Six-cylinder O.H.V. Engine & Clutch

TS882

4

MODEL DESIGNATIONS

94635 Victor '3300' Estate Car 201 cu in (3.3 litre) O.H.V. engine.

94669 Victor '3300' Saloon 201 cu in (3.3 litre) O.H.V. engine.

94869 Ventora Saloon 201 cu in (3.3 litre) O.H. V. engine.

VEHICLE IDENTIFICATION AND ENGINE NUMBERS

The vehicle identification number is stamped on a plate attached to the left-hand front wheelhouse panel, under the bonnet. On early models, the plate is attached to the left-hand front door pillar.

The engine number is stamped on a pad on the cylinder block, adjacent to the fuel pump.

Code letters stamped on a pad between the distributor and the fuel pump identify the engine compression ratio, i.e. 'BH'- High compression; 'B L'- Low compres..c;ion.

SPECIFICATIONS

CAPACITIES- NOMINAL

Engine

Total- Dry engine Refill Refill -With filter change

Fuel Tank

Cooling System

Without Car Heater .. With Car Heater

Firing Order ..

Compression Ratio

High Compression Engine Low Compression Engine

ENGINE

Compression Pressure at Cranking Speed - Hot

*Maximum permissible variation between cylinders is 20 lb/sq in.

Cylinder Head

Permissible Distortion on Attachment Face Longitudinally Transversely

Permissible Depth of Cylinder Head After Refacing Valve Seating Angle .. Valve Seating Width

Intake Exhaust

Valves

Stem Diameter - Standard Intake Exhaust ..

Stem Clearance in Cylinder Head Intake Exhaust ..

Valve Seat Angle Valve Head Thickness

Intake Exhaust ..

.. 91mp pints

.. 81mp pints

.. 8.75 Imp pints

.. 12 Imp gals

.. 14.7 Imp pints

. . 15.8 Imp pints

.. 1, 5, 3, 6, 2, 4.

.. 8.5 to 1

.. 7.0 to 1

.. * 125 lb/sq in minimum

.. 0.005 in maximum

.. 0.003 in maximum

.. 3.400 in minimum

.. 45°

.. 0.040/0.060 in

.. 0.060/0.080 in

.. 0.341 0/0.3417 in

.. 0.3703/0.3710 in

.. 0.0010/0.0027 in

.. 0.0017/0.0034 in

. . 440

.. 0.025 in minimum

.. 0.035 in minimum

5

Valve Springs

Free Length - Nominal Assembled Height .. Spring Load at 1.61 in

Valve Tappets

Diameter Clearance in Block

Valve Timing

Intake Valve Maximum Opening Point

Valve Clearance - Hot

Cylinder Block

Permissible Depth of Block After Refacing (top face to main bearing cap face)

Permissible Distortion on Top Face Longitudinally Transversely

Cylinder Liner- Service Cylinder bore for liner installation Piston oversize for use with liners

Piston Rings

Ring Gap in Cylinder Bore Top ring .. Centre ring

Thickness (top to bottom face) Top and centre rings

Clearance in Piston Groove Top ring .. Centre ring

Pistons

Clearance in Cylinder Bore

Connecting Rods

Bearing Housing Bore End Float on Crankpin

Crankshaft and Bearings

Crankpin Diameter .. Crankpin Clearance in Bearing Crankpin Fillet Radius Crank Throw Main Journal Diameter Main Journal Fillet Radius

6

.. 1.86 in

.. 1.56 in maximum

.. 571b

.. 0.8735/0.8740 in

.. 0.0005/0.0020 in

.. 109° after T.D.C.

.. 0.013 in

.. 8.987 in minimum

.. 0.005 in maximum

.. 0.003 in maximum

.. 3. 764/3.765 in

.. 0.020 in maximum

.. 0.010/0.021 in

. . 0.008/0.022 in

.. 0.0927/0.0937 in

.. 0.0016/0.0036 in

. . 0.0011/0.0031 in

.. 0.0007/0.0012 in

.. 2.1855/2.1860 in

.. 0.0060/0.0072 in

.. 2.060/2.061 in

. . 0.0010/0.0032 in

.. 0.078/0.094 in

.. 1.622/1.627 in

.. 2.4993/2.5003 in

.. 0.078/0.094 in

Main Journal Clearance in Bearing Front Front intermediate Rear intermediate Rear

Rear Intermediate Main Journal- Regrind length 0.003 in oversize thrust washers 0.006 in oversize thrust washers .. 0.009 in oversize thrust washers ..

Rear Face of Crankshaft Flange to Rear Face of

...

Rear Intermediate Main Bearing Journal - Regrind dimension 0.003 in oversize thrust washers 0.006 in oversize thrust washers 0.009 in oversize thrust washers

Crankshaft End Float Permissible Crankshaft Run-out Main Bearing Housing Bore .. Service Main Bearing Cap Shim Thickness

Camshaft and Bearings

Journal Diameter Clearance in Bearing End Float Thrust Plate Thickness

Crankcase Ventilator Valve

Spring Load at 0.28 in

Oil Pump

Driving Impeller Spindle Diameter .. End float .. Clearance in pump body

Driven Impeller Spindle Diameter Impellers

End clearance in body Radial clearance in body Backlash between teeth Clearance on driven spindle

Oil Pressure Relief Valve Plunger diameter .. Plunger clearance in body Spring load at 1.90 in

Oil Pressure- Hot ..

.. Zero/0.0015 in

.. 0.000510.0020 in

.. 0.0005/0.0020 in

. . Zero/0.0020 in

.. 1.254/1.258 in

.. 1.260/1.264 in

. . 1.266/1.270 in

.. 9.835/9.845 in

.. 9.832/9.842 in

.. 9.829/9.839 in

.. 0.002/0.012 in

.. 0.0015 in maximum

.. 2.6655/2.6660 in

. . 0.002 and 0.003 in

.. 1.8687/1.8692 in

.. 0.0055 in maximum

.. 0.002/0.004 in

.. 0.195/0.200 in

.. 7-7% oz

.. 0.4983/0.4987 in

. . 0.003/0.006 in

. . 0.0012/0.0025 in

.. 0.4951/0.4956 in

.. 0.002/0.005 in

.. 0.0015/0.0035 in

.. 0.005/0.013 in

.. 0.0010/0.0023 in

.. 0.5605/0.5613 in

. . 0.0007/0.0025 in

.. 12 lb 5 oz

.. 40-50 lb/sq in at 3000 r.p.m.

7

Fuel Grade

High Compression Engine Low Compression Engine

Fuel Pump

Make and Type Delivery Pressure Diaphragm Spring Load at 0.64 in

Carburetter

Make and Type Identification Numbers

Synchromesh transmission: Right drive Left drive

Powerglide transmission: Right drive Left drive

Choke Tube .. Main Jet Power Jet Idling Jet Pump Discharge Nozzle Orifice Needle Valve Seating Needle Valve Washer Thickness Fuel Level (float installed)

High Altitude Jet Settings Main jet:

5000 - 7000 ft 7000 - 10,000 ft 10,000 - 15,000 ft

Power jet: 5000 - 7,000 ft 7000 - 1 0,000 ft 10,000- 15,000 ft

Manifolds

FUEL AND EXHAUST

Flange Relationship -Checked on surface plate

Exhaust Manifold Valve Shaft diameter Bush bore - reamed Shaft clearance in bushes ..

