Reliant ROBIN 850 Instruction manual

Contents
Section A
B
c
D
E
F
G
H
J
K
L
M
N
p
Q
R
s
T
u
v
General Specification
Lubrication and maintenance
Frame
Front suspension
Rear suspension
Steering
Cooling system
Engine
Gearbox
Clutch
Driveshaft
Rear axle
Brakes
Road wheels
Exhaust system
Fuel system
Body
Interior
Heater
Electrics
Windscreen washer
Optional extras
Tightening torques

INTRODUCTION
In accordance with the Reliant Motor
Company's policy of continuous design
improvement.
it has been necessary to include
this supplement in the Robin Saloon and Van
Workshop Manual.
The supplement covers the changes made
to
the vehicle from chassis No. 5J/8A/1 001-
5J /8A/11 51 and chassis No. 5J3/13201152
onwards, with the introduction of the 850
engine.
This supplement
prin~d on coloured paper is
intended
to be read in conjunction with the
existing Workshop Manual. 'R' Part No. 90293.
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:
'R' Part Number 91769
ROBIN850
Workshop Manual
Suppl·ement
Service Department
Reliant Motor Company Limited,
Two Gates, Tamworth, Staffordshire
Telephone: Tamworth 4151
Telex: 341051
Parts Supply Department
The Reliant Motor Company Limited
Lynn Lane, Shenstone, Staffordshire
Telephone: Shenstone 480671

Robin 850 Workshop Manual Supplement
General specification
Engine
No. of cylinders
Bore of cylinders
Stroke of crankshaft
Cubic capacity
Compression ratio and pressure
Valve clearance
Inlet
Exhaust
Performance data
Brake horse-power (max)
Torque (max)
Lubrication system
Pump
Filter
Oil pressure
Gearbox
4 in line
62·50mm (2·46in)
69·09mm (2·72in)
848cc (51·75cu.in.)
9·5:1 at 140 psi
Hot
0·25mm (0·01 Oin)
0·25mm (0·010in)
40·00 at 5,500 rpm
Cold
0·152 mm (0·006in)
0·152mm (0·006in)
5·53kgm (461bft) at 3,500 rpm
Submerged eccentric rotor type
External full flow type
3·16kg/sqcm (451b/sqin)
Four forward speeds and reverse, synchromesh on all forward gears.
Ratios Top 1·000:1
Rear axle
Type
Ratio
Brakes
System
Size- front
-rear
Handbrake
Ignition
12 volt battery and coil
Contact breaker gap
Spark plugs -type
-gap
Firing order
Ignition timing
Cooling system
3rd 1·320:1
2nd 2·050:1
1st 3·880:1
Reverse 3·250:1
Spiral bevel gear, semi-floating
3·23:1
Hydraulically operated internal expanding
to all wheels
177·8 x 38·1 mm (7 x 1·50in)
177·8 x 31·75mm (7 x 1·25in)
Lever type operating rear brakes mechanically
Negative earth
0·38 mm (0·015in)
Motorcraft
AG R 32
0·64mm (0·025in)
1, 3, 4, 2
T.D.C.
Pressurised radiator, pump assisted circulation and three-bladed fan driven by a ·v· belt from
engine pulley.
Radiator cap pressure 0·49kg/sqcm(7·01b/sqin)
Fuel system
Carburettor
Fuel pump
Air cleaner
Clutch
Type
Operation
S.U. semi-downdraught HS2 1-!
Mechanical type
Paper element type
Spring pressure plate assembly
with single
dry plate
Cable
1

