JAGUAR 4.2 MARK 10 MODEL SERVICE MANUAL 6 Jaguar srimisn LevLaneue Tinnes caren) COVENTRY, ENGLAND. ‘Telephone: ALLESLEY 2121 (P.B.X.) Coe BENTLEY'S SECOND Telegrams: JAGUAR, COVENTRY Telex 31672 © JAGUAR CARS BRITISH LEYLAND UK LIMITED, 1972 Publication No, €.136/2INDEX TO SECTIONS GENERAL INFORMATION... ENGINE 2 CARBURETTERS AND FUEL SYSTEM COOLING SYSTEM. ured GEARBOX AND OVERDRIVE AUTOMATIC TRANSMISSION PROPELLER SHAFT . REAR AXLE STEERING FRONT SUSPENSION REAR SUSPENSION BRAKES WHEELS AND TYRES BODY AND EXHAUST SYSTEM HEATING AND WINDSCREEN WASHING EQUIPMENT ELECTRICAL AND INSTRUMENTS vo ® = zo 8 nizeSECTION A GENERAL INFORMATION 4.2 MARK 10 MODEL LSSS=__ aS Note: All references in this Manual to “righthand side" and “left-hand side” are ‘made assuming the person to be looking from the rear of the car or unit,Car Identification General Data: Dimensions and weights Capacities Performance Data. Instruments Controls and Accessories Starting and Driving Overdrive Automatic Transmission oo Data ‘Automatic Gear Changes ‘Automatic Transmission Maintenance Summary of Maintenance ‘Recommended Lubricants Recommended Hydraulic Fluid Special Service Tools Service Departments Conversion Tables. Page A.2 INDEX Page AB Aa Ad AS Ag AL A20 All A2 ADs Ams A2s A26 A26 AQT A2B “a2GENERAL INFORMATION CAR IDENTIFICATION i imperative that the car and engine numbers together with any prefix or sufix letters are quoted in any corres- Pondence concerning this vehicle. Ifthe unit in question i the gearbox or overdrive the gearbox number and any prefix (oF sufix letters must also be quoted. This also applies when ordering spare parts, Car Number Stamped on the top of the right-hand front wheel arch, Suffix “DN” t0 the car mumber indicates that an overdrive is fitted, Engine Number Stamped on the right-hand side of the cylinder block above the oil filter and at the front of the cylinder head casting, 17, 18 or |9 following the engine number denotes pa the compression ratio Fig. 1. Location ofthe car number. Gearbox Number ‘Stamped on a shoulder at the left-hand rear corner of the gearbox casing and on the top cover. Letter “N” at the end of the prefix letters indicates ‘that an overdrive is fitted, Key Number... ‘Two different types of key are provided to enable the car to be let with the luggage compartment and glovebox locked on the occasions when it is required to leave the ignition key with the car. (i) The round headed key operates the ignition ‘witch, fuel tank filler lids and the door locks. (i) The rectangular headed key operates the locks Fig. 2. Location of the engine number, for the luggage compartment lid and the glovebox. Page A3GENERAL INFORMATION Fig. 3. Location of the gearbox number. Fig. 4. The identification numbers are also stamped on Eplate ertoched to the eftehand front wing valance GENERAL DATA DIMENSIONS AND WEIGHTS ee Teack—front and ear. a . . 410" (47m) Overall length oo SS | 16" 10" (513 m) Overall width ono moo Ss ’ 64" (1.93 m) Overall height .. oop oe 2 46H (38m) Ground clearance. 7 Boe 5 s. 64 (165 mm.) Turning circle : ee . 370" (11-28 m) Weight (dry, approximate) .. +. oo . 35 ewt. (1778 ks.) CAPACITIES Imperial US. —_ Litres Engine refill (including filter) ooo ef 12 pints 14h pints 6-75 Gearbox (without overdrive)... oe es ape 1s Gearbox (with overdrive) 6. Sve 4pints AB pints 225 Automatic transmission unit (from dry) 1S pints 18 pints 8S Rear axle, 7 pints 3k pints 1S Cooling system (including heater) oo 244 pints 294 pints 14 Petrol tanks—left-hand.. oe ok ee Or eo oo oe ee Page AdGENERAL INFORMATION PERFORMANCE DATA ‘The following tables give the relationship between engine revolutions per minute and road speed in miles and kilometres per hour. Ts recommended that engine revolutions in excess of §,000 per minute should not be exceeded for long periods. ‘Therefore, if travelling at sustained high speed on motorways, the accelerator should be released occasionally to allow the car to overrun for a few seconds. AXLE RATIO 354: 1 ROAD SPEED ENGINE REVOLUTIONS PER MINUTE Kilometres Mites First Second Thied Top per hour per hour Gear Gear Gear Gear 1076 698 “7 354 16 10 1408 | 913 iz 61S 463 32 20 | 2816 [- 1826. 1230 926 48 30 4223 (2740 ‘1845, 1390 | ~ 64 40 5632 3652 2460 1852 0 50 4565 3075 2315 96 2) - 60 “| | 5480 3690 2780 w2 70 ~ 4305 ir 3241 128 #0 4520 3708 [ 144 CU $535 4167 160 100 E ~ | 4630 116 110 5053 Page ASGENERAL INFORMATION AXLE RATIO 3.77 : 1 (Ratio for cars fitted with an overdrive) ROAD SPEED ENGINE REVOLUTIONS PER MINUTE nm | soo | ma | To kitomeces | tes | Ger | Ge | Gear | Gear | Overt clone | ee | tae | ar | So | Sar | a |_| oo L 16 | on 973 654 493 383 - LL : 32 20 I 2998 1946 1308 986 166 L . @ |e | ws | em | ee | wo [no a | wwf me [we |e » |» a ee oc %* | @ a ra mee eso ees a [8 wa |e | wo | we [1 oo | a8 me | a0 an [a 76 Note: The figures in these tables are theoretical and actual figures may vary slightly from those quoted due to such factors as tyre wear, pressures etc, Page ASGENERAL INFORMATION AXLE RATIO 331:1 (Optional extra U.K., standard equipment for Europe) i S - 16 10 1316 | 854 515 433 ~ 337 iz 32 20 | 2632 [ 1708 1150 866 [ 674 48 30 | 3048 2563 Ins 1300 | volt @ [| ae | ae [a0] ee 80 \ 50 4270 2875 2165 7 1685 lo» |e [ae | ef ae oe ie fm ren eos a |=) [ee] 580] ape) ee @ | [cae | a] 116 10 4763 i 3707 P| ae | Note: The figures in these tables are theoretical and actual figures may vary slightly from those quoted due to such factors as tyre wear, pressures ete, Page A.7GENERAL INFORMATION 9N 2B 617 B19 20 21 22 Page AS Fig. 5. Instruments and controls—Right hand drive, u 2 13 1415 16171819 202122 Fig. 6, Instruments and contols—Left band drive. Amneter. ual gauge. Lighting switch Oil presare gauge. Water temperature gauge Revolution counter. Speedometer Automatic transmission ‘lector lever or overdrive Switch leer lnterioriap light switch. Pore ight switch, ‘Heater fan switch Ieniton snitch. Cigar lighter. ‘Starter swith, Fue! tank change-over ite Windseren wiper switch. Windsereenwasher switch, Clock adjuster. Flashing direction indica ‘eran eaten fing Horn ring. Speedometer tip control Brake fluid levelfand bra warning Tigh Brake fluid levelinand- trae warning Tigh. ‘Speedometer Revolution counter. “Automate transmission ‘cletor lever or overdrive switch ever. Water temperature gauge it presure gue. Lighting swith. Fuel gate. “Ammeter ‘Flashing dvection indica ‘oad adie fine Speedometer trip comet ‘Hor ring. (Clock adjuster. Interorimap ligh switch ‘Pane ight switch, {Heater Jan switch. ‘Starter swith Cigar lgher Tenition swith Fuel tank change-over teh Windscreen wiper site. 1 WindscrenwasherswitchGENERAL INFORMATION INSTRUMENTS Ammeter Records the flow of current into or out of the battery. The flow of current is adjusted to the state of charge of the battery; thus when the battery is fully charged the alternator provides only a small ‘output and therefore little charge is registered on the ammeter, whereas when the battery is low a continuous high charge is shown, Oil Pressure Gauge The electrically operated pressure gauge records the oil pressure being delivered by the oil pump to the engine; it does not record the quantity of oil in the sump. ‘The minimum pressure at 3,000 r.p.m. when hot should not be less than 40 Ib, per square inch, Note: After starting up a period of approximately 20 seconds will elapse before the correct reading is obtained. Water Temperature Gauge The electrically operated water temperature ‘gauge records the temperature of the coolant by means of a bulb screwed into the inlet manifold water jacket. Fuel Level Gange Records the quantity of fuel in the supply tank in use, To obtain readings for the opposite tank operate the fuel changeover switch on the instru ‘ment panel. Readings will only be obtained when the ignition is switched “ON”, ‘Note: Lift the switch lever for the leftchand tank, lower for the right-hand tank as shown on the indicator strip. Electric Clock The clock is built into the revolution counter instrument and is powered by the battery. The clock hands may be adjusted by pushing up the ‘winder and rotating, Starting is accomplished in the same manner, Revolution Counter Records the speed of the engine in revolutions per minute. ‘Speedometer Records the vehicle speed in miles per hour, total mileage and trip mileage (kilometres on certain export models). The trip figures can be set to zero by pushing the winder upwards and rotating clockwise, ‘Headlight Warning Light ‘A warning light marked “Headlamps” situated in the speedometer, lights up when the headlights are in the full beam position and is automatically ‘extinguished when the lights are in the dipped beam position. Fig.7. Warning lights in speedometer, Ignition Warning Light A.red warning light (marked “Ignition” situated in the speedometer, lights up when the ignition is switched “on” and the engine is not running. This light does not provide any indication of the state of ‘charge nor does it indicate if the fan belt has broken. Always switch “off” when the engine is not running. Page ASGENERAL INFORMATION Flashing Direction Indicators-Warning Lights ‘The warning lights are in the form of green arrows, one at each side of the quadrant situated ‘behind the steering wheel. ‘When the flashing indicators are in operation one of the arrows lights up on the side selected. Fig. 8. Fashng direction indicator warning lights ‘Side Lamp Warning ‘A blue warning light situated on the side facia ‘between the speedometer and the revolution.counter lights up when the side lamps are switched “on”, Page A.10 Brake Level and Handbrake Warning Light A. warning light (marked “Brake Fluid— Handbrake") situated on the facia behind the steering wheel, serves to indicate if the level in the brake fluid reservoir has become low, provided the ignition is “on.” As the warning light is also illuminated when the handbrake is applied, the handbrake must be fully released before it is assumed that the fluid level is low. If with the ignition “on” and the handbrake fully released the ‘warning light is illuminated the brake fluid must be “topped up” immediately As the warning light is illuminated when the handbrake is applied and the ignition is “on” a two-fold purpose is served. Firstly, to avoid the possibility of driving away with the handbrake applied, Secondly, asa check that the warning light ‘bulb has not “blown if on first starting up the car with the handbrake fully applied, the warning light does not become illuminated the bulb should be changed immediately. Fig. 9. Broke fluid level and handbrake warning light,GENERAL INFORMATION CONTROLS AND ACCESSORIES Accelerator Pedal Controls the speed of the engine. Brake Pedal Operates the vacuum-servo