8

.. 97 octane minimum

.. 90 octane minimum

.. AC, FG

.. 2%- 3% lb/sq in

.. 8-8% lb

.. Zenith 42 WI AT

.. 3151

.. 3152

.. 3153

.. 3154

. . 36 mm (single bar)

.. 155

.. 185 ".50 .. 70 .. 2.25 mm .. 2.00 mm .. 23 mm from top face

of float chamber

.. 152

.. 150

.. 145

.. 185

.. 182

.. 180

•. With exhaust manifold flanges contacting surface plate, clear­ance between intake manifold flanges and plate must not be more than 0.014 in

.. 0.3080/0.3085 in

.. 0.3115/0.3135 in

.. 0.0030/0.0055 in

COOLING SYSTEM

Radiator

Leak Test Pressure .. 20 lb/sq in .. 13%- 17% lb/sq in Filler Cap Pressure Valve Opening Pressure ..

Fan Belt Tension . . 55 lb, equivalent to 0.38 in deflection midway between fan and alternator pulleys under load of 5 to 7 lb

Thermostat

Make Valve Opening Temperature Valve Fully Open Temperature Valve Fully Open Position - Measured from flange ..

Operating Lever Free Travel ..

Disc Hub Springs

Number Colour

CLUTCH

.. Western Thomson

.. 85°- 89°C

.. 99°- 102°C

.. 0.54 in minimum

.. 0.06 in

.. 6

.. Orange/violet

TORQUE WRENCH DATA

Connecting Rod Nuts . . . . . . . . * 41 lb ft

Crankshaft Main Bearing Bolts . . . . . . * 82 I b ft

Cylinder Head Bolts and Nut . . . . . . . . t 82 lb ft

Flywheel Bolts . . . . . . t 47 lb ft

Flexplate Bolts . . . . . . t 47 lb ft

Clutch to Flywheel Bolts . . . . . . t 17 lb ft

Torque Converter to Flexplate Bolts . . . . . . t 25 lb ft

* Oiled threads t Clean dry threads

9

RECOMMENDED LUBRICANTS- OVERSEAS

Usage SAE Viscosity Number Specification

Engine

Above 0° c 20W or 10W- 40 GM 6041- M

0° C to -12° C 10W or 10W- 30 or

Below -12° C 5W or 5W- 20 GM4745-M

or

Oil intended for Service MS

Clutch Cable Adjusting Clevis

--- GM 4530- M

Transmission Front Cover Sleeve

Clutch Operating Shaft and Bushes

Clutch Pedal Shaft, Bushes and Clevis -- GM 4550- M

Throttle Linkage

Main Drive Pinion Splines -- GM 4733- M

Water Pump Seal --- Castor oil base grease harmless to rubber

Paste of heavy mineral oil with 25% by Oil Seals ---

weight of molybdenum disulphide

10

_. _.

RECOMMENDED LUBRICANTS- UNITED KINGDOM

Usage BP Castro I Duckham's Esso Gulf Mobil Petrofina Regent Shell

Esso Gulfpride Fin a Havoline Super Extra Single G Multigrade Oil

Shell Castrol Mobil oil Visco-Static GTX 020-50 Motor Oil 10W/30 Super Motor Oil 10W/30

Super 10W/40 10W/30 Motor Oil

or or or or 10W/30 or or

Castrolite NOL 20 or Gulfpride Havoline or Mobil oil or Shell X 100 En ergo I

10W/30 Esso Motor Fina Motor Oil SAE 20W

Arctic 20/20W Engine Motor Oil 20/20W Oil 20/30 20/20W

20W/30

Where operators of a mixed Vauxhall/Bedford fleet, with gasoline and diesel engines of Vauxhall manufacture, prefer to use one oil for both types of engine, this must be one of our approved SAE 20 engine oils, to Specification Ml L- L-21 04A, Supplement 1, as recommended for all Bedford engines.

Esso Gulfsil Regent Clutch Cable Energrease G.G. Graphite Grease Grease

Adjusting Clevis C.3G Castro lease Grease Grease G.G7/8G Mobilgrease Fina Marson 904 Retinax or MS3 or or Special LM2 AM

Transmission Front Energrease LBM.10 Esso MP or or

Cover Sleeve L.21M Grease Grease Gulflex Molytex

(Moly) Moly Grease 2

Clutch Operating Shaft and Bushes

Clutch Pedal Shaft, -- -- Keenol -- -- -- -- -- --Bushes and Clevis

Throttle Linkage

Main Drive Pinion Esso Splines Energrease Castrolease LB.10 Multipurpose Gulflex Mobil grease Fina Marson Marfak Retlnax

L.2 LM Grease Grease A MP HTL2 Multipurpose A H 2

Castro I/ Girling 0.4590

Water Pump Seal -- Rubber Rubber TSD 803 -- -- -- - --Grease Grease (Red)

Oil Seals Rocol Anti-Scuffing Paste or Croda Grease GP/G.6691

12

ENGINE

ENGINE MOUNTINGS 14

VALVE TIMING CHECK 16

VALVE ROCKERS AND PUSH RODS 16

VALVE TAPPETS .. 19

CYLINDER HEAD AND VALVES .. 20

TIMING COVER AND CHAIN 24

CRANKCASE VENTILATOR VALVE 25

CRANKCASE BREATHER .. 25

OIL FILTER 26

OIL PAN 26

01 L PUMP AND STRAINER 27

FLYWHEEL 31

FLEXPLATE 32

ENGINE REMOVAL AND INSTALLATION 32

CRANKSHAFT REAR SEAL 33

PISTONS AND CONNECTING RODS 33

CRANKSHAFT AND MAIN BEARINGS 37

TIMING WHEELS AND CAMSHAFT 40

CYLINDER BLOCK 43

The engine is a 201 cu in six-cylinder unit with push rod operated valves.

The crankshaft is supported by four main bearings and shaft end float is controlled by thrust washers each side of the rear intermediate bearing. A spring-loaded oil seal is provided at the front of the crankshaft and a two-piece lip type oil seal at the rear. The pistons have solid skirts and recessed crowns; low compression pistons have a larger recess than the high

compression pistons.

____________________ ............

Four bearings support the camshaft which is chain driven; a thrust plate bolted to the cylinder block controls camshaft end float. Inclined valves operate direct in the cylinder head. The heads on the high and low compression engines are identical.

The oil pump is driven from the camshaft by skew gears, one of which is riveted to the pump driving spindle and has offset dogs to drive the distributor. The pump incorporates a spring· loaded plunger type relief valve. A full-flow type oil filter with detachable element is bolted

to the crankcase.

For crankcase ventilation, air enters through a wire gauze breather on the push rod cover, and after circulating through the crankcase, is extracted from the rocker cover via a hose connected to a ventilator valve in the intake manifold.

13

14

ENGINE MOUNTINGS

The engine front mountings are attached to brackets on the cylinder block and front axle crossmember.

The rear mounting is interposed between the transmission rear cover and a crossmember bolted to the underbody longitudinal members. Each end of the crossmember is insulated from the underbody members.

Either front mounting can be renewed after

removing bolt attaching mounting to engine

bracket and raising engine. When removing

left-hand mounting, ensure battery is discon-

nected so that alternator cannot be shorted

by bolt wrench.

Mountings are interchangeable side for side

and each has a spot of white paint (arrowed)

on top flange to identify their usage for the

201 cu in engine.

Support rear of transmission before removing

crossmember and rear mounting. Mounting

must be installed so that tab (arrowed) locates

in recess in transmission rear cover.

