Haynes Toyota Celica Owners Workshop Manual 0856962295, 9780856962295

Citation preview

TOYOTA 1971 thru 1978 a 113 cu

120 cu in

(1858 cc) (1968 cc) a 134 cu in (2189 cc) in

Owners Workshop Manual

Digitized by the Internet Archive in

2010

http://www.archive.org/details/toyotacelicaowneOOhayn

Toyota Celica

Owners Workshop Manual by J H Haynes Associate

Member

of the Guild of IVIotonng Writers

and Peter Strasman MISTC

Models covered

Toyota Celica ST. 113, 120 & 134 cu Toyota Celica GT. 120 & 134 cu in. Toyota Celica Liftback. 134 cu in. Coverage includes 4

in.

& 5 speed manual

gearboxes, plus automatic

85696 229 5

ISBN

©Haynes

Publishing Group 1977 No part of this book may

be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording or by any information storage or retrieval system, without permission in writing from the copyright holder. All rights reserved.

Printed

in

England

HAYNES PUBLISHING GROUP SPARKFORD YEOVIL SOMERSET ENGLAND distributed in the

USA by

HAYNES PUBLICATIONS 861 LAWRENCE DRIVE NEWBURY PARK CALIFORNIA 91320 USA

INC

Acknowledgements Our thanks are due to the Toyota Motor Sales Company Limited, for their assistance with technical information and the supply of certain illustrations. Also, to Castrol Limited who supplied lubrication data. Champion Sparking Plug Company Limited for the provision of spark plug photographs. The bodywork repair photographs used in this manual were provided by Lloyds Industries Limited

who

supply 'Turtle Wax", 'Dupli-Color' and a range of other

Holts products. Special thanks are

m

helped

due

to

all

of the people at Sparkford

who

the production of this manual. Particularly, Martin

Penny and Les Brazier who carried out the mechanical work and the photographs, respectively; and Rod Grainger who

took

edited the text.

About this manual Its

aims This

is

a

manual by

owner/maintainer for practical

a practical

ovwier/maintainers; the author, and those assisting him, learned

models the only thorough way, by studying all available information and then going ahead and doing the work, under typical domestic conditions and with a typical range of tools, backed only by their experience as keen car men over a

about

this range of

number of years. Unlike other books of most of the photographs

hands in author, and the assuming no special

this nature, therefore, the

are

instructions cover every step in

those of

the

full detail,

knowledge on the part of the reader except how to use tools and equipment in a proper manner, firmly and positively but with due respect for precise control where this is required.

Using the manual The manual is divided

into thirteen Chapters, each covering a

logical sub-division of the vehicle.

into

Sections,

numbered with

The Chapters

single

figures

are each divided

and the decimal

Be discreet about borrowing tools; even with great care, accidents still happen, and the replacement of a lost or damaged tool can be costly. Do not be offended, if refused; the owner may have had an unhappy experience already! The policy of the manufacturer of these vehicles is one of continuous development, and designs and specifications are

in (eg; 5.1, 5.2,

freely illustrated, especially in those parts

a detailed

individually or in

sub-Section described.

There

of

related groups)

the

text

the

same

as the Section or

where the operation they show

is

an alphabetical index at the back of the manual as weW as a contents list at the front. References to the 'left' or 'right' of the vehicle are in the sense of a person in a seat facing forwards towards the engine. Where appropriate, fault diagnosis instructions are given at is

jobs require special tools and where these are the manual points this out, otherwise, alternative

Certain essential

5),

where there is sequence of operations to be carried out. There are forms of two illustrations; figures and photographs. The figures are numbered in sequence with decimal numbers, according to their position in the Chapter eg; Fig. 6.4 is the 4th drawing/ illustration in Chapter 6. Photographs are numbered (either is

Points for the reader The accumulation of good tools normally must take place over a period of time and this is the one expense which the do-it-yourself owner must face. Cheap tools are never wortn having, as they are not cheap in the long run. They rarely last, often make the work more difficult, and may even cause accidental damage which could cost more to put right than the cost of a good tool in the first place.

with

5.3 etc). It

'if all else fails, read the handbook'. It is better, and almost always quicker, to say: 'This could be one of several things, so let's have a look at the Haynes manual before trying anything'.

methods are

(eg;

Sections into paragraphs (or subSections), numbers following on from the Section they are

the end of Chapters. Accurate diagnosis of troubles depends on a careful, and above all, systematic approach, so avoid the attitude

frequently spares

given.

being changed as a result.

It

follows naturally that

may sometimes be purchased which

original

part

removed and from the

part

differ

both from the

referred

to

in

this

manual. However, suppliers of genuine Toyota spare parts can usually settle queries about interchangeabiliry by reference to the latest information issued by the manufacturer. (Read the Section, 'Buying spare parts'). Every care has been taken to ensure the accuracy of this manual but no liability can be accepted by the authors and publishers for any loss, damage or injury caused by any errors in or omissions from the information given.

Contents Chapter

Introduction to the Toyota Celica The Toyota Celica was first introduced in 1971. Up until mid-1972, a 1 13 cu. in engine was used but thereafter the bore was increased to provide an engine of 120 cu. in displacement. A manual, four-speed gearbox is fitted as standard with automatic transmission option available from 1973. In late

1973

a

GT

version vuas introduced having a five-speed

other changes in specification. Automatic not available on GT models. Most changes and modifications have been of a minor nature to both mechanical and bodywork components. A full emission control system is installed on all models after

and

gearbox

transmission

is

mid- 1972

Buying spare parts and vehicle identification numbers Buying spare parts

Vehicle identification

Spare parts are available from many sources, for example garages, other garages and accessory stores, and motor factors. Our advice regarding spare parts is as follows: Officially appointed Toyota garages This is the best source of parts which are peculiar to your car and otherwise not generally available (eg; complete cylinder heads, internal gearbox components, badges, interior trim etc). It is also the only place at which you should buy parts if your car is still under warranty;

Toyota

-

non-Toyota components may invalidate the warranty. To be sure of obtaining the correct parts

the

storeman your

car's

it

will

engine

always be necessary to give

and

chassis

number, and

if

possible, to take the old part along for positive identification.

Remember

that

many

parts are available on a factory exchange

Give as

numbers

much information

as

possible

when buying them.

Quote the car model, year of manufacture and body, serial and engine numbers. Modifications are a continuous and unpublicised process carried out by the vehicle manufacturers so accept the advice of the parts storeman w*ien purchasing a component. Spare parts lists and manuals are compiled upon a numerical basis and individual vehicle numbers are essential to the supply of the correct component. The engine serial number is stamped on the left-hand side of the cylinder block, close to the engine oil dipstick. The vehicle serial number is stamped on the engine compartment rear firevuall and it is repeated on the top of the instrument panel

where

it is

visible

from outside.

scheme - any parts returned should always be clean! It obviously makes good sense to go straight to the specialists on your car for type of part for they are best equipped to supply you. These are often very Other garages and accessory stores places to buy material and components needed for the maintenance of your car (eg; oil filters, spark plugs, bulbs, fan belts, oils and grease, touch-up paint, filler paste etc). They also sell general accessories, usually have convenient opening hours, often charge lower prices and can usually be found not far from this

good

home. Motor

factors

-

Good

factors

will

stock

all

of

the

more

important components which wear out relatively quickly (eg; clutch components, pistons, valves, exhaust systems, brake cylinders/pipes/hoses/seals/shoes and pads etc). Motor factors will often provide new or reconditioned components on a part exchange basis - this can save a considerable amount of money. Vehicle

serial

number on engine compartment firewall

Vehicle number on instrument panel

Location of engine number

2

S

^2 o o

o o

o o

o

o

o o

====== ^

I

:

I

i

:

:

:

:

:

:

.

.

.

.

.

.

~

i^ ^1 C €

S^ ri

c o S

o oc E E o o

5


Vacuum

switching

valve

Outlet valve Fig. 3.5 Fuel

pump

Fresh

air inlet

valves Fig.

3.6 Diagrammatic layout of carbon canister type fuel evaporative emission control

Fig. 3.8 Accelerator Fig. 3.7

Automatic choke adjustment marks

pump stroke

adjustment

Chapter 3/Carburation;

fuel,

A good spurt of fuel should be ejected from the end of the pipe every second revolution of the engine.

4

6

pump

Fuel

-

removal and installation

there is very little fuel left in the tank, to remove the drain plug and drain the fuel and discard it. 2 If the tank is severely contaminated, withdraw the tank as previously described and remove the fuel level sender unit. 3 Use two or three changes of fuel and shake the tank

vigorously until

Disconnect the inlet and outlet pipes from the pump by 1 unscrewing the two unions. 2 Unscrew and remove the two bolts which secure the pump to the cylinder block. Withdraw the

pump

together with insulator

and gaskets. 3 Installation is a reversal of removal but use a both faces of the insulator.

new

45

exhaust and emission control systems

4

Should

it is

clean.

develop, do not be tempted to solder over the is a specialist job and unless lengthy safety precautions are observed, it can be a very dangerous procedure. a leak

hole. Fuel tank repair

It will probably be as economical to purchase a have the original repaired.

new tank

as to

gasket on

10 Fuel contents gauge and sender unit 7 1

2

Fuel

pump

Remove Remove

-

1 The testing of these units is described together with the other instrumentation in Chapter 10.

dismantling, servicing and reassembly

the securing screvus and

lift

off the cover

(1

).

the gasket (2).

3 Scratch an alignment mark on the flange edges of the upper and lovwr halves of the pump body and then remove the flange securing screws and separate the two halves. 4 From the lower body, unhook the diaphragm operating rod from the rocker arm by depressing the rod and at the same time twisting it sideways. Withdraw the diaphragm rod assembly. 5 Extract the oil seal, retainer and spring. 6 If essential (due to a worn rocker arm), the pin (13) may be removed and the arm and spring removed. 7

Examine

all

components

for wear.

If

this

is

severe,

it

will

probably be just as economical to renew the pump complete, on an exchange basis. 8 Check the operation of the valves in the upper body, by alternatively sucking and blowing with the mouth at the inlet and outlet ports. When blowing through the inlet port, the valve should open. It should close positively when sucked. When blowing through the outlet port, the valve should close. It should open when sucked. The valves are staked in position and in the event of a fault occurring, it is recommended that a new upper body complete with valves is obtained.

9

If

the

pump components

good order, obtain

are in

a repair

11 Fuel evaporative emission control (charcoal canister) system

description and servicing

This system is designed to reduce the emission of fuel vapour 1 atmosphere by directing the vapour from the fuel tank through a separator to an absorbent charcoal canister. At road speeds above 11 mph the vacuum switching valve operates and the vapour v\Xiich has been stored in the canister is drawn into the inlet manifold where it is then burned as a controlled fuel/air mixture within the engine combustion chambers. 2 The fuel tank filler cap incorporates a valve w/hich opens to admit air should a partial vacuum be created within the tank as a result of vapour removal. 3 The check valve maintains pressure in the fuel tank to prevent any fuel entering the vapour extraction line when the tank is being filled. 4 Regularly inspect the condition and security of the system connecting hoses and the filler cap seal and renew them where to

necessary.

5

6

Renew the check valve every 6,000 miles. Renew the charcoal canister every 5 years whichever

kit

which will contain all the necessary renewable items. The diaphragm rod assembly cannot be dismantled and is renewed

intervals,

complete.

their rectification.

7

is

or at 50,000 mile

the sooner.

Refer to Section 28, of this Chapter for fault

symptoms and

10 Reassembly is a reversal of dismantling. Align the flange mating marks and tighten the flange securing screws evenly and in

diametrically opposite sequence. Final tightening should be

carried out with the rocker

8

Fuel tank

1

Drain

-

the

arm

removal and installation fuel

from

the

tank

into

a

suitable

(capped)

container.

Disconnect the fuel outlet pipe from the tank. 3 Remove the fuel tank shield. 4 Disconnect the electrical lead from the terminal of the fuel contents sender unit. 5 With the charcoal type evaporative emission system with which these cars are equipped (see Section 11), take care when disconnecting the tank to separator hoses not to damage the 2

check valve. 6 Disconnect the flexible section of the fuel filler hose and then unbolt and remove the fuel tank. 7 Installation is a reversal of removal but make good any sealing mastic which was removed during withdrawal of the tank.

9

Fuel tank

1

Over

the

a

-

servicing

and repair

of the fuel tank.

-

general description

It is

A dual barrel downdraught type carburetor is fitted to all 1 models and incorporates an automatic choke vuhich Is actuated by heated gas from the exhaust manifold. 2 The carburettor fitted to 8R series engines differs from that fitted to 18R-C engine as it does not have a high speed valve or reloader mechanism. On carburetors fitted to 18R-C engines, a diaphragm unit actuates the secondary throttle valve, also the primary and secondary throttle linkage is of different design. 3 Reference should be made to Specifications Section for full details of jets and other components fitted to the two carburetors.

1

3 Automatic choke

When

-

adjustment

mark on the choke cover is in alignment with the center index mark on the choke housing, then the choke valve plate should be fully closed provided that the ambient temperature is about 77°F (25°C) or below. As the temperature rises (during engine warm-up) so the valve plate will gradually open until it is fully open with the engine at normal operating 1

the

temperature. 2 Variations

may accumulate in good idea periodically when

period of time, sediment and water

bottom

12 Carburetor

fully depressed.

a

may

in air temperature in which the car is operating be compensated for by turning the choke cover clockwise low temperatures) and anti-

to richen the starting mixture (in

46

Chapter 3/Carburation;

fuel,

exhaust and emission control systems

clockwise to weaken it (in higher temperatures). Each graduation on the choke housing will vary the choke temperature setting of 90F (I50C).

14 Slow running 1

The use of

a

-

adjustment

vacuum gauge and

for this operation (later

a tachometer will be required models are equipped with tachometers

as standard).

2

Run

3

Check that the valve clearances are correctly adjusted, the is correct and all the emission control settings are

the engine until normal temperature

is

reached.

ignition timing as specified.

4

Connect the tachometer

instructions and connect the

in

accordance with the maker's to the tapped hole in

5

If

1

limiter cap

a plastic travel

Is

not fitted to the mixture

control screw then preset the screw by gently screwing it into contact with its seat and then unscrewing it between 2 and 2Vi turns.

6 Start the engine and adjust the throttle control screw until on manual gearbox cars the engine speed is 650 rev/min. (indicated on the tachometer). On cars with automatic transmission (selector in 'N') adjust the engine speed to 800 rev/min. 7 Now turn the mixture control screw either within the limits of the limiter cap (if one is fitted) or as necessary to obtain the maximum reading on the vacuum gauge. Re-adjust the throttle control screw if necessary, so that the engine resumes its specified idling speed.

15 Accelerator 1

pump

-

adjustment

The correct accelerator pump stroke

is

v\^en the center of

the pivot pin of the operating lever has a travel of 0.18

2

Where adjustment CA' - Fig. 3.8).

is

required, carefully

In.

bend the connecting

link

16 Carburetor 1

Remove

-

removal and installation

the air cleaner.

Disconnect the fuel inlet pipe from the carburetor. Disconnect the distributor vacuum pipe from the carburetor, also the automatic choke heater pipes and the throttle control

2 3

linkage.

Unscrew the carburetor flange securing from the inlet manifold.

4

bolts

and

lift

the unit

removal but always use new gaskets and check the slow-running adjustment after installation, as previously described in this Chapter. 6 On some models, a solenoid fuel cut-off valve is fitted to the carburetor and where this is fitted, the electrical lead to the valve will have to be disconnected before the carburetor can be removed.

5

Installation

17 Carburetor

is

a

(8R

reversal

engine

1

2

On

series

type)

-

dismantling

and

models carburetors, remove the reloader connecting and the connecting link. the reloader lever from the primary lever throttle

early

Remove

shaft.

3 Remove the accelerator pump lever screw, the lever and the connecting links for the accelerator pump and fast idle. 4 Remove the automatic choke connecting link and the flexible boot.

Exploded view of

BR

series engine

2

automatic choke cover

40

plate

3 automatic choke housing

type carburetor

valve connecting link throttle positioner adjusting

screw plug

4

connecting link

5

vacuum piston

40A 40B

6

pivot pin power piston stop spring power piston

41 42 43 44

power valve power jet

45

7

8 9 10 11

19

20

washer upper body

cam

accelerator accelerator

rod

follower

pump pump

rod spring connecting

fast idle

connecting link

21

fuel inlet needle valve

valve shaft

thermostatic valve

48 return spring 49 fast idle adjustinj

'O' ring

50

main body fuel union and

51 primary

throttle shaft

52 53

screw

filter

screen

22 float pivot pin 23 float 24 flexible boot 25 accelerator pump plunger 26 plunger spring 27 check ball retainer 28 check ball 29 fuel level gauge glass 29A 'O' ring 30 glass retainer 30A stop washer 31 stop

32 slow jet 33 pump discharge weight 34 check ball 35 primary main Jet 36 secondary main jet 37 throttle positioner diaphragm valve

38

fast idle

link

secondary venturi primary cover

39

gasket

fast idle sliding

46 high speed 47 arm

12 13 14 15 16 17 18

of

reassembly

link cover

Fig. 3.9

vacuum gauge

the inlet manifold.

throttle positioner lever throttle positioner

diaphragm

lever

spring fast idle

arm

throttle shaft link secondary throttle lever

54 55 return spring 56 throttle speed adjusting screw 57 spring 58 fast idle cam 59 spring 60 choke valve plate 61 reloader cover

62 reloader cover 63 choke lever 64 accelerator pump

lever

65 stop

lever spring high speed valve stop lever reloader lever 68 reloader connecting link 69 high speed valve 70 primary throttle valve shaft 71 primary throttle valve

66 67

72 73 74 75 76

throttle

body /flange

secondary throttle valve shaft secondary throttle valve mix ture adjusting screw spring

47

-32

(See page

46

for key)

48'

43-

41—LI

S^

ft

(See page

62

46

64

for key)

49

Fig.

3.10 Early model carburetor reloader link cover connecting link (2)

(1)

Fig. Fig.

3.12 Removing automatic choke connecting link boot (2) - 8R engine type

(1

Location of accelerator pump lever screw (3) lever (4) connecting link (5) and fast idle link (6) early 8R engine type

Fig. 3.11

pump

)

and

3.13 Removing throttle positioner diaphragm valve link (2) - 8R engine type

(1

and valve

flexible

It

Fig.

Fig. 3.14 Removing carburetor upper body

- 8R

engine type

3.15 Removing the Venturis (1) from an carburetor

8R

engine type

50 Removing the slow running jet engine type carburetor

Fig. 3.16.

8R

Fig. 3.17. Removing the check ball retainer - 8R engine type carburetor

Fig.

Fig.

3.18 Removing the power valve and main jets (plugs removed) float chamber of 8R engine type carburetor

from the

Fig.

3.20 Removing the high speed valve plate

— 8R

(2)

3.19 Removing the throttle shaft link (1) connecting arm secondary throttle shaft lever (3) primary throttle shaft and fast idle adjusting lever (5) from 8R engine type carburetor

lever (4)

engine type

carburetor

Fig.

m-i

3.22 Internal components of the automatic choke engine type carburetor

— 8R

Chapter 3/Carburation;

fuel,

51

exhaust and emission control systems

5 Remove the two screws which secure the throttle positioner diaphragm capsule and allow the diaphragm unit to drop. 6 Disconnect the throttle positioner diaphragm capsule connecting link and withdraw the unit. Remove the screws which secure the upper body to the main 7 carburetor body and remove the upper body upwards to avoid damaging the accelerator pump plunger or float. 8 Remove the stop seal, the accelerator pump plunger and spring.

Turn the main body upside down and catch the stop, the accelerator pump discharge weight and the ball. 10 If essential, the throttle positioner lever can be removed from the main body also the stop lever spring and the high speed valve

9

stop lever.

