Reliant Kitten Saloon Instruction manual

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Kitten Saloon and Estate
Workshop Manual
Incorporating the Factory supplement pack
©The Reliant Motor Company Limited July 1975 Remastered January 2011 by Atodini

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Introduction Contents
This Workshop Manual contains all the
relevant information to assist Reliant Dealers to
service and maintain the Kitten Saloon, Estate and Van
Models.
Dismantling, assembly and adjustment
procedure for all major units and associated parts are
dealt with in detail.
A comprehensive stock of spare parts are
available from Reliant Dealers. a spare parts list is
available for use when ordering. Only genuine Reliant
"R" parts should be used.
Service Department
Reliant Motor Company Limited
Two Gates Tamworth
Staffordshire B77 1HN
Telephone Tamworth 4151
Telegrams Reliant Tamworth 4151
Telex 341501
Parts Supply Department
The Reliant Motor Company Limited
Lynn Lane Shenstone
Staffordshire WS14 0ED
Telephone Shenstone 480671
Original "R" Part No. 91048
General Specification pages3-4
Lubrication and Maintenance pages5-14
Section A Chassis Frame page15
B Front Suspension pages16-20
C Rear Suspension pages21-22
D Steering pages23-28
E Cooling System pages29-33
F Engine pages34-51
G Gearbox pages52-57
H Clutch pages58-61
J Drive Shaft pages62-63
K Rear Axle pages64-71
L Brakes pages72-79
M Road Wheels pages80-81
N Exhaust System page82
P Fuel System pages83-88
Q Body pages89-98
R Interior pages99-104
S Heater pages105-106
T Electrics pages107-134
U Windscreen Washer pages135-136
V Tightening Torques pages 137-138

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General Specification
Engine
Number of Cylinders 4 in-line
Bore of cylinders 62.50 mm (2.46 in)
Stroke of crankshaft 69.09 mm (2.72 in)
Cubic capacity 848 cc (51.77 cu in)
Compression ratio saloon/estate 9.5 to 1
van 8.5 to 1
Speed at 1,000 rpm in top gear saloon/estate 17 mph (37.4 kph)
van 15.5 mph (25 kph)
Valve clearance -
Inlet 0.25 mm (0.010 in) Hot 0.152 mm (0.006 in) Cold
Exhaust 0.25 mm (0.010 in) Hot 0.152 mm (0.006 in) Cold
Performance Data
Brake Horse Power (maximum) 40.0 at 5,500 rpm
Torque (maximum) 6.38 kg/m (46 lb ft) at 3,500 rpm
Lubrication System
Pump Submerged eccentric rotor type
Filter External full-flow type
Oil Pressure 3.16 kg/sq cm (45 lb/sq in)
Ignition System
12 Volt battery and coil Negative Earth
Contact breaker gap 0.38 mm (0.015 in)
Sparking Plugs - Type Motocraft AGR 32
Gap 0.64 mm (0.025 in)
Firing Order 1, 3, 4, 2
Ignition Timing 10° BTDC
Cooling System
Pressurised radiator, pump assisted circulation and four-bladed fan driven by a "V" belt from engine pulley
Radiator cap pressure 0.492 kg/sq cm (7 lbs/sq in)
Fuel System
Carburettor Emission controlled SU type HS2 - 1¼ in
Fuel Pump AC Delco mechanical
Air Cleaner Paper element type
Clutch
Type Single dry plate 158.75 mm (6.25 in) diameter
Operation Cable
Gearbox
Four forward speeds and reverse. Synchromesh on all forward gears
Ratio: Top 1.00:1
Third 1.32:1
Second 2.05:1
First 3.88:1
Reverse 3.25:1
Rear axle
Type Spiral bevel gear semi floating
Ratio saloon/estate 3.23:1
van 3.545:1
Brakes
System Lockheed hydraulically operated internal expanding to all wheels
Size - Front 177.8 x 38.1 mm (7 in x 1.50 in)
Rear 177.8 x 31.25 mm (7 in x 1.25 in)
Handbrake Lever type operating rear brakes mechanically by cable linkage
Suspension
Front Reliant independent - wishbones, coil springs, damper units and anti roll
bar
Rear Reliant - progressive rate leaf spring, telescopic damper units.

