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SECTION H - RJH-Heritage Switzerland

1. SA Fig 24 Armature insulation test iv Inspection of Moulded Gear Examine the gearwheel especially the teeth for signs of wear or damage If the gearwheel needs renewing a shaft and gear service re placement assembly will have to be fitted Re assembly Reassembly is the reverse of the dismantling pro cedure A liberal quantity of Ragosine Listate grease is necessary for lubrication of the gearwheel teeth the gearwheel cam and the worm gear on the armature shaft The total quantity of grease must not be less than 15 cce Apply Shell Turbo 41 oil to the bearing bushes armature shaft bearing surfaces sparingly gearwheel shaft and the felt oiler washer in the yoke bearing thoroughly soak Reassembly of Yoke Before refitting the armature to the yoke inspect the inside of the yoke and ensure that the thrust disc and the felt oiler washer are in place in the yoke bearing The correct method of assembly is with the thrust disc flat against the end face of the bearing followed by the felt oiler washer which must have a hole in the centre to allow the captive ball bearing in the end of the armature shaft to contact the thrust disc If the felt oiler is renewed check that the replace ment is provided with the necessary hole and if not make a 4 3 mm diameter hole in the centre of the felt A felt oiler without a hole could result in the armature end float becoming excessive in service due to
2. es r Fig oe Sectioned view of the upper and lower steering columns showing the nylon plugs Page LY s 2 Ht fi SECTION II STEERING Power assisted DESCRIPTION The power assisted steering system available as optional equipment consists of three main components the rack and pinion steering unit the pump and the reservoir interconnected by flexible hoses The pump is mounted on the left hand side of the engine the reservoir being attached to brackets secured to the left hand sub frame A shield protects the reservoir on left hand drive cars from the exhaust manifold heat The upper and lower columns remain the same in detail as stated in Section I page IY s 1 DATA Steering Gear Make Adwest Engineering Co Ltd Type Rack and Pinion Number of turns lock to lock Turning circle Oil Pump Make Hobourn Eaton Location Left front of engine Operating Pressure 1 000 1b sq in 70 3 kg cm 2 Front Wheel Alignment 4 1 6 3 2 mm toe in Page ITY s 1 STEERING POWER ASSISTED OPERATION STEERING GEAR Oil is supplied from the reservoir via the output side of the pump to the steering unit pressure hose and is then returned from the steering unit to the reservoir return hose A continuous flow of oil is pumped through the system whilst the engine is running but pressure builds up only when the steering wheel is turned The steering gear is basically a normal rack and pinion manual
3. As the liquid is absorbing the heat from the air the refrigerant ts caused to vaporise or boil Refrigerant 12 boils at 20 F 29 C at atmospheric pressure The vapour has more coil to pass through before its exit and as the warm air is still imparting heat to the refrigerant vapour and as the vapour Is In a saturated State any further heat absorbed by it creates a super heat and its temperature begins to rise Condensation of the moisture in the air occurs simultaneously with the reduction of the air tem perature This water condensate is drained out of the evaporator assembly and discharged through drain pipes Frequently the condensate will drain from the evaporator case very soon after the car comes to rest and the blower is switched off and this will create a condensate puddle underneath the car This is a natural condition and no investigation as to cause is necessary No routine maintenance is required and any repairs can only be carried out if the evaporator is removed from the car Page RY s 1 AIR CONDITIONING REFRIGERATION EQUIPMENT Fig 6 The evaporator unit Removal Slide the seats back to the full extent of the slides Remove all refrigerant from the system by Pumping Down Disconnect all pipe unions and blank off the ends to prevent the ingress of dirt or moisture Withdraw the drive screws securing the side fixing bracket to the bedy panel Carefully ease the uni
4. PANEL LIGHT DIMMING RESISTOR The resistor unit is comprised of a wire resistance attached to two Lucar cable contact blades mounted on an insulating carrier plate The plate 1s secured to two studs on the back face of the instrument panel by means of distances peices nuts and lockwashers Excessive force should not be used when connecting the cable terminals to the blades This may force the blade retaining tongues through the insulating plate and allow the resistor to make contact with the metal face of the panel resulting in a short circuit in the side light feed line BATTERY INDICATOR This instrument is a voltmeter with a specially calibrated dial which indicates the condition of the battery It does not register the charging rate of the alternator The position of the needle with a charged battery will be within the area marked Normal Removal Disconnect the battery and lower the instrument panel Disconnect the cables noting the location for reference when refitting Detach the illumination bulb holder Remove two nuts and clamp strap and withdraw the instrument forward through the panel Refitting Refitting is the reverse of the removal procedure ELECTRICAL AND INSTRUMENTS Check the condition ot the battery by means of the panel shown below RED Off Charge BATTERY BATTERY CHARGE CHARGE EXTREMELY LOW LOW Se is rrr CC M ment e g headlamps etc switched on but with the engin
5. Top up the reservoirs to the correct level and apply the brake several times until the pedal feels solid FRONT CALIPERS Removal Jack up the car and remove the front wheel s Disconnect the caliper fluid feed pipe from the union and seal the pipe and union Remove the locking wire withdraw the mounting bolts and lockwashers and detach the caliper Locate the caliper in position and secure with the mounting bolts and lockwashers Lockwire the bolts after fully tightening Reconnect the caliper feed pipe to the union and bleed the braking system as detailed on page LIO REAR CALIPERS Removal The rear suspension unit must be removed in order to withdraw the rear calipers Proceed as described in Section K Rear Suspension and support the suspension unit under its centre Disconnect the handbrake compensator linkage from the handbrake operating levers Discard the split pins and withdraw the clevis pins Lift the locking tabs and remove the pivot bolts together with the retraction plate Remove the friction pad carriers from the caliper bridges by moving them rearwards round the discs and withdrawing from the rear of the rear suspension _assembly Remove the hydraulic feed pipe at the caliper and plug the hole to prevent the entry of dirt Remove the friction pads from the caliper as described previously Remove the front hydraulic damper and road spring unit as described in Section K Rear Suspens
6. With the assembly removed from the rack tube carry out the following checks With a soft mallet drift out the valve and pinion assembly from the housing Examine the teflon rings These should bea loose fit in their grooves and the outer diameter should be free from cuts scratches or similar blemishes Ensure that there is no relative movement at the trim pin between the valve sleeve and the shaft Check that there is no wear in the torsion bar assembly pins by ensuring that there is no free move ment between the input and output pinion shafts Examine the housing bore for signs of wear particularly on the rubbing surfaces of the teflon rings Examine the needle roller bearings for damage or wear If during the above checks any fault is found the complete assembly must be replaced as a unit Replacing the Top Seal Drift out the shaft assembly as detailed above Remove the circlip and extract the top and back up Page ITY s 6 relation to the rack housing Remove tnree nylon locking nuts retaining valve body assem bly to the rack housing Withdraw the assembly and discard the joint Note the location of the pinch bolt slot before withdrawing the housing f The unit is now separated into its two major components that is valve and pinion assembly and the rack and tube assembly Depending on the fault either of these or both can be dismantled and the faulty component replaced Do not disturb the outer ball jot
7. Check the outer ball joint and replace if necessary Re assemble to the track rod and adjust the length between the ball pin centres to the figure as noted on removal This should be 8 75 22 2 cm IT IS IMPORTANT that both track rods are of equal length Refit the inner ball joint and spring to the rack shaft and tighten fully Secure with new tabwasher Apply a generous coating of the recommended grade of grease to the inner ball housing and refit the bellows and tighten the clips Reconnect the track rod to the steering arm and check the front wheel alignment as detailed on page lHY s 9 STEERING POWER ASSISTED CHECKING THE HYDRAULIC SYSTEM A number of faults in the steering system can be caused by inefficiencies in the hydraulic circuit see page IIY s 10 for Fault Finding chart The following checks can be carried out without removing any components from the car Before starting any of this work the fluid should be checked for correct level and for lack of froth Pump Blow Off Pressures Fit a pressure gauge into the return line start the engine and run at idling speed Turn the steering to full lock and continue to increase the steering wheel effort until the pressure ceases to increase The peak pressure should lie between 950 and 1 000 Ib sq in 66 8 70 3 kg cm 2 and should not increase with engine r p m If however the pressure is below 950 lb sq in 66 8 kg cm 2 at tickover but rises to
8. Decelerate to RPM No advance butor Service Vacuum of mercury and in timing Advance and note advance and note advance In timing Type Number Unit advance in degrees below ins Springs in degrees in degrees kbelow Number Inches Degrees of mercury Number RPM Degrees RPM Degrees RPM 2 79 1800 84 104 13 g 1250 6 8 22 D6 4I0GOA 54415894 9 24 54 44 25415562 2 300 84 10 800 5 7 7 0 3 650 2 4 Y 525 0 14 6 0 4 m M rr rm a Auto advance weights Lucas number 54413073 ee ae 7 One inch of mercury 0 0345 kg cm Cat Page PYS ELECTRICAL AND INSTRUMENTS FUSE UNITS CIRCUITS Headlamps Main Beam Headlamps Dip Beam Horns In line In line Traffic Hazard Warning System Side Panel Tail and Number Plate not Germany Lamps Horn Relay Washer Radiator Fan Motor and Stop Lamps Flashers Heater Wiper Choke Fuel Water and Oil Gauges Headlamp Flasher Interior Lamps and Cigar Lighter Heated Backlight when fitted Radio Optional Extras THE ALTERNATOR MODEL 11AC 43 AMP DESCRIPTION The Lucas 11 AC alternator is a lightweight machine designed to give increased output at all engine speeds Basically the unit consists of a stationary output winding with built in rectification and a rotating field winding energised from the battery through a pair of slip rin
9. Performance Testing Equipment required D C supply of appropriate voltage D C voltmeter first grade moving coil 0 3 amp D C ammeter 0 15 Ib sq in 0 1 kg sq cm pressure gauge Pushbutton with normally open contacts Two jet nozzle On off tap 100 c c capacity measure 4 ft 6 in 1 37 m length of plastic tubing Connect up the equipment as shown in Fig 1 The water level in the container must be 4 101 6 mm above the base of the pump assembly The pressure gauge and nozzle must be 18 45 72 cm above the water level Open the tap Depress the button for approxi mately five seconds and check the voltmeter reading which should be the same as the supply voltage On releasing the switch close the tap to ensure that the plastic tubing remains charged with water Empty the measuring cylinder Open the tap and operate the push switch for precisely ten seconds after which period release the switch and close the tap During the ten second test the current and pressure values should be in accordance with those given in Data and at least 35 c c of water should have been delivered Page OY s 3 HEATING AND WINDSCREEN WASHING EQUIPMENT PRESSURE GAUGE PLASTIC TAP TUBING CONNECT TO THE APPROPRIATE TEE CONNECTOR MOTOR TERMINALS STANDARD TWO JET LEVEL NOZZLE DF WATER IOOCC MEASURE AMMETER BATTERY SUPPLY PUSH SWITCH Fig 1 Performance testing th
10. 43 Screw Page LY s 10 Secure the valve housing to the master cylinder body by fitting the two hexagon headed screws 2 complete with spring washers and tighten each screw to a torque of 160 180 Ib ins 1 8 2 kg m A new gasket should be fitted between the valve housing and the master cylinder body Stretch the reaction valve diaphragm onto the diaphragm support through the hole in the valve housing so that it engages the depression in the valve piston Using the fingers only stretch the valve rubber which is formed with the groove around its inside diameter onto the valve stem flange insert the valve stem through the hole in the valve cover and secure it by placing the other valve rubber over the valve stem and fitting the snap on clip The valve cover assembly can now be placed into position on the valve housing ensuring that all the holes line up and that the hose connections are in line with each other at the bottom of the unit Secure the valve cover assembly by fitting the five self tapping screws Hold the master cylinder in an upright position valve uppermost and place the air filter together with the rubber washer in position upon the valve cover with the small spring on the snap on valve stem clip Carefully locate the air filter cover over the air filter and press it firmly home If the trap valve assembly has been dismantled insert the small clip into the trap valve body ensuring that it does not become dis
11. A control in each carburetter enables the choke to be varied for summer and winter operation and takes the form of a spring loaded plunger operating against the cam To check the setting note the position of the stop cross pin If lying in the horizontal slot in the casting the choke is set for winter operation To adjust for Summer running depress the spring loaded pin and turn through 90 Release and check that the cross pin is at right angles to the slot 38628 Fig 5 The choke limiting spindle in the Winter setting inset shows the Summer setting IDLING There is no separate circuit for idling The fuel is provided by the jet orifice the amount being con trolled by jet needle relationship established during manufacture and the speed of idle by adjustment of the throttle stop screw which limits the closure of the throttle when the accelerator pedal is released To cater for variations in engine stiffness when manufactured an idle trim screw is provided Engine stiffness dictates idling air consumption and a new and very stiff engine wil require more air than Page QY s 6 one which has become free The trim screw may be adjusted to provide a slightly leaner mixture fot any engine found to be extremely stiff on production engine test When fully seated the maximum enrich ment 1s achieved and emission figures will be within requirements the engine having freed to a value equivalent to the
12. ITEMS THAT MUST NOT BE CHANGED a The jet assembly b The piston c The depression chamber cover d The position of the metering needle If any of the above items require changing the sub assemblies or the complete carburetter s must be renewed In the case of the metering needle it is quite permissible to replace the needle providing the procedure outlined previously is carefully followed EXHAUST EMISSION CONTROL EQUIPMENT The recommended equipment for servicing should include at least the following Ignition Analyser Cam Angle Dwell Meter oscilloscope Ohmeter Ignition Timing Light Voltmeter Engine Exhaust Combustion Tachometer Analyser Vacuum Gauge Cylinder Leak Tester Carburetter Balance Distributor Advance Tester Meter It is important that test equipment has regular maintenance and calibration The following equipment covers most of the re quirements for engine testing and tuning of vehicles fitted with exhaust emission control devices Equipment made by other suppliers may also be adequate Equipment Type Model Manufacturer Oscilloscope engine 1020 or 720 Sun Electric tuning set and exhaust Corp gas analyser Page QY s 15 _ NN e a Su SECTION R AIR CONDITIONING REFRIGERATION EQUIPMENT DESCRIPTION Air conditioning equipment is available as an optional extra and is fitted in addition to the car heating and ventilating system standard on all cars The air conditioning e
13. POWER ASSISTED SERVICING Checking The Reservoir Oil Level The oil reservoir is mounted on the right hand side of the engine It is important that absolute cleanliness is observed when replenishing with oil as any foreign matter that enters may affect the hydraulic system Remove the filler cap check the oil level and top up if necessary with the recommended grade of fluid The correct level of the oil is just above the filter element Rack and Pinion Housing The rack and pinion housing is attached to the front suspension crossbeam A grease nipple located in the rack adjuster pad for the lubrication of the rack and pinion assembly is accessible from underneath the front of the car from the driver s side Lubricate sparingly with the recommended grade of lubricant Do not over lubricate the housing to the extent where the bellows at the end of the housing become distended Qver lubricating may also block the air transfer pipe Check that the clips at the ends of the bellows are fully tightened otherwise the grease will escape from the housing Steering Tie Rods Lubricate the ball joints of the two steering tie rods with the recommended lubricant When carrying out this operation examine the rubber seals at the bottom CHECKING AND The following adjustments can be carried out on the car all others which may develop require the removal of the unit from the chassis RACK RATTLE This is usually apparent when trav
14. needle valve assemblies with new washers Remove the damper assembly from the top cover and break the wire seal Unscrew the four cover fixing screws and carefully lift off the cover Remove the piston return spring and lift out the piston assembly Drain off the oil from the damper reservoir centre of guide rod Slacken the metering needle clamping screw and withdraw the needle from the piston Place the needle carefully to one side to avoid damage Remove the four screws attaching the diaphragm retaining ring to the top of the piston Lift off the ring and diaphragm Fit the new diaphragm into the top of the piston ensuring that the locating tag is recessed into the aperture provided Secure in position with the retaining ring and the four screws Check the spring action of the needle in its housing at the top of the shank Fit the needle into the base of the piston lining up the flat portion with the locking screw Using a straight edge placed lightly against the small shoulder on the needle not the casing press the assembly into the piston until the straight edge aligns the shoulder of the needle with the flat surface of the piston Lightly tighten the locking screw taking care not to collapse the needle housing Shoulder alignment of the needle is critical and great care must be taken during this operation Correctly fitted the needle will be baised towards the throttle and the shoulder of the needle will be exactly flush wi
15. until the required setting is obtained Use care in making this adjustment as a small amount of adjuster movement causes an appreciable difference in the voltage reading Recheck the setting by first stopping the engine then again running the alternator at 3 000 EDT Remount the control unit and disconnect the voltmeter om amp h E Fig 17 4 TR Alternator Control A Potentiometer adjuster Pape PY s 13 ELECTRICAL AND INSTRUMENTS WARNING LIGHT CONTROL UNIT Model 3AW DESCRIPTION The Model 3AW warning light unit is a device connected to the centre point of one of the pairs of diodes in the alternator and operates in conjunction with the ignition warning light to give indication that the alternator is charging The unit is mounted on the bulkhead adjacent to the control box and is similar in appearance to the flasher unit but has different internal components consisting of an electrolytic polarised capacitor a resistor and a silicone diode mounted on an insulated ase with three Lucar terminals The unit is sealed therefore servicing and adjust ment is not possible Faulty units must be replaced Due to external similarity of the 3AW warning light unit and the flasher unit a distinctive green label 1s attached to the aluminium case of the 3AW unit Checking Check by substitution after ensuring that the remainder of the charging circuit including the drive belt is functioning satisfactorily W
16. washers and insulating pieces brush box screws and the 2 B A hexagon headed setscrew Withdraw the stator and diode heat sink assemblies from the slip ring end cover Close up the retaining tongue at the root of each field terminal blade and withdraw the brush spring together with the terminal assemblies from the moulded brushbox REASSEMBLY Reassembly of the alternator is the reverse of the dismantling procedure Care must be taken to align the drive end bracket lamination pack slip ring and bracket correctly Tighten the three through bolts evenly to a maxi mum torque of 45 to 50 lb ins 0 518 to 0 576 kgm Restake the nuts after tightening Tighten the brush box fixing screws to a maximum torque of 10 lb ins 0 115 kgm IMPORTANT It is important to ensure that a 045 1 28 mm gap exists between the non pivotal end of the heat sinks see Fig 15 When reassembling the alternator INSPECTION OF BRUSHGEAR EARLY MODELS a maxi Measure brush length A new brush is 3 15 88 mm long a fully worn brush is 3 97 mm and must be replaced at or approaching this length The new brush is supplied complete with brush spring and Lucar terminal blade and has merely to be pushed in until the tongue registers To ensure that the terminal is properly retained carefully lever up the retaining tongue with a fine screwdriver blade so that the tongue makes an angle of 30 with the terminal blade The normal b
17. 29 Float assembly 2 10 Floating lever 30 Float chamber ee z s 11 Washer 31 Pivot pin 2 z 12 Shakeproof washer 32 O ring ja 13 Nut 33 Needle valve 14 Diaphragm 34 Special washer fp OR pe 4 15 Idle trim screw 35 Choke assembly Fi a Es 16 Gasket 36 Needle Cs 17 By pass valve 37 Spring os i pon uj 18 Gasket 38 Throttle stop screw X7 fo 19 Spring 39 Throttle spindle assembly r w 20 Cover 40 Piston ai 21 Seal 4 Diaphragm r 5 Inset Lead seal L n K K K Fig 11 Exploded view of the rear carburetter Page QY s 10 12 000 Miles Service For this service period one Yellow Emission Pack Part No 11549 is required for the two carburetters This pack contains 2 float chamber gaskets 2 O rings for the float chamber plugs and 2 needle valve washers Additionally 4 manifold carburetter gaskets and 2 spacers will be required Remove the carburetters as follows Remove th ee setscrews securing the air trumpet to each carburetter and withdraw the engine breather b G 4 f if cy ms ey f r h i My yf if H if le f EXHAUST EMISSION CONTROL pipe from the air box Lift off the air cleaner Thin gaskets are fitted between each trumpet and car buretter and these should be carefully placed to one side for use when refitting Remove the gasoline pipes from the float chambers R
18. 32 ee E to ot ll ee te ill a JF F EE E r ll Dh hy eee ee ee I Fig 32 A Side lamp bulb B Flasher bulb FRONT FLASHER BULB REPLACEMENT Proceed as detailed for Side Lamp Bulb REAR BRAKE LIGHT BULB REPLACEMENT Remove the four screws and detach the glass The rear braking light bulb is the lower one of the two exposed and is removed by pressing inwards and rotating anti clockwise When refitting a replacement bulb note that the pins are offset Fig 33 A Rear flasher bulb B Rear Brake bulb REAR FLASHER BULB REPLACEMENT Proceed as detailed for Rear Brake Light Bulb Replacement The flasher bulb is the top one of the two exposed INTERIOR LIGHT BULB REPLACEMENT 2 2 Release the spring side clip and withdraw the retain ing tongue on the glass cover from the slot in the lamp base Remove the faulty bulb and replace with one of the correct value When refitting ensure that the retaining tongue is inserted in the slot in the base before locking into position ee Fig 34 Interior lamp bulb removal 2 2 INTERIOR LUGGAGE LIGHT BULB REPLACEMENT Open 2 seater Proceed as detailed in the 3 8 E type Service Manual page P 26 te ss Fig 35 Interior lamp bulb removal open 2 seater ELECTRICAL AND INSTRUMENTS NUMBER PLATE LAMP BULB REPLACEMENT Remove two screws and detach the glass and rim R
19. 35 grammes of the recommended lubricant Do not lubricate the housing to the extent where the bellows become distended Over lubrication may also block the air transfer pipe Refitting Refitting is the reverse of the removal procedure Reconnect the high and low pressure hoses care being taken to ensure that the connections are perfectly clean Refit the lower and upper steering columns as detailed on page sILY s 8 Refill the reservoir to the full mark of the dipstick with the recommended grade of Automatic Trans mission Fluid Bleed the system as follows a With the engine running turn the steering from lock to lock a few times to expel any air which may be present indicated when all lumpiness has disappeared b Check the fluid level in the reservoir and top up if necessary with the recommended grade of fluid The correct level is just above the filter element Page IIY s 7 STEERING POWER ASSISTED STEERING COLUMN The upper and lower steering columns and mount ings are of the collapsible type designed to comply with U S A Federal Safety Regulations The collapse points are retained by nylon plugs which will shear on impact allowing the steering wheel and columns upper and lower to move forward NO ATTEMPT must be made to repair the units if damaged due to accident NEW replacement items MUST be fitted UPPER STEERING COLUMN Description The upper steering column inner is composed of two sepa
20. INSTRU MENTS Re engagement of the starter cranking motor will not be possible until the key is returned to the Park position This is a safety device introduced to prevent damage to the starter drive through accidental engagement when the engine is running SERVICING No servicing is possible with the exception of the switch carrier contact plate which can be replaced if faulty as follows 1 Disconnect the cables at the connectors 2 Remove two hexagon headed screws and plain washers and withdraw the contact plate with attached harness 3 Refit by reversing the removal procedure Note The contact plate is indexed and cannot be fitted incorrectly Two Lucas 6RA relays are Incorpcrated in the circuits controlled by the ignition switch to prevent overloading of the switch contacts Both units are located under the screen rail facia Operation of the individual relays should be checked when testing for a fault in the ignition starter switch circuits Fig 43 The Steering column lock dismantled The lock is shown removed from the column for clarity Page PY s 37 r SECTION Q EXHAUST EMISSION CONTROL To meet U S A Federal and Canadian engine emission requirements the Jaguar 4 2 Litre engine has been modified in relation to carburation induction system and ignition as follows The Duplex Manifolding System employs the metering system of the carburetters to feed fuel mixture to the combustion
21. Page JIY s 3 Renew ball joint and track rod as an assembly Remove the rack and renew the bush SECTION J FRONT SUSPENSION The front suspension remains basically the same as that detailed in Section J 3 8 E Type Service Manual with the exception of the removal of the wheel hubs when steel spoked wheels are fitted and the torsion bar settings The routine maintenance periods are increased from those stated previously Wheel Swivels Lubricate the nipples four per car fitted to the top and bottom of the wheel swivels A bleed hole is provided in each ball joint The hole being covered by a nylon washer which lifts under pressure and indicates when sufficient lubricant has been applied The nipples are accessible from underneath the car Wheel Bearings Removal of the wheel bearings will expose a grease nipple in the wheel hubs Lubricate sparingly with the recommended grade of lubricant If excess grease is pumped into the bearing the grease will exude into the bore of the hubs Wire wheels or through a small hole drilled centrally in the hub end cap Pressed steel wheels TORSION BAR SETTING Check that the car is full of petrol oil and water and that the tyre pressures are correct Place the car on a perfectly level surface with the wheels in the straight ahead position Check the measurement from the centre line of the inner fulcrum of each lower wishbone assembly to the ground This should be 9 22 86
22. Service Carburetter Hydraulic Damper Top up the hydraulic piston damper as detailed in the 1 000 miles Free Service Page QY s 4 EVERY 12 000 MILES Fit Emission Pack Part No 11549 coloured Yellow to the carburetters See page QY s 11 for details Air Filter Renew the air filter element as detailed in the Service Manual If the car is operating in dusty territory inspect at 6 000 miles and renew if necessary Crankcase Breather Disconnect the breather pipe from the front of the engine and the air filter Remove the pipe Remove the nuts securing the breather and withdraw the flame trap Wash the flame trap and pipe in gasoline and refit Renew the gaskets located on each side of the flame trap Examine all hoses renew if necessary Check that all clamps are tight allowing no air leakage Fig 4 The crankcase breather Inlet Manifolds Check tightness of all secondary throttle housing and inlet manifold securing nuts Check tightness cf nuts securing primary mixture pipe to secondary throttle housing It is important to ensure that no leaks exist at any of these joints Exhaust System Check the exhaust system for leaks Renew any parts showing signs of deterioration Spark Plugs Renew the spark plugs with the recommended grade Cylinder Head Check the torque of the cylinder head securing nuts 696 lb ins and check the cylinder head gasket for leaks Fuel Line Filter At the recommended interval or mor
23. bellows seal assembly by hand on the shaft to a position beyond the taper of the shaft Assemble the shaft seal washer in the bellows seal assembly checking that the assembly and the shaft are free from dirt Assemble the seal washer so that the raised rim is away from the bellows seal and that the notches in the washer line up with the nibs in the bellows assembly Cover exposed surfaces of the shaft seal washer with clean refrigerant oil Install new rectangular section O ring in the crankshaft mating surfaces for seal plate Place the new front seal plate over the shaft and line up the holes Push the seal plate evenly against the crankcase and retain in this position while inserting and tightening two diametrically opposed bolts in sert the remaining four bolts and tighten evenly to the correct torque figure Rotate the shaft by hand 15 20 revolutions to seat the seal Cylinder Head and Valve Plate Assembly For the best results the compressor should be removed from the engine as detailed previously in this section Clean off all road dirt and dismantle on a clean bench Remove ten bolts from the cylinder head assembly and detach the valve plate and head assembly by lightly tapping upwards with a soft nosed mallet Note the location of the valve plate in relation to the cylinder head for reference when refitting Remove the valve plate from the cylinder head by holding the plate and tapping sideways against the head