2
Suspension
Front
Rear
Steering
Type
Turning circle
Chassis data
Type
Wheelbase
Track,
Ground clearance
Exterior dimensions
Overall length
Overall
width
Overall height
Loading height
Load
width -maximum
Load height-;-maximumaperture
Load height -maximum
Inside vehicle
Length behind rear seat
Length
with rear seat folded
Length oi floor platform
General Specification
Patented leading arm suspension controlled
by heavy duty coil spring and hydraulic
damper unit
Long semi-elliptical double leaf spring, rubber
mounted
with double acting hydraulic shock
absorber and anti-roll bar
Worm and peg
8·23m (27·0ft)
Box section with tubular cross members
2159mm
(85·0 in)
1244·6mm (49·0in)
127mm (5·0in)
Saloon
3327-4mm (131·0in)
1422·4mm (56·0in)
1371·6mm (54·0in)
990·6mm (39·0in)
(Ground to tailgate sill)
1028·7mm (40·5in)
(Width at tailgate sill)
457·2mm (19·0in)
(Tailgate aperture height)
863·6mm (34·0in)
584·2mm (23·0in)
(up to spare wheel)
1079·5mm (42·5in)
(up to spare wheel)
Van
3327·4mm (131·0 in)
1422·4mm (56·0in)
1371·6 mm (54·0 in)
533-4mm (21·0in)
(Ground to van floor)
850·9mm (33·5in)
(Rear door aperture)
762·0mm (30·0in)
(Rear door aperture)
889·0mm (35·0in)
~93·1 mm (26·5 in)
Load floor
width behindrearseat 965·2mm (38·0in)
1168·4mm (46·0in)
1219·2mm (49·0in)
965·2mm (38·0in)
Load capacities
Saloon -Capacity of boot area, rear seat up, spare wheel in
position
below tonneau cover 0·2306cu m (8·5cuft)
0·849cu m (30·0cuft)
1·416cum (50·0cuft)
1·132cu m (40·0cuft)
Saloon<-- Capacity of rear compartment with rear seat folded,
spare wheel in position, up to roof level
Van -Total c·apacity of rear area, with spare wheel in
position, and the front passenger
area
Van -Capacity of complete rear compartment, with spare
wheel in position
Kerb weight
Saloon
Van
. Gross recommended vehicle weight
Capacities
Engine (including filter)
Gearbox
Rear axle
Steering box
Cooling system, including heater
Fuel tank
Tyres
Type
Size -Standard
-Optional
436kg (9621b)
436 kg (9621b)
793·78kg (17501b)
3·13 litres (5·50 pints)
0·64 litres (1·125 pints)
1·28 litres (2·25 pints)
0·19 litres (0·33 pints)
2·84 litres (5 pints)
27·27 litres (6 gallons)
Crossply (tubeless)
5.20 X
10
5 .. 90 X 10

Lubrication and ma intenance
Figure 1 Lubrication points
1 Rear axle filler/level plug
2 Gearbox filler/level plug
3 Steering box
4 Oil filler cap - engine
5 Front hub
Lubrication points
Grease gun points
Oil
Oil
Oi l
Oi l
Gr ease
The grease gun non-return lub ricators, shown in
Figure 1 should be well cleaned
of dirt and old
grease before application
of a high pr essu re
grease gun. U
se only the g rea se shown on the
recommended lubricant chart on page 4.
Servi ce schedule
The operations listed below should be carried out
at
th e mileages show n or at the equivalent
monthly intervals, whichever occur first.
l
ubri ca tion
Check and top up eng in e oil l eve l
Change engine oil
Check and top up gearbox oil level
Change gea rbox oil
Ch eck and top up rear axle oil
Ch eck and top up steering box oil level
Oil or gr
ease all lubrication points
>-
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6 Front suspension -swivel pin
7 Oil filter
8 Master cylinder
9 Handbrake cable
10 Propshaft
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X X X
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Grease
Renew
Top up fluid
Grease
Grease
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X X X
X X X
X X X