assisted disc brakes fon all four wheels. (Clutch Pedal On overdrive and standard transmission cars, ‘connects and disconnects the engine and the trans- mission. Never drive with the foot resting on the pedal and do not keep the pedal depressed for long, periods in traffic. Never coast the car with a gear ‘engaged and clutch depressed. Headlight Dipper Situated on the toe boards tothe left ofthe clutch, pedal. The switch is of the change over type and if the headlights are in the Full beam position a single pressure on the control will switch the lights to the dipped beam position and they will remain so until another single pressure switches them to the full ‘beam position again. R 2 4 Fig. 10. Gear postions. Gear Lever (Overdrive and Standard Transmission Models) Centrally situated and with gear positions i ted on the control knob. To engage reverse gear first press the gear lever against the spring pressure before pulling the lever rearward, Always engage neutral and release the clutch when the car is at rest. Overdrive Switch Lever For full instructions on the operation of the over- rive, see page A.20. ‘Automatic Transmission Selector Lever For full instructions on the operation of the automatic transmission, see page A.21 Fig. 11. Handbrake control release the handbrake ‘urn the control the direction shown Handbrake Control Positioned under the dash behind the steering wheel. The handbrake operates mechanically on the rear discs only and is provided for parking, driving away on a hill, and when at a standstill in traffic. To apply the brake, pull the lever handle outwards and the trigger will automatically engage with the ratchet. To release the handbrake turn the lever handle anti-clockwise until the ratchet is disengaged and allow the control to return to the fully OFF position, Page A.11GENERAL INFORMATION Fig, 12, Front seat adjustment. Seat Adjustment Both the front seats are adjustable for reach. Push the lever, situated beside the inside runner, towards the centre of the car and slide into the required position. Release the lock bar and slide ‘until the mechanism engages with a click. The seat back is adjustable from the vertical to the fully reclined position. Fig, 13,- Reclining sat ack adjustment lever. Page A.12 To adjust, lift the lever located between the seat and the propeller shaft tunnel cover and adjust the seat back to the desired position. Release the lever to lock the seat back in position. Steering Wheel Adjustment Rotate the knurled ring at the base of the steering ‘wheel hub in an anti-clockwise direction so that the steering wheel may be slid into the desired position. ‘Turn the knurled ring clockwise to lock the steering wheel. Fig. 4, Storing whee adjustment Front Door Locks ‘The front doors may be opened from the outside bby pressing the button incorporated in the door handle, The doors are opened from the inside by pulling the interior handles rearward. Both front doors ean be locked from the inside by pushing the interior handles forward and allowing them to return to their original position; this feature only applies if the doors are fully closed before operating the interior handles. Both front doors can be locked from the outside bby means of the ignition key; the locks are incor- porated in the push buttons of the door handles. To lock the right-hand door insert the key in the lock, rotate anti-clockwise as far as possible and allow the lock to return to its original position—the door is now locked, To unlock the right-hand door tur key clockwise as far as possible and allow the lock to return to its original position, To lock the left-hand door rotate key clockwise; to unlock, rotate key anti-clockwise.KEYLESS LOCKING is obtainable by first Pushing the interior door handle fully forward and allowing it to return to its original position, If the door is now closed from the outside with the push button of the handle fully depressed the door will ‘become locked. Waming: If the doors are to be locked by this ‘method the ignition key should be removed beforehand (or the spare key kept om the driver's person) as the only ‘means of unlocking the front doors is with this key. Rear Door Locks ‘The rear doors may be opened from the outside bby pressing the button incorporated in the door handle, The doors are opened from the inside by ‘pushing the interior door handle forward. The rear doors are locked by pulling the interior door handles rearward. Hora Depress the semi-circular ring or the centre button of the steering wheel to operate the twin horns. Ignition Switch Inserting the key provided in the switch and ‘turing clockwise will switch on the ignition. ‘Never leave the ignition on when the engine has stopped, a reminder of such circumstances is pro- vided by the ignition warning light situated in the speedometer. Interior/Map Light Switch ‘The map and interior lights are controlled by a three position switch marked “Interior/Map". Lift the switch lever to the second position to operate the map light situated above the instrument panel. For interior lights lift the switch lever to the third position. To provide ease of entry into the car at night the interior lights are automatically switched ‘on when any one of the doors is opened and are ‘extinguished when the door is closed. Lighting Switch From “Off” can be rotated clockwise into two positions, giving in the first location, side and tail, in the second location, head, side and tal GENERAL INFORMATION Panel Light Switch Lift the switch lever (marked “Panel”) to enable the instrument to be read at night and to provide illumination of the switch markings. The switch has two positions “Dim” and “Bright” to suit the driver’s requirements. The panel lights will only ‘operate when the side lights are switched on. ‘Starter Switch Press the button (marked “Starter”) with the ignition switched on, to start the engine, Release the switch immediately the engine fires and never ‘operate the starter when the engine is running. ig. 1S. Flashing direction indicator contro. ‘Flashing Direction Indicators ‘The “flashers” are operated by a lever behind the steering wheel. To operate the flashing direction indicators on the right-hand side of the car, move the lever clockwise; to operate the leftchand side indicators move the lever anti-clockwise. While the flashing indicators are in operation one of the ‘warning lights in the quadrant behind the steering whee! lights up on the side selected. Headlight Flasher To “flash” the headlights as a warning signal, lift and release the flashing indicator lever in quick succession. The headlights can be “flashed” when the lights are “off” or when they are in the dipped ‘beam position; they will not “flash” in the main ‘beam position. Page A.13GENERAL INFORMATION On cars for the Italian market the headlights can be flashed when in the “off” position or when the lights are in the main beam position. Headlights so fitted cannot be “flashed” when dipped. Fig. 16. Method of “flashing the heights" Glovebox Light A light in the glovebox is automatically illumina~ ted when the lid is opened and the sidelights are Braking Lights ‘Twin combined tail and brake lights are situated ‘at the rear of the car. The latter automatically Lights up when the footbrake is applied Reversing Lights ‘The twin reversing lights are automatically brought into operation when reverse gear isengaged and "ue ignition is switched on. Loggage Compartment Illumination ‘The luggage compartment is automatically illu- inated by a light when the lid is opened. The light operates only when the sidelights are switched Cigar Lighter To operate, press the holder into the socket (marked “Cigar” on the indicator strip) and remove the hand, On reaching the required temperature, the holder will return to the extended position. Do not hold the lighter in the “pressed in” position. Page A.14 Windscreen Wipers ‘The wipers are controlled by a three position sswiteh (marked “Wiper” on the indicator strip). Lift the switch to the second position (Slow) which is recommended for all normal adverse weather conditions and snow. For conditions of very heavy rain and for fast driving in rain lift the switch to the third position (Fast). This position should not be used in heavy snow or with a drying windsereen, that is, when the load on the motor is in excess of normal; the motor incorporates a protective cut-out switch which under conditions of excessive load cuts off the current supply until normal conditions ae restored. When the switch is placed in the “Of” position the wipers will automatically return to a position along the lower edge of the screen. Windsereea Washer For full instructions on the use of Windscreen Washing Equipment see Section O. Heating and Ventilating Equipment For full instructions on the use of the Heating and Ventilating Equipment see Section O. Scuttle Ventilator ‘The scuttle ventilator is operated only by the Heating and Ventilating controls see Section O, Fig. 17. Bonnet lock controlBonnet Lock Control ‘The bonnet lock is controlled from the driving ‘compartment. To open the bonnet pull the lever situated behind the facia on the right-hand side This will release the bonnet which will now be retained by the safety catch. Insert the fingers under the rear edge of the bonnet and lift up the safety catch. ‘The bonnet is automatically retained in the fully ‘open position by the action of the hinge torsion bars. The bonnet is self-locking when pushed down firmly into the closed position. Fig. 18. Plunger to operate font N.D.V. No Draught Ventilation AAlll doors are fitted with no draught ventilation windows incorporating quick locking plungers ‘The ventilation windows may be pushed open as far as required by pressing the handle centre button and turning the handle, When operating a vent window ensure that the handle is turned until the button clicks. (This is an anti-theft device). It will bbe observed that initial openings of the front ‘window gives extraction of air from the body. When the window is opened further, air is forced into the body due to the angle of the ventilator and forward motion of the car. It should be observed that using the N.D.V. windows as extractors (that is, partially open) has, to a minor degree, the effect of demisting the windscreen. GENERAL INFORMATION ‘Spare Wheel and Jacking Equipment ‘The spare whee! is housed in the luggage compart- ment. To remove the spate wheel, rotate the serrated nut securing the wheel clamp in position. Lift the clamp clear of the tyre and remove the wheel. ‘The jack and wheel brace are retained in clips accessible when the spare wheel is removed, The container for the hand tools, bleeder tube and sparking plug is housed in the luggage com- partment behind