When installing crossmember, ensure insulators

'A' are assembled as shown, i.e. with bosses

engaged in holes in crossmember.

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@

~ 508

--~

A<..____ ~ (g)

~ 1 1 564

15

16

VALVE TIMING CHECK

Valve timing can be checked without removing timing cover. Procedure is as follows:

(a) With engine at T.D.C. (using U/C mark on flywheel) and No. 1 cylinder valves closed, temporarily attach a pointer to timing cover, and mark U/C on a piece of masking tape attached to periphery of crankshaft vibration damper.

(b) With rocker cover removed, mount a dial gauge over No. 1 intake valve with gauge plunger contacting valve spring cap.

(c) Turn engine in normal direction until valve is approximately fully open and set gauge to zero. Turn engine back until gauge reading is approximately 0.020 in, then turn in normal direction and mark tape when gauge reading is 0.005 in. before and after valve fully open position. Make a line midway between these two marks. If valve timing is as specified, circumferential measurement 'A' between U/ C line and midway line, should be between 5.20 and 5.50 in.

VALVE ROCKERS AND PUSH RODS

The valve rockers operate direct on a hollow

shaft mounted in brackets bolted to the cylinder

head. The rocker adjusting screw engages the

cupped end of a push rod.

The front and rear brackets are located by dowels for rocker shaft alignment.

VALVE ROCKERS AND PUSH RODS- Valve Clearance Adjustment

Valve clearance adjustment must be carried out

with engine idling at normal operating tempera-

ture.

After slackening locknut, use Adjuster D 1031 to

turn adjusting screw until specified clearance is

obtained. Recheck clearance after tightening

locknut.

VALVE ROCKERS AND PUSH RODS- Removal

For removal of rocker cover it is necessary to remove heater cover and air cleaner, also on right drive to slacken throttle cable support bracket. Before removing rocker gear, disengage oil pipe retaining clip from rocker shaft and withdraw pipe.

Single push rods can be removed by ensuring

corresponding valve is closed, slackening adjusting

screw and sliding rocker along shaft.

When lifting off rocker gear ensure the two

dowels locating front and rear brackets are not

dislodged.

17

18

VALVE ROCKERS AND PUSH RODS- Inspection and Reconditioning

If there is evidence of inadequate lubrication,

turn engine and check for oil flow from oil feed

drilling (arrowed) in cylinder head stud.

Oil supply to rockers is affected by a crimping

in rocker gear oil pipe. Check dimensions of

crimping as follows: 'A'- 0.12 in, 'B'- 0.025 in.

VALVE ROCKERS AND PUSH RODS- Installation

S3993

When assembling rockers and brackets to shaft,

locate shaft oil inlet hole at the top and towards

rear end of assembly. Ensure that end brackets

are those counterbored for location on dowels,

and assemble end tension springs with their

wider coils in contact with lock springs.

When installing rocker gear, ensure that front

and rear brackets engage dowels. Check that oil

pipe is securely retained by clip ( 1), and peg

(2) is fully engaged with shaft.

SIO

Final adjustment of valve clearance should be carried out with engine idling at normal operating temperature.

VALVE TAPPETS

After removing distributor, rocker gear and push

rod cover, tappets can be withdrawn. When

installing, smear tappets with graphited oil.

____,

19

20

CYLINDER HEAD AND VALVES

The cylinder head has inclined valves operating direct in the head. The valve rockers operate direct on a hollow shaft mounted on brackets; the end brackets are dowelled for shaft alignment. The rockers are positively lubricated by oil fed through oilways in the camshaft, cylinder block and a drilled cylinder head stud engaged by the rocker shaft oil pipe. The head and gasket on high and low compression engines are identical.

CYLINDER HEAD- Disassembly

After removing water pump, water distributor

tube can be withdrawn from cylinder head for

cleaning.

CYLINDER HEAD- Inspection and Reconditioning

t=======::::::;l_j t

Renew a valve if thickness of head 'A', after re- A

facing, is below specified minimum.

512

Replacement exhaust valves have an aluminium coating fused to seat face to improve heat conductivity; no attempt must be made to remove this coating by polishing or grinding. Used valves may be refaced.

After refacing valve seatings in cylinder head,

assemble valve spring cap and split collars and

check that height from cylinder head to underside

of cap does not exceed specified valve spring

assembled height. If this height is exceeded when

measured with a new valve, seating is too deep

and cylinder head is unfit for further service.

~

IT--- -' ' ----- I t t 1 __ !__...._ __ ~ ---"---, I ..._ __ ,_--- . ____ ,.

Cylinder head may be refaced, provided head

depth 'A' is not reduced below minimum,

otherwise pre-ignition, overheating and attendant

troubles may occur. When refacing head, contact

surface must be ground-finished as cutter marks,

however small, can be detrimental to gasket life.

A @ [)~@ L @ @I

SIJ

21

22

CYLINDER HEAD- Inspection and Reconditioning (contd)

53997

If width of seating 'A' exceeds that specified,

seating width must be reduced to within

specified limits using a 20° stone.

If valve stem to guide clearance is excessive,

guide must be reamed to appropriate diameter

with Reamers Z8500, Z8501 and Z8502 for

intake valves and Reamers VR2044, VR2045

and V R 2046 for exhaust valves, to accommodate

a valve with stem 0.003, 0.006 or 0.012 in

oversize, respectively.

Replacement valves with oversize stems are

identified by a number, representing oversize

in thousandths of an inch, stamped on stem.

After installing new expansion plugs in top of

cylinder head, they must be staked using a punch

with a 0.18 in diameter end. The three

indentations for each plug must overlap edge of

bore.

CYLINDER HEAD- Reassembly and Installation

After installing valves, ensure that water distributor

tube (1) is installed, and intake manifold collars

(2) are assembled to intake ports.

Smear Wellseal jointing compound on both sides of cylinder head gasket. The gasket is common to both high and low compression engines, and marked 'FRONT'.

Cylinder head bolts and nut must be tightened

gradually and evenly to specified torque in order

shown.

When refilling cooling system add one Vauxhall Stop Leak pellet.

-

S3999

515

To ensure full circulation of water through heater radiator, set heater control in HOT position and run engine at a fast idling speed, then top up radiator.

23

24

TIMING COVER AND CHAIN

Before removing timing cover, it is necessary to remove fan and pulley, also crankshaft pulley and vibration damper which is a push fit.

After removing timing cover, temporarily install

crankshaft pulley and bolt, and rotate engine until

valve timing marks ( 1) on timing wheels are in

line. After withdrawing chain detachable link (2),

which is polished for identification, remove

chain .

When pressing in a new seal ( 1), timing cover must

be supported (2) and a disc (3) inserted between

seal and press arbor. Seal lip should be towards

inside of cover.

When installing chain, ensure timing marks on wheels are in line and assemble link spring clip with its legs trailing.

When installing cover, smear each side of gasket with Wellseal jointing compound.

Before tightening cover bolts, locate Aligner

Z8575 on crankshaft spigot to engage and align

oil seal concentric with pulley land.

CRANKCASE VENTILATOR VALVE

If crankcase ventilator valve spring is weak or distorted, or valve seat is worn, valve assembly must be renewed. Check valve for free operation prior to installing in intake manifold.

c::IC::::::] 516

CRANKCASE BREATHER

Crankcase breather can be withdrawn from push

rod-cover by removing bolt. After cleaning wire

gauze element inside breather, oil element. When

installing, ensure leather washer 'A' is adjacent

to push rod cover.