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Steering
Type Rack and pinion
Turning Circle 7.32 m (24 ft)
Castor 12°
Camber 1° positive
Toe-in Zero
King pin inclination 9°
Conforming to European Safety Regulations
Chassis Data
Type Box section with tubular cross members and channrel section diagonal cross
bracing.
Wheelbase 2146 mm (84.65 in)
Track, front and rear 1244.6 mm (49 in)
Ground clearance (fully laden) 127.0 mm (5.0 in)
Wheels and tyres Saloon/Estate Van
Road wheels 350B x 10 350B x 10
Tyres 145 x 10 radials 520 x 10 cross ply
Capacities
Engine including filter 3.13 litres (5.50 pints)
Gearbox 0.64 litres (1.125 pints)
Rear axle 1.28 litres (2.25 pints)
Steering rack and pinion 0.19 litres (0.33 pints)
Cooling system including heater 3.69 litres (6.5 pints)
Fuel tank 27.3 litres (6 gallons)
Vehicle Dimensions Saloon Estate Van
Overall length 3327.4 mm (131 in) 3346.5 mm (131.75 in) 3346.5 mm (131.75 in)
Overall width 1422.4 mm (56 in) 1422.4 mm (56 in) 1422.4 mm (56 in)
Overall height 1397 mm (55 in) 1397 mm (55 in) 1397 mm (55 in)
Loading height 1016mm (40 in) 508 mm (20 in) 508 mm (20 in)
(ground to tailgate sill) (ground to rear floor) (ground to rear floor)
Load width - maximum 1028.7 mm (40.5 in) 850.9 mm (33.5 in) 850.9 mm (33.5 in)
(width at tailgate sill) (rear door aperture) (rear door aperture)
Load height - maximum aperture 457.2 mm (19 in) 749.3 mm (29.5 in) 749.3 mm (29.5 in)
(tailgate aperture height) (rear door aperture) (rear door aperture)
Load height - maximum inside vehicle 850.9 mm (33.5 in) 876.3 mm (34.5 in) 876.3 mm (34.5 in)
Length behind rear seat 647.7 mm (25.5 in) 693.1 mm (26.5 in)
Length with rear seat folded 1092.2 mm (43 in) 1168.4 mm (46 in)
Load floor width behind rear seat 952.5 mm (37.5 in) 952.5 mm (37.5 in)
Load capacities
Saloon - capacity of boot area, rear seat up, spare wheel in position
below tonneau cover 0.230 cu m (8.5 cu ft)
Saloon - capacity of rear compartment with rear seat folded, spare
wheel in position, up to roof level 0.849 cu m (30 cu ft)
Estate - capacity of rear compartment with spare wheel in position
and rear seat up 0.270 cu m (9.5 cu ft)
Estate - capacity of complete rear compartment, with spare wheel
in position and rear seat folded 1.132 cu m (40 cu ft)
Van - capacity with front passenger seat installed 1.189cu m (42 cu ft)
Van - capacity with front passenger seat removed 1.500 cu m (53 cu ft)
Kerb weight
Saloon 505.81 kg (1114 lb)
Estate 538.9 kg (1187 lb)
Van 515 kg (1134 lbs)
Maximum towing weights
Gross laden vehicle weight 862 kg (1900 lb)
Approximate payload 320 kg (700 lb)
Maximum recommended front axle weight 363 kg (800 lb)
Maximum recommended rear axle weight 550 kg (1210 lb)
Recommended towing weight (maximum) 406 kg (896 lb)

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Lubrication and maintenance
The maintenance periods fall in to well classified categories.
1. Regular weekly attention.
2. Maintenance at the first 1,000 miles (1500 km).
3. Maintenance at 6,000 mile (10,000 km) intervals - standard
service.
4. Maintenance at 12,000 mile (30,000 km) intervals - major
service.
The standard and major service intervals are designed to ensure
safety and reliability under most operating conditions. However, if
your operating conditions are severe, you cover a very low annual
mileage or have a high proportion of short journeys, a supplementary
service is recommended at intervals of 3,000 miles (5000 km).
This intermediate service is particularly important with increasing
vehicle mileage, after the first 12,000 miles (20,000 km). This
supplementary service is limited to simple checks and adjustments,
easily carried out by an owner, all of which are described in the
following pages of this manual. The work can, of course, be entrusted
to a dealer if you prefer.
Details of the intermediate service together with the standard and
major services, are included in the "Key to service" booklet.
Presentation of this service booklet to any Reliant dealer will ensure
proper completion of the maintenance operations.
The operations listed below should be carried out at the mileages
shown.
Operation
Lubrication
Check and top up engine oil level
X X
Change engine oil X X X X X X X
Change oil filter
X X X X X X X
Check and top up gearbox oil
X
X
X
X
Change gearbox oil
X X X
Check and top up rear axle oil
X
X
X
X
X
X
Clean oil filler cap and connecting hose X X X X X X X
Oil or grease all lubrication points
X
X
X
X
X
X
X
Lubricate throttle linkage and top-up carburettor damper X X X X X X X X
Lubricate all locks and hinges
X
X
X
X
X
X
X
General
Check air cleaner element
X
X
X
X
Replace air cleaner element X X X
Tighten cylinder head, sump and manifold fixings
X
X
X
X
X
X
X
Check and adjust valve clearances X X X X X X X
Check and adjust fan belt tension
X
X
X
X
X
X
X
X
Examine and adjust or replace distributor points X X X X X X X X
Clean coil, distributor cap and HT leads
X
X
X
X
X
X
Clean and adjust spark plugs X X X
Replace spark plugs
X X X
Remove and clean carburettor X X X
Change fuel filter
X
X
X
Check and top-up master cylinder X X
Check hydraulic system, bleed and top-up
X X X X X X
Replace hydraulic system fluid and seals or replace units, replace hoses X
Inspect brake system for leaks and hoses for chafing
X X X X X X X
Examine brake shoes X X X X X X X
Adjust brakes
X X X X X X X X
Check handbrake cable and adjust X X X X X X
Check security of wheels
X X X X X X X X
Adjust tyre pressures and inspect condition of tyres X X X X X X X X X
Check and adjust clutch
X X X X X X X
Check condition of steering rack gaiters X X X X X
Check body, suspension, steering retaining fixings and connections
X X X X X X X
Check and adjust front wheel bearings X X X X X
Repack front wheel bearings and adjust
X
Check front wheel toe-in, also rear wheel alignment X X X X
Weekly First 1,000 miles (1,500 km) 3,000 miles (5,000 km) 6,000 miles (10,000 km) 12,000 miles (20,000 km) 18,000 miles (30,000 km) 24,000 miles (40,000 km) 30,000 miles (50,000 km) 36,000 miles (60,000 km)