24. bulb lights up in both tests or does not light up in either then the diode is defective and the appropriate heat sink assembly must be replaced The above procedure is adequate for service purposes Any accurate measurement of diode resistance requires factory equipment Since the forward resistance of a diode varies with the voltage applied no realistic readings can be obtained with battery powered ohmmeters If a battery ohmmeter is used a good diode will yield Infinity on one direction and some indefinite but much lower reading in the other WARNING Fig 10 Stator winding continuity test Ohmmeters of the type incorporating a hand driven generator must never be used for checking diodes cry i n Fig 11 Stator winding insulation test Jo eee 4064 3 Fig 12 Method of testing diodes e o PTTL LE A y eo SY Fue A 3 jm f X Ama F Pe cs i a i z Ge S Wee VAT RT Sooo sar See _ fai as _ a Fig 13 Exploded view of the slip ring end cover i Stator 4 Warning light terminal AL 8 Rotor slip ring brush 2 9 Through bolts 3 2 Star point 5 Field terminal 2 l Page PY s 10 3 Negative heat sink anode 6 Slip ring end cover 1 SONNER E base diodes black E S il Positive heat sink and cathode 7 Terminal blade retaining tongue base diode red ALTERNATOR DIODE HEAT SINK REPLA
25. centre plug and wash all metal parts in cleansing solvent Re assemble the carburetters as follows Refit the needle valve with the new washer to the float chamber body and screw home tightly Replace the float assembly after inspecting for distortion or damage To ensure correct float level measure the float height as follows Invert the carburetter so that the float tag closes the needle valve Measure from the face of the carburetter body with the gasket removed to the top of each float The correct height should be 16 5 5 mm Fig 13 Checking the float height Dimension A should be 16 5 5 mm Fit a new O ring to the centre plug With the new gasket in position refit the float chamber and tighten the securing screws from the centre outwards Refit the carburetters to the manifold with the new gaskets and spacers Reconnect the carburetter linkage Reconnect the gasoline pipes and top up the hydraulic piston damper of each carburetter with Zenith Lube Pack or SAE 20 engine oil to within 4 of the top of the centre rod Leaving the clamping bolts on the throttle spindles loose unscrew the throttle stop screws to permit the primary throttles in each carburetter to close com pletely Screw in the stop screws to the point where Page QY s 12 the ends of the screws are just contacting the casting Rotate each screw 14 turns to open the throttles an qual amount and to provide a basis from which the fi
26. chamber to the downstream side of the primary throttle en riching the gases in the combustion chamber to a combustible level sA HYDRAULIC DAMPER At any point in the throttle range a temporary enrichment is required when the throttle is suddently opened A hydraulic damper is arranged inside the hollow guide rod of the piston to provide this The guide rod itself is filled with Zenith Lube Pack or SAE 20 engine oil to within 4 of the end of the rod When the throttle is suddenly opened the immediate upward motion of the piston is resisted by the damper For this brief period a temporary increase in the depression over the jet orifice is achieved and the mixture 1s enriched Downward movement of the piston is assisted by a coil spring RECOMMENDED SERVICE PROGRAMME It is necessary to maintain the carburetters at peak efficiency to control engine emission therefore the following service recommendations should be carried out EXHAUST EMISSION CONTROL 3859B Fig 10 The hydraulic damper Sectioned view showing the gil level in the pis on guide Page QY s 9 EXHAUST EMISSION CONTROL 1 Hydraulic damper 22 Seal 2 O ring 23 Gasket 3 Cover 24 Temperature compensator 4 Diaphragm securing ring housing 5 Piston return spring 25 Tapered plug 6 Needle securing screw 26 Bi metallic blade 7 Butterfly 27 Plastic cover f 3 8 Bush 28 Jet assembly gn 9 Pick up lever
27. chambers through two manifolds Two throttles are employed the primary being in its normal position in the carburetter and the secondary located in the water jacketed secondary throttle housing The linkage between the two throttles is so arranged that on part throttle opening employed during most city driving and cruising the secondary throttle remains closed routing the mixture through the primary mixture pipe and returning it to the inlet manifold downstream of the secondary throttles This circuit ensures complete homogeneity of fuel mixture resulting in a constant air fuel ratio being distributed to the cylinders so that an overall leaner mixture can be employed It also avoids the deposition of wet fuel in the inlet manifold which is a major cause of engine emissions After approximately 25 of primary throttle opening the secondary throttle comes into operation until at full throttle both butterflies are fully opened and the mixture passes straight through both manifolds so that maximum power is maintained A modified distributor with redesigned power curve is fitted in conjunction with this system the ignition timing being 5 B T D C static 10 B T D C at 1 000 r p m ROUTINE MAINTENANCE Owing to the critical emission limits which must be maintained throughout the lifetime of the engine it is imperative that the following routine maintenance instructions are carried out conscientiously at the recommended milea
28. current smoothing since current continues to flow in the diode after the excitation voltage is removed from the field l The elimination of radio interference is achieved by connecting condenser CI between the base and collector terminals of TI to provide negative feed back At high temperatures a small leakage current may flow through the Zener diode even though the latter is in the nominally non conductive state Resistor R6 provides a path for this leakage current which otherwise would flow through T1 base circuit and adversely affect the regulator action A thermistor is connected in parallel with resistor R3 The thermistor is a device whose resistance increases as the temperature falls and vice verse Any alteration in its ohmic value will modify the voltage distribution across the potential divider and thus affect the voltage value at which the Zener diode begins to conduct so matching the changes which take place in battery terminal voltage as the temperature rises CHECKING AND ADJUSTING THE CONTROL UNITS Important Voltage checking and setting procedure may be carried out only if the alternator and associated Wiring circuits have been tested and found satisfactory in conjunction with a well charged battery i e charging current not exceeding 10 amperes VOLTAGE CHECKING Run the alternator at charging speed for eight minutes This operation applies when bench testing or testing on the car Leave the existing connec
29. cylinder is of conventional design consisting of a single cast iron cylinder housing a steel black oxided piston sealed by a single hydraulic cup This piston is deeply skirted to engage the operating push rod The smaller intermediate piston housed in its own bore in the nose of the master cylinder is actuated by hydraulic pressure generated within the main chamber Mounted on the end of the master cylinder the reaction valve consists of a pair of flow control valves which sequence the flow of air to the booster Both control valves are operated bythe intermediate piston in the master cylinder A flat plate interposed between the two master cylinder pistons enables the inter mediate piston to function mechanically in the event of an hydraulic failure BRAKES Re FARRA Pat FEES Sk a m 5 Eoy Om eO a a a a i 5 r dmn eo oe aap ee ae og ge aS eee ears aE as rra YT ELLE Zs 2 Le oo ee i reales oe ie i oe a SP is Fig Dual line servo braking system The booster portion of the integral booste Slave cylinder assembly consists of a pressed tank which houses a moulded phenolic resin I and a rubber rolling diaphragm A push rod secured to the piston extends through the forward face of the tank into the slave cylinder This push rod provides the principal motive force for the tandem pistons On the forward face of the boost tank is
30. down otherwise an abnormal amount of oil may leave the compressor due to the sudden pressure of reduction on the refrigerant oil in the crankshaft case Page RY s 2 EQUIPMENT Unscrew the oil Jevel plug slowly and tleed off the remaining pressure in the crankcase until the gauge reads zero Complete the removal of the plug The oil level plug is located in the rear face of the crankcase Two plugs are fitted but one only need be removed Insert the dipstick made from a piece of wire suitably bent through the plug hole until it contacts the bottom of the crankcase Withdraw the dipstick and measure the wetted portion The oil depth obtained should be approximate to the figure shown in the Oil Level chart below The oil should not be allowed to fall below the Minimum level shown in the chart If oil is added do not exceed the figure shown in the chart It is essential that only oil of the correct specification and grade is used The oil level should also be checked after placing a new compressor in operation charging or repairing a compressor or after adding refrigerant to the system OIL LEVEL Factory charge of 11 fluid ounces Minimum height Maximum height 1 5 33 3 mm 1 22 2 mm 13 34 9 mm RECOMMENDED LUBRICANTS SUN OIL CO 3 G 3 G dual inhibited Oil TEXACO Cappela B cual inhibited Ol SHELL Clavus 53 BP Energol LPT 100 CHARGING AND SERVICING A REFRIGERATION SYSTEM Ch
31. em minimum If any adjustment is required this should be carried out in accordance with the instructions given in I Section J Page J 15 of the 3 8 E Type Service Manual The correct dimensions for the hole centres for setting links are as follows Without air conditioning equipment 4 2 E Type Open Sports 1733 45 16 cm L H D 1738 45 16 cm L H D 173 45 6 cm R H D 17H 45 6 cm R H D 184 46 06 cm L H D R H D 4 2 E Type F H C 4 2 E Type Open Sports 4 2 E Type F H C 4 2 E Type 2 2 With air conditioning equipment 4 2 E Type Open Sports 173 45 6 cm L H D R H D 4 2 E Type F H C 1732 45 6 cm L H D R H D 4 2 E Type 2 2 1848 46 5 cm L H D R H D This method ensures that the headlamps centres are maintained at the correct height from the ground level necessary to conform to U S A Federal Regulations Which is 24 60 9 cm FRONT HUBS Pressed Steel Wheels If the car is fitted with pressed steel wheels available as optional equipment the hub nut and split pin retaining the hub to the stub axle js accessible after prising off the end cap Further removal dismantling bearing end float and refitting details remain as stated on Page J 13 of the 3 8 E Service Manual Fig 1 The dimension for checking the front suspension riding eht A 9 22 8 em P
32. fitted incorrectly pressure is applied to one pole piece only Bench Testing If the motor has been overheated or if any part of the motor housing is damaged a replacement motor unit must be fitted HEATING AND WINDSCREEN WASHING EQUIPMENT Armature If the armature is damaged or if the windings are loose or badly discoloured a replacement armature must be fitted The commutator must be cleaned with a fluffless cloth moistened in petrol or if necessary polished with a strip of very fine glass paper The resistance of the armature winding should be checked with an ohmmeter This resistance should be in accordance with that given in Data Brushes If the carbon is less than 7 1 59 mm long a new brush must be fitted Check that the brushes bear firmly against the commutator Re assembling Re assembling of the unit is the reverse of the dismantling procedure However the following points should be noted Make sure the bearing recess in the motor is filled with Rocol Molypad molybdenised grease Remove excessive grease from the face of the bearing boss Check that the pole piece assembly does not rock and that the pole pieces are firmly located in the circular spigot Ensure that the pole piece assembly and clamping member are the right way round Before replacing the motor unit on the cover ensure that the armature coupling is pushed fully home and that the intermediate coupling is in place
33. gasket Trap valve body Washer Banjo Copper gasket Body Bearing Secondary cup Seal Piston Fig 3 Exploded view of the master cylinder and reaction valve Return spring 23 Piston washer 30 Seal 37 Sorbo washer Rubber boot 24 Main cup 31 Piston 38 Spring Spring retainer 25 Retainer 32 Valve housing 39 Filter cover Push rod 26 Spring 33 Diaphragm support 40 Valve stem Spirolox circlip 27 Retainer 34 Valve rubber 41 Valve rubber Circlip 28 Lever 35 Valve cap 42 Valve cover Bearing 29 Seal 36 Filter 43 Screw Page LY s 8 MASTER CYLINDER AND REACTION VALVE Dismantling Fig 3 Unscrew and remove the fluid outlet adaptor 6 and extract the trap valve assembly 7 from the outlet port Remove the rubber boot 17 from the mouth of the cylinder bore compress the piston return spring 16 and unwind the spirolox circlip 20 from the heel of the piston The spring retainer 18 and piston return spring 16 can at this stage be removed Press the piston 15 down the bore and with the aid of special circlip pliers Tool number 7066 extract the circlip 21 from the mouth of the cylinder bore Care should be taken during this operation not to damage the finely machined cylinder piston The piston assembly complete with nylon bearings and rubber seals can be withdrawn from the cylinder bore Remove the plastic bearing 22 complete with O ring 14 seconda
34. i s O A y a gn vw o e Pies fo ot a T T oon r z S Ss a 2 PEELE f I d TFE a Page RY s 3 AIR CONDITIONING REFRIGERATION EQUIPMENT Preliminary Check Carry out preliminary checks as detailed below before proceeding with any further tests 1 Check that the fan is operating and that the blades are not fouling 2 Check that the compressor clutch is engaging or releasing satisfactorily when the air conditioning system is switched on 3 Check that air is not present in the system by observing the sighting glass attached to the receiver drier unit Run the engine at fast idle speed 1 000 r p m and check the sighting glass Repeat at 1 800 r p m Gradually increase the speed of the engine to the high range and check the sighting glass at intervals Bubbles in the sighting glass will indicate that air is present in the system 4 Check for frosting on the compressor valves 5 Check by feel for varying temperatures in the various pipe lines indicating blockage in the line system 6 Place a thermometer in the air duct run the car on the road and note the drop in temperature _ with the system on or off or if available place a cooling fan in front of the condenser Check that the condenser is clear of mud road dirt or flies preventing the free passage of air over the condenser unit If the fault persists after carrying out these tests the services
35. inside the solenoid plunger Here enclosed at the outer end by a retaining cup it forms a plunger within a plunger and it is spring loaded against the tip of the engaging lever inside the plunger clevis link THE ROLLER CLUTCH Torque developed by the starting motor armature must be transmitted to the pinion and flywheel through an over running or free wheeling device which will prevent the armature from being rotated at an excessively high speed in the event of the engaged position being held after the engine has started The roller cluich performs this function The operating principle of the roller clutch is the wedging of several plain cylindrical rollers between converging surfaces The convergent form is obtained by matching cam tracks to a perfectly circular bore The rollers of which there are three are spring loaded and according to the direction of drive are either free or wedge locked between the driving and driven members The clutches are sealed in a rolled over steel outer cover and cannot be dismantled for sub sequent reassembly THE STARTER SOLENOID The starter solenoid is an electro magnetic actuator mounted pick a back fashion on the yoke of the pre engaged starter motor It contains a soft iron plunger linked to the engaging lever the starter switch contacts and a coil consisting of a heavy gauge pull in or series winding and a lighter gauge hold on or shunt winding Initially both windings are energi
36. loading the thermostat switch contacts When air conditioning is fitted a second relay is also included to over ride the thermostat switch when the car is stationary and the air conditioning system is working THERMOSTAT Checking Check by substitution or by the following test procedure Drain off sufficient water from the radiator and remove the switch from the header tank Wire the switch in series with a 12 volt battery anda 1 5 watt bulb and suspend in water with a thermo ELECTRICAL AND INSTRUMENTS TRNG TA fA 3963 Fig 40 Location of horn and alternctor relays A Horn relay B Alternator Ignition relay C Air conditioning equipment relay when fitted Claset shows the connections 11 Remove the cable from terminal W2 Purple Black and earth the terminal to a clean part of the frame The relay coils should now operate and close the contacts Reconnect cable iv Remove cable from terminal C2 Brown Purple Check for continuity by means of an earthed test lamp Check with the horn button depressed and the ignition ON Replace the relay if faulty COOLING FANS meter Heat the water and note the temperature at which the contacts close and the bulb lights up Cool the water and note the temperature at which the contacts open Replace if faulty Renew the joint between the tank and the thermo stat switch if damaged TEST DATA Closing temperature de gt Gae
37. m Service valve locknut 65 70 ft Ib 8 983 9 674 kg m Shaft Seal Assembly Replacement Remove the compressor unit as detailed previously in this section Remove the clutch assembly as detailed on page RY s 7 Place the compressor on the work bench with shaft uppermost Wash or clean the seal plate and adjoining surfaces to remove all dirt Remove seal plate assembly after withdrawing six bolts Gently pry plate loose being careful not to scratch or nick the crankcase mating surfaces or edges Remove the carbon nose and spring assembly by prying behind the drive ring When removing the seal assembly from the shaft care must be taken that the crankshaft is not scratched If the rubber seal around the shaft does not come out with the carbon nose and spring assembly remove the seal with long nosed pliers pulling on the edge of the grommet Remove all dirt and foreign material from crank shaft mating surfaces to seal plate exposed crankshaft and adjacent surfaces Page RY s 5 AIR CONDITIONING REFRIGERATION EQUIPMENT Remove the new carbon shaft seal washer from the bellows seal assembly Parts are contained in the shaft seal assembly kit Coat the exposed surface of the crankshaft with clean refrigerant oil Dip the new bellows of the seal assembly and shaft seal washer in refrigerant oil Place the bellows seal assembly over the shaft with the end for holding the shaft seal washer facing the shaft end Push the
38. of a qualified Refrigerant Engineer should be obtained THE COMPONENTS The following pages contain the General Descrip tion Removal and Refitting details for the components used in the system THE COMPRESSOR UNIT Description The compressor unit used in the JAGUAR Air conditioning system is the TECUMSEH H G 500 The compressor is a completely sealed unit with the exception of the suction and discharge ports to which are attached the service valves The cold low pressure refrigerant is pulled into the suction service valve indicated by the word SUC TION stamped on the cylinder head through the valve plate and into the suction chamber The compression stroke of the piston closes the valve and forces the compressed vapour into the discharge chamber The vapour is them pumped through the discharge service valve indicated by the word DISCHARGE stamped on the cylinder head and so into the system Removal It will only be necessary to remove the compressor from the engine if any major repair work is carried out Servicing to the cylinder head valve and valve plate can be done with the unit in situ Remove the aluminium cap from the suction service valve close the valve by rotating the square end of the valve stem anti clockwise Page RY s 4 Remove the cap from the suction gauge port and connect a pressure gauge to the port union Open the valve and check the pressure recorded If the gauge shows a pr
39. of the wheel rim to the nose or outer edge of the hub shell and from the rim to the flanged or inner end of the shell Dismantling reassembling and adjustment details remain the same as that detailed in the 3 8 E Type Service Manual Section M Warning Chromium plated wire wheels are protected by a clear lacquer which under normal circumstances should never be removed Should removal become necessary due to dismantling the wheel however the best results can be obtained by using British Domolac L10 12 Cellulose Thinners UNDER NO CIRCUMSTANCES SHOULD A WIRE SPOKED WHEEL BE FITTED TO THE CAR IN AN UN LACQUERED CONDITION To re lacquer the wheels should be treated with NECOL which is an I C I clear cellulose air drying lacquer This will obviate rust stains originating at the unprotected threaded portion of the spokes SECTION N BODY AND EXHAUST SIDE FACIA PANEL Removal Disconnect the battery Remove the screen rail facia Withdraw all warning light and panel illumination bulb holders Note the location for reference when refitting Remove the chrome ring nut and withdraw the dipper switch from the panel Disconnect the speedometer drive cable from the instrument head Withdraw the plastic retaining clip and seperate the plug and socket connection attached to the tachometer cables Disconnect the brake fluid warning light cables Disconnect the control cable from the heater air outlet ducts after releasing
40. or is generating less than the battery voltage No separate current limiting device is Incorporated the inherent self regulating properties of the alternator effectively limit the output current to a safe value A Lucas 3AW warning light control unit is incorporated in the circuit The output control unit and the alternator field windings are isolated from the battery when the engine is stationary by a Lucas 6RA relay incorporated in the circuit k 4 4 7 D AA e a A El wy p 8 at A a y cal oe IN 3192 aan 56 ak Fig 2 Exploded view of the Lucas 11 AC alternator Stator laminations Silicon diodes 6 Slip ring end bracket 1 Shaft nut 2 Bearing collar 3 Through fixing bolts 3 4 Drive end bracket 5 Key 6 Rotor field winding 7 Ship rings 8 9 10 li Needle roller bearing 12 Brush box moulding 13 Brushes 14 Diode heat sink 15 Stator windings 16 Rotor 17 Bearing retaining plate 18 Ball bearing 19 Bearing retaining plate rivets 20 Fan 21 Spring washer Page PY s 5 ELECTRICAL AND INSTRUMENTS PERFORMANCE DATA Nominal voltage 12 volts Nominal d c output hot in amperes 43 amperes Stator phases 3 Phase connections Star Resistance phase at 68 F 20 C 5 0 107 ohms Resistance of rotor windinginohmsat 3 845 68 F 20 C REMOVAL Disconnect the cables from the terminals on the slip ring end cove
41. steering with a torsion bar controlled rotary value embodied in the input shaft and a hydraulic cylinder The piston in the hydraulic cylinder is connected to the rack Steering lock stops are incorporated in the gear unit THE VALVE UNIT This is a rotary type control valve The valve rotor which is also the input shaft to the steering gear has three grooves machined in it These grooves lie between three grooves in the valve sleeve when no load is applied to the steering wheel the rotor being centred in the sleeve by a torsion bar When steering effort is applied at the wheel this is transmitted via the torsion bar to the rotor The torsion bar is however slender and the manual effort causes it to twist thus allowing the rotor to rotate in the sleeve The relative movement of the grooves in the rotor to the grooves in the sleeve allows hydraulic pressure from the pump to operate on either side of the piston thus assisting the movement of the rack THE PRESSURE PUMP The pressure pump is a roller type belt driven unit The relief valve is set to operate between 950 and 1 000 Ib sq in 66 8 70 3 kg cem The flow control valve is set at 2 2 Imp galls per min 10 litres min 21 U S pints per min No servicing or adjustment is possible with the pump Replacement units can be obtained on an exchange basis from THE SPARES DIVISION JAGUAR CARS LTD COVENTRY ENGLAND Page IfY s 2 STEERING
42. the correct figure with increased engine speed then the trouble is caused either by a faulty relief valve in the pump or by excessive internal leakage in the steering gear Fit a pressure gauge into the pressure line with an ON OFF tap in series with the gauge and the steering unit Start the engine open the tap and turn the steering to full lock Check the pressure reading on the gauge This should read 1 000 1b sq in 70 3 kg cm 2 Fig 3 If the pressure does not rise to this figure close the tap for a maximum of 5 seconds and note the gauge reading This should be 1 000 lb sq in 70 3 kg om 2 relief valve pressure If this reading is obtained the leaks are confined to the steering unit which should be removed and overhauled If the reading 1s not obtained the fault lies in the pump Faulty pumps cannot be serviced New replace ment units can be obtained on an exchange basis from The Spares Division Jaguar Cars Ltd Coventry England STEERING GEAR Removal Remove the bonnet as detailed in Section N page NY s 3 Remove the radiator as detailed in Section C page DY s 1 Turn the steering wheel until the Allen screw in the lower column universal joint is accessible insert an Allen key and remove the screw Disconnect the hoses from the steering unit and catch the oil which will drain away Blank off the connections and unions to prevent the ingress of dirt Remove the nuts and wa
43. the locking screw securing the inner cable to the air duct operating spindle Remove the locknut securing the outer cable to the air duct bracket Withdraw the cable and collect the loose adaptor Remove the two thumbscrews and lower the centre instrument panel Release two setscrews securing the two heater inner control cables to the control levers and withdraw the cables Withdraw two slotted screws and one setscrew nut and washer securing the side facia panel to the centre panel support bracket and two nuts and washers securing the panel to the support bracket at the base of the screen pillar and remove the panel Refitting Refitting is the reverse of the removal procedure Reconect the heater and air outlet control cables ensuring that the full movement of the levers is main tained Reconnect the warning and panel light illumination bulb holders as noted on removal GLOVE BOX Removal Disconnect the battery Remove the screen rail facia Withdraw two screws and nuts and detach the grab handle from the mounting brackets Withdraw the choke warning light bulb holder from the socket at the rear of the glove box panel Release the locking screw and disconnect the choke operating cable from the lever cars equipped with Exhaust Emission Control only Lower the centre instrument panel Remove the securing setscrews nuts and washers as detailed for the side facia panel and detach the glove box Refitting Refitting is t
44. the panel to the screen FRONT BUMPER Removal The front bumper is comprised of three components right and left hand outer sections and a centre section Sections are detachable after removing the bumper as a complete assembly Remove the four setscrews lock and plain washers securing the outer sections to the bonnet The set screws are accessible through cut out portions in the underside of the sections Dismantle the bumper after removing the two setscrews lock and plain washers securing the outer sections to the centre and the two setscrews securing the over ricers NY s 2 Remove the motif if required after withdrawing two drive screws spring clip and the backing plate Refitting Reassembly and refitting is the reverse of the removal procedure Renew the beading between the bumper sections and the over riders if worn or damaged Fig 3 Front bumper removal The arrows indicate the mounting points REAR BUMPER Removal The rear bumper is comprised of three components right and left hand and centre sections Sections are detachable after removal of the bumper as an assembly Remove the two setscrews lock and plain washers and two nuts securing the bumper outer sections to the body the setscrews are located within the wheel arch Release the two setscrews located above the rear lamps Withdraw the two setscrews securing the reverse lamp carrier brackets and remove the bumper assembly Dismantle the bu
45. the ring nut Any movement will place the mounting brackets out of phase with each other Refit the rack adjuster pad spring adjuster screw and locknut but do not attempt to carry out any rack adjustment at this stage Final Assembly Place a new seal joint over the three studs in the rack housing Refit the pinion housing noting the position as STEERING POWER ASSISTED marked on removal Check that the pinch bolt slot is in the same relative location as noted on removal when engaging the pinion with the rack teeth Allow for the spiral in the pinion assembly when reassembling Fit the self locking nuts and tighten down evenly Refit the inner ball joints and track rods as an assembly as detailed on page IY s 4 under Ball Pin Knock If the inner ball joint is to be replaced due to wear a new unit complete with track rod must be obtained ADJUSTMENT OF THE JOINT IS NOT PERMISSIBLE Refit the outer ball joints if removed adjust the length of each track rod to 8 75 22 2 cm between the ball joint centres IT IS IMPORTANT that the track rods are of equal length Adjust the rack back up pad as detailed on page HYS Refit the grease nipple and the external pipes Coat both rack ball housings with 2 oz 56 7 grammes of the recommended grade of grease fit the bellows and secure with the clips to the track rod and steering housing i Apply a grease gun to the nipple in the back up adjuster pad and inject 1 oz 28
46. the shaft and gear from the gearbox taking care not to lose the dished washer fitted beneath the gearwheel It is not normally necessary to dismantle the shaft and gear assembly since this is serviced only in an assembled condition However should it become necessary to assemble the moulded gearwheel Page PY 6 25 ELECTRICAL AND INSTRUMENTS to the location plate and shaft it is essential to fit the gear wheel in the correct one of the two alternative positions to maintain the original parking position of the wiper blades The gearwheel is correctly fitted to the location plate and shaft when the zero mark on the location plate is positioned furthest away from the gearwheel cam Unscrew and remove the two fixing bolts from the motor yoke and carefully remove the yoke assembly and armature While removed the yoke must be kept well clear of swarf etc which may otherwise be attracted to the pole pieces Undo the two sets of fixing screws and remove from the gearbox the brushgear and the terminal and switch unit assemblies linked together by the con necting cables Bench Inspection After dismantling examine individual items i Brush replacement The original specified length of the brushes is sufficient to last the life of the motor If due to accidental damage to the brushes or faulty commutator action it becomes necessary to renew the brushes the complete brushgear service assembly must be fitted The brushgear a