25

26

OIL FILTER

The oil filter has a spring-loaded disc type by-pass

valve 'A' which ensures oil circulation should the

element become choked. Filter has a detachable

element and can be removed from casing after

unscrewing bolt.

A new gasket (arrowed) must be installed in

cylinder block recess. Ensure that casing is

seating against gasket before tightening bolt.

OIL PAN

For removal of pan it is necessary to remove

front suspension (see Training Manual TS 884).

It is also necessary, on models with synchromesh

transmission, to remove clutch housing braces

(1), bottom cover (2), plate (3) and front cover (4);

on models with Powerglide transmission,

removal of flywheel housing braces, and

converter housing bottom and front covers, is

entailed.

OIL PUMP AND STRAINER

The gear type pump, retained in the cylinder block with

an external setscrew and locknut, is driven by skew gears

from the camshaft. The pump body incorporates a

plunger-type pressure relief valve. Oil from the oil pan

is drawn through a strainer and a suction pipe connected

to the pump cover. Delivery of oil is via a pipe connected

to a drilling in the cylinder block then through a full-flow

filter to the main gallery.

@~

OIL PUMP AND STRAINER- Removal and Disassembly

After removing front suspension and oil pan,

pump can be withdrawn after disconnecting

suction pipe support ( 1), detaching oil delivery

pipe (2) from cylinder block, and removing

pump retaining setscrew.

518

27

A

28

OIL PUMP AND STRAINER- Reconditioning

0

519

Driven impeller spindle must be a tight fit in pump

body; relative position of this spindle in body is

as shown, dimension 'A' being 0.02 in. End of

driving spindle should be 0.06 in (dimension

'B'), from end of impeller.

Before installing drive gear, hold driving

impeller against body and check that metered

oil hole in spindle is fully uncovered when

aligned with slot.

Where a new driving spindle is being installed, press drive

gear on to spindle to give specified end float at 'A' when

impeller (arrowed) is in contact with body, before

drilling rivet hole with a 5/32 in diameter drill. Lubricate

spindle with graphited oil.

01 L PUMP AND STRAINER- Reassembly

After placing strainer screen in position, bend

down three tabs to retain screen firmly.

29

30

OIL PUMP AND STRAINER- Reassembly {contd)

When assembling oil suction pipe to pump, push

pipe {arrowed) firmly against seating in cover and

locate pipe so that relationship shown at 'A' is

0.64 in. before tightening pipe union.

OIL PUMP AND STRAINER- Installation

S4009

Before installing oil pump, align steel ball in

flywheel with notch in timing aperture, with

No. 1 cylinder on compression stroke.

To ensure that pump drive gear offset dogs will be

in correct location when pump is installed, turn

drive gear until dogs are positioned as shown.

After installing oil pump, check that angular

setting of drive gear offset dogs are at 'A' or

within range of 'A' to 'B'.

FLYWHEEL

2

The composite flywheel and flexplate assembly ( 1)

has a shrunk-on ring gear (2) and three dowels (3)

which protrude from the rear face for location of the

clutch. The assembly is attached to the crankshaft by a

securing plate (4) and bolts.

Flywheel and flexplate are balanced as an assembly and

should not be separated.

To remove ring gear, split gear with a chisel and lift it out of groove in flywheel. Do not drive gear off flywheel.

Ring gear must be installed so that tooth

chamfers face direction of rotation (arrowed)

of flywheel. Flywheel bolts must be tightened

evenly to specified torque.

31

32

2

524

FLEXPLATE

On models with Powerglide transmission, a flexplate to

which the ring gear is welded, connects the transmission

torque converter to the crankshaft. The attachment of

the flexplate to the crankshaft is by a securing plate and

bolts.

The Powerglide transmission and torque converter should

be removed as an assembly, see Training Manual TS743.

Withdraw flexplate evenly off crankshaft register to avoid

distortion of plate.

When installing, flange (1) carrying ring gear should be

facing towards engine. Flexplate attaching bolts (2) must

be tightened evenly and to the specified torque.

ENGINE REMOVAL AND INSTALLATION

To facilitate engine removal, remove transmission, bonnet, air cleaner, radiator and heater cover. For removal and installation of Powerglide transmission, see Training Manual TS743.

After lifting out engine, it must not be allowed to rest on flywheel or flexplate, as this may distort flexplate and render it unfit for further service.

CRANKSHAFT REAR SEAL

Removal of engine and crankshaft is necessary for access to the crankshaft rear oil seal. When removing crankshaft, remove connecting rod caps and bearings, leaving pistons and connecting rods in cylinder bores.

It is essential to thoroughly clean old sealing compound

from seal housings in block and cap. Apply Hylomar

SQ32/M jointing compound to the outside surface

'A' of seal, and install with lip of seal towards front of

engine. Seal ends should be flush with faces of block

and cap.

Renew cap oil seals when installing front and rear main bearing caps.

PISTONS AND CONNECTING RODS

The pistons have recessed crowns,

the high compression engine

A 525

piston 'A' having a smaller recess

than the low compression engine

piston 'B'. The engine compression

is identified by a stamping on the

crankcase. The offset piston pins are

fully floating and are retained by

circlips. A B 54012

The outer face of the top compression ring is inlaid with molybdenum. A conventional internally-stepped ring is used in the piston centre groove whereas the scraper ring is of the steel rail type.

Each connecting rod has an oil squirt hole through one side of bearing housing to direct oil on to thrust side of cylinder wall.

33

34

PISTONS AND CONNECTING RODS- Removal

Engine removal is necessary for access to pistons

and connecting rods. Piston and connecting

rod must be withdrawn from top of cylinder

bore.

PISTONS AND CONNECTING RODS- Inspection and Reconditioning

When assessing piston to cylinder bore clearance, and when reboring, maximufD accuracy in piston and bore measurement is essential.

As piston skirt is ground both oval and tapered,

it is imperative that piston size is measured only

at right-angles to piston pin and 0.10 in. from 0 bottom of skirt.

534

Micrometer spindle must turn freely so that it can be adjusted up to piston with a very light turning effort. If micrometer is adjusted to get a frictional feel over piston, it will show several tenths of thousandths smaller than the actual size. With practice fractional thousandths can be measured accurately.

When checking cylinder bores it is not sufficiently

accurate to take a direct reading from an inside

micrometer. For maximum accuracy, a cylinder

gauge should be used, in conjunction with the

same micrometer as used for measuring piston.

By this method, any discrepancy between

individual micrometers is avoided.

·rr· · :t-~ · rr ' l l i ' ' \ • ! : ; -: 9'i ,! ' :

~ .. ~: . ...,-.... -- ':"

For production purposes, eight grades of piston, identified by a letter on piston crown, are used. These grades represent 0.00025 in. subdivisions of an overall size range of 0.002 in. Pistons available for service are:

Standard-grades Y, TY, W, TW. Oversize-0.005, 0.020 and 0.040 in.

Before installing new bearings, check that

connecting rod bearing housing bore is with-

in .specified limit.

In production built engines, crankshafts with 0.010 in undersize crankpins may be used as alternative to standard shafts. Bearings should be ordered against numbers listed in Parts Catalogue and any discrepancies between markings on original bearings and replacement bearings should be ignored.

35

PISTONS AND CONNECTING RODS- Reassembly

When assembling piston to connecting rod, locate piston as

shown: (1) arrow head in piston indicates front of piston,

(2) piston pin offset, (3) centre line of piston, (4) oil squirt ·

hole.