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Operation
Check door operation, locks and hinges
X
X
X
X
X
X
X
Top-up battery, check connections X X X X X X X X X
Top up radiator coolant
X
X
X
X
X
X
X
X
X
Check for oil and water leaks X X X X X X X
Check all controls, lights, horn, instruments
etc.
X
X
X
X
X
X
X
X
X
Check headlamp alignment X X X X X X
Check washer reservoir and top-up
X
X
X
X
X
X
X
X
X
Check external condition of exhaust system X X X X X X
Check and if necessary renew windscreen
wiper blades
X
X
X
Road test
Check brake function X X X X X X X X
Adjust ignition timing and dwell angle
X
X
X
X
X
X
X
Adjust carburettor X X X X X X X
Warning: Emission controlled carburettors require special attention
Routine maintenance - Engine
Check and top-up engine oil level
1. Withdraw dipstick. Wipe clean and replace. remove
again and note oil level indicated by trace of oil to the full mark on
the dipstick.
2. If necessary top-up with a recommended grade of oil to
the full mark on the dipstick. Do not over fill (figure 2)
Drain engine oil and refill
This operation is best carried out when the engine is warm.
1. Place a suitable receptacle under the drain plug and
unscrew the plug slowly until oil begins to escape. When the rate
of flow lessens, remove the plug completely and allow the oil to
drain for a few mintues. (figure 3) Care should be taken to ensure
that no dirt or grit enters the sump whilst the plug is removed.
2. Clean the plug thoroughly and check the condition of
the sealing washer. If damaged the washer should be replaced
Weekly First 1,000 miles (1,500 km) 3,000 miles (5,000 km) 6,000 miles (10,000 km) 12,000 miles (20,000 km) 18,000 miles (30,000 km) 24,000 miles (40,000 km) 30,000 miles (50,000 km) 36,000 miles (60,000 km)

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otherwise oil leaks may result. refit the plug and screw in tightly.
Refill the sump via the oil filler cap with the recommended grade
of oil. A flushing oil can be used to advantage on engines which
have done a considerable mileage, particularly if the
recommended oil change intervals have not been adhered to.
Figure 2 Engine oil level dipstick
1. Dipstick
Renewing oil filter
This operation is best carried out when the engine is warm.
1. Place a suitable receptacle under the drain plug and
unscrew the plug slowly until the oil begins to escape. When the rate
of flow lessens, remove plug and allow oil to drain for a few minutes.
Clean and replace drain plug.
2. Grasp the oil filter with both hands, turn in an anti-
clockwise direction, remove and discard. (figure 4)
3. Clean the cylinder block face. Fit a new filter and screw
firmly home.
4. Refill the sump via the oil filler cap with the recommended
grade of oil to the "full" mark on the dipstick.
5. Start engine and check for oil leaks between filter and
cylinder block face.
Oil Filler Cap
The cap is a push-pull fit. The oil filler cap contains a wire gauze
element and should be washed in clean paraffin. Dip the cap in clean
oil and wipe thoroughly before refitting.
The oil filler cap also acts as an engine ventilator and is connected via
a hose to the carburettor. It is important that the hose is maintained
in good condition and connected securely. air leaks will result in
misfiring and erratic running.
Check and top-up cooling system
Warning: Do not remove radiator filler cap when the engine is hot.
1. Remove radiator filler cap.
2. If necessary, top up with water until the top header tank of
the radiator is approximately two thirds full. Some vehicles will have a
radiator that has a coolant level indicator visible in the filler neck.
Replace the filler cap.
Check leaks from cooling and heater system
1. Check hose connections and tightness of clips.
2. Check radiator drain plug (if fitted).
3. Check cylinder block drain plug.
4. Examine cylinder block core plugs
5. Examine heater water system for leaks
Figure 3 Sump and gearbox drain plugs
1. Sump drain plug
2. Gearbox drain plug
Check and top-up brake fluid reservoir
1. Wipe clean the reservoir cap and surrounding area and
remove the cap. Examine the fluid level and top up to the bottom of
the reservoir filler neck.
Use only new fluid of the correct specification, taken from a
sealed container for topping up. Never under any circumstances use
fluid that has been previously bled from a system to top up the master
cylinder reservoir as it may be aerated, have too much moisture
content or possibly be contaminated.
Note: Castrol Girling "Crimson" brake fluid has been used for initial
fill. If not available to top up use Castrol Girling "Universal" or a listed
alternative.
Check and top-up windscreen washer fluid reservoir
Examine the water level in the plastic windscreen washer
reservoir and if necessary top-up with clean water.
Caution: Do not use Glycol anti-freeze solutions or denatured
alcohol (methylated spirits). The use of these chemicals will
discolour the paintwork and will damage the wiper blades.
Check and top-up battery
1. Check the electrolyte level, which, when correct should just
cover the separators. Top-up if necessary using distilled water only.
2. Remove the battery connections, wipe clean and before
refitting, smear the terminal posts with petroleum jelly (vaseline).
3. Check the specific gravity of the electrolyte (see section T)
Top-up carburettor piston damper
1. Unscrew and withdraw the plug and piston from the top of
the suction chamber (figure 5)
2. Note that the oil level, which, when correct, is 13 mm (½in)
above the top of the hollow piston rod. Top-up if necessary with clean