Lubrication and maintenance 2
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Clean oil filler cap, check air cleaner element X X X X X
Replace air cleaner element X X X
Change oil filter X X X X
Repack front wheel bearings X
Adjustments
Tighten all cylinder head, rocker shaft, sump
and manifold fixings
to correct torques X X X X
Check and adjust valve clearances X X X X
Check and adjust fan belt tension check for
wear X X X X
Examine and adjust distributor points, renew
if necessary X X X X X X
Clean coil, distributor cap and H.T. leads X X X
Remove and clean carburettor X X X
Clean and adjust sparking plugs X X X
Renew sparking plugs v
"'
Check hydraulic system, bleed and top up
master cylinder
as necessary X X X X
Check and top up master cylinder ?S necessary X X X
Inspect brake system for leaks and hoses
for chafing X X X X X X
Examine brake linings for wear, blow out
X X X X
Adjust brakes X X X X X X
Check and adjust clutch
X X X X X X
Adjust pressures and check condition of tyres X X X X X X X
Check security of wheels X X X X X X
Check front wheel bearings, adjust if necessary X X X X
Check all body, suspension nuts and bolts,
and steering connections X X X X
Check door operation, hinges and lock
X X X X X X
General
Top up battery X X X X X X X
Top up radiator coolant level X X X X X X X
Check battery connections X X X
Check for water and oil leaks X X X X

Lubrication and maintenance 3
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Check all controls, lights, horn, instruments,
windscreen wiper, etc. X X X X X
Check headlamp alignment X K X
Check windscreen washer reservoir X
Road test
Adjust carburettor and ignition as necessary X X X X X X
Check brake function X X X X X X
Every 36,000 miles (60,000km) the hydraulic
braking system should be overhauled, checking
all bundy pipes and replace all flexible hoses.
Replace brake wheel and master cylinderseals, or
replacethe units. Change the hydraulic brake fluid.

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Approved lubricants (Winter and Summer) I
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Mobil Castro I Esso B.P.
Shell Petrofina Duckhams
Regent Texaco 1 0
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Engine Mobiloil Castrolite Esso Extra
B.P. Super Shell
Fin a Q Havoline ::J
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Super or CastroI Motor Oil Viscostatic Super Multigrade Motor Oil Motor Oil 3
Mobiloil GTX 10W/30 or 10W/40 or
Motor Oil Motor Oil
10W/30 or
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Special Uniflo Energol
SAE
10W/30 or 20W/50
::J
20W/50
20W
20W/50
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Gearbox Mobilube CastroI
Esso Gear Gear Oil Spirax Fin a Hypoid 80 Multigear
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GX 80 Hypoy Oil GX 80
SAE 80 EP 80 EP Pontonic Lubricant
(')
CD
Light MP SAE 80 EP 80
Rear axle
·Mobilube CastroI Esso Gear Gear Oil Spirax
Fin a Hypoid 90 Multigear
GX 90 Hypoy Oil GX SAE 90 EP 90 EP Pontonic Lubricant
90/140
MP SAE 90 EP 90
Steering box Mobilube Castrol. Esso Gear Gear Oil Spirax
Fin a Hypoid 80 Multigear
GX 80 Hypoy Oil
GX 80
SAE 80 EP
80 EP Pontonic Lubricant
Light MP
SAE 80 EP 80
Front hub
Mobilgrease CastroI
Esso
Energrease Retinax A
Fin a LB 10
Marfak
MP LM Multi-purpose
L2
Marson
Grease
All
Grease Grease H HTL 2 Purpose
Grease
gun
Mobilgrease CastroI
Esso MP Energrease Shell
Fin a LBM
10
Molytex
(Chassis) Super MS3 Grease
L21M Retinax
AM Marson Grease
Grease 2
Grease (Moly)
LM2
Brake reservoir
Castrol Girling Fluid (Crimson)
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Section A
The frame
Checking for squareness 2

The frame Section A
249·0mm
250·0m
!
9·80" )
9·85'1
291 ·0mm ( 11-45 ")
292-()mm ( 11-50" )
Figure 1 Frame checking dimensions
Figure 2 Frame checking diagram
173-0mm ( 6·81" )
114·0mm (6· 85 ")
0
8
B
1
D