Unscrew the main body from the throttle body/flange. There two accessible from above and one from below. 1

are three securing screws,

reassemble the components using

35 Within

choke

automatic

the

screws and peening their

housing,

install

the

piston

connector to the choke shaft using the screw with the shouldered head. Do not forget to include the screw ockwasher or the screw may project enough to cause the choke valve plate to bind. Now insert the sliding rod, the fast idle cam follower I

and the flexible boot. 36 To the automatic choke housing, fit the plate, the gasket and the cover, making sure that as the cover is offered up, the end of the bi-metal spring engages on the choke shaft lever. Secure the cover with three screws and their spring washers so that the mark on the cover aligns with the center mark on the housing index. 37 Refit the fuel inlet union and filter to the upper body. 38 Turn the upper body upside down and install the power piston spring, power piston and its stop. 39 Fit the fuel inlet valve components, tightening the needle

Remove the primary (larger) and secondary (smaller) Venturis unscrewing their securing screws. Remove the slow-running jet. Extract the check ball retainer using a pair of long-nosed pliers and then eject the ball by turning the carburettor upside-

valve seat securely.

down. 15 Remove the power valve assembly from the bottom of the float chamber. Unscrew the power jet from the power valve. 16 Remove the fuel level gauge assembly from the carburetor body by unscrewing the two securing screws. 17 Remove the plugs which cover the primary and secondary main jets and then unscrew the main jets. 18 Remove the thermostatic valve (three screws) from the main

float

12 by 13 14

new

ends.

40

the

Fit

body

and

float

adjustment by

the float

If

pin.

Now

hang by

its

pivot

its

letting the float

inverted).

arm

is

check

the

own weight

float

(upper

of straight tab design, a gauge

body. Do not attempt to dismantle the valve. 19 Unscrew and remove the mixture control and throttle speed control screws and their springs. 20 Remove the throttle shaft link, the primary throttle shaft

in wide should just slide between the lowest point of the and the face of the upper body, no gasket being in position. Where the float arm is of curved tab design, a gauge 0.34 in wide should be used. A piece of flat steel strip can easily be made up into suitable gauges. Where the specified clearances are incorrect, bend the tab as required. 41 Now raise the float gently to the end of its stroke and measure the distance between the top of the fuel inlet needle valve plunger and the operating tab of the float arm. Where this exceeds 0.04 in bend the two right-angled tabs at the end of the float arm as necessary. 42 Fit the fuel level gauge assembly to the main body noting that the glass must be installed so that the dot is to the inside

arm, connecting arm and the fast idle adjusting lever. 21 Only if essential, detach the secondary throttle return spring

43

0.20

with the bubble to the outside. Fit

a

new

'O'

and remove the throttle lever from the shaft. 22 The primary, secondary and high speed butterfly valve plates

assembly. This valve

are better not disturbed unless the valve plates or shafts are worn. The valve plate securing screws are peened over and they

which might occur

have to be filed off before they can be unscrewed. 23 Remove the float pivot pin from the upper body and remove the float, at the same time extract the fuel inlet needle valve component parts. Remove the fuel inlet union and filter gauze.

venturi.

will

24 Remove the power piston stop and extract the power piston and spring. 25 Remove the automatic choke cover, gasket and plate. 26 From within the automatic choke housing, remove the fast idle cam follower, the sliding rod and the piston connector. 27 The choke valve, shaft and lever should only be removed if essential, as the valve plate securing screws are peened over and they will have to be filed flat before they can be unscrewed. 28 The vacuum piston and connector can be extracted from the automatic choke housing if required but the unloader tab will have to be bent slightly to facilitate their withdrawal. 29 If the automatic choke housing is removed from the carburetor upper body, retain the small '0' ring type seal from the connecting vacuum passage. 30 With the carburetor now completely dismantled, wash all components in clean fuel and inspect them for wear, damage or

ring is

seal

and then the thermostatic valve

designed to admit additional

that they cause fuel

44 45

Install

v\/hen

the high speed valve stop and spring.

Refit the primary and secondary

main

46

Refit the

power

valve

complete with povver

which

will

contain

all

the essential gaskets,

then discard the old items. 33 Commence reassembly by fitting the automatic choke housing to the carburetor upper body. Ensure that the vacuum connecting passage '0' ring seal is in position and that the lower

housing retaining screw is the longer one. 34 If the choke valve plate and shaft

were

dismantled.

plugs

Is

If the primary and secondary throttle butterfly valve plates have been dismantled, refit them to their shafts (thinner valve plate to the primary shaft). Do not peen the new valve plate

49

securing

screws

or

fit

the

throttle

shaft

circlips

centralizing shims have been fitted to provide perfect

of the valve plates within their bores.

until

the

movement

The thicker shim should be

on the throttle arm side. 50 Refit the mixture control screw and spring, screwing it in it is lightly seated and then unscrewing it 2Y2 turns for a

installed

basic setting pending final adjustment

kit

jet

washer

spring and the plunger.

Blow through jets and passages using a tyre pump. Never probe them with wire or their calibration will be ruined. It is worth checking the jet calibrations against those listed in Specificat'ons in case a previous owner has substituted any of incorrect size.

jet (a

not installed under the power valve). 47 Install the primary and secondary Venturis and gaskets. The secondary (smaller) venturi fits in the right-hand aperture and the primary (larger) venturi on the left-hand side when viewed from the float chamber end of the carburetor body. 48 Insert the accelerator pump check ball, ball retainer, plunger

until

them with ones of 32 Obtain a repair

and the

jets

and washers.

cracks.

31

air directly

overcome any rich mixture problems under-hood temperatures a^e so high to expand and overflow into the carburetor

to the inlet manifold to

when

the engine

is

started

up. 51

Refit the throttle linkage and springs.

52 Assemble the high speed valve plate and shaft in a similar manner to that described for the primary and secondary valve plates.

53 Check the clearance between the edge of the high speed valve plate and the carburettor bore. A gauge which is between 0.014 and 0.030 in diameter should be used for this. If adjustment is required, bend the tab on the arm of the high speed valve shaft. 54 Refit the reloader lever (early carburetors). 55 Install the main body to the throttle body flange using a new

52

(Zf Fig.

Fig.

3.23 Removing the vacuum piston from the automatic choke / housing — 8R engine type carburetor 2

3

3.24 Correct assembly of automatic choke components engine carburetor

shouldered screw

4

fast idle

cam

piston connector

5

flexible

boot

sliding

A

ARM OF GAUGE SHOULD

follower

rod

(Adjust tne raised position)

^rql

JUST TOUCH FLOAT. THE ^Z 5 MM ARM IS BEING USED (FOR FLOATS WITH STRAIGHT TABS)

GASKET NOT

Fig.

3.26 Float stroke adjustment dia^'am

— 8R

engine

carburetor

POSITION

IN

FOR FLOATS WITH CURVED TAB USE

9.3

MM ARM FLOAT LEVEL AND STRAIGHT TAB NEEDLE AND SEAT ASSEMBLIES ARE NOT INTERCHANGEABLE

NOTE: CURVED

Fig.

3.25 Float

level

— 8R

adjustment diagram

— 8R

engine carburetor

To

Fig.

carbureter flange

3.27 Sectional view of thermostatic valve engine carburetor

— 8R

53

Retaining Ring

Shim

Shim

Retainer Ring

Retainer

Rmg ;^^^«

"^

m

Shim

Retaining Ring

3.28 Throttle butterfly valve plate components engine carburetor

Fig,

Fig.

1

3.29 Throttle linkage components carburetor

4 5

secondary throttle lever

2 return spring 3 primary throttle

6

shaft

-

8R

— 8R

engine Fig.

3.30 Installing reloader connecting link carburetor

— 8R engine

fast idle lever

fasttdle screw throttle shaft link

POSITION CHOKE PLATE

WITH 51° GAUGE

©

GAUGE

IN

POSITION ON

PRIMARY THROTTLE VALVE

^^^ FULLY OPEN THROTTLE VALVES i

'

BEND LIP TO MAKE CONTACT WITH TAB

V

®

Fig. 3.31

BEND STOP TO OBTAIN FULL OPENING ANGLE OF 90O

Checking opening of primary throttle valve plate

8R

Fig.

3.32 Checking opening of secondary throttle valve plate

8R

-

FULLY OPENED AND ADJUSTED PRIMARY THROTTLE VALVE

engine carburetor

—

engine carburetor

GAUGE

IN

POSITION ON

SECONDARY THROTTLE VALVE

® Fig.

3.33 Checking unloader adjustment

- 8R

engine carburetor

BEND LINK AS REQUIRED TO OBTAIN FULL OPENING ANGLE OF 90°

54

©SET

BOTH THROTTLE VALVES AT CORRECT 90° FULL OPENING

ANGLE

\

\^

®

©COMPLETELY OPEN

POSITION STOP

PRIMARY THROTTLE VALVE

AGAINST CASTING WITH BOTH THROTTLE VALVES WIDE OPEN

® LOCKED

OUT SECONDARY THROTTLE VALVE CLEARANCE

® BEND STOP TAB IF NECESSARY

® OBTAIN CLEARANCE

(0.7 MM) BY BENDING THE LOCKOUT

LEVER TAB

Fig.

3.34 Checking secondary throttle stop adjustment

Fig.

— 8R

engine carburetor

3.35 Adjusting primary to secondary throttle lockout clearance — BR engine carburetor

CO POSITION

OPEN PRIMARY

CHOKE PLATE

WITH 20° GAUGE

THROTTLE VALVE ©UNTIL SECONDARY THROTTLE VALVE BEGINS TO OPEN BEND LINKAGE TO OBTAIN NECESSARY CLEARANCE

© ARM

BEND RELOADER LINK OBTAIN CLEARANCE

®T0

1@CLEARANCE SHOULD ,1

Fig. 3.36 Adjusting clearance between high speed valve plate lockout lever and secondary valve stop lever — BR engine carburetor

Fig. 3.37

APPROX

Checking reloader adjustment

1.5

TO

— 8R

3

BE

MM

engine

carburetor

©POSITION STOP (BEND AS REQUIRED)

ADJUSTING SCREW FOR REQUIRED CLEARANCE (0.03 TO 1.03 MM)

©SCREW

TIP SHOULD CENTERED RELATIVE TO SCRIBE MARK ON TAB

BE

CHOKEPLATE IN CLOSED POSITION

Fig.

3.39 Adjusting throttle positioner linkage on carburetor

3.38 Making initial setting of fast idle screw for primary throttle plate opening on 8R engine type carburetor Fig.

8R

engine

Chapter 3/Carburation;

fuel,

55

exhaust and emission control systems

gasket and making sure that it is fitted the correct way round and that it does not mask any drillings. 56 Fit the throttle positioner lever and the stop lever spring also the throttle positioner diaphragm capsule connecting link.

57 Refit the check ball, weight, stop and seal into the pump discharge cavity in the main body. 58 Install the upper body using a new gasket and secure the throttle positioner diaphragm capsule beneath two of the upper

body securing screvus. 59 Connect the throttle positioner link. 60 Install the flexible boot on the fast idle

sliding rod and fit the between the sliding rod and the fast idle adjusting lever. 61 Fit the 'U' shaped lever to the choke shaft and connect the reloader link between the lever on the choke shaft and the reloader lever. Ensure that the linkage rod washers are correctly link

Fig.

positioned.

62 On early models, install the reloader cover. 63 Reconnect the accelerator pump link to the primary shaft arm making sure to include the spring. 64

end into the upper body. 65 Connect the acclerator pump tuck

pump

the flexible boot over the

Install

throttle

plunger shaft and

the

pump

lever

to

the

lever to the plunger and then upper body by means of its

18 Carburetor i8R engine series type) and reassembly

-

adjustments and setting

after dismantling

1 Check that the primary throttle butterfly valve plate opens fully. If necessary, bend the stop to adjust. 2 Check that the secondary throttle butterfly valve plate also opens fully and if necessary, bend the link to achieve this. 3 Check and adjust the unloader if necessary by opening the primary and secondary throttle valve plates fully and checking that the choke valve plate is open through 51°. If adjustment is necessary, remove the automatic choke housing cover and bend the tab on the fast idle cam follower. 4 With both the primary and secondary valve plates fully open, check that the stop is against the carburetor body. If not, bend

the tab.

Open

the primary

Open

and check that 0.028 in. otherwise

throttle valve plate fully

the secondary valve plate to bore clearance

bend the lock out

is

lever tab.

throttle valve plate until the secondary At this stage there should be a clearance of 0.020 in between the lock out lever of the high speed valve plate shaft and the valve stop lever. 7 Open the choke valve plate through 20° when the clearance between the reloader lever and the secondary throttle shaft should be between 0.06 and 0.12 in. If necessary, bend the

6

the primary

throttle valve plate just begins to open.

reloader link.

choke valve plate when the primary throttle valve plate should be open by between 0.0012 and 0.0410 in. the idle screw in, or out, to obtain the specified Screw fast clearance measured between the edge of the valve plate and the

8

Fully close the

bore.

Check

the throttle positioner adjusting screw is in alignment with the mark on the primary shaft arm tab. Bend the tab if necessary to obtain the correct alignment. 10 Check the accelerator pump stroke adjustment and standard

9

that

setting of the automatic

choke

as described in

previous Sections

of this Chapter.

A

gauge for measuring the valve plate opening angles can

easily be

made from

a protractor

19 Carburetor (8R engine

and thin

series type)

bar.

final

adjustments after

installation

and run it to normal operating temperature. cleaner removed, open the throttle quicklv and

1

Start the engine

2

With the

air

4

6 7

8 9

shouldered pivot screw.

5

2 3 5

its

secure

/

3.40 Exploded view of 18R

- C

sliding rod fast idle cam follower

accelerator accelerator

pump pump

rod spring link

connecting link secondary throttle shaft diaphragm spring diaphragm lever secondary throttle valve plate

engine type carburettor

44 plug 45 gasket

46 47

filter

gauge

gasket

48 needle

49 50

valve

float

float pivot pin

51 power piston spring

52 power piston 53 power piston stop

10

spring

1

collar

12 13 14

secondary kick lever

54 power valve 55 power jet

fast idle adjusting lever

56 primary

fast idle ad/us ting

screw

spring

15 16 17 18 19 19

20 21

22 23

primary throttle lever primary throttle shaft arm fast idle adjusting screw primary throttle shaft primary valve plate primary throttle valve plate throttle body/flange thro ttle speed screw spring throttle speed screw mixture adjusting screw spring

24 mixture adjusting screw 25 choke shaft 26 fast idle cam 27 fast idle cam spring 28 choke valve plate 29 accelerator pump lever 30 throttle positioner adjusting screw

31

32 33 34 35 36 37 38 39 40

venturi

57 secondary venturi

58 gasket 59 gasket 60 accelerator 61 spring 62 check ball retainer

63

ball

64 gasket

65 66 67 68 69 70

stop

weight ball

slow jet main jet gasket secondary main jet

71 gasket 72 plug 73 primary main jet 74 diaphragm unit cover 75 gasket

76 spring 77 diaphragm 78 diaphragm housing

throttle positioner diaphragm valve throttle positioner link

80

return spring bracket

connector

81

seal

throttle positioner lever

82 cover 83 gasket

automatic choke cover gasket plate

automatic choke housing gasket

screw piston pin

41 piston connector 42 vacuum piston 43 upper body

79 washer

84 Thermostatic

valve

85 'O' ring 86 Gaslet 87 Fuel level gauge glass

88 Class retainer 89 IVIain body 90 Primary air bleed

56

®h7

(Key on page 55)

57

^f^: '^68

747576-

7778

(Key on page 55)

8^

58

Fig. 3.41

Solenoid-operated fuel cut-off valve fitted to some 18

Fig.

R-C engine type carburetors

Fig.

3.42 Checking adjustment of secondary throttle shaft kickarm on 18 R-C engine type carburetor

3.43 Checking the secondary contact angle on 18 R-C engine type carburetor

Throttle positioner

Fig.

Computer Relay

3.44 Layout of transmission controlled spark system (TCS)

Speed sensor

Vacuum

Fig.

3.45 Location of thermosensor used system

in

emission control

switching valve

Fig. 3.46 Position of distributor octane control (A) when TCS system is operational and (B) when TCS system is switched off

Chapter 3/Carburation; check that

pump

fuel

jet into

fuel,

exhaust and emission control systems

can be seen being sprayed from the accelerator

the primary (larger) venturi.

3 Have an assistant open the throttle fully by depressing the accelerator pedal to the limit of its travel and then check that the throttle valve plates are fully open.

Check that the choke valve plate is fully open at normal engine operating temperature. 5 With the engine idling, remove the vacuum hose from the

59

and the automatic choke setting in the same way as described in Section 18 for the 8R series unit, except that when carrying out the unloader adjustment, the choke valve plate should be open through 43°.

4

throttle positioner

vacuum 6 Run

pipe at the carburetor end. the engine at a speed of

throttle positioner

22 Carburetor (18R-C engine type)

screw so that

it

These are identical with those described

tab on the primary throttle shaft arm. Reconnect the hose to the throttle positioner diaphragm 7 The engine should now idle smoothly and the throttle

23 Emission control system 1

positioner adjusting screw should be held just above the tab by the vacuum action of the diaphragm capsule unit.

8

Finally, in

adjust the Section 14.

and mixture screws,

slow-running

20 Carburetor (18R-C engine type)

The carburetor

-

description

(a)

Evaporative emission control system (see Section 11, this Chapter) Transmission controlled spark system (TCS).

of

dismantling and reassembly

fitted to the

fitted to the

valve

Although

dismantling and reassembly described for the 8R series additional work will be required. 3 Remove the connecting link (5) from the 4 Disconnect the diaphragm plunger shaft lever (8) and detach the return spring (10).

2

Section 19.

Positive cranlccase ventilation (see Chapter 1)

(i)

as

18R-C engine differs from the 8R series engines by not having a high speed or reloader mechanism. A diaphragm unit actuates the secondary throttle valve and the primary and secondary throttle linkage is of different design on the 1 8R-C engine carburetor. one

in

The system used comprises three separate arrangements:

(Hi)

1

adjustments after

1400 rev/min and adjust the just makes contact with the

capsule.

described

final

-

installation

diaphragm capsule. Disconnect the distributor

operations

are similar unit

the

to the following

sliding rod (1

).

from the diaphragm

2 The transmission controlled spark system reduces emissions of oxides of nitrogen from the exhaust by controlling the distributor advance and retard characteristics very precisely according to engine temperature and vehicle speed. The

System includes computer, relay,

special

a

distributor,

a

throttle

TCS

positioner,

thermosensor and a vacuum

speed sensor,

svwtching valve.

3

The

emission

control

system

comprises

three

primary

circuits:

The throttle positioner

(i)

circuit,

which controls exhaust is designed to open the

emission during deceleration. This device

throttle valve plate very slightly vi/nen the accelerator pedal

is

5 Remove the diaphragm operating mechanism from the main body (89). Remove the gasket (81). 6 Dismantle the throttle operating mechanism by removing the

released, in order to increase the fuel/air supply to ensure complete combustion and to minimize the discharge of exhaust

four screws and lockwashers which secure the diaphragm housing cap (74) to the housing (78). Separate the gasket (75) diaphragm spring (76) and diaphragm (77). 7 Although the reassembly operations are almost identical with those for the 8R type carburetor, the following paragraphs

When the car is operating at medium and high speeds, the speed sensor causes the vacuum switching valve to be energized by the speed marker relay. The valve actuates and allows air to be introduced into the throttle positioner diaphragm. The throttle positioner is then retained in this position by the tension

describe the special procedure necessary v\^en refitting the secondary throttle diaphragm and external throttle linkage. 8 Locate the diaphragm in the diaphragm housing, center the spring in the diaphragm and position the gasket on the housing. 9 Fit the diaphragm housing cap, using three screws and lockvuashers and then locate the back spring stop under the fourth screw and lockvvasher. 10 Use a new seal (81) in the recess in the upper body. 11 Connect the diaphragm operating rod to the lever (8) of the secondary throttle shaft. 12 On some models of this carburetor, a solenoid operated fuel cut off valve is fitted to prevent engine run-on when the ignition is switched off.

of the return spring.