47. the wiper arms are operating R H D Cars Disconnect the primary link motor to wheelbox from the ball joint on the wheelbox spindle Manually operate the non adjustable link con necting the two wiper spindles to the extreme left position Adjust the ball joint socket on the link until it fits on the ball whilst maintaining the position of the lever to the left Disconnect the socket and turn to the right clock wise four complete turns i e shorten the length of the rod between the socket and the motor Refit the socket on the ball and secure with the iocknut L H D Cars Proceed as for R H D cars but for the following exceptions Manually operate the non adjustable link to the extreme richt and after adjustment turn the ball socket four complete turns to the left anti clockwise to increase the length of the rod Pape PY 5 37 ELECTRICAL AND INSTRUMENTS THE INSTRUMENTS ELECTRIC CLOCK Description The electric clock fitted in the centre of the instru ment panel is a fully transistorised instrument powered by a mercury cell housed in a plastic holder attached to the back of the clock Frontal adjustment is provided by means of a small knurled knob for setting the hands and a slotted screw for time keeping regulation To reset the hands pull out the knurled knob rotate and release To regulate the time keeping turn the slotted screw with a small screwdriver towards the positive sign if gaining a
48. to an accident or other cause will not prevent the system operating on the remaining lamps ELECTRICAL AND INSTRUMENTS THE STARTER MOTOR DESCRIPTION The purpose of the pre engaged or positive engage ment starting motor is to prevent premature pinion ejection Except on occasions of tooth to tooth abutment for which special provision is made the starter motor is connected to the battery only after the pinion has been meshed with the flywheel ring gear through the medium of an electro magnetically operated linkage mechanism After the engine has started the current is auto matically switched off before the pinion is retracted CR Fawn Ze 48 gt Z QOO On reaching the out of mesh position the spinning armature is brought rapidly to rest by a braking device Fhis device takes the form of a pair of moulded shoes driven by a cross peg in the armature shaft and spring loaded and centrifuged against a steel ring insert in the commutator end bracket Thus with the supply switched off and the armature subjected to a braking force the possibility is minimised of damaged teeth resulting from attempts being made to re engage a rotating pinion A bridge shaped bracket is secured to the front end of the machine by the through bolts This bracket carries the main battery input and solenoid winding 2 Fig 18 The Pre engaged Starter Motor Model M45G I Actuating solenoid 9 Jump ring 17 Band c
49. until all the tubes are filled Replace the vent cover The electrolyte level is now correct DO NOT under any circumstances top up the battery by using the normal type of battery filler which incorporates a plunger valve in the filler neck The use of this type of filler will depress the sliding tubes and allow the battery to be overfilled Important The vent cover must be kept in position at alf times except when topping up Distilled water should always be used for topping up In an emergency however clean soft rain water collected in an earthernware container may be used Note Never use a naked light when examining a battery as the mixture of oxygen and hydrogen given off by the battery when on charge and to a lesser extent when standing idle can be dangerously explosive Clean off any corrosion from the battery cable terminals and coat with vaseline before re connecting Rentoval Unscrew the two wing nuts retaining the battery strap remove the fixing rods and strap Disconnect terminals and lift out the battery from the tray WARNING Rubber sealing plugs are not incorpor ated in the manifold filler cover When removing the battery it is ESSENTIAL that extreme care is taken to ensure that it is NOT tipped to any degree Failure to ensure this will result in acid spillage which may cause severe acid burning to the operator and to tthe car Refifting Refitting is the reverse of the removal procedure Page P
50. wheel must be adjusted individually by means of the tie rods to give half the total toe in of a to 4 1 6 to 3 2 mm Procedure Set the front wheels in the straight ahead position Centralise the steering by removing the grease nipple from the rack adjuster pad and inserting the centralising tool Jaguar Part No 12297 Check the alignment of the front wheels by using light beam equipment or an approved tract setting gauge Jf adjustment is required slacken the locknuts at the outer end of each tie rod release the outer clips securing the rack housing bellows to avoid distortion after turning the tie rods Turn the tie rods by an equal amount in the necessary direction until the alignment is correct Tighten the locknut and re check Ensure that the bellows are not twisted and tighten the clips REMOVE THE CENTRALISING TOOL and refit the grease nipple to the rack adjuster pad Fig 4 Page ILY s 9 FAULT External oil leaks from Rack and Pinion unit Leak at reservoir Leak at pump shaft Steering veering to right or left Heavy steering when driving Heavy steering when parking Steering effort too light Poor straight running Noise from pump Rattle when travelling on rough roads Page ITY s 10 FAULT FINDING CHART POSSIBLE CAUSE Damage or wear to seals or in correct tightening of unions or bolts Cover gasket damaged Hose connection loose Worn or damaged seals on shaf
51. CEMENT The alternator heat sink assembly consists of two mutually insulated portions one of positive and the Other of negative polarity The diodes are not in dividually replaceable but for service purposes are supplied already pressed into the appropriate heat sink portion The positive carries three cathode base diodes marked black When soldering the interconnections M grade 45 55 tin lead solder should be used Great care must be taken to avoid overheating the diodes or bending the diode pins The diode pins should be lightly gripped with a pair of suitable long nosed pliers acting as a thermal shunt and the operation of soldering carried out as quickly as possible Fig 14 Use of thermal shunt when soldering diode connections After soldering to ensure adequate clearance of the rotor the connections must be neatly arranged around the heat sinks and tacked down with MMM EC 1022 adhesive where indicated in Fig 15 The stator connections must pass through the appropriate notches at the edge of the heat sink ELECTRICAL AND INSTRUMENTS Fig 15 Showing the silicon diodes and connection in the slip ring end cover The feeler gauge inserted between the diode carriers BEARINGS Bearings which are worn to the extent that they allow excessive side movement of the rotor shafts must be renewed The needle roller bearing in the slip ring end cover is supplied complete with the end cover To renew the dri
52. CONTROL Carburetter Hydraulic Piston Damper o Unscrew and withdraw the hydraulic piston damper Zenith Lube Pack or if this is not available use from the piston cover SAE 20 engine oil to within 4 of the top of the rod Top up the hollow guide rod of the piston with Replace the damper securely Fig 1 Schematic layout of the carburetters and linkage showing the direction of the gas flow Page QY s 2 EXHAUST EMISSION CONTROL AAA NSM Hix My Fig 2 Slow running adjustment screw Ignition Timing As the ignition timing of an emission controlled engine is critical the greatest possible care must be taken to ensure that the correct figure is obtained Adjust the distributor vernier scale to the central positron With the engine running at exactly 1 000 r p m check the timing with a stroboscope and adjust by means of the vernier control on the distributor to W BLD The timing scale is located on the rim of the crankshaft damper To check the distributor advance characteristics at higher r p m refer to Distributor Test Data on page OY s 5 Cylinder Head Nuts Check the torque of the cylinder head nuts Torque 696 lbs ins tightening in sequence as detailed in the Service Manual Inlet Manifolds Check the tightness of all inlet manifold system securing nuts Tighten the carburetter mounting nuts Fig 3 Fast idle adjustment Gap between screw and cam Should be 067 Page
53. Data remove the motor and check that the pump impeller shaft turns freely If the shaft is difficult to turn the water pump unit must be replaced If the shaft turns freely the fault lies in the motor which must be dismantled and its component parts inspected Dismantling Disconnect the external tube and the electrical connections and remove the cover from the container Remove the self tapping screw which secures the motor to the cover and pull away the motor unit Take care not to lose the loose intermediatecoupling which connects the armature coupling to the pump spindle coupling Remove the armature coupling from the armature shaft as follows Hold the armature shaft firmly with a pair of snipe nosed pliers and using a second pair of pliers draw off the armature coupling Remove the two self tapping screws from the bearing plate The bearing plate and rubber gasket can now be removed Remove the two terminal screws The terminal nuts and brushes can now be removed and the armature withdrawn Take care not to lose the bearing washer which fits loosely on the armature shaft The pole assembly should not normally be disturbed If however its removal is necessary make a careful note of its position relative to the motor housing The narrower pole piece is adjacent to the terminal locations Also the position of the pole clamping member should be observed When fitted correctly it locates on both pole pieces but if
54. ENT THE ELECTRICAL SYSTEM GENERAL DESCRIPTION The electrical system consists of a combined rotary ON OFF fan blower variable speed switch and thermostat control a fan blower motor one external resistor an in line fuse and a magnetic clutch unit with the necessary wiring A second relay is included in the radiator fan circuit when air conditioning equipment is fitted the purpose being to over ride the OTTER thermostat switch located in the header tank when the system is switched on and so ensuring that the radiator cooling fan motors are operating This relay is additional to the one included in the radiator fan circuit fitted to all cars The rotary switch outer control ring controlling the blower motor speeds is wired in series with the resistor unit to give OFF L Low M Medium and H High positions See circuit diagram Fig 5 In the L M or H positions the circuit is completed from the ignition switch via the fuse and relay through the thermostatic switch central control knob to the compressor drive clutch Progressive rotation of the thermastat control in the direction of the arrow will result in the switch con tacts remaining closed until the capillary tube from the switch inserted into and in between the fins of the evaporator coils senses a temperature that is below the manual setting When this temperature is reached the contacts will open and the ci
55. ER SWITCH A Lucas 47SA combined ignition starter switch replaces the separate switches previously used Fig 29 The ignition starter switch location when air conditioning system is fitted I Auxiliaries 2 femtion OFF 3 lenition ON f Siarter The switch is mounted on a bracket attached to the steering column if Air conditioning equipment Is installed the bracket is attached to the evaporator unit In conjunction with the 47SA ignition starter switch a Lucas 6RA relay is included in the alternator circult This functions as a field isolating relay the relay coil being energised by operation of the tgnition switch Removat Remove the locking ring and withdraw the switch through the bracket with the brass locknut and wave washer Page PY s 30 Disconnect the cables and remove the switch Note the location of the cables for reference when refitting The ock barrel can be withdrawn by inserting a thin rod through a hole in the body of the switch and depressing the plunger in the lock Insert the key and turn to the OFF position to gain access to the plunger Refitting Refitting is the reverse of the removal procedure When refitting a new lock barrel check that the number on the face of the barrel and the key is the same as that on the barrel removed This will be identical to the door locks Insert the key in the Jock and turn the switch to the OFF position before inserting the barrel
56. ING Removal Remove the upper steering column as detailed previously Remove the nut lockwasher and bolt securing the column to the lower universal joint and withdraw the column rearwards through the grommet Note If the steering column has not been damaged by impact ie if the nylon plugs in the column have not sheared excessive force must NOT be used to separate the column and the lower universal joint Refitting Refitting is the reverse of the removal procedure Check that the bolt holes in the universal joint register correctly with the groove machined in the column splines Tighten the pinch bolt to a torque of 16 18 lb ft 2 2 25 Kem IMPORTANT Excessive force as noted under Removal must not be used when reassembling the universal joint to the column UNDER NO CIRCUMSTANCES should a mallet or similar tool be used when engaging the splines in the joint or the column If the splines will not engage freely inspect for damage or burrs and carefully remove with a fine file NO ATTEMPT must be made to repair any nylon plugs which have sheared due to impact STEERING HOUSING The rack and pinion assembly is identical to that shown in Fig 3 page I5 of the 3 8 E Type Service Manual with the exception of the rack pre load corzponents The belleville washer and disc are replaced by a spring and retaining cap The method of adjustment and the rack and float figure remain as stated on page I7 n
57. QY s 3 EXHAUST EMISSION CONTROL It is important to ensure that no air leaks exist at any of these joints otherwise the mixture will be weakened to a point where idling will be effected Idle Trim Screw Screw in the idle trim screw to obtain the opti mum quality of idling EVERY 3 000 MILES Engine Oil Change the engine oil Low speed city driving in hot dusty territory or in very cold weather may produce conditions conducive to oil dilution and sludge formation In these con ditions the engine oil and the filter should be changed every 1 000 miles Distributer Contact Breaker Gap Clean points and adjust the contact breaker gap as detailed in the Service Manual Adjust the gap to 014 016 Verify correct dwell angle see Diagnosis Chart Ignition Timing Check ignition timing as detailed in the 1 000 miles Free Service Distributor Lubrication Lubricate the distributor as detailed in the Service Manual Sparking Plugs Clean and adjust and test the spark plugs Check on an oscilloscope and renew any doubtful plugs Set the gap between the side wire and the centre electrode to 025 NOTE Misfiring of a plug will cause incomplete com bustion of the mixture and raise the engine emission levels above the specified limits Engine Idle Speed Adjust the engine idle speed as detailed in the 1 000 miles Free Service Fast Idle Speed Adjust the fast idle speed as detailed in the 1 000 miles Free
58. SECTION H REAR AXLE The rear axle final drive unit remains identical to that stated in the 3 8 E Type Service Manual with the exception of the following details Axle Ratios U S A CANADA Manual transmission only Zs ss oh ai 354 1 All other countries Manual transmisston only geg a T P 307 1 Automatic Transmission 2 2 only U S A and CANADA _ a se ee Automatic Transmission 2 2 only all other countries a 2883 HALF SHAFT UNIVERSAL JOINTS Grease nipples see the 3 8 E Type Service Manual Page H8 Early cars were reintroduced from the commencement of production of Series 2 cars Access to the nipples of the outer joints is gained by removing the plastic sealing plugs from the joint covers The universal joints should be greased every 6 000 miles 10 000 km Page HY s 1 an SECTION STEERING GENERAL DESCRIPTION The upper and lower steering columns and the mountings are of the collapsible type designed to comply with the U S A Federal Safety Regulations The collapse points are retained by nylon plugs Which will shear on Impact allowing the steering wheel and columns upper and lower to move forward NO ATTEMPT must be made to repair the units if damaged due to accident NEW replacement items MUST be fitted UPPER STEERING COLUMN Description The upper steering column inner is composed of two separate sliding shafts retained to a fixed leng
59. Withdraw two screws and detach the unit from the mounting panel Remove two screws and detach the thermostat unit from the fan switch Refitting Refitting is the reverse of the removal procedure Page RY s 14 EQUIPMENT OTTER THERMOSTAT OVER RIDING RELAY Checking The relay is the top one of the two mounted on the carrier bracket attached to the sub frame cross member between the radiator fans Disconnect and remove the relay Note the cable connections for reference when refitting Connect a 12 volt supply to terminals W1 and W2 Connect a test lamp wired in series with a 12 volt battery to terminals Cl and C2 If the relay contacts are closing the bulb will become illuminated Replace if faulty Fig 9 The radiator cooling fan circuit diagram with over riding relay incorporated 1 Control switch feed 2 Over riding relay 3 Otter thermostat switch 4 Fan relay 5 Fuse No 6 6 Radiator fan motors
60. Y s ELECTRICAL AND INSTRUMENTS Before refitting the cable connectors clean the terminals and coat with petroleum telly Persistent low state of charge First consider the conditions under which the battery is used If the battery is subjected to long periods of discharge without suitable opportunities for recharging a low state of charge can be expected A fault in the alternator or control unit or neglect of the battery during a period of low or zero mileage may also be responsible for the trouble Manifold Vent Cover See that the ventilating holes in the cover are clear Level of Electrolyte The surface of the electrolyte should be just level with the tops of the separator guards If necessary top up with distilled water as detailed or page PY s 1 Any loss of acid from spilling or spraying as opposed to the normal loss of water by evaporation should be made good by dilute acid of the same specific gravity as that already in the cell Cleanliness See that the top of the battery is free from dirt or moisture which might provide a discharge path Ensure that the battery connections are clean and tight e AAO Fig 1 Method of topping up the Lucas C A batiery Page PY s 2 Hydrometer Tests Measure the specific gravity of the acid in each cell in turn with a hydrometer To avoid misleading Teadings do not take hydrometer reading immediately after topping up The reading given by each cell
61. age JY s 1 Mount WwW Line ree ts GOJI Cet Ana meniup a m g bt natt Srt lt a Ar oi SECTION L BRAKES DATA Caliper type Girling bridge type with quick change pads Brake disc diameter front ae ne m 53 re ii LI 27 9 cm rear Ki ra p a e a T 10 25 4 cm Master cylinder bore diameter ii Sy yi X iy nf f 2 23 mm Master cylinder stroke M zig 4 3 4 ws ni we 2 30 33cm Servo unit type T p T a i Lockheed Dual line Main friction pad material ae Ne i 3 A ya Mintex M 59 Handbrake friction pad material ra a si N Si ii Mintex M 34 Page LY s l Pace Ex 25 2 BIA OT a ee ah ee eh Oe a E Key to Figs 1 Fluid at feed pressure Fluid at master cylinder delivery pressure Fluid at system delivery pressure Vacuum Air at atmospheric pressure Slave cylinder primary chamber Outlet port front brakes Inlet port for secondary piston Outlet port rear brakes Vacuum Air pressure Diaphragm Filter Air control spool To rear brakes To front brakes Dual slave cylinder Servo unit Master cylinder Brake reservoirs To manifold To reservac Reaction valve Atmospheric pressure Weltty ile ZA 4 MIM 5 DESCRIPTION The dual line servo braking system consists of an integral vacuum booster with tandem slave cylinder a master cylinder combined with a booster reaction valve and two fluid reservoirs The master
62. ain the internal parts Locate the other piston return spring 16 over the heel of the piston together with the pressed steel spring retainer 18 slide the spring retainer down the finely machined portion of the piston against the load of the spring and fit the spirolox circlip 20 into the groove ground around the heel of the piston Using the fingers only stretch a new valve seal 29 and O ring into position on the valve piston and insert the assembly into the valve box Page LY s 9 BRAKES 2 4 6 8 9 10 2 zis i 3 I5 7 43 SY ut ao a Ala RIL 6 8 ANN AITITA a ratte t a TAR ff dig Teas jt Ee a iggi Ip z nm EANN R i i 29 2 25 23 22 35 34 32 26 24 Fig 4 Sectioned view of the master cylinder and reaction valve 1 Diaphragm 23 Piston washer 2 screw 24 Main cup 3 Shakeproof washer 25 Retainer 4 Gasket 26 Spring 5 Gasket 27 Retainer 6 Outlet adaptor 28 Lever 7 Trap valve body 29 Seal 8 Washer 30 Seal 9 Inlet adaptor 31 Piston 10 Copper gasket 32 Valve housing 11 Body 33 Diaphragm support 12 Bearing 34 Valve rubber 13 Secondary cup 35 Valve cap ise SCAN 36 Filter ek AOR l 37 Sorbo washer 16 Return spring i 17 Rubber boot aS PENG 18 Spring retainer ape FET CONEE Os Puh rod 40 Valve stem 20 Spirolox circlip 41 Valve rubber 21 Circlip 42 Valve cover 22 Bearing
63. ained at the low pressure figure of the suction of the compressor The small orifice at the ball valve seat is minute com pared to the lines going to and passing from it thereby producing this dividing point At this point of course the suction pressure drops abruptly and the temperature of the liquid refrigerant correspondly drops The small droplets of water that have been maintained as water in liquid form on the high side are suddenly subjected to the extreme cold tem perature of the low side They become icy or an icy sludge and can either completely block the orifice at the ball seat of the valve or form an erratic sludge at that point that will go away and come back at frequent intervals A solid plug of ice will render the system inoperative and the suction pressure reading at the compressor will drop into a deep vacuum as the com pressor will cause removal of everything from the ice block to the compressor The sludge will reduce the effectiveness of the system and the suction pressure reading will be erratic An excellent way to determine whether an expansion valve difficulty is ice or something else this of course after having observed a suction reading that is in vacuum would be to heat the body of the valve in the vicinity of the ball seat taking care not to over heat the diaphragm and observe the suction reading If ice is there the heating will immediately melt it liquid will charge into the evaporator the suction
64. air known to be in good condition If this rectifies the fault fit new blades ii Low Wiping Speed or Irregular Movement of the Blades To determine whether a low wiping speed is due to excessive mechanical loading or to poor motor performance the rotary link must first be disconnected from the transmission linkage and the light running current and speed of the motor can then be checked under no load conditions Measuring Light Running Current and Speed Connect a first grade moving coil ammeter in series with the motor supply cable and measure the current consumption Also check the operating speed by timing the speed of rotation of the rotary link or moulded gearwheel The current consumption and speed are given in Data If the motor does not run or current consumption and speed are not as stated an internal fault in the motor is indicated and a replacement unit should be fitted or the motor removed for detailed examination If current consumption and speed are correct check for proper functioning of the transmission linkage and wiper arin spindles Removal 4 2 litre Open Sports and F H C Disconnect the battery Remove the two thumbscrews and lower the instrument panel ELECTRICAL AND INSTRUMENTS Remove two drive screws and detach the hazard warning unit carrier plate Disconnect the drive link from the ball joint on the centre wheelbox Remove the P V C cable strap from the body of the windscreen wiper motor and di
65. and F H C Models Removal Right or Left Hand Housing Disconnect the battery ELECTRICAL AND INSTRUMENTS Withdraw the wiper arm from the spindle housing to be removed Unscrew the large nut securing the housing to the scuttle and remove the distance piece and rubber seal washer Lower the instrument panel after removing the two retaining screws in the top corners Remove the four nuts and washers retaining the screen rail facia assembly Two are accessible from the centre aperture and one each at the outer edges below the screen rail Disconnect the ball joint from the spindle lever From inside the car remove two nuts and washers securing the housing bracket to the base plate and wiilidraw the housing Remoyal Central Housing Disconnect the battery Remove all wiper arms from the spindles Lower the instrument panel remove the screen rail facia and outer housings as detailed previously Remove the large nut distance piece and rubber seal washer from the centra housing Withdraw the housing and carrier plate assembly through the scuttle panel and complete the removal through the left hand aperture in the bulkhead inner panel WIPER MOTOR LINKAGE SETTING 2 2 cars It is essential that the wiper motor primary linkage motor to wheelbox is adjusted as detailed below if the link length is altered from the original dimension or if a new link ts fitted Failure to carry out these instructions will result in a knock when
66. arburetter drain pipes and remove the starter motor through the chassis frame The two setscrews are accessible from beneath the car or through an access panel in the right hand side of the gearbox tunnel Remove the front carpet to expose the panel Refitting Refitting is the reverse of the removal procedure Care must be taken when refitting the two setscrews which have a fine thread that they are not cross threaded Insert the distributor and rotate the rotor until the drive dog engages correctly and secure with the clamping plate setscrew Note If the clamping plate has been removed from the distributor or its position altered the engine must be re timed as detailed in Section B SERVICING Checking the Brusngear and Commutator Remove the starter motor from the engine Release the screw and remove the metal band cover Check that the brushes move freely in the brush boxes by holding back the spring and pulling gently on the flexible connection If a brush is inclined to stick remove it from its holder and clean its sides with a petrol moistened cloth Replace the brushes in their original position in order to retain bedding Brushes which will not bed properly or have worn to 4 7 94 mm in length must be renewed See page PY s 20 for renewal procedure Page PY s 18 Check the tension of the brush springs with a spring balance The correct tension should be 52 ozs 1 47 kg on a new brush Repla
67. arging an air conditioning system will not be necessary unless leaks develop in the system resulting in loss of the refrigerant or in the event of any com ponents being disconnected or removed This service can only be performed by a fully qualified Refrigeration Service Engineer who will have the necessary equipment IMPORTANT The air conditioning equipment is manufactured for use only with Refrigerant 12 dichlorodifluoro methane and extreme care must be taken never to use methylchloride refrigerants gauge gauge gauge AIR CONDITIONING REFRIGERATION EQUIPMENT The chemical re action between methylchloride and the aluminium parts of the compressor will result in the formation of products which burn spontaneously on exposure fo air or decompose with violence in the presence of moisture To ensure efficient operation of a refrigeration unit all air and non condensable gases must be completely evacuated from the system before inserting the refrigerant charge A sufficient jjantity of refrigerant should be obtained before commencing operations and should be available from any qualified Refrigerant Service Suppliers under the following trade names FREON 12 ARCTON 12 ISCEON 12 or any refrigerant to specification R 12 The re frigerant is available in 1 2 10 25 or 145 Ib 0 454 0 907 4 536 11 34 or 65 7 kgm containers The lower weight being in canisters the higher weights being in steel cylinde
68. aring projecting slightly from the mouth of the bore Place the gasket 7 in position on the end face of the slave cylinder using the plastic bearing as a location spigot and fit the vacuum shell 14 abutment plate 17 and locking plate 16 Insert the three securing screws 15 and tighten down to a torque of 150 170 Ib ins 1 7 1 9 kg m Bend the tabs on the locking plate against the flats on the three screws Locate the diaphragm support return spring 8 centrally inside the vacuum shell fit the diaphragm support 10 to the push rod and secure it by dropping the key 12 into the slot provided in the diaphragm support Stretch the rubber diaphragm 11 into position on the diaphragm support ensuring that the bead around its inside diameter fits snugly into the groove in the diaphragm support If the surface of the rubber diaphragm appears wavy or crinkled this indicates that it is not correctly seated To ease assembly smear the outside edges of the diaphragm liberally with Lockheed disc brake lubricant Fit the end cover using Churchill Tool No J 31 Note As it is possible to fit the end cover in three different positions ensure that the end cover hose connections line up with the slave cylinder inlet and outlet ports when assembly is complete Page LY s 7 BRAKES 16 17 18 19 20 21 22 Diaphragm Screw Shakeproof washer Gasket Bolt Outlet adaptor Copper
69. arning A faulty diode in the alternator or an inter mittent or open circuit in the alternator to battery circuit can cause excessive voltages to be applied to the warning light unit To prevent possible damage to a replacement unit it is important to first check the voltage between the alternator AL terminal and earth Run the engine at 1 500 r p m when the voltage should be 7 7 5 volts Page PY s 14 measured on a good quality moving coil voltmeter If a higher voltage is registered check that all charging circuit connections are clean and tight then if necessary check the alternator rectifier diodes before fitting a replacement 3AW unit TRAFFIC HAZARD WARNING DEVICE OPTIONAL EQUIPMENT Description The system operates in conjunction with the four flashing turn indicator lamps fitted to the car The operation of the dash panel switch will cause the four turn indicator lamps to flash simultaneously A red warning lamp is incorporated in the circuit to indicate that the hazard warning system 1s in operation A 35 amp in line fuse incorporated in the sub pandl circuit The flasher unit is located and is similar in appear ance to the one used for the flashing turn indicators but has a differenti internal circuit A correct replace ment unit must be fitted in the even of failure The pilot lamp bulb is accessible after removing the bulb holder from the rear of the panel Failure of one or more of the bulbs due
70. axle output shaft flange Withdraw the halfshaft from the bolts noting the number of camber shins between the universal joint and the brake disc Knock back the tabs and unscrew the two pivot bolts securing the hand brake pad carriers to the caliper Remove the pivot bolts and the retraction plate Withdraw the handbrake pad carriers from the aperture at the rear of the cross members Knock back the tabs at the caliper mounting bolts Remove the keeper plate on the caliper and using a hooked implement withdraw both brake pads Disconnect the brake fluid feed pipe at the caliper Unscrew the mounting bolts through the access holes in the brake disc Remove the bolts Withdraw the caliper through the aperture at the front of the cross member Tap the halfshaft universal joint and brake disc securing bolts back as far as possible Lift the lower wishbone hub carrier and halfshaft assembly upwards until the brake disc can be with drawn from the mounting bolts Refitting Refitting the brake discs is the reverse of the removal procedure The securing bolts must be knocked back against the drive shaft flange when the new disc has been fitted Refit the rear suspension as described in Section K Rear Suspension Bleed the brakes eee ee h ONS PAn E SO a a ae oP NDA Rw Ne BRAKES Fig 6 Exploded view of a rear brake caliper Rear caliper assembly R H Piston Seal Dust seal Friction pad Pin Cl