The frame Section A
Checking for squareness
1 Reference to Figure 1 shows the critical
points by which the Saloon and Van chassis
should be checked for squareness. Transfer
these points
to the floor and letter them as
shown in Figure 2.
2 Connect the letters in pairs
by drawing a
line between them, using a straight edge, AA,
BB, CC and DD, as shown.
3 Measure from each point in turn
to the
centre and
join up all centres thus producing a
centre datum line
XX. The diagram on the floor
should then be similar to Figure 2.
4 A further check on squareness must be made
by joining up all the diagonals, the lengths of
which must be equal, and bisect each other on
the datum line.
Chassis distortion is always assessed by the
amount and direction
of any transverse or
diagonal lines from the datum line.
Severe damage to the chassis frame is readily
apparent. In some cases, however, lesser damage
may cause distortion
of the frame, which may
not
be easily detected by visual inspection.
Even when the vehicle has suffered only
superficial damage
it is possible that the frame
members may have been displaced, causing
misalignment of the road wheels.
It is recommended that the alignment
of the
front and rear suspension attachment points is
checked including wheelbase dimensions.
See General Specification.
All components including front suspension and
rear road springs must be removed
to provide
access
to the checking points. The checking
must
be carried out on a surface table or level
floor.
2

Section B
Front Suspension
Routine maintenance 2
Front hubs 2
Stub axle assembly 3
Damper unit 4
Radius arm assembly 5

Figure 1 Front suspension
1 Front suspension un1t
2 Ferrule bush
3 Ferrule sleeve
4 Bolt
5 Nut
6 Radius arm
7 Bush. radius arm
8 Cap. radius
arm
9 Set screw. rad ius arm
10 Lockwasher. radius arm
11 Nut. radius arm
12 Stub axle
13 Swivel pin
14 Taper pin
15 Lubricator. swivel pin.
16 Bush. swivel pin top
17 Bush. swivel pin bottom
18 Thrust washer. swivel pin
19 Peg. thrust washer
20 Thrust washer. stub axle
21 Welch plug. swivel pin
22 Front hub
23 Wheel stud
24 Retaining washer hub
25 Nut. front
hub
26 Split pin, nut
27 Locking device. hub nut
28 Cap. front hub •
29 Bearing. front hub outer
30 Bearing. front hub inner
31 Felt. oil seal
32 Retainer
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Front suspension Section B
Description
Front suspension is provided by a Reliant
Motor Group patented leading arm design
controlled by a heavy duty combined coil spring
and damper unit.
Chassis mounting is by means
of two rubber
bushes and caps locating onto brackets
we ld ed
to the chassis front cross member. A bracket
on the upper cross member provides a mounting
for the damper unit.
Routine maintenance
Other than the greasing of the swivel pin and
periodic examination for signs
of damage and
wear the front suspension assembly requires no
attention except for regular cleaning.
Before dismantling any part
of the suspension
assembly, jack up the front
of the vehicle under
the chassis side member and
fit suitable stands.
Front hub and bearings
To remove (see Figure 1)
1 Slacken
off the front brake adjustment
(see Section L).
2
Unscrew~ UNF countersunk screw and
remove brake drum.
3 Prise
out the hub cap and remove split pin
from locking ring and
st ub axle shaft.
4 Remove locking ring and unscrew front hub
retaining nut.
5 Withdraw front hub assembly complete
with '0 ' washer, inner and outer taper bearings,
and oil seal.
6 Remove outer taper bearing and then tap
out bearing track from hub using a suitable drift.
7 Using the same drift from inside the hub tap
out the inner bearing track. complete with
bearing and oil seal.
8 Check components for wear and replace if
necessary for subsequent reassembly.
To reassemble
1 Locate inner bearing track in its housing in
the hub and ensure it is firmly and squarely
seated. Then insert taper bearing into bearing
track.
2 Firmly
fit oil sea l and reta iner in hub.
3 Repack the front hub
with the approved
grease in the
area between the inner bearing
and outer bearing location.
4 Locate outer bearing track in the hub, again
ensuring that
it is firmly and squarely seated.
Then insert taper bearing into bearing track.
5 Position front hub assembly on the stub
axle and secure with ·o·washer and
fir UNF
nut , tightening until all resistance is taken up
when turning the hub.
2
6 Slacken the nut back until a bearing end
float
of between 0· 051 -0·152mm (0 · 002-
0·006 in) is obtained. A dial gauge is preferable
for this operation, but
if not available. slacken
off retaining nut half a flat. equivalent of 30 °
(see Figure 2).
Figure 2 Slackening of hub retaining nut
Figure 3 Centre punch marks on retaining nut
and stub axle shaft
1 Centre punch marks
2 Retaining ring
3 Split pin