When assembling a new scraper ring (arrowed)

do not separate rails (1) from spacer (2) as

these are temporarily bonded together with

oil-soluble material. After placing insert (3)

and expander (4) in piston bottom groove,

assemble rails and spacer with gaps in line as

supplied.

Note that top face of lower compression ring is

stepped.

When assembling top compression ring, face

3 526 marked 'TOP' must be towards top of piston.

36

PISTONS AND CONNECTING RODS- Installation

Before installing a new piston or rings in a worn bore, pass a hone equipped with fine grade stones, wetted with paraffin, three or four times through bore to remove highly polished surface. This will facilitate bedding-in of new rings.

Ring gaps must be equally spaced around piston

with scraper ring gap away from camshaft. Install

piston so that arrow head on piston crown faces

forward. Tighten connecting rod nuts to

specified torque. .. - 54013-__.j

CRANKSHAFT AND MAIN BEARINGS

The crankshaft is supported by four main bearings

and shaft end float is controlled by thrust

washers each side of the rear intermediate

bearing. A two-piece lip type oil seal is

provided at the rear of the shaft and a spring-

loaded seal at the front.

37

38

CRANKSHAFT AND MAIN BEARINGS- Removal

Crankshaft can be removed leaving pistons and connecting rods in cylinder bores.

Before removing crankshaft, check end. float to

determine if thrust washers on rear intermediate

bearing are worn. Oversize thrust washers are

serviced.

CRANKSHAFT AND MAIN BEARINGS- Inspection and Reconditioning

In production built engines, crankshafts with 0.010 in. undersize main journals and/or crank­pins may be used as an alternative to standard size shaft.

Replacement shafts are to standard dimension. Bearings should be ordered against numbers listed in Parts Catalogue and any discrepancies between markings on original bearings and replacement bearings should be ignored.

4 2

529

It is permissible to regrind main journals and crankpins to a maximum of 0.040 in. undersize provided oil seal land ( 1) is not damaged, or can be cleaned up to within specified limits. Fillet radius of each main journal (4) and crankpin (3), also the crank throw (5) of a reground shaft, must be within specified limits. When regrinding thrust faces (2) of rear intermediate main journal, whatever dimension 'A' is obtained, the corresponding dimension 'B' must be maintained to ensure correct location of crankshaft relative to crankcase.

If, with main bearing cap bolts tightened to

specified torque, a main bearing housing

vertical bore diameter is less than specified

lower limit, bearing cap must be renewed.

Joint face of replacement cap is machined 0.004 to 0.005 in. below bearing housing axis and shims must be used to adjust vertical diameter to within specified limits. Shims 0.002 and 0.003 in. thick are supplied and each check with replacement cap must be made with cap bolts tightened to specified torque. Shim thickness side for side may differ by 0.001 in.giving a vertical bore diameter variation of 0.0005 in. Selected shims must be kept to their respective cap to ensure correct reassembly.

CRANKSHAFT AND MAIN BEARINGS- Installation

Before installing crankshaft, install a new rear seal in crankcase and rear main bearing cap.

When installing thrust washers each side of rear

intermediate bearing, note that oil grooves must

face towards adjacent thrust face of crankshaft.

5403~

39

40

CRANKSHAFT AND MAIN BEARINGS- Installation (contd)

When installing front main bearing cap, its

front face must be in alignment with front face

of crankcase.

When installing front and rear main bearing cap

oil seals, coat first piece of felt with jointing

compound and drive home this and subsequent

felts. Approximately six felts are required for

each groove. Ensure that felts are tightly packed,

and leave about 0.06 in.of felt projecting as at

'A'.

TIMING WHEELS AND CAMSHAFT- Removal

Camshaft removal necessitates removal of

engine. Withdraw shaft carefully to avoid

damage to bearings.

Timing wheel should be withdrawn from crank­

shaft with a three-legged drag.

TIMING WHEELS AND CAMSHAFT- Inspection and Reconditioning

Camshaft rear bearing housing is sealed by an

expansion plug ( 1). Before driving out bearing

(2) and expansion plug, flywheel or flexplate

must first be removed. Before installing new plug,

smear periphery of plug and bore with Wellseal

jointing compound.

When installing camshaft bearings, ensure that

bearing oil holes coincide with oilways in

cylinder block. Each bearing must be located

so that notch is towards rear of block. Replace-

ment bearings are pre-finished to size.

54039

531

41

42

TIMING WHEELS AND CAMSHAFT- Inspection and Reconditioning (contd)

Camshaft rear intermediate bearing is identified

by two oil holes 'A' and 'B'. Smaller hole 'A'

should coincide with oil feed drilling to rocker

shaft oil pipe.

TIMING WHEELS AND CAMSHAFT- Installation

Press timing wheel on to camshaft until clearance

between front journal and thrust plate, represent­

ing camshaft end float, is within specified limits.

Smear tappets and camshaft with graph ited

oil. Ensure that oil feed drilling ( 1) in crankcase

front plate is free from obstruction, and timing

marks (2) are in line when installing chain.

Assemble chain link spring clip with its legs

trailing.

CYLINDER BLOCK

5ll

An oil gallery extends from front to rear of the cylinder block and is sealed by screwed plugs. Oilways direct oil from the gallery to the crankshaft and camshaft bearings and a vertical drilling above the camshaft rear intermediate bearing directs oil to the rocker gear. Two dowels protrude from the rear face for location of the clutch housing.

Cylinder block top face may be refaced provided

dimension 'A' is not reduced below specified

minimum after refacing, otherwise pre-ignition,

overheating and attendant troubles may occur.

When refacing, top face must be ground-finished

as cutter marks, however small, can be detrimental

• t ... to gasket life.

43

44

- - -· ·- -- ---- -

CYLINDER BLOCK (contd)

Use Remover V R2022 for withdrawing cup

plugs. To facilitate removal, drive plug inwards

slightly to break seal.

When installing, smear periphery of plug with

sealing compound.

FUEL AND EXHAUST THROTTLE CONTROL LINKAGE 45

FUEL TANK 46

FUEL PUMP 47

CARBURETTER AIR CLEANER 49

AUTOMATIC CHOKE 49

CARBU RETTER 54

MANIFOLDS .. 60

EXHAUST SYSTEM 63

The fuel system incorporates a downdraught type carburetter with an automatic choke unit. The carburetter air cleaner has a detachable element. A diaphr.agm type fuel pump supplies the carburetter from a tank mounted below the luggage trunk floor.

The intake manifold is bolted to the exhaust manifold and is heated by exhaust gases through a valve which is thermostatically controlled.