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engine oil, SAE 20 or 20/50 grade and refit the hexagon plug and
piston assembly
Figure 4 Engine Oil Filter
1. Oil filter
2. Oil pressure relief valve
3. Oil pressure switch
Lubricating distributor
1. Remove distributor cap.
2. Lift off rotor arm.
3. Apply a few drops of oil to the felt pad in the centre of the
rotor spindle.
4. Lightly grease the cam surface.
5. Wipe away surplus oil and grease.
6. Refit the rotor arm and distributor cap.
Check condition and adjust distributor points
1. Remove the distributor cap and rotor arm.
2. Turn the engine so that the heel of the contact breaker is
on the highest point of the cam. (it may be necessary to remove the
sparking plugs to eliminate resistance caused by engine compression).
3. Slacken the slotted head screw in the contact plate and
adjust until the gap is 0.38 mm (0.015 in) (Figure 6). The gap is
measured with a suitable feeler gauge and pressure should be applied
to the points, with the feeler gauge inserted, whilst the screw is being
tightened.
4. Retighten the screw and make a further check with the
feeler gauge in case tightening has altered the setting.
5. Reposition the rotor arm squarely on the distributor cam
boss with the slot and lug in line. Press the rotor into position on the
spindle
Note: When the rotor is fitted to the spindle the lower face does not
abut the cam.
If the points are badly worn or pitted they should be replaced. For
replacement procedure see Section T.
Clean and adjust spark plugs
1. Remove each spark plug in turn from engine.
2. Clean the electrodes with a wire brush or plug cleaner.
3. Using a 0.64 mm (0.025 in) feeler gauge, check the gap and
adjust if necessary by bending the side electrode towards or away
from the central electrode as necessary.
4. Discard plugs which have badly burned electrodes or
cracked ceramic insulators. A centre electrode in good condition will
still have a square form without signs of wear.
Figure 5 Carburettor - lubrication
1. Suction chamber.
2. Damper.
3. Fuel trap.
5. Refit the plugs complete with washers and tighten to a
torque of 2.1 kg/m (15 lb/ft)
Check torque of cylinder head nuts
Cylinder head nuts should be tightened to a torque of 3.46 kg/m (25
lb/ft). The three 5/16 in unf nuts fitted to the spark plug side must be
tightened to a torque of 2.07 kg/m (15 lb/ft). The correct sequence for
cylinder head nuts tightening is shown in Section F
Check and adjust valve rocker clearances
Valve clearances are 0.152 mm (0.006 in) cold, 0.254 mm (0.010 in)
hot.
1. Remove rocker cover.
2. Remove spark plugs.
3. Turn engine in normal running direction in order to open
and close the valves and check in the following order:
No. 1 valve with No. 8 valve fully open.
No. 2 valve with No. 7 valve fully open.
No. 3 valve with No. 6 valve fully open.
No. 4 valve with No. 5 valve fully open.
No. 5 valve with No. 4 valve fully open.
No. 6 valve with No. 3 valve fully open.
No. 7 valve with No. 2 valve fully open.
No. 8 valve with No. 1 valve fully open.
When adjustment is made the valve must be in the fully closed
position (figure 7).
4. Refit spark plugs.
5. Refit rocker cover, renewing gasket if necessary and secure
with nuts and washers.

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Clean air filter element
1. Clean the outside of the air filter body and release the two
clips retaining the body to the base plate. (figure 8)
2. Carefully withdraw the element from the base plate.
3. Clean the base plate and body interior
4. Clean between folds of the element using a low pressure air
line or soft brush.
Figure 6 Distributor - general view
1. Locking/adjustment screw.
2. Cam spindle lubrication pad.
3. Breaker arm pivot post.
4. Terminal post.
5. Low tension lead.
Figure 7 Valve clearance - tappet adjustment
1. Feeler gauge.
2. Adjusting screw.
3. Lock nut.
5. refit the element or replace with a new element ensuring
the plastic ends of the element are smeared with petroleum jelly or
grease to facilitate sealing.
6. Replace the body and secure with the two clips.
Note: The frequency necessary for cleaning or replacing the element
will depend on the severity of the operating conditions and where
there are heavy dust concentrations or unusually severe conditions
more frequent attention should be given to the cleanliness of the unit.
Figure 8 Air Cleaner
1. Body.
2. Element.
Figure 8A Air cleaner from chassis No 6F7/14701001sal,
6F7/14801002 estate, 6H1/14901043 van
1. Body
2. Element
Figure 9 Fan belt adjustment
1. Adjustment locking screw.
2. Alternator front mounting bolt.

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Adjust and check condition of the fan belt
The fan belt should be sufficiently tight to drive the alternator and
water pump without loading the bearings unduly. The adjustment is
correct when the belt can be moved laterally 13 mm (½ in) at the mid
point between the alternator and water pump pulleys. (figure 9)If
adjustment is necessary proceed as follows:
1. Slacken the alternator front mounting bolt.
2. Slacken the adjustment locking screw at the front of the
alternator allowing it to be moved on the slotted strap.
3. Pivot the alternator away from the engine until the correct
slack is achieved. Maintain the alternator in this position and tighten
the locking screw and front mounting bolt. Re-check the adjustment.
Note: The front lower mounting must be slackened completely before
making any adjustment as any strain on the lower fixings could distort
or damage the mountings.
Regularly examine the fan belt for wear and renew if necessary.
Figure 10 Gearbox oil level and drain plugs
1. Filler/level plugs.
2. Drain plug.
Check security of starter and alternator fixing bolts
Starter Motor
Using a torque wrench set to 4.15 to 4.84kg/m (30 to 35
lb/ft) check tightness of attachment nuts and bolts.
Alternator
1. Check tightness of front mounting bolt - 2.1 to 2,7 kg/m (15
to 20 lb/ft).
2. Check alternator to strap locking screw - 1.1 to 1,3 kg/m (8
to 18 lb/ft).
Check security of engine mountings
The engine and gearbox assembly is secured to the frame at three
points.
1. Check tightness of front right and left hand attachment nuts
- 2.76 to 3.46 kg/m (20 to 25 lb/ft).
2. Check tightness of gearbox rear attachment nuts - 2.07 to
2.49 kg/m (15 to 18 lb/ft).
Check/adjust carburettor settings
Start the engine and warm to normal running temperature. Push the
choke control fully home.
1. Ensure the fast idling screw is clear of the choke cam.
2. Adjust idling screw to achieve an idling speed of
approximately 800 to 850 rpm. Should these adjustments fail to
achieve satisfactory results refer to Section P.
Lubricate accelerator linkage
Using an oil can, lubricate the accelerator linkages on the carburettor.
Wipe away surplus oil (figure 5)
Routine maintenance - under body
Check and top-up gearbox oil
1. Place the vehicle on ramp or over pit.
2. Remove gearbox level plug and observe oil level correct
when in line with the bottom of the level hole threads (figure 10).
3. If necessary top up via the level hole using a pump type oil
can with a flexible nozzle charged with the recommended oil until the
level is correct.
Figure 11 Rear axle oil filler/level plug
1. Filler/level plug.
Figure 12 Driveshaft grease nipples
1. Sliding spline grease nipple.
2. Universal joint grease nipple.