Front suspension Section B
7 Mark the position by centre punching the
nut and stub axle (see Figure 3).
8 Fit locking ring over retaining nut ensuring
two of the castelations line up with the split
pin hole in the stub axle shaft. Then fit split pin
to lock hub retaining nut.
9 Move the hub assembly to ensure end float
is still apparent.
1
0 Refit hub cap.
11 Replace brake drum, retaining with single
:\ UNF countersunk screw and readjust front
brake.
12 Refit front wheel, remove stands and jack
down the vehicle.
Stub axle assembly
To remove and dismantle (see Figure 1)
1 Jack up the fro
nt of the vehicle and fit
suitable stands.
2 Remove front hub assembly
as described in
previous operation.
3 Disconnect brake fluid flexible hose at the
mounting bracket bolted
to the steering arm.
Plug the hose to prevent loss of fluid and ingress
of dirt.
4 Unscrew i UNF nut, complete
with plain
washer and disconnect track rod from steering
arm.
5 Unscrew the short and long
-Ptr UNF bolts,
complete
with lockwashers, and remove steering
arm from brake back plate and stub axle, noting
position
of flexible brake hose mounting bracket.
Figure 4 Swivel pin removal
6 Remove
two set screws and lo ckwashers
and then slide the brake plate assembly back
onto the radius
arm .
7 Drill a small hole in the
two welch plugs
which are located in the top and bottom of the
swivel pin housing of the stub axle. The plugs
can then be prised free.
8 Tap out the taper pin, securing the swivel
pin in position, using a suitable drift.
9 Using
MCA tool No. P176 as shown in
Figure 4 or a suitable drift remove the swivel
pin from the stub axle.
3
10 Separate the stub axle from pivot arm and
remove
top and bottom thrust washers, including
pegged thrust washer.
11 Remove swivel pin bushes from stub axle
using Tool No. RT 7904 on a suitable drift
(see
Figure 5).
12 Check the swivel pin and bushes for wear
replacing
if necessary for subsequent
re -assembly. The two welch plugs, having be en
drilled, will need replacing.
Figure 5 Swivel pin bush removal
To re-assemble and replace
1 Locate new swivel pin bushes in stub axle
housing using Tool No. RT 7904 (see Figure 6).
Ensure the lubrication holes
of the bushes align
with those of the grease nipples.
2 Before complete
re -assembly check the fit
of the swivel pin. If the fit is obviously too
tight the bushes should be reamed out with
Tool No. RT 7919 as shown in F igure 7 until
a tight push fit is obtaioed.