71. being taken out of it In the ordinary way this condition predominates and your battery is continuously being recharged by the alternator whenever the engine is running above idle If however the engine is continually running slowly as may be the case in traffic or when in winter lights and cold starting make extra demands on the battery you may find the rate of discharge exceeds the rate of charge that is to say the battery is running down as will be indicated on your Battery Condition Indicator and you may need an extra charge if battery charge low or extremely low is indicatec by the instrument LAMPS HEADLAMP Sealed beam units are fitted to all cars with the exception of certain European Countries which retain the pre focus bulb see Bulb Data Chart The beam setting and unit replacement instructions diller from those stated on Page P 24 as follows Beam Setting If beam setting adjustment is required prise off the headlamp rim retained by spring clips Switch on the headlamps and check that they are on Main beam The setting of the beams is controlied by two screws A and B on Fig 30 The top screw A js for vertical adjustment i e to raise or lower the beam turn the screw anti clockwise to lower the beam or clockwise to raise the beam The side screw B ts for horizontal adjustment i e to turn the beam to right or left To move the beam to the right turn the screw clockwise To mov
72. by turning it through approximately 90 to allow the pedals to pass through the hole in the bulkhead Refitting Refitting is the reverse of the removal procedure When refitting the securing nuts inside the car ensure that the plain nut and the shakeproof washer are fitted on the short stud in the bottom centre position Ensure that the brake fluid warning light wires are fitted with one feed wire red and green and one earth wire black to each reservoir cap When tightening the banjo union nut ensure that the petrol feed pipe is clear of the rear float chamber Bleed the brake and clutch hydraulic systems SECTION M WHEELS AND TYRES DESCRIPTION Pressed spoke or wire spoke wheels the latter in spray painted form are available as alternative standard equipment Chromium plated wire spoke wheels are fitted as Special Equipment only Dunlop 185VR15 SP SPORT tubed tyres are fitted as standard equipment whitewall tyres being available to special order only Whitewall tyres only will be fitted to cars sold in U S A or CANADA These tyres will have the MAXIMUM LOAD ING and MAXIMUM PRESSURE information moulded on the wall of the tyre necessary to conform to U S A FEDERAL REGULATIONS This information together with Seating Capacity Seating Distribution and Recommended Tyre Size data is also quoted on a panel attached to the inside of the glove box lid Type standard equipment Pressed spoke Wire s
73. ce Manual with the exception of the following details The recessed handle is secured to the remote control unit by a central fixing screw and not by a pin Removal of the screw will permit the handle to be withdrawn The remote control unit is not supplied in the locked position as was the previous model and no provision is made for the insertion of a pin when refitting see Page N23 under Locating the Remote Control Unit Any adjustment necessary when reconnecting the link can be made by utilising the elongated holes in the control unit mounting plate NY s 3 BODY AND EXHAUST SYSTEM Fig 8 Ca ae a a el ae NY s 4 Exploded view of the door lock mechanism Fig 7 Location of the screws securing the door lock control aD Exterior handle fixings i le Ente Hlon nana Remote control fixing screw Lever pin wave washer and clip Siker Penre M N O Spring clip Q Striker R T Adjustable link Striker lever Dowel Locknut Latch fixing screw SECTION O HEATING AND WINDSCREEN WASHING EQUIPMENT HEATER The heater unit remains the same as that stated in the 3 8 E Type Service Manual with the exception of the following items 1 Heater air controls 2 Heater temperature controls 3 Heater fan switch 4 Air distributor controls Fig 1 Heating and ventilating controls A Heater air controls B Heater temperature controls C Heater fan switch D Heater outle
74. ce each existing brush in turn with a new brush to enable the tension of the brush springs to be tested accurately Check that the commutator is clean and free from oil or dirt If necessary clean with a petrol moistened cloth or if this is ineffective rotate the armature and polish the commutator with fine glass paper DO NOT use emery cloth Blow out all abrasive dust with a dry air blast A badly worn commutator can be reskimmed by first rough turning followed by diamond finishing DO NOT undercut the insulation Commutators must not be skimmed below a diameter of 145 38 89 mm Renew the armature if below this limit SERVICING Testing in position Check that the battery is fully charged and that the terminals are clean and tight Recharge if necessary Switch on the lamps together with the ignition and operate the starter control If the lights go dim and the starter does not crank the engine this indicates that the current is flowing through the starter motor windings but the armature is not rotating for some reason The fault is due possibly to high resistance in the brush gear or an open circuit in the armature or field coils Remove the starter motor for examination If the lights retain their full brilliance when the starter switch is operated check the starter motor and the solenoid unit for continuity If the supply voltage is found to be applied to the starter motor when the switch is operated the unit must be re
75. ck off the rack adjuster pad fully before removing the pinion housing and readjust to give O10 254 mm end play as detailed under Rack Rattle after refitting Note the position of the pinch bolt slot in the input shaft before removing and ensure that the slot is in the same position after refitting Allow for the spiral in the pinion when reassembling BALL PIN KNOCK Ball pin knock evident when turning to left or right is due to wear in the inner ball assembly This will only be apparent after long periods of service and on no account must any adjustment be attempted to reduce wear which may have developed A new ball pin track rod assembly must in ALL cases be fitted The new assembly will be supplied less the outer ball pin and bellows which must be ordered separately if required The ball pin track rod assembly can be removed with the rack in situ as follows Disconnect the track rod on the side to be removed from the steering arm Remove the bellows retaining clip from the rack housing Fold the bellows back until the inner ball joint is exposed Knock back the ears of the tab washer which locks the inner ball joint assembly to the rack shaft remove the ball joint and track rod as a unit and collect the spring Check the length of the track rod between the inner and outer ball pin centres Release the outer ball joint locknut remove the joint and nut and withdraw the bellows after releasing the clip
76. cket to the under side of the scuttle Remove two bolts nuts lockwashers and distance pieces securing the upper mounting bracket to the support bracket on the body Withdraw the upper column from the splines on the lower column Note If the steering column has not been damaged by impact i e if the nylon plugs in the inner column or the top mounting bracket have not sheared excessive force must NOT be used to separate the upper universal joint from the lower column Refitting Refitting is the reverse of the removal procedure Set the road wheels in the straight ahead position and check that the bolt holes in the lugs of the upper column universal joint register correctly with the groove machined in the lower column splines Tighten the pinch bolt to a torque of 16 18 lb ft 2 2 2 5 kgm IMPORTANT Excessive force as noted under Removal must not be used when reassembling the universal joint to the column UNDER NO CIRCUMSTANCES should a mallet or similar tool be used when engaging the splines in the joint and column If the splines will not engage freely inspect for damage or burrs and remove with a fine file NO ATTEMPT must be made to repair any nylon plugs which have sheared due to impact Dismantling Dismantling is confined to removing the steering column adjuster locknut the splined shaft and the direction indicator switch as detailed on page ILY s 8 LOWER STEERING COLUMN Description The
77. d spirits must NOT be used The use of this chemical will discolour the paintwork SERVICING Testing in Position a Testing with a voltmeter Connect a suitable direct current voltmeter to the motor terminals observing the polarity as indicated on the moulding housing Operate the switch Ifa low or zero voltage is indicated the No 6 fuse switch and external connections should be checked and corrected as necessary If the voltmeter gives a reverse reading the con nections to the motor must be transposed If supply voltage is registered at the motor terminals but the unit fails to function an open circuit winding or faulty brush gear can be suspected Dismantle the motor as described under the heading Dismantling b Checking the external nozzles and tubes If the motor operates but little or no water is delivered to the screen the external tubes and nozzles may be blocked Remove the external plastic tube from the short connector on the container and after checking that the connector tube 1s clear operate the washer switch If a jet of water is ejected check the external tubes and nozzles for damage or blockage If no water is ejected proceed as detailed under Dismantling Page OY s 2 c Testing with an ammeter Connect a suitable direct current ammeter in series with the motor and operate the switch If the motor does not operate but the current reading exceeds that given in
78. datum at which the original trim screw setting was carried out Finger pressure only should be used when tightening the trim screw care being taken not to over tighten EXHAUST EMISSION CONTROL Fig 6 The idle trim screw JET NEEDLE RELATIONSHIP The jet needle relationship not only governs the correct idle mixture but also the correct mixture strength throughout the range During development it was found desirable to have the needle central in the jet This not being practicable to achieve the needle has been biased permanently on one side of the jet to rub lightly against the jet orifice The needle profile has been evolved to compensate for the known air leak consistency being obtained by manufacturer s setting of the leak adjuster screw and therefore a constant fuel air ratio is maintained All carburetters therefore produce a consistent flow from the given needle profile To meet emission control requirements carburetters must be kept within very narrow flow bands Exhaustive testing on Jaguar engines decided the optimum jet position in the orifice and therefore all carburetters have the jets pressed into position toa pre determined depth thereby eliminating any possible maladjustment in service Every unit is flow tested by the carburetter manufacturer ensuring that all car buretters are supplied within the desired limits On throttle opening the piston rises withdrawing the tapered jet meter
79. e coil and the resultant drop in tem perature This relays the actual condition of the coil outlet to the expansion valve power element more accurately provides metering of the fluid and more positively prevents liquid slugs from leaving the evaporator coil If the capillary tube should lose some of its vapour charge the power element will weaken so that the Page RY s 8 valve will close too frequently and therefore starve the coil and the efficiency of the refrigeration system would be impaired A low suction pressure of the compressor would result If the expansion valve screen were to become clogged with some foreign substance flow of the liquid would be reduced and the coil would starve the efficiency of the system would be impaired and a low suction pressure would result The effects of moisture or water in a refrigerant system will be covered more thoroughly under section Receiver Dryer Assembly however one of its effects can be pointed out here One of the charac teristics of Refrigerant 12 is that it can carry in suspension minute droplets of water These droplets remain as liquid water in the high pressure side because of the high pressure side s temperature It now reasons that the discharge pressure of the com pressor is maintained clear to the ball seat of the expansion valve This point is the dividing point of the refrigeration system Everything from it to the suction inlet of the compressor is maint
80. e direction turn indicator switch lever Maintenance In the event of the horns failing to sound or per formance becoming uncertain check before making adjustments that the fault is not due to external causes Check as follows and rectify as necessary i Battery condition ii Loose or broken connections in the horn circuit iit Loose fixing bolts It is important to keep the horn mountings tight and to maintain rigid the mounting of any unit fitted near the horns iv Faulty relay Check by substitution after veri fying that current is available at terminal C2 cable colour brown purple and terminal W1 cable colour Green v Check that fuse No 3 50 amperes and fuse No 6 35 amperes have not blown Note Horns will not operate unless the ignition Is switched on Page PY s 34 Adjustment As the horns cannot conveniently be adjusted in position remove and mount securely on a test fixture A small serrated adjusting screw located adjacent to the horn terminal is provided to take up wear of moving parts in the horn Turning this screw does not alter the pitch of the horn note Connect a moving coil ammeter in series with the horn supply feed The ammeter should be protected from overload by connecting on ON OFF switch in parallel with its terminals Keep this switch ON except when taking readings that is when the horn is sounding Turn the serew clockwise until the horn operates within the specified limit
81. e frequently if sediment build up is evident slacken the locknut swing the retaining clip to one side and remove the glass bowl sealing washers and filter Wash the glass bowl in gasoline Fit a new filter element with new sealing washers and re assemble Distributor Contact Breaker Gap Clean points and adjust contact breaker gap as detailed in the Service Manual Adjust the gap to 014 016 Verify correct dwell angle see Diagnosis Chart Ignition Timing Check ignition timing as detailed in the 1 000 mile Free S rvice EVERY 24 000 MILES Carburetters Remove lead seal and fit Red Emission Pack Part No 11791 to carburetters See pages QY s 12 to QY s 13 Fit new lead seal after completion Valve Clehrances Check the valve clearances as detailed in the Service Manual Clearances cold inlet 004 exhaust 006 Valve Timing Check valve timing as detailed in the Service Manual THE STROMBERG EXHAUST EMISSION CONTROL Contact Breaker Points Renew contact breaker points as detailed in the Service Manual Adjust points gap to 014 016 Check ignition timing as detailed in the 1 000 Miles Free Service Verify correct dwell angle see Diagnosis Chart Compression Pressures Compression pressures must be checked with all spark plugs removed carburetter throttles wide open and the engine at normal running temperature Disconnect the black white low tension lead from the coil before operating th
82. e ignition starter switch to check pressures All cylinders should be even and approximately 150 p s i If one or more cylinders show low compression a full investigation into engine condition must be made on an Electronic Engine Tester such as a Sun 1020 See diagnosis chart DISTRIBUTOR TEST DATA CENTRIFUGAL TIMING ADVANCE With a stroboscopic timing light check the advance characteristics of the distributor at the following r p m R P M DEGREES 1200 13 17 1600 22 26 2900 29 33 4400 37 41 75 CD2SE EMISSION CARBURETTER DESCRIPTION The STROMBERGE 175 CD2SE carburetter is a development of the constant depression carburetter which operates on the principle of varying the effective areas of choke and jet orifice in accordance with the degree of throttle opening engine speed and engine load A number of special features have been intro duced to meet the needs of engine emission control Fuel passes into the float chamber via a needle valve where flow is controlled by the needle valve and twin floats mounted on a common arm Fuel in the jet orifice is controlled at the same level as that in the fioat chamber by means of cross drillings in the jet assembly Clearance around the piston in its vertical bore permits air to leak into the mixing chamber and thus lower the depression A drilling is taken from the atmospherically vented region beneath the diaphragm to meet a further drilling that breaks into the mi
83. e not running the indicator settles in this section your battery requires attention WELL CHARGED BATTERY Ideally the in dicator should settle in this section when the ignition and elec trical equipment e g headlamps etc are switch ed on and the engine is not NORMAL CHARGING VOLTAGE LOW This condition may be indicated when the head lights and other equipment arein use CHARGING VOLTAGE SATISFACTORY The indicator should point to this section when the engine is running above idle RED On Charge CHARGING VOLTAGE TOO HIGH If the indicator continues to point to this section after 10 minutes running either your volt age regulator requires adjust ment or some other fault has running IMPORTANT developed All readings on the indicator should be ignored when the engine is idling since readings may vary at very slow engine speeds due solely to operation of the voltage regulator OFF CHARGE This means more energy is being used from your battery than is being replaced by the alternator on your car This condition is satisfactory provided it does not persist for long periods when the engine is running above idle or at speed If the indicator remains in the section it may mean that you have a broken or slipping fan belt a faulty alternator a badly adjusted voltage regulator or some other fault ON CHARGE This means your battery is having more energy put into it than is
84. e of the removal procedure Recharge the system on completion Testing for Leaks When removed from the car the condenser unit can be leak tested if required as follows Seal off the outlet pipe union with a suitable cap nut and sealing disc Connect a refrigerant container one of the small capacity canisters is preferable by a suitable length of flexible hose to the condenser inlet union Open the container valve and allow a quantity of refrigerant 12 to enter the condenser To test pass the leak detector hose around all the condenser tubes paying particular attention to the U bends at the ends of the tubes If any leaks are detected it is advisable to replace the faulty unit as effective repairs are difficult to carry out without special equipment Fig 5 The condenser mounting A B C D Fan thermostat switch Radiator mounting strap Condenser upper monting Condenser lower monting THE EVAPORATOR GENERAL DESCRIPTION The evaporator of fin and tube construction con tained in a case which also houses the blower fan is mounted below the instrument panel A metered supply of low pressure cold refrigerant is drawn through the evaporator coils by the suction side of the compressor Heat laden air from the car interior is pulled over the coil by the centrifugal fan and the temperature difference between the hot air and cold refrigerant causes a heat transfer from the warm air to the cold liquid
85. e secondary piston C and fluid under pressure flows simultaneously from the two output ports B and D to the front and rear brakes REMOTE SERVO AND Removal Remove the trim on the floor recess panel on the left hand side of the car This will disclose the three nuts securing the remote servo to the bulkhead Withdraw the three nuts Drain the fluid from the system Disconnect the four brake pipe unions and the two flexible hoses SAFETY FACTORS In the event of a fluid line failure in the pipe linking the master cylinder to the slave cylinder or the pipe linking the master cylinder to the fluid supply tanks the reaction valve will be actuated mechanically by the master cylinder piston providing the booster pressure to the front and rear brakes A failure in the fluid line coupling the slave cylinder to the rear brakes will result in the slave cylinder secondary piston travelling to its fullest extent down the bore This has the effect of isolating the rear brake line from the rest of the system and permitting normal fluid pressure to build up in the front brake line If a fault exists in the front brake line the slave cylinder piston will travel along the bore until it contacts the other piston and the two pistons will then travel along the bore together to apply the rear brakes In the case of leaks in either the air or vacuum pipes both front and rear brakes may still be applied by the displac ment of fluid at mast
86. e the beam to the left turn the screw anticlockwise Th u AVi Fig 30 Adjustment of the screw A will alter the headlamp beams in the vertical plane adjustment of the screw B will alter the headlamp beams in the horizontal plane Page PY s 31 ELECTRICAL AND INSTRUMENTS Sealed Beam Unit Replacement Prise off the headlamp rim retained by spring clips Remove the three cross headed screws and detach the retaining ring Note Do not disturb the two beam sctting screws Withdraw the sealed beam unit and unplug the adaptor Replace the sealed beam unit with one of the correct type see Lamp Bulbs On cars fitted with bulb light units proceed as directed above until the unit is removed Release the bulb retaining clips and withdraw the bulb Replace with a bulb of the correct type see Lamp Bulbs When reassembling note the groove in the bulb plate which must register with the raised portion on the bulb retainer Fig 31 Headlamp sealed beam unit removal The arrow indicates one of the spring clips retaining the rim SIDE LAMP BULB REPLACEMENT Remove three screws and detach the lens Remove the bulb by pressing inwards and rotating outwards Check the condition of the lens seal when refitting On cars for certain European countries the side lamp bulb is mounted in the headlight unit and is accessible after removing the light unit as detailed under Headlamps Page PY s
87. e windscreen washing equipment Page OY s 4 SECTION P ELECTRICAL AND INSTRUMENTS BATTERY LUCAS CAII 7 Description The Lucas Model C A battery as listed above is a new type fitted with an air lock device Aqualok which simplifies the topping up procedure This device consists of a one piece vent cover and six sliding tubes perforated to act as air valves and fitted one to each cell aperture The tubes are automatically raised when the vent cover is removed and depressed when the cover is refitted Air or added water is admitted to the cell venting chamber via the tube perforations only while the tubes are in the depressed position No provision is provided in the battery top cover for the insertion of the prong of a heavy discharge tester DATA Battery type CA 11 7 Voltage 12 Number of plates per cel l1 Capacity at foe rate 53 eni at 20 hour rate 60 Maintenance Wipe away any foreign matter or moisture from the top of the battery and ensure that the connections and fixings are clean and tight Check the electrolyte level weekly In extreme cold conditions the battery should be topped up immediately prior to driving the car so that the electro lyte mixing can occur to prevent freezing of the added water Topping up the battery should be carried out with the car on a reasonably level surface Remove the vent cover If the acid level is below the bottom of the tubes pour distilled water into the trough
88. eat off to the surrounding heat mediums Refrigerant 12 vapour at 120 lb per sq in 8 43 kg cm 2 occupies approximately 23 cubic feet 65 m 3 per 1 Ib 0 454 kg of weight The liquid refrigerant 12 occupies approximatley 1 3 cubic feet 036 m 3 per 1 1b 0 454 kg of weight or the liquid takes approximately 1 18th as much space Consequently the quicker the condenser manu factures liquid the sooner there will be more space in which the compressor can unload its charge of vapour and the compressor head pressure will be lower for a given heat load condition Page RY s 10 It is essential that the condenser is cooled efficiently by the passage of the car through the air Any obstruction such as dirt mud or any foreign matter will prevent the lowering of the refrigerant temperature resulting in increased head pressure Normally the condenser will be of a lower tempera ture than the car radiator Any lowering of the efficiency will increase the temperature of tl e condenser to a point where it may be higher than the car radiator and allow the engine to overheat No routine maintenance is necessary Removal Remove the bonnet as detailed in Section N Body and Exhaust Remove all refrigerant from the system by Pump ing Down Withdraw all securing screws and detach AIR CONDITIONING REFRIGERATION EQUIPMENT the condenser unit after disconnecting the hoses Refitting Refitting is the revers
89. eed Page PY s 24 design the direction of rotation of the armature depends on the polarity of the supply of its terminals If it is necessary to run the motor while it is removed from the vehicle the nega tive supply cable must be connected to motor terminal number 1 and the positive supply cable to terminal number 5 for normal speed or terminal number 3 for high speed see Fig 23 Fig 23 ISW Wiper wiring diagram A Moulded terminal connector on cable harness B Terminal connector on wiper motor C Limit switch D Armature E 52 SA switch Switch internal connections NORMAL SPEED HIGH SPEED 4 5 2 4 Systematic Check of Faulty Wiping Equipment Unsatisfactory operation if the supply voltage to the motor is adequate may be caused by a fault that ts mechanical or electrical in origin Before resorting to dismantling consideration should be given to the nature of the fault The symptoms and remedial procedure associated with the more common causes of wiper failure or poor performance are described in 1 and ii below 1 Frictional Wiper Blades Excessive friction between apparently satis factory wiper blades and the windshield may result in a marked reduction in wiping speed when the blades are operating on a windshield that is only partially wet A further symptom is that the blades become noisy at each end of the wiping arc When possible the blades should be temporarily replaced with a p
90. eel assembled to a location plate and shaft Power from the motor is transmitted through the gearwheel location plate and shaft to finally a rotary link which serves as a coupling between the motor and the links which operate the wiper arm spindles Associated with the terminal assembly is a two Stage plunger operated limit switch The plunger is actuated by a cam on the underside of the moulded gearwheel inside the gearbox When the manually operated control switch is moved to OFF or park the motor continues to operate under the automatic control of the limit switch As the wiper blades near the parked position the first stage contacts open and the motor is switched off but continues to rotate under Its Own momentum The second stage contacts to which are connected the positive and negative brushes then close and regenerative braking of the armature takes place to maintain consistent parking of the blades Two speed operation is provided by a third stepped brush incorporated in the brushgear assembly When the main control switch is moved to the high speed position the positive feed to the normal brush is transferred to the third brush and a higher than normal wiping speed is obtained The higher speed should not be used in heavy snow or on a partially wet windshield The blades and arms fitted to the two models are of different lengths and are individually cranked for Right hand and Left hand drive cars Note The wiper b
91. elling on rough surfaces Adjust as follows 1 Release the locknut retaining the rack pad adjusting screw 2 Screw the rack adjusting screw until a firm resistance is felt and back off th of a turn 224 maximum of the ball housing to see if they have become dis placed or split In this event they should be re positioned or replaced as any dirt or water that enters the joint will cause premature wear Do not over lubricate the ball joints to the extent where grease escapes from the rubber seal Fig 1 Front Wheel Alignment Check the front wheel alignment as detailed on page ITY s 9 if uneven wear is evident on the tyres ADJUSTMENT ON CAR Firmly grip the ball pin arm protruding from the pinion end of the steering gear and by moving it towards the rack back up pad a spring resistance should be felt The total amount of play at the rack pad should not exceed 010 254 mm Check by removing the grease nipple and inserting a dial indicator through the rack pad and rack adjusting screw until the stem contacts the back of the rack By pulling the rack against the spring the total amount of end play can be measured If the spring resistance is negligible remove the Page IIY s 3 STEERING POWER ASSISTED rack pad screw and check that the spring is not broken The clearance should be the minimum that will allow smooth operation of the steering unit with no binding at any point throughout the full tra
92. emove the nut lock washer and plain washer securing thelinkage from the primary to the secondary throttles at the primary spindles of the rear car buretter Fig 12 The choke cable connections Detach the link Replace the washers and nuts on the spindle for safe keeping Repeat the operation for the front carburetter Release the bolts securing the inner cables to the choke levers and withdraw the outer casings from the clips at the sides of the carburetters Remove four nuts spring washers and plain washers securing each carburetter to the studs on the primary inlet manifold Disconnect the central link between the throttle slave shaft and the carburetter spindles Withdraw both carburetters as an assembly Separate the units by slackening the Clamps on the throttle spindles It is important to dismantle and assemble each carburetter individually to avoid the possibility of similar parts being interchanged between carburetters Page QY s 11 EXHAUST EMISSION CONTROL Unscrew the float chamber fixing screws and with draw the float chambers vertically away from the body to clear the float mechanism Remove the float chamber gaskets Unclip the float pivot pin Note the fitted position of the float assembly The flat portion of the float must be uppermost when refitted with the carburetter in an inverted position Unscrew the hexagon bodied needle valve from the float chamber body Remove the O ring from the
93. eplace the faulty bulb with one of the correct value Check the condition of the seal before refitting SS Se f aah seat ile iat 3 ue ane E a ae ee R A a mA Fig 36 Number plate lamp bulb removal REVERSE LAMP BULB REPLACEMENT Remove the two retaining screws and detach th lamp glass Lift the upper contact and withdras the bulb Check the condition of the lens seal befor refitting Fig 37 Reverse lamp bulb removal Page PY s 33 ELECTRICAL AND INSTRUMENTS TRAFFIC HAZARD INDICATOR BULB REPLACEMENT Remove the chrome bezel and unscrew the bulb from the holder HEATED BACK LIGHT INDICATOR BULB REPLACEMENT Proceed as detailed under Traffic Hazard Indicator Bulb AUTOMATIC TRANSMISSION INDICATOR BULB REPLACEMENT Remove the drive screws detach the arm rest and transmission unit cover Unscrew the gear control knob Withdraw two screws and remove the gear indicator cover Replace the bulb with one of the same value 24 volts T 3871 Fig 38 Automatic transmission indicator bulb removal HORNS MODEL 9H DESCRIPTION The horns are mounted on brackets attached to the sub frame lower cross member The horns are now mounted on brackets attached to the sub frame lower cross member The horn circuit operates through a Lucas 6RA relay the contacts C1 and C2 closing when the relay coil is energised by depressing the horn switch button located in th