THROTTLE CONTROL LINKAGE

2

~~~6

3

The cam type throttle control lever ( 1) on the carburetter is cable operated. The inner cable (2) is connected to the accelerator pedal shaft lever (3) and retained by a washer (4) and spring clip (5). Earlier cables were retained by a spring clip only. The off position of the pedal is predetermined by a stop plate and buffer (6) on the shaft lever. A threaded sleeve (7) and locknuts (8 and 9) provides cable adjustment.

45

46

THROTTLE CONTROL LINKAGE (contd)

When installing a throttle cable, it is important that cable end is assembled to lever in direction arrowed as shown in 'A' for right drive, and in direction arrowed in 'B' for left drive. This ensures that relationship between cable and hole in dash panel is maintained to give a straight run for cable.

When stop plate buffer is against dash panel and throttle lever is in closed position, adjust nuts on threaded sleeve to provide a small amount of slackness in cable. Tighten nuts against cable mounting bracket, and check for full opening and closing of throttle.

FUEL TANK

The fuel tank is mounted on the underside of the luggage trunk floor and has a filler pipe projec!ing through the rear quarter side panel.

When installing tank gauge unit, ensure gauge

is located with wire terminal to the top.

FUEL PUMP

-· e fuel pump incorporates a diaphragm,

operated by a rod and link coupled to a rocker

arm in contact with an eccentric on the engine

~ ltJ ~t //~ a ~ camshaft. Pressure build-up in the pump when the

carburetter needle valve is closed, holds the

diaphragm downwards against spring pressure and

gO I ~~

Ll allows the rocker arm to idle without operating the

ink.

- ~~ f~j'<:-be'

583 .

FUEL PUMP- Disassembly and Reconditioning

Before parting pump cover, mark flanges to ensure

correct relationship when reassembling.

If valves are to be renewed, carefully prise valves out of pump cover. Do not remove rocker arm unless parts need renewal.

To renew rocker and associated parts, rocker arm can be withdrawn after removing pin retainers (2) and driving out pin (3). Diaphragm rod oil seal and retainer ( 1) can be removed, using a draw bolt and sleeve, after removing staking

around retainer.

When installing rocker arm (6) and link (4), locate spacers (5) each side of link, and secure pin with new retainers. 6

584

47

A

48

FUEL PUMP- Reassembly and Installation

52240

Diaphragm and rod assembly must be pressed

down and turned through 90° to engage rod

with rocker arm link and to align location tab

on diaphragm with lug on body.

Locate the valves as shown, inlet 'B' and outlet

'A'. Valves should be tapped or pressed into

position, using sleeve with a bore diameter 0.56

in. and external diameter 0.68 in. Stake body in

six positions around each valve.

When installing pump cover, ensure diaphragm

is flexed correctly by pushing rocker arm towards

pump until diaphragm is flat. Position cover with

marks on both flanges in line, tighten screws

finger tight. After operating rocker arm several

times to align diaphragm, hold arm towards

pump to hold diaphragm at bottom of stroke,and

tighten screws diagonally and evenly.

hen installing pump, assemble heat insulator

1) adjacent to pump, and ensure that baffle

gasket (2) has edges of its slot projecting away

from pump.

CARBURETTER AIR CLEANER

The air cleaner contains a detachable pleated

paper element and is mounted on a rubber sleeve

assembled to the carburetter.

Clean element by lightly tapping end surfaces.

Do not attempt to clean element by washing,

brushing or by using compressed air. Check that

gaskets are correctly positioned in shell and in

cover when installing element.

AUTOMATIC CHOKE

537

The carburetter choke flap spindle is coupled to a piston ( 1) which is vacuum operated by depression in the intake manifold and controlled by a thermostat (2) heated by clean air drawn through airways in a heat mass (3). Heat stored up in the heat mass prevents the thermostat cooling off too quickly and over-choking a warm engine. The choke flap is held closed by the thermostat when the engine temperature is below 15°C.

54028

49

50

AUTOMATIC CHOKE- Adjustment

Normal setting of the automatic choke is

indicated by a blue dot on rim of thermostat

cover ( 1) in line with a mark (2) on housing.

This setting should not normally require altering.

1 Checking or adjusting the setting cannot be

accurately carried out unless carburetter is

allowed to normalize to shop temperature for

at least four hours; removal of heat mass and

thermostat cover will accelerate normalization.

Choke flap spindle (3) and fast idle cam (4)

should be checked for free operation before

proceeding with choke adjustment.

After removal of thermostat cover and heat

mass, check that choke piston (arrowed) is

level with end of cylinder when choke flap

'A' is closed.

3efore adjusting setting, insert packing sufficient

o position throttle stop screw clear of fast idle

cam when choke flap is closed. Check shop

temperature which normally should be 16°

to 21 °C.

When installing heat mass and thermostat cover,

rotate clockwise so that free end of thermostat

contacts choke piston crankpin. For initial

setting, rotate cover slowly until choke flap front

edge is just in contact with wall of air intake. If

the flap, as it is being closed, is vibrated slightly

by lightly tapping the rear with a finger, point

of contact with air intake can more readily be

determined.

Having made this initial setting, rotate cover one serration clockwise. For every 6°C above normal shop temperature rotate cover one serration anti-clockwise, and for every 6°C below normal shop temperature rotate cover one serration clockwise. If original setting was incorrect, re-mark cover to align with mark on housing.

51

52

AUTOMATIC CHOKE- Adjustment (contd)

When reassembling air pipe to choke thermostat

cover, after completing adjustment of setting, hold

cover in position with a wrench when tightening

pipe union to ensure choke setting is not

disturbed.

AUTOMATIC CHOKE- Removal and Disassembly

After removing carburetter, withdraw thermostat cover, heat mass and insulating plate from housing, and remove thermostat from heat mass.

Remove piston by disconnecting crank from

choke flap spindle and rotating through 90°.

Remove locating washer from spindle prior to

removing thermostat housing from carburetter.

AUTOMATIC CHOKE- Inspection

For efficient working of the choke, it is important

that drilling (arrowed), and other interconnecting

air passages between thermostat housing, cylinder

and carburetter, are clear.

AUTOMATIC CHOKE - Reassembly and Installation

Ensure that locating washer is positioned on choke

~ ap spindle with serrated side of washer facing

outwards. Assemble crank to spindle with piston

'evel with end of cylinder when choke flap is

closed, see under 'Adjustment'.

Before installing heat mass, assemble thermostat

to heat mass as shown.

After installation of heat mass and thermostat cover, adjust setting of choke as detailed

under 'Adjustment'.

hen installing carburetter, hold thermostat

cover in position with a wrench when tightening

oipe union to ensure choke setting is not

distu rbed.

S411!#

53

54

CARBURETTER

3

$4018

The Zenith 42 WI AT carburetter is the single

choke tube downdraught type incorporating

an automatic choke ( 1) a piston type acceleration

pump, and a diaphragm-type economy device

(2). The throttle is operated by a cable

operated cam type lever (3).

PRECAUTIONS WHEN CLEANING JETS

When an acceleration pump discharge nozzle is

removed with carburetter installed on engine,

pump piston 'A' must not be operated as this

will dislodge from drilling arrowed, a pump ball

valve which could fall into engine.

To avoid risk of fire, main jet 'A' must never be

removed when engine is hot. Always place a

cloth below carburetter to soak up fuel which

will drain when removing main jet.

CARBURETTER- Idling Adjustment

Warm up engine until choke flap is fully opened by automatic choke, i.e. with throttle stop screw contacting low (top) step of fast idle cam.