Front suspension Section 8
Figure 6 Swivel p in bush replacement
3 Position the square thrust washers in the
stub axle housing, ensuring they are seated
squarely over the sw ivel pin bushes.
4 Fit the round thrust washer to the pivot arm
and check that the thrust washer pegs
are
securely located.
5 Locate the stub axle over the pivot arm, tap
in the swivel pin and secure in position
with
the taper pin. Seal the top and bottom of the
swivel with new welch plugs.
6 Lubricate the swivel pin with recommended
grease through the
two grease nipples located at
the top and bottom
of the stub axle housing.
7 Refit brake back plate to stub axle securing
in position
with two -h UNF set screws and
lockwashers.
Figure 7 Reaming of swivel pin bushes
8 Positiion flexible brake hose mounting
bracket; then secure steering arm to stub axle
and brake back plate with long and short
-fs UNF bolts and lockwashers.
9 Reconnect steering arm to track rod with
i UNF nut and plain washer.
4
10 Reconne ct flexible brake ho se at mounting
plate.
11 Refit front hub assembly, as described
earlier in this section. Refit brake drum and road
wheel and readjust brakes.
12 Jack down the vehicle, remove stands and
bleed the brake hydraulic system. see Section L.
Damper unit
To remo ve (see Figure 1)
1 Remove ! UNF bolt and se lf locking nut
and release damper unit from radius arm
mounting bracket.
2 Repeat operation at damper unit mounting
on chassis upper cross member and remove
unit
from the vehicle.
3 Check top and bottom ferrule bushes and
sleeves for wear replacing if necessary.
4 Replace in reverse order.
Radius arm asse mbly
To remove (complete with s tub axle a nd
hub assembly)
1 Jack up the vehicle and fit suitable stands.
2
Di sconnect the flexible brake hose at the
mounting bracket bolted
to the stee ri ng arm.

Front suspension Section B
Plug the hose to prevent loss of brake fluid and
ingress
of dirt.
3 Unscrew i UNF nut, complete
with plain
washer and disconnect track rod from steering
arm.
4 Remove lower bolt and self locking nut and
disconnect damper unit from its housing on the
the radius arm.
5 Remove i UNF set screws nuts and
lockwashers and detach the
two caps and rubber
bushes securing the radius arm assembly
to the
lower chassis cross member.
6 The radius arm assembly, complete
with
stub axle and hub assembly can be withdrawn
from the vehicle and dismantled as required.
7 Replace in reverse order, remove stands,
jack
down the vehicle and bleed the brake
hydraulic system.
5

Section C
Rear Suspension
Routine maintenance 1
Leaf spring 1
Damper unit ?
Anti-roll bar 2
Bump stop 2

Rear suspension
Description
Rear suspension is provided by damper assisted
single taper leaf springs and an anti-roll bar.
The rear
of the springs are suspended and
pivotted on shackles attached
to the chassis.
Four
'U' bolts secure the springs to the rear
axle. The damper units are secured to
mountings on the rear axle and chassis
crossmember tube.
Routine maintenance
The rubber bushes of the damper units, leaf
springs and rear shackles should be kept clear
of oil and grease and should be replaced when
any signs
of wear are apparent.
Figure 1 Rear suspension
1 Rear spring
2 Bush
13 Shackle
14 Bush
Section C
Periodically check the damper units to ensure
full movement is obtained. A siezed unit will
only give minimal movement and result in a
hard ride.
Leaf spring
To remove (see Figure 1)
1 Jack up the vehicle under the axle
differential,
fit suitable stands under the chassis
and remove road wheel.
2 Unscrew four i UNF nuts and locknuts,
remove the
two ·u·bolts securing axle to
leaf spring.
3
Remove! UNF bolts and self locking nuts
securing leaf spring to rear shackle and chassis
mounting.
25 Bolt. damper to axle
26 Nut. damper to axle
3 Bo lt
4 Nut
15 Bolt. shackle to f ra me
16 Nu t. shackle to frame
27 Spacer. damper to axle
28 Washer. damper to axle
29 Anti-roll bar5 Washer
6 ·u· bolt. spnng to axle
7 Nut. spring to axle
8 L oc knut. spring to axle
9 Clamp plate. rear spring
10 Bump stop
11 Lockwasher
12 Nut
17 Washer. shackle to frame
18 Bolt. spring to shackle
19 Nut. spring to shackle
20 Rea r damper
21 Bush
22 Bolt. damper to frame
23 Washer. damper to frame
24 Nut. damper to frame
30 Clamp
31 Set screw. clamp
32 Lockwash er. clamp
33 Bush. anti-roll bar
34 Link assembly R.H.
35 Lockwasher. link
36 Nut. link
1