the spare wheel. Page A.15,GENERAL INFORMATION Release the catch and withdraw the container from the retaining clips. Rotate the turnbutton to ‘open the lid. ‘Two Pin Plug Socket A two pin plug socket is situated under the bonnet forward of the battery. The socket may be ‘used to “trickle charge” the battery, or to provide an inspection lamp point. Foe! Tank Fillers ‘The two fuel tank filler are situated in recesses in the rear wings, The filler lids are fitted with locks ‘opened by the round-headed key provided. Fig. 21. Unlocking the fet rank filler i Luggage Compartment To open the luggage compartment, insert the square-headed Key in the lock situated between the twin reversing lamps and unlock by rotating anti- clockwise through half a turn, Release the catch lever located beneath the lock and raise the lid. ‘The lid is retained in the fully open position by ‘means of torsion bar springs. Interior Driving Mirror This is of the dipping type. Move the lever, situated under the mirror, to the left for night driving to avoid being dazzled by the lights of a following car. Page A.16 Fig, 22. Opening the luggage compariment Ash Trays ‘Three ash trays are provided, one being mounted centrally below the instrument panel and one ‘mounted in the back panel of each front seat above the picnic tables To remove the front ash tray for cleaning pur- ‘poses, lift the retaining spring blade and withdraw the tray. To remove the rear ash trays press down the retaining spring. Fig, 23, Inveror driving mibror dipping operation‘Wheel Changing Whenever possible, the wheel changing should be ‘carried out with the car standing on level ground and in all cases with the handbrake fully applied. ‘The spare wheel is housed in the luggage com- partment; the wheel changing equipment being. accessible when the spare wheel is removed. ‘Unlock the luggage compartment by turning the key in the lock, situated between the twin reverse lamps through half-a-turn, Lift the catch lever located beneath the lock and raise the lid as far as possible where it will be retained by the action of the hinge torsion bars. Remove the spare wheel after rotating the serrated. ‘nut and lifting the clamp clear of the tyre. Remove the jack and wheel brace from the retaining clips. Fig. 4. The jack psn for rating the righthand Detach the wheel nave plate by levering off with the blade end of the wheel brace. Using the wheel brace loosen, but do not remove the wheel nuts; all wheel nuts have right-hand threads, that is, they are unscrewed anti-clockwise. Remove the ‘rubber plug from the jacking socket adjacent to the wheel to be removed, insert the square portion of the jack well home into the socket and rotate the GENERAL INFORMATION = J | ra 2k mtn te eres meh po ea hhandle attached to the jack clockwise. Raise the car until the wheel is clear of the ground. Remove the wheel nuts and withdraw the road wheel, ‘Mount the spare wheel on the fixing studs and start all five nuts on the threads by rotating clock- ‘wise. Apply the wheel brace and run up all the nuts ‘until they are tight. Rotate the jack handle anti-clockwise and lower the jack until the full weight of the car is on the wheel. Finally tighten all wheel nuts. Fit the nave plate over two of the three mounting posts and secure by a sharp tap from the hand at a point in line with the third mounting post. ded in the back of each front seat and are opened by pulling the handles upwards and outwards until the tables assume a horizontal position, With the tables in the opened position two angled vanity mirrors will be exposed. ‘Seat Belts Anchorage points for seat belts are incorporated in the construction of the car as shown in Fig. 26. Page A.17GENERAL INFORMATION CAUTION NEGATIVE EARTH Fig. 27. Showing negative earth battery connection. IMPORTANT ‘This model hasa Negative Earth (ground) system and certain ofthe electrical components are different to those fitted to positive earth cars. When fitting auxiliary equipment or replacing any of the electrical ‘components use only those specified for this particular model or ensure that they are suitable for use ‘with negative earth. Do NOT run the engine with the alternator electrical cables disconnected or loose otherwise the alternator may burn out. Page A.18GENERAL INFORMATION STARTING AND DRIVING Prior to starting Before starting the engine the new owner should be familiar with the location and function of the instruments and controls. Ensure that the water level in the radiator and the cillevelin the sump are correct. Check for sufficient petrol in the tanks. Place the gear lever in the neutral position and check that the handbrake is applied. Starting from Cold It is not necessary to use any manual choke con- trol when starting from cold, since the auxiliary starting carburetter is entirely automatic and con- trols the mixture strength without assistance from the driver. ‘The starting carburetter automatically cuts out when the temperature of the water in the cylinder head reaches 35°C. When starting from cold do not depress the accelerator pedal until the engine has run for a few seconds. ‘Warming up Do not operate the engine at a fast speed when first started but allow time for the engine to warm up and the oil to circulate, A thermostat is incor- porated in the cooling system to assist rapid warming up. In very cold weather run the engine at 1,500 r.p.m. with the car stationary until a rise in temperature is indicated on the temperature gauge. Driving (@) Careful adherence to the “Running-in”” Instructions given on this page will be amply repaid by obtaining the best performance and utmost satisfaction from the car. (b) The habit should be formed of reading the oil pressure gauge, water temperature gauge and ammeter occasionally as a check on the correct functioning of the car. Should an abnormal reading ‘be obtained an investigation should be made immediately. (© Always start from rest in first gear. To start in ‘a higher gear will cause excessive clutch slip and premature wear. Never drive with a foot resting on the clutch pedal and do not keep the clutch de- pressed for long periods in trafic. (@) The gearbox is provided with synchro-mesh ‘on all forward gears. When changing down a smoother gear change will be obtained ifthe accelerator islet depressed to provide the higher engine speed suitable for the lower gear. Always fully depress the clutch pedal ‘when changing gear. (©) Gear changing may be slightly stiff on a new car but this will disappear as the gearbox becomes “run-in”. (f) Always apply the footbrake progressively; fieroe and sudden application is bad for the car and. tyres. The handbrake is for use when parking the car, when driving away on a hill and when at a standstill in trafic. “‘Running-in” Instructions Only if the following important recommendations are observed will the high performance and continued good running, of which the Jaguar is capable, be obtained, During the “running-in” period do not allow the engine to exceed the following speeds and particularly do not allow the engine to labour on hills; itis preferable to select a lower gear and use a higher speed rather than allow the engine to labour at low speed: First 1,000 miles (1,600 km.) .. 2,500 rpm. From 1,000—2,000 miles (1,600—3,200 km.) 3,000 r.p.m. Have the engine sump drained and refilled and the oil filter attended to as recommended at the free service, that is, after the first 1,000 miles ((,600 km.). Page A.19GENERAL INFORMATION OVERDRIVE ‘The Laycock de Normanville overdrive unit (Gited as an optional extra) comprises a hydraulic- ally-controlled epicyclic gear housed in a casing which is directly attached to an extension at the rear of the gearbox. When brought into operation, the overdrive reduces the engine speed in relation to the road speed. This permits high road speeds with low engine revolutions resulting in fuel economy and reduced engine wear. Fig. 28. Overdrive switch lever. Page A.20 Operation ‘The overdrive will operate in top gear only and is brought into action by means of the lever behind the steering wheel on the right-hand side of the column. Operate the lever clockwise to engage the overdrive and anti-clockwise to bring the drive into top (4th) gear. When the overdrive is in operation the word “Overdrive” in the quadrant behind the steering wheel becomes illuminated. When the sidelights are switched on, the light is automatically dimmed. Use of the clutch pedal when changing into or out of overdrive is unnecessary but to ensure ‘maximum smoothness of operation particularly when changing down from overdrive to top gear, the accelerator pedal should be slightly depressed. Do NOT bring the overdrive into operation at high speed with a wide throttle opening; release the accelerator momentarily when engaging overdrive. For driving in towns, heavy traffic, or hilly ‘country when the maximum flexibility and low speed performance is required the overdrive manual ‘switch should be placed in the “Out” position which will bring the drive into normal top gear rat For normal driving in open country the overdrive should be brought into operation when the required cruising speed has been obtained.GENERAL INFORMATION AUTOMATIC TRANSMISSION Operation The automatic transmission incorporates an hydraulic torque converter in place of the flywheel and clutch. This converter is coupled to an hhydraulically operated planetary gearbox which provides three forward speeds and reverse. Operation of the automatic transmission is controlled by the driver through the selector lever, ‘mounted on the steering column behind the steering wheel. The quadrant markings, from left to right are P, R, N, D2, DI, L. The selector lever can be moved freely between N—D2and DI—L. To move the lever between D2 and DI or to the P o R positions the lever must be lifted towards the steering wheel. ‘Warning: Neither P nor R should be engaged whilst the car is in motion, ‘mechanically locked by means of the parking pawl which engages ‘with external teeth formed on the ring gear integral with the driven shaft. Park should not be selected when the car is in motion. Use of the Park position is recommended when- ever the car is parked with or without the engine running. Preparatory to re-starting on a steep gradient, apply the brakes before disengaging P to prevent the cir from rolling; disengagement of the parking. pawl will be audible. R (Reverse) ‘The “R” position provides reverse ratio. Do not select Reverse when the car is moving forward. N (Neutral) All clutches are disengaged and there is no drive beyond the torque converter. The handbrake must be applied whenever Neutral is selected and the car is at rest. D2 (Drive range, 2nd gear start) In the Drive 2 position, the