Carburetter idling adjustment is carried out with

mixture volume control screw ( 1) in conjunction

with throttle stop screw (2).

Initial setting of volume control screw ( 1) is

approximately 1 Y.! turns out from fully-in

position. Anti-clockwise rotation of screw

enriches mixture.

With synchromesh transmission, idling speed should be 500 to 650 r.p.m.

On models with Powerglide transmission, idling adjustment must be carried with transmission in Drive or Reverse. Ensure that parking brake is applied and take care not to speed up engine unduly, otherwise car will move. Adjust to obtain smoothest idling with minimum creep.

CARBURETTER- Fuel Level Check

Before removing float chamber cover to check

fuel level, run engine to ensure that float

chamber is filled with fuel, and check that car

·s standing level.

uel level should be as specified and must be

crecked from top face of float chamber. Do not

disturb float when taking a measurement.

55

56

CARBURETTER- Removal and Disassembly

When removing carburetter, hold automatic

choke thermostat cover in position with a

wrench when slackening pipe to ensure choke

setting is not disturbed.

Power jet ( 1), idling jet (2) and pump discharge

nozzle (3) are accessible after removing float

chamber cover. Removal of idling jet, and main

jet located below float chamber, enables main

discharge tube (4) to be pushed out by applying

light pressure to top of tube. After detaching

pump discharge nozzle, invert carburetter to

remove pump ball valve from drilling below nozzle.

CARBURETTER- Reassembly

When installing main discharge tube, row of air

bleed holes ( 1) must be on the underside; slight

rot ation may be necessary to align its location

"ats (2) with those in carburetter body so that

-ube lip projects into small choke tube. Install

ain jet with a new seal ring (3).

11 s

538

3

'/ I

54113

57

s 114 -

58

CARBURETTER- Reassembly (contd)

54116

Before installing pump discharge nozzle with a

new gasket (1),place ball valve on its sealing below

tapped hole (2) in which nozzle retaining screw fits.

The ball is not spring-loaded. DO NOT tap ball on

to its seating otherwise it will become wedged

in drilling.

When assembling accelerator pump piston rod

to throttle lever, connect lever to lower hole in

rod and secure with a spring clip.

After installing power jet operating rod and

economy unit, ensure that rod moves freely

in guide bore under influence of diaphragm

spring.

Be sure float pivot pin retainer is installed with

its curved edge marked TOP uppermost.

CARBURETTER- Installation

When installing carburetter, assemble a gasket

on each side of heat insulator, and check that

mixture distribution corrector 'A' is located with

its ends engaged in slots of gasket on manifold.

Do not over-tighten carburetter attaching nuts.

hen reassembling air pipe to choke thermostat

cover, hold cover in position with a wrench when

- ghtening pipe union to ensure choke setting is

ot disturbed.

54117

59

60

MANIFOLDS

The intake and exhaust manifolds are bolted

together at the centre. An integral vapourizing

chamber ( 1) in the intake manifold is heated by

exhaust gases controlled by a heat valve (2)

thermostatically controlled and incorporated

in the exhaust manifold.

MANIFOLDS- Disassembly

When removing carburetter from manifolds, hold

automatic choke thermostat cover in position

with a wrench when slackening pipe union to

ensure choke setting is not disturbed.

MAN I FOLDS- Inspection and Reconditioning

To ensure intake manifold to cylinder head

joints are leak proof when manifolds are installed,

relationship between intake manifold flanges

with those of exhaust manifold must be within

specified limit. If clearance, representing flange

relationship, is in excess of maximum, stud

holes in intake manifold may be opened out to

provide adjustment of manifold position.

711

Before removing exhaust manifold heat valve, close valve as at 'C' and scribe on manifold a line projected from shaft slot.

Install bushes flush with manifold and ream bores to specified limit. Before arc welding valve to shaft at points 'A', observe the following:

(a) Align shaft slot, short side uppermost, with line scribed on manifold and position shaft so that its shoulder is 0.28 in, dimension 'B', from manifold.

(b) Maintain position of shaft and locate valve so that it contacts manifold at points 'C' and 'E' and has a clearance at 'D' not in excess of 0.10 in.

After installing thermostat and stop 'F', check that stop contacts spindle just before heat valve has reached its fully open position.

MAN I FOLDS- Reassembly

When assembling intake and exhaust manifolds

together, narrow flange of gasket aperture should

contact intake manifold.

61

62

MAN I FOLDS- Reassembly (contd)

The mixture distribution corrector 'A' should be

installed so that its ends engage slots of gasket on

manifold. When installing carburetter, ensure that

a gasket is reassembled to each side of heat

insulator. Do not overtighten attaching nuts.

Hold automatic choke thermostat cover in

position with a wrench when tightening pipe

union nut to ensure choke setting is not dis-

turbed.

MAN I FOLDS- Installation

When installing manifolds ensure that collars ( 1)

and gaskets ( 2) are assembled to intake ports of

cylinder head.

Bolts attaching manifold must be tightened evenly, after which intake-to-exhaust manifold nuts must be tightened. A sealing washer is used on long bolt located through centre of intake manifold.

EXHAUST SYSTEM

~5 , \ rrJ ...----------

11

,...

·1 )

712

The exhaust system comprises a front pipe and resonator, twin intermediate pipes and silencers, and tail pipes. The front pipe and resonator is supported at the rear end by a rubber suspension ring ( 1) hooked to a bracket clamped to the front end of the right-hand intermediate pipe. The silencers are supported by rubber suspension rings (2) to a bracket attached to the body under­panel and incorporating a rubber snubber (3) to restrict upward movement of the assembly. The tail pipes are supported by shear type mountings (4).

When installing exhaust system position resonator support bracket (5) so that clearance 'A' between silencer strap and snubber, is 0.26 in. Before tightening left-hand tail pipe clamps (6 and 7) ensure that clearance 'B' between pipe and Panhard rod mounting is not less than 0.86 in.

63

64

COOLING SYSTEM

CORROSION PREVENTATIVE 64

FAN BELT TENSION .. 64

THERMOSTAT 65

WATER PUMP 65

RADIATOR AND FILLER CAP 67

The cooling system includes a radiator, a centrifugal belt-driven pump with fan, and a capsule type thermostat located in a housing integral with the water pump body. A pressure/vent radiator filler cap pressurizes the system, raising the boiling point of the water, thereby reducing water loss. Two drain taps are provided, one in the radiator bottom tank and one at the centre of the right-hand side of the cylinder block.

CORROSION PREVENTATIVE

To prevent corrosion and subsequent silting up of the cooling system, 1/8 pint of Vauxhall Corrosion Preventative should be added when refilling system, also when Vauxhall Anti-Freeze has been added.

FAN BELT TENSION

Belt tension must be as specified, and should be

checked midway between fan and alternator

pulleys.

If a lever is used to move alternator, it is essential that leverage is applied ONLY to drive end shield of unit and NOT against stator or rear end shield.

When a new fan belt has been installed, belt tension should be checked after 1000 miles in service.

THERMOSTAT

To check if thermostat valve opening temperature and

valve fully open position are within specified limits,

suspend thermostat and a thermometer in a container

of water. Gradually heat and agitate water, but do not

allow thermostat or thermometer to rest on bottom as

this will result in a false temperature reading. Note that

fully open position is measured at 'A'.

A retainer secures the pump shaft

and bearing in the pump body.

A self-adjusting seal is located in

the body and contacts a rotor.

Both rotor and pulley flange are a

press fit on the shaft.

WATER PUMP