21 Carburetor (18R-C engine type) and reassembly

-

adjustments and setting

contaminants.

throttle

valve

plate

If is

the accelerator pedal

held slightly

mechanism instead of returning

is

now

released, the

open by the positioner

to the idling position.

When

the car speed enters the low speed range (11 to 14 vacuum switching valve to be de-energized and with the vacuum in the inlet manifold acting on the throttle positioner diaphragm, the positioner is released from the throttle valve plate which then returns to the normal

mph)

the speed sensor causes the

idling position. (a) The thermosensor circuit monitors the temperature of the engine coolant and if it is not within specified limits, the information is relayed to the computer and the TCS system will not be actuated. (Hi) The TCS circuit controls the ignition timing to ensure optimum combustion at low speeds. This is achieved by the use of a vacuum switching valve (which controls the distributor

through the diaphragm unit) and a speed sensor and marker. The

after dismantling

below 36 mph unless the a higher speed to one not less than mph, the TCS system is operational and the distributor is held at the static timing setting. At speeds over 36 mph, the TCS system is off and normal distributor distributor does not advance at speeds

Adjust the secondary throttle valve initial kick-up mechanism the following manner. 2 Hold the primary throttle butterfly valve plate in the fully 1

in

open position and measure the clearance between the edge of the secondary throttle valve plate and the bore. This should be between 0.004 and 0.012 in otherwise bend the double folded tab of the secondary throttle shaft kick arm. 3 Adjust the secondary contact angle. To do this, open the primary valve plate through 31° and observe whether the two linkage contact tabs are just touching.

If

not,

bend the outer tab

as necessary.

4

Check the unloader adjustment, the accelerator pump stroke

car has just decelerated 1 1

from

mph. At speeds below

advance characteristics are

1 1

in

operation.

24 Emission control components

-

maintenance and testing

1 No routine maintenance is specified beyond occasionally checking the security of the vacuum hoses and electrical leads. 2 It will be appreciated however that the correct setting and

60

Chapter 3/Carburation;

fuel,

exhaust and emission control systems

adjustment of the fuel system and the ignition system components, also the valve clearances are essential pre-requisites to an emission controlled engine. 3 The thermosensor is screwed into the side of the cylinder head. To test its operation, have the engine idling at normal operating temperature and then disconnect the lead. Increase the engine speed and observe whether the octane selector on the distributor moves inwards (ignition advanced). This test simulates the conditions when engine coolant temperature is below 140OF (60°C) and the TCS System is not operating. Now reconnect the lead to the thermosensor and repeat the operation, the octane selector on the distributor should move outwards (ignition retarded) to prove that the TCS system is operational at temperatures between 140OF (600C) and 203°F (950C). 4 To test the operation of the throttle positioner, raise the rear wheels of the car off the ground, chock the front wheels and have the engine idling at normal operating temperature. Engage 2nd gear or selector position '2' (automatic transmission). Now increase the engine speed past 25 mph but do not exceed 35 mph. Observe the throttle positioner which should engage. Release the throttle and the throttle positioner unit should delay the closure of the throttle valve until the speed drops to 1 1 mph. Shift the gearlever or speed selector lever to the neutral position

and the throttle positioner should disengage. 5 TCS system. A general check of the operation of the system may be carried out by again raising the rear wheels of the car and allowing the engine to idle at normal operating temperature. Now engage 2nd gear or selector position '2' (automatic transmission). Increase the engine speed past 35 mph and observe vi^ether the distributor octane selector moves inwards. Now decelerate and while the speed is above 35 mph, the octane selector should move outwards.

26 Emission control system

circuits

-

gauge, an

ohmmeter

25 mph but under 35 mph and observe lamp goes out at 25 mph. Decelerate and check that the lamp comes on at 11 mph. If the lamp does not work as indicated, then there is a fault in the speed marker relay or the sensor or both. To check these components, switch off the engine and rotate one of the rear roadwheels (gearshift in neutral and the opposite rear roadwiheel securely chocked or held stationary) in the forward direction of rotation, one complete revolution. Count the pulsations using the test lamp or ohmmeter. There should be either 4 to 6, evenly spaced pulsations according to the type of speedometer installed. If the pulsations are correct, renew the speed marker relay but if they are incorrect, renew the speedometer head. 8 Computer. With the engine running at normal operatiffg temperature, the rear v\^eels raised and 2nd. gear engaged or the speed selector in '2 (automatic transmission insert the test lamp probe into the vacuum svi/itching valve connector plug as shown. The test lamp should remain extinguished indicating that the computer is on. Slowly accelerate to over 35 mph when the test lamp should light up indicating that the computer is off. Now decelerate to below 14 mph and the test lamp should go out indicating that the computer is on. Where these tests do not prove positive, recheck the functioning of the speed marker relay and sensor. Where no fault can be detected in the latter components, renew the computer. Emission control system components are sealed units and cannot be repaired but only renewed complete. accelerate slowly to over

that the test

(

26 Accelerator pedal and linkage

testing

1 The following tests can only be carried out if you are in possession of a tachometer (or the car is equipped with one), a

vacuum

running at normal operating temperature and the rear roadwheels insert the test lamp probe mto the vacuum switching The lamp should illuminate and the throttle positioner should drop. With 2nd gear engaged, raised,

valve connector plug as shown.

The linkage is of rod and balljoint type. No maintenance is 1 normally necessary beyond occasionally applying a drop of oil to the balljoints.

and a test lamp.

event of a fault developing, in the system, first check that the engine oil, coolant and transmission oil levels are correct, also that the fan belt tension is as specified and the

2 With the accelerator pedal fully depressed, check that the carburettor throttle valve is fully open. 3 With the accelerator pedal released, check that the throttle

system is correctly timed and components properly maintained and set. The carburetor should be in perfect tune.

4

2

In the

ignition

Thermosensor. With the engine running at normal operating temperature, disconnect and reconnect the lead from the thermosensor terminal several times. With the hand resting on the vacuum switching valve, actuation of the valve will be felt. 4 If the valve does not actuate, disconnect the lead from the

3

thermosensor and

insert the test

lamp probe into the terminal of

vacuum switching valve connector plug. Withdraw the test lamp probe and re-insert it several times and feel whether the vacuum switching valve actuates and the test lamp lights up. If neither happens, renew the vacuum switching valve.

is back against its stop on the carburettor. Should either of the two preceding checks prove that the is incorrectly set, adjust it by means of the accelerator connecting rod. Release the locknuts and rotate the rod to

lever

linkage

increase or reduce

its

length as necessary.

27 Exhaust system and manifolds

the

5 Switch off the engine and disconnect the thermosensor lead. Use an ohmmeter to check the resistance of the thermosensor, this should be 2000 ohms at a coolant temperature of 178°F (81°C).

If

outside the specified resistance, drain

the cooling

system and renew the thermosensor. If the vacuum switching valve still does not actuate, then the computer (mounted below the instrument panel on the drivers' side) must be faulty and it should be renewed. 6 Throttle positioner. With the engine running at normal operating temperature, insert the probe of the test lamp into the vacuum switching valve connector plug as shown. The test lamp should illuminate and the throttle positioner itself will drop because the vacuum source has been sealed off. Pinch the vacuum purge line and the throttle positioner should lift. Where these two tests prove positive then it can be assumed that the vacuum switching valve (TCS and throttle positioner sections), the thermosensor, the throttle positioner, the distributor and the

computer (temperature circuit) are all functioning correctly. 7 Speed marker relay and speed sensor. With the engine

1

The exhaust system

is

supported on flexible mountings and

incorporates two main mufflers and an expansion box. 2 Regular examination of the exhaust pipe and mufflers

is

vrorthwhile as small defects may be repairable when if left without attention the components will almost certainly require renewal, probably as complete sections. Any leaks, apart from the noise factor, may allow poisonous gases to enter the car. 3 As the sleeve connections and clamps are usually very difficult to separate, it is usually quicker and easier to remove the complete system from the car before attempting to renew a section. It can be expensive if a good section is damaged when trying to separate a bad section from it. 4 To remove the system, lackup the car at the front and rear and disconnect the front downpipe from the exhaust manifold. 5 Disconnect all the flexible mountings and withdraw the complete system from below and to the rear of the car. 6 Cut away the bad sections, taking care not to damage

adjacent ones which are to be refitted. File off any burrs at the ends of th; new sections of pipe and 7 smear them with grease. Slip the clamps over the pipes and connect the sockets but do not tighten the clamps at this stage. 8 Push the complete system under the car and raise it so that

61

f2\YOU SHOULD FEEL THE V_yVACUUM SWITCHING VALVE ENERGIZE

PROBE

IN THIS

TERMINAL

CONNECT AND DISCONNECT SEVERAL TIMES

THIS LEAD

COMPUTER (PLUG CAN BE CONNECTED OR DISCONNECTED) THERMOSENSOR Fig.

VACUUM SWITCHING VALVE

3.47 Thermosensor test circuit No.

\ THERMOSENSOR

3.48 Thermosansor test circuit No. 2

OHMMETER RED PROBE TO TERMINAL

OHMMETER BLACK PROBE

GROUNDED

THERMO SENSOR WIRE

3.49 Thermosensor test circuit No. 3

TOP VIEW VSVPLUG

VSVPLUG TEST PROBE LIGHT Fig.

'^ VSVPLUG

1

Fig.

Fig.

,^-0

jT

-^

3.50 Throttle positioner test circuit

PURGE LINE

62

TOP VIEW VSV PLUG

'^

PROBE

IN THIS

TERMINAL

VACUUM SWITCHING VALVE

Fig. 3.51

Speed marker relay and speed sensor

test circuit

No.

1

REAR WHEEL Fig.

3.52 Speed marker relay and speed sensor test circuit No. 2

TOP VIEW VSV PLUG

VACUUM SWITCHING VALVE

Fig.

3.53 Computer test circuit

63

Chapter 3/Carburation; fuel, exhaust and emission control systems the fiont pipe can be bolted to the manifold and the rear tailpipe

mounting connected. 9 Now turn the mufflers that they

when

will

to obtain their correct attitudes so not touch or knock against any adjacent parts

the system

is

deflected to one side or the other.

10 Tighten all clamps and flexible mountings. 11 When removing or refitting the manifolds, always use new gaskets and do not tighten the inlet to exhaust manifold connecting bolts until the bolts which secure the assembly to the cylinder head have been fully tightened.

Fig.

3.54 Accelerator linkage components

2 3

pedal support bracket accelerator pedal support bearing

4

return spring

J

10

5 rod 6 adjuster rod

Fig.

1

2 3

heat insulator manifold gasket choke heater pipe (outlet)

4

5

7

rubber boot

8 bracket 9 throttle 1

link rod support bracket connecting rod

3.55 Inlet and exhaust manifold components

choke heater pipe inlet manifold

(inlet)

6 exhaust manifold 7

in ternal

choke heater pipe

8 9

gasket olive

10 union

64

Chapter 3/Carburation;

28 Fault diagnosis

-

fuel,

exhaust and emission control systems

Carburation; fuel and emission control systems

Symptom Fuel system and carburation Excessive fuel consumption (Carburation and ignition faults)

filter choked. Leakage from pump, carburetor, fuel

Air

Float

lines or fuel tank.

chamber flooding.

Distributor condenser faulty. Distributor weights or vacuum capsule faulty. Mixture too rich. Contact breaker gap too wide. Incorrect valve clearances.

Tyres under inflated. Dragging brakes. Insufficient fuel delivery or

weak mixture

Clogged

fuel line filter.

Fuel inlet needle valve clogged.

pump valves. pump diaphragm split.

Faulty fuel Fuel

Fuel pipe unions loose. Fuel

pump

cover leaking. manifold gasket or carburetor flange gasket leaking. Incorrect adjustment of carburetor. Inlet

Emission control system Crankcase ventilation Oil fume seepage from engine

Stuck or clogged

PCV

valve.

Split or collapsed hoses.

Fuel evaporative control Fuel odour

Choked carbon Stuck

Vapour

will

not be drawn into manifold

filler

canister.

cap valve.

Collapsed or split hoses. Vacuum switching valve defective.

Speed sensor defective.

Rough running engine

Defective check valve.

Transmission controlled spark (TCS) TCS off when engine cold and raced

Defective distributor

vacuum

capsule.

Defective thermo sensor. Defective

TCS on when

TCS

vacuum switching

valve.

Defective thermo sensor.

engine hot and raced

off at incorrect speed ranges with engine hot

Defective

vacuum switching

valve.

Defective

vacuum switching

valve.

Defective speed sensor.

Throttle delay

System

fails

to operate at

25

mph

during acceleration

Linkage requires adjustment. hose to diaphragm split.

Vacuum System

fails

to turn off at

1 1

mph

during deceleration

Defective diaphragm. Defective

vacuum switching

valve.

Defective speed sensor.

Note: The efficiency of the fume emission control system is also dependent upon the correct setting and adjustment of all other engine components. These include the ignition, cooling and lubrication systems, the valve clearances and the condition generally of the engine. Refer to the appropriate Sections and Chapters of this manual for servicing procedures.

Chapter 4 Ignition system Coil polarity

and

testing

...

...

...

...

Condenser (capacitor) removal, testing and refitting ... ... ... Contact breaker adjustment ... ... Contact breaker points removal and refitting -

-

-

... ... ...

...

Distributor (early type)

-

dismantling

...

...

...

...

Distributor (early type)

-

reassembly

...

...

...

...

Distributor

•

inspection and servicing ... ... ... - dismantling, inspection and re-

Distributor (late type)

...

12 4 2 3

8 10 9

assembly

...

removal and installation Dwell angle checking ... General description Ignition system - fault finding ... Ignition system fault symptoms Ignition timing checking and adjustment Spark plugs and HT leads Distributor

,

-

-

-

Specifications

System type

Battery, coil, distributor.

Firing order

1-3-4-2

Distributor Contact breaker points gap Dwell angle

0.016 to 0.020 in. 50 to 54° 0.20 to 0.24 microfarad

...

Condenser capacity

...

Static timing:

8R

10°

engine

8R-C engine: Up to March 1971

BTDC

at

600 rev/min

8R-C engine:

0° (TDC)

After (Vlarch 1971 and models with

TCS system

650 rev/min 10° BTDC at 650 rev/min at

18R-C engine: gearbox ... Auto. Transmission

7°

(Vlanual

Centrifugal advance

BR

engine

8R-C engine

18R-C engine: Manual

Auto, transmission

Vacuum advance 8R

engine

8R-C engine

in 'N'

BTDC

at

650

66

Chapter 4/lgnJtion system 18R-C ervgine: Manual gearbox

1200 2700 5200 1400 3400 5200

Auto, transmission

Spark plugs Type Gap Torque wrench setting Spark plugs

1

Begins 4.7 7.5

Begins

6 9

NGK BP6ES 14 mm 0.028 to 0.032 in. Ibf

ft

15

...

the movable contact breaker arm is on the 4 high points of the cam. Removal of the spark plugs will make turning the engine

General description

easier.

The ignition system comprises the following components: The battery which provides a current of 2.3 amps to the

when

the engine

The

coil

running.

is

ignition/starter switch.

The coil which acts as a transformer to step up the 12 volt battery voltage to many thousands of volts, sufficient to jump the spark plug gaps. The rotor

which comprises, contact breaker, condenser, cap with brush and centrifugal and retard mechanism and is driven by the oil

distributor

arm,

distributor

vacuum advance and

pump

Examine the contact faces of the (now open) points and if they are pitted or burned then they must be removed and dressed as described in the next Section. 5 If the points are in good order, check the gap by inserting a feeler gauge of between 0.016 and 0.020 in (0.4 and 0.5 mm) in thickness. Insert the feeler blade in a vertical position and if the gap is correct, it will just fall by its own weight. If the gap is incorrect, adjust the fixed contact arm by loosening the retaining 4

drive shaft at half crankshaft speed.

The spark plugs which are the medium to ignite the compressed mixture in the combustion chambers. Low and high tension wires connecting the various components. When the ignition is switched on a current flows from the battery live terminal to the ignition switch through the coil primary winding to the moving contact breaker inside the distributor cap and to earth when the contact breaker points are the closed position. During this period of points closure, the current flovire through the primary winding of the coil and in

screw

slightly

and moving

necessary,

as

it,

by

means of

a

screwdriver blade inserted in the cut-out in the contact arm. 6 When the gap is correct, tighten the contact arm screw, remove the feeler blade, replace the dust proof cov^r, rotor arm and distributor cap. Check that the ring spanner has besn removed from the crankshaft pulley bolt. Reconnect the HT leads.

3

Contact breaker points

-

removal and refitting

magnetises the laminated iron core which in turn creates a magnetic field through the oil primary and secondary windings. Each time the points open due to the rotation of the

Carry out operations 1 and 2 of the preceding section. 2 Detach the spring retaining clip from the top of the contact breaker arm pivot post. 3 Unscrew the nuts on the LT terminal on the outside of the distributor body just enough to enable the contact arm lead and

distributor cam, the current flow through the primary winding

spade terminal to be withdrawn, then

of the coil

is interrupted. This causes the induction of a very high voltage (25000 volts) in the coil secondary winding. This HT (high tension) current is distributed to the spark plugs in

correct firing order sequence by the rotor the cap brush and HT leads.

A condenser

fitted

is

the

to

arm and by means of and connected

setting of

the

ignition

advanced to meet varying operating conditions by the

ignition

timing as described

in

Section

6.

The

centrifugal counterweights fitted in the base of the distributor

body and by vacuum from the a capsule linked to the movable

inlet

manifold operating through

distributor baseplate.

Slight variations of the static ignition setting

means of the vernier adjuster

Remove

the securing screw and

arm from the baseplate. 5 Examine the points. After

a

lift

the movable

arm from

the fixed contact breaker

period of operation, one contact

compensate

may be made by for different fuel

This

is

a

normal condition which should be removed by dressing

the faces squarely on an oilstone.

6 Excessive pitting of the contact points may be caused by operation with an incorrect gap, the voltage regulator setting too high, faulty or wrong type of condenser loose distributor baseplate or battery terminal clamps.

Where contact breaker points are so badly worn or the pitting would be required to eliminate it, they they should be renewed. 8 Wipe the faces of the points with methylated spirit before installing, smear the high points of the cam with petroleum jelly. 9 Refit the rotor, cap and HT leads. 7

so deep that excessive rubbing

To improve

qualities.

electrodes

included

to

lift

the baseplate.

4

face should have a pip and the other a crater caused by arcing.

distributor

between the moving contact breaker and earth to prevent excessive arcing and pitting of the contact breaker points. The actual point of ignition of the fuel/air mixture which occurs a few degrees before TDC is determined by correct static is

1

in

the intensity of the spark at the spark plug^ high speed running, an external resistor is

during the ignition primary circuit.

4

Condenser (capacitor)

-

removal, testing, refitting

The condentnr ensures that with the contact breaker points open, the sparking between them is not excessive to cause severe pitting. The condenser is fitted in parallel and its failure will 1

2

Contact breaker

1

Pull off the

to

4

HT

adjustment leads

from the spark plugs and mark them

1

for easy refitting.

2 Spring back the distributor cover securing clips and lift the cover to one side. Withdraw the rotor and the dustproof cover. 3 Using a spanner on the crankshaft pulley securing bolt, rotate the engine in

its

normal direction of rotation

until the heel of

automatically cause failure of the ignition system as the points will be prevented from interrupting the low tension circuit. Testing for an unserviceable condenser may be effected by 2 switching on the ignition and separating the contact points by hand. If this action is accompanied by a blue flash then

condenser

failure

is

indicated. Difficult starting, missing of the

67 External resistor

Fig. 4.2

Adjusting the contact

fareaicer

points gap

Fig. 4.1 Ignition circuit

Timing Pointer

Fig. Fig.

