всего в инструкции Volkswagen Transporter 1600 (1979) должна находится:
- информация относительно технических данных устройства Volkswagen Transporter 1600 (1979)
- название производителя и год производства оборудования Volkswagen Transporter 1600 (1979)
- правила обслуживания, настройки и ухода за оборудованием Volkswagen Transporter 1600 (1979)
- знаки безопасности и сертификаты, подтверждающие соответствие стандартам

Почему мы не читаем инструкций?

Как правило из-за нехватки времени и уверенности в отдельных функциональностях приобретенных устройств. К сожалению само подсоединение и запуск Volkswagen Transporter 1600 (1979) это слишком мало. Инструкция заключает ряд отдельных указаний, касающихся функциональности, принципов безопасности, способов ухода (даже то, какие средства стоит использовать), возможных поломок Volkswagen Transporter 1600 (1979) и способов решения проблем, возникающих во время использования. И наконец то, в инструкции можно найти адресные данные сайта Volkswagen, в случае отсутствия эффективности предлагаемых решений. Сейчас очень большой популярностью пользуются инструкции в форме интересных анимаций или видео материалов, которое лучше, чем брошюра воспринимаются пользователем. Такой вид инструкции позволяет пользователю просмотреть весь фильм, не пропуская спецификацию и сложные технические описания Volkswagen Transporter 1600 (1979), как это часто бывает в случае бумажной версии.

Почему стоит читать инструкции?

Прежде всего здесь мы найдем ответы касательно конструкции, возможностей устройства Volkswagen Transporter 1600 (1979), использования отдельных аксессуаров и ряд информации, позволяющей вполне использовать все функции и упрощения.

После удачной покупки оборудования/устройства стоит посвятить несколько минут для ознакомления с каждой частью инструкции Volkswagen Transporter 1600 (1979). Сейчас их старательно готовят или переводят, чтобы они были не только понятными для пользователя, но и чтобы выполняли свою основную информационно-поддерживающую функцию.

Содержание руководства

  • Страница 1

    Owner s Worksho p Manua l[...]

  • Страница 2

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

  • Страница 3

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

  • Страница 4

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

  • Страница 5

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

  • Страница 6

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

  • Страница 7

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

  • Страница 8

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

  • Страница 9

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

  • Страница 10

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

  • Страница 11

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

  • Страница 12

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

  • Страница 13

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

  • Страница 14

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

  • Страница 15

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

  • Страница 16

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

  • Страница 17

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

  • Страница 18

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

  • Страница 19

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

  • Страница 20

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

  • Страница 21

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

  • Страница 22

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

  • Страница 23

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

  • Страница 24

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

  • Страница 25

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

  • Страница 26

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

  • Страница 27

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

  • Страница 28

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

  • Страница 29

    [...]

  • Страница 30

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

  • Страница 31

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

  • Страница 32

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

  • Страница 33

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

  • Страница 34

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

  • Страница 35

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

  • Страница 36

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

  • Страница 37

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

  • Страница 38

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

  • Страница 39

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

  • Страница 40

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

  • Страница 41

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

  • Страница 42

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

  • Страница 43

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

  • Страница 44

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

  • Страница 45

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

  • Страница 46

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

  • Страница 47

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

  • Страница 48

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

  • Страница 49

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

  • Страница 50

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

  • Страница 51

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

  • Страница 52

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

  • Страница 53

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

  • Страница 54

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

  • Страница 55

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

  • Страница 56

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

  • Страница 57

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

  • Страница 58

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

  • Страница 59

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

  • Страница 60

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

  • Страница 61

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

  • Страница 62

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

  • Страница 63

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

  • Страница 64

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

  • Страница 65

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

  • Страница 66

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

  • Страница 67

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

  • Страница 68

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

  • Страница 69

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

  • Страница 70

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

  • Страница 71

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

  • Страница 72

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

  • Страница 73

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

  • Страница 74

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

  • Страница 75

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

  • Страница 76

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

  • Страница 77

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

  • Страница 78

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

  • Страница 79

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

  • Страница 80

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

  • Страница 81

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

  • Страница 82

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

  • Страница 83

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

  • Страница 84

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

  • Страница 85

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

  • Страница 86

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

  • Страница 87

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

  • Страница 88

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

  • Страница 89

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

  • Страница 90

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

  • Страница 91

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

  • Страница 92

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

  • Страница 93

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

  • Страница 94

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

  • Страница 95

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

  • Страница 96

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

  • Страница 97

    [...]

  • Страница 98

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

  • Страница 99

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

  • Страница 100

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

  • Страница 101

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

  • Страница 102

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

  • Страница 103

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

  • Страница 104

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

  • Страница 105

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

  • Страница 106

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

  • Страница 107

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

  • Страница 108

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

  • Страница 109

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

  • Страница 110

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

  • Страница 111

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

  • Страница 112

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

  • Страница 113

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

  • Страница 114

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

  • Страница 115

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

  • Страница 116

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

  • Страница 117

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

  • Страница 118

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

  • Страница 119

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

  • Страница 120

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

  • Страница 121

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

  • Страница 122

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

  • Страница 123

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

  • Страница 124

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

  • Страница 125

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

  • Страница 126

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

  • Страница 127

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

  • Страница 128

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

  • Страница 129

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

  • Страница 130

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

  • Страница 131

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

  • Страница 132

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

  • Страница 133

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

  • Страница 134

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

  • Страница 135

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

  • Страница 136

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

  • Страница 137

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

  • Страница 138

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

  • Страница 139

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

  • Страница 140

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

  • Страница 141

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

  • Страница 142

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

  • Страница 143

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

  • Страница 144

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

  • Страница 145

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

  • Страница 146

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

  • Страница 147

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

  • Страница 148

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

  • Страница 149

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

  • Страница 150

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

  • Страница 151

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

  • Страница 152

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

  • Страница 153

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

  • Страница 154

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

  • Страница 155

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

  • Страница 156

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

  • Страница 157

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

  • Страница 158

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

  • Страница 159

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

  • Страница 160

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

  • Страница 161

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

  • Страница 162

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

  • Страница 163

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

  • Страница 164

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

  • Страница 165

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

  • Страница 166

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

  • Страница 167

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

  • Страница 168

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

  • Страница 169

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

  • Страница 170

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

  • Страница 171

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

  • Страница 172

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

  • Страница 173

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

  • Страница 174

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

  • Страница 175

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

  • Страница 176

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

  • Страница 177

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

  • Страница 178

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

  • Страница 179

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

  • Страница 180

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

  • Страница 181

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

  • Страница 182

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

  • Страница 183

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

  • Страница 184

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

  • Страница 185

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

  • Страница 186

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

  • Страница 187

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

  • Страница 188

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

  • Страница 189

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

  • Страница 190

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

  • Страница 191

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

  • Страница 192

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

  • Страница 193

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

  • Страница 194

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

  • Страница 195

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

  • Страница 196

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

  • Страница 197

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

  • Страница 198

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

  • Страница 199

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

  • Страница 200

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

  • Страница 201

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

  • Страница 202

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

  • Страница 203

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

  • Страница 204

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

  • Страница 205

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

  • Страница 206

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

  • Страница 207

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

  • Страница 208

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

  • Страница 209

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

  • Страница 210

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

  • Страница 211

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

  • Страница 212

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

  • Страница 213

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

  • Страница 214

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

  • Страница 215

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

  • Страница 216

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

  • Страница 217

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

  • Страница 218

    ^ [...]

  • Страница 219

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

  • Страница 220

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

  • Страница 221

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

  • Страница 222

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

  • Страница 223

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