94. er cylinder pressure SLAVE CYLINDER Remove the battery and carrier bracket for the battery tray Withdraw the bolt securing the slave cylinder to the mounting bracket on the outer side member Remove the servo together with the slave cylinder Refitting Refitting the servo is the reverse of the removal procedure Bleed the system after replenishing with fresh fluid MASTER CYLINDER AND REACTION VALVE Removal Drain the fluid from the system Disconnect the two hydraulic pipes from the master cylinder Dis connect the vacuum hose from the reaction valve Remove the clevis pin which is retained by a split pin securing the brake pedal to the master cylinder push rod from inside the car In the case of right hand drive cars remove the top of the air cleaner and re Page LY s 4 action valve prior vwo removing the two nuts securing the master cylinder to the mounting On left hand drive cars the master cylinder and reaction valve can be removed as a complete unit Refitting Refitting is the reverse of the removal procedure Bleed the system after replenishing with fresh fluid SERVICING THE UNi11 General Prior to dismantling either the remote servo or the master cylinder reaction valve assembly it is advisable to obtain repair kits containing all the necessary rubber parts required during overhaul Three separate repair kits are available as follows a Remote servo repair kit b Reaction valve repa
95. ese are checked and found correct and the clute is still inoperative it should be replaced Remoyal Disconnect the cable at the snap connector Remove the compressor setscrew and flat washer anc withdraw the clutch unit If the rotor and pulle assembly will not release from the compressor shaft insert a U N C setscrew and tighten The roto assembly should then release Refitting Refitting is the reverse of the removal procedure THE EXPANSION VALVE GENERAL DESCRIPTION The expansion valve is an automatic thermal valve located in the evaporator assembly case see F ig 1 The valve is the dividing point between the high and low pressure sides of the system and automatically meters the high pressure high temperature liquic refrigerant through a small orifice controlled by a ball valve into the low pressure cold temperature side of the evaporator coil Page RY s 7 AIR CONDITIONING REFRIGERATION EQUIPMENT The low pressure is created by the pull of the suction side of the compressor The expansion valve used in the Jaguar air con ditioning equipment consists of a thermal bulb and capillary tube charged with vapour refrigerant a diaphragm power element balancing spring ex ternal equalising pressure tube valve seat actuating pin ball seat inlet port and screen and outlet port Liquid refrigerant under high pressure enters through the inlet port screen and tends to open the ball valve against the return spr
96. essure above zero close the suction service valve and start the engine to operate the compressor until suction pressure is reduced to 2 lb sq in 0 1406 kg cm F Stop the engine and close the discharge service valve Unscrew the large hexagon gland nuts and remove the service valves from the compressor unit Release the jockey pulley pivot bolt swing the pulley bracket down and remove the drive belt Withdraw the two bolts securing the carrier bracket to the exhaust manifold and the cylinder block With draw the carrier bracket lower pivot bolt Disconnect the clutch cable and remove the unit Detach the carrier bracket from the compressor Note The left hand valve cover on the engine cannot be removed with the compressor in position To give the necessary clearance to enable the cover to be removed proceed as follows Release the jockey pulley pivot bolt swing the pulley bracket down and remove the compressor AIR CONDITIONING REFRIGERATION EQUIPMEN drive belt Withdraw two bolts securing the carrier bracket to the exhaust manifold and the cylinder block Release the lower bracket pivot bolt and swing the unit away from the engine DO NOT DISCONNECT THE COMPRES SOR HOSE CONNECTIONS FROM THE COMPRESSOR Fig 3 The compressor tie bracket and lower pivot mounting point Refitting Refitting is the reverse of the removal procedure Ensure that the pulleys are in line check with a straight edge before fina
97. event the inter coil connectors from connecting with the yoke Draw the pole shoes and coils out of the yoke and lift off the coils Fit the new field coils over the pole shoes and place them in position inside the yoke Ensure that the taping of the field coils is not trapped between the mating surfaces of the pole shoes and the yoke Locate the pole shoes and field coils by lightly tightening the retaining screws Replace the insulation piece between the field coil connections and the yoke Finally tighten the screws by means of the wheel operated screwdriver while the pole pieces are held in position by a pole shoe expander or a mandrel of suitable size Bearings and Bearing Replacement The commutator and drive end brackets are each fitted with a porous bronze bush and the intermediate bracket is fitted with an indented bronze bearing Replace bearings which are worn to such an extent that they will allow excessive side play of the armature shaft The bushes in the intermediate and drive end brackets can be pressed out whilst that in the com mutator bracket is best removed by inserting a 14 29 mm tap squarely into the bearing and with drawing the bush with the tap Before fitting a new porous bronze bearing bush immerse it for 24 hours in clean engine oil SAE 30 to 40 In cases of extreme urgency this period may be shortened by heating the oil to 100 C for 2 hours and then allowing the oil to cool before removing
98. forward by causing the operating bush to compress the engagement spring thus allowing the upper end of the lever to move sufficiently rearwards to close the starter switch contacts The armature then rotates and the pinion slips into mesh with the flywheel ring gear under pressure of the compressed engagement spring THE LOST MOTION SWITCH OFF DEVICE As it is desirable that the starter switch contacts shall not close until the pinion has meshed with the flywheel ring gear therefore it is important that these same contacts should always re open before the pinion has been retracted or can be opened in the event of a starter pinion remaining for some reason enmeshed with the flywheel ring gear To ensure this a measure of lost motion is designed into some part of the engagement mechanism its effect being to allow the starter switch or solenoid contacts which are always spring loaded to the open position to open before pinion retraction begins Several methods of obtaining lost motion have been adopted but each depends upon the yielding of a weaker spring to the stronger system return drive demeshing or dis engagement spring of the solenoid plunger Page PY s 16 This initial yielding results in the switch contacts being fully opened within the first 4 3 18 mm of plunger return travel this action being followed by normal drive retraction Solenoid model 10S has a weaker Jost motion spring located
99. ge intervals Failure to comply with these recommendations may result in engine emissions falling outside U S A Federuai or Canadian limitations 1 000 MILES FREE SERVICE After the car has completed 1 000 miles from delivery the following checks relating to Engine Emission Control should be carried out together with other Free Service details as shown in the Service Maintenance Voucher Booklet Engine Oil Change the engine oil Distributor Contact Breaker Gap Adjust contact breaker points to 014 016 gap as detailed in the Service Manual Verify correct dwell angle see Diagnosis Chart Distributor Lubrication Lubricate the distributor as detailed in the Service Manual Sparking Plugs Clean the sparking plugs and adjust the gap to 025 Engine Idle Speed Allow the engine to warm up to normal operating temperature Adjust the idle speed by turning each adjuster screw an equal amount to give slow running speed of 750 r p m on standard transmission cars 650 r p m on cars with automatic transmission with the selector lever in the neutral position Check the synchronisation of the carburetters by using a balance meter Fast Idle Speed Ensure that the choke control cam on the rear carburetter is in the fully off position Release the locknut and turn the fast idle abutment screw until the gap between the cam and the screw is 067 Tighten the locknut and re check the gap Page QY s 1 EXHAUST EMISSION
100. gs Page PY s 4 The stator consists of a 24 slot 3 phase star connected winding on a ring shaped lamination pad housed between the slip ring end cover and the drive end bracket The rotor is of 8 pole construction and carries a field winding connected to two face type slip rings It is supported by a ball bearing in the drive end bracket and a needle roller bearing in the slip ring end cover see Fig 2 The brushgear for the field system is mounted on the slip ring end cover Two carbon brushes one positive and one negative bear against a pair of concentric brass slip rings carried on a moulded disc attached to the end of the rotor The positive brush is always associated with the inner slip ring There are also six silicon diodes carried on the slip ring end cover these being connected in a three phase bridge circuit to provide rectification of the generated alternating current output see Fig 2 The diodes are cooled by air flow through the alternator induced by a 6 15 24 cm ventilating fan at the drive end The alternator ts matched to an output control unit Model 4TR which is described on page PY s 11 This unit controls the alternator field current and hence the alternator terminal voltage A cut out is not included in the control unit as the diodes in the alternator prevent reverse currents o O O D ELECTRICAL AND INSTRUMENTS from fiowing through the stator when the machine is stationary
101. gs 2 needle valves and washers 4 throttle spindle seals 4 teriperature com pensator seals 2 by pass body gaskets 2 piston diaphragms and 2 hydraulic damper seals Additionally the following will also be required 4 secondary throttle housing carburetter gaskets and spacers secondary throttle housing manifold gasket I primary mixture pipe secondary throttle housing gasket IMPORTANT Dismantle and assemble each car buretter individually to avoid the possibility of inter changing similar parts between carburetters Remove the carburetters as detailed under the 12 000 miles service Drain sufficient water from the cooling system to allow the level of coolant to fall below the throttle housing Disconnect the water pipes from the housing Remove four nuts and washers securing the primary mixture pipe to the secondary throttle housing Release the four nuts securing the secondary throttle housing to the inlet manifold these are located behind the manifold Disconnect the clamping bolt securing the front throttle slave shaft to the rear throttle slave shaft If automatic transmission is fitted disconnect the link between the automatic transmission throttle control shaft and the front throttle slave shaft Withdraw the secondary throttle housing together with the front throttle slave shaft For each carburetter carry out the instructions detailed under 12 000 miles Service In addition to this service however fit the new
102. h 4 Speed and current consumption high torque low 5 Armature does not rotate high current consumption 6 Armature does not rotate high current consumption 7 Excessive brush movement causing arcing at commutator 8 Excessive arcing at the commutator 9 Excessive noise when engaged 10 Pinion engaged but starter motor not rotating O Assume motor to be in normal operating condition High resistance in brush gear e g faulty connec tions dirty or burned commutator causing poor brush contact Tight or worn bearings bent shaft insufficient end play armature fouling a pole shoe or cracked spigot on drive end bracket Short circuited armature earthed armature or field coils Short circuited windings in field coils Oe a Open circuited armature field coils or solenoid unit If the commutator is badly burned there may be poor contact between brushes and com mutator Earthed field winding or short circuit solenoid unit Armature physically prevented from rotating Low brush spring tension or out of round com mutator Thrown or high segment on commu tator Defective armature windings sticking brushes or dirty commutator Pinion does not engage fully before solenoid main contacts are closed Check pinion movement as detailed under Setting Pinion Movement Pinion movement excessive Solenoid main con tacts not closing Check pinion
103. he pick up tube is not submerged in liquid refrigerant and is receiving a mixture of liquid and vapour and the vapour is therefore causing bubbles in the liquid giving the appearance of foam This indicates that the liquid charge in the receiver is insufficient and the system needs more refrigerant The cotton bobbin preparation used as a filter in the system filters out all impurities and foreign matter It is possible for refrigerant under high temperature to re act with refrigerant oil in the compressor and form a precipitation which if not effectively filtered out will eventually clog the expansion screen The silica gel molecular sieve desiccant absorbs and prevents passage of any moisture which may be present in the refrigerant Refrigerant 12 is a hydrocarbon containing the chlorine and fluorine halogens which is formed with methane The hydrogen found in water can under certain temperature conditions hydrolize with the chlorine and fluorine to form hydrochloric and hydrofiuorine acids The hydrochloric acid will attack copper of which all condenser and evaporator coil tubes are made and carry the copper to steel portions of the system such as rod and valve plates Page RY s 9 AIR CONDITIONING REFRIGERATION If the resultant copper plating becomes too thick it may seriously affect the efficiency of the compressor unit The hydrofluori acid formed is an etching acid and can seriously attach and pit the fi
104. he reverse of the removal procedure Check when reconnecting the choke control cable that the full movement of the lever is maintained when the choke is operated SCREEN RAIL FACIA Removal Disconnect the battery and lower the centre instrument pancel Remove two nuts lock and plain washers securing the facia to the centre panel supports Remove two drive screws securing the facia to the demister panel 2 2 cars only Remove two nuts lock and plain washers securing the facia to the body side panels at the base of the screen pillars Detach the flexible demister conduit pipes from the deiister nozzles Disconnect the two cables from the map light Remove the facia complete with demister nozzles Fig 1 Screen rail facia NY s 1 BODY AND EXHAUST SYSTEM Refitting Refitting is the reverse of the removal procedure Utilizing the elongated holes in the mounting brackets adjust the forward edge of the facta to the screen rail DEMISTER PANEL 2 2 cars only Removal Remove the screen rail facia as detailed previously Remove four setscrews nuts and lockwashers securing the panel support brackets to the instrument panel support brackets Detach the conduits from the four demister nozzles Remove the panel complete with the demister nazzles Fig 2 Demister panel 2 2 cars Refitting Refitting is the reverse of the removal procedure Utilising the elongated holes in the centre brackets adjust the forward edge of
105. hine at ambient temperature A low current reading will indicate either a faulty alternator or poor circuit wiring connec tions If after checking the latter in particular the earth connections a low reading persists on repeating the test refer to paragraph 5 In the case of a zero reading switch on the ignition and check that the battery voltage is being applied to the rotor windings by connecting a voltmeter between the two cable ends normally attached to the alternator field terminals No reading on this test indicates a fault in the field isolating relay or the wiring associated with this circuit Check each item in turn and rectify as necessary 5 If a low output has resulted from the test des cribed in paragraph 4 and the circuit wiring is in order measure the resistance of the rotor coil field by means of an ohmmeter connected between the field terminal blades with the external wiring disconnected The resistance must approximate 3 8 ohms When a ohmmeter is not available connect a 12 volt DC supply between the field terminals with an ammeter in series The ammeter reading should be approximately 3 2 amperes Fig 4 A zero reading on the ammeter or an infinity reading on the ohmmeter indicates an open circuit in the field system that is the brush gear slip rings or Winding Conversely if the current reading is much above or the ohmmeter is much below the values given then it is an indication of a short ci
106. hine the rotor poles or to true a distorted shaft STATOR Unsolder the three stator cables from the heat sink assembly taking care not to overheat the diodes see 4h page 6 Check the continuity of the statar windings by first connecting any two of the three stator cables In series with a test lamp of not less than 36 watts and a 12 volt battery as shown in Fig 10 Repeat the test replacing one of the two cables by the third cable Failure of the test lamp to hight on either occasion means that part of the stator winding is open circuit and a replacement stator must be fitted ELECTRICAL AND INSTRUMENTS Test for defective insulation between stator coils and lamination pack with a mains test lamp Connect the test probes between any one of the three cable ends and the lamination pack If the lamp lights the stator coils are earthing and a replacement stator must be fitted Before re sol dering the stator cable ends to the diode pins check the diodes DIODES Fach diode can be checked by connecting it in series with a 1 5 watt test bulb Lucas No 280 Fig 7 Measuring the rotor winding resistance with an ohmmeter Fig 8 Measuring the rotor winding resistance with an ammeter and battery Fig 9 Insulation test of rotor winding Page PY s 9 ELECTRICAL AND INSTRUMENTS across a 12 volt D C supply and then reversing the connections Current should flow and the bulb light in one direc tion only If the
107. hould be in line with and towards the throttle spindle Replace the diaphragm if damaged When replacing the depression chamber cover the damper ventilation boss must be towards the air intake 6 Throttles not synchronised Reset correctly using a balance meter 7 Temperature compensator not working properly With the engine and the carburetters cold re move the cover from the temperature compen sator assembly The tapered valve should be seated in this instance Check the operation by carefully lifting of the valve off its seat When released the valve should return freely If damage prevents the mechanical operation functioning corre tly renew the compensator unit 8 If high mileage has been covered inspect the throttle spindles and end seals for wear Check the spindles for fractures renew if suspect Hesitation or Flat Spot Possible causes are as enumerated for Erratic or Poor Idling but with the addition of the following 1 Damper inoperative Check the oil level and top up with light engine oil 2 Piston return spring omitted Heavy Fuel Consumption Points covered under the two previous headings may contribute to heavy fuel consumption Addition ally check that there ts no fuel leakage from the float chambers or centre plug O ring Replace as necessary SPECIAL PARTS In an endeavour to maintain engine emission within the legislated limits the following parts must not be changed in service
108. ing items remains as detailed on pages P8 P9 of the 3 8 E Type Service Manual 1 Recharging from an external supply 2 Preparing new unfilled uncharged batteries for Service 3 Preparing new Dry charged batteries for Service ELECTRICAL AND INSTRUMENTS DISTRIBUTOR NOT U S A AND CANADA A waterproof cover is incorporated in the distributor assembly located between the distributor cap and body This cover is detachable after removing the DATA Ignition Distributor Type 22D6 41060A 8 to 1 Compression Ratio 9 to 1 Compression Ratio 41060A Cam dwell angle 34 43 Contact breaker gap 0 014 0 016 0 36 0 41 mm 18 24 ozs 512 682 gms Contact breaker spring tension Measured at free contact IGNITION DISTRIBUTOR VACUUM TIMING ADVANCE TESTS The distributor must be run immediately below the speed at which the centrifugal ad vance bezins to function to obviate the possibility of an distributor cap and disconnecting the cable from the contact breaker spring post IGNITION TIMING 8 to Compression Ratio 9 BTDC 9 to 1 Compression Ratio 10 BTDC TEST DATA CENTRIFUGAL TIMING ADVANCE TESTS Mount distributor in centrifugal advance test rig and set to spark at zero degrees at 100 r p m incorrect reading being registered Distri Lucas Lucas Vacuum in inches No advance Lucas Acelerate to RPM
109. ing clip THE INSTRUMENT PANEL The instrument panel differs from that fitted to all previous cars in respect of the following items 1 Rocker Switches Replacing tumbler switches 2 Battery Indicator Replacing Ammeter 3 Panel Light Dimming Resistance Replacing resistance previously attached to the panel light switch 4 The combined Ignition starter switch which is now mounted on a separate sub panel These switches were previously two separate items mounted in the instrument panel 5 The Cigar Lighter Now located in the console below the instrument panel was previously part of the instrument panel assembly THE SWITCHES The rocker switches are mounted in a sub panel which is attached to the instrument panel by four self tapping screws Individual switches may be removed without de taching the sub panel cluster as follows Removal Disconnect the battery Lower the instrument panel Remove the cables from the switch noting location for reference when refitting Press in the two locking tabs located at the bottom and the top faces of the switch body and push the switch through the aperture Refitting Press the switch into the panel aperture until the nylon locking tabs register Reconnect the cables as noted on removal Page PY s 29 ELECTRICAL AND INSTRUMENTS H_a Fig 28 Instrument panel rocker switch removal Inset shows arrowed the nylon locking tabs THE IGNITION START
110. ing needle held in its base from the jet orifice so that the fuel flow is increased pro portionate to the greater air flow The metering needle is variable along its length and has been machined to very close limits Page QY s 7 EXHAUST EMISSION CONTROL Fig 7 Cut away view showing the Jet Needle relationship As the needle profile has been developed from exhaustive testing it is vitally important to maintain correct results in regard to engine emission control that only the recommended needle is used For correct identification the needle is stamped with the figure BIE on the shank Variations in mixture strength caused by heat transfer to the carburetter castings are significant in the context of the extraordinary precision demanded by emission requirements A temperature compen sator is incorporated to cater for this condition An air flow channel permits air passing through the carburetter to by pass the bridge section A bimetallic blade regulated the movement of a tapered plug which adjusts the quantity of air by passed to the mixing chamber Two screws attach the temperature com pensator assembly to the body and two seals are provided to ensure that no leakage can occur at the joint with the body Page QY s The assmbly is preset and unless necessary due to the tapered plug sticking should not be r adjusted in service If malfunctioning of the compensator is suspected and the tapered plug move
111. ing tension The thermal bulb which is clipped to the outlet line of the evaporator is sensitive to the temperature of the vapour leaving the coil The last portion of the evaporator coil is absorbing additional heat from the air passing over due to the action of the fans The vapour of the coil becomes super heated and the temperature rises The thermal bulb receives this temperature rise and the pressure of the vapour within the bulb correspondingly increases This pressure increase operating against the diaphragm and actuating needle opens the valve against the spring pressure and allows a flow of liquid to the coil As the liquid in the coil progresses towards the outlet the coil super heat is reduced the pressure on the diaphragm and the actuating needle is relieved and the spring again forces the ball seat to close the flow of liquid In this way the valve senses the demands of the system and meters the correct amount of liquid refrigerant and also prevents a liquid slug from entering the compressor In order to balance the liquid pressure on the ball seat plus the diaphragm and spring forces an equal force is necessary operating on the underside of the diaphragm The external equaliser is used for this purpose This taps pressure from the outlet of the evaporator to the chamber behind the diaphragm of the valve By utilising the external equaliser an account is made of the small amount of pressure drop that occurs in th
112. ing the eccentric pivot pin securing nut and turning the pin until the correct setting 1s obtained Note The head of the arrow stamped on the end of the eccentric pivot pin should be set only between the ends of the arrows cast in the drive end bracket Turning the screw to the left anti clockwise will increase the gap between the pinion and the thrust washer turning to the right clockwise will decrease the gap Reconnect the battery and recheck the setting After setting tighten the securing nut to retain the pin position CHECKING OPENING AND CLOSING OF STARTER SWITCH CONTACTS The following checks assume that pinion travel has been correctly set Remove the copper link connecting solenoid terminal STA with the starting motor terminal Connect through a switch a supply of 10 volts d c to the series winding that is connecting between the solenoid Lucar terminal and large terminal STA DO NOT CLOSE THE SWITCH AT THIS STAGE Connect a separately energised test lamp circuit across the solenoid main terminals Insert a stop in the drive end bracket to restrict the pinion travel to that of the out of mesh clearance normally a nominal 4 3 17 mm An open ended spanner or spanners of appropriate size and thickness can often be utilised for this purpose its jaws em bracing the armature shaft extension Energise the shunt winding with a 10 volt d c supply and then close the switch in the series winding circu
113. ing the upper mounting bracket to the Support bracket on the body Withdraw the upper column from the splines on the lower column Note If the steering column has not been damaged by impact i e if the nylon plugs in the inner column or the top mounting bracket have not sheared excessive force must NOT be used to Separate the upper universal joint from the lower column Refitting Refitting is the reverse of the removal procedure Set the road wheels in the Straight ahead position and check that the bolt holes in the lugs of the upper column universal joint register correctly with the groove machined in the lower column Splines Tighten the pinch bolt to a torque of 16 18 Ib ft 2 2 2 5 kgni IMPORTANT Excessive force as noted under Removal must not be used when reassembling the universal joint to the column UNDER NO CIRCUMSTANCES should a mallet or similar tool be used when engaging the splines in the joint and column If the splines will not engage freely inspect for damage or burrs and remove with a fine file NO ATTEMPT must be made to repair any nylon plugs which have sheared due to Impact Dismantling Dismantling is confined to removing the steering column adjuster locknut the splined shaft and the direction indicator switch as detailed on page 1 8 LOWER STEERING COLUMN Description The lower steering column comprises two sliding shafts retained to a fixed length by nylon plugs Page TY s 1 STEER
114. instrument into the master cylinder fluid outlet port and easing the valve piston assembly along its bore until it can be removed by hand Important No attempt should be made to withdraw the valve piston assemblv along its bore by using pliers Assembling Prior to assembly liberally coat all rubber seals and plastic bearings with the exception of the two valve rubbers with Lockheed disc brake lubricant Holding the master cylinder body at an angle of approximately 25 to the horizontal insert the lever 28 tab foremost into the cylinder bore ensuring that when it reaches the bottom of the bore the tab on the lever drops into the recessed portion provided Place the piston washer 23 on the piston head convex face towards the piston flange together with a new main cup 24 and press the plastic spring retainer 25 onto the piston head extension Drop the pressed steel spring retainer 27 into the bottom of the bore following up with the piston return spring 26 When these two parts have been assembled it is advisable to recheck the position of the lever Press the piston assembly into the cylinder bore and locate the rectangular section plastic bearing 12 secondary cup 13 and bearing 22 together with seal 14 into the mouth of the cylinder bore Press the assembly down the bore to its fullest extent and with the aid of the special circlip pliers Tool number 7006 with K points fit the circlip to ret
115. ion Pape LY s BRAKES JSP 586 Fig 5 Exploded view of front caliper 1 Caliper body 5 Dust seal 2 Outer piston 6 Seal 3 Inner piston 7 Dust seal 4 Seal and remove the four self locking nuts from the half shaft inner universal joint Withdraw the joint from the bolts and allow the hub carrier to move outwards support the carrier in this position The caliper can now be removed from the aperture at the front of the cross member Refitting Refitting is the reverse of the removal procedure Fit the fluid supply ptpe and the bridge pipe Bleed the braking system THE FRONT BRAKE DISCS Removal Jack up the car and remove the road wheel Dis connect the flexible hydraulic pipe from the frame connection and plug the connector to prevent ingress of dirt and loss of tluid Discard the locking wire and remove the two caliper mounting bolls Remove the caliper Remove the hub as described in Section J Front Suspension THE REAR BRAKE DISCS Removal Remeve the rear suspension unit as described in Section K Rear Suspension Invert the suspension and remove the two hydraulic damper and road spring units as described in Section K Rear Suspension Remove the four steel type self locking nuts securing the halfshaft inner universal joint and brake disc to Page LY s 12 8 Friction pad li Brake bleed nipple 9 Retaining pin 12 Dust cap 10 Clip 13 Anti chatter clip the
116. ion before attempting to remove the seal 25 and piston washer 24 Removal of the plastic spring retainer 26 is sometimes difficult but as a new one is provided in the repair kit this part should be replaced To remove the trap valve assembly unscrew and remove the adaptor 1 from the fluid outlet port If it is necessary to remove the shim like clip from the body of the trap valve 29 ensure that this part is not distorted in any way Page LY s 5 BRAKES Page LY s 6 ee lt e SOON DAR wWN o Fig 2 Exploded view of the remote servo Outlet connection Gasket Inlet connection Piston Pin Retaining clip Gasket Spring Push rod Diaphragm support Diaphragm Key Cover Vacuum cylinder shell Screw Locking plate 18 19 20 2i 22 23 25 26 AT 28 29 30 3l Abutment plate Bearing Seal Spacer Cup Piston Cup Piston washer Seal Retainer Slave cylinder body Spring Trap valve Stop pin Gasket Assembling Assemble the trap valve 29 complete with spring and clip into the outlet port and secure it by fitting the fluid outlet adaptor 1 together with the copper gasket 31 Prior to further assembly lightly coat the four rubber seals to be replaced in the slave cylinder bore with Lockheed Disc Brake Lubricant Locate the piston washer 24 over the piston head extension convex face towards the piston flange and u