4.4 The timing marks

4.3 Removing the contact breaker points 1

spring clip

2

movable arm

3

fixed contact

Front

Fig. 4.6 Distributor installation

Center

Lmege^.^g

diapam

3^^^,^^ ^^^^

Line Fig.

4.5 The distributor vernier adjuster

Fig.

Fig. 4.7 rf

4.8 Testing the centrifugal advance mechanism

Rotor arm in alignment with No. 1 spark plug contact cap after correct installation of distributor

in distributor

68

Chapter 4/lgnition system

engine after several miles running or badly pitted points are other indications of a faulty condenser.

3 Start the engine and set the slow running speed to 650 rev/ min preferably by using a tachometer.

3 The surest test is by substitution of a new unit. 4 To remove the condenser, unscrew its retaining screw and detach its lead from the LT terminal on the distributor body.

4

Refitting

is

a reversal of

Project the light from the stroboscope onto the timing cover pointer and pulley mark. Each flash of the stroboscope indicates that No.

cylinder has fired and

1

mark

pulley

removal.

if

the timing

appear to be stationary and

will

in

is

correct, the

alignment with

the pointer.

5

Distributor

-

Remove No.

5 Where the mark is not in alignment with the pointer, release the distributor clamp bolt and turn the distributor body until

removal and installation

spark plug and place a finger over the hole to feel the compression being generated as the engine is rotated by means of the crankshaft pulley bolt. 2 As soon as compression is felt this will indicate the No. 1 piston is rising on its compression stroke. Continue turning the engine until the timing mark (not TDC mark) on the crankshaft pulley is in line with the pointer on the timing cover. 3 Remove the distributor cap and mark the rim of the distributor body at a point opposite to the center line of the contact end of the rotor arm. This is equivalent to alignment 1

with No.

1

1

contact

in

the distributor cap.

4 Disconnect the LT wire from the terminal on the distributor body. 5 Disconnect the vacuum tube from the distributor advance diaphragm unit. 6 Unbolt the distributor clamp plate and withdraw the distributor from the recess in the crankcase. 7 The distributor cap may be withdrawn if the HT leads are first disconnected from the spark plugs and coil center socket. 8 If the engine is turned while the distributor is removed, reset the crankshaft pulley timing mark opposite the timing cover pointer (No. 1 piston on compression stroke) as described in paragraph one of this Section. 9 Turn the rotor arm so that its center-line is in alignment with the mark made on the distributor body rim before removal. If a new distributor is being fitted then mark the rim of the body after the rotor arm has been aligned with No. 1 contact in the distributor cap.

10 Set the octane selector so that its center graduation line is opposite to the setting mark on the diaphragm unit. 1 Hold the distributor over its recess in the crankcase so that a line drawn through the vacuum diaphragm unit makes an angle of

30° with

they do coincide. Tighten the clamp bolt. A useful check on the correct operation of the vacuum advance mechanism may be made by replacing the vacuum pipe to the distributor and still using the stroboscopic light as for checking the timing (just described), slowly increase the speed of the engine.

misalignment should increase in proportion to the increase in engine speed. This proves correct operation of the vacuum advance mechanism. No movement between the pulley mark and pointer indicates either a break in the vacuum pip>e or an unserviceable diaphragm unit. 6 Slight alterations to the ignition timing should be carried out by means of the octane selector. This may be required when fuels of different octane ratings are used. 7 To adjust, drive the vehicle at a steady road speed (in top manual gearbox or 'D' automatic transmission) at about gear 25 mph. Suddenly depress the accelerator pedal to the floor and -

sound of 'pinking' (pre-detoriation). If evident, cap from the octane selector and turn it in the direction only enough to prevent 'pinking' on retest. Where

listen

for the

remove the 'R'

plastic

is thought to be retarded or a fuel of higher being used, turn the octane selector in the 'A'

the ignition timing

octane rating

is

movement would cause the engine to 'pink'. Turning the octane selector through one graduation is equivalent to altering the ignition timing by 10 degrees. direction until any further

With the engine switched off, it is a good idea to check the operation of the centrifugal advance mechanism. To do this, remove the distributor cap and turn the rotor arm fully

8

clockwise. Release the rotor arm and ensure that the way to its original position. If it fails to

it

returns

do

so,

all

the

counterweights are sticking or the return springs are broken or stretched.

the center-line of the engine.

12 Using a screwdriver, turn the slot in the oil pump driveshaft (visible at the bottom of the distributor recess) so that it is in alignment with the torque on the bottom of the distributor

7

Dwell angle

1

On modern

driveshaft.

13 Holding the distributor the rotor

The timing mark on the pulley should now move out amount of

of alignment with the timing cover pointer and the

in

the predetermined position, turn

arm anticlockwise 30°.

14 Insert the distributor into the crankcase and as the gears mesh the rotor will rotate in a clockwise direction and become aligned with the mark made on the rim of the distributor body. The distributor should be pushed right down to fully engage the driveshaft tongue with the slot. The rotor will be opposite No. 1 spark plug contact in the distributor cap. 15 Rotate the distributor body until the contact breaker points are just about to open and then tighten the distributor clamp

-

checking engines, setting the distributor contact breaker

gap must be regarded as the initial setting. For optimum engine performance, the dwell angle must be checked. The dwell angle is the number of degrees through which the distrributor cam turns between the closing and opening of the contact breaker points. It can only be checked with a dwell meter. 2 The correct dwell angle is between 50 and 54 degrees. If the angle is too large, increase the points gap, if too small, decrease the points gap.

plate bolt, (photo)

16 Refit the distributor cap, connect the LT and the

vacuum

HT

leads

and

8

Distributor (early type)

1

Remove

pipe.

17 Check the timing with

a

stroboscope as described

in the

next

Section

Section.

2 3

6

Ignition timing

1

Check the

-

checking and adjustment

timing cover pointer and the timing notch on the pulley (not the notch) with white paint. The position of this slot will vary in accordance with engine type and static advance setting (see Specifications Section). 2 Disconnect the vacuum pipe from the distributor diaphragm

TDC

unit.

from

the engine, as described In

5.

Remove Remove

the distributor cap, rotor

arm and dust proof

cover.

the contact breaker assembly and the cap from the

vernier adjuster.

Remove

vacuum diaphragm

unit by withdrawing the and the circlip (3). Remove the distributor cap spring clips, the externally 5 mounted condenser and the LT terminal from the distributor body. 6 Remove the contact breaker mounting plate (movable) and

4 ignition timing using a stroboscope. First paint the

dismantling

the distributor

the

retaining screws

the

baseplate

distributor

(

1

and

(fixed)

2)

as an

body by screws.

assembly. This

Is

secured to the

DISTRIBUTO

DISTRIBUTOR SHAFT

PRIMARY TERM DISTRIBUTOR HOUSING

BREAKER PLATE

ASSEMBLY

GOVERNOR WEIGHT

CONDENSER

CONTACT POINT

REAKER ARM DISTRIBUTOR

CAM

ASSEMBLY Fig. 4.9

Construction details of early type distributor

«>3t^Y Fig.

?

2 4

20

16 body

counterweight spring counterweight counterweight spring

17 'O' ring seal 18 clamp plate 19 spiral gear 20 pin

5

shaft

6

steel thrust washer plastic washer

7

-19

4.10 Exploded view of early type distributor

cam

8 9

condenser

JO

cap spring

1

circlip

12 13 14 15

vacuum diaphragm

21 cap

22 carbon brush 23 rotor 24 dustproof cover

terminal insulator

25 contact breaker arms

clip

plastic cover rubber washer cap spring clip

unit

26 movable plate 27 baseplate 28 thrust washer 29 wave washer 30 circlip

70

Fig.

Fig.

4.12 Removing the contact breaker movable plate fron an early type distributor

Fig.

4.14 Removing the counterweight from an early type

4.11 Diaphragm unit retaining screw (1) ground lead (21 on early type distributor

and

circlip (3)

Fig.

4.13 Removing the cam securing screw from early type

distributor

distributor

BREAKER PLATE STATIONARY

7.1

PLATE

QO

Fig.

-

17.60Z 500gr)

(200

4.16 Movable plate turning force diagram (early type distributor)

Fig.

t

2 3

4.15 Exploded view of baseplate assembly on early type distributor

circlip

4

fixed baseplate

wave washer

5

movable plate

shims

Mm Fig.

4.17 Location of counterweights and springs on early type distributor 1 and 2 counterweights 3 and 4 springs

Fig.

4.18 Fitting the cap clips on an early type distributor

71

Chapter 4/lgnition system Unscrew and rennove the central cam screw and pull 7 cam from the top of the distributor shaft. Remove the mechanical advance counterweights and 8 Note carefully the positions of the two springs as they

off the springs.

are not

interchangeable.

9

out the rivetted end of the pin which secures the spiral gear/spacer to the bottom end of the distributor shaft. 10 Drive out the pin and withdraw the shaft upwards through Carefully

drill

the body, retaining any washers and shims.

9

Distributor

-

inspection and servicing

the

later type distributor, dismantling is very similar to the procedure described in Section 8, except that the cap securing clips are secured by internally located screws, the contact breaker assembly must not be dismantled and circlips are used to secure the counterweights. 2 Inspection of components for wear is similar to that described for the earlier type distributor except that if the force required to turn the movable baseplate exceeds 2.2 lbs when lubricated with engine oil, then the assembly must be renewed complete. 3 Reassembly is similar to the earlier type distributor but if

endfioat of the distributor shaft

wear between the shaft and body. If evident, it will to exchange the complete distributor for a reconditioned one rather than attempt to repair the old unit. Check the fit of the counterweights on their pivot posts. The 2 maximum clearance is 0.008 in. 3 Examine the distributor cap for cracks and for burned or eroded contacts. Check the carbon brush in the center of the cap interior. If it has worn to less than 0.28 in in length, renew it. 4 Separate the contact breaker swivel plate from the baseplate. Do this by removing the circlip and carefully detaching the small components. Do not lose the rolling balls. Renew any items which are worn or distorted. When the movable and fixed plate 1

Check

for

be more economical

them apart with the fingers. If the clearance in adjust by means of different thickness adjusting washers. A force of between 7.1 and 1 7.6 oz should be needed to turn the movable plate, using a spring balance. 5 Check the teeth on the spiral gear and renew the gear if it is worn or chipped. are assembled, prise is

greater than 0.008

10 Distributor

(early type)

-

Lubricate the shaft with clean engine oil locate the washers on the shaft (plastic between two steel ones) and then insert it into the distributor body. 2 Fit the spiral gear and insert the retaining pin but do not its

end

must be checked.

at this stage as the shaft endfioat

The correct endfioat

those available

new in

single thrust

outside that specified (0.006 washer must be selected from in, 0.106 in and 0.0114

is

thicknesses of 0.098

in.

The baseplate assembly is secured to the distributor body with clips. Note carefully the location of the distributor cap positioner and that the ground lead is secured under the cap clip screw nearest the LT terminal on the distributor body. 4

12 Coil polarity and testing 1

High

tension current should be negative at the spark plug HT current is positive at the spark plug LT leads to the coil primary terminals have

terminals.

If the terminals then the

been incorrectly connected. A wrong connection can cause as much as 60% loss of spark efficiency and can cause rough idling and misfiring at speed. 2 With a negative earth electrical system, the LT lead from the distributor connects with the negative (primary) terminal on the coil.

reassembly

1

peen

to 0.020 in), a

between 0.006 and 0.020 in tested with feeler gauges inserted between the spiral gear and the distributor body. Where the endfioat is outside that specified, add or remove the steel thrust washers as necessary. 3 When the correct endfioat is achieved, peen over the end of is

3 The simplest way to test a ohmmeter is available use it to

coil Is by substitution. If an carry out the following checks but first apply a 1 2 volt current to the coil to bring it to normal operating temperature. 4 Check the primary resistance between the coil (+) and (— terminals which should be between 3.3 and 4.3 ohms. 5 Check the secondary resistance (secondary to primary terminals) this should be between 7500 and 10000 ohms. 6 Insulation breakdown can only be satisfactorily tested using a megohmmeter between the coil casing and the primary terminal. The resistance should be in excess of 50 megohms.

the spiral gear securing pin.

4 fit

Apply engine oil to the counterweight pivot posts and then the counterweights and springs. Note particularly the position number of coils and the longer

13 Spark plugs and

HT

leads

of the spring with the shorter

hook. 5 Smear the distributor shaft with grease, fit the cam and secure with the central screw. 6 Refit the distributor cap spring clips. 7 Install the breaker plate assembly into the distributor body

making sure that the diaphragm actuating

link pivot

is

positioned

correctly to receive the link.

with the Fit the vacuum diaphragm engaging its baseplate pivot post and securing it with the circlip. 9 Fit the contact breaker assembly to the baseplate but do not link

8

tighten the securing screws at this stage.

the

adjust the contact breaker points, as described

standard are listed in the Specification page. 2 At intervals of 6000 miles, the plugs should be removed, examined, cleaned and if worn excessively, renevi/ed. The condition of the spark plug will also tell much about the overall condition of the engine. 3 If the insulator nose of the spark plug is clean and white, with no deposits, this is indicative of a v\«ak mixture, or too hot a plug. If the top and insulator nose is covered with hard black looking deposits, then this is indicative that the mixture is too rich. Should the plug be black and oily, then it is likely that the engine is fairly worn, as well as the mixture being too rich. 5 If the insulator nose is covered with light tan to greyish brown deposits, then the mixture is correct and it is likely that

4

diaphragm unit ground lead. The contact breaker lead and condenser lead should then be connected to the terminal on the distributor body. 11 Refit the distributor to the engine (Section 5) and then 10 Connect

The correct functioning of the spark plugs is vital for the proper running and efficiency of the engine. The plugs fitted as 1

in

Section

2.

12 Check the ignition timing, as described in Sections 6 and 7. 13 A smear of petroleum jelly should be applied to the high points of the cam when all adjustments are complete.

is in good condition. If there are any traces of long brown tapering stains on the outside of the white portion of the plug, then the plug will have to be renewed, as this shows that there is a faulty joint between

the engine

6

the

11 Distributor

(late

type)

dismantling,

inspection

and

reassembly 1

Although there are

detail differences in the

components of

plug

body and the

insulator,

and compression

is

being

allowed to leak away. 7 Plugs should be cleaned by a sand blasting machine, which will free them from carbon more thoroughly than cleaning by hand. The machine will also test the condition of the plugs under

72 ROTOR SPRING

-ROTOR CAP HOLD DOWN SPR

CONTACT

-VACUUM UNIT •

P

DAMPING SPRING

CONDENSER

BREAKER PLATE

GOVERNOR WEIGH

CONDENSER

CAP SPRING

HOLDER Fig.

4.19 Constructional details of

Fig.

4.20 Exploded view of

later

later

type distributor

type distributor

LT terminal assembly

7

8 rubber washer 9

pin

15

4

condenser cap clip counterweight spring

13 steel thrust washer 14 shaft assembly

10

5

circlip

11

spiral gear 'O' ring seal distributor body

16 diaphragm unit 17 baseplate assembly 18 contact breaker assembly

1

2 3

6 counterweight

12

vernier control cap

VERNIER PLASTIC CAP

cam

19 ground lead distributor cap positioner

20

21 dustprooi cover

22 rotor arm 23 carbon brush 24 cap

Measuring plug gap. A

feeler gauge of the correct size (see system specifications) sfiouid fiave a slight 'drag' when between the electrodes. Adjust gap if necessary

ignition slid

Normal. Grey-brown deposits, lightly coated core nose. Gap increasing by around 0.001 in (0.025 mm) per 1000 miles 1 600 km). Plugs ideally suited to engine, and engine in good (

condition

Adjusting plug gap. The plug gap is adjusted by bending the earth electrode inwards, or outwards, as necessary until the correct clearance is obtained. Note the use of the correct tool

Carbon fouling. Dry, black, sooty deposits. Will cause weak spark and eventually misfire. Fault: over-rich fuel mixture. Check: carburettor mixture settings, float level and jet sizes; choke operation and cleanliness of air filter. Plugs can be reused after cleaning

Oil fouling. Wet, oily deposits. Will cause weak spark and eventually misfire. Fault: worn bores/piston rings or valve guides; sometimes occurs (temporarily) during running-in period. Plugs can be re-used after thorough cleaning

Overheating. Electrodes have glazed appearance, core nose very white - few deposits. Fault: plug overheating. Check: plug value, ignition timing, fuel octane rating (too low) and fuel mixture (too weak). Discard plugs and cure fault immediately

Electrode damage. Electrodes burned away; core nose has burned, glazed appearance. Fault: pre-ignition. Check: as for 'Overheating' but may be more severe. Discard plugs and remedy fault before piston or valve damage occurs

Split core nose (may appear initially as a cracl DIMMER SWITCH \

'

Fig.

12.21 Instrument panel and controls (ST

-

automatic transmission)

Chapter 12/Bodywork and

180

three position switch. During normal forward motion of the car, is forced into the air mtake and passes through the heater matrix absorbing heat and then carrying it to the car interior.

air

22 Heater 1

1 Disconnect the control cables from the arms on the heater body and after removing the control lever assembly mounting screws, withdraw the assembly leaving the panel in posiiton.

Defroster nozzles 12 These can be removed, after first withdrawing the housing or the glove compartment, according to which

removal and installation

An advantage

fittings

of the heater installation

is

that in the event of

fault occurring, individual components can be without having to withdraw the complete assembly.

a

removed

Heater motor

cluster

tide

Is

being given attention. 13 Malfunction of the heater may be due to one or more various factors. These include a blockage in the heater hoses or matrix, incorrectly adjusted or connected controls, faulty booiter motor, air in the heater system or a faulty thermostat in the

2

Disconnect the defroster hoses from the heater body and then disconnect the electrical leads to the motor. 3 Unscrew and remove the mounting bolts from the motor flange and withdraw the motor from the heater body.

engine cooling system. 14 In the event of the heater matrix being blocked, then it should be inverted and reverse flushed with a cold water hose. Where this procedure does not clear it then an exchange unit should be obtained. Do not use checmical cleaners in the heater

Heater body and matrix

matrix

4

perforated.

use.

15 Installation

Drain the cooling system, retaining the coolant for further Remove the gearshift (or speed selector) lever knob. 5 Remove the center console and peel back the carpet. 6 Remove the ashtray/ventilator louver assembly. If a clock is fitted, disconnect the leads before the louver is withdrawn very far. If

an

air

conditioning control is fitted, the control lever knob off before the louver assembly can be withdrawn

must be pulled at

or

the fine cooling tubes

is

will

either clog or

a reversal of removal but

become

check the setting of

the control cables by observing the operation of the air control flaps

when

the control levers are

moved between

the limits of

their travel.

16

Refill the

lever

on

cooling system with the heater temperture control

'HI'.

all.

7 Disconnect the defroster hoses from the heater body also the coolant hoses, electrical leads and heater controls. 8 Unscrew and remove the mounting bolts and withdraw the heater body towards the right (facing the front of the car).

Control panel 9 Remove the ashtray/ventilator louvre assembly from above the front part of the center console.

10

Pull off the control lever knobs after removing their small securing grub screws.

23 Air conditioning system description and maintenance -

1 This optionally specified system comprises a heating and cooling unit, a belt driven compressor, a condenser and a receiver together with the necessary temperature controls and stabilizers. 2 The oil filled compressor is drivien by belt from the

crankshaft pulley and incorporates a magnetic type clutch. 3 The air conditioning control is mounted above the ashtray on the center ventilation louvre panel. 4 A layout of the air conditioning system is shown from the

as RtCflVER Fig.

12.22 Air conditioning system, circuit and layout

Chapter

1

2/Bodywork and

181

fittings

point of view of interest but servicing

home mechanic

as

special

is

equipment

beyond the scope of the is needed to purge or

recharge the system with refrigerant gas and dismantling of any part or component must not be undertaken without having first

discharged the system pressure. This

is

a job for the professional

refrigeration engineer.