Page 11
4. Wipe clean and refit level plug. Tighten to a torque of 2.07
to 2.76 kg/m (15 to 20 lb/ft)
Check and top up level of rear axle oil
1. Place the vehicle on ramp or over pit.
2. Wipe clean the level plug and surrounding area and remove
plug (figure 11).
3. Observe oil level which is correct when level with the
bottom of the level hole threads.
4. If necessary, top up via the level hole, using a pump type oil
can with a flexible nozzle, charged with a recommended oil, until the
level is correct.
5. Wipe clean the level plug and refit. Tighten to 2.07 to 2.76
kg/m (15 to 20 lb/ft)
Lubricate drive shaft
1. Place the vehicle on ramp or over pit.
2. Using a grease gun charged with a recommended lubricant.
Figure 13 Handbrake cable grease nipples
1. Grease nipples
Apply grease via the nipple located at the gearbox end of the drive
shaft and to the nipple on each of the universal joints.
Lubricate handbrake cable and cable guides
1. Place the vehicle on ramp or over pit.
2. Using a grease gun charged with a recommended lubricant,
apply grease to the cable by means of the two grease nipples (figure
13) Apply grease at any area of the exposed inner cable and liberally
coat the cable guides on the axle with grease to prevent the inner
cable binding on the guides.
Check hydraulic system and fuel system pipes for chafing, leaks
and corrosion
Follow the run of all brake hydraulic pipes and ensure that at no point
are they chafing against body or frame members. Note and report any
corroded section of pipe. Examine all joints for leaks whilst a second
person applies pressure to the brake pedal. Check that the flexible
hoses are not kinked or strained when the steering is turned from lock
to lock.
Examine the run of the fuel line from tank to carburettor and ensure
that at no point is it chafing against the body or fouling components.
Check the rubber connections between sections of pipe are not
unduly stained, perished or split.
Check exhaust system for leakage and security
Check security of the exhaust connections and manifold bolt
tightness. Examine the system for corrosion and deterioration.
Check tightness of suspension fixings, tie-rod levers, steering unit
attachments and steering universal coupling bolts plus check
gaiters for damage
Rear suspension
1. Check tightness of nuts and bolts securing the leaf springs
and shackles to the frame.
2. Check tightness of nuts and bolts securing the upper and
lower ends of the dampers to the rear axle and chassis frame.
Figure 14 Headlamp adjusting screws
1. Horizontal adjustment screw.
2. Vertical adjustment screw.
Front suspension
3. Check tightness of all nuts and bolts securing the upper and
lower wishbones to the frame.
4. Check upper and lower fixings of the coil spring damper
units.
5. Check nuts connecting the lower wishbones to the vertical
link fulcrum.
6. Check security of the track rod ends to steering arm nuts.
7. Check tightness of all anti roll bar fixings.
Steering unit attachment
8. Check tightness of rack assembly fixings - 2.07 to 2.5 kg/m
(15 to 18 lb/ft).
9. Check for and ascertain cause for any backlash in the
steering.
10. Examine steering rack gaiters and check condition / leakage.
Steering rack couplings
11. Check pinch bolts through universal couplings - 3.46 to 4.15
kg/m (25 to 30 lb/ft).
Check tightness of drive shaft connecting bolts
1. Place the vehicle on ramp or over pit.
2. Check tightness of coupling bolts at both ends of propellor
shaft -3.46 to 4.15 kg/m (25 to 30 lb/ft).