~~~ ~~ ~ .~

' '

WATER PUMP- Removal and Disassembly

When withdrawing rotor use a three-legged drag.

Seal can then be withdrawn from body.

If shaft and bearing is to be renewed, tap out

shaft and bearing complete with pulley flange.

71~

65

8

66

WATER PUMP- Reassembly

Shaft and bearing must be pressed into body, long end of shaft first, until bearing contacts shoulder in body bore.

53986

After installing shaft and bearing, press a new

retainer on to end of pump body.

Before installing seal in body, ensure seal is

correctly assembled. Grooves ( 1) in sleeve must

engage pips (2) in casing.

When installing seal, smear periphery ( 1) and

thrust face (2) with recommended grease.

Pulley flange must be pressed on to shaft

until dimension 'A' is 3.90 in. when pulley has a

nominal front flange diameter of 4.24 in. and

either a steel or plastic fan. With a 5.12 in.

diameter pulley and a plastic fan, dimension 'A'

should be 3.96 in. Rotor must be pressed on

shaft until dimension 'B' is 0.12 in.

When installing plastic fan, note that distance piece is assembled with its flat surface against front side of fan. Where a steel fan is used, the distance piece must have its flat surface against fan pulley.

RADIATOR AND FILLER CAP

The cooling system is pressurized to 15 lb/sq in

by a radiator filler cap incorporating a pressure

valve ( 1) which seats in the radiator filler neck,

and a vacuum or vent valve (2). At this pressure,

the engine operating temperature can be up to

125°C. 2 594

If possible, avoid removing filler cap while engine is at operating temperature, since hot water and steam will spray out. This is normal for all pressure-type cooling systems.

Should it become necessary to remove cap while engine is hot, care must be exercised. Place a cloth over cap, turn cap to first detent position until all pressure is released, then completely remove. On no account must cap be removed in one motion.

To ensure cooling system operates within

specified limits, it is important that both valves

and valve seating in filler neck are in serviceable

condition. To check opening pressure of filler

cap pressure valve, a pressure tester must be used.

This equipment can also be used for testing

cooling system for water leaks.

67

68

RADIATOR AND FILLER CAP (contd)

To check valve seating in radiator filler neck,

operate tester until specified cap pressure is

obtained. If pressure drops, check for leaks on al!

external connections and water pump before

carrying out a further examination of neck

seating.

The radiator has a tube and centre type core

which is soldered direct to top and bottom water

tanks.

CLUTCH

CLUTCH CABLE . . . . . . . . . . . . 70

CLUTCH PEDAL AND SUPPORT . . . . . . . . 71

CLUTCH OPERATING SHAFT AND RELEASE BEARING . . 72

CLUTCH . . . . . . . . . . . . . . 73

CLUTCH HOUSING . . . . . . . . . . . . 73

CLUTCH PI LOT BUSH . . . . . . . . . . 74

The clutch is a diaphragm spring type comprising a pressure plate and cover assembly and a disc. The diaphragm spring, which is interposed between the plate and cover, is attached to the cover by three drive straps. Operation of the clutch is by a pendant pedal, a cable, operating lever and shaft, and release bearing.

~

~f(~ 718

69

/.;

70

CLUTCH CABLE

~~~@@~a <f' 719

When clutch inner cable has been disconnected from pedal and operating lever, cable can be withdrawn after removing outer cable anchor nut 'A' which secures cable to pedal support.

Ensure insulating washers (1) are located each

side of pedal support before securing with

anchor nut (2).

When reconnecting lower end of cable, clevis

pin must be installed in upper hole (4) in

operating lever, and long end of return spring

hooked through bracket upper hole (1). Check that boot (2) is engaged in groove in outer cable.

Note that a plain washer and a spacer (3) i.e. brass nut, are assembled above front end of cable bracket to align cable.

CLUTCH PEDAL AND SUPPORT

The pendant type clutch pedal has nylon bushes

and is mounted on a common shaft with the

brake pedal. The shaft is retained in the support

by a spring pin at one end and split pin at the

other.

Clutch pedal can be removed leaving support in

position. To allow upper end of clutch pedal to

be withdrawn through slot (arrowed) in support

oracket, it is necessary to remove footbrake

1Dedal, and on right drive cars other than Ventora,

e parking brake lever.

When installing pedal, lubricate shaft bushes with recommended grease.

~

724

If necessary, pedals and support bracket can be removed as an assembly complete with clutch cable after removing brake servo and master cylinder assembly, also parking brake lever on right drive cars other than Ventora.

71

72

CLUTCH OPERATING SHAFT AND RELEASE BEARING

Clutch operating lever free travel 'A' should be

checked by moving lever forward. To obtain

specified free travel, rotate clevis adjusting

sleeve as required, after slackening locknut. Pedal

free travel is not a reliable indication of

operating lever free travel.

Note that cable clevis pin is installed in upper

hole in operating lever, and a plain washer and

spacer (brass nut) are assembled above front

end of cable bracket to align cable .

To allow clutch operating shaft and release bearing to be withdrawn, transmission must first be removed. Shaft is retained in position by a spring clip at one end, and the operating lever secured by a cotter at the other.

Shaft bushes must be prised out to enable shaft

to be removed. Rotate engine to bring a depression

in clutch cover opposite a shoulder in housing

to provide clearance for withdrawal of shaft.

Push lever end of shaft through housing and with-

draw shaft downwards.

Do not wash or degrease release bearing. Before installing operating shaft and lever, smear recommended grease on bushes, also on transmission front cover sleeve and main drive pinion splines before installing transmission.

CLUTCH

Clutch cover and pressure plate assembly cannot be disassembled. If any part is considered unfit for further service, assembly must be renewed.

When installing clutch disc ensure that marked

side is towards flywheel. Tighten bolts evenly

and diagonally to specified torque.

CLUTCH HOUSING

Before clutch housing can be removed, it is necessary to remove the transmission, clutch, starter and flywheel.

Housing is located by dowels at each side of

crankcase. When installing, ensure that dowels

are located in crankcase.

73

74

CLUTCH PILOT BUSH

Use Remover Z8527 to withdraw clutch pilot

bush.

To install bush, locate bush (1) on Installer

Z8566 and turn adjusting nut until pilot

projects slightly through bush. Pilot is used for

correct sizing of bush bore and therefore must

be free from burrs. Drive bush into crankshaft

until installer sleeve contacts shaft (2). Withdraw

pilot by screwing down nut. Bush is oil impreg­

nated and does not require lubricant on assembly.

GENERAL INDEX

A Air Cleaner ..

Automatic Choke

c Camshaft and Timing Wheels

Carburetter ..

Carburetter Air Cleaner

Clutch

Clutch Cable

Clutch Housing

Clutch Operating Shaft and Release Bearing

Clutch Pedal and Support

Clutch Pilot Bush

Cooling System

Corrosion Preventative

Crankcase Breather ..

Crankcase Ventilator Valve

Crankshaft and Main Bearings

Crankshaft Rear Seal

Cylinder Block

Cylinder Head and Valves

E Engine

Engine Mountings

Engine Removal and Installation

Exhaust System

Fan Belt Tension

Flexplate

Flywheel

Fuel and Exhaust

F

49

49

40

54

49

73

70

73

72

71

74

64

64

25

25

37

33

43

20

12

14

32

63

64

32

31

45

Fuel Pump

Fuel Tank

L Lubricants Recommended

Manifolds

Oil Filter

Oil Pan

Oil Pump and Strainer

M

0

p

Pistons and Connecting Rods

Precautions When Cleaning Jets

R Radiator and Filler Cap

Recommended Lubricants

s Specifications

T Thermostat ..

Throttle Control Linkage

Timing Cover and Chain

Timing Wheels and Camshaft

Torque Wrench Data

v Valve Clearance Adjustment

Valve Rockers and Push Rods

Valve Tappets

Valve Timing Check . .

w Water Pump ..

47

46

10

60

26

26

27

33

54

67

10

5

65

45

24

40

9

17

16

19

16

65

75