117. ip Bridge pipe Bleed screw Dust cap Handbrake mechanism assembly Pad carrier assembly R H outer Pad carrier assembly R H inner Anchor pin Operating lever Return spring Ii 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 JSPI59A Pawl assembly Tension spring Anchor pin Adjusting nut Friction spring Hinge pin Split pin Protection cover Protection cover Belt Washer Bolt Split pin Bolt Retraction plate Tab washer Page LY s 13 BRAKES THE BRAKE CLUTCH PEDAL BOX ASSEMBLY Removal L H Drive Remove the servo vacuum pipe and clips Drain the brake and clutch fluid reservoirs Remove fluid inlet pipes from the clutch and brake master cylinders Plug the holes Remove the brake fluid warning light wires Remove the brake and clutch reservoirs Remove the fiuid outlet pipes from the brake and clutch master cylinders Plug all holes Remove the brake and clutch pedal pads from inside the car Remove the dash casing in accordance with the instructions contained in Section N Body and Exhaust The nuts securing the pedal box assembly to the bulkhead are now exposed and can be removed together with two distance pieces and the brake pedal stop plate Note that there are six self locking nuts and one plain nut with a shakeproof washer The plain nut is located on the bottom centre stud Remove the brake clutch pedal box assembly by turning it through approximately 90
118. ir kit c Master cylinder repair kit When either of the units have been dismantled the component parts should be washed in denatured alcohol industrial methylated spirits Parts that have been washed should be thoroughly dried using a clean lint free cloth or pressure line and then laid out on clean paper to prevent dirt being assembled into the servo or master cylinder and reaction valve assembly Examine all metal parts for damage with particular reference to those listed below and make renewals where necessary a the reaction valve piston and bore b the master cylinder piston and bore c the servo slave cylinder pistons and bore d the servo push rod stem If any of the vacuum hose connections have become loose in service these must be rectified prior to reassembly The vacuum non return valve is a sealed unit and if faulty it must be replaced by a new assembly THE REMOTE SERVO Fig 2 Dismantling Support the servo slave cylinder in the jaws of a vice shell uppermost with specially formed wooden blocks placed either side of the cylinder and against the jaws of the vice Fit the cover removal tool Churchill Tool No J 31 to the end cover and secure it by fitting the three nuts BRAKES Turn the end cover in an anti clockwise direction until the indents in the servo shell line up with the small radii around the periphery of the end cover Remove the end cover from the servo Remove the dia
119. is fully on and T2 fully off As C2 charges the feed back current falls to a degree at which the combination of Zener diode current and feed back current in the base circuit of Tl is no longer sufficient to keep Tl fully on Current then begins to flow again in the base circuit of T2 The voltage at F now commences to fall reducing the feed back current eventually to zero As T2 becomes yet more conductive and the voltage at F falls further current in the feed back circuit reverses in direction thus reducing still further the base current in Tl This effect 1s cumulative and the circuit reverts to the condition where T1 is fully off and T2 is fully on The above condition is only momentary since C2 quickly charges to the opposite polarity when feed back current is reduced and current again flows in o 3 ee ee ee eee eer kS Fig 16 4TR Control Unit Circuit Diagram A Control unit B Field isolating device C Rotor field winding D Alternator Pape PY 10 E 12 volt battery F Stator winding rectified output G Thermistor the bas circuit of T1 The circuit thus oscillates switching the voltage across the alternator field winding rapidly on and off Transistor T2 is protected from the high induced voltage surge which results from the collapse of the field current by the surge quench diode D connected across the field windings This diode also provides a measure of field
120. it The solenoid contacts should close fully and remain closed as indicated by the test lamp being switched on and emitting a steady light Switch off and remove the stop A i SE 7 D I F 4 l me i m er j TY x 2 ae i a F E e r y T i Fig 11 Checking the opening and closing of the starter switch contacts A Core B Shunt winding C Series winding D Plunger E Clevis pin F Lost motion device G Starter terminal H Solenoid terminal I Battery terminal J Accessories terminal K Spindle and moving contact assembly Switch on again and hold the pinion assembly in the fully engaged position Switch off and observe the test lamp The solenoid contacts should open as indicated by tne test lamp being switched off ELECTRICAL AND INSTRUMENTS WINDSCREEN WIPER LUCAS MODEL 15W DESCRIPTION The windscreen wiper assembly consists of a two speed motor coupled by connecting rods to three wiper arm spindle bearings Open Sports and F H C or two spindles 2 2 Windshield wiper motor model 15W is designed to operate a link type wiper installation The motor is self switching to the OFF or park position A two pole permanent magnet field is provided by two ceramic magnets which form part of the yoke assembly Inside the motor gearbox a worm gear on the armature shaft drives a shaft and gear assembly comprising a moulded gearwh
121. l Opening differential 3 5 FAN MOTOR Checking Disconnect the cables and check the fan motors by connecting to a 12 volt battery Remove for inspection if faulty Page PY s 35 ELECTRICAL AND INSTRUMENTS Inspection Withdraw the two through bolts and detach the end cover Expand the retaining spring and lift off the two brush carriers as an assembly Note The brushes are loose in the carriers and care must be taken that they are not misplaced when removed Examine the commutator and clean with a petrol moistened cloth or fine glass paper if dirty or scored 3786 Fig 41 Exploded view of the fan motor FAN RELAY Checking Check that fuse No 6 has not blown Replace if necessary Check that the current is present at terminal C2 Green with the ignition ON Earth the terminal WI Black red switch on the ignition and check by means of an earthed test lamp that current is available at terminal Cl Black green If air conditioning system is fitted check the over riding relay as detailed under Horn relay Ignore reference to horn button Refer to the wiring diagram when checking Fig 42 The radiator fan relays A Fan relay B Over riding relay STEERING COLUMN LOCKS Description Steering column locks if fitted replace the normal Starter Ignition Switch The lock mounted on a bracket attached to the steering column has five operative positions as follo
122. lades are manufactured with special anti smear properties Renew only with genuine Jaguar replacement parts Page PY 6 23 ELECTRICAL AND INSTRUMENTS 4 2 E Type RHD 104 R H crank 12 LHD 104 L H crank 12 SERVICING 5 Note Since the motor is of permanent magnet Fig 22 Exploded view of the 15W windscreen wiper motor 1 Yoke fixing bolts 2 Yoke assembly comprising two permanent magnet poles and retaining clips and armature bearing bush 3 Armature i 4 Brushgear comprising insulating plate and brushboxes brushes springs and fixing bolts 5 Dished washer 6 Shaft and gear 7 Gearbox cover 8 Cover fixing screws 9 Limit switch fixing screws 10 Gearbox 11 Flat washer 12 Rotary link 13 Link fixing nut 14 Limit switch assembly 15 Nylon thrust cap MAINTENANCE All bearings are adequately lubricated during manufacture and require no maintenance Oil tar spots or similar deposits should be removed from the windshield with methylated spirits denatured alcohol Silicone or wax polishes must not be used for this purpose Efficient wiping is dependent upon keeping wiper blades in good condition Worn or perished blades are easily removed for replacement DATA MOTOR i Typical light running 1 5 amp current i e with the normal rotary link disconnect speed ed from the trans 2 0 amp mission after 60 high 7 seconds from cold sp
123. lly tightening the securing bolts Re charge the system as detailed on pages RY S 00p RY S 00 When refitting the service valves check that the mounting surfaces on the valves and the compressor are clean and that the O ring valve mounting gaskets are in good condition If deformed broken or split replace with new gaskets Align the valves correctly to the cylinder head and tighten to a torque of 65 70 ft Ib 8 983 9 674 kg m Special care should be taken to ensure that no dirt or foreign matter enters the compressor during installa tion A new replacement compressor should not be lef unsealed to the atmosphere longer than is absolutel necessary for actual preparation and installation Ir no case should the compressor be open to the atmo sphere for longer than five minutes Check the oil level as detailed on page RY s 2 When replacing parts and re inserting bolts anc setscrews the specified torque requirements shoulk not be exceeded see table below Bolts should always be run in so that the bol heads make contact and then be rightened evenly tc the correct torque figures Location Torque Cylinder head 20 24 ft Ib 2 764 3 316 kg m Crankshaft end 15 20 ft lb 2 073 2 764 kg m Seal plate 6 10 ft lb 0 829 1 382 kg m Mounting 14 17 ft lb 1 934 2 349 kg m Front bearing lock nuts 6 ft lb 0 829 kg m Connecting rods 7 ft Ib 0 967 kg m Oil filler plug 18 20 ft 1b 2 487 3 040 kg
124. lower steering column comprises two sliding shafts retained to a fixed length by nylon plugs Removal Remove the upper steering column as detailed previously Remove the nut lockwasher and bolt securing the column to the lower universal joint and withdraw the column rearwards through the grommet Note If the steering column has not been damaged by impact ie if the nylon plugs in the column have not sheared excessive force must NOT be used to separate the column and the lower universal joint Refitting Refitting is the reverse of the removal procedure Check that the bolt holes in the universal joint register correctly with the groove machined in the column splines Tighten the pinch bolt to a torque of 16 18 lb ft 2 2 2 5 kgm IMPORTANT Excessive force as noted under Removal must not be used when reassembling the universal joint to the column UNDER NO CIRCUMSTANCES should a mallet or similar tool be used when engaging the splines in the joint or the column If the splines will not engage freely inspect for damage or burrs and carefully remove with a fine file NO ATTEMPT must be made to repair any nylon plugs which have sheared due to impact STEERING POWER ASSISTED FRONT WHEEL ALIGNMENT It is ESSENTIAL that the following instructions are carried out when checking the front wheel align ment otherwise steering irregularities may result Important Inflate all tyres to the recommended pressures Each
125. lve mating fac are clean Apply a light film of refrigerant oil to both face fit the valve and tighten the locknut to the corre torque as detailed on page RY s 5 Position the valves at an angle of 45 to clear t bonnet when the pipe lines have been connected THE MAGNETIC CLUTCH GENERAL DESCRIPTION The magnetic clutch consists of two major parts the holding coil and the rotor pulley assembly When an electrical circuit is completed through the holding or field coil to ground the clutch coil is electrically energised creating a magnetic field This couples the plates against the tension of the spring which is connected to the pulley forming an integral part with respect to motion Inasmuch as the belt is driving the pulley and all parts are coupled the com pressor is driven at its tapered shaft through the key Upon breaking the coil electrical circuit the mag netic field is broken and the pulley revolves freely around the compressor shaft and bearing Shims are provided at the hub of the plate for adjusting the plate clearance Too small a clearance can cause a Scraping of the plates Too great a clearance will cause short circuiting of the magnetic clutch which will weaken the field The approximate current consumption of th magnetic clutch is three amps at 12 volts Very little maintenance is required on this assembly Any clutch slipping should be traced to either in correct clearance or low voltage to the clutch I th
126. milar capacity See Diagnosis Chart for test pro cedure CARBURETTER FAULT FINDING Service complaints can generally be broken down into three main categories a Erratic or poor idling b Hesstation or flat spot c Heavy fuel consumption Under these headings possible causes are put forward together with suggestions Page QY s 14 Erratic or Poor Idling 1 Incorrect fuel level caused by maladjustment of the floats and or worn or dirty needle valves Check the float level Wash the needle valve in clean gasoline replace the valve if worn 2 Piston sticking Check for free movement of the spring loaded metering valve needle Clean the piston rod and guide Lubricate the rod and guide with a few drops of light oil 3 Metering needle incorrectly fitted Check that the shoulder of the needle is flush with the face of the piston and that the needle is biased to wards the throttle Check the needle identifi cation and ascertain that the correct needle is fitted Check that the needle housing has not been distorted by over tightening of the securing screw 4 Partially or fully obstructed diaphragm ventilation holes Check that the air cleaner element and Casing are correctly fitted and that the air trumpet carburetter gaskets are not causing obstruction 5 Diaphragm incorrectly fitted or damaged Check the location with the depression chamber cover removed The two depression holes at the base of the piston s
127. mounted the tandem slave cylinder which consists of a single cast iron cylinder housing two pistons in tandem each piston having its own inlet and outlet port Either piston will in the event of a failure operate independently OPERATION Fig 1 When the system is at rest both sides of the boost system are continuously exhausted by the engine manifold depression As the brake pedal is depressed the master cylinder Page LY s 3 BRAKES piston moves along the cylinder building up pressure and forcingsfluid out to the primary chamber of the slave cylinder A Simultaneously the intermediate piston in the end of the master cylinder closes the diaphragm valve G in the reaction valve and in so doing isolates the vacuum E from the air pressure side F of the boost system Further progress of the intermediate piston along its bore will crack the air control spool 1 in the reaction valve thus admitting air at atmospheric pressure to the rear of the boost cylinder piston The air enters the system through a small cylindrical filter H on the reaction valve The pressure imbalance created by the admission of air to the pressure side of the boost system will push the boost piston down the cylinder transmitting a linear force through the push rod to the primary piston of the slave cylinder Forward motion of the primary piston supple mented by the output of the master cylinder transmits hydraulic pressure to th
128. moved from the engine for examination Sluggish or slow action of the starter motor is usually due to a loose connection causing a high resistance in the motor circuit Check as described above If the motor is heard to operate but does not crank the engine indication is given of damage to the drive BENCH TESTING Remove the starter motor from the engine Disconnect the battery Disconnect and remove the starter motor from the engine see page PY 5 18 for the removal procedure Measuring the light running current With the starter motor securely Clamped in a vice and using a 12 volt battery check the light running current and compare with the value given on page FAULT DIAGNOSIS ELECTRICAL AND INSTRUMENTS P X s 15 If there appears to be excessive sparking at the commutator check that the brushes are clean and free to move in their boxes and that the spring pressure is correct Measuring lock torque and lock current Carry out a torque test and compare with the values given on page PY s 17 If a constant voltage supply is used it is important to adjust this to be 7 6 volts at the starter terminal when testing An indication of the nature of the fault or faults may be deduced from the results of the no load and lock torque tests Symptom Probable Fault SUE Gas l Speed torque and current consumption correct i Speed torque and current consumption low 3 Speed and torque low current consumption hig
129. movement as detailed under Setting Pinion Movement Page PY s 19 ELECTRICAL AND INSTRUMENTS DISMANTLING Disconnect the copper link between the lower solenoid terminal and the starting motor yoke Remove the two solenoid unit securing nuts Detach the extension cables and withdraw the solenoid from the drive end bracket casting carefully disengaging the solenoid plunger from the starter drive engagement lever Remove the cover band and lift the brushes from their holders Unscrew and withdraw the two through bolts from the commutator end bracket The commutator end bracket and yoke can now b removed from the intermediate and drive end brackets Extract the rubber seal from the drive end bracket Slacken the nut securing the eccentric pin on which the starter drive engagement lever pivots Unscrew and withdraw the pin Separate the drive end bracket from the armature and intermediate bracket assembly Remove the thrust washer from the end of the armature shaft extension using a mild steel tube of suitable bore Prise the jump ring from tts groove and slide the drive assembly and intermediate bracket from the shaft To dismantle the drive further prise off the jump ring retaining the operating bush and engagement spring BENCH INSPECTION After dismantling the motor examine individual items Replacement of brushes The flexible connectors are soldered to termina tags two are connected to brush boxes and two are co
130. mper after removing the two setscrews lock and plain washers securing the outer sections to the centre and the two setscrews securing the over riders Refitting Refitting is the reverse of the removal procedure Renew the beading between the bumper sections and the over riders if worn or damaged Fig 4 Rear bumper removal The arrows indicate the mounting points BONNET The removal and refitting procedure remains identical to that stated in the 3 8 E Type Service Manual Page N amp 8 with the addition of the following Withdraw the split pin washer and clevis pin and detach the front number plate tie rod fork end from the chassis front cross tube Fig 3 Bonnet hinge mounting points BODY AND EXHAUST SYSTEM WINDOW REGULATOR The window regulator remains the same basically as that detailed on Page N21 of the 3 8 E Type Service Manual with the exception of the method of securing the regulator handle This is now secured to the control unit by a central fixing screw and not by a pin Removal of this screw will permit the handle to be withdrawn Fig 6 Location of the screws and nuts securing the window regulator to the door panel DOOR LOCK MECHANISM Door locks fitted to the E Type Series 2 cars incorporate an anti burst feature while the remote control units have recessed handles The removal refitting and adjusting details remain the same as those quoted in the E Type Servi
131. nal idling speed can be set Ensure that the fast idle screw is clear of the choke cam otherwise incorrect synchronising will result Check that both choke cams are in contact with the stops With the instrument panel choke control pushed home fully reconnect the choke cables to the cams Check that both cams operate simultaneously Start the engine and warm up to the normal operating temperature Check the synchronising of the throttles with a balance meter and tighten the clamping bolts on the throttle spindles Set the throttle stop screws to give the correct idling speed as stated in Routine Main tenance Turn each screw by an equal amount Adjust the fast idle as detailed on page OY s 6 _ If oare is exercised in setting each throttle opening to the same extent no difficulty should be encountered in obtaining satisfactory idling and smooth acceleration Refit the vacuum pipe to the by pass valve Refit the air cleaner and the engine breather pipe NOTE The idling quality and acceleration depend to a large extent upon general engine condition and it is therefore essential to check the engine on an Electronic Engine Tester such as the Sun 1020 or other make of similar capacity See Diagnosis Chart for test pro cedure 24 000 Miles Service This is a more comprehensive service for which one RED Emission Pack Part No 11791 will be required for each carburetter This Pack contains 2 fioat chamber gaskets 2 O rin
132. nd towards the minus sien if losing Moving the indicator scale through one division will alter the time keeping by five minutes per week The action of resetting the hands automatically restarts the movement The window of the clock is a plastic moulding and should only be cleaned with a cloth or chamois leather slightly dampened with water Oil petrol or other fluids associated with cleaning are harmful and must not be used A i R EA leasa Fig 25 Clock inia A Handsetting B Time regulator MAINTENANCE The mercury cell life is in the region of 18 months throughout which it ensures a steady and continuous voltage to the clock Renew the cell at this period to maintain perfect time keeping Page PY s 28 Battery Replacement Remove the instrument panel retaining screws and lower the panel Lever the battery out of the holder and discard Press the new battery into the holder Refit the panel Fig 26 Renewing the electric clock battery Clock Remoyal Lower the instrument panel Withdraw the illumination bulb holder from the back of the clock Remove the two nuts and the clamp strap from the back of the clock Withdraw the clock complete with the battery holder from the instrument panel Refitting Refitting is the reverse of the removal procedure THE REVOLUTION COUNTER TACHOMETER Description The revolution counter is an impulse tachometer instrument incorporating
133. nely polished surface of the compressor valve plate It is therefore of the utmost importance that the water is not allowed in the system and that small amounts be absorbed in a good drier SERVICING If the drying agent in the receiver drier unit becomes completely absorbed with water the unit must bc removed and returned for reclaiming The receiver drier unit can only be completely serviced with the use of special equipment If the system is allowed to remain open for a long period of time or for a shorter period in very humid conditions the drier unit must always be changed before putting the care back in service DO NOT REMOVE the protective sealing caps from a new unit until it has been fitted and is ready for coupling to the pipe unions EQUIPMENT Fig 4 The receiver drier mounting A Thermostat switch radiator fan B Radiator strut C Condenser top mounting D Condenser bottom mounting Removal Pump Down the system i Disconnect the pipe lines and blank off the unions and pipe lines Release the clip and withdraw the receiver unit Refitting Refitting is the reverse of the removal procedure Recharge the system THE CONDENSER GENERAL DESCRIPTION The condenser is a single unit mounted in front of the radiator matrix The function of the condenser is to cause removal of the vapour super heat and to effect a change of state from vapour to liquid by passing the high latent h
134. ng and if worn or scratched renew complete Remove the outer circlip and withdraw the piston Note any shims which may be fitted between the inner circiip and the piston Remove the O ring from the shaft and replace with the new part contained in the Seal Kit Refit the piston and secure with circlips Check that end float between piston and circlip does not exceed 010 If this condition exists reduce end float by adding a shim IMPORTANT Check that the piston rotates freely between the circlips on completion Remove the O rings and seal from the centre seal housing and discard Replace with new parts contained in the Seal Kit Insert the housing into the tube with the lips of the seal facing towards the centre Line up the hole in the housing with the hole in the tube and secure with the union Insert the rack in the rack housing Extreme care must be taken to ensure that the oil seal in the housing is not damaged by the rack teeth Remove the OQ ring and oil seal from the end cap Check the condition of the Clevite bearing and replace if worn or damaged with a new bearing A mandrell machined to the internal diameter of the bearing should be used when refitting to prevent the bearing collapsing Renew the oil seal and O ring and refit the end cap Line up the location marks made during removal and secure with the ring nut Care must be taken to ensure that the end cap does not turn when tightening
135. nnected to free ends of the field coils Unsolder these flexible connectors and solder the connectors of the new brush set in their place The brushes are pre formed so that bedding to the commutator Is unnecessary Check that the new brushes can move freely in their boxes Commutator A commutator in good condition will be burnished and free from pits or burned spcts Clean the com mutator with a petrol moistened cloth Should this be ineffective spin the armature and polish the com mutator with fine glass paper remove all abrasive dust with a dry air blast If the commutator is badly Page PY s 20 worn mount the armature between centres n a lathe rotate at high speed and take a light cut with a very sharp tool Do not remove more metal than is necessary Finally polish with very fine glass paper The INSULATORS between the commutator seg ments MUST NOT BE UNDERCUT Commutators must not be skimmed below a diameter of 145 38 89 mm Armature Lifted conductors If the armature conductors are found to be lifted from the commutator risers overspeeding is indicated In this event check that the clutch assembly is operating correctly Fouling of armature core against the pole faces This indicates worn bearings or a distorted shaft A damaged armature must in all cases be replaced and no attempt should be made to machine the armature core or to true a distorted armature shaft Insulation test To check arma
136. nts unless these are to be removed for replacement If the ball joints are removed for any purpose check the total length of the tie rods before releasing the locknut Tie rods must be re assembled to an equal length Of 875 22 2 Cm OF COMPONENTS seals Replace with the new seals contained in the seal kit and refit the circlip Refit the shaft assembly and reassemble the housing to the rack tube with a new gasket Renewing the Pipe Union Seats If worn or damaged the pipe union seats can be renewed by tapping a suitable thread in the internal bore of the seat and inserting a setscrew with an attached nut and plain washer Tighten down the nut against the housing base and withdraw the seat Fit new seat by inserting in the housing and tapping home square with a soft drift Rack and Rack Housing The following items will be available as replace ment parts 1 Rack 2 Rack Housing 3 Clevite Bearing 4 Seal contained in Seal Kit Replacement rack housings will be complete with end cap seals Clevite bearing and needle bearing Remove the valve and pinion housing as detailed previously Mark the location of the end cap in relation to the rack tubing Unscrew the ring nut retaining the end cap to the rack tube and withdraw the cap Remove the union from the rack tube and push out the centre seal housing from the pinion housing end of the tube Check the condition of the piston and ri
137. over 2 Return spring JO Thrust washer 18 CE bracket 3 Clevis pin 1l Armature shaft extension iO Thactwashes 4 Eccentric pivot pin 12 Field coils 5 Engaging lever 13 Pole shoe Poe OOS nes BUS 6 Roller clutch 14 Armature 21 Brake shoes and cross peg 7 Porous bronze bush 15 Yoke 22 Brake ring 8 Thrust collar 16 Commutator 23 Brushes Pape PY s15 ELECTRICAL AND INSTRUMENTS terminals short extension cables being connected between these and the corresponding solenoid terminals TOOTH TO TOOTH ABUTMENT The electro magnetically actuated linkage mech anism consists essentially of a pivoted engaging lever having two hardened steel pegs or trunnion blocks which locate with and control the drive through the medium of a groove in an operating bush This bush is carried together with the clutch and pinion assem bly on an internally splined outboard driving sleeve the whole mechanism being housed in a cut away flange mounting snout shaped end bracket This operating bush is spring loaded against a jump ring in the driving sleeve by an engagement spring located between the bush and the clutch outer cover The system return or drive demeshing spring is located round the solenoid plunger On the occurrence of tooth to tooth abutment between the ends of the starter pinion teeth and those of the flywheel ring gear the pegs or trunnion blocks at the lower end of the engaging lever can move
138. p h 2 25 kg cm 2 25 kg cm For speeds up to 40 lb sq in 40 1b sq in maximum 2 81 kg cm 2 81 kg cm Tyres for Winter Use When snow conditions make the use of special tyres necessary Dunlop Weathermaster SP 44 185x15 For use on rear wheels to replace SP Sports tyres Maximum permitted speed 100 m p h 32 Ib sq in 160 k p h 2 25 kg cm TYRES General Information The Dunlop tyres specified have been specially designed for the high speeds possible with this car When replacing worn or damaged tyres and tubes it is essential that tyres with exactly the same char acteristics are fitted Due to the high speed performance capabilities of the car it is important that no attempt is made to Page MY s 1 WHEELS AND TYRES repair damaged or punctured tyres All tyres which are suspect in any way should be submitted to the tyre manufacturer for their exam ination and report The importance of maintaining all tyres in perfect condition cannot be too highly stressed IMPORTANT The use of standard inner tubes with Weather master tyres is NOT permissible Special tubes are available and are identified by the size and lettering Weathermaster Only These special tubes should NOT be used with standard tyres WIRE SPOKE WHEELS Description Dunlop cross spoked wheels are fitted as optional equipment Cross spoking refers to the spoke pattern where Page MY s 2 the spokes radiate from the well
139. phragm 11 from its groove in the diaphragm support 10 and with the servo removed from the jaws of the vice apply a gentle pressure to the diaphragm support and shake out the key 12 The diaphragm support 10 and diaphragm support return spring 8 can then be removed Bend down the tabs on the locking plate 16 and remove the locking plate abutment plate 17 and servo shell 14 from the slave cylinder by unscrewing and removing three screws 15 Extract the seal 19 and bearing 18 from thc mouth of the slave cylinder bore which will permit the removal of the push rod 9 together with the slave cylinder piston assembly The push rod may be separated from the piston by sliding back the spring steel clip 6 around the piston and removing the pin 5 It is not necessary to remove the cup 21 from the piston as a new piston together with a cup are contained in the repair kit Unscrew and remove the fluid inlet connection 3 and extract the piston stop pin 30 from the base of the inlet fluid port To facilitate this operation apply gentle pressure to the secondary piston 4 Tap the open end of the slave cylinder body with a hide or rubber hammer to remove the secondary piston together with the piston return spring 28 from the bore The rubber seal 25 located in the groove adjacent to the heel of the piston may be removed but it is advisable to first remove the spring retainer 26 from the piston head extens