Page 12
Routine maintenance - exterior
Adjust front hubs
Refer to Section B
Check and adjust front and rear wheel alignment with tracking
equipment
Use standard garage equipment and check as described in Section D
Inspect brake linings for wear and drums for condition
Front brakes
1. Jack up the vehicle until one front wheel is clear of the
ground.
2. Remove the road wheel and fully slacken off the brake
adjusters.
3. Remove the brake drum. Note: The relative position of the
drum to the hub must be noted before removal for correct
reassembly.
4. Check the lining material thickness. Linings which are
bonded to the shoes must not be allowed to wear below 1/16" in
thickness. Riveted shoes must be replaced when the material wears
within 1/32" of the rivet heads.
5. If the linings are serviceable, replace the brake drum
ensuring it is aligned as originally fitted.
6. Refit the road wheel and re-adjust the brake. Repeat the
operation with the opposite front wheel.
Rear brakes
1. Jack up the vehicle until one rear wheel is clear of the
ground.
2. Release the handbrake.
3. Check the linings as described for the front wheels.
4. If the linings are serviceable, refit the drum and road wheel
and re-adjust the brake. Repeat for other rear wheel.
Check tightness of road wheel nuts
1. Remove nave plate.
Check tightness of wheel nuts - 4.15 to 4.84 kg/m (30 to 35 lb/ft)
Check condition of tyres and depth of tread
1. Check tyre tread depth using a depth gauge and ensure that
the depth exceeds the current legal requirements.
2. Examine around the tread and side walls of the tyres for
damage or cracking/perishing due to age, including the spare. Since it
is dangerous (and illegal in the UK) ensure that cross-ply and radial-ply
tyres are not mixed on the same axle. 145 x 10 Radial tyres only are
fitted as original equipment.
Check and adjust tyre pressures including the spare
Check tyre pressures when the tyres are cold, i.e. before a run. A tyre
set to the recommended pressure when hot will be under inflated
when cool.
Using a tyre pressure gauge, check that the tyres are inflated to the
following pressures:
Normal load: Saloon/Estate Front 1.41 kg/cm² (20 lb/in²)
Rear 1,55 kg/cm² (22 lb/in²)
Van Rear 1.69 kg/cm² (24 lb/in²)
Full load: Saloon/Estate Front 1.41 kg/cm² (20 lb/in²)
Rear 1.99 kg/cm² (28 lb/in²)
Van Rear 2.11 kg/cm² (30 lb/in²)
Check and adjust headlamp beam alignment
The front grill/bezel has two screwdriver holes for adjustment of the
headlamp beam setting screws.
Beam aiming can best be accomplished using equipment such as a
"Lucas beam setter" or "Lav-L-Lite".
Horizontal adjustment is obtained with the top beam setting screw,
vertical with the lower screw (Figure 14).
Check and if necessary replace windscreen wiper blades
Renew wiper blades when vision is impaired due to unsatisfactory
clearance of water from the windscreen.
To remove wiper blades.
1. Lift wiper arm, complete with blade, away from the
windscreen.
2. Tilt wiper blade assembly away from the wiper arm
(towards windscreen) to disengage it from the locating lug.
3. Hold wiper blade assembly in this position and lift the leaf-
spring at the rear of the wiper blade assembly, then slide the blade off
the wiper arm.
To refit wiper blade
1. Slide the wiper blade assembly over the wiper arm until the
lug on the wiper arm locates in the hole in the wiper blade.
Routine maintenance - interior
Check operation of window controls and door latches/locks
Operate window winders and check operation of interior and exterior
door handles and locks. Adjust/repair as necessary.
Lubricate all locks, door hinges and striker plates
Sparingly oil above components. Wipe away excess lubricant.
Check condition and security of seat fixings and seat belts
1. Operate driver's seat adjuster and slide the seat to it's
rearmost extent.
2. Check tightness of the front seat to floor mounting nuts and
bolts.
3. Operate adjuster and slide the seat to it's forward extent.
4. Check tightness of rear seat runner fixings.
5. Check correct operation of seat reclining mechanism
(where fitted).
6. Fold seat forward to check correct operation of seat lock.
Repeat above for passenger seat.
Examine seat belts carefully for chafing/fraying and check mountings
for tightness. Check seat belt latches operate correctly.
Check function of all electrical systems
Test the operation of the following equipment:
Lights: main beams, dipped beams, side lamps, panel lamps, courtesy
light, rear number plate lamp, brake lights, panel warning lights
(ignition, oil, main beam, flasher).
Check flashers, horn, heater blower, heated rear window (where
fitted), windscreen wipers and washers.
Check alternator and starter motor for correct operation.

Page 13
Routine maintenance - road test
Road test car and check brake function. Carry out any remedial work
required indicated by the road test e.g. adjustment of brakes,
carburettor or ignition timing. Note: Specialist equipment is needed to
ensure that carburation adjustment does not result in the vehicle
infringing the emission regulations.

Page 14
Lubrication chart (not listed in order of preference)
(British Isles)
Mobil Castrol Esso BP Shell Petrofina Duckhams Texaco
Engine
Mobiloil super
or mobiloil
special
20w50
Castrolite
Castrol
20w50
Esso Extra
Motor Oil
10w30 or
Uniflo
BP Super
Viscostatic
10w30 or
Energol SAE
20w
Shell
Super
Motor Oil
Fina
Multigrade
motor oil
10w30 or
20w50
Q20-50
Motor Oil
Havoline
motor oil
10w30 or
20w50
Gearbox Mobilube
HD 80
Castrol Hypoy
Light
Esso Gear Oil
GX 80
Gear Oil
SAE 80EP
Spirax
80 EP
Pontonic
MP SAE 80
Hypoid 80 Multigear
EP 80
Rear Axle Mobilube
HD 90
Castrol Hypoy Esso Gear Oil
GX 90/140
Gear Oil
SAE 90 EP
Spirax
90 EP
Pontonic
MP SAE 90
Hypoid 90 Multigear
EP 90
Steering
Rack & Pinion
Mobilube
HD 90
Castrol Hypoy Esso Gear Oil
GX 90/140
Gear Oil
SAE 90 EP
Spirax
90 EP
Pontonic
MP SAE 90
Hypoid 90 Multigear
EP 90
Front Hub Mobilgrease
MP
LM Grease MP Grease H Energrease L2 Retinax A Marson HTL2 LB 10 Marfak
Chassis Mobilgrease MS3 Grease MP Grease Energrease
L21M
Retinax AM Marson LM2 LBM 10 Molytex
Brakes
Castrol Girling Universal Brake & Clutch Fluid or
Lockheed Super 105 Fluid or any fluid to J1703
specification