car starts from rest in second gear and operates automatically between second and third gears. At, or below, a preset maximum vehicle speed, downshifts from 3rd to 2nd may be effected by depressing the accelerator fully. (“Kickdown” position). First gear is not obtainable in this position but D2 is suitable for normal driving where maximum acceleration is not required. In this position, the car will not roll back on hills as long as the engine is running. D1 (Drive range, Ist gear start) When in the D1 position, the car starts from rest in first gear and operates autontatically through all three forward ratios. Upshifis and downshifts ‘occur in accordance with car speed and throttle position. At, or below, preset maximum road speeds down- shifts may be effected from 3rd to 2nd, from 2nd to Ist,or, directly, from3rdto Ist. Thisisaccomplished by depressing the accelerator fully. (“Kickdown" position). TL CLockup) Lockup position provides overriding control for cither first or second gear with engine braking in either ratio, Page A.21GENERAL INFORMATION ‘When starting from rest in the lockup position the transmission starts in Ist gearand remainsin that gear regardless of road speed or throttle position. Maximum engine braking is available in this gear. In either D1 or D2 with the transmission in 3rd seat, the selection of L will cause an immediate downshift to second gear. This will provide ‘moderate engine braking when the throttle is closed. If the road speed is reduced to approximately 16 mph. 25 kp.h,) the transmission will downshift automatically from second to first and provide ‘maximum engine braking. ‘Once first gear is attained, no upshift will be possible until the selector lever is removed from the L position. Starting A starter inhibitor switch ensures that the starter will operate only when the selector is in either the P ot N position. ‘Engine Braking ‘When engine braking isrequired whilst descending steep hills apply the footbrake to reduce speed to approximately 60 m.ph. (96 k-p.h,) or below. Move the selector lever to the L position to obtain ‘an immediate downshift to second gear. from 3rd to Ist gear. Rocking the Car In order to extricate a car from mud, sand or show, employ a constant slight throttle opening and rock the car backwards and forwards by alternately selecting the R and D2 positions. ‘Maximum ratio of torque converter Low gear reduction. Intermediate gear reduction Direct drive—no converter Reverse gear reduction .. Page A.22 Stopping To bring the car to rest, release the accelerator and apply the brakes. If the car is temporarily stopped for traffic lights, etc., the selector lever may be left in whatever forward range itis in, but the foot or handbrake should be applied to stop any tendency for the car to “creep”. Parking ‘When the car is stationary select the P (Park) position. ‘Pash Starting tis possible to effect an engine start by pushing the car. To do this, select N and switch the ignition ON. Depress accelerator pedal approximately } and ‘when the car reaches approximately 20 m.p.h. (32 k.p.h,) select D2 or L. Do NOT tow the car to start the engine—it may overtake the towing vehicle. Towing ‘The car may be towed with a dead engine in an cemergenty. Before towing ensure that the trans- mission fluid is at the correct level. Towing should be done with the transmission selector in the N position and speed should not exceed 30 m.p.h. 8kp-h). If the car is being towed because of transmission damage, the propeller shaft should be removed or towing should be done by lifting the rear wheels from the ground, Failure to do this may result in further extensive transmission damage. Do NOT select “P” is in motion, or “R” whilst the car DATAGENERAL INFORMATION AUTOMATIC GEAR CHANGES Selector Throttle Upshitts Downshifts Position Position 12 23 32 31 24 MPH. 67 10-12 6-12 = 36 DI 31-36 54-58 18.31 = = 42-46 66-73 59-67 16-20 16-20 - 10-12 6-12 = - D2 - 54-58 1831 7 = . 6-73 59-67 - = L = = 0 = 9.17 KPH. Minimum, 10-11 16-19 10.19 = 5-10 DI Fall 50-58 87-93 29-50 ~ — Kickdown 68-74 106-117 95-108 26-32, 26-32 Minimum, - 16-19 10-19 - - D2 Full . 87-93, 29-50 - = Kickdown 7 66-73, 95-108 7 = L Zero = - ” ~- 14-27 Page A.23GENERAL INFORMATION AUTOMATIC TRANSMISSION MAINTENANCE EVERY 3,000 MILES (5,000 KM.) (Checking Transmission Fluid Level ‘The transmission filler tube is located on the right hand side of the engine under the bonnet just Forward of the bulkhead. Check the fluid level ‘every 3,000 miles (5,000 km.).. Before checking the fluid level, the car should be on Ievel ground and the transmission should be at the normal operating temperature. Set the handbrake and select P position. ‘The engine should be at normal idle. ‘While the engine is running, remove the dipstick, ‘wipe clean and replace in the filler tube in its correct, position. Withdraw immediately and check. If necessary, add fluid to bring the level to the FULL mark on the dipstick. The difference between FULL and LOW marks on the stick represents approximately 1+ pints (2 U.S., pints ot 0-75 litres). Be careful not to overfill. If fluid is checked with the transmission cold, a false reading will be obtained and filling tothe FULL ‘mark will cause it to be overfile. Ifit is found necessary to add fluid frequently it will be an indication that there is a leakage in the transmission and it should be investigated immedi- ately to prevent damage to the transmission. Page A.24 Total fluid capacity (including cooler) 15 Imperial pints from dry (18 USS. pints 8°5 litres). Fluid Changing ‘The transmission fluid should be changed after the first 1,000 miles (1,600 km.) of operation. No periodic fluid changes are recommended except when other transmission service is necessary. If the oil pan is removed for other service the fluid should be drained and replaced with fresh fluid. Fig. 30, Automatic transmission dipstickGENERAL INFORMATION SUMMARY OF MAINTENANCE DAILY Check radiator water level Check engine oil level. WEEKLY Check tyre pressures (including spare wheel). MONTHLY Check battery electrolyte level and connections, EVERY 3,000 MILES (5,000 KM.) Check radiator water level Check tyre pressures (including spare wheel) Check battery electrolyte level and connections Check fluid level in automatic transmission unit (if fitted). Check fluid level in power-assisted steering Check fluid level in brake and clutch master cylinder reservoirs. Check gearbox oil level Check rear axle oil level. Drain engine sump and refill Clean oil filter element. ‘Top up carburetter hydraulic piston dampers. Lubricate distributor and check contact points. ‘Clean, adjust and test sparking plugs. (Check carburetter slow running. EVERY 6,000 MILES (10,000 KM.) Carry out 3,000 mile (6,000 km.) service. Lubricate all grease nipples (excluding wheel bearings). Renew oil filter element, Clean carburetter filters. Clean fuel feed ne filter. Examine brake friction pads for weat. Clear drain holes in bottoms of doors. Adjust top timing chain (if necessary. ‘Check front wheel alignment. Check driving belts for wear. Carry out oil can lubrication of (a) seat runner and adjusting mechanism (b) handbrake lever ratchet (c) door locks (d) luggage compartment hhinges and lock (e) bonnet hinges and catches (() windscreen wiper arms (g) accelerator and cat- bburetter linkage (h) fuel filler cover hinge. EVERY 12,000 MILES (20,000 KM.) Carry out 3,000 and 6,000 mite (5,000 and 10,000 km.) service. Drain and refill gearbox. Clean overdrive oil pump filter (if overdrive fitted), Drain and refill rear axle, Renew air cleaner element. Renew sparking plugs Lubricate front and rear wheel bearing hubs. (Check front and rear wheel bearings for end-float (Additional charge for adjustment). Check exhaust system for leaks. Check and tighten all chassis and body nuts, bolts and screws. EVERY 21,000 MILES (35,000 KM.) ‘Adjust front and rear bands (automatic trans- mission). Page A.25GENERAL INFORMATION. RECOMMENDED LUBRICANTS Component Mott | caval | sean | Exo ap, | Duckham| Regent | catterFFexaco ‘Eso fxr Motor | | 7} | oil swi20* 020-50 | Havoline Engine + | Mobitol | Castotiter | shel Super | Esso Extra Motor | Visco | Sor) | 20W/40 or Special® | or Cantal | "on | “Oirtow/o™ astoor | “owt St es Exta Motor | { ‘Oi 20/40" Upper elinder librieation | Mobil | Castollo | Shell UCL, Esso UCL | Adoid luppertue| orDonaxU] UCL. iguid Dinribuoy olen pons | Mao | Col | X00 Esso Esergol | NOL itcaniabeeation "> | xt 0 Moro | SAE | "30 20W/30 ‘Gearbox ‘Mobilube | Castrol | Spirax | Esso Gear OW" | Gear Oi | Fiypoid Rear ale GX | Hypoy | Ee | “Gaia |SaEo0ER) "¥0' ‘Front whee! bearings i Rear wheel beatings Mobile | Esso Mult | Datributor eam srease | Castotse | Reinax | purpose preawe [Enererease! LB.10 | Marfak Steering tlerods we | SEN | SA " fies Wheel Svcs | Rear wishbone pivots | ‘Trane ‘Automatic wansmision unit Mobiltuid) Caco! | She | Exo Automatic | mition | Nolmatic | Texamatic Power steering syste TO. Donax | “Tramsmton” | "Fluid ‘Hud 78 Find Tpea ‘These oils NOT to be used in engines requiring overhaul RECOMMENDED HYDRAULIC FLUID Braking System and Clutch Operation Dunlop Disc Brake Fluid is recommended. This conforms to SAE 70 R3 specification modified for additional safety to give a higher boiling point. Where this is not available, only uid guaranteed to conform to SAE 70 R3 specification which is fully miscible with Dunlop Disc Brake Fluid, may be used as an alternative. Page A.26GENERAL INFORMATION SPECIAL SERVICE TOOLS Distributors and dealers should obtain the Churchill special tools (ie. tool numbers marked by an asterisk) illustrated in this manual direct from Messrs. V. L. Churchill & Co. Ltd., London Road, Daventry, Northants., P.O, Box No. 3 Section ENGINE, OVERDRIVE REAR AXLE ‘STEERING Description ‘Timing chain adjuster 1.2)" Valve spring compressor (J.6118)* Crankshaft rear seal sizing tool (J.17)* Valve guide bore reamer (J.18)* Hydraulic test equipment (L:301)* Freewheel assembly ring (L178)? Operating piston remover (L.300)* Multi-purpose hand press (SL.14)* used with:— Pinion bearing inner race remover (SL.14-1/* ferential side bearing cone remover (SL.14-3)* “Multi-purpose handle ($50)* used with:— Differential side bearing cone replacer (SL.550-1)* Pinion outer bearing cup replacer (SL.S60-4)* Pinion inner bearing cup replacer (SL.550-5)* Pinion cone setting gauge (SL.3)* Pinion oi seal replacing collar (SL.4)* ub inner and outer bearing cup replacer (J20A)* Adaptor (20-1) ub endfoat master spacer and inner bearing cone replacer (J.15)* Hub endfloat dial gauge (.13)* Hub remover (ID 1C)* Hub outer bearing cone remover (J.16B)* Steering box centralising gauge (1.27)* Power steering gauge adaptor (1.28)* Power steering assembly sleve (3.30)* Valve seal expander (1.32)* Valve seal compressor J.33)* Sector shaft spine seal protector (1.34)* Rotor spine seal protector (.35)" FRONT SUSPENSION Front coil spring compressor (JD.68)* REAR SUSPENSION BRAKES Rear spring compressor (J.11A)* used with SL.14 above Rear wishbone pivot dummy shaft (J.14)* Piston resetting tool Master cylinder clearance setting gauge (J.26)* Master cylinder return spring compressor (J.29)* Servo end plate remover (J.31)* Page A.27GENERAL INFORMATION SERVICE DEPARTMENTS Factory: ‘The Service Division, Jaguar Cars Limited, Coventry, England. Telephone No. Coventry 27677 (P.B.X.) London: ‘Messrs. Henlys Ltd., ‘The Hyde, Hendon, London, N.W.9. ‘Telephone No, Colindale 6565 USA: ‘The Technical Service Department Jaguar Cars Ine. 42/50, 21st Street, Long Island City 1. New York, U.S.A. ‘The Technical Service Department, Saguar Cars (Canada) Ltd. ‘8505 Delmeade Road, Montreal 9 Quebec, Canada. Page A28GENERAL INFORMATION CONVERSION TABLES METRIC INTO ENGLISH MEASURE 5 millimetre is approximately 1/25", and is exactly 03937" | centimetre is approximately 4" and is exactly 3937" 1 metre is approximately 399", and is exactly 39-37" or 1.0936 yards 1 kilometre is approximately # mile, and is exactly 6213 miles. 