140. point on R2 the breakdown point therefore reflects the value of the output voltage Thus at breakdown voltage the Zener diode conducts and current flows in the base emitter circuit of the driver transistor T Also by transistor action current will flow in the collector emitter portion of TI so that some of the current which previously passed through RI and the base circuit of T2 is diverted through T1 Thus the base current of T2 is reduced and as a result so also is the alter nator field excitation Consequently the alternator output voltage will tend to fall and this in turn will tend to reduce the base current in Tl allowing increased field current to flow in T2 By this means the field current is continuously varied to keep the output voltage substantially constant at the value determined by the setting of R2 To prevent overheating of T2 due to power dis sipation this transistor is operated only either in the fully on or fully off condition This is achieved by the incorporation of the positive feed back circuit consisting of RS and C2 As the field current in transistor T2 starts to fall the voltage at F rises and current flows through resistor R5 and capacitor C2 thus adding to the Zener diode current in the base circuit of transistor Tl This has the effect of increas ing the current through Tl and decreasing still further the current through T2 so that the circuit quickly reaches the condition where T1
141. poke spray painted Wire spoke chromium plated Five studs and nuts Centre lock knock on hub cap special equipment Fixing Pressed spoke Wire spoke Rim Section Pressed spoke 6 JK Wire spoke SK Tyres Make Dunlop Type 185VR15 SP SPORT IMPORTANT It is particularly important that tyres of different makes or types or those having different tread patterns should not be mixed on individual cars as this may adversely affect the handling and steering characteristics A car should not of course be driven on bald tyres or on tyres which have only part of the tread showing Driving with badly worn tyres on wet roads also greatly increases the risk of aquaplaning with consequent loss of steering and braking The importance of having tyres that are in good condition of the correct type cannot be overstressed The Dunlop 185VR15 SP SPORT tyres fitted as original equipment are specially produced to suit the performance of the car and a change of make or tyre should not be made unless an assurance is given by the tyre manufacturer concerned that the alternative type is suitable for the car under maximum perform ance conditions INFLATION PRESSURES PRESSURES SHOULD BE CHECKED WHEN THE TYRES ARE COLD SUCH AS STANDING OVERNIGHT AND NOT WHEN THEY HAVE ATTAINED THEIR NORMAL RUNNING TEMP ERATURES Dunlop SP Sport 185VR15 Front Rear For speeds up to 125 32 1b sq in 32 1b sq in m p h 200 k
142. pressure will increase sharply AIR CONDITIONING REFRIGERATION EQUIPMENT If the loss of the thermal bulb charge is suspect it can be subjected to unusual heat by wrapping it with a person s hand This unusual heat will cause the expansion valve to flood the coil if the thermal bulb charge is normal and an abnormally high suction reading will result If the suction pressure does not cease whenever this stabilises and a constant pro rise it can be assumed that the power element is duction of liquid is produced to the expansion valve weak and they are quite normal The air conditioning valve is pre set by the manu facturer of the valve for the correct opening and of course results in unusually high suction pressure readings As soon as the slug of liquid passes the thermal bulb point on the coil outlet the expansion valve as described will close These erratic con ditions which are observed as pressure readings will Removal operating super heat and therefore spring tension field adjustments are not to be made If the valve meters too much liquid which would constantly maintain an excessive suction presure reading this would be a result of a defective spring tension or adjustment and the valve should be replaced Erratic conditions sometimes occur at the expansion valve when the system is first started These conditions result in erratic suction pressure readings that are unusually high While a system lies dormant th
143. pring pressure by using a push type spring gauge Push each spring back against its spring until the brush face is flush with the housing The gauge should then register 8 16 oz 227 454 grammes Replace a brush assembly which gives a reading appreciably outside these limits where this is not due to the brush movement being impeded for any reason INSPECTIGN OF SLIP RINGS The surfaces of all slip rings should be smooth and uncontaminated by oil or other foreign matter Clean the surfaces using a petrol moistened cloth or if there is any evidence of burning very fine glasspaper On no account must emery cloth or similar abrasives be used No attempt should be made to machine the slip rings as any eccentricity in the machining may adversely affect the high speed performance of the alternator The small current carried by the rotor winding together with the unbroken surface of the slip rings mean that the likelihood of scored or pitted slip rings is almost negligible ROTOR Test the rotor winding by connecting an ohmmeter Fig 7 or 12 volt D C Fig 8 supply between the slip rings The readings of resistance or current should be as given on page PY s 6 Test for defective insulation between each of the slip rings and one of the rotor poles using a mains low wattage test lamp for the purpose If the lamp lights the coil is earthing therefore a replacement rotor slip ring assembly must be fitted No attempt should be made to mac
144. quipment is comprised of ithe following components A compressor magnetic clutch condenser unit a receiver drier and evaporator unit and expansion valve a thermostatic control and interconnecting lines The expansion valve and thermostatic control are contained in the evaporator case The refrigerant used as to Specification R 12 Refrigerant 12 which is a halogenated hydrocarbon dichlorodifluoromethane A basic knowledge of refrigeration systems and the use of the special tools required is necessary before any Service operations can be attempted It is therefore ESSENTIAL that only qualified Refrigeration Service Engineers should carry out any repair work necessary IT IS DANGEROUS FOR ANY UNQUALIFIED PERSON TO ATTEMPT TO DISCONNECT OR REMOVE ANY PART OF THE AIR CONDITIONING SYSTEM If during repair work on the car it becomes necessary tO remove any part of the air conditioning system DO NOT DISCONNECT THE HOSE CONNECTIONS until the system has been pumped down that is until all the refrigerant has been removed WARNING EXTREME CARE SHOULD BE EXERCISED IN HANDLING THE REFRIGERANT LIQUID REFRIGERANT AT ATMOSPHERIC PRESSURE BOILS AT 20 F 29 C SERIOUS INJURY MAY OCCUR IF ALLOWED TO CONTACT THE EYES DO NOT SMOKE WHILST CHARGING THE SYSTEM For operating details refer to page RY s 13 under The Electrical System Fig 1 A Compressor D Condenser B Discharge
145. r Note the colour and location of the cables with Lucar termination for reference when refitting Remove the drive belt by pushing the spring loaded jockey pulley inwards and lifting the belt over the alternator pulley Remove the two bolts securing the alternator to the mounting bracket and adjuster link Withdraw the alternator REFITTING Refitting is the reverse of the removal procedure When replacing the alternator belt hold the spring loaded jockey pulley in towards the block and only release when the belt is sitting securely in the vee tracks SERVICE PRECAUTIONS Important 4 2 E Type cars are equipped with transistors in the control box unit and diode rectifiers in the alternator Page PY s 6 The car electrical system must NOT be checked with an ohmmeter incorporating a hand driven generator until these components have been isolated REVERSED battery connections will damage the diode rectifiers Battery polarity must be checked before connections are made to ensure that the connections for the car battery are NEGATIVE earth This is most important when using a slave battery to start the engine NEVER earth the brown green cable if it is dis connected at the alternator If this cable is earthed with the ignition switched ON the control unit and wiring may be damaged NEVER earth the alternator main output cable or terminal Earthing at this point will damage the alternator or circuit NEVER
146. rate sliding shafts retained to a fixed length by nylon plugs the outer column being pierced in a lattice form The inner shaft assembly is supported in the outer column by two pre lubricated taper roller bearings A gaiter covers the pierced portion of the outer column to seal against the ingress of dirt Removal Disconnect the battery Withdraw the self tapping screws and remove the under scuttle casing above the steering column Disconnect the cables contained in the direction indicator switch harness Note the location of the connections for reference when refitting Withdraw the ignition key remove the ring nut and detach the ignition lock from the mounting bracket on the steering column Note If the car is fitted with air conditioning equip ment the switch will be mounted on a bracket attached to the evaporator unit and need not be removed If the car is fitted with a steering column lock removal of the lock will not be possible and it will be necessary to disconnect the attached cables at the snap connectors Release three grub screws in the steering wheel hub and remove the steering wheel motif Remove the locknut hexagon nut and flat washer and withdraw the steering wheel from the splines on the inner column Remove the nut lockwasher and pinch securing bolt the upper universal joint to the lower steering column Page ITY s 8 Remove two nuts and lockwashers securing the upper column lower mounting bra
147. rcuit in the rotor winding in which case the rotor slip ring assembly must be changed ELECTRICAL AND INSTRUMENTS aR ALTER WAT CR CONTROL RWGAS INTL A SJEA E PLAE Se Fig 3 Detach the terminal connectors from the base of the control unit Fig 4 Testing the alternator with an ammeter C Battery A Alternator B Ammeter DISMANTLING THE ALTERNATOR Fig 2 Disconnect the battery and remove the alternator as detailed on page PY s 6 Remove the shaft nut 1 and spring washer 21 Withdraw the pulley and fan 20 Remove bolts 3 noting that the nuts are staked to the through bolts and that the staking must be removed before the nuts are unscrewed If the threads of the nuts or bolts are damaged new bolts must be fitted when reassembling Pace PYS ELECTRICAL AND INSTRUMENTS Mark the drive end bracket 4 lamination pack 8 and slip ring end bracket 10 so that they may be reassembled in correct angular relation to each other Care must be taken not to damage the lamination pack when marking Withdraw the drive end bracket 4 and rotor 16 from the stator 8 The drive end bracket and rotor need not be separated unless the bearing requires examination or the rotor is to replaced In the latter case the rotor should be removed from the drive end bracket by means of a hand press having first removed the shaft key 5 and bearing collar 2 Remove the terminal nuts
148. rcuit to the magnetic clutch will be broken The clutch will disengage and cease to drive the compressor As the temperature in the evaporator rises the thermostat will again close and the clutch re engage The manual setting is progressive in the direction of the arrow towards COOLER Maximum clockwise rotation will give the coldest coil temperature without opening the clutch circuit Minimum rotation will open the clutch circuit most frequently as Its sensing temperature is the highest and will keep the evaporator coil at a warmer temperature The normal setting would be approximately three quarters of full rotation Icing of the evaporator coil which restricts and can ultimately block the air flow into the car occurs more during days of moderate temperature and relative high humidity Position the thermostat to a HIGHER TEMPER ATURE setting to correct this condition HIGHER TEMPERATURE thermostat settings may have to be employed in moderate temperatures cloudy days or night time driving These conditions are also conducive to icing as the relative humidity increases when the sun is obscured The extreme left thermostat setting that is with the white indicator mark vertical is OFF and the clutch circuit will always remain open Nw S E o4 ci wal t G wi ofa 2 ira 9 ooo cop i D a w 7 B Fig 8 The evaporator circuit diagram 1 Alternator Fuse No 6 In line fuse Control swi
149. rough Remove the Radio Heater control panel as detailed in Section N The air conditioning thermostat will remain in position after detaching the control knob Remove the gearbox console cover as detailed in Section N Remove all refrigerant from the system by pumpin g down Remove the clip securing the thermal bulb to the outlet pipe the night for example the vapour in the evaporator coil can condense and when the refrigeration system Disconnect the pipe unions and withdraw the valve is begun a slug of liquid can make its way towards the compressor At least the condition of the entering substance to the compressor is wet or dense This Refitting Refitting is the reverse of the removal procedure Re charge the system on completion THE RECEIVER DRIER SIGHTGLASS ASSEMBLY GENERAL DESCRIPTION The functions of the receiver drier assembly and sight glass are to filter the liquid refrigerant to absorb any water that may be preval nt in the system and to provide a storage tank of liquid refrigerant in which a pick up tube submerged in the liquid will ensure that a solid column is available to supply the expansion valve A sight glass is provided in the outlet line of the assembly to enable a visual check of the fluid flow to be made If the sight glass is clear this indicates that a solid column of pure colourless refrigerant is passing through conversely if bubbles or foam are visible this indicates that t
150. rs 1 Ib 9 oz 0 862 kgm will be the approximate weight of refrigerant 12 required to complete the charging operation SERVICE DIAGNOSIS The following Service Diagnosis chart is included to assist the Service Engineer in fault finding SERVICE DIAGNOSIS CHART E EE lt lt y lt rm a H 2o lt lt l 46a1 A re p fje ial M ace ra in a ia 3 oe e SMR 3 G SYMPTOM o Ss 5 zA f te f j jan Qs 5 oa Oo aa M iq Se ki y g jan 5 2 3 am t mE Unusually low reading of compound Unusually high reading of compound gauge Unusually low reading of high pressure Very low reading on high pressure gauge coupled with very high reading on compound gauge Unusually high reading of high pressure gt C qn e SA BA UOIsuUedXS DATDOFOCq 9 X X X my Pn n Aa Ea enle 70 oy 5 18 S8 2 2 3 4r s ale Si a laagi Fe le Iia a a y 7 oG Z rR o o 46 9 wn 5 O 35 r rt soa leo TiS 2s ail a is ae mt 5 ae O ho 7 Le eSis poe eo pee a m T m O O O w loa Z m y i O O Q amp T o e Wer Q 5 2 p peor Ca Q ya e gt J T T U T a Q go lt amp r J u m D am o ra i wn u a E a a fe gt a 2119 6 Ilo ran o l a 4 ren 3 T m 5 a m O o si oo Ii uo z 5 e ag a o x ge o a il ge A ar o oa fa QO e n pa O gt n R gg 5 A O p p
151. run the alternator on open circuit with the field windings energised that is with the main lead disconnected otherwise the rectifier diodes are likely to be damaged due to peak inverse voltages WARNING When using electric welding equipment for car accident repair it is advisable to carry out the following precautions l Disconnect the battery 2 Disconnect the main output and AL cables at the alternator 3 Disconnect all cables at the 4TR control unit SERVICING Testing the Alternator in position In the event of a fault developing in the charging circuit check by the following procedure to locate the cause of the trouble 1 Disconnect the battery 2 Disconnect the cable brown from the alternator Output terminal and connect a good quality moving coil ammeter between the disconnected cable and the output terminal 3 Detach the terminal connector block from the base of the control unit and connect the black and brown green cables together by means of a short length of cable with two Lucar terminals attached This operation connects the alternator field winding across the battery terminals and by passes the output control unit Fig 3 4 Reconnect the battery earth lead Switch on the ignition and start the engine Slowly increase the engine speed until the alternator is running at approximately 4 000 r p m 2 000 engine r p m Check the reading on the ammeter which should be approximately 40 amperes with the mac
152. rush spring pressures are 4 5 oz 113 to 142 gms with the spring compressed to 23 19 84 mm in length and 74 to 8 oz 212 to 242 gms Page PY s 8 with the spring compressed to 33 10 31 mm in length These pressures should be measured if the necessary equipment is available Check that the brushes move freely in their holders If at all sluggish clean the brush sides with a petrol moistened cloth or if this fails to effect a cure lightly polish the brush sides on a smooth file Remove all traces of brush dust before re housing the brushes in their holders 4321 Fig 6 Showing the brush removal later cars INSPECTION OF BRUSHGEAR LATER MODELS Later model alternators will have side entry cables The characteristics of the alternator remain the same as the previous model side entry cables with the exception of the method of inspection and the fixing of the brush gear as detdiled below The brush length when new is 3 15 9 mm The serviceability of the brushes may be gauged by measur ing the amount by which they protrude beyond the brushbox moulding when in the free position For a brush to remain serviceable this should exceed 0 2 5 mm Renew the brush assemblies if the brushes are worn to or below this length The new brush is supplied complete with brush spring and Lucar terminal blade and is retained in position by a plate secured with a single fixing screw Check the brush s
153. ry cup 13 and rectangular section plastic bearing 12 from the piston by sliding the assembly along the finely machined portion Due to the plastic spring retainer 25 being an interference fit onto the piston head extension this part is likely to become damaged during dismantling In view of this a new spring retainer is contained in the appropriate repair kit To remove the spring retainer hold the piston on a bench piston head downwards applying a downwards force to the back face of the spring retainer with a slim open ended spanner The piston return spring 26 pressed steel retainer 27 and lever 28 may at this stage be withdrawn from the cylinder bore Remove the filter cover 39 and collect the filter 36 sorbo washer 37 and spring 38 Unscrew and remove the five screws securing the valve cover 42 remove the valve cover assembly from the valve housing 32 which can be dismantled further by prising off the snap on clip securing the valve rubber 34 The valve stem 40 complete with the other valve rubber 41 can now be withdrawn from the valve housing and the valve rubber removed from the valve stem flange The reaction valve diaphragm 1 can now be separated from the diaphragm Support 33 and by unscrewing the two hexagon headed screws 2 the valve housing can be separated from the master cylinder body BRAKES Removal of the valve piston 31 assembly can be effected by inserting a small blunt
154. s freely when tested carefully by hand with the engine hot or cold the compensator assembly must be changed for a new unif Fig 8 Cuf away view of the temperature compensator THROTTLE BY PASS During periods of engine over run high emissions will occur if the fuel air mixture in the combustion chambers is not of sufficient strength when diluted by exhaust gas to support combustion To overcome this problem a device is fitted to the carburetters which consists of a by pass formed in the carburetter around the primary throttle under the control of a vacuum operated valve The vacuum signal to the valve is via an internal drilling in each carburetter The flow of this circuit is determined by the size of the ports the valve always lifting to full travel As the throttle remains on its stop the primary induction circuit only is in use ensuring that even mixture is fed through the primary system to all six combustion chambers This valve is pre set and provided it is free from air leaks requires no adjustment It is possible however that small particles of foreign matter may lodge under the valve seating causing leakage and consequent high idling speed In these circumstances the valve cover should be removed and the valve and seating cleaned Manifold depression acting on the valve diaphragr will cause the valve to open when the value is reached that will overcome the valve spring tension This allows fuel to feed from the mixing
155. s of 6 5 7 0 amperes Zo 2885 Fig 39 The Lucas 9H hor A Contact break er adjustment seren B Slotted centre core Do not disturh Service Replacements When fitting replacement horns it is essential that the following procedure be carried out 1 Refit the lockwashers in their correct positions one at each side of the mounting bracket centre fixing ii Ensure after positioning the horn that the centre fxing bolt is secure but not over tightened Over tightening of this bolt will damage the horn it Ensure that when a centre fixing bolt or washers other than the originals are used the bolt is not screwed into the horn to a depth greater than 41 17 5 mm Muted Horns Holland only These horns are muted to comply with the Dutch Traffic Regulations and incorporate a rubber plug Inserted in the trumpet Horn Relay Checking If the horn relay is suspected check for fault by substitution or by the following method 1 Check that fuses No 3 and No 6 have not blown Replace if necessary ii Check with a test lamp that current is present at the relay terminal WI Green and C2 Brown Purple Switch on the ignition before checking terminal W1 RADIATOR Twin electrically motor driven cooling fans are fitted automatic operation being controlled by a thermostat switch mounted in the radiator header tank A Lucas 6RA relay is incorporated in the circuit to prevent over
156. s the unit detailed in the 3 8 Service Manual The Lucas 5SJ screen jet is an electrically operated unit comprising a small permanent magnet motor driving a centrifugal pump through a 3 piece Oldham type coupling The water container is moulded in high density polythene DATA 4 5 lb sq in 0 32 kg sq cm Minimum water delivery pressure Minimum water delivery per second 3 5 c c Container capacity is 24 pints 1 1 litres Usable quantity of water xa 2 pints 1 litre Diameter of nozzle orifice 0 25 0 28 6 3 7 mm Nominal voltage of unit ai fe 12 Maximum current consumption 2 amps Resistance between commutator segments 2 8 3 ohms Page OY s HEATING AND WINDSCREEN WASHING EQUIPMENT Filling Up The correct water level is up to the bottom of the container neck Do not overfill or unnecessary splashing may result Always replace the filler cover correctly after filling up Tt is not possible to empty the container with the pump Refilling is necessary when the water level has fallen below the level of the pump Keep the pump filter clean and the container free from sediment Cold Weather The water container can be given a safe degree of protection down to 28 F 33 C by the use of proprietary antifreeze solutions such as marketed by Trico or Holts Instructions regarding the use of the solvent will be found on the container Denatured alcohol methylate
157. sconnect the cables by withdrawing the cable plug from the socket Mark the position of the throttle fulcrum lever bracket relative to the bulkhead remove two setscrews and detach the bracket It is not necessary to dis connect the throttle control pads Remove four setscrews securing the motor mounting plate to the bulkhead and withdraw the motor with the attached drive link 4 2 litre 2 2 Disconnect the battery Remove the top facia panel as detailed in Body and Exhaust System Section N page NY s 1 Disconnect the motor drive link from the ball joint on the L H wheel box Remove the cable strap and plug as detailed above Remove the setscrews securing the mounting plate to the bulkhead and withdraw the motor Dismantling Remove the gearbox cover The rotary link may be fitted to the gearwheel shaft in one of two positions 180 apart depending on the parking requirement of the windshield in stallation To ensure that the original parking position is maintained the position of the rotary link in relation to the zero mark on the gearwheel location plate must be noted before removing the link Important The moulded gearwheel inside the gearbox must be prevented from moving while the rotary link fixing nut is slackened or on reassembly tightened This is most easily achieved by securing the rotary link in a vice while the nut is turned Remove the fixing nut and withdraw the rotary link and flat washer Remove
158. sed in parallel when the starter device is operated but the pull in winding is shorted out by the starter switch contacts at the instant of closure its purpose having been effected Magnetically the windings are mutually assisting Like the roller clutch assembly the starter solenoid is sealed in a rolled over steel outer case or body and cannot be dismantled for subsequent reassembly ELECTRICAL AND INSTRUMENTS STARTER MOTOR PERFORMANCE DATA Model M45G Pre engaged Lock Torque 22 6 1b ft 3 13 kg m with 465 amperes at 7 6 terminal volts Torque at 1 000 r p m orgue a Lon span 9 6 lb ft 1 33 kg m with 240 amperes at 9 7 terminal volts Light running current 70 amperes at 5 800 to 6 500 r p m SOLENOID SWITCH DATA Closing Coil Resistance 0 36 to measured between terminal STA with copper link removed 0 42 ohms and Lucar termirial Hold on Coil Resistance 1 49 to measured between Lucar terminal and solenoid outer case 1 71 ohms Pape PY s 17 ELECTRICAL AND INSTRUMENTS REMOVAL DISCONNECT THE BATTERY EARTH LEAD Disconnect and remove the transmitter unit from the top of the oil filter Disconnect the battery cable and solenoid switch cable from the starter motor Remove the distributor clamping plate retaining screw and withdraw the distributor Remove the two setscrews and lock washers securing the motor to the housing gently bend away the c
159. shers and disconnect the track rod ball joints from the steering levers using a suitable extractor Remove the bolts nuts and washers securing the steering gear unit to the frame assembly as detailed under Steering Housing Removal on page L6 and withdraw the unit Note If the steering column has not been damaged by impact i e if the nylon plugs in the column have not sheared excessive force must NOT be used to separate the pinion shaft and the lower universal joint Page ITY s 5 STEERING POWER ASSISTED Dismantling Thoroughly clean the outside of the unit before attempting to dismantle Remove the sub assemblies or components as follows a Remove the external pipes b Remove the wire clips retaining the bellows to the steering unit and fold back the bellows to expose the ball joints c Knock back the tab washer securing the inner ball pin to the rack shaft Remove the inner ball pin and track rod as a unit DO NOT dismantle the ball pin assembly Collect the thrust spring and spacer d Release the locknut retaining the rack adjusting pad screw remove screw spring and pad e Mark the location of the pinion housing in EXAMINATION Valve and Pinion Housing Assembly The valve and pinion housing assembly will be available for Service Replacement purposes as a complete unit only with the exception of the top seal and the associated back up seal the housing gasket and the pipe union seats
160. should be approxi mately the same If one cell differs appreciably from the others an internal fault in the cell is indicated The appearance of the electrolyte drawn into the hydrometer when taking a reading gives useful indication of the state of the plates If the electrolyte is very dirty or contains small particles in suspension it is possible that the plates are in a bad condition The specific gravity of the electrolyte varies with the temperature therefore for convenience in com paring specific gravities this is always corrected to 60 F 16 C which is adopted as a reference temperature The method of correction is as follows For every 5 F 2 8 C below 60 F 16 C deduct 0 002 from the observed reading to obtain the true specific gravity at 60 F 16 C For every 5 F 2 8 C above 60 F 16 C add 0 002 ito the observed reading to obtain the true specific gravity at 60 F 16 C The temperature must be that indicated by a ther mometer actually immersed in the electrolyte and not in the air temperature Compare the specific gravity of the electrolyte with the values given in the table and so ascertain the state of charge of the battery If the battery is in a discharged state it should be recharged either on the vehicle by a period of daytime running or on the bench from an external supply as described under Recharging from an External Supply All Service procedure concerning the follow
161. sing the fingers only assemble the two rubber seals 23 and 25 onto the piston so that their concave faces oppose each other Press the spring retainer 26 onto the piston head extension with both seals in position Fit the piston return spring 28 to the secondary piston and assemble into the slave cylinder bore spring leading Press the piston assembly down the cylinder bore using a short length of brass bar until the drilled piston flange passes the piston stop pin hole Insert the piston stop pin 30 into the fluid inlet port and secure it by fitting the inlet adaptor 3 complete with the copper gasket 2 Place the push rod 9 in the primary piston and with the aid of a small screwdriver compress the small spring within the piston to enable the pin 5 to be inserted Prior to fitting the pin retainer 6 it is important to establish that the small coil spring is loaded between the heel of the piston and the pin Ensure that the pin does not pass through the coils of the spring Fit the spring retainer by sliding it into position along the piston ensuring that no corners are left standing proud after assembly BRAKES Using fingers only fit a new cup 21 into the groove on the piston so that its lip concave face faces towards the piston head and assemble the piston into the slave cylinder bore Insert the spacer 20 gland seal 19 and plastic bearing 18 into the slave cylinder counterbore leaving the be
162. sor and one known as the service port for connecting to the pressure gauge Page RY s 6 by means of a flexible hose The valve setting 1s accomplished by rotating the stem normally covered by an aluminium cap either clockwise or counter clockwise With the discharge valve in the bdck seated position fully counter clockwise the refrigerant flow 1s AIR CONDITIONING REFRIGERATION EQUIPMEN from the compressor to the refrigerant line In the suction valve this is in the opposite direction With the valve in the forward seated position clockwise the valve is blocking the seat to the refrigerant Jine and the flow is from the compressor through the service port The two valves are identical with the exception that the discharge valve has a 4 refrigerant fitting connection and the suction valve has a fitting connection If the valves are positioned anywhere between the fully back seated and fully forward seated positions all three ports would be opened and therefore there would be a passage to the compressor and lso the service ports This would be the position in which the system could be operating and at the same time recording pressure reading No service is possible on the valves and if fault Should be replaced Removal Remove all refrigerant from the system by Pum ing Down Disconnect all pipe lines unscrew the locknu and remove the valves Refitting Ensure that the cylinder and va