Page 15

Page 16
Section B
Contents
Routine maintenance
Operation 1 Front suspension assembly - removal and
replacement
Operation 2 Anti-Roll bar - Removal and replacement
Operation 3 Damper and spring assembly - removal and
replacement
Operation 4 Upper ball joint - removal and replacement
Operation 5 Lower ball joint and pivot bracket - removal
and replacement
Operation 6 Upper wishbone - bush replacement
Operation 7 Lower wishbone and strut - bush replacement
Operation 8 Vertical link - removal and replacement
Operation 9 Front hub - overhaul
Operation 10 Hub bearing adjustment
Description
The independent front suspension comprises upper and lower
wishbone assemblies and vertical links assisted by coil spring and
damper units.
The upper wishbones are attached to a ball joint on the vertical link
and secured and pivoted to the vehicle chassis suspension tower.
The lower wishbone assembly, secured to a lower ball joint on the
vertical link, supports the coil spring and damper unit. Two brackets
bolted to the chassis support the wishbones, which are also pivoted.
Routine maintenance
The front suspension should need little or no maintenance other than
the lubrication of the upper wishbone ball joint and the lower
wishbone ball joint and at major services the re-packing of the front
wheel bearing.
Lubricating nipples are situated at the upper wishbone ball joint
(figure 2) and at the lower fulcrum ball joint (figure 3). Apply three or
four strokes of a grease gun every 6,000 miles (10,000 km).
The front wheel bearings are lubricated by means of grease packed in
the hub on assembly. Repacking of front wheel bearings should be
carried out every 36,000 miles (60,000 km).
Operation 1 Front suspension assembly - removal and
replacement
To remove (figure 1)
1. Place vehicle on a ramp or support on chassis stands.
2. Remove nave plate and road wheel.
3. Remove brake drum.
Front Suspension
4. Remove the damper bottom fixing nut and withdraw bolt
from damper bush.
5. From inside the engine compartment, remove the damper
top fixings, comprising nut and locknut, rubber spacer and two
retaining cups.
Note: Access to the fixing on the r/h side of the vehicle can be
facilitated by the removal of the heater flexible hose.
6. Remove the bottom wishbone to pivot bracket fixings to
facilitate removal of the damper assembly.
7. Withdraw the damper assembly.
8. Remove track rod end nut and using a splitter separate the
track rod end from the steering arm.
9. Disconnect the hydraulic brake flexible hose from the
bundy pipe at the support bracket and plug to prevent fluid leakage or
dirt ingress.
10. Remove the two nuts securing the top wishbone pivot
brackets to the frame.
11. Remove the nut, cup washer and rubber spacer securing
the anti-roll bar link to the lower wishbone.
12. Remove the bolt, nut and spacer tube securing the strut to
the lower wishbone.
13. Remove the nut and bolt securing the nut to the frame.
14. Remove the nut and bolt securing the lower wishbone
assembly to the frame.
15. Repeat the procedure for the opposite suspension unit.
To replace
Replace in the reverse order and bleed the brake hydraulics. Check
camber and tracking (Section D)
Operation 2 Anti-Roll bar - Removal and replacement
To remove
1. Place vehicle on ramp, or support on suitable chassis
stands.
2. Remove the nut, cup washer and rubber spacer from the
link stud on the left hand wishbone.
3. remove the two bolts securing the anti-roll clamping rubber
bar to the left-hand chassis rail.
4. Repeat operations 3 and 3 for the right-hand side. (figure 4)
5. The anti-roll bar complete with links can be lowered from
the frame, withdrawing the link bushes from the lower wishbones.
Replace in reverse order.
Operation 3 Damper and spring assembly - removal and
replacement
To remove (figure 1)
1. Place vehicle on ramp, or support on suitable chassis
stands.
2. Remove road wheel.
3. From inside the engine compartment, remove the damper
top fixings, comprising nut and locknut, rubber spacer and two
retaining cups.
Note: Access to the fixing on the r/h side of the vehicle can be
facilitated by the removal of the heater flexible hose.
4. remove damper bottom fixing nut and spacer and withdraw
the bolt from the bush.
5. Remove the bottom wishbone to pivot bracket fixings to
facilitate removal of the damper assembly.
Replace in reverse order and check camber and tracking (section D).

Page 17

Page 18
Figure 2 Upper wishbone ball
joint lubricator
1. Ball joint - grease nipple
Operation 4 Upper ball joint - removal and replacement
To remove (figure 1)
1. Place vehicle on ramp or support on suitable chassis stands.
2. Remove road wheel.
3. Disconnect the hydraulic brake flexible hose from the
bundy pipe at the support bracket and plug to prevent fluid leakage or
dirt ingress.
4. Remove the nut securing upper ball joint to vertical link,
releasing the brake pipe support bracket.
5. Using a suitable ball joint splitter, release the ball joint
taper from the vertical link.
6. Remove the bolts and nuts securing the upper wishbone
pivots and remove the wishbone complete with upper ball joint.
Note: If the wishbone bolts cannot be withdrawn because of the
damper, the wishbone pivot brackets can be removed by releasing the
nyloc nuts securing the brackets to the frame.
7. Remove the external circlip securing the ball joint to the
wishbone and prise or press the ball joint from the mounting plate in
the wishbone assembly.
Reassemble in reverse order.
Operation 5 Lower ball joint and pivot bracket - removal
and replacement
To remove (figure 1)
1. Place vehicle on ramp or support on suitable chassis stands.
2. Remove road wheel.
3. Remove bolt, nut and spacer securing damper bottom bush
to lower wishbone.
4. Remove bolt and nut securing the lower ball joint pivot
bracket assembly to the lower wishbone.
5. Remove the split pin from the castellated nut securing the
lower ball joint to the vertical link.
6. Remove the castellated nut.
7. Release the taper on the shank of the ball joint from the
vertical link and remove the ball joint and pivot bracket assembly.
replace in the reverse order, tightening the castellated nut to 4.29 to
4.98 kb/m (31 to 36 lb/ft) and renewing the split pin.
Figure 3 Lower fulcrum - lubricator
1. Bleed screw
2. Lower fulcrum - grease nipple
Operation 6 Upper wishbone - bush replacement
To remove (figure 1)
1. Dismantle upper wishbone assembly as sequence 1-5 of
operation 4.
2. Press out the wishbone bushes.
3. Press in the new bushes ensuring that they are centred in
the wishbone.
4. Refit the wishbone as in operation 4. Check camber setting
see Section D
Operation 7 Lower wishbone and strut - bush replacement
To remove (figure 1)
1. Place vehicle on ramp or support on suitable chassis stands.
2. Remove road wheel.
3. Remove nut, spacer and bolt securing strut to lower
wishbone.
4. Remove nut and bolt securing strut to bracket on frame.
5. Remove nut, spacer and bolt securing bottom of damper to
lower wishbone.
6. Remove nut and bolt securing lower wishbone to lower ball
joint pivot bracket.
7. Remove bolt, lock washer and nut plate securing lower
wishbone to frame. Press out the bushes from strut and lower
wishbone and replace bushes ensuring new bushes are centred
correctly.
reassemble in reverse order. Check tracking and camber settings see
Section D.
Operation 8 Vertical link - removal and replacement
1. Place vehicle on ramp or support on suitable chassis stands.
2. Remove road wheel.
3. Remove nut from track rod end ball joint and disconnect
the ball joint from the steering arm.
4. Disconnect the hydraulic brake flexible hose from the
bundy pipe at the support bracket and plug to prevent fluid leakage or
dirt ingress.
5. Remove bolt, nut and spacer securing damper bottom fixing
to lower wishbone.