1 kilogramme is approximately 2 Ibs, and is exactly 221 Ibs. 1 ie is approximately 14 pints, and is exactly 176 pints. “To.convert metes to yards, multiply by 70 and divide by 6 To convert kilometres to milks, multiply by 5 and divide by 8 (approx). ‘To convert lites to pint, multiply by 88 and divide by 50 ‘To convert grammes 10 ounces, multiply by 20 and divide by 567 ‘To find the cubical contents ofa motor eylindr, square the diameter (or bore), multiply by 07858, and multiply the result by the stroke, 1M.P.G.-0354 kilometres pe lire oF 284 les per kilomete MILES INTO KILOMETRES, Kilo, | Mies | ilo. | ies || ito. | Mites ff Kilo. | mites |] ito. | Mites T i 16 10 Fy 1 6 2 @ a 2 1 id 104 2 13} o z % aw 3 i 1B ne 3 zo & 2s © 2 ‘ at 8 ie ub ah rs Sol So 55 5 5 20 a 3 BY % au 100 a 6 3 a 6 36 Fr 3 a 200 | 134 5 a BR th uo bt 2 ui S00} beh & 3 B th is Be 5 ay 40 | ba 5 a Fa rr a dal S a soo] i 0 ot 3 1h ry 2a 5s ul im | an u & 3s 16 a ast Se Mi noo | 435 2 at 2 1 2 | db a cy am | 387 5 a 2% i 3 det it 3 boo | 388 ie q Fy 1 4 2 9 368 woo | eal 15 3 2 18 3 2 PINTS AND GALLONS TO LITRES Litres Lites tires Lees Pints Gatloos | approx Enact Pints Gallons | Approx. Exact 1 as 37 0 5 B nes 2 i ' ri a & H io 3 i | y a 6 - - nes 4 ; a 20 o a 64 3640 5 i a 354 R 3 a 2095 6 2 | 3 310 0 10 ay $350 PH 5 BE 1368 is uv 30 S008 2 4 ia 1830 36 2 St Seo Page A.29GENERAL INFORMATION RELATIVE VALUE OF MILLIMETRES AND INCHES mm. ater | am ee ee i | Z 6 35 2 B 2 a 3 3 a 3 % 3010 4 B Ey % 31 3 » s o 386 8 x s a 3190 5 2 2 2 ine a 3 s & en 5 4 2 4 Hon o 8 @ s gs i 3% et & 29 2 a @ a jase 3 8 & a see 6 8 a 8 soe 5 * & = 3503 é a & 3 3st 0 2 e 3 saat @ a a a sae 5 # 8 34 08 2» & % 38 ia a % si 9% 316 a 2 R % 3609 B a a % hasn FA 3 % % sn % 05603 & 3 109 35370 RELATIVE VALUE OF INCHES AND MILLIMETRES Iaches ° : * + * * ° 00 32 48 ea 73 wa 1 ae ae | a2] at | 8 aes 2 oe me | Se | St cd a3 3 ie Ba | gro | ms | ar Ee 4 1016 3 | vse | aoeo | ames 127 5 110 2 | ire | ie | tae 18 é 14 3 | isa | tee | 1a ahs laches + i + i = © ° BT 59 | ang BI me | 22 | Be i aH a3 | 23 | Ma | feo | Be | Be 2 es & | a | ot | ia | Bo | ie 3 9 Sr Sy | $3 | gee | sea | aoe 4 13 3 | pi | aor | ep | me | ase 5 1397 tas | las | ter | las | iz | oe ‘ 1651 iS | ised | ois | mo | ites | ae Page A.30SECTION B ENGINE 4.2 MARK 10 MODEL AmsINDEX ‘Air cleaner Alternator. Bottom chain tensioner: Removal Refitting Camshafts: Removal Refitting Overhaul Compression pressures Connecting rod and bearings Removal Overhaul Refitting Big-end bearing replacement Crankshaft: Removal Overhaul Refitting Crankshaft damper and pulley: Removal Overhaul Refiting, ‘Crankshaft rear oil seal: Description Removal : Replacing the seal Refiting Cylinder block Overhaul Cylinder head: Removal Overhaul Refitting Page B.2 Page Bq B.I6 Bos Bos B36 B37 Ba? Bt B34 B34 B35 B35 B37 B37 B38 B40 B40 B38 B38 B39 B39 BaD Baa Bad BadINDE X (continued) Data Decarbonising and grinding valves Engine—removal and refting Engine—to dismantle Engine-—to assemble Engine mountings Engine stabiliser Exhaust manifolds Removal Refitting Flywheel: Removal Overhaul Refitting Ignition timing Inlet manifold: Removal Refitting Oil filter: Removal Refitting : Element replacement il pump: Removal Dismantling Overhaul Reassembling Refitting Oil sump Removal Refitting Page BS Ba Bai B22 B26 B70 BAL Bas Bas Bas Bas Bas Bas BSI BSI Bay Bay Bas Bs2 B32 B32 B53 B53 BSS BSS Page B.3INDEX (continued) Pistons and gudgeon pins: Removal .. Overhaul Refitting Routine maintenance Sparking plugs: Service procedure ‘Analysing service conditions Standard gap setting Sparking plug inserts Special tools ‘Tappets, tappet guides and adjusting pads: Removal of tappets and adjusting pads Overhaul : Timing gear: Removal Dismantling Overhaul Assembling Refitting Valves and springs: Removal Overhaul Valve clearance adjustment Refitting Valve guides: Replacement Valve seat inserts: Replacement Valve timing Page BA Page BSS BS6 BSB Bs Bs B60 B60 B72 Bol B61 Bo Be B62 B62 BOS Bos Bos B66 B67 Bor Bos BeENGINE ‘The 42 Mark 10 has the twin overhead camshaft XK type engine, fitted with an “S” type cylinder head with straight ports and 3" lift camshafts, Compression Ratio | Engine No. Prefix Colour of Cylinder Head 7A; 8:1 7D Gold 9:1 Compression ratios of 7:1, 8:1, and 9:1 are specified for the 4-2 Mark 10 engine, the differences in compres sion ratio being obtained by varying the crown design of the piston. The compression ratio of an engine is indicated by /7, /8 or /9 following the engine number. DATA Camshaft ‘Number of journals Four per shaft Journal diameter. 1-00" — 0-005" — 0.001" (25-5 mm. —0-013 mm.) 0025 mm.) ‘Thrust taken : Front end ‘Number of bearings : Four per shaft (ight half bearings) ‘Type of bearing... : ‘White metal steel backed shell Diameter clearance, my 0.0005" - 0-002" (0013 - 0.05 mm.) Permissibleend float. ww. oo 0-004" - 0-006" (0:10-0:15 mm.) Tightening torque—Bearing cap nuts =. 15 Ib. ft. (175 1b, in.) (20 Kem) Connecting Rod Length centre to centre. ua (19°68 cm.) Big end—Bearing type co : Lead bronze, steel backed Page B.SENGINE Bore for big end bearing Big end—Width .. Big end—Diameter clearance . Big end—Side clearances Bore for small end bush ‘Small end bush—Type ‘Small end-—Width Small end bush—Bore diameter Tightening torque—connecting rod bolts (Crankshaft ‘Number of main bearings Main bearing—Type Journal diameter Journal length—Front Journal ength—Centre.. Journal length—Rear .. 0. ws Journal length—Intermediate .. Page B.6 2-288" — 2.2335" (56-72 ~ 56-73 mm) 1g" 0-006" = 0-008" (30:16 - 0.15 mm) 0-20 mm.) 0.0015" - 0.0033" (0.037 - 0083 mm.) 0.0058" — 0-0087" (015-022 mm) 1-00" + 0-0005" (25-5 4 0013 mm.) Phosphor bronze—steel backed let (r-4 mm) 0-875" + 0.0002" —0-0000" (2222 +0005 mm), 0-000 mm. 37 Mb. f. (450 Ib. in.) (51 Kem.) 7 Lead bronze, steel backed shell 2750" - 2.1508" (85 ~ 6:86 mm) Te (69.06 mm, 1¥°+0001" 0.0005" (3437 4 0.025 mm. 00125 mm.) ue (42-86 mm) 1" 4 0-002" (8096 + 0.05 mm.)ENGINE Thrust taken c Centre bearing thrust washers, ‘Thrust washer—Thickness 0-092" +. 0-001" and 0-096" +. 0-001" (233 + 0-025 mm. and 2-43 + 0-025 mm.) Eni clearance : : 0-004" - 0.006" (0:10-0:15 mm.) Main bearing length ae 1" 0005" oe (8+ 3: 013 mm) Intermediate 1 + 000s" (255 £013 mm.) Diameter clearance : 00025" - 0.0042" (0.063 ~ 0106 mm.) Crankpin—diameter 2.086" + 0-0006" — 0.0000" (5298 +0015 mm) —0-000 mm.) Length 18" + 00007" — 0-002" 0-16 +0018 mm.) 0-006 mm.) Regrind undersize 0-010", 0.020", 0.030" and 0-040" (025, 0-51, 0-76 and 1-02 mm.) Minimum diameter for regrind — 0-040" (mm) Tightening torque—main bearing bolts 83 Ib. ft. (1,000 Ib. in.) (U5 Kem) Cylinder Block Material we noe “Brivadium” dry liners Interference fit . 0-001" ~ 0-005" (0-025 - 0-127 mm.) (Overall length of liner 6959" ~ 6979" (17-39 = 1745 em) Outside diameter of lead-in 3-758" - 3-760" (9395 - 94 mm.) Page B.7Size of bore honed after assembly—in cylinder block— ‘Nominal .. Main line bore for main bearings Cylinder Head Type Material Valve seat angle—Inlet .. Exhaust ‘Tightening torque—Cylinder head nuts order Gudgeon Pin Dee | tog Inside diameter... : Outside diameter. ‘Lubricating system Oil pressure(hot) il pump—Type aoe —Clearance at end of lobes —End clearance —Clearance between outer rotor and body Page BS 3.4625" (6297 mm) 29165" + 0-0005" — 0.0000" (7408 400125 mm. —0-0000‘inm.) Straight Port (Gold Top) Aluminium alloy 45° 45° 54 Ib. ft. (650 Ib. in.) (75 kgm) 1,5,3,6,24 No. 1 cylinder being at the rear of the engine Fully floating 3-00" (75 mm.) (1587 mm.) 08750" - 08752" (2222-2223 mm) 40 Ib,/sq in. at 3,000 r.p.m, Eccentric rotor 0-006" maximum (OAS mm.) 0.0025" maximum (0-06 mm.) 0.010" maximum (0-25 mm.)ENGINE Piston and Piston Rings Make. : » 2 Brico ‘Type. a Semi-split skirt Piston: Skirt clearance o-go11" - 0-0017" (measured at the bottom of skirt at 90° to gudgeon pin axis) (0028" - 0-043 mm.) Gudgeon pin bore : 08751" ~ 08753" (2-188 - 21883 mm.) Compression height 7:1 compression ratio, Lae" = 184i" (46-76 ~ 46-89 mm.) 8:1 compression ratio oo. 2.069" - 2.064" (52-42 ~ 52-55 mm.) 9:1 compression ratio, 2247" - 2.242" (5694 — 57-07 mm.) Piston Rings Number Compression 2 Oil control 1 (Maxitlex) Piston rings—Width ‘Compression . 0.0770" - 0-0780" (1:97 ~ 2:00 mm) Oil contro! en Self expanding Piston rings—Thickness iCompresionee se on ISI" — 0-158" (8-775 ~ 395 mm.) Piston rings—Side clearance in groove Compression oe . 001" - 0-003" (0-02 - 0.07 mm) Oil control be 0001" - 0.003" (002 - 007 mm) Piston rings—Gap when fitted to cylinder bore ‘Compression 0-015" - 0-020" (38-051 mm) Oil control . 0.015" - 0.033" (038-082 mm.) Page BOENGINE Sparking Plugs Make Type Bo Gap (7:1, 8:1 and 9:1 compression ratios) ‘Tappets and Tappet Guides ‘Tappet—Material Outside diameter —Diameter clearance Tappet guide—Inside diameter (before reaming) —Reaming size (when fitted to cylinder head) Interference (shrink) fit in head ‘Timing Chains and Sprockets Type Piteh Number of pitches—Top chain ‘Bottom chain : Crankshaft sprocket—Teeth oF. Intermediate sprocket (outer) —Téeth.. Intermediate sprocket (inner)—Teeth, Camshaft sprocket—Teeth Idler sprocket Valve Timing Inlet valve opens Inlet valve closes Exhaust valve opens : Exhaust valve closes . Page B.10 Champion NY 0025" (0-63 mm.) Cast iron (chilled) 13738" — 13742" (3489 - 34:90 mm.) 0.0008" - 0-0019" (0-02-0048 mm.) 1353" - 1357" (3437 — 34-48 mm.) 1375"4- 00007" 0.0000" (34925 mm.