163. ssembly must be renewed if the main dia metrically opposed brushes are worn to in 4 8 mm or if the narrow section of the third brush is worn to the full width of the brush Check that the brushes move freely in the boxes ii Check Brush Springs The design of the brushgear does not allow for easy removal of the brush springs This is due to the fact that similar to the brushes the springs are expected to last the life of the motor and should not normally require renew ing In the unlikely event of the spring pressure failing to meet the specified requirements the complete brushgear service assembly must be renewed in a similar manner to that necessary for servicing the brushes Note the location of the cables before un soldering for reference when refitting To check the spring pressure on the end face of the brush with a push type spring gauge push until the bottom of the brush is level with the bottom of the slot in the brush box when the spring pressure reading should be 5 7 oz f 140 200 ef Page PY s 26 iii Testing and Servicing the Armature Use armature testing equipment to check the armature windings for open and short circuits Test the insulation by using a mains test lamp Fig 24 Lighting of the lamp indicates faulty insulation lf the commutator is worn it can be lightly skimmed while the armature is mounted in a lathe Afterwards clear the inter segment spaces of copper swarf fp M
164. t Unbalanced tyre pressures or faulty tyres Steering gear out of trim Low tyre pressures Tightness or stiffness in column and or steering and suspension joints Loose pump belt nearly always accompanied by a squealing noise Insufficient pressure from pump due to defective pump valve or restricted hoses Insufficient pressure due to high leaks in steering gear Worn torsion dowel pins or torsion bar broken Incorrect tyre pressures Incorrect toe in Belt loose indicated by squealing during parking manoeurvres Other pump noises are due to wear or damage Wear between rack and pinion assembly Wear at ball joints at the ends of the rack Wear in the rack housing bush REMEDY It is most important that source of the leak is traced before any attempt is made to rectify Once the leak is located tighten the unions or bolts or replace the seals as necessary Renew gasket Tighten hoses Replace pump Check as detailed on Page IIY s 4 Inflate tyres Grease or replace components Check pump belt replace if necessary Remove restriction or check pump pressure as detailed on Page ITY s 5 Replace pump if faulty Confirm high internal leaks If proven remove the rack unit from the car and replace seals Remove valve housing and fit new unit Inflate Check and reset as necessary Check belt and necessary Replace pump replace as Adjust rack pad adjuster screw as detailed on
165. t controls The outlets situated under the duct behind the facia panel are fitted with finger operated direction controls Fully rotating the right hand knob clockwise and the left hand knob anti clockwisetwill cut off all air to the interior of the car and direct the supply to the ducts at the base of the windscreen Reverse rotation of the knobs will re direct air progrccsively from the wind screen to the car interior VENT CONTROL CABLES Removal Withdraw the parcel tray on each side of the dash by removing four drive screws and four thumb screws Release the locknuts securing the outer cables to the vent bracket Disconnect the cables and collect the loose adaptor Unscrew the cable from the centre finisher and withdraw the assemblies A thin spanner will be required to remove the outer casing from the finisher Refitting Reverse the removal procedure to refit the cables AIR TEMPERATURE CONTROLS Removal Remove the screen rail facia as detailed in Section N Page NY s 1 Withdraw two small screws and detach the knobs from the levers Release the locking screws and disconnect the control cables Remove the self locking nut and withdraw the lever pivot pin Note the plain washer located between the levers Refitting Refitting is the reverse of the removal procedure Check that full movement of the levers is maintained when connecting the cables WINDSCREEN WASHER Description The Lucas 5SJ windscreen washer replace
166. t forward until the top fixing clips are clear of the bottom edge of the facia panel and lower the unit to the floor of the car Extract the drive screws and remove the cover from the front of the case Lift the thermostat capillary tube away from the evaporator coils and withdraw the evaporator assembly away from the case Note Care must be taken when the assembly has been removed that the drain pipes and unions underneath are not damaged by contact with the floor or work bench Support the assembly on blocks to keep the pipes clear Page RY s 12 Fig 7 The evaporator facia mounting Refitting Refitting is the reverse of the removal procedure Recharge the system on completion Testing for Leaks When removed from the car the evaporator can be leak tested if required as follows Seal off the outlet union with a suitable cap nut and sealing disc Connect a refrigerant container one of the small capacity canisters obtainable ts preferred by a suitable length of flexible hose to the evaporator inlet union Open the container valve and allow a quantity of refrigerant 12 to enter the evaporator coil To test pass the leak detector hose around all tubes paying particular attention to the U bends at the ends of the tubes If any leaks are detected it is advisable to replace the faulty unit as effective repairs are difficult to carry out without special equipment AIR CONDITIONING REFRIGERATION EQUIPM
167. tch Resister Motor Thermostat switch Clutch Relay D o TAM PWN Page RY s 13 AIR CONDITIONING REFRIGERATION THE EVAPORATOR FAN MOTOR Checking Switch on the fan motor Check at the low medium and high positions to ensure that the resistor is working correctly Removal Remove two cap nuts and detach the radio ashtray console Lower the evaporator unit as detailed on page RY s 12 Disconnect the feed and earth cables withdraw the four retaining screws and remove the fan and motor assembly Check the fan for damage and renew if necessary The fan is a balanced assembly and care must be taken to ensure that any balance pieces fitted are not displaced Refitting Refitting is the reverse of the removal procedure Renew the cork gasket if damaged and ensure that the earth connection is clear and tight when re assembling THE THERMOSTAT If the thermostat 1s not automatically switching OFF the compressor drive clutch unit at the pre set temperature check that the capillary tube is positioned between the fins of the evaporator coil The thermostat and capillary tube assembly is a sealed unit and must be changed if faulty Removal Lower the evaporator unit as detailed on page RY s 12 Withdraw the retaining screws and detach the top panel from the case Carefully remove the capillary tube from the evaporator coils With a small screwdriver used as a lever remove the two control knobs
168. tch control Care must be taken at all times to ensure that the battery alternator and control unit are correctly connected Reversed connections will damage the semi conductor devices employed in the alternator and control unit OPERATION When the ignition is switched on the control unit is connected to the battery through the field isolating switch or relay By virtue of the connection through Page PY s 1 ELECTRICAL AND INSTRUMENTS RI see Fig 16 the base circuit of the power trans istor T2 is conducted so that by normal transistor action current also flows in the collector emitter portion of T2 which thus acts as a closed switch to complete the field circuit and battery voltage is applied to the field winding As the alternator rotor speed increases the rising voltage generated across the stator winding is applied to the potential divider consisting of R3 R2 and R4 According to the position of the tapping point on R2 a proportion of this potential 1s applied to the Zener diode ZD The latter is a device which opposes the passage of current through itself until a certain voltage is reached above which it conducts comparatively freely The Zener diode can thus be considered as a voltage conscious switch which closes when the voltage across it reaches its breakdown voltage about 10 volts and since this is a known proportion of the alternator output voltage as determined by the position of the tapping
169. th by nylon plugs the outer column being pierced in a lattice form The inner shaft assembly is supported in the outer column by two pre lubricated taper roller bearings A gaiter covers the pierced portion of the outer column to seal against the ingress of dirt Removal Disconnect the battery Withdraw the self tapping screws and remove the under scuttle casing above the steering column Disconnect the cables contained in the dire tion indicator switch harness Note the location of the connections for reference when refitting Withdraw the ignition key remove the ring nut and detach the ignition switch from the mounting bracket on the steering column Note If the car is fitted with air conditioning equip ment the switch will be mounted on a bracket attached to the evaporator unit and need not be removed Release three grub screws in the steering wheel hub and remove the steering wheel motif Remove the locknut hexagon nut and flat washer and withdraw the steering wheel from the splines on the inner column Disconnect the cables from the steering column lock if fitted Note the location of the cables for reference when refitting Remove the nut lockwasher and pinch bolt securing the upper universal joint to the lower steering column Remove two nuts and lock washers securing the upper column lower mounting bracket to the under side of the scuttle Remove two bolts nuts lockwashers and distance pieces secur
170. th the piston face EXHAUST EMISSION CONTROL Gt STRAIGHT Fig 14 Positioning the needle in the piston Carefully enter the piston and diaphragm assembly into the main body guiding the needle into the jet with a finger in the air intake Locate the outer tag of the diaphragm into the recess at the top of the body Check the assembly by looking down the piston to ascertain that the two depression transfer holes are towards and in line with the throttle spindle and that the needle is biased towards the throttle Replace the piston spring hold the piston against the spring with a finger through the air intake and fit the cover This method will prevent the piston from moving out of position The cover must be fitted with the damper ventilation boss towards the air intake Replace the four cover screws and tighten down evenly Check the movement of the piston freedom of movement over the full travel is essential and when released from the uppermost position the piston should fall with a sharp click onto the bridge of the carburetter Page QY s 13 EXHAUST EMISSION CONTROL Top up the piston damper fit new seal and refit the damper assembly Remove the two screws securing the temperature compensator unit to the body and withdraw the assembly Take out the inner seal from the car buretter body and remove the outer seal from the valve Renew both seals and refit the assembly to the carburetter body Tighten the two scre
171. the ball bearing wearing away the felt After the end float adjustment has been made Soak the felt oiler in Shell Turbo 41 oil The yoke fixing bolts should be tightened to a torque of 12 16lb in 0 138 0 184 kg m If a service replacement armature is being fitted it is advisable to first slacken the armature end float thrust screw before tightening the yoke fixing bolts Afterwards reset the thrust screw Armature End Float Adjustment Armature end float is 0 002 0 008 0 05 0 2 mm To obtain a satisfactory end float adjustment with the motor and gearbox completely assembled position the unit with the thrust screw uppermost tighten the thrust screw until abutment takes place and then slacken it off one quarter turn and secure it in this position by tightening the locknut WINDSCREEN WIPER SPINDLE HOUSINGS 2 2 Models Remoyal Disconnect the battery Remove both windscreen wiper arms Lower the instrument panel and remove the screen rail facia assembly Disconnect the motor link rod from the ball joint on the left hand spindle lever Unscrew the large nuts securing the housings to the scuttle and remove the distance pieces and rubber seal washers Withdraw the twin spindle and carrier plate assembly through the scuttle panel and complete the removal through the left hand aperture in the bulkhead inner panel Housings are replaceable only as a complete assembly comprising both housings and carrier plate Open Sports
172. the bush Fit new bushes by using a shouldered highly polished mandrel approximately 0 0005 013 mm greater in diameter than the shaft which is to fit in the bearing Porous bronze bushes must not be reamed out after fitting as the porosity of the bush will be impaired After fitting a new intermediate bearing bush lubricate the bearing surface with Rocol Molypad molybdenised non creep or similar oil ELECTRICAL AND INSTRUMENTS CHECKING THE ROLLER CLUTCH DRIVE A roller clutch drive assembly in good conditio will i Provide instantaneous take up of the drive in th One direction it Rotate easily and smoothly in the other i Be free to move round or along the shaft spline without roughness or tendency to bind Similarly the operating bush must be free to slid smoothly along the driving sleeve when the engage ment spring is compressed Trunnion blocks mus pivot freely on the pegs of the engaging lever A moving parts should be smeared liberally with She Retinax A grease or an equivalent alternative Fig 19 The roller clutch drive components A Alternative contruction pinion pressed and clear ringed into driven member B Spring loaded rollers C Cam tracks D Driven member with piniop E Driving member F Bush G Engagement spring H Operating bush I Driving sleeve Page PY lt s 2 ELECTRICAL AND INSTRUMENTS REASSEMBLY After cleaning all par
173. tions to the alternator and control unit undisturbed Connect a high quality voltmeter between control unit terminals positive and negative If available use a voltmeter of the sup pressed zero type reading 12 to 15 volts Switch on an electrical load of approximately 2 amperes e g side and tail lighting Start the engine and run the alternator at 3 000 r p m 1 500 engine r p m ELECTRICAL AND INSTRUMENTS The voltmeter should now show a reading of 13 9 to 14 3 volts at 68 to 78 F 20 to 26 C ambient temperature If not but providing the reading obtained has risen to some degree above battery terminal voltage before finally reaching a steady value the unit can be adjusted to control at the correct voltage see Adjusting If however the voltmeter reading remains un changed at battery terminal voltage or conversely increases in an uncontrolled manner then the control unit is faulty and as its component parts are not serviced individually a replacement unit must be fitted ADJUSTING Stop the engine and withdraw the control unit mounting screws Invert the unit and chip away the sealing compound which conceals the potentiometer adjuster see Fig 7 Check that the voltmeter is still firmly connected between terminals ve and ve Start the engine and while running the alternator at 3 000 r p m turn the potentiometer adjuster slot clockwise to increase the setting or anti clockwise to decrease it
174. to allow the pedals to pass through the hole in the bulkhead Removal R H Drive Remove the air cleaner elbow and the carburetter trumpets Remove the servo vacuum pipe and clips Drain the brake and clutch fluid reservoirs Remove the fluid inlet pipes from the clutch and brake master cylinders Plug the holes Slacken the rear carburetter float chamber banjo nut and bend the petrol feed pipe towards the ficat chamber Remove the brake fluid warning light wires Page LY s 14 Remove the brake and clutch reservoirs Remove the fiuid outlet pipes from the brake and clutch master cylinders Plug all holes Remove the five screws securing the reaction valve assembly to the valve housing and withdraw the complete assembly The valve housing can be removed by unscrewing the two setscrews together with the shakeproof washers which secure the housing to the body of the master cylinder Remove the throttle bell crank bracket Remove the brake and clutch pedal pads from inside the car Remove the dash casing in accordance with the instructions contained in Section N Body and Exhaust The nuts securing the pedal box assembly to the bulkhead are now exposed and can be removed together with two distance pieces and the brake pedai stop plate Note that there are six self locking nuts and one plain nut with a shakeproof washer The plain nut is located on the bottom centre stud Remove the brake clutch pedal box assembly
175. torted and locate the spring on the reduced diameter of the trap valve body Assemble the trap valve complete spring innermost into the master cylinder fluid outlet port Place a copper gasket under the head of the fluid outlet adaptor and screw the adaptor into the fluid outlet port If the fluid inlet adaptor has been removed this must be replaced in the same manner using a copper gasket under the head The master cylinder push rod and convoluted rubber boot can best be fitted during the installation of the assembly FRICTION PADS Renewal riction pads should be renewed if it is found on visual examination through the caliper apertures that they have worn down to an approximate thickness of 4 3 2 mm Withdraw the hairpin clips and extract the pad retaining pins On front brakes remove the anti chatter clips from around the retaining pins and pad backing plates Withdraw the pads BRAKES To enable new pads to be inserted it will be necessary to lever the pistons back down the cylinder bores It is advisable to half empty the brake fluid reservoirs otherwise forcing the pistons back will eject fluid from the reservoirs with possible resultant paint damage Insert new pads Line up the holes in the backing plates and caliper bodies Fit the retaining pins and hairpin clips fit the anti chatter clips to front pads Ensure that the pads are free to move on the pins to allow for brake application and automatic adjust ment
176. transistors and a printed circuit the pulse lead coloured WHITE being wired in circuit with the S W terminal on the ignition coil and the ignition switch Mechanical drive cables or an engine driven gener ator are not required with this type of instrument The performance of this instrument is not affected by the distributor contact setting by corrosion of the sparking plug points or by differences tn the gap settings Connection to the back of the instrument is by means of a locked plug and socket the contacts being offset to prevent incorrect coupling Remoyal Disconnect the battery Remove the screen rail facia assembly as detailed on Page NY s 1 to gain access to the instrument Remove the two knurled nuts earth lead and instru ment retaining pieces Withdraw the tachometer from the facia panel and remove the illumination bulb holders Disconnect the plug and socket as follows Pinch together the prongs of the plastic retaining clip and withdraw from the plug and socket assembly Fig 27 Detach the plug from the socket and complete the removal of the instrument IMPORTANT Do not detach the green and white cables connected to the plug and the instrument Fig 27 The tachometer plug and socket assembly Inset shows the clip in its fitted position ELECTRICAL AND INSTRUMENTS Refittizg Refitting is the reverse of the removal procedure Reconnect the plug and socket assembly and lock with the retain
177. ts reassembly of the starting motor is a reversal of the dismantling procedure given on page PY s 20 but the following special points should be noted i The following parts should be tightened to the maximum torques indicated Nuts on solenoid copper terminals 20 Ib in 0 23 kgm Solenoid fixing bolts 4 5 lb ft 0 62 kgm Starting motor through bolts i 8 Olb ft 0 83 kgm ii When refitting the C E bracket see that the moulded brake shoes seat squarely and then turn them so that the ends of the cross peg in the armature shaft engage correctly with the slots in the shoes Setting Pinion Movement Fig 10 Connect the solenoid Lucar terminal to a 6 volt supply DO NOT use a 12 volt battery otherwise the armature will turn Connect the other side of the supply to the motor casing this throws the drive assembly forward into the engage position Foe P I ee ni fs He i L IP a kam TEENS ig ye REE LE e PAIS J a 1 The m a l i j nii e AU ANU reel 005 0150127 ila Fig 20 Setting pinion movement Page PY s 22 Measure the distance between the pinion and the thrust washer on the armature shaft extension Make this measurement with the pinion pressed lightly towards the armature For correct setting the dimension should be 0 005 to 0 015 0 13 to 0 38 mm Disconnect the battery Adjust the setting by slacken
178. ture insulation use a 110 volt a c test lamp The test lamp must not light when con nected between any commutator segment and the armature shaft If a short circuit is suspected check the armature on a growler Overheating can cause blobs of solder to short circuit the commutator segments If the cause of an armature fault cannot be located or remedied fit a replacement armature Field Coils Continuity Test Connect a 12 volt test lamp and battery between the terminal on the yoke and each tndividual brush with the armature removed from the yoke Ensure that both brushes and their flexible connectors are clear of the yoke If the lamp does not light an open circuit in the field coils 1s indicated Replace the defeative coils Insulation test Connect a 110 volt a c test lamp between the terminal post and a clean part of the yoke The test lamp lighting indicates that the field coils are earthed to the yoke and must be replaced When carrying out this test check also the insulated pair of brush boxes on the commutator end bracket Clean off all traces of brush deposit before testing Connect the 110 volt test lamp between each insulated brush box and the bracket If the lamp lights this indicates faulty insulation and the end bracket must be replaced Replacing the field coils Unscrew the four pole shoe retaining screws using a wheel operated screwdriver Remove the insulation piece which is fitted to pr
179. valve E Sight glass C Suction valve F Cotton bobbin l HOT VAPOUR 2 LIQUID 3 G Dessicant H Receiver drier assembly J Expansion valve The schematic refrigeration circuit Capillary tube Blower assembly Air flow outlet Air flow inlet Page RY s 1 Z eR COLD VAPOUR AIR CONDITIONING REFRIGERATION PERIODICALLY Compressor Drive Belt Adjusting Perjodically check the compressor drive belt and adjust to the correct tension by means of the adjuster pulley i e e a p ap sa n a C 8 of f amp 2 eo om C pete ecen HHI FANINI BA AEE WM Resi Fig 2 The compressor drive belt adjustment point Every 12 Months Compressor Level Checking A manifold gauge set must be available before this maintenance operation can be carried out At every 12 monthly period check the oil level in the compressor as follows Operate the system until the desired interior body temperature is obtained and the crankcase is warm Stop the engine and connect the manifold gauge set Start the engine and note the gauge readings Slowly forward seat turn clockwise the suction service valve until the compressor gauge reads 2 Ib per sq in 0 1406 kg cm F Stop the engine at this point and quickly fully close the suction valve Forward seat the discharge service valve Note It is important that the suction service valve is closed slowly when pumping the system
180. ve end ball bearing following the withdrawal of the rotor shaft from the drive end bracket proceed as follows a File away the roll over on each of the three bearing retaining plate rivets and punch out the rivets b Press the bearing out of the bracket c Locate the bearing in the housing and press it home Refit the bearing retaining plate using new rivets Note Before fitting the replacement bearing see that it is clean and if necessary pack it with high melting point grease such as Shell Alvania No 3 or an equivalent lubricant ALTERNATOR OUTPUT CONTROL UNIT MODEL 4 TR GENERAL Model 4 TR is an electronic control unit Jn effect its action is similar to that of the vibrating contact type of voltage control unit but switching is achieved by transistors instead of vibrating contacts A Zener diode provides the voltage reference in place of the voltage coil and tension spring system No cut out is required since the diodes incorporated in the alter nator prevent reverse currents flowing No current regulator is required as the inherent self regulating properties of the alternator effectively limit the output current to a safe value The control unit and the alternator field windings are isolated from the battery when the engine is Stationary by a special double pole ignition switch On cars fitted with a steering column lock the field windings are isolated by means of a relay replacing the ignition swi
181. vel STEERING VEERING TO RIGHT OR LEFT If the car steers to the right or left when being driven in the straight ahead position or if unequal efforts are required to turn the steering to the right or left carry out the following preliminary tests before proceetiing further Check the tyre pressures and tyre wear and change the front tyres from one side to the other If the pull changes direction then the trouble lies with one or both of the front tyres If the pull remains unchanged check the steering geometry If no improvement is apparent the fault must be in the trimming of the valve in the steering unit Fit a 100 lb per sq in 7 kg cm 2 pressure gauge in the return line start engine and allow to idle Note the pressure gauge reading which should be 40 Ib per sq in 2 8 kg cm 2 approximately Turn the steering to the left and right by a small equal amount The pressure should increase by an egual amount irrespective of the direction the steering is turned If the pressure is not balanced as indicated by a slight fall in pressure on one side before rising the valve and the pinion assembly must be replaced If on starting the engine the steering kicks to one side replace valve and pinion assembly as detailed on page IIY s 6 under Dismantling and Re assembling Fig 2 Page IIY s 4 The pinion assembly can be removed without detaching the rack housing assembly from the car if necessary Ba
182. with a soft mallet Remove all particles of gasket from the surface of the cylinder head and the cylinder taking care not to scratch the mating surfaces or edges Fit the new valve plate gasket contained in Valve Plate Kit Keep the gasket dry Place the new valve plate assembly over the gasket so that the letter S stamped on the plate is visible and on the same side as the word Suction cast on the front of the crankcase Locate the new cylinder head gasket on the valve plate as noted on removal Fit the cylinder head Check that the word Suction on the head is on the same side as the word Suction on the crankcase Insert the bolts through the cylinder head valve plate and gaskets Tighten all bolts evenly in a diagonal sequence to the correct torque figure Refit the mag metic clutch Refit the compressor unit to the engine and re charge the system Leak test all joints on completion After a period of two hours from time of assembly re torque the cylinder head bolts SERVICE REPLACEMENT UNITS obtainable from JAGUAR DISTRIBUTORS or DEALERS Replacement compressors are not available on an exchange basis and must be replaced with new units THE COMPRESSOR SERVICE VALVES DESCRIPTION Two service valves Suction and Discharge are located on the crankcaseand secured by locknuts Each of these valves has three ports or openings one to which the refrigerant line is connected one opening to the compres
183. ws 1 Lock 2 Park 3 Accessories 4 Ignition 5 Start During the assembly of the switch lock to the column the hexagon portions of the lock securing bolts which are of the necked type are sheared when fully tightened and cannot subsequently be removed thus preventing unauthorised removal of the lock Page PY 5 30 IMPORTANT The steering column lock is brought into action when the key is turned to the LOCK position and then removed IMMEDIATELY THIS IS DONE IT BECOMES IMPOSSIBLE TO STEER THE CAR It is therefore important to remember that if the ignition is switched off whilst the car is in motion the key should not be turned past the PARK position The ignition key should NEVER be removed from the lock whilst the car is moving OPERATION 1 Lock This is a locked stop position The key can be removed leaving the steering locked by engagement of the lock bolt with the register in the inner steering column 2 Park This is the normal stop position The key can be removed leaving the car capable of being steered with the ignition OFF 3 Accessories This position will allow the operation of accessories such as Radio and Electric Window Lift control when either is fitted with the ignition OFF The key cannot be removed 4 ON This is the normal starting position On release the key will automatically return to the ignition ON position IMPORTANT ELECTRICAL AND
184. ws evenly Remove the two screws and detach the compensator cover Check for free movement of the valve by lifting the plug from its seat On releasing the valve should return freely Do not strain the bi metal strip or attempt to alter the adjustment It is permissible to ensure that there is consistent radial clearance around the valve to allow for thermal expansion If the valve is sticking remove the securing nut and screw Lightly clean the bore and the plug with a gasoline moistened cloth Refit the bi metal strip and re tension by tightening the nut until the valve is just seated DO NOT TIGHTEN BEYOND THIS POINT Unscrew the three setscrews securing the by pass valve body and lift the assembly from its seat Prise out the throttle spindle seal and renew before re placing the by pass body with a mew gasket Renew the throttle spindle seal on the other side of the carburetter spindle Repeat this operation on the rear carburetter Refit the secondary throttle housing and mixture pipe with new gaskets Refit the water pipes to the secondary throttle housing and top up the coolant to the correct level Refit the carburetters to the secondary throttle housing with new gaskets and spacers Fit new wire and seal to the dashpot Re connect the throttle spindles controls and set the carburetters as detailed in the 12 000 Miles Service Check the engine performance on an Electronic Engine Tester such as the Sun 1020 or other make of si
185. xing chamber downstream of the piston An adjusting screw with a conical tip 1s inserted into the drilling and is adjusted by the manufacturer to bring each carburetter to a common leak datum and sealed with a plug which must not be disturbed in any circumstance Page QY s 5 EXHAUST EMISSION CONTROL COLD STARTING Pulling out the choke control on the instrument panel operates a lever at the side of each carburetter which rotates a disc in the starting device in which a series of holes of different diameters are drilled In the fully rich position all these holes will be in com munication with the starting circuit and will provide the richest mixture Gasoline is drawn from the float chamber via a vertical drilling adjacent to the central jet through the starting device and into the throttle body between the piston and the throttle disc Simul taneously the cam on the choke lever will open the throttle disc beyon the normal idle position to ensure a faster idle speed and prevent stalling As the choke is gradually pushed to the OFF position fewer and smaller holes will limit the gasoline feed from the float chamber thereby progressively weakening the mixture to a point where the choke s fully home and the mixture strength ts governed by the Factory setting of the main jet and the idling speed determined by the setting of the throttle stop screw NOTE DO NOT DEPRESS THE ACCELER ATOR PEDAL WHEN STARTING FROM COLD

SECTION H - RJH-Heritage Switzerland

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