5

COMPRESSOR

BOLT

f

his

(lOmm 25mm)

MOUNT

To maintain optimum performance the owner should limit operations to the following items. la) Checking the drivebelt tention. There should be a total deflexion of Vi in. at the midway point of the longest run

OLT (8mm 45mml

BOLT i8mm

BOLT

J

(bl

(10mm 25mml

Icj

Id)

COMPRESSOR LOWER STAY

IDLE

PULLEY le)

DLE PULLEY BRACKET

Fig.

12.23 Air conditioning system compressor mounting and idler pulley

BLOWER MOTOR ACTUATOR

of the belt. Where adjustment is required, release the locknut on the idler pulley adjuster bolt and screw the bolt in or out as required, Checking the security of all hoses and unions. Checking the security of the electrical connections. Removing and washing Iperiodically) the air filter screen which is located in the air inlet in front of the evaporator which is mounted below the instrument panel, Use a soft brush to remove accumulations of dust and dirt from the fins of the condenser which is mounted ahead of the radiator During the cold season, operate the air conditioner for a few minutes each week to lubricate the interior of the compressor which is normally disconnected by nonengagement of the magnetic clutch facia control in the 'OFF' position.

MICROSWITCH

COOLING UNIT BRACKET

Fig.

12.24 Location of interior

air

conditioning components including

air filter

screen

Chapter 13 Supplement Ignition timing (High Altitude) Distributor (mechanical contact breaker) -overhaul Spark plugs and HT leads

Engine General description Engine - operations possible when in car and method of removal Engine dismantling - cylinder head, rocker shafts and camshaft Engine dismantling - timing gears and chain ... Engine dismantling - pistons and connecting rods Engine dismantling - piston rings and piston pins Engine dismantling - crankshaft and main bearings ... Lubrication system, oil pump and filter Crankcase ventilation system ... Engine examination and renovation ... Engine reassembly - crankshaft and main bearings ... Engine reassembly - pistons, rings, connecting rods, oil pan and flywheel Engine reassembly timing gear, chain and cover Engine reassembly • cylinder head Valve lash - adjustment Engine -final assembly and installation

Igniter (semi-transistorized ignition) -description

and

testing

Fully transistorized ignition system -description

and precautions

...

Distributor (transistorized ignition) -maintenance

.

Distributor (transistorized ignition) -overhaul

Manual transmission General description

-

Automatic transmission General description

-

Rear axle General description Pinion oil seal - renewal

Braking system

Cooling system General description ... Cooling system - draining filling Cooling system ... Water pump and fluid coupling Drivebelts adjustment ...

Brake pedal -adjustment Pressure regulating valve

-

Electrical system

removal and refitting

Starter

-

Fuel system General description Air cleaner element - renewal ... Temperature controlled air cleaner -description and testing

...

pump

...

-

testing

...

Radios, tape player and speaker refitting

-

removal and

...

Heated rear window - precautions and repair Windshield wiper motor and linkage - removal and refitting

...

Wiper motor -overhaul Electro sensor panel

-

description

Suspension and steering General description

fault finding

Spark Control

and

•

and

-

Fuel contents sender unit

and

gear type) -description

Relays • location Clock regulation

removal and refitting - removal and refitting Fuel Evaporative Emission Control system ... Carburetor - idling adjustment Carburetor - fast idle adjustment Throttle Positioner System - checking and adjusting Carburetor - removal and refitting Carburetor - overhaul Emission control system - description Exhaust Gas Rprirculation (EGR) System description, maintenance and fault finding ... Air Injection (All System - description, maintenance Fuel

motor (reduction

... ... overhaul ... ... ... Fuses Water temperature transmitter and gauge Instruments - removal and refitting Steering column combination switch ... Bulbs - renewal ...

(SO System

fault finding

Auxiliary Acceleration

Pump

Manifolds and exhaust system

-

testing ...

Catalytic converter

-

description and precautions

Catalytic converter

-

checking, removal and refitting

Fuel system safety devices

-

Bodywork and fittings

description, maintenance

-

1976 on

...

15 16 17 18 19 20

General description Windshield glass - removal and refitting Ojarter window regulator and glass ... Rear door (lift bfick) - removal and refitting ... Front bumper (impact absorbing type) - removal and refitting

...

Rear bumper (impact absorbing type) Ignition system General description Distributor

-

refitting

Ignition timing (except High Altitude)

refitting

...

...

...

...

Heater • removal and refitting ... Air conditioning Remotely controlled external mirror

-

...

...

removal and

183

Chapter 13/Supplement

Introduction

This supplementary chapter covers models produced from 1974 Including those versions equipped with the larger capacity 1

20R type engine. 2 ST and GT hardtop two door coupe models the

lift

are featured, also

back two door.

3 The special equipment fitted to vehicles destined for operation In California is also included. 4 The information given in this chapter concerns changes in construction and design as applicable to these later models, all other details are as shown in the text of the original twelve chapters.

5 The specifications listed in this supplementary chapter are revised or additional to the original specifications given at the beginning of each of the chapters 1 to 12.

SPECIFICATIONS Engine General Bore and stroke

3.48 X 3.1 5 in (88.5 x 80.0 mm) 133.6 cu in (2189 cc) 8.4: 1 96 @ 4800 rev/min (90 BHP California) 120 lb/ft @ 2800 rev/min (16.6 kg/m) 1 -3 -4 -2

...

Total piston displacement

Compression

ratio

Maximum BHP Maximum torque

...

Firing order

Cylinder head Material

Aluminium

...

Maximum

permissible warpage

0.006

in

(0.15

mm)

Cylinder block Material

Cast-iron

...

Maximum

permissible warpage

Bore

Maximum Maximum Maximum

permissible cylinder bore wear permissible bore difference between cylinders permissible taper or out of round

Pistons and rings Standard piston diameter Oversize 0.50

3.4827 to 3.4839 3.5024 to 3.5035 3.5220 to 3.5232 0.8663 to 0.8669 0.8661 to 0.8667 0.004 to 0.012 in

Oversize 1.00 Piston pin diameter Piston pin bore

in

piston

end gap

Piston ring

0.002 in (0.05 mm) 3.482 to 3.4854 in (88.5 to 88.53 0.008 in (0.2 mm) 0.002 in (0.05 mm) 0.0008 in (0.02 mm)

mm)

in

(88.46 to 88.49 mm) (88.96 to 8839 mm) (89.46 to 89.49 mm) (22.004 to 22.019 mm)

in

(22.00 to 22.015

in in

in

(0.1 to 0.3

mm)

mm)

Piston ring to groove clearance

Compression rings

0.008

...

Oil control ring

in (0.2

mm)

zero (spring type) to 0.0020 in (0.03 to 0.05

mm)

Length (between centres) Big-end bore Standard endf loat

5.441 to 5.445 in (138.20 to 138.30 2.2047 to 2.2057 in (56.0 to 56.024 0.006 to 0.010 in (0.16 to 0.26 mm)

mm) mm)

Maximum

0.012 in (0.3 mm) 0.8666 to 0.8672 in (22.012 to 22.027 mm) 0.0002 to 0.0004 in (0.005 to 0,01 1 mm) 0.0006 in (0.015 mm) 0.0010 to 0.0021 in (0.025 to 0.055 mm) 0.003 in (0.08 mm)

Piston to cylinder wall clearance

0.0012

in

Connecting rods

endfloat

Small end bush internal diameter (after reaming) Piston pin to small end bush running clearance Maximum piston pin to small end bush running clearance Big-end bearing running clearance Maximum permissible big-end running clearance

Crankshaft No. of main bearings

...

...

Endfloat

0.0008 to 0.008

Maximum Maximum

permissible endfloat out-of -round or taper for journals and crankpins Crankshaft journal and crankpin running clearance ...

0.12 in (0.3

Maximum

0.003

journal or crankpin running clearance Crankpin journal finished diameter Standard bearing ... Undersize ... ... ...

in

(0.02 to 0.20

mm)

mm)

0.0004 in (0.01 mm) 0.0010 to 0.0022 in (0.025 to 0.055 in (0.08

mm)

mm)

2.3613 to 2.3622 2.3504 to 2.3508

in in

(59.976 to 60.000 (59.701 to 59.71 1

Flywheel

Maximum

permissible run-out

...

0.008

in (0.2

mm)

Camshaft Standard endfloat

Maximum

...

permissible endfloat

Bearing running clearance

0.0031 to 0.0071 in (0.08 to 0.18 0.010 in (0.25 mm) 0.0004 to 0.0020 in (0.01 to 0.05

mm) mm)

mm) mm)

184

Chapter 13/Supplement

Maximum bearing Cam lift (inlet) Cam lift (exhaust)

running clearance

Camshaft journal finished diameter

Maximum

-

...

Standard bearing

journal out-of-round or taper

0.004 in (0.1 mm) 1 .6783 to 1 .6819 in (42.63 to 42.72 1 .6806 to 1 .6841 in (42.69 to 42.78 1 .2984 to 1 .2990 in (32.98 to 33.00 0.008 in (0.2 mm)

mm) mm) mm)

Valves Head diameter inlet

1.608 to 1.620 1.411 to 1.423

...

exhaust

in in

(4055 (35B5

to 36.15

mm) mm)

to 41 .15

Overall length inlet

exhaust Valve stem diameter inlet

...

...

...

...

in

4.46

in

(115.0 (113.4

mm) mm)

0.3138 to 0.3144 0.3136 to 0.3142

...

exhaust Standard stem to guide clearance

0.0006 to 0.0024 0.0012 to 0.0026

inlet

exhaust Maximum stem to guide clearance inlet

452

0.003 0.004

...

exhaust Valve head contact angle Valve lash (Hot)

in

(0.08

in

(0.10

in

(757

to 7.99 to 7.98

mm) mm)

in

(0.02 to 0.06

mm) mm)

in (7.97

in (0.03 to

0.07

mm) mm)

45° 0.008 0.012

inlet

exhaust

in (0.2

in (0.3

mm) mm)

Valve guide overall length inlet

...

...

...

...

...

exhaust Valve guide inner diameter (after reaming) Valve guide outer diameter Standard Oversize 0.05 Valve guide projection ... Valve spring free length Valve rocker shaft outside diameter ... Rocker arm bush running clearance ... Maximum permissible running clearance

Engine oil capacity With filter Without filter

Torque wrench

-

engine

Thermostatic valve bolt Inlet manifold bolts valve

Exhaust manifold bolts Cylinder head/rocker bolts (Stage (Stage 2)

(49.5 to 55.5

(58.5 to 59.5 in (8.01 to 8.03 in

mm) mm) mm)

1.787

in

(45.4

mm)

US US

qts

(45

litres)

qts (3.7 litres)

Ibf ft

Nm

15 15 15

21

21

21

11

15

35 25 40 64

48

11

35 55 88 15

Distributor drive gear bolt

65

90

Rocker cover bolts Exhaust pipe flange nuts Timing cover bolts

11

15

32

44

1

)

...

(Stage 3)

Front chain cover bolts

Crankshaft pulley bolt Oil

pan bolts

...

...

...

...

...

Big-end bearing bolts Main bearing bolts

Flywheel bolts

15

11

...

...

Bellhousing to cylinder block bolts Driveplate to torque converter bolts

...

94 9 47 80 68 50

131

12 65 111

94

32

Cooling system Radiator cap pressure rating

Thermostat opens Fully

open

Fluid capacity

US Ib/in2

(05 kg/cm2)

179.6°F (82°C)

203°F (95"C) 8.5 qts (8

litres)

Fuel system Fuel Type

pump

Discharge volume

mm) mm)

1.6287 to 1.6295 in (15.97 to 1559 mm) 0.0004 to 0.0020 in (0.01 to 0.05 mm) 0.003 in (0.08 mm)

3.9

settings

in

0.5521 to 0.5528 in (14.023 to 14.041 0.5541 to 0.5548 in (14.073 to 14.091 0.63 in (16.0 mm)

4.8

Camshaft bearing cap bolt

EGR

...

1 .949 to 2.185 2.303 to 2.343 0.315 to 0.316

Electrically In

excess of

-operated 1 .3 qt/min

185

Chapter 13/Supplement

Discharge pressure Fuel tank capacity

...

...

...

...

...

2.1 to 4.3 Ib/in^ litres)

diameter speed

Manual gearbox Automatic transmission

0.0476 0.0697

settings

manifold bolts

EGR

valve

Exhaust manifold bolts Exhaust pipe flange nuts Carburetor flange nuts

...

(1.21

in

(1.77

800 rev/min in 'N'

...

Inlet

in

-

mm) mm)

0.0201 in (0.51 mm) 0.020 in (0.5 mm) 0.020 in (0.5 mm)

Pump jet

Fast idle speed

...

Dual barrel, downdraught

Primary main jet diameter Secondary main jet diameter Primary slow jet diameter Power jet diameter ...

Torque wrench

...

15.3 gallons (58

Carburetor Type

Idling

...

fuel system

and emission control system

186

Chapter 13/Supplement

Propeller shaft Universal joint Bearing cup circlip thickness availabi

0.0945 0.0965 0.0984 0.1004

lity

in

(2.40

in

(2.45

in

(250 (255

in

mm) mm) mm) mm)

Rear axle Ratio

3.727

Oil capacity

1.3 qt (1.2 litres)

Electrical system Starter motor (reduction gear type) Rotational speed (no load) Minimum brush length (wear limit)

0.39

1

:

More than 3500 rev/min (10.0

in

mm)

-1975

Fuses

Fuses cover marking Tail meter PL

Circuit protected

Horn stop

Ignition key buzzer, stop lights, horns, hazard

room

Instrument panel

lights,

glove box, parking, side marker,

warning

tail

and licence plate

Fuse rating (A) 15

lights

lights

20

Cigar lighter, clock, air conditioner, interior and courtesy lights

20

Radio

Radio and stereo tape player

15

Heater gauge

Back-up, brake warning instruments

Turn gen.

Alternator regulator, turn signal lights

15

Ignition coil

Ignition coil positive terminal

15

Wiper

Windshield wiper and washer

IS

Lighter,

Fuses

-

lights, heater, air

conditioner blower, heater rear window,

20

1976 onwards

Tail

Front parking, side marker,

Stop

Stop, hazard warning lights, horn ignition key buzzer

Lighter

Cigar lighter, clock, interior, door courtesy, and luggage

Heater

Heater, air conditioner blower motor, seat belt warning light and buzzer .light

Back-up

lights.

tail,

instrument panel

15

lights

20 compartment

15

lights

20

Instruments

window

Defog

Heated rear

Turn

Turn

signal lights.

Engine

Main

relay. Voltage regulator Ignition terminal

Radio

Radio and tape player

15

Windshield wiper and washer

15

15 15

Bulbs Headlights (inner sealed beam)

beam) ... Luggage compartment (liftback) (outer sealed

Wattage

Number

37.5 37.5/50 5

4002

4001

12V/3CP

Suspension and steering Front suspension Coil spring free length

...

Color

14.80 Green

in

mm)

(376.0

Front end alignment Except

Camber Castor

GT

0°20'to 1°20' 1° 20' to 2° 20'

8°

Steering axis inclination

7 to

Toe

0.04 to 0.12

In

GT

0°30'to 1°30' 1° 15' to 2° 15"

7° 10' in

1

Full steering lock turning angles Inside

wheel

Outside wheel

36° 10' to 38° 28° 15'toa2°

-0' 15'

.0

to

to 3.0

8°

10'

mm

Chapter

1

Wheels ST and GT Hardtop Lift

187

3/Supplement

5'/2j

X 14

5J X 14

back

Tires Size

175 SR 14 185/70 HR 14 185/70 SR 14 165 SR 14

ST

GT

Pressures (front *

For speeds

and

rear)

in excess

Torque wrench

of 75

mph

24 Ib/in^ (1.7 kg/cm^) (120 km/h) increase pressures by 4 Ib/in^ (0.3 l'ti5

Fig. 13.32.

Camshaft sprocket engaged with timing chain

Fig.

1

Fig. 13.33. Installing oil

3.34. Timing gears and chain

Distributor drivegear

6

Crankshaft pulley

7

Oil pump drivegear

8

4

Camshaft sproclg spring (3) slow jet 14) and power valve (5)

Fig. 13.69.

pump

Automatic choke

Chapter

6

Remove

1

the fuel inlet needle valve, spring, plunger and seat.

pump plunger and then unscrew the power piston remove the power piston and spring. 8 Extract the three securing screws and withdraw the automatic choke housing cover, plate and gasket. 9 Remove the (now exposed) choke lever and then extract the three body screws and remove the choke housing. 10 Remove the choke breaker, relief lever and link. 11 Do not remove the choke valve plate or spindle unless absolutely essential in which case the ends of the peened valve plate screws will have to be filed off before they can be 7

Extract the

207

3/Supplement

9

"

retainer and

unscrewed. 12 Extract

the

xrews

securing

venturi

and withdraw the

Venturis.

13 14 1 5 16 17

Remove Remove Remove Remove Remove

valve

the the

pump jet, the 'O' ring, pump damping spring,

the slow jet arxJ

power

spring and ball. retainer and ball. Fig. 13.70. Location of plugs (1) and main jets (2) static valve cover (3)

valve.

the jet plugs and the main

jets.

and thermo-

the cover from the thermostatic valve, extract the

and the

'O'

The thermostatic

ring.

must not be

valve

dismantled.

18 If required, the sight glass and the throttle positioner assembly can be removed from the carburetor body. 19 Remove the auxiliary acceleration pump inlet plug and ball. Remove the outlet plug, spring and ball.

20 Remove the

pump

auxiliary acceleration

housing, the dia-

phragm, spring and gasket 21

Remove

the

return spring and link so that the secondary

throttle valve actuating

diaphragm assembly and

'0' ring

can be

withdrawn.

22 Remove the fuel cut off solenoid valve and the fast idle cam. 23 Extract the three securing screws and separate the carburetor body, insulator and flange. The flange should not be dismantled unless absolutely essential as the throttle valve plates are again secured with peened screws. 24 Clean and inspect all parts for wear or damage. Clean out the jets with compressed air but never prolae them with wire, and then compare their markings with those listed In the Specifi-

Fig. 13.71. Location of auxiliary acceleration (1), outlet plug (2)

and housing

pump

Inlet plug

(3)

cations in case a previous owner has substituted any for ones of Incorrect size. Inspect the diaphragm for splits or perforation.

25 Obtain

a

repair

kit

which

will

contain

all

the necessary

gaskets, seals and other renewable items.

26 Reassembly

out

by

the

dismantling operations but observe the following essential points of detail also the adjustments. is

carried

reversing

27 Make sure that the choke housing engages with

its

locating

pin.

28 Align the choke bi-metal spring so that it engages with the lever as the housing cover is installed. Set the housing cover line, the plate notch and the housing line all in alignment before tightening the cover screws. Fig. 13.72. 7

Secondary throttle valve actuating diaphragm connections 4 Solenoid fuel cut-off valve

Spring

2 Link 3 Diaphragm

Fig. 13.73.

Choke housing

5

Fast idle

cam

locating pin

Fig. 13.74.

Engaging choke bl-metal spring with lever

208

Fig. 13.76. Float

Fig. 13.75. /

adjustrrrant tab

A

Choke housing alignment marks 2

Center line

arm

Plate notch

3

Housing mark Fig. 13.77. Float

Fig. 13.79. Accelerator

Fig. 13.78. Throttle valve stop levers (1)

Primary

EGR

Carburetor

(2)

arm adjustment tab B

pump stroke

adjustmerrt diagram

Secondary

valve

n Vacuum switching valve Fig. 13.81.

Removing cover from

EGR

warning cancel switch

Exhaust manifold Air

Fig. 13.80.

pump

The EGR system

Air by-pass valve

Fig. 13.82.

Air switching valve

EGR warning switch re-tet button Fig.