+ 0018 mm.) = 0000 mm) - 0003" (0-07 mm) 18° BT.D.C. ST ABD. ST BBD 18 ATC. (with valve clearances set at O01" (025 mm)ENGINE ‘Valves and Valve Springs Valves—Material, Inlet. Silicon chrome steel Exhaust 21-4-NS Valve head diameter—Inlet 2. G 13" 0002" (4445 mm. 0-05 mm.) Exhaust So 14" 0-002" (4127 mm.+: 005 mm.) Valve stem diameter—Inlet and Exhaust 6... fe" 0-0025" 06" —0-0035° (7-95 mm.—-09 mm.) Valve lift .. eee ef oe ¥ (4mm) Valve clearance—Inlet .. 2. 0-004" (0-10 mm), ears 6) 0.006" (O15 mm), Valve seat angle—Inlet .. a 4s Exhaust of hr a Valve spring—Free length—Inner - ig (42mm), Outer We" (49-2 mm), Valve spring—Fitted length—Inner_ . . 1s" (30-96 mm.) Our Met (3334 mm) Valve spring—Fitted load—Inner weve 30:33 I, (13-76 kg.) Outer. mon 48375 Ib. (2194 kg) Valve spring—Solid length (max.)—Inner ao o8i0" (20:57 mm.) we om mb 0-880" (2235 mm.) Page B.I1ENGINE ‘Number of free coils—Inner .. Outer .. Diameter of wire—Inner —Outer Valve Guide and Valve Seat Insert Valve guides—Material ‘Valve guide—Length—Inlet Exhaust Valve guide—Inside diameter—Inlet .. Exhaust Interference fit in head Valve seat inserts—Material —nside diameter—Inlet —Exhaust Interference (shrink) fit in head, Page B.12 12 SWG (0-108") (2:64 mm) 10 SWG 0-128") (325 mm) Cast iron et (46-0 mm.) Hie (49-21 mm.) te" 0-0005" 0.0015" (794 mm.—0013 mm.) —0038 mm.) fo" 0.0005" (7-94 mm. 001 mm.) 00005 - 0.0022" (0013 - 0-055 mm.) Cast iron (centrifugally cast) 14'+ 0-003" 0001" (38-1 mm.+ 0076 mm.) 0025 mm.) 1379 - 1383" (3503 ~ 35:13 mm.) 0003" (0.076 mm.)FUEL REQUIREMENTS FOR 9:1 and 8:1 COMPRESSION RATIO ENGINES I the engine of your car is fitted with 9:1 compression ratio pistons (indicated by /9 after the engine number) use only Super grade fuel with a minimum octane rating of 98 (Research method). If a car is fitted with 8:1 compression ratio pistons (indicated by /8 after the engine number) use Premium grade fuel with a minimum rating of 94 (Research method). If, of necessity, the car has to be operated on lower octane fuel do not use full throttle otherwise detonation may occur with resultant piston trouble. ENGINE Page B.13ENGINE ROUTINE MAINTENANCE DAILY ‘Checking the Engine Oil Level Check the oil level with the car standing on tevel ‘ground otherwise a false reading will be obtained. Remove the dipstick and wipe it dry. Replace and withdraw the dipstick; if the oil level is on the knurled patch, with the engine hot or cold, ‘no additional oil is required. If the engine has been run immediately prior to making an oil level check, wait one minute after switching off before checking the oil level. Note: Almost all modern engine oils contain special additives, and whilst itis permissible to mix the recommended brands it is undesirable, If itis desired to change from ‘one brand to another this should be done when the sump is drained, and the Oil Company's recommendation in regard to flushing procedure should be Followed. EVERY 3,000 MILES (5,000 KM.) ‘Changing the Engine Oil Note: Under certain adverse operating con- ditions, conducive to oil dilution and sludge formation, more frequent oil changing than the normal 3,000. mile (5,000 km.) period is advised. Where the ccar is used mainly for low-speed city driving, stop-start driving particularly in ‘cold weather or in dusty territory the oil should be changed at least every 1,000 miles (1,600 km.). ‘The draining of the sump should be carried out at the end of a run when the oil is hot and therefore ‘will flow more freely. The drain plug is situated at the right-hand rear corner of the sump. When the engine oil is changed, the oil filter which is situated fon the right-hand side of the engine, must also receive attention, Unserew the central bolt and remove the canister and clement. Thoroughly wash these parts in petrol and allow to dry out. When replacing the canister ensure that a new circular rubber seal is fitted in the filter head. (Attention is drawn to the importance of renewing the filter element at 6,000 smile (10,000 km.) intervals. Page B.14 Note: Fig. 1. The engine dipstick Fig. 2. The engine ol filer ‘Almost all modern engine oils contain special additives, and whilst itis permissible to mix the recommended brands it is undesirable. Ifit is desired to change from fone brand to another this should be done when the sump is drained, and the Oil ‘Company's recommendation in regard to flushing procedure should be followed.Fig. 4. The engine filter i removed by unscreming. {he bott "Aa" and “withdrawing the. constr aed ‘element. The oil pressure reef lve ts situated behind the outer “8 Distributor—Lubrication Take care to prevent oil or grease from getting on or near the contact breaker points. Remove the moulded cap at the top of the distributor by springing back the two clips. Lift off the rotor arm and apply a few drops of engine oil around the screw (A, Fig. 5) now exposed. It is not necessary to remove the screw as it has clearance to permit the passage of oil. ‘Apply one drop of oil to the post (B) on which the contact breaker pivots. Lightly smear the ‘cam (C) with grease. Lubricate the centrifugal advance mechanism by injecting a few drops of ‘engine oil through the aperture at the edge of the contact breaker base plate. Distributor Contact Breaker Point Adjustment Check the gap between the contact points with ENGINE fecler gauges when the points are fully opened by ‘one of the cams on the distributor shaft. A ‘combined screwdriver and feeler gauge is provided in the tool kit. ‘The current gap is 0-014-0-016" (0'36-0-41 mm). If the gap is incorrect, slacken (very slightly) the ‘contact plate securing screw and adjust the gap by turning a screwdriver in the slot in the contact, plate, clockwise to decrease the gap and anti- clockwise to increase the gap. Tighten the securing serew and recheck to gap. Examine the contact breaker points. If the ‘contacts are burned or blackened, clean them with a fine carborundum stone or very fine emery cloth ‘Afterwards wipe away any trace of grease or metal dust with a petrol moistened cloth. Fig. 6. Checking the gap—the screw "A" secures the fzed ‘oniact pate; the contact plate is adjusted by trning a ‘screwdriver in slot Page B.ISENGINE Cleaning of the contacts is made easier if the contact breaker lever carrying the moving contact, is removed. To do this, remove the nut, insulating piece and connections from the post to which the end of the contact breaker spring is anchored. The contact breaker lever can now be lifted off its pivot post. Sparking Plugs Every 3,000 miles (5,000 km.) or more often if operating conditions demand, withdraw, clean and reset the plugs. ‘The only efficient way to clean sparking plugs is to have them properly serviced on machines specially designed for this purpose. These machines operate with compressed air and utilise a dry abrasive material specially graded and selected to remove harmful deposits from the plug insulator without damaging the insulator surface. — In addition the majority of the machines incorporate electrical testing apparatus enabling the plugs to be pressure tested to check their electrical efficiency and gas tightness. ‘The gap between the points should be 0.025" (0.64 mm). When adjusting the gap always move the side wire—never bend the centre wie. The Champion Sparking Plug Co. supply a special combination gauge and setting tool, the _use of which is recommended. Every 12,000 (20,000 km.) a new set of plugs of the recommended type should be fitted. To save petrol and to ensure easy starting, the plugs should be cleaned and tested regularly. EVERY 6,000 MILES (10,000 KM.) Drive Belts—Check for Wear ‘The drive belts should be examined for wear periodically and the alternator belt should be ‘checked for adjustment, Routine adjustment is not necessary in the case of the fan and steering box pressure pump as the drive belt is automatically adjusted by means of a spring loaded jockey pulley. To remove the fan and steering pump belt, slacken the adjustment belt in the steering pump supporting strap and press the body of the pump in towards the engine. Place the new belt in position over the fan, crankshaft and jockey pulleys. Press the jockey pulley against the spring and pass the belt over the pressure pump pulley. Page B.16 Pill the pressure pump away from the engine as far as possible and tighten the securing bolt. Alternator Belt Tension Release the top mounting bolt (the nut “A” is welded to the support bracket and cannot be turned). ‘Release the button mounting nut “B” and swing the alternator upwards away from the engine until the correct belt tension is obtained. Re-tighten the mountings. ‘When correctly tensioned it should be possible to depress the belt 4° (17 mm.) between the two pulleys. Fig. 7. Alternator belt adjustment Oil Filter Element It is most important to renew the oil filter clement every 6,000 miles (10,000 km.) as after this ‘mileage it will have become choked with impurities. To guard against the possibility of the filter being neglected to the extent where the element becomes completely choked, a balance valve is ‘incorporated in the filter head which allows ‘unfiltered oil to by-pass the clement and reach bearings. This will be accompanied by a drop in rormal oil pressure some 10 Ib,/sq. in. (0.703, kg./em2) and if this occurs the filter element should be renewed us soon as possible. To gain access to the element, unscrew the central bolt when the canister complete with the element can be removed. Thoroughly wash out the canister with petrol and allow to dry before inserting the new element.When replacing the canister ensure that a new circular rubber seal is fitted in the filter head. ‘Top Timing Chain Tension If the top timing chain is audible adjust the tension as follows: This operation requires the use of a special tool to enable the adjuster plate to be rotated. To gain access to the adjuster plate remove the breather housing attached to the front face of the cylinder head. Slacken the locknut securing the serrated adjuster plate, Tension the chain by pressing the locking plunger inwards and rotating the adjuster plate in an anti-clockwise direction. When correctly tensioned there should be slight flexibility on both outer sides of the chain below the camshaft sprockets, that is the chain must not be dead tight. Release the locking plunger, and securely tighten locknut, Refit the breather housing. ENGINE EVERY 12,000 MILES (20,000 KM.) Air Cleaner ‘The air cleaner is of the paper element type and is situated in the right-hand wing valance accessible from inside the engine compartment. No maintenance is necessary but the element should be renewed every 12,000 miles (20,000 km.) ‘or more frequently in dusty territories. A clogged leaner element will cause heavy fuel con- sumption. To gain access to the element detach the flexible hose connecting the cleaner to the air intake pipe after removing rubber joint from the pipe and the hose clip from the air cleaner cover plate. Turn the two quick-release screws securing the air cleaner cover plate anti-clockwise through 90° and withdraw plate with the attached element. ‘Remove the thumb nut and retainer plate from the base of the unit and withdraw the element. Fie. 8. Removing the air cleaner eee. Page B.17ata dey Recommended Lubricants | most | castrot | sHELL se. [pucknast| _aegenr Esso Extra Motor)} =~ oi sw)a0" {| Motigt | caucotie,| Set, | Bas dats Motor 20-50 | Havotine Special” | or Castro! XL| Super On | On 1o7Wa0" Visco Static | “or OWiA0 Esso Extra Motor sso0r | or 10W/30" oil 20W 0" ‘Upper elindsr lubrication Mobil | Castollo [shel UCL. Exo ‘Aacous at Uppertube Jor Donax U. uct. vcr | tes | UEr * These oils must NOT be used in engines requiring overhaul I an SAE 30 of 40 oil has previously ben used in the engine a sight increase in cil consumption may be noticed but this will be compensated by the advantages pnned. 