Page 19
Figure 4 Anti-Roll bar removal
6. Remove nut and bolt securing lower ball joint pivot bracket
to lower wishbone
7. Separate lower ball joint pivot bracket from wishbone.
8. Remove nut from upper ball joint and, using a suitable tool,
separate the vertical link and hub/brake assembly, from the upper ball
joint and wishbone assembly.
9. Remove brake drum.
10. Prise the hub cap from the hub and wipe grease from end
of stub axle
11. Remove split pin, castellated nut and washer from stub
axle.
12. Withdraw the hub complete with bearings and felt oil seal.
13. Reassemble in reverse order, renewing stub axle split pin.
Bleed brakes and adjust.
Operation 9 Front hub - overhaul
1. Place vehicle on ramp or jack up.
2. Remove front wheel.
3. Remove brake drum.
4. Prise off the hub cap and wipe grease from stub axle end.
5. Remove split pin, castellated nut and washer from stub
axle.
6. Withdraw the hub complete with bearings and felt oil seal.
7. Ease out the inner cone and roller assembly from the outer
bearing. On no account must the inner cone be levered out as this
may cause damage to the roller cage.
8. tap out the outer bearing track from the hub using a
suitable drift.
9. Using the same drift, tap out the inner bearing track
complete with bearing and felt seal. Carefully inspect the bearings for
wear, scoring or pitting on the tracks or rollers. If excessive wear is
apparent the bearings must be renewed.
Before commencing re-assembly it is essential that the hub is
scrupulously cleaned of old grease paying special attention to the area
between the bearings. If only one bearing is to be replaced then the
remaining bearing must be cleaned free of old grease before re-
packing. Do NOT use paraffin to clean bearings.

Page 20
Figure 6 Hub nut adjustment
Re-assembly
1. Locate the outer track of the inner bearing in its housing in
the hub and ensure it is firmly and squarely seated. Pack the inner
cone and roller assembly with the recommended grease (see
lubrication chart Page 13) and insert the cone in to the bearing track.
2. Renew the felt seal. This should be securely attached to the
retainer with "Hermatite" liquid jointing compound or similar oil
resistant adhesive. When dry, soak the seal and retainer assembly
with oil with the surplus squeezed out before firmly fitting it in the
hub.
3. Lightly grease the front hub with the approved grease, in
the area between the inner and outer bearings.
Note: Over packing the hub with grease can lead to overheating and
possible bearing failure.
4. Locate the outer bearing outer track in the hub, again
ensuring that it is firmly and squarely seated. Pack the outer bearing
cone and roller assembly with an approved grease and insert the cone
in to the bearing track.
5. Position the front hub assembly on to the stub axle and
secure with the large retaining washer and the castellated nut,
tightening finger tight until slight resistance can be felt whilst turning
the hub.
6. Slacken the nut back until a bearing float of between 0.05
to 0.15 mm is obtained. A dial gauge is preferable for this operation
but if one is not available, slacken the nut off half a flay, equivalent to
30 degrees (figure 6).Note: The importance of the correct end float
cannot be over emphasised. Over tightening the bearings will cause
overheating and subsequent bearing failure.
7. Fit a new split pin to the castellated nut.
8. Seal the centre vent hole of the hub cap with grease and
apply a quantity to the inside of the cap. Fit the cap to the hub.
9. Refit the brake drum.
10. Refit the road wheel and take the opportunity of testing for
bearing end float by rocking the wheel at the outside diameter of the
tyre. There should be approximately 1.5 mm (1/16") movement at the
tyre periphery.
11. Adjust brakes.
Operation 10 Hub bearing adjustment
Checking
1. Jack up the car and remove the front wheel.
2. Ensure that the brake shoes are not dragging or restricting
movement and rotation of the hub. Slacken off the hoes or remove
the brake drum as necessary.
3. Check the bearing end-float. a correctly adjusted hub will
have end-float within 0.05 to 0.15 mm (0.002 to 0.006 in). a dial gauge
should be used for checking purposes.
Adjusting
4. Prise off the hub cap.
5. Wipe off grease from the end of the stub axle.
6. Remove the split pin from the castellated nut and discard.
7. Tighten or slacken the castellated nut as necessary to
achieve the correct end-float. (see Operation 9)
8. Fit a new split pin.
9. Clean the hub cap and partially fill with fresh grease,
ensuring that the vent hole is sealed with grease.
10. Fit the hub cap.
11. Refit the brake drum (if removed) and adjust the brake.
12. Fit the road wheel and remove car from jack.