1333. Air

Exhaust manifold

Injection Syttan

209

Chapter 13/Supplement

29 Having reassembled the float, check do this, invert the air horn so that the inlet valve

by

surface of the

its

the float adjustment.

To

float depresses the fuel

own

air

weight. Measure the distance betvueen the horn (no gasket) and the nearest point of the

This should be 0.20 in (5.0 mm) otherwise bend the tab A of the float arm. (Fig. 13.76). 30 (Mow lift the float gently with one finger and measure the gap

float.

between the end of the fuel inlet valve and its contact point on the float. This should be 0.04 in (1.0 mm) otherwise bend tabs B on the float arm. (Fig. 13.77). 31 When installing the main jets, note that the primary jet is brass colored and the secondary jet is plated (chrome). 32 When reassembly is complete, open the primary and secondary throttle valve independently and check that the valve plates are at right angles to the flange mating surface

when they

are

if necessary by bending the stop levers. 33 Open the primary throttle valve plate fully and then check that the secondary throttle valve plate has opened slightly so

fully open. Adjust

mm

diameter) can be passed that a twist drill (0.008 in - 0.2 between the edge of the valve plate and the flange wall. Bend the secondary throttle lever if necessary to achieve this.

34 Close the choke valve plate with the fingers and check the clearance between the edge of the primary throttle valve plate and the bore. This should be 0.047 in (1.2 mm) measured with a twist drill of suitable diameter. Turn the fast idle screw if necessary.

35 Open the primary throttle valve plate fully and check that the angle of the choke valve plate is at 50° to the bore. Make up a template or use a protractor for this and adjust if necessary by bending the fast idle lever. 36 Push the choke opener rod fully

in

with the fingers and check

the angle of the choke valve plate. This should be at 55° from the bore otherwise bend the choke opener link rod. 37 Push in the choke breaker rod and check the angle of the

choke valve plate. This should be at 40° from the bore otherwise bend the relief lever. 38 Adjust the throttle positioner screw so that the gap between the edge of the primary throttle valve plate and the bore is: Manual gearbox Automatic transmission

39

If

0.024 0.020

in (0.6 in (0.5

mm) mm)

the idle mixture screw has been removed, refit

it

Finally check the accelerator

0.177

in (4.5

mm). Bend

pump

if

description,

This system recirculates a proportion of inert exhaust gas combustion chambers in order to reduce the combustion temperature. 2 This has the effect of reducing the volume of nitrogen oxide 1

into the

produced. 3 The system is controlled by sensors and a recirculation valve which actuate the flow of gases at pre-determined engine temperature levels and vehicle speed. 4 At the intervals specified in 'Routine Maintenance' at the beginning of this Chapter, remove the lid from the air cleaner and with the engine idling, connect the EGR valve directly to the inlet manifold using a length of vacuum hose. A bubbling noise should be heard from the carburetor. Disconnect the temporary hose from the inlet manifold when the bubbling noise should cease. If the test does not work out as described, renew the EGR valve.

5

Periodically inspect the security and the condition of the

vacuum hoses and

leads in the system. On cars built up until 1975 and equipped with the EGR system, a warning light is incorporated in the speedometer as a reminder that after a period of 25,000 miles the EGR system must be checked. Once this has been done, the light must be

6

re- set.

Normally the EGR warning light comes on when the ignition key is turned to 'START' to indicate that the system is functioning correctly and is out at all other times until the pre-set mileage has been covered when it will come on and stay 7

on, until re-set.

8 To reset the warning light and in consequence the maintenance interval, use a pin wrench to unscrew the cover securing screw from the warning cancel switch. 9 Withdraw the cover and push the switch button in the direction of the re-set arrow. Refit the cover.

14 Air Injection (Al) System

and

stroke which should be

the cranked part of the rod

-

-

description, maintenance and

fault finding

gently screw it in until it seats then unscrew it 1 % turns to give a position which will enable the engine to be started.

40

(EGR) System

13 Exhaust Gas Recirculation maintenance and fault finding

necessary

to adjust the stroke.

1

The system

utilizes a belt-driven air

compressor to

inject air

in close proximity to the exhaust ports to mix with the hot gases discharged from the combustion chambers to promote further burning of any remaining unburnt HC or CO.

2 The volume of air injected is dependent upon the engine temperature, speed and load and deceleration conditions. These are controlled by the various system valves.

12 Emission control system -description 1

In

later

addition to the devices described in Chapter 3, Section 23, are now equipped with the following additional

cars

3 At the specified intervals, check the tension of the air compressor drive belt (see Cooling section, this Chapter). 4 Check the security of all system hoses and connections. 5 Remove the lid from the air cleaner and with the engine idling, check with the finger that air is not being discharged from the by-pass hole in the air cleaner. 6 Disconnect the hose which

systems:

Exhaust Gas Recirculation (EGR) System. b) Air Injection (A I) System. c) Spark Control (SO System. a)

2 Essential components of the overall scheme to reduce the emission of exhaust fumes include semi or fully transistorized ignition systems, dealt with in an earlier Section of this Chapter, also the automatic temperature controlled air cleaner (Fuel Section of this Chapter) and the design of the carburetor with special reference to the following:

runs between the Vacuum Transmitting Valve and the Thermostatic Vacuum Switching Valve from the Thermostatic Valve end. Check that air is discharged from the by-pass hole within a period of from 25 to 40 seconds of disconnecting the hose. 7 Reconnect the hose, rev up the engine and abruptly release the throttle. Air should be felt being ejected from the by-pass hole.

8

With the engine

still

idling,

disconnect the hose from the Air

Automatic choke.

on the carburetor. Temporarily connect the hose to the inlet manifold and check to see if air is being discharged from the by-pass hole within a period not exceeding

Auxiliary accelerator pump. Choke opener (not 1975 models). Throttle positioner

two seconds from the time of disconnection of the hose. 9 Disconnect the hose from its temporary connection to the inlet manifold and check that no air is ejected from the by-pass

Injection control port

hole.

3 A catalytic converter is installed on operation in California or at high altitudes.

cars

destined

for

10 Reconnect

the

hose to

carburetor, refit the air cleaner

the lid

Air

Injection

port

on the

and switch off the engine.

210

Chapter 13/Supplement

11

If

one

any of the foregoing

of the valves

must be

tests

do not prove

satisfactory, then

faulty and should be renewed.

Al Control Port IS Spark Control ISC) System fault finding (previously

TCS

-

description, maintsnanca and

system)

The system delays the vacuum advance of the ignition timing 1 order to minimise the production of noxious gases. Under normal circumstances, advancing the Ignition increases engine output by causing more vigorous combustion, the penalty being that higher combustion temperatures are created. 2 The period during which the vacuum advance is delayed is controlled by the system valves according to engine temperature and load in order to avoid spoiling overall engine performance in

more than 3

Fig. 13.84.

Explanatory diagram for check of Air Injection

System vacuum transmitting valve

is

essential.

At the specified maintenance

intervals, start the engine and let it idle. Open the throttle several times in quick succession and watch to see that the vernier adjuster on the distributor moves. 4 Now connect no. 8 hose of the Thermostatic Vacuum Switching Valve directly to the distributor and repeat the engine revving when the vernier adjuster should not be seen to move. 5 Reconnect the hose to the Thermostatic Vacuum Switching Valve and switch off the engine. 6 If the foregoing tests do not prove satisfactory, attach a piece of tubing to the diaphragm unit of the distributor and suck the end of the tube with the mouth. If the vernier adjuster moves under these conditions then the diaphragm unit is satisfactory. Have your dealer check the Thermostatic Vacuum Switching 7 Valve and the Vacuum Switching Valve in that order to establish which component is at fault.

Choke Breaker

(Dark Blue) - M/T for Calif. (Yellow) - Others

Location of emission control system valves and connections (not High ahituda models) snitching valve TVSV Thermostatic vacuum AAP Auxiliary acceleration transmitting valve switching valve TP Throttle positioner Air switching valve VCV Vacuum control valve Fig. 13.85.

VSV VTV

ASV

Vacuum Vacuum

pump

Chapter

:!;

!!:

1

1

3/Supplement

211

212

Exhaust manifold components

Fig. 13.89. Fig. 13.U8. Inlet

manifold components 1

1

2

3 4 5

2

Coolant hose union Manifold Casket Gasket Cover plate

Al

Inner heat insulator

Exhaust manifold

3 Casket 4

5

Casket Outer heat insulator

SYSTEM

£ c

CO-

H,6 Air

Thermo Sensor

Pump

1

Warning Light Ignition Svuitch

1 Fig. 13.90. Catalytic converter

system

:

213

Chapter 13/Supplement

platinum or palladium to form a catalyst which, when hot exhaust gases pass through it, the HC and CO content is oxidised and converted into water and carbon dioxide. 2 An essential part of the system is the perfect functioning of the Air Injection (Al) System. 3 The following precautions must be observed where a car is equipped with a catalytic converter.

Thermo Sensor

Do

not allow a very low fuel level in the fuel tank but keep it well filled at all times. The maximum duration of engine idling must be kept to twenty minutes and fast idling to ten minutes when carrying out repairs or in traffic jams. c) Do not rely only on engine braking on long down grades. d) Never turn the ignition key off while the car is moving, el Use only unleaded fuel. a)

b)

A warning light is fitted to the instrument panel on cars equipped with a catalytic converter. The light should come on only while the engine starter motor is turning and go out as soon 4

Fig. 13.91. Catalytic converter

attachments

engine fires, 5 If the warning light comes on at another time, carry out the following procedure as the light will indicate that the catalytic converter is overheating. 6 Stop the car and allow the engine and exhaust system to cool. Do not park over long grass as the heat from the catalytic as the

converter

may

Once the

7

set

it

on

fire.

car has cooled

be prepared to stop again

down, proceed

in the

engine

may

at a slower speed

the warning light

if

comes

and

on.

downgrade or

a misfire condition

cause the warning light to

come on but under

Extended deceleration on

8

a

these circumstances the system should resume normal operation

once the engine throttle

is

open again or the

misfire has been

rectified.

19 Catalytic converter

-

checking, removal and refitting

pump

Fig. 13.92. Fuel

check valve (1976 on)

inspect the system electrical connections for security and check that the converter has not been dented by

Regularly

1

If any dents are found deeper than 0.8 in (20.0 then the converter must be renewed. Check the pipe connections. If any pellets can be heard rattling within the catalytic converter then the unit must be

flying stones.

mm) 2

renewed. 3 Make sure that damage to the exhaust system has not forced the catalytic converter closer to the car floor pan than it was originally installed.

The Thermo Sensor can only be removed after the catalytic converter has been withdrawn. 5 To remove the converter, unplug the electrical lead from the 4

thermo

Check

sensor.

Release the suspension rings, unbolt the ends of the catalytic

6

^

Valve

.

I

In

converter, push the rear section of the exhaust system towards

the rear of the car and pull

away the converter.

If the thermo sensor is to be removed, hold the converter upright with the sensor at the top so that as it is unbolted, the

Fig. 13.93. Carburettor

banjo union check valve (1976 on)

7

catalyst granules will not

New

8

fitting guide. it

spill

out.

converters are supplied complete with a plastic sensor

Do

not remove the guide but insert the sensor into

and use a new sealing gasket.

9

Refitting

is

a reversal of removal.

20 Fuel system safety devices

-

1976 on

order to prevent fuel spillage in the event of an accident in which the car turns over, three small modifications have been carried out to later cars. 2 A check valve is included in the relief valve of the fuel pump. When the pump is not operating, the valve is closed by a spring 1

and

In

fuel

is

automatically cut-off.

3 A second check valve is fitted into the banjo union of the carburetor which cuts off fuel coming in from the fuel tank. 4 The piping which runs from the fuel tank to the carbon

Fig. 13.94. Re-designed fuel evaporative control

(1976 on)

system piping

214 Starter

rel

Ignition Coil

Igniter

Batterv Fig. 13.95. Ignition circuit

Fig. 13.96.

BTDC mark

aligned with timing cover pointer

Fig. 13.98. Reluctor setting (fully transistorized distributor installed)

Fig. 13.99. Vacuum hose disconnection for checking ignition timing on cars with High Altitude Compensation System

215

Chapter 13/Supplement

of the fuel evaporative control system has been redesigned to prevent any leakage from the canister when it is not in its normal attitude.

canister

IGNITION SYSTEM

1

General description

1

The

Ignition

system circuit

is

as

shown and

includes an

igniter.

2

Distributor

•

2 When the timing has been checked and adjusted in accordance with the specified figures, unplug and reconnect the hose and still using the stroboscope, check that the timing is now at 13°BTDC. The point on the pulley will have to be estimated for this test as no 13° mark is made during manufacture. If it is still at 8° BTDC pinch the vacuum hose between the MAC valve and the 3 way connector when the timing should advance to 13°. If it does not, check for split hoses or faulty MAC valve.

installation

5

Distributor (mechanical contact breaker type)

1

The operations

but detail differences

from the 1

the

overhaul

are similar to those described in in

the

Chapter 4

components should be observed

illustrations.

Turn the crankshaft until no. 1 piston (nearest the front of engine) is rising on its compression stroke. This can be

ascertained by removing no.

1

spark plug, placing a finger over

the plug hole and feeling the compression being generated as the crankshaft is rotated. 2 Continue turning until the first notch (BTDC) on the

crankshaft pulley comes opposite to the line on the timing cover. Do not confuse the BTDC mark with the TDC mark.

Hold the distributor outside its recess so that the vernier is vertical and at the top. 4 Now turn the rotor arm so that its contact end is in alignment with the upper body /cap clip. 5 Push the distributor firmly into position and as the distributor drive gears mesh, the rotor will turn in an anti-clockwise direction to take up the attitude shown with the contact end of the rotor arm in alignment with no. 1 segment in

6

Spark plugs and

HT

leads

The arrangement of the spark plug leads and their sequence of connection should be noted from the illustration, particularly when new leads are being made up or fitted. 1

3

adjuster

the distributor cap.

6 are

7

Igniter (semi-transistorized ignition system)

description and

1

With

this

system, signals made by the opening and closing of

the contact breaker points actuate transistors inside the igniter which in turn 'make' and 'break' the primary current.

2

The arrangement improves engine

operation

Turn the distributor body until the contact breaker points just about to separate. With fully transistorized ignition, set

-

testing

and also prolongs the

life

starting

and low speed

of the contact breaker

points.

the reluctor to just begin to cut the lines of flux. Install the distributor

compound

clamp

plate

having

bolt

applied

some

jointing

to the threads.

7

Refit the distributor cap, the heads and

8

Check the timing

as described

in

vacuum

pipe.

Sections 3 or 4 which

follow.

3

Ignition

(except cars with High Altitude

timing

Compen-

sation System)

1

Make

sure that the dwell angle

necessary as described

2

Make

in

Chapter

sure that the engine

is

as specified

by adjusting

it if

4, Section 7.

at

is

normal operating temperature

and that the carburetor is adjusted to the specified idling speed. 3 Connect a stroboscope in accordance with the marker's instructions and paint the BTDC notch on the crankshaft pulley and the line on the timing cover with quick-drying white paint. 4 Start the engine and point the light from the stroboscope at the marks. Each flash of the stroboscope indicates that no. cylinder has fired and if the timing is correct, the BTDC notch on the pulley will appear stationary and in alignment with the line on the timing cover. 5 Where the mark is not in alignment, release the distributor clamp plate bolt and turn the distributor body until the marks do coincide. Retighten the clamp plate bolt. Where the movement of the distributor necessary to correct the timing is only very slight, this can be carried out by turning the vernier adjuster instead of releasing the clamp plate bolt. 6 Switch off the engine and disconnect the stroboscope. i

4

Ignition

timing

(cars

with

High

Altitude

Compensation

System) 1

The operations

are similar to those described in the preceding

vacuum hose which runs to the MAC valve must be disconnected from the inner section of the vacuum diaphragm and the open end of the hose plugged. Section, except that the

Fig. 13.100.

Views of distributor (mechanical contact breaker type)

216 Fig. 13.101.

Exploded view of distributor (mechanical contact breaker typel /

2 3

Grease plug

Cam Counterweight spring

4

E

5

Counterweight

6

Insulator

7

Rubber packing Cap clip

8

ring

9

Vernier cap

10

Body

11

'Oring

12 13 14 15 16 17

Gear Washer Spring

Washer Bearing

Washer

18 Shaft

19 Diaphragm unit 20 Cap 21 Rotor arm 22 Dustproof cover 23 Contact points cover 24 Contact breaker points 25 Baseplate 26 Damper spring

FRONT CYLINDER HEAD

^ VERNIER ADJUSTER ^,

J

\

I

DIAPHRAGM UNIT

Fig.

13.102. Spark plug lead connecting diagram

217

Chapter 13/Supplement 3 If all other components of the Ignition system have been checked and the system is still faulty, check the igniter in the following way. 4 Turn the ignition key on and using a voltmeter, check that there is 12 volts at the terminal on the coil external resistor. Connect the leads from the voltmeter as shown. 5 Assuming that this test is satisfactory, disconnect the LT lead from the distributor and with the ignition still switched on, ground the end of the LT lead several times in quick succession. If no spark is produced, then the igniter is faulty and must be renewed.

Fully transistorized ignition system description and precautions

8

1

(GT

California

1977 on)

3

The advantages

of this system include the following:

Improved low speed operation. b) Improved starting. a)

c)

No

erosion oi contact points.

d) Reduction in exhaust emission.

4

With

Do not Check

this system, never incorrectly connect the battery leads. disconnect a battery lead while the engine is running.

periodically

the

igniter

unit

is

satisfactorily igniter.

maintenance

9

Distributor (transistorized ignition)

1

Normal maintenance consists of wiping the cap clean and

-

-

The major differences between this system and other types employ a distributor having a mechanically-operated

which

contact breaker are in the absence of the contact breaker assembly and the provision of a special coil and an igniter. 2 A reluctor is used to interrupt the low tension current instead of a set of contact points and this is mounted within the distributor body together with a magnet and a pick-up coil.

checking the security of .all leads. 2 At the specified intervals, check the air signal generator and the reluctor. Use a feeler this and adjust if necessary by releasing the The correct gap should be between 0.008 and 0.4 mm). 3 Ignition timing is as described in earlier Chapter.

ON-0 Fig. 13.103. Igniter test circuits

Ignition Coil

n

Fig.

that

grounded. Keep water away from the distributor and the

13.104. Fully transistorized ignition circuit

gap between the blade to measure generator screws.

0.016

in (0.2

and

Sections of this

218

Fig. 13.105.

Views of

transistor type distributor

— 25

3

Fig. 13.106. Exploded view of transistorized type distributor

i

Grease plug Reluct or

Counterweight spring Counterweight Shaft assembly

^^,

Washer Spring Thrust bearing

Washer 10 Dustproof gasket 1

12 13 14 15 16 17 18 19

Steel washer

Rubber

seal

Vernier adjuster cap

Body 'O' ring

Gear Pin

Diaphragm unit Clamp

20

Baseplate 21 Signal generator 22 Dustproof cover

23 Rotor arm 24 Cap 25 Rubber cap

219

Chapter 13/Supplement

10 Distributor (transistorized ignition)

-

overhaul

Disconnect the distributor cap and push it to one side complete with attached leads. 2 Disconnect the LT lead at the connector plug. 3 Unscrew and remove the distributor clamp plate bolt and 1

^Kt

withdraw the distributor from the engine. 4 Pull off the rotor arm and lift off the dust cover followed by its

»>

sealing gasket.

Extract the screws which hold the signal generator to the baseplate and withdraw the generator. 6 Remove the LT connector plug after extracting the securing screw. This screw also retains the vacuum diaphragm unit which

5

can now be withdrawn from the distributor body. 7 Remove the baseplate retaining screws and clips. 8 In order to remove the gear from the distributor shaft, a flat will have to be ground on the lower part of the gear and the pin driven out. 9 Unscrew and remove the two screws from the underside of the distributor body and then drive out the shaft by tapping it

N

Fig. 13.107.