1 According to availability in the country of operation Capacity Imperial == «US. Litres Engine - rfl (including filter) 12 pints 14g pints 6-75 aNIDNaENGINEorate aNIDN3ENGINE ENGINEENGINE ENGINE REMOVAL AND REFITTING REMOVAL (Fig. 11) Disconnect the battery (1). Remove the bonnet (2) (for details see Section N). Drain the engine sump (3). Drain the cooting system (4). Remove the air cleaner (5). Remove the radiator (6). Disconnect the starter cables (7). Remove the H.T. Lead from the coil (8). Disconnect the engine harness line plug and socket (9). Remove the cables from the revolution counter generator (10). Disconnect the main throttle shaft (11). Remove the water hoses from the heater unit (12). Disconnect the fuel feed pipe at the fuel filter bowl (13). Remove the vacuum pipe from the check valve a4). Remove the brake vacuum reservoir pipe (15). Disconnect the power-assisted steering pump and secure to avoid damage (16). Disconnect the exhaust pipes and remove the ‘wo sealing rings (17). Disconnect the earth strap (18). Disconnect the alternator cables (19). (On the automatic transmission models proceed as follows: (a) Remove the nut securing the selector cable pivot pin to the selector lever (20) together with bracket and disconnect the cable. (b) Disconnect the speedometer cable (21). (©) Disconnect the oil cooler pipes from the bottom water pipe assembly (22).6 In the case of standard and overdrive models proceed as follows: (a) Remove the console and gear lever grommet 23). (b) Remove the gear lever knob (24). (©) Disconnect the solenoid wires at the snap ‘connectors (25). (4) Disconnect the speedometer drive cable (26). (€) Disconnect the clutch slave eylinder (27) from the clutch housing. Jack up the rear engine mounting (28) and remove the four setscrews, spring washer and oval washers. Lower the jack slowly to relieve the tension on the mounting spring. Remove the mounting and spring ensuring that the four packing pieces between the mounting. and body are not mistaid. Unscrew the mounting pin and remove the upper spring seat (29). Remove the four propelier shaft securing. nuts and disconnect the universal joint (30). Support the engine on litng tackle by means of the engine iting straps. Remove the two front engine mounting bolts (31). Remove the sut and washer from the stabiliser between the rear of the cylinder head and the bulkhead (32). Lower the rear of the engine on the lifting tackle, ‘support on the jack and withdraw forwards. ENSURE THAT THE CAMSHAFT OIL FEED PIPE AND THE IGNITION TIMING POINTER ARE NOT DAMAGED. REFITTING Refitting is the reverse of the removal procedure ‘but it is important to adjust the engine stabiliser (Gee page B.71). [Note that the cables from the revolution counter ‘generator may be replaced on either terminal. Page B21ENGINE ENGINE TO DISMANTLE GENERAL The following instructions apply when the engine ‘components are removed in the following sequence ‘with the engine unit out ofthe chassis. Dismantling of sub-assemblies. and the removal of individual components when the engine is in the chassis frame are dealt with separately in this section, ‘All references made in this section to the top or bottom of the engine to be in the normal upright position. References to the left- oF right-hand side assume the engine to be upright and looking from the rear. REMOVAL OF FAN AND STEERING PUMP BELT Slacken the link between the steering pump and water pump, press the jockey pulley in towards the engine and remove the belt REMOVAL OF ALTERNATOR DRIVE BELT Slacken the top mounting bolt and remove the bottom mounting nut. Swing the alternator inwards and remove the belt Refiting Refitting is the reverse of the removal procedure. DO NOT use a tool to lever the belts on or off as this may break the endless cords in the bet. REMOVE STARTER Remove the two set pins and spring washers securing the starter to the clutch housing and remove the starter motor. REMOVE ALTERNATOR Remove top mounting bolt (A, Fig. 7) and bottom mounting nut (B, Fig. 7). Remove alternator and mounting strap. REMOVE GEARBOX Unscrew the four setscrews and remove the cover plate from the front face of the clutch housing. Remove the set bolts and nuts securing the clutch housing to the engine and withdraw the ‘gearbox unit. Page B22 REMOVE DISTRIBUTOR Slacken back the clips and remove the cover ‘complete with high tension leads. Disconnect the ‘white/black cable from the distributor. Slacken the clamp plate bolt and withdraw the distributor. Remove the setscrew and clamp plate, Note the cork seat in the recess at the top of the distributor drive hole. REMOVE CYLINDER HEAD Disconnect the distributor vacuum feed pipe trom the front carburetter, Remove the high fension leads from the sparking plugs and lead ‘cartier from the cylinder head studs. Remove the bolt securing the high tension lead clip to the timing cover. Remove the sparking plugs. Dis- ‘connect the camshaft oil feed pipe from the rear of the cylinder head. Remove the eleven dome nuts from each camshaft cover and lift off the covers. Remove the four dome nuts securing the breather housing and withdraw the housing and gauze baffle, Release the tension on the camshaft chain bby slackening the nut on the eccentric idler sprocket shaft, depressing the spring-loaded stop peg and rotating serrated adjuster plate clockwise. Anti- clockwise rotation of the serrated adjuster viewed from the front of the engine tightens the chain, Break the locking wire on the two setscrews securing the camshaft to their respective camshafts ‘Remove the setscrews and withdraw the sprockets from the camshafts with the chain in position. Having once disconnected the camshaft sprackets do NOT rotate the engine or camshafts. Slacken the fourteen cylinder head dome nuts and six nuts securing the front of the cylinder head a part of a turn at a time in the order shown until the nuts become free. Lift off the cylinder head complete with exhaust manifold and inlet manifold Remove and scrap ihe cylinder head gasket. REMOVE CLUTCH AND FLYWHEEL Unscrew the six setscrews securing the flange of the clutch cover to the flywheel and remove the clutch assembly. Note the balance marks “B” stamped on the clutch cover and on the edge of the flywheel.Fig. 12. Adjusting the 100 timing chain using Churchill Too! Number 2 ano To Tic. ~ Fost oF Pécs IMPORTANT Fig. 13. The top timing chain adjusting tol (Churchill - ” ni onan fot ENGINE Knock back the tabs of the locking plate securing the ten flywheel bolts. Unscrew the fly ‘wheel bolts and remove the locking plate. Remove the flywheel from the crankshaft flange by gently tapping with a rawhide mallet. REMOVE CRANKSHAFT DAMPER Knock back the tab washer, unscrew the large centre bolt (43, Fig. 30). Remove the four set pins, shakeprogf washers and the plain washer. Remove the crankshaft pulley and insert two levers behind the damper and ease it off the split cone—a sharp tap on the end of the cone will assist removal. REMOVE POWER STEERING PUMP Remove the power steering and water pump belt. Disconnect the low pressure and high pressure pipes from the rear of the steering pump. Plug pipes to avoid loss of oil, Disconnect the adjusting link from the oil pump. Remove the two nuts securing the oil pump to the mounting bracket. REMOVE WATER PUMP Unscrew the bolts and three nuts, and remove the water pump from the timing cover. Note the gasket between the pump and timing cover. REMOVE OIL FILTER Detach the short length of flexible pipe between the oil filter head and the oil sump. Unscrew the five bolts with plain and copper washers securing the oil filter head to the cylinder block and remove the filter head. REMOVE SUMP Drain the sump by removing the hexagon plug ‘and washer from the right-hand side of the sump. Remove the 26 setscrews securing the sump to the crankcase and the four nuts securing the sump to the timing cover. The sump can now be removed. REMOVE OIL. PUMP AND PIPES ‘Tap back the tab washers and unscrew the two bolts securing the oil feed pipe from the oil pump to the bottom face of the crankease. Withdraw the pipe from the pump. Page B23,ENGINE Remove'the nut and bolt securing the oil pump inlet pipe clip to the bracket on the main bearing cap. Remove the nut and bolt secur ng the oil pump inlet pipe clip in the bracket on the oil pump. Withdraw the pipe from the pump. ‘Tap back the tab washers and unscrew the three bolts securing the oil pump to the front main bearing cap. The oil pump can now be withdrawn. Remove the coupling shaft from the squared end of the distributor and oil pump drive shaft. REMOVE PISTONS AND CONNECTING RODS {As the pistons will not pass the crankshaft it will be necessary to withdraw the pistons and connecting rods from the top. Remove the split pins from the connecting rod bolt nuts and unscrew the nuts. Remove the ‘connecting rod cap, noting that the corresponding ceylinder numbers on the connecting rod and cap are together. Withdraw the piston and connecting rod from the top of the cylinder block. Note: Split skirt pistons MUST be fitted with the split opposite to the thrust side, that is, with the split on the leftchand ot exhaust side of the engine. To facilitate correct fitting the pistons crowns are marked “Front.” REMOVE TIMING COVER Remove the two bolts securing the jockey pulley to the timing cover. Remove the remaining bolts securing the timing cover to the front face of the cylinder block. Remove the tim’ng cover, noting that the cover is located to the cylinder block by ‘two dowels. REMOVE TIMING GEAR ASSEMBLY When removing the bottom timing chain tensioner from the engine, remove the hexagon hhead plug and tab washer from the end of the body. Insert an Allen key into the hole until it registers in the end of the restraint cylinder. Turn the Allen key clockwise until the restraint cylinder can be felt to be fully retracted within the body. The adjuster head will then be free of the chain, Page B24 Knock back the tab washers on the two set bolts securing the chain tensioner to the cylinder block. Withdraw the bolts and remove the tensioner together with the conical gauze filter fitted in the tensioner oil feed hole in the cylinder block; this should be cleaned in petrol. Unscrew the four set bolts securing the front ‘mounting bracket to the cylinder block. Release the tabs of the tab washers and remove the two serew= driver slotted setscrews from the rear mounting bracket; these setscrews aso secure the inter ‘mediate timing chain damper bracket. ‘The timing gear can now be removed. REMOVE DISTRIBUTOR DRIVE GEAR ‘Tap back the tab washer securing the distributor drive gear nut and remove the mut and washer. ‘Tap the squared end of the distributor drive shaft through the gear, noting that the gear is keyed to the shaft Remove the gear and thrust washer and with- draw the drive shaft REMOVE CRANKSHAFT Knock back the tab washers securing the 14 main bearing cap bolts. Unscrew the bolts and remove the main bearing caps, noting the corres- ‘ponding numbers stamped on the caps and bottom face of crankcase and also the thrust washers fitted to the recesses in the centre main bearing caps, Detach the bottom half of the crankshaft rear oil seal by unserewing the two Allen screws. Note that the two halves are located by hollow dowels. The crankshaft may now be lifted out of the crankcase, When overhauling an engine it is advisable to replace the asbestos oil seal at the rear of the crankshaft (see Page B.36). FIT PISTONS AND CONNECTING RODS Turn the engine on its side. Remove the connecting rod caps and fit the pistons and con- necting rods to their respective bores from the top of the cylinder block, using a suitable piston ring ‘compressor, Tool No. 38U3. The cylinder number is stamped on the connecting rod and cap, No, 1 cylinder being at the rear.Semi-split skirt pistons MUST be fitted with the split opposite the thrust side, that is, with the split on the left-hand or exhaust side of the engine. To facilitate correct fitting, the piston crowns are marked “Front.” Fit the connecting rod caps to the connecting rods with the corresponding numbers together. Fit the castellated nuts and tighten to a torque of 37 Ib. fe (5.1 kgm). Secure the nuts with split pins. FIT CRANKSHAFT GEAR AND SPROCKET Fit the Woodruff key to the inner slot and tap the distributor crankshaft gear into position with the widest part of the boss to the rear (see Fig. 29). it the Woodruff key to the outer slot and tap the crankshaft timing gear sprocket into position. Fit the oil thrower and distance piece. ‘Turn the engine until Nos. I and 6 pistons are on TDC. FIT DISTRIBUTOR AND OIL PUMP DRIVE GEAR Ensure that the Woodruff key on the distributor drive shaft is in good condition and renew if necessary. Place the drive shaft into position with the offset slot in the top of the shaft as shown in Fig. 14, Fig. 14, Showing the position of the distributor dive shaft ‘offet when Number 6 Gront) piston ison Top Dead Cenre, ENGINE Withdraw the shaft slightly maintaining the same slot postion and place the thrust washer and drive ‘ear on the end ofthe shaft. Press the shaft into the drive gear ensuring that the key engages the keyway correctly. Fit the pegged tab washer with the peg in the keyway of the drive gear. Fully tighten the mut and secure with the tab washer. Check the end float of the shaft which should be 0-004-0:006" (0:10-0:15 mm, If no clearance exists fit a new oil pump/dis- Uributor drive gear which will restore the clearance. JInan emergency ifa new drive gear is not available, the thrust washer may be reduced in thickness by rubbing down on a pie of emery cloth placed on a surface plate. Page B.25ENGINE ENGINE TO ASSEMBLE GENERAL All references in this section to the top or bottom. of the engine assume the engine to be upright, irrespective of the position of the unit when the reference is made, References to the let- or right= hhand side assume the engine to be upright and ooking from the rear. FIT DISTRIBUTOR DRIVE SHAFT BUSH I a new bush isto be fitted, press the bush into the bore ofthe lug at front of eylinder block. ‘Ream the bush in position to a diameter of: # +000050" (19:05 mm. +0012 mm.) —0-00025" 0006 mm.) FIT CRANKSHAFT Fit the main bearing shells to the top half of the ‘main line bore in the cylinder block. Lay the crankshaft in the bearing shells. Fit the bottom half of the crankshaft rear oil seal to the top half which is bolted to the cylinder block behind the rear main bearing. The two halves are located by hollow dowels and secured with Allen screws. If the asbestos seal has been replaced, ensure that it ‘has been well lubricated with colloidal graphite before fitting the crankshaft and lower half of the seal. The two halves of the oil seal housing are supplied only as an assembly together wilh the dowels and screws. If the crankshaft rear asbestos seal has been replaced, ensure that the seal has been correctly sized and lubricated as detailed on Page 37 before fitting the crankshaft. Fit the centre main bearing cap with a thrust ‘washer, white metal side outward, to the recess in each side of cap. Tighten down the cap and check the crankshaft end float, which should be 0-004- 0006" (0:10-0:15 mm.). The thrust washers are supplied in two thicknesses, standard and 0-004" (0-10 mm, oversize and should be selected to bring, the end float within permissible limits. The oversize thrust washers are stamped +0004" (0-10 mm.) (on the steel face. Fit the main bearing caps with the numbers stamped on the caps with the corresponding ‘numbers stamped on the bottom face of the crankcase, Page B.26 Fig. 1S. The crankshaft thrust washers Fig. 16. Showing the corresponding numbers on the main ‘Bearing cap and he erankease.2 8 4, 1s, 16, 1 ENGINE Fig. 17. Exploded view ofthe timing gear, ‘Camshat sprockets Adjusting pat Girctip Guide pia Star washer Circip Front bracket Rear bracket eer sprocket (21 teeth) Eccentric shaft Micro adjustment plate Phaneee pin Spring Intermediate sprocket Sha Shims Circip Peg 1. 20. 2. 2, 2 2. 2s, 2. 28 2. 20. 31 2. 3 34 3s. 36. Upper timing chain Lefthand damper Right-hand damper Distance piece Lower timing chain Intermediate damper Vibration damper Hydraulic tensioner Shim iter gale Fron timing cover Gasket it seal ‘Adjusting bracket Fan belt tensioner bracket Torsion spring Jockey pulley carier Aockey pulley Page B27ENGINE Fit the main bearing cap bolts and tab washers ‘and tighten to a torque of 83 Ib.ft. (11.5 kgm). ‘Test the crankshaft for free rotation. ‘The tab washers for the rear main bearing bolts are longer than the remainder and the plain ends should be tapped down around the bolt hole bosses. FIT OIL PUMP AND PIPES. Fit the coupling shaft between the squared end of the distributor drive shaft and the driving gear of the oil pump. Secure the oil pump to the front ‘main bearing cap by the three dowel bolts and tab ‘washers, Check that there is appreciable end-float ofthe short coupling shaft. Fit the oil delivery pipe from the oil pump to the bottom face of the erank- cease with a new “O" ring and gasket. Fit the suction pipe with a new "O” ring at the oil pump end. TO ASSEMBLE TIMING GEAR (Fig. 17) Fit the eccentric shaft (10) to the hole inthe front ‘mounting bracket (7). Insert the spring (13) and plunger pin (12) for the adjustment plate (11) to the hhole in the front mounting bracket (7). Fit the serrated plate (11) and secure with shakeproof ‘washer and nut, Fit idler sprocket (9) to the eccentric shaft (10). Fit the intermediate sprocket (14) to the shaft (15) with the larger sprocket forward and press the shaft through the lower central hole in the rear ‘mounting bracket (8). Secure with key (18) at the rear of the bracket. it chain (19) to the small intermediate sprocket ‘and chain (23) to the large intermediate sprocket. ‘Loop upper timing chain under the idler sprocket and offer up the front mounting bracket to the rear mounting bracket with the two chain dampers interposed between the brackets. Pass the four securing bolts through the holes in the brackets, chain dampers and spacers noting that shakeproof washers are fitted under the bolt heads, Secure the two mounting brackets with four stud nuts and shakeproof washers. FIT TIMING GEAR Turn the engine upside down. Fit the lower timing chain damper (26) and bracket to the front face of the cylinder block with two set bolts and locking plate. Page B28 ‘Turn the timing gear assembly upside down and offer it up to the cylinder block. Loop chain (23) over the crankshaf. sprocket and secure the ‘mounting brackets to the front face of the cylinder block with the four long securing bolts. TIMING CHAIN TENSIONER Place the timing chain tensioner, backing plate and filter in position so that the spigot on the tensioner aligns with the hole in the eylinder block. it shims as necessary, between the backing plate and cylinder block so that the timing chain runs centrally along the rubber slipper. Fit the tab ‘washer and two securing bolts. Tighten the bolts ‘and tap the tab washers against the bolt heads. tis important that no attempt is made to release the locking mechanism until the adjuster has been finally mounted in the engine WITH THE TIMING CHAIN IN POSITION. ‘Remove the hexagon headed plug and tab washer from the end of the body. Insert the Allen Key into the hole until it registers in the end of the restraint cylinder. Turn the key clockwise until the tensioner hhead moves forward under spring pressure against the chain, Do not attempt to turn the key anti- clockwise, nor force the tensioner head into the chain by external pressure. Refit the plug and secure with the tab washer. FIT TIMING COVER Fit the circular oil eal to the recess in the bottom face of timing cover, ensuring that seal is well ‘bedded in its groove. Fit the timing cover gasket with good quality jointing compound and secure the timing cover to the front face of the timing cover with the securing, bolts noting that the jockey pulley is attached to the right-hand side of the timing cover by two of the securing bolts, FIT OIL SUMP Fit a new sump gasket to the bottom face of the crankcase. Fit the cork seal to the recess in the rear ‘main bearing cap. Fit the sump to the crankcase and secure with the 26 setscrews, four nuts and washers. Note: The short setscrew must be fitted to the right-hand front corner of the sump.