Removing

distributor

LT connector plug screw

with a plastic faced mallet. 10 Withdraw the washer, spring and thrust bearing from the distributor shaft and then detach the counterweight springs. 11 Prise the grease plug from the upper end of the shaft to expose the screw. Extract the screw and withdraw the reluctor. 12 Prise off the counterweight circlips and lift the counterweights from their pivot posts. 13 With the distributor dismantled, clean all components and inspect

them

for wear.

14 Reassembly

is

a

Renew

parts as necessary.

of

reversal

dismantling but observe the

following essential requirements. 15 Make sure that the '10' mark on the reluctor

is

opposite the

stop on the governor plate. 16 Pack grease into the recess at the top of the shaft before

Fig. 13.108.

Removing

distributor baseplate

installing the grease plug.

17 Make sure that the washers, bearing and spring are installed to the shaft exactly as

shown

18 Make sure that the holes

in in

the illustration. the

body and the bearing retainer two retaining screws.

are in alignment before inserting the

A new

gear and pin will have to be installed. Peen the pin in a vice so that both ends of the pin are equally spread. 20 Install the vacuum diaphragm unit so that its groove engages

19

with the baseplate pin. 21 Adjust the air gap and set the vernier adjuster to the center line.

Install the distributor as described earlier in this Chapter. Refit the cap and leads and check the timing.

22

Fig. 13.109. Distributor gear

Fig. 13.110.

Removing screws from underside

of distributor

ground away for pin removal

body Fig.

13.111. Extracting distributor shaft screw

220

Chapter 13/Supplement

Fig. 13.112.

Removing

reluctor assembly

Fig. 13.113. Prising off a distributor

counterweight

circlip

Spring

Washer (Blue)

I

Bearing

/

Washer (Thrck)

Fig. 13.114. Correctly aligned reluctor

Fig.

Fig. 13.115. Correctly

13.116. Peening distributor gear locking pin

Fig. 13.117.

assembled distributor shaft

Engaging diaphragm unit groove with distributor baseplate pin

MANUAL TRANSMISSION 1

General description

1

The ST models

are

gearbox while the

GT

W50

(five

AUTOMATIC TRANSMISSION 1

equipped with the W40 (four speed) type and Liftback versions are fitted with the

1

GerMral description

The model A40 automatic transmission (described in Chapter is available as an option on ST versions only.

6, Part 2)

speed) unit.

Operations and specifications are as described in Chapter 6, although there are minor differences to the external 1 castings and components as will be seen after reference to the

2

Part

REAR AXLE

illustrations.

3 No torsion spring Is used in the gearshift selector mechanism on the four speed gearbox. 4 The design of the gearshift swing arm has been modified in the five speed unit.

1

General description

rear axle used from 1975 onwards, although of similar type to that used in earlier cars, has some modified internal 1

The

221

Chapter 13/Supplement

Fig. 13.1 18.

W40

type gearcase components

Front bearing retainer

7

Plug

12

Dowel pin

2 3

Oil seal

8

Main casing

13

Clutch bellhousing

9

Mainshaft rear bearing

Gasket

retainer

Intermediate plate Reinforcement bracket Drain plug

20

4

14 15

5

Filler/level

10

Dowel pin

16

Hollow dowel

22

6

Gasket

1

Gasket

17

Extension housing

1

Fig. 13.119.

plug

W40

components including

type gearshift selector mechanism

a collapsible type pinion bearing spacer.

This necessitates a change

pinion

in

the procedure tor renewing the

described in the next Section.

oil seal as

Fig. 13.120.

W50

18 19

21

Bush Oil seal Dust seal Dust seal retainer Dust deflector

type gearshift selector mechanism

and tap in a new oil seal squarely (using a piece of tubing as a drift) until the end face of oil seal is 0.16 in (4.0 mm) below the neck of the differential 10 Wipe the

oil

seal

recess clean

the

carrier.

11

2

1

2

3

Pinion

oil seal

-

renewal

Jack up the rear axle and support securely. Remove the roadwheels and the rear brake drums. Disconnect the propeller shaft from the pinion flange and

rest the shaft to

Now wind

one

side.

round the pinion flange and attach it to a spring balance. Observe and record the force required to start the 4

a cord

pinion flange turning. This is the pinion bearing preload. 5 Remove the cord and spring balance. 6 Hold the pinion flange quite still by bolting a length of flat steel to two of the holes in the pinion flange and then unscrew the pinion nut. A ring wrench of good length will be required for this as the nut

is

very tight.

Remove

8

the nut, washer and pinion flange. Detach the dust deflector.

9

Using a two legged puller, extract the defective

7

Fit the dust cover

grease and push

oil seal.

it

and then smear the pinion coupling with oil seal and

carefully through the lips of the

onto the pinion splines. 12 Fit the washer and nut, hold the pinion flange quite still and tighten the nut to a torque wrench setting of not more than 78 lb/ft.

13 Using the cord and spring balance, check the starting torque If it is less than that originally recorded, tighten the nut in increments of 10 Ibf ft (1.3 kgf m) until the force required to start the pinion flange turning matches that recorded before dismantling. 14 If the nut is tightened excessively then the internal collapsible spacer will be overcompressed and the pinion flange, bearing and spacer will have to be withdrawn and a new spacer installed and the adjustment procedure started again. 15 When adjustment is correct, stake the nut, refit the propeller shaft, the brake drums and the roadwheels and lower the car to of the pinion flange.

the ground.

222

Exploded view of the rear axle

223

Chapter 13/Supplement

Fig. 13.124.

Exploded view of reduction

gear type starter motor J

@

224

Chapter 13/Supplement

Fig. 13.126.

Fig. 13.130.

Withdrawing

Alignment of

starter

starter gear housing

motor solenoid and

field

Fig.

frame

gear housing can be withdrawn from the solenoid.

out the clutch assembly and the gears. 8 Extract the ball from the clutch shaft hole. 9 Pull the brushes from their holders and remove the brush holder assembly. 10 Pull the armature from the field frame. 11 Renew any worn components. Servicing is carried out in a similar way to that described in Chapter 10, Section 15. 12 Commence reassembly by greasing the armature rear bearing and inserting the armature into the field frame. 13 Install the brush holder making sure that the locating tab is 7

Pull

correctly aligned.

14

Install the

13.127. Extracting ball from starter motor clutch shaft hole

Fig.

13.131. Location of fuse block

18 Insert the ball Into the clutch shaft hole. 19 Fit the clutch and then smear the gear teeth with grease and fit

the gear housing.

20 Reconnect 21

the leads to the solenoid terminals.

Install the starter

motor

to the engine.

The fuse block is located adjacent to the hood release control 1 handle and protects circuits as shown.

brushes and check that the positive (+) lead wires

are not grounded.

15

Fit the felt seal to the

armature shaft and the 'O' ring to the

3

Water temperature transmitter and gauge

-

testing

field frame.

16 Assemble the armature/field frame to the solenoid switch aligning the bolt anchors with the mark on the switch casing. 17 Smear the bearing surfaces with grease and then install the pinion and idler gears.

The terminals on the back of the gauge are now marked A and B. The resistance between them should be 55 ohms. 2 The water temperature transmitter should be tested using an 1

ohmmeter

in

conjunction with the following table.

225

Chapter 13/Supplement

Resistance between switch and ground

Coolant temperature

1220F 176°F 2120F 2480F

154 ohms 25 ohms 27.5 ohms 16 ohms

(50OC) (80OC) (100OC)

(120°C)

4

Instruments- removal and refitting

1

Disconnect the battery.

2 3 its

4

knobs from the four heater control levers. and prise the heater control panel from

Pull off the

Insert a screwdriver

location.

Extract

the

of

the

section

screws now exposed and pull out the lower escutcheon panel far enough to be able to

disconnect the electrical plug, then completely remove the panel. 5 Reach round behind the combination meter and disconnect the electrical plug and speedometer cable. 6 Release the instrument mounting screws and remove the combination meter, the combination gauge and the clock as required. 7

Refitting

5

Steering

is

a reversal of removal.

column combination switch

Access to the switch can be obtained after first removing the steering column lower shroud. 2 Removal of the switch can only be carried out after first withdrawing the steering wheel. 3 Before disconnecting the switch multi-pin plugs, disconnect 1

the battery.

Fig. 13.133.

Fig. 13.132.

Water temperature gauge terminals Fig. 13.134.

Fig.

Fuse layout (1976 models)

13.135. Prising out the heater control lever panel

Removing

a heater control lever

knob

1®®© i^mm iW—

Fig.

llll—i

111^—

13.136. Instrument lower escutcheon panel screws

226

Fig.

13.137. Instrument panel

components (removable) Fuse cover Lower escutcheon panel Rear compartment ashtray Rear console Console upper front panel Gearshift lever

knob

Center console Heater control panel Front ashtray 10 Instrument panel 11

Glove compartment door

12 Glove compartment 13 Fresh air duct 14 Right-hand lower

escutcheon panel Combination gauge 16 Fresh air duct 17 Left-hand lower escutcheon panel 18 Safety pad 15

Fig.

13.138.

Method

of disconnecting speedometer cable fron

speedometer

pos*^

1

Cap

2 'C clip 3 Switch knob 7

Fig.

13.139. Steering column switch

4

Ball

5

Stop plate Switch holder

6

Switch contact plate

227

Chapter 13/Supplement

Any fault in the switch is best overcome by renewal but the lighting knob can be dismantled if new internal components can be obtained to repair it. 5 Prise out the end cap from the switch knob, remove the 'C clip, turn the knob one 'click' and pull it from the shaft. 6 Rotate the switch holder and catch the ball and spring as they are ejected. Reassemble by reversing the dismantling operation noting 7 4

that the tab on the contact plate

fits

into the larger slot in the

switch holder.

6

Bulbs

-

renewal

Bulbs in the following lamps are accessible for renewal after 1 removal of the lens securing screws and the lens. Front turn signal. Front side marker. Front parking. Rear side marker (Liftback only). Luggage compartment (Liftback only). 2 The bulbs from other lamps are withdrawn as described in Chapter 10, Section 29 with the exception of the rear bulbs on the Liftback. These can be reached after removing the small panel from within the luggage area.

Fig. 13.140.

Access panel to rear lamp bulbs (Liftback)

Fig. 13.141.

7

Relays

-

location

1

A number

are

shown

in

of relays are used

and their location and purpose

the illustration.

addition to those shown, a light control relay is mounted on the left-hand front suspension strut tower within the engine compartment. 3 When a fault develops in a system and the fuse and connecting wiring have been checked, then the relay concerned should be removed and a substitute connected. 4 All relays are sealed units and cannot be repaired.

2

In

8

Clock

1

Should the clock lose or gain

-

regulation

it

can be adjusted with the

regulator screw.

2 Remove the plastic dust cover from the rear of the clock and turn the screw with a small screwdriver, as necessary, in the appropriate direction. 3 Turning the screw through 90° will advance or retard the setting by about three minutes a day.

Regulator Screw

Fig. 13.142.

Clock regulator screw

Location of relays

Seat belt unlock or buzzer

F

Ignition

Turn signal Main relay Fuse block

G

H

Spark control computer Seat belt warning

I

Light failure indicator

Fuel

pump

flasher

228

Repair Agent

Broken Wire Masking Paper Tape Fig. 13.143.

7

Fig. 13.144.

Heated rear window element repair diagram

Arm and blade assembly

2 3

Motor

4

Link rod Link

5

Radio retaining bar and screws

Grille

Fig. 13.145.

Fig. 13.146. Prising

Windshield wiper motor and linkage

wiper link from motor crankarm

Fig.

(RHD shown)

13.147. Disconnecting link from wiper spindle arm

229

Chapter 13/Supplement

9

Radio, tape player and speaker

-

removal and installation

1 Pull off the radio knobs, unscrew and remove the locknuts and withdraw the console upper front panel. If only a radio is fitted, remove the retainer bar and then 2 withdraw the radio until the leads at the back can be disconnected and the radio removed. 3 If a radio and tape player are fitted, remove the console upper front panel as previously described and then remove the console box. To do this, extract the eight securing screws and unscrew the knob from the gearshift lever. Lift the front of the box upwards and withdraw it while pushing the rear in a forward

5 Extract the securing screws and remove the small cover panels from the engine compartment rear fire wall. 6 On the wiper motor side of the linkage, disconnect the link from the spindle arm. Use a large screwdriver to do this. 7 From the spindle arms, unscrew the locknuts and remove the distance pieces and seals. 8 Push the spindles into the cowl interior and then withdraw

the linkage through the center service hole. 9 Installation is a reversal of removal but make sure that the motor has been run and switched off at the park position with the wiper switch before installing the wiper arms to the spindles. The arms and blades should be parallel with the bottom of the

windshield frame.

direction.

4 Extract the mounting bracket screws and withdraw the radio and tape player as one unit until the rear connecting leads can be

12 Wiper motor

-

overhaul

detached.

5

To remove

the speaker, withdraw the instrument escutcheon

panel as described earlier

6

in this

Chapter.

Unscrew and remove the speaker mounting nuts and lower

the speaker then disconnect the leads. Installation of all units is a reversal of removal. 7

10 Heated rear wirxlow 1

2

-

precautions and repair

Clean the interior surface of the glass with water only. Do not scratch the surface with rings which may be on the

fingers.

3

Do

not stick labels over the heating elements

on the

inside of

the glass.

4

Should

a break

occur

in the

heating element, a repair can be

carried out to save the cost of renewing the window. 5 Clean the point of breakage of the glass with solvent

and then masking tape to bridge the gap as shown. 6 Obtain repair liquid (Dupont No. 4817) and apply with a fine brush. After two minutes remove the masking tape. 7 Do not operate the heated rear window for at least 24 hours stick

after repair.

The wiper motor normally has a very long, reliable life and 1 when it does become worn it is usually more satisfactory to renew it for a new or rebuilt unit. 2 Where the necessary spare parts are available, however, it can be overhauled in the following way. 3 With the motor removed as described in the preceding Section, mark the relationship of the crank arm to the motor spindle and then remove the crankarm. 4 Remove the gear housing cover plate and then extract the driveshaft gear.

5 Remove the two gear housing securing screws and withdraw the gear housing from the stator. The armature shaft comes away with the stator and care must therefore be taken to avoid the brushes becoming displaced and damaged by the worm gear. 6 Remove the two stator nuts and pull out the armature. Extract the steel balls from both ends of the armature shaft. Remove the brushes and springs from their holders. The cover plate can be separated from the gear housing once the brush connectors have been detached from the brush holder

7

8

terminals.

Inspect all components for wear. The brushes should be renewed if they have worn to below 0.24 in (6.0 mm) in length. 10 Renovate the commutator as described for the starter motor

9

in 1 1

Windshield wiper motor and linkage

-

removal and

refitting

Chapter 10, Section 15.

Check the driveshaft endfloat. If this is more than 0.008 mm), renew the thrust washer. 12 Reassembly is a reversal of dismantling, but observe the

11

in (0.2

Unscrew the domed nuts from the wiper arm spindles and 1 pull the arm/blade assemblies from their splines. 2 Disconnect the electrical plug from the wiper motor. 3 Release the wiper motor mounting screws and pull the motor far enough away to be able to separate the wiper link and crank arm by prising with a large screwdriver. 4 Remove the motor.

Fig. 13.148.

Wiper arm spindle distance piece

following points.

13 Grease

all

gears, bushes, bearings

and friction surfaces before

assembly.

14 Stick the balls in position at the ends of the armature shaft with grease. 15 Remove the tape from the nut slots ir; the stator and engage

Fig. 13.149.

Withdrawing wiper linkage

230

i,

Fig. 7

2

Fig. 13.151.

13.150. Exploded view of the windshield wiper motor

Crankarm components Gear housing cover plate

3

Driveshaft

Wiper motor gear housing alignment with stator

Fig.

components

4 Armature and stator

5 Thrust balls 6 ' Gear housing

Fig. 13.152. Refitting tape to

13.153. Measuring height of wiper motor auto stop switch lever

wiper motor

®

Chapter

1

the gear housing tab with the notch on the stator. 16 Make sure the stator is correctly aligned, drop the nuts into

and refit the tape. 17 Adjust the armature shaft thrust screw until any endfloat

their slots, insert the screws

is

removed and tighten the locknut. 18 Before installing the gear housing cover plate check the height of the auto stop switch lever which should be 0.4 in (10.0

just

19 Align the marks made before dismantling when crankarm.

13 Electro sensor panel

On

2 At frequent intervals, switch on the ignition and depress the check button four times and observe that all the captions light up. If any one of them does not, investigate the reason and rectify immediately. 3 The systems and components monitored by the panel are:

SYSTEM OR COMPONENT

mm).

-

INDICATES

installing the

Low

Engine oil Brake booster Radiator Brake stop lights

description

an electro sensor panel is installed below the purpose is to indicate any malfunction in a number of components and systems so that immediate rectification can be 1

231

3/Supplement

later cars,

radio. Its

level

Insufficient

Low

W. washer

Low Worn front disc pads Low fluid level

Tail lights

Bulb or fuse blown

electrolyte level

Battery Lining wear

COMPSNENTS MARKER. FRONT SIDE, LH RH MARKER. REAR SIDE, LH RH OIL PRESSURE WARNING RADIO

COMPONENTS

ALTERNATOR BATTERY CIGARETTE LIGHTER CLOCK COMBINATION METER

RH SWITCH KNOB TAIL, LH RH STOP, LH

CONDENSER COOLER IDLE UP

TURN SIGNAL. FRONT. LH RH TURN SIGNAL. REAR. LH RH TURN SIGNAL INDICATOR. LH MAGNET CLUTCH IFor Cooler!

EMISSION CONTROL SYSTEM CHOKE HEATER COIL

MOTORS HEATER BLOWER

CHOKE RELAY EMISSION CONTROL COMPUTER EXH TEMP WARNING LIGHT INSPECTION CONNECTOR SPEEDSENSOR

STARTER WASHER WIPER

RADIO

THERMO S/m Foe Coolant THERMO SENSOR For CCo ICalif.l VACUUM SWITCHING VALVE ESP SYSTEM ANALYZER COMPUTER BRAKE PAD WEAR SENSOR COOLANT LEVEL SENSOR

HORNS. LO HI IGNITER IGNITION COIL IGNITION COIL DIODE

lOPTI

REGULATOR RESISTER

IFoi

RELAYS COOLER FUEL PUMP LIGHT CONTROL

HORN

ELECTROLYTE LEVEL SENSOR ENGINE OIL LEVEL SENSOR INDICATOR PANEL LIGHT FAILURE RELAY OK SHIFT SWITCH PRIMARY WARNING LIGHT VACUUM WARNING SWITCH W, WASHER LEVEL SENSOR .8if

MAIN RELAY

(For Brake V

SEAT BELT SYSTEM BUZZER. IFor Seat Belt Warningl SEAT BELT BUCKLE SWITCH SEAT BELT RELAY SEAT BELT WARNING LIGHT

STEREO TAPE PLAYER SPEAKER. FRONT SPEAKER. REAR

H2AR0

lOPTI

SWITCHES BACK. UP LIGHT

BRAKE FLUID LEVEL WARNING

DEFOGGER DIFFERENTIAL

DIMMER DOOR GLOVE BOX LIGHT LIGHT CONTROL HEATER BLOWER

IForCalif.l

.IGHTS

AUTOMATIC T/M INDICATOR BACKUP. LH RH BRAKE WARNING

HORN IGNITION

CIGARETTE LIGHTER CLEARANCE. FRONT, LH RH

INTERIOR LIGHT

CLOCK COMBINATION METER DISCHARGE WARNING DOOR COURTESY GLOVE BOX HEADLIGHT, LH RH HEATER CONTROL HIGH BEAM INDICATOR

OIL PRESSURE

NEUTRAL SAFETY PANEL LIGHT CONTROL PARKING BRAKE LIGHT STOP LIGHT TURN SIGNAL & HAZARD

UNLOCK WARNING WINDSHIELD WIPER AND WASHER

INTERIOR LICENSE PLATE

H-,3

LUGGAUGE LOOM MAP

Key

for Celica wiring diagram (For

USA and

level

Bulb or fuse blown

carried out.

FLASHER, TURN SIGNA FUEL CUT SOLENOID FUEL GAUGE FUEL PUMP FUEL SENDER FUSE BOX FUSIBLE LINK

vacuum

coolant

Canada)

-

1976. See pages 232-233 for diagram

232

233

234

235

236

237 GRID LOCATION

238

Chapter 13/Supplement

SUSPENSION AND STEERING

Fig. 13.156.

Fig. 13.157.

Removing windshield moulding

Rear seat cushion securing bolts

(1)

and seat back

securing bolts 12)

ABC

Fig. 13.158. Liftback rear

A

door components

239

Fig. 13.159.

Front turn signal

light

connectors

Fig. 13.161.

Fig. 13.160.

Front bumper stay bolts and ground cable

Front bumper stay outer mounting bolt

Fig. 13.162.

Front bumper components

A Bumper bar B Stay

C

D

Extension Inner pressing

E Reinforcement F Filler

G Mounting plate H Spacer J

Stay

K

Overrider

L

Shock absorber

®

&

240

Chapter 13/Supplement

6

Rear bumper (impact absorbing typel

removal and

instal-

lation

Hardtop models Peel back the covering from the trunk floor and prise out the 1 grommets which cover the bumper mounting stay bolts. 2 Unscrew and remove the bolts and withdraw the bumper assembly complete. Liftback models 3

Withdraw the

carpet, floor panel and spare wheel

from the

luggage area.

Fig. 13.163.

Rear bumper bolt grommets

and bolts

(II

on

(21

Hardtop

4 Remove the interior trim panel from the rear of the luggage compartment. This is removable after extracting the securing screws and then bending the panel but take care not to deform it too much or it will crack. Extract the securing screws and remove the right-hand floor 5 panel bracket. As the bracket is withdrawn, unclip the electrical wires from their clamps on the underside of the bracket. 6 Extract the grommets now exposed and unscrew the bumper

mounting bolts. Withdraw the bumper assembly complete. Dismantling of the rear bumper assemblies can be

stay

7

8

carried out

after reference to the appropriate illustration.

9

Installation

7

Heater

-

is

a reversal of removal.

removal and installation

Heater blower 1

Peel

off

separate the

2

Open

adhesive tape and disconnect the clips and supply duct from the heater unit.

the air

the securing clip and disconnect the air inlet butterfly

valve control cable. Fig.

1

13.164. Luggage compartment (Liftback) trim panel

Carpet and floor par>el

2

Trirr>

panel

3 Release the nuts which secure the top and bottom of the blower assembly, withdraw the assembly far enough for the blower motor leads to be disconnected and then remove the blower.

Heater body and matrix 4 Drain the cooling system. 5 Disconnect the heater coolant hoses at the engine compart-

ment rear fire wall. 6 Working inside

the car, remove the center console complete. 7 Remove the lower finish panel from the left-hand side of the instrument panel.

Remove the air ducts. Remove the radio and tape player. 10 Remove the under tray. 1 Remove the instrument panel to cowl reinforcement bracket. 12 Remove both front seats. 13 Remove the heater ducting to the rear passenger compart-

8

9

ment. 14 Disconnect the two heater control cables and disconnect the Fig. 13.165. Right-harKJ floor panel bracket (Liftback luggage area). Securing screws arrowed

electrical leads.

15 Release the heater mounting bolts and withdraw the unit. Take care not to spill any coolant remaining in the heater matrix onto the carpet. Control panel 16 Remove the ashtray. 17 Remove the knobs from the heater control levers and then withdraw the heater indicator panel. 18 Remove the instrument finish panel. 19 Remove the undertray. 20 Disconnect the heater control cables and the leads from the blower switch. 21 Unscrew and remove the control panel securing screws and

withdraw the panel. 8

Fig.

13.166. Rear bumper bolt grommets Liftback

(II

and bolts

(2)

on

Air conditioning

Compressor location The location of the compressor 1

is

shown with

its

flexible

241

Fig.

J

13.167. Rear bumper components (Hardtop)

242

Chapter 13/Supplement

connections (Fig. 13.172). 2 When carrying out major engine overhauls, only remove the compressor as far as the flexible hoses will allow. 3 Never disconnect the system unless the refrigerant has been discharged by your Toyota dealer or by a qualified refrigeration engineer.

4

Other major components of the air conditioning system are the engine compartment.

9 1

Remotely controlled external mirror

A

remotely controlled external mirror GT models.

is

fitted to the

door on

the driver's side on

The internally mounted control knob is secured by a spring clip which is accessible after the trim panel has been removed. 2

shown within

A

243

COMPRESSOR

LIQUID LINE TUBE

RECEIVER

LIQUID LINE TUBE Fig. 13.174.

Adjusting

Underhood components of the

air

conditioning system

Knob

Fig. 13.175.

Remotely controlled external mirror

Use of English As

this

in

will

list

in England, it uses the appropriate English component names, phrases, and spelling. Some of these differ from America. Normally, these cause no difficulty, but to make sure, a glossary is printed below. In ordering spare parts remember the probably use these words:

book has been written

those used parts

Glossary

English

American

Interior light

Accelerator

Antenna Gas pedal

Alternator

Generator (AC)

Dome lamp Counter shaft Primary shoe

Anti-roll bar

Stabiliser or

Leading shoe (of brake) Locks

English

Aerial

Layshaft (of gearbox)

sway bar

Latches

Battery

Energizer

Motorway

Bodywork

Sheet metal

Number

Bonnet (engine cover! Boot lid Boot (luggage compartment)

Hood

Paraffin

Kerosene

Trunk Trunk

Petrol

Gasoline Gas tank

Bottom

1st gear

'Pinking'

'Pinging'

Firewall

Quarter Retread Reverse

Quarter

gear

Bulkhead Camfollower

or tappet

Carburettor

lid

Freeway, turnpike

Petrol tank

Valve lifter or tappet Carburetor

light

Back-up Valve cover

Barrel

Rocker cover Roof rack

Circlip

Snap

Saloon

Clearance

Lash Ring gear (of differential) Rotor/disk

Seized Side indicator lights Side light

Crownwheel

ring

window

Recap

Catch Choke/venturi

Latch

Car top carrier

Sedan Frozen Side marker

Driveshaft

Silencer

Parking light Muffler

Pitman arm

Spanner

Wrench

Sill

Dynamo

Convertible Generator (DC)

Earth (electrical)

Ground

Split pin

Engineer's blue

Prussion blue

Steering arm

Cotter pin Spindle arm

Estate car

Station

Sump

Oil

Exhaust manifold Fast back (Coupe)

Header Hard top Trouble shooting Float bowl

Tab washer

Tang; lock

Tailgate

Liftgate

Disc (brake) Propeller shaft

Drop arm Drop head coupe

Fault finding/diagnosis Float

chamber

Lash Coast

Free-play

panel (beneath doors)

Split cotter (for valve spring cap)

wagon

Valve

Throw-out bearing High

gear

Transmission

Halfshaft

Axle-shaft

Van

retainer)

pan

Top

Trackrod (of steering) Trailing shoe (of brake) Transmission Tyre

Piston pin or wrist pin

pin

Rocker panel Lock (for valve spring

Thrust bearing

Shift

Freewheel

lights

Tappet

Gearchange Gearbox

Gudgeon

etc.

Licence plate

plate

lifter

Tie-rod (or connecting rod)

Secondary shoe

Whole

drive line

Tire

Panel wagon/van

Handbrake

Parking brake

Vice

Vise

Hood

Soft top

Hot spot

Heat

riser

Wheel nut Windscreen

Indicator

Turn

signal

Wing/mudguard

Lug nut Windshield Fender

Interior light

Dome lamp

Miscellaneous points

An "Oil seal" is fitted to components lubricated by grease! A "Damper" is a "Shock absorber", it damps out bouncing, and

absorbs shocks of

bump

i

npact.

Both names are correct, and both are used

haphazardly.

from the Bendix type that is common in America, so different descriptive names result. The shoe end furthest from the hydraulic wheel cylinder is on a pivot; interconnection between the shoes as on Bendix brakes is most uncommon Therefore the phrase "Primary" or "Secondary" shoe does not apply. A shoe is said to be Leading or Trailing A "Leading" shoe is one on which a point on the drum, as it rotates forward, reaches the shoe at the end worked by the hydraulic cylinder before the anchor end. The opposite is a trailing shoe, and this one has no self servo from the wrapping effect of the rotating drum. Note that

British

drum brakes

are different

Index lamp switch adjustment - 102 Automatic transmission (A40type); adjustments - 104 starter inhibitor/reverse

Accelerator pedal and linkage - 43, 201 Air conditioning system

-

60

Air cleaner

Air Injection

-

181, 240

System -209

throttle link connecting rod adjustment

Auxiliary acceleration

pump

21

-

Alternator:

131 dismantling and reassembly - 132 extension housing oil seal - 104 maintenance - 131 precautions - 131 description

regulator testing

-

136

- 39 Automatic choke - adjustment Automatic transmission: -

-

-

renovation

-

131

130 - 22

-167,238

fresh air ventilator

45

27

- 108 maintenance - 102 removal and installation - 104 specifications - 101 torque wrench settings - 101 Automatic transmission (A30 type): brake band adjustment - 104 selector linkage adjustment - 102

fault diagnosis

maintenance - 130 removal and installation

description

-

102,220 -

131 electrolyte replenishment -

Body:

Antifreeze

driveplate servicing

Battery charging

Big-end bearings

removal and refitting - 132 - 132 testing in vehicle - 131 servicing

description

B

-

front fender

hood

-

-

176

169

76 - 176 maintenance - 167, 169 repair major damage 169 repair - minor damage - 1 68 trunk lid - 176 - 1

interior extractor vent

Braking system: bleeding hydraulic system

booster - 127 description - 118 disc - renovation - 121

-

123

-

102

246

Index 118

disc pads

drums

renovation

-

fault diagnosis flexible hoses

-

-

adjustment - 66 removal and refitting Cooling system: description 38, 199 draining - 38, 199 drivebelts adjustment

123

128 123

front disc caliper

-

121

master cylinder - 123 parking brake - 125 pedal

-

fault diagnosis

125,223

rear

-

127, 223

drum brake shoes 1 18 drum wheel cylinders 121 -

brake

rigid

lines

-

123

- 1 17 torque wrench settings - 1 1 - impact absorbing type

specifications

Bumpers

-

176, 238

c Camshaft: bearings

-

25,

removal - 17, 188 renovation - 25 Capacities - 10, 187 Carburetor (18 R-C engine):

201

37, 184

-

Crankcase ventilation system - 22, 195 Crankshaft: reassembly -28, 195 removal - 18 renovation - 22 Cylinder block - renovation - 28 Cylinder bores - renovation - 22 Cylinder head: installation - 32 reassembly - 197 removal - 17, 188 servicing

-

25

pump 46

accelerator

D

-

adjustment and setting

Dimensions

auto, choke

Distributor:

- 59 45 description 45 dismantling and reassembly - 59 fault diagnosis - 64 removal and installation -46 slow running adjustment - 46 specifications - 42 Carburetor (8R engine): -

-

accelerator

-

41

flushing

specifications

-

-

-39,201 -38

filling

pressure regulating valve rear

66

-

-

pump 46 -

adjustment and setting auto, choke - 45 description

-

55

45

-

203

-

71

-215 215

installation

overhaul

-

reassembly (early type) - 71 removal and installation - 68 -

71

-217

transistorised ignition

dismantling and reassembly -46 fault diagnosis - 64 idling adjustment overhaul - 204

dismantling (early type) -68 dismantling and reassembly (late type) dwell angle - 68

servicing -

187

10,

-

Doors: locks- 170 quarter window regulator and glass - 1 72, 238 removal, refitting and adjustment - 172, 238 rattles

- 1

69

Drivebelt adjustment

-

41

,

201

removal and installation - 46, 204 slow running adjustment - 46 specifications

-

42

Electrical system:

throttle positioner system

Carpets

-

maintenance

-

-

203

167

Catalytic converter:

description and precautions -21 checking, removal and refitting -213 Clutch:

adjustment

-

76

fault

-

79

76 diagnosis -82 -

hydraulic system - 79 installation - 81 master cylinder dismantling and reassembly - 79 master cylinder removal and refitting - 79 operating cylinder dismantling and reassembly - 79 operating cylinder removal and refitting -79 pedal

-

-

1

bulbs clock

-

143 30

-

renewal

-

227

description

-

145, 227

-

130

fault diagnosis

-

151

and gauge

fuel level transmitter

bleeding hydraulic system description

ammeter battery

79

-

140

- 140, 224 hazard warning and turn signal lamps heated rear window - 229

fuses and fusible link

-

140

headlamp sealed beam unit - 143 ignition switch - 143 instruments and warning lamps - 143, 225 light switch - 143 oil pressure switch and gauge - 143 radio, tape player and speaker • 149, 229 relays 227 seat belt electrical interlock systems - 149 -

release bearing renewal

-

81

removal 79 renovation - 80

sensor panel

-

specifications

-

76, 185

torque wrench settings - 76 Coil polarity and testing - 71 Condenser - 68 Connecting rods: reassembly - 37, 195 removal - 18, 191 renovation 22 Contact breaker points: -

-

specifications

231 129, 186

-

column combination switch - 143 water temperature transmitter and gauge - 140, 224 windshield wiper - 145, 147, 229 Emission control system: steering

description

-

45, 59,

fault diagnosis

-

64

maintenance - 59 45 60

servicing

•

testing -59,

209

247

Index

Engine:

removal and refitting

ancillary

ancillary

components refitting components removal

description

34

Hood

17

Horn Hubs

15

-

dismantling

-

-

examination of components fault diagnosis

adjustment

(front)

-

149

-

and adjustment

servicing

22, 195

-

36

-

-

188

17,

-

180

-

176

-

Igniter

assembly and installation - 198 oil seals renewal 28 operations with engine in position - 15, 187 operations with engine removed - 15 reassembly - 28, 195 removal method 15 renovation - 22, 195 separation from automatic transmission - 15 separation from gearbox 15 start-up after overhaul 36 specifications 1 1, 183 supplement 187 torque' wrench settings - 13 Engine/automatic transmission reconnecting 34 Engine/manual gearbox reconnecting - 34 final

-

-

-

-

•

-215

Ignition system:

-

- 66, 215 dwell angle - 68 fault diagnosis - 74

description

fully transistorized

-

217

semi transistorized - 215 specifications -65, 185 timing 68, 215 switch 143 torque wrench settings - 66 Introduction 5 Introduction -supplement - 183 -

-

-

•

-

Jacking points

Engine/transmission; installation

-

10

34

-

removal - 15 Exhaust Gas Recirculation (EGR) System -209 Exhaust system and manifolds 60, 21 •

recommended

Lubricants

-

6

Lubrication chart -6 Lubrication system

-

21, 193

F Fan - 40 Flywheel

-

27

servicing

Manual transmission 220 Main bearings: reassembly - 28 removal - 18 renovation - 22 Maintenance routine 7 -

Fuel contents sender unit

201

Fuel evaporative emission control system Fuel filter - servicing - 43

Fuel

45, 201

-

pump:

description

-

43

-

removal and refitting servicing

-

-

45, 201

•

45

Fuel system.

-21

Oil filter

description

-

42, 201

fault diagnosis

-

safety devices

specifications

Oil pan:

64 213

refitting

removal

42, 184

-

torque wrench settings

Oil -

43

Oil

pump pump

-

-

32, 195

18 reassembly -

driveshaft

-

28

servicing

-

27

Fuel tank:

removal and refitting servicing

-

-

45

45 Piston/connecting rod assemblies: reassembly - 28

Gearbox (manual): description - 85 fault diagnosis

-

removal

-

18, 191

Piston rings:

100

reassembly and refitting - 28, 195 removal - 18, 193 renovation - 25 Piston pin - removal - 18, 193

removal and installation -85 - 83 torque wrench settings 85 Gearbox (manual -4-speed): countershaft and reverse gear dismantling -89

specifications

-

Pistons:

servicing -91

-

-

input shaft servicing

-

center bearing

-

fault diagnosis

-

28, 195

109 1

12

front sliding sleeve/yoke

removal and refitting -

98

specifications

-

torque wrench settings

-

-

Quarter

-

-

window

H Radiator

Radio

-

-

39

149,229

-

-

1 1

109

109, 186

98

mainshaft servicing 98 oil seals renewal 98 reassembly 98

Heater -177, 240 description - 176

-

Propeller shaft:

renewal 90 reassembly 90 Gearbox (manual - 5-speed): countershaft and reverse gear servicing dismantling - 96 oil seals

reassembly and refitting renovation 25 -

input shaft servicing -91 mainshaft servicing - 89

238

-

109

-

157

248

Index

Rear axle:

radius rod - 113 113

157

-

axle shafts

specifications

bearings

stabilizer bar

-

description

-

113, 220

differential carrier fault diagnosis

-

1

15

halfshafts-113 - 1 13

fault diagnosis

oil seal

-

lateral

removal and refitting -115 specifications - 113, 186 torque wrench settings - 113

Remote Rocker

controlled external mirror

parts

-

buying

7,

-

242

187

166

control rod

-

-

Tape players - 149, 229 Thermostat - 39 Throttle Positioner System - 203 Timing components - renovation - 25 Timing gear: reassembly -28, 197 removal - 18, 190 renovation - 25 Towing points - 10 Tyre pressures - 153 Tyres - 165

5

-

control system

-

210

plugs -71, 215 plug chart (colour)

-

73

Starter motor:

description

-

136, 223

dismantling - 138 reassembly - 138 removal and installation servicing

154

17, 188

-

servicing - 27 Routine maintenance

Spare Spark Spark Spark

-

shaft:

removal

-

general description 15, 221

1

-

154, 238 161 lower control arm - 161 shock absorbers - 154 specifications - 153, 186 torque wrench settings - 154 upper control arm - 161

oil seals

pinion

157

torque wrench settings Suspension (rear): coil spring - 161

116

-

153, 186

-

-

138

U

and testing - 138 - 138

testing in vehicle

Universal joints -dismantling and reassembly

Steering:

Upholstery maintenance

column and shaft 163 column lock - 165 combination switch 225 description - 154,238

167

-

-

V Valves:

-

fault diagnosis

-

166

installation

front wheel alignment

-

165

gear -dismantling and reassembly gear - housing - 163 linkage

-

servicing -

163

-

-

32/34, 198

32

25

-

Vehicle identification numbers

-

5

w

163

- 153, 186 torque wrench settings - 154 wheel - 163

specifications

Suspension (front): crossmember - 161 fault diagnosis

-

166

general description leg

clearances adjustment

-159

lower arm

-

154, 238

Water pump: fluid coupling

removal and Wheels -165

1

59

-

40, 201

Windshield glass -170, 238 Windshield washer - 149 Windshield wiper - 145, 147, 229

Wiper motor -

-40,201

refitting

-

229

Wiring diagram

-

150

Printed by

Haynes Publishing Group Sparkford Yeovil Somerset England

-

111

Models covered by Toyota Celica ST, GT and Liftback; 113, 120 & 134 cu in (1858, 1968 & 2189

this

manual

cc)

Covers 4- and 5-speed manual transmissions and automatic transmission. Does not cover restyled models introduced 1978.

What the Get to know your vehicle

!

Clear step-by-step illustrations cover inspection, repair, disassembly and installation of the engine, cooling, emission control, ignition, electrical, braking, suspension and steering systems. Also

manual transmission, From tune-ups and specifications to troubleshooting and body fittings, this manual includes everything you clutch and drive train.

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85696